Integrated Roll Surface Treatment for Grinding and Laser Texturing
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Solution Overview
Problem
Existing surface treatment machines for cylindrical bodies, such as rolling mill rolls, require separate machines for grinding and texturing, leading to increased handling time, space occupation, and depreciation costs due to the need to move rolls between machines.
Innovation Solution
A machine and method that integrate grinding and texturing capabilities into a single unit, allowing for simultaneous or sequential processing of rolls without the need to move them between separate machines, thereby reducing handling time and space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate machines are used for grinding and texturing, then each machine can be optimized for its specific function, but the handling time and space occupation increase
Solution Approach 1:
The patent combines two previously separate machines (grinding machine and texturing machine) into a single integrated machine. The grinding device and texturing device are mounted on the same frame structure, allowing both operations to be performed on the roll without removing it from the machine. This eliminates the handling time required to move rolls between separate machines while maintaining the specialized functions of each device.
Solution Approach 2:
The integrated machine serves multiple functions by incorporating both grinding and texturing capabilities in one device. The machine can perform grinding operations to restore the roll profile and eliminate defects, followed by texturing operations to create the desired surface roughness pattern, all without requiring the roll to be removed or transferred to another machine.
2Manufacturing precision
If separate machines are used for grinding and texturing, then each machine can be dedicated to its specific treatment, but the space occupation and depreciation costs increase
Solution Approach 1:
The patent merges the grinding machine and texturing machine into a single integrated unit with a common frame structure. Both the grinding device and texturing device are mounted on the same frame, sharing structural components and support systems. This consolidation reduces the total space required compared to having two separate machines while maintaining full functionality of both treatment processes.
3Adaptability or versatility
If the roll is moved between separate machines, then different treatments can be applied, but the treatment time increases
Solution Approach 1:
The integrated machine combines grinding and texturing operations in one device, allowing the roll to remain stationary on the frame while both treatments are applied sequentially. The grinding device can restore the roll profile and eliminate defects, followed by the texturing device that creates the desired surface roughness pattern, all without removing the roll from the machine.
Solution Approach 2:
The machine incorporates movable components that allow the grinding device and texturing device to be positioned and adjusted dynamically. The grinding device can be moved along the roll length and its depth of engagement adjusted, while the texturing device can be positioned to apply texturing patterns at specific locations. This dynamic adjustability provides treatment flexibility equivalent to separate machines while eliminating handling time.
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
The integrated machine and method significantly reduce the time required to restore the surface features of rolls, minimize space occupation, and lower operational costs by eliminating the need for separate grinding and texturing machines.
Implementation Method 1
The texturing group (40) comprises a laser head (403) movable over a working zone (200) for texturing at least part of the surface (2) of the roll (1), the laser head (403) being configured to emit a laser beam directed towards the surface (2) of the roll (1)
Implementation Method 2
A first type of treatment provides for reconditioning the surface of the roll by removing a certain material thickness from the roll. This process, generally conducted through a grinding wheel, is known as grinding and allows to restore the profile
Data Source
AI summary
A machine for carrying out surface treatments onto rolling mill rolls, which includes a supporting structure extending along a longitudinal direction of development, a casing placed at least partially to cover the supporting structure, at least two supporting elements placed on the supporting structure opposed to each other and aligned along a rotation axis parallel to the longitudinal direction of development, a rotation motor configured to put in rotation the roll when supported by the two supporting elements, a grinding group slidably connected to the supporting structure and which includes a grinding tool, a texturing group slidably connected to the supporting structure and which includes a laser head, and a control unit placed in signal communication with the grinding group and with the texturing group and configured to control the grinding group and the texturing group.