Reversing Roll Stand Lubrication Layout for Lower Rolling Forces
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Solution Overview
Problem
Reversing roll stands experience high friction and rolling forces due to high pickling roughness, leading to increased production time and reduced product quality, with existing lubrication methods often inefficient and causing coolant discharge issues.
Innovation Solution
A method and apparatus where a lubricant is sprayed as a mixture with a carrier gas exclusively on the run-out side of a rolling pass, and coolant is applied only on the run-in side, optimizing lubrication and cooling to minimize waste and enhance adhesion, using a control unit to manage spraying bars and cooling bars for targeted application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If lubricant is applied during rolling to reduce friction, then rolling forces are reduced, but lubricant consumption increases and causes discharge issues
Solution Approach 1:
The patent applies lubricant locally only on the run-out side of the rolling pass where friction is most critical, rather than uniformly across the entire rolling surface. This localized application reduces lubricant consumption while maintaining effective friction reduction in the critical zone.
Solution Approach 2:
The lubricant is applied in advance on the run-out side before the material enters the high-friction zone, allowing the lubricant to be already in position when needed, improving lubrication efficiency and reducing overall lubricant requirements.
2Temperature
If coolant is applied during rolling to reduce temperature and wear, then working roller temperature is reduced, but coolant discharge problems occur
Solution Approach 1:
The coolant is applied locally only on the run-in side of the rolling pass where the material first contacts the rollers and heat generation begins, rather than across the entire rolling zone. This localized cooling reduces coolant consumption and prevents discharge issues while maintaining effective temperature control.
Solution Approach 2:
The patent segments the cooling function by applying coolant separately on the run-in side, distinct from the lubrication zone on the run-out side. This spatial segmentation allows independent optimization of cooling and lubrication functions, preventing coolant discharge while maintaining temperature control.
3Force
If lubricant is applied on run-in side to lubricate working rollers, then friction is reduced, but lubricant is washed away by coolant and loses effectiveness
Solution Approach 1:
The patent inverts the conventional sequence by applying lubricant on the run-out side instead of the run-in side. This reversal prevents the lubricant from being washed away by coolant application, as the lubricant is applied after the cooling function has been performed, ensuring lubrication effectiveness is maintained.
Solution Approach 2:
The patent segments the lubrication and cooling functions into separate spatial zones: cooling on the run-in side and lubrication on the run-out side. This segmentation prevents the harmful interaction where coolant washes away lubricant, allowing both functions to perform effectively without interference.
4Manufacturing precision
If high friction is tolerated to avoid lubricant use, then strip cleanliness is improved, but rolling forces become excessively high and production time increases
Solution Approach 1:
The patent applies lubricant locally only on the run-out side rather than uniformly, minimizing the lubricant's contact with the strip surface and reducing contamination risk while still providing sufficient friction reduction to maintain acceptable rolling forces and production efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces lubricant and coolant consumption, improves lubrication efficiency, and prevents coolant discharge, allowing for more precise application and reduced production time while maintaining product quality.
Implementation Method 1
The lubricant is dispensed in a mixture with a carrier gas, wherein the mixture is sprayed onto the working rollers or/and onto the rolled material
Implementation Method 2
The lubricant is dispensed in a mixture with a carrier gas
Data Source
AI summary
The invention relates to a method and a rolling device for rolling a rolled material. The rolled material is guided through a roll gap between two working rollers of a reversing roll stand, alternatingly in two opposing rolling directions. A lubricant for lubricating a contact zone is introduced into the contact zone in which the rolled material is in contact with the working rollers, and a coolant is applied to the rolled material and/or the working rollers. In a mixture with a carrier gas, the lubricant is sprayed onto the working rollers and/or onto the rolled material exclusively on an outlet side of a pass. The coolant is applied to the working rollers and/or to the rolled material exclusively on an inlet side of a pass.