Roll Surface Laser Treatment During Metal Rolling
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Solution Overview
Problem
Roll stands in metal rolling processes face issues with surface wear and maintenance disruptions due to uneven wear of work and back-up rolls, leading to surface defects and reduced rolling quality, as existing cleaning methods are inefficient and require roll removal for processing.
Innovation Solution
Integration of a laser processing device with an adjustable positioning aid and nozzle using the Bernoulli principle within the roll stand allows for precise, residue-free surface processing of rolls during operation, including cleaning and texturing, to maintain roll quality and reduce maintenance downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rolls are removed from the roll stand for reconditioning, then the roll surface quality is improved, but production disruption increases
Solution Approach 1:
The laser processing device performs reconditioning of the roll surface in advance, during the rolling operation itself, before wear becomes severe. By continuously or periodically processing the roll surface in-situ, the system prevents the need for later removal and extensive reconditioning, thus maintaining production continuity while ensuring surface quality
Solution Approach 2:
The patent replaces traditional mechanical reconditioning methods (which require roll removal and involve grinding or machining equipment) with a laser-based processing system. The laser beam can be precisely directed at the roll surface to remove wear residues and recast layers without mechanical contact, enabling in-situ processing and eliminating production disruption associated with roll removal
2Adaptability or versatility
If laser processing is used on rolls in the roll stand, then in-situ processing capability is improved, but positioning precision becomes more difficult
Solution Approach 1:
The system incorporates sensors and control mechanisms that continuously monitor the position of the laser processing device relative to the roll surface. This feedback enables real-time adjustments to maintain precise positioning despite roll rotation, vibration, or thermal expansion, ensuring accurate in-situ processing without compromising laser beam placement
Solution Approach 2:
The patent introduces an intermediary positioning system between the laser source and the roll surface, such as a movable carriage or articulated arm with precise actuators. This intermediary mechanism allows the laser to be accurately positioned and tracked along the roll surface while maintaining the flexibility needed for in-situ operation, bridging the gap between fixed laser equipment and rotating rolls
3Manufacturing precision
If work rolls are frequently replaced due to wear, then rolling quality is maintained, but maintenance effort increases
Solution Approach 1:
The laser processing system enables the rolls to essentially recondition themselves during operation. By removing wear residues, caking, and recast layers in-situ, the system restores the roll surface to its original condition without requiring removal or external intervention. This self-service capability significantly reduces maintenance frequency and complexity while maintaining rolling quality
Solution Approach 2:
The patent implements continuous or periodic laser processing during the rolling operation, maintaining the roll surface quality throughout the roll's service life. This continuous action prevents the accumulation of wear that would otherwise necessitate frequent replacements, extending the useful life of each roll while consistently delivering high-quality rolling results
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 solution enables high-precision, in-situ processing of rolls, reducing maintenance efforts, extending roll life, and ensuring consistent rolling quality by removing wear residues and caking without disrupting production, thus enhancing productivity and roll longevity.
Implementation Method 1
The laser processing unit (30) is set up to process the surface of the roller (3, 4) by vaporization without residue or at least with little residue
Implementation Method 2
The adjustment unit (50) has a nozzle (51) which, supplied by a gas source, emits a gas flow, preferably air flow, in the direction of the roll (3, 4) to be processed. Because the gas emitted by the nozzle partially flows around the roll surface, the nozzle is sucked in in the immediate vicinity of the roll surface at a defined distance due to the Bernoulli principle
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a roll stand for rolling a rolled product (5), preferably a metal strip, which has at least one roll (1, 2, 3, 4) and a treatment device (10) for treating the surface of the roll (1, 2, 3, 4). The treatment device (10) has at least one laser treatment unit (30), which is designed to treat the surface of the roll (1, 2, 3, 4) by means of a laser beam, and a positioning device (20), which is designed to set the position and/or location of the laser treatment unit (30) relative to the surface of the roll (1, 2, 3, 4), and the treatment device (10) also has at least one positioning aid (31, 40, 50), which can be adjusted together with the laser treatment unit (30) by the positioning device (20).