Roll Surface Conditioning Tool for Online Contamination Removal
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Solution Overview
Problem
The existing rolling processes for aluminum strips and foils face issues with rapid roll wear and surface contamination due to deposit formation on back-up and work rolls, leading to frequent roll changes and surface quality deterioration, and existing solutions either require high maintenance efforts or pose safety risks.
Innovation Solution
A rolling device with a conditioning tool that mechanically removes contamination from the roll surface during operation, using a wedge-shaped tool with a cutting edge that moves in the longitudinal direction of the roll, allowing for online cleaning and reducing maintenance downtime, while using a cleaning stone with embedded particles that are compatible with rolling oils to prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deposits are removed from rolls at regular maintenance intervals, then roll service life is extended and surface quality is improved, but production downtime increases
Solution Approach 1:
The conditioning tool performs preliminary cleaning action on the roll surface during rolling operation, removing deposits before they can cause significant wear or surface defects. This continuous preliminary maintenance eliminates the need for frequent production-stop maintenance intervals
Solution Approach 2:
The conditioning tool operates continuously during rolling operation, maintaining the roll surface in a clean state throughout the production process. This continuous action replaces periodic maintenance interruptions with uninterrupted cleaning functionality
2Object-generated harmful factors
If liquid jet under high pressure is used to treat roll surface, then deposit removal is effective, but explosive mixtures can form requiring special safety precautions
Solution Approach 1:
The patent replaces the liquid jet mechanical cleaning system with a conditioning tool that uses controlled mechanical contact and friction to remove deposits. This substitution eliminates the high-pressure liquid injection that could create explosive aerosol mixtures while maintaining effective deposit removal
Solution Approach 2:
The patent converts the potentially harmful high-pressure liquid jet into a beneficial controlled mechanical conditioning process. By using a conditioning tool with specific geometric features (rake face, cutting edge), the harmful explosive aerosol generation is eliminated while achieving effective deposit removal through controlled mechanical action
3Reliability
If conditioning processes are used to remove deposits, then roll surface is cleaned, but rolling oil can become contaminated
Solution Approach 1:
The conditioning tool acts as an intermediary between the deposit removal process and the rolling oil. By using a conditioned surface approach with specific tool geometry, the cleaning action is directed at the deposit without allowing cleaning agents or tool materials to contaminate the rolling oil
Solution Approach 2:
The patent changes the parameters of the cleaning process by using a conditioning tool with specific geometric features (rake angle, cutting edge configuration) that enable deposit removal through controlled mechanical action rather than chemical or high-pressure liquid methods, thereby preventing rolling oil contamination
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 solution enables effective and economical conditioning of roll surfaces, reducing production downtimes and maintaining surface quality by preventing contamination of rolling oils, and ensuring the cleanliness of the roll surfaces without damaging them.
Implementation Method 1
a conditioning tool with which contamination can be mechanically removed from the surface of the roll during rolling operation
Data Source
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AI summary
The invention relates to a rolling device (100) having a roll stand (102) comprising a roll (104a-b, 106a-b). The rolling device (100) has a conditioning tool (112a-d), by means of which contamination can be mechanically removed from the surface of the roll (104a-b, 106a-b) during the rolling operation. The rolling device (100) has a driven transport device (114a-d), by means of which the conditioning tool (112a-d) can be moved across the surface of the roll (104a-b, 106a-b) substantially in a longitudinal direction of the roll during the rolling operation. The invention further relates to a method for conditioning a roll surface, wherein contamination, in particular a coating, is mechanically removed from the surface (202) of a roll (104a-b, 106a-b) by means of a conditioning tool (112a-d). The conditioning tool (112a-d) is moved across the surface (202) of the roll (104a-b, 106a-b) substantially in a longitudinal direction of the roll during the removal of the contamination, and the contamination is removed during the rolling operation of the roll (104a-b, 106a-b).