Detachable Roll Cartridge Handling for Faster Mill Roll Changes
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Solution Overview
Problem
The existing roll-changing devices for rolling mills face challenges in automating the roll-changing process, leading to increased manual intervention, safety risks, and high operational costs due to the need for extensive crane system activity during roll transportation and loading/unloading.
Innovation Solution
A detachable cartridge system is integrated into the roll-changing carriage, equipped with receiving spaces for rolls and load attachment means for crane hooks, allowing for automated transport and secure handling of rolls using an overhead crane, reducing manual labor and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If individual rolls are transported separately between the rolling mill stand and the roll-changing carriage, then the roll-changing process can be performed, but the process becomes difficult to automate and requires high level of crane system activity
Solution Approach 1:
The system is segmented into modular cartridges that can be pre-loaded with rolls in a roll workshop and then transported as complete units to the rolling mill stand. This segmentation allows automated handling of entire cartridge units rather than individual rolls, reducing crane system complexity while maintaining automation capability.
Solution Approach 2:
The cartridge serves as an intermediary carrier between the roll workshop and the rolling mill stand. Rolls are loaded into cartridges in advance at the roll workshop, and these pre-loaded cartridges are then transported to the rolling mill stand using the overhead crane. This intermediary structure enables automated processes at both locations while minimizing crane activity during the actual roll-changing operation.
2Reliability
If individual rolls are transported separately, then the roll-changing process can be performed, but manual intervention is increased leading to safety problems
Solution Approach 1:
By segmenting the roll handling into modular cartridges, the system reduces the number of manual interventions required. Personnel only need to handle complete cartridge units rather than individual rolls, significantly improving safety by minimizing exposure to escaping rolls during crane activities.
Solution Approach 2:
Rolls are pre-loaded into cartridges in advance at the roll workshop before being transported to the rolling mill stand. This preliminary action allows rolls to be prepared and secured in a controlled environment, reducing the need for manual handling during the actual roll-changing operation and improving personnel safety.
3Productivity
If individual rolls are transported separately, then the roll-changing process can be performed, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The modular cartridge system allows rolls to be prepared and loaded in parallel at the roll workshop while other operations occur at the rolling mill stand. This segmentation enables concurrent operations, significantly reducing the total time required for the roll-changing process and improving productivity.
Solution Approach 2:
Rolls are pre-loaded into cartridges in advance at the roll workshop, allowing this labor-intensive task to be performed during non-critical periods. When roll-changing is needed at the rolling mill stand, the pre-loaded cartridges are already ready for immediate transport and installation, dramatically reducing the time required for the actual roll-changing operation.
Data Source
AI summary
A roll-changing device (1) for changing the working and/or intermediate rolls (2) of a rolling mill stand includes a roll-changing carriage (3), with which rolls (2) to be changed out or in can be transported. In order to further develop such a roll-changing device in such a way that it is possible to ensure simplified and safe loading and unloading of a roll-changing carriage, the roll-changing device (1) includes a cartridge (4) that can be detachably arranged in the roll-changing carriage (3). The cartridge (4) is provided with receiving spaces (5) for the rolls (2).