Roll Neck Machining for Roundness and Concentricity Correction
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Solution Overview
Problem
In steel rolling processes, the eccentricity of back-up and work rolls leads to gage variations in flat rolled sheet products, which are challenging to accurately measure and correct, affecting the quality and efficiency of the rolling process.
Innovation Solution
A measure-then-machine (MTM) system that includes a machine frame supporting a roll measuring subsystem and a roll machining subsystem. The system uses powered support rolls, radial probes, laser interferometer systems, and a metal removing device to accurately measure the roundness and concentricity of rolls and perform necessary machining to correct any deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional roundness measurement methods are used, then measurement capability is limited, but measurement precision is insufficient for detecting small eccentricities
Solution Approach 1:
The system performs preliminary measurement of roll roundness and eccentricity using radial probes and laser interferometers before machining. The controller calculates the true axis of rotation and determines the precise amount of metal removal needed, allowing for minimal material removal while achieving the required roundness tolerance.
Solution Approach 2:
The patent replaces traditional mechanical measurement methods with laser interferometer systems that use optical fields to measure radial positions with high precision. The laser interferometers detect positional changes through interference patterns, providing sub-micron measurement capability without mechanical contact.
2Measurement precision
If multiple measurement points are used to improve accuracy, then measurement precision increases, but device complexity increases
Solution Approach 1:
The measurement system uses multiple radial probes that can measure both roundness and concentricity simultaneously. The same laser interferometer system and controller that calculate the true axis of rotation also determine the optimal machining path, allowing one measurement system to serve multiple functions and reducing overall device complexity.
Solution Approach 2:
The controller acts as an intermediary that processes data from multiple radial probes and laser interferometers, calculates the true axis of rotation, and determines the optimal machining parameters. This centralized processing simplifies the system architecture by providing a single point of coordination for all measurement and machining operations.
3Manufacturing precision
If precise roundness measurement is achieved, then manufacturing precision improves, but measurement time increases
Solution Approach 1:
The system continuously rotates the roll during measurement, allowing radial probes to collect data from all circumferential positions simultaneously. The laser interferometers continuously track positional changes, and the controller continuously processes data to maintain the true axis of rotation calculation, enabling complete measurement in a single continuous operation rather than multiple discrete measurements.
Solution Approach 2:
The system performs preliminary measurement and calculation of the true axis of rotation before machining begins. This preliminary action allows the machining operation to proceed directly with precise control, eliminating the need for iterative measurement and adjustment cycles during the actual machining process.
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 MTM system enables precise measurement and correction of roll roundness and concentricity, reducing gage variations and improving the quality of steel products by minimizing thickness variations and enhancing the efficiency of the rolling process.
Implementation Method 1
one or more laser interferometer systems aligned to measure distance along the Y-axis for a corresponding one of the one or more radial probes
Implementation Method 2
one or more radial probes received for respective radial movement in parallel to a Y-axis of the machine frame
Implementation Method 3
a first pair of powered support rolls that receives a first roll neck; and (ii) a second pair of powered support rolls that receives a second roll neck
Data Source
AI summary
An apparatus, computer program product, and method provide for increased economy in maintaining working and backup rollers that are used to producing sheet metal of uniform thickness. Left and right necks of the roller are supported and rotated. A radial measurement is made of left and right necks to calculate a center of rotation of each neck. Radial positions of reference spheres centered at each end that define a gage reference line (GRL) are measured. Material is removed from the necks to not only increase roundness but also to move the center of rotation of each neck toward the GRL, enabling grinding/machining of a body portion of the roller to restore roundness with reduced waste of material.