Roll Forming Roller Stack Change by Horizontal Support Translation
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Solution Overview
Problem
Current roll forming machines require significant time and overhead cranes for changing rollers due to the need to lift and reposition stacks vertically, leading to slow and cumbersome operations.
Innovation Solution
An operating unit that allows rollers to be moved as a unit on a horizontal plane, with adjustable distance and precise positioning, eliminating the need for vertical lifting and overhead cranes by using a movable support structure with rotating and sliding coupling means, enabling easy movement along the processing line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If stacks are removed and repositioned with vertical movement using overhead cranes, then rollers can be changed between different cages, but the operation becomes slow and requires considerable infrastructure
Solution Approach 1:
The patent changes the movement dimension from vertical to horizontal. The movable support structure translates the stack along a horizontal axis between cages, eliminating the need for vertical lifting and overhead cranes. This dimensional change resolves the contradiction by enabling rapid roller changes without the time-consuming vertical operations.
Solution Approach 2:
The patent introduces a movable support structure as an intermediary mechanism between the stack and the cages. This mediator enables the stack to be transported horizontally along a guide track, facilitating quick roller changes without direct vertical handling. The intermediary structure eliminates the need for heavy overhead cranes while maintaining adaptability.
2Adaptability or versatility
If overhead cranes are used to lift and reposition stacks, then rollers can be changed, but the infrastructure requirements and operational complexity increase
Solution Approach 1:
By switching from vertical to horizontal movement, the patent eliminates the need for overhead cranes and high sheds. The movable support structure travels along a horizontal guide track at ground level, dramatically simplifying infrastructure requirements while preserving the ability to change rollers between cages.
Solution Approach 2:
The patent replaces the complex overhead crane mechanical system with a simpler movable support structure that translates horizontally along a guide. This substitution eliminates heavy lifting mechanisms, reducing device complexity while maintaining roller changing functionality.
3Loss of time
If rollers are moved as a unit on a horizontal plane, then the time for stack changes is reduced, but a mechanism for horizontal movement must be provided
Solution Approach 1:
The patent segments the support structure into a movable portion carrying the stack and a fixed guide structure. The movable support translates along the horizontal guide track, enabling quick stack changes. This segmentation creates a relatively simple mechanism compared to overhead cranes, reducing time while adding minimal complexity.
Solution Approach 2:
The movable support structure is designed as a simplified copy of traditional vertical lifting mechanisms, adapted for horizontal movement. It uses similar mechanical principles (tracks, carriers, actuation) but in a horizontal configuration, reducing complexity while achieving faster operation.
Data Source
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AI summary
Operating unit for a roll forming machine, comprising a cage (10), configured for being connected to a base (B), and a stack (G), comprising: at least two rollers (R1,R2), rotating around axes (X1,X2) which are horizontal and perpendicular to a direction of advancement (A) of the roll forming machine; an upper support (21), which supports a first roller (R1); a lower support (22), which supports a second roller (R2); an intermediate support (23), interposed between the upper support (21) and the lower support (22); coupling means (31,32), structured for constraining to each other the upper support (21), the lower support (22) and the intermediate support (23) with the sole possibility of vertically translating one with respect to the other; the upper support (21) and the lower support (22) are movable between a working position, in which they are spaced apart from the intermediate support (23), and a changing position, in which the upper support (21) rests on the intermediate support (23) which, in turn, rests on the lower support (22).