Roller Grinder for Quarter Wave Prevention
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Solution Overview
Problem
Existing roll stands struggle to produce flat and undulation-free rolling stock with high quality, particularly in suppressing quarter waves, as conventional methods like roll shifting and bending are limited in effectiveness and require significant adjustment ranges.
Innovation Solution
A roll stand design where axially displaceable rolls have contours formed by superimposing basic and additional functions, allowing for the suppression of quarter waves through controlled roll grinding, ensuring an offset crown that maintains flatness and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional roll shifting and bending methods are used, then some profile control is achieved, but quarter waves cannot be effectively suppressed
Solution Approach 1:
The work rolls are given different local geometries through asymmetric contouring, where one roll has a contour formed by a first basis function and the other by a second basis function. This local differentiation in roll geometry creates the necessary offset crown to suppress quarter waves while maintaining overall flatness control.
Solution Approach 2:
The invention applies asymmetry by designing the two work rolls with non-identical contours - one with a first basis function and the other with a second basis function. This asymmetric configuration is specifically intended to suppress quarter waves, which cannot be addressed by symmetric conventional roll bending methods.
2Manufacturing precision
If roll contours are designed with basis functions to suppress quarter waves, then flatness control is improved, but roll service life decreases due to increased maximum pressures
Solution Approach 1:
The invention changes the geometric parameters of the roll contours by superimposing additional functions onto the basis functions. These parameter modifications optimize the crown profile to suppress quarter waves while controlling the maximum pressures to an acceptable level, thereby balancing flatness control with roll service life.
3Manufacturing precision
If asymmetric roll contours are used to suppress quarter waves, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The roll contour is segmented into multiple functional components: a first basis function, a second basis function, and additional functions that can be superimposed. This segmentation allows the complex asymmetric contour to be constructed from simpler, manageable mathematical functions, facilitating both manufacturing and adjustment.
Solution Approach 2:
The invention introduces adjustability through axially displaceable work rolls, allowing the asymmetric contour configuration to be dynamically adjusted during operation. This enables optimization of the offset crown for different rolling conditions while maintaining the quarter wave suppression capability.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a roller stand (1) that has a roller stand frame (3) in which working rollers (4, 5), or working rollers (4, 5) and support rollers (8, 9), or working rollers (4, 5), intermediate rollers (10, 11), and support rollers (8, 9) are mounted. The rollers (4, 5, 8, 9, 10, 11) can be rotated about a respective rotational axis (6, 7). In a roller stand (1) without intermediate rollers (10, 11), the working rollers (4, 5) can be moved relative to one another in the direction of the respective rotational axis (6, 7), i.e. axially. In a roller stand (1) with intermediate rollers (10, 11), the same applies to the working rollers (4, 5) or the intermediate rollers (10, 11). Each of the axially movable rollers (4, 5 or 10, 11) has an effective barrel length (L) and a curved contour (R1, R2) which extends over the entire effective barrel length (L). Each of the axially movable rollers (4, 5 or 10, 11) has a contour (R1, R2) made by superimposing a respective base function (B1, B2) with a respective additional function (Z1, Z2). The base functions (B1, B2) and the additional functions (Z1, Z2) are functions of the location (x) in the direction of the respective rotational axis (6, 7). The base functions (B1, B2) are determined so as to complement each other in a specified relative axial position in an unloaded state of the axially movable rollers (4, 5 or 10, 11) and form a convex or concave roller gap profile depending on a movement direction upon being moved from the axial position. The sum of the additional functions (Z1, Z2) is a symmetrical function, which is monotonous on both sides, with respect to the barrel center of the axially movable rollers (4, 5 or 10, 11) in the unmoved state.