Roll Contour Grinding Path Correction
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Solution Overview
Problem
Existing methods for grinding the contour of a roll barrel, particularly with steep curves, suffer from significant grinding errors due to complex mechanisms and limited adjustability, leading to increased wear and extended grinding times.
Innovation Solution
A method that calculates an optimized grindstone path by incorporating a wear model and correction curve, ensuring even wear and minimizing errors by superimposing the target contour with a correction function, which accounts for grindstone dimensions and shape, allowing for pre-determined path calculation before the grinding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a complex swiveling mechanism is used to adjust the grinding wheel angle, then the grinding wheel can be tangentially adjusted along the roll contour, but the mechanism becomes very complex with minimal play requirements and mechanical angle limitations
Solution Approach 1:
The patent replaces the complex mechanical swiveling mechanism with a computer-controlled system that calculates and guides the grinding wheel path using software algorithms. The grinding wheel is positioned and guided by CNC control based on pre-calculated trajectories, eliminating the need for mechanical swiveling joints and their associated complexity while maintaining or improving grinding precision.
Solution Approach 2:
The patent applies preliminary action by pre-calculating the grinding wheel path and trajectory before the actual grinding process. The computer system computes the optimal path considering the roll contour, grinding wheel dimensions, and material properties in advance, allowing the grinding wheel to follow the predetermined path without requiring complex real-time mechanical adjustment mechanisms.
2Shape
If the grinding wheel is guided to follow the target contour, then the desired roll shape is achieved, but grinding defects occur at steep transitions and edge regions due to additional material removal
Solution Approach 1:
The patent applies preliminary anti-action by pre-calculating and compensating for expected grinding defects in the path computation. The computer system anticipates where material removal errors will occur at steep transitions and edge regions, and adjusts the grinding wheel trajectory in advance to counteract these effects, preventing rather than correcting the defects.
Solution Approach 2:
The patent implements feedback by measuring the actual roll contour after grinding and comparing it with the target contour. The computer system uses this feedback information to calculate correction curves and adjust the grinding wheel path for subsequent grinding operations, progressively improving the surface quality and reducing defects at critical regions.
3Manufacturing precision
If correction curves are calculated and applied to adjust the grinding path, then grinding errors are minimized, but additional grinding time is required
Solution Approach 1:
The patent applies preliminary action by calculating the correction curve and optimized grinding path before the grinding process begins. The computer system performs all necessary computations including wear model predictions and path optimizations in advance, so that during the actual grinding operation, the wheel simply follows the pre-calculated trajectory without requiring iterative corrections that would extend cycle time.
Solution Approach 2:
The patent applies parameter changes by using the wear model to predict how the grinding wheel characteristics will change over time and adjusting the grinding path parameters accordingly. The computer system modifies the grinding wheel trajectory, speed, and engagement parameters based on predicted wear patterns, achieving high precision while optimizing the grinding cycle time by preventing excessive material removal.
4Productivity
If a wear model is incorporated into the calculation rule, then the grinding wheel wear becomes more uniform and utilization improves, but the calculation complexity increases
Solution Approach 1:
The patent replaces complex mechanical wear compensation mechanisms with a computer-based wear model. The software calculates predicted wear patterns based on material properties, grinding parameters, and wheel characteristics, automatically adjusting the grinding path to achieve uniform wear distribution. This computational approach is more flexible and easier to modify than mechanical wear compensation systems.
Solution Approach 2:
The patent applies self-service by implementing a wear model that continuously monitors and predicts grinding wheel wear, automatically adjusting the grinding parameters and path without external intervention. The computer system serves itself by using the wear predictions to optimize its own operation, maximizing wheel utilization and extending wheel life through automated parameter adjustment.
Data Source
Figure 1a~1b
Figure 2
Figure 3~4
AI summary
The invention relates to a method for grinding the contour of the body (110) of a roll (100), in particular a roll having a roll contour having a steep curve course in a roll stand for rolling metal strip, having the following steps: specifying a target contour for the body (110) of the roll and grinding the contour of the body (110) by guiding a grindstone (200) along a grindstone path D(x). In order to reduce grinding errors and grinding times, the method also provides the following steps according to the invention: determining a grinding error e or grinding error function E(x) at least over individual length segments of the body (110) in the axial direction x; calculating a correction curve C(x) at least over the individual length segments of the body (110) in the axial direction x, wherein the correction curve C(x) avoids the determined grinding error e; and calculating the grindstone path D(x) for guiding the grindstone (200) by superposing the target contour A(x)+B(x) for the body (110) with the correction curve C(x).