Roll Changer Assembly for Automated Backup Roll Replacement
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Solution Overview
Problem
The existing method for changing back-up rolls in a roll stand is complex and time-consuming, requiring the displacement of the lower back-up roll and the use of an indoor crane, which leads to high setup costs and unavailable crane time for other operations.
Innovation Solution
A method and device where a roll-changing chair is introduced into the roll stand via extension rails, allowing the upper back-up roll to be lowered onto it, enabling either the upper or a unit of both back-up rolls to be moved out or in without displacing the lower roll, using a two-part roll-changing chair design that reduces load on the extension rails and allows for automated operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lower backup roll is moved out of the stand area to mount the roll changer on it, then the roll changer can be installed, but the setup time increases and costs increase
Solution Approach 1:
The patent introduces a shifting device as an intermediary component that enables the roll changer to be mounted on the lower backup roll without requiring the roll to be moved out of the stand area. The shifting device provides a platform for roll changer installation while the lower backup roll remains in its operational position, thus eliminating the time-consuming move-out-and-move-back sequence.
2Ease of manufacture
If the lower backup roll is moved out and then back in with the roll changer mounted, then the roll changer is installed, but costly setup time is required
Solution Approach 1:
The shifting device serves as a mediator that allows the roll changer to be installed on the lower backup roll while it remains in the stand area. This intermediary mechanism eliminates the need for the lower backup roll to be moved out and back in, significantly improving setup efficiency and reducing costly downtime.
3Ease of operation
If a crane is used to lift the upper backup roll off the roll changer, then the replacement can be completed, but the crane becomes unavailable for other operations
Solution Approach 1:
The patent implements a self-service mechanism where the upper backup roll is lowered onto the roll changer using the rolling stand's own lowering device, rather than requiring an external crane. This self-contained operation allows the upper backup roll to be positioned and secured without crane intervention, making the crane available for other operations and improving overall productivity.
4Strength
If the roll changer is designed as a two-part structure, then the load on extension rails is reduced, but the device complexity increases
Solution Approach 1:
The roll changer is divided into two separate parts: a lower part that remains in the stand area and an upper part that can be extended out. This segmentation allows the lower part to bear the weight and support the lower backup roll, while the upper part can be moved independently on the extension rails. This reduces the load on the extension rails during roll changes while managing the complexity through modular design.
Data Source
Figure 1~2
Figure 3~4
Figure 5.1~5.2
AI summary
The invention relates to a device (10) and a method for changing backup rolls (12) on a rolling mill stand (11). In this process, after the work rolls have been extended, a roll changer (14) is inserted into the rolling mill stand (11) transversely to the rolling direction (W), wherein the roll changer (14) can be supported with a lower part (16) thereof on mounting blocks (18.2) of the lower backup roll (12.2) and the upper backup roll (12.1) can be lowered onto the roll changer (14). The roll changer (14) is moved into the rolling stand (11) via the exit rails (24) provided for the work rolls of the rolling stand (11), whereby, after the upper backup roll (12.1) has been lowered onto the roll changer (14), either only the upper backup roll (12.1) or a unit formed from the lower and upper backup rolls (12.1, 12.2) is/are moved out of the rolling stand (11).