Rolling Machine Forming Roller Substitution Mechanism
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Solution Overview
Problem
Current rolling machines require lengthy and labor-intensive processes for substituting forming rollers, involving disassembly of multiple components, which increases production costs and downtime due to the need for specialized labor and the handling of heavy rollers.
Innovation Solution
A rolling machine design that allows for the substitution of forming rollers without disassembling any components, utilizing a support structure with hydraulic actuators and rotary transmission members that can move forming rollers between extended and retracted positions, enabling quick exchange of rollers through a telescopic mechanism and alignment with support keys, reducing the need for mechanical tie rods and specialized labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If forming rollers are substituted by disassembling multiple mechanical components, then the rollers can be exchanged, but the substitution process becomes lengthy and labor-intensive
Solution Approach 1:
The forming roller assembly is segmented into independent components: the roller itself, the support shaft, and the tie rod connection system. This allows the roller to be exchanged independently by simply detaching the tie rod, without requiring disassembly of the entire machine structure. The segmentation enables quick roller substitution while maintaining structural integrity.
Solution Approach 2:
The tie rod connection system is extracted as a separate, easily detachable component that links the support shaft to the roller. This extraction creates a simple coupling mechanism that can be quickly disconnected and reconnected, enabling rapid roller substitution without complex disassembly procedures.
2Adaptability or versatility
If forming rollers are substituted by disassembling multiple mechanical components, then the rollers can be exchanged, but specialized labor is required
Solution Approach 1:
The assembly is segmented into modular components with standardized interfaces. The tie rod connects to the support shaft through a simple, standardized connection that can be operated by ordinary personnel without specialized training, eliminating the need for expert technicians for routine roller changes.
Solution Approach 2:
The tie rod connection system is designed to be self-servicing, allowing operators to perform roller substitutions independently without requiring assistance from specialized labor. The simple connection mechanism enables operators to quickly detach and attach rollers following basic procedures.
3Adaptability or versatility
If forming rollers are substituted by disassembling multiple mechanical components, then the rollers can be exchanged, but production costs increase
Solution Approach 1:
The segmented design with standardized tie rod connections reduces manufacturing costs by allowing components to be produced independently using standard machining processes. The simplified assembly reduces labor costs during both manufacturing and operation, leading to lower overall production costs.
Solution Approach 2:
Extracting the tie rod connection as a separate, simple component reduces manufacturing complexity and cost. The detached connection system requires fewer precision-machined parts and less complex assembly procedures, directly lowering production expenses.
4Adaptability or versatility
If forming rollers are substituted by disassembling multiple mechanical components, then the rollers can be exchanged, but machine downtime increases
Solution Approach 1:
The segmented roller assembly with independent tie rod connections enables rapid roller changes without shutting down the entire machine. Operators can quickly detach the tie rod and replace the roller while the machine remains operational, minimizing downtime and maintaining high productivity.
Solution Approach 2:
The extracted tie rod connection system allows for quick roller detachment and replacement. This simple coupling mechanism can be rapidly disconnected and reconnected, enabling roller substitutions to be performed in minimal time and preventing production interruptions.
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
This solution significantly reduces the time and labor required for roller substitution, decreases production costs, and enhances operational efficiency by allowing roller changes without machine disassembly, thus minimizing downtime and increasing output.
Implementation Method 1
a rolling machine design that allows for the substitution of forming rollers without disassembling any components, utilizing a support structure with hydraulic actuators and rotary transmission members that can move forming rollers between extended and retracted positions
Data Source
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AI summary
Rolling machine (1) for making impressions on cylindrical bodies, which comprises a support structure (2) mechanically connected to two or more forming rollers (6), each fit on a respective rotary transmission member (21) and provided with a shaped profile susceptible of rotating on a cylindrical body to be formed, placeable along a central work axis (A) of the machine (1). The machine (1) also comprises two or more hydraulic actuators (15), each of which mechanically associated with the support structure (2) and rotatably supporting a corresponding rotary transmission member (21) in order to move the forming roller (6) along a respective first transverse axis (R) perpendicular to the central work axis (A), and comprises two or more motors (16), each of which mechanically connected to a corresponding rotary transmission member (21) in order to actuate the corresponding forming roller (6) in rotation around the rotation axis (Z) thereof. In particular, such rolling machine (1) comprises two or more actuator means (22), each mechanically associated with a corresponding rotary transmission member (21) in order to move the latter between a forward position, in which it is fit with the relative forming roller (6), supporting it on the corresponding hydraulic actuator (15), and a retracted position, in which it is removed and free from said relative forming roller (6). In addition, each rotary transmission member (21) is telescopically extensible in order to compensate for the movement between the forward and retracted positions.