Cold Rolling Mill Conversion Using Existing Foundations
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Solution Overview
Problem
Existing cold rolling mills face challenges in upgrading their capacity efficiently, particularly from single stand to twin stand or twin stand to tandem mills, due to high shutdown times and increased costs, with current solutions requiring significant civil works and downtime.
Innovation Solution
A flexible conversion method for cold rolling mills that allows upgrading from a single stand to multiple stands by utilizing existing foundations, adding additional stands during production with minimal downtime, and integrating new auxiliary equipment to achieve higher production capacity without reversing the rolling operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional conversion methods are used to upgrade from single stand to twin stand or twin stand to tandem mill, then production capacity is increased, but shutdown time increases to approximately two months
Solution Approach 1:
The patent applies preliminary action by preparing the mill for future expansion in advance. Civil works foundations are designed and constructed to accommodate additional stands before they are actually installed. This allows the conversion process to proceed much faster when expansion is needed, reducing shutdown time from two months to significantly less time, while still achieving the desired increase in production capacity.
2Productivity
If conventional conversion methods are used to upgrade mill capacity, then production capacity is increased, but conversion costs increase
Solution Approach 1:
The patent applies universality by designing civil works foundations that serve multiple functions and future needs. The foundations are constructed to accommodate not only the current stands but also future additional stands and auxiliary equipment. This multi-functional design allows the same infrastructure to support different production capacities over time, reducing the need for additional civil works during conversion and thereby lowering overall conversion costs.
3Productivity
If conventional conversion methods are used with significant civil works, then mill capacity is upgraded, but the complexity of the conversion process increases
Solution Approach 1:
The patent applies segmentation by dividing the conversion process into distinct phases: civil works preparation, stand installation, and auxiliary equipment integration. The civil works are designed as separate, modular foundations that can be constructed independently of the rolling stands themselves. This segmentation allows each component to be prepared and installed separately, reducing the overall complexity of the conversion process while achieving the desired capacity upgrade.
Data Source
AI summary
A flexible conversion method of a reversible rolling mill having at least one rolling stand erected on first civil works foundations and a first production capacity, into an upgraded rolling mill having more than one rolling stand and a second production capacity, the second production capacity being higher than the first production capacity, the reversible rolling mill including: an uncoiling device or pay-off reel and a first recoiling device or entry tension reel on a first side or entry side of the stand; a second recoiling device or delivery tension reel on a second side or delivery side of the stand; standard auxiliary and operation equipment necessary for normal operation and control of the reversible rolling mill, the standard auxiliary and operation equipment necessary for normal operation and control of the reversible rolling mill including mainly or at least a roll coolant tank, pumps, filters, heat exchangers and piping.