Reform Tub Iris Shear Unit for Coil Weight Control

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Solution Overview

Problem

Older wire rod mills face challenges in upgrading to produce half coils or customer-specified weights due to space constraints and high costs associated with retrofitting a reform tub with separate shear and support systems, as they lack the necessary vertical height for installing retractable supports and shears.

Innovation Solution

A combined unit comprising an actuator and retractable support members with shear blades, which are pivotable and controlled by a coil height sensor and controller, allowing for the minimization of vertical height requirements and integration of additional support stages without altering the structural arrangement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate shear and support systems are installed in the reform tub, then coil cutting and support functions are achieved, but vertical height requirements increase and retrofitting costs increase

Engineering Contradiction:

Improvecoil weight specification capabilityVSAvoidvertical height

Core Design Contradiction:

Adaptability or versatilityVSLength of stationary object

Solution Approach 1:

The patent combines the shear blade function and support member function into a single integrated component. The support member includes a blade that can cut the rod, eliminating the need for separate shear and support systems. This merging reduces vertical height requirements and retrofitting costs while maintaining the ability to produce coils of customer-specified weights.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support member is designed to perform multiple functions: it provides structural support for the coil during forming and simultaneously acts as a cutting blade when needed. This multi-functional design eliminates the need for separate dedicated shear equipment, reducing overall system height and complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If separate shear and support systems are installed in the reform tub, then coil cutting and support functions are achieved, but equipment costs and installation complexity increase

Engineering Contradiction:

Improvecoil weight specification capabilityVSAvoidnumber of separate systems

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the shear blade function and support member function into a single integrated component. The support member includes a blade that can cut the rod, eliminating the need for separate shear and support systems. This merging reduces vertical height requirements and retrofitting costs while maintaining the ability to produce coils of customer-specified weights.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Length of stationary object

If floor excavation is performed to install reform tub with irises and shear, then sufficient vertical space is created, but installation cost and complexity increase

Engineering Contradiction:

Improveavailable vertical heightVSAvoidretrofitting complexity

Core Design Contradiction:

Length of stationary objectVSEase of manufacture

Solution Approach 1:

The patent combines the shear function and support member function into a single integrated component. The support member includes a blade that can cut the rod, eliminating the need for separate shear and support systems. This merging reduces vertical height requirements and retrofitting costs while maintaining the ability to produce coils of customer-specified weights.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Instead of increasing vertical space through floor excavation to accommodate separate systems, the invention inverts the approach by reducing the vertical space requirement through functional integration. The combined design fits within existing height constraints without requiring structural modifications.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS10773288B2Reform tub iris to also include coil shear

Publication Date: 2020.09.15 PRIMETALS TECHNOLOGIES USA LLC

AI summary

A combined iris and shear unit for a coil forming device is provided that includes an actuator and a plurality of support members coupled together in series to support formation of a coil and connected to the actuator. Each support member further comprises a retractable shear blade. The actuator adapted to cause movement of the support members between an open position with the blades of the combined iris and shear unit being retracted away from the reform tub wall, so that coil forming takes place within the reform tub without interference. A support position with the blades extends into the reform tub and providing support for the coil; or a shear position for cutting the coil before it is extracted.