Rolling Stand Grooved Roll Calibration via Laser Feedback
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Solution Overview
Problem
In rolling stands used for manufacturing seamless pipes, it is challenging to accurately set and calibrate the pressing position of grooved rolls, particularly in 3-roll and 4-roll type mandrel mills, leading to thickness deviations due to dimensional tolerances and installation errors, which existing methods struggle to address effectively.
Innovation Solution
A rolling stand design featuring grooved rolls arranged at specific angles (120 degrees for 3-roll and 90 degrees for 4-roll configurations) with strategically placed straight portions on their flange surfaces allows for easy determination and calibration of the pressing position, enabling precise alignment and reducing thickness deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If grooved rolls are arranged in 3-roll or 4-roll type mandrel mills with high degree of freedom in relative position, then the rolling stand can handle complex rolling operations, but it becomes difficult to decide reference position and regulate pressing position of grooved rolls
Solution Approach 1:
A laser displacement meter is introduced as an intermediary measurement tool between the grooved rolls and the control system. The laser displacement meter measures the actual position of grooved rolls relative to the pass line center, providing precise feedback data that enables accurate pressing position regulation even in complex 3-roll and 4-roll configurations where traditional mechanical reference methods fail.
2Reliability
If dimensional tolerance and installation error of grooved rolls and tool holding are considered, then manufacturing reality is reflected, but pressing position cannot be set according to design value
Solution Approach 1:
The system implements feedback control by using the laser displacement meter to continuously measure the actual pressing position of grooved rolls. The measured position data is compared with the target pressing position, and the control system automatically adjusts the grooved roll position to compensate for dimensional tolerances and installation errors, ensuring the pressing position matches the design value despite manufacturing variations.
Solution Approach 2:
Traditional mechanical reference systems and manual measurement methods are replaced with an optical measurement system (laser displacement meter). This substitution provides non-contact, high-precision measurement that eliminates the accumulation of mechanical errors and enables accurate pressing position control even when accounting for manufacturing tolerances and installation variations.
3Ease of manufacture
If flange portions of opposing grooved rolls are brought into contact to decide reference position in 2-roll type mandrel mill, then pressing position can be regulated, but this method cannot be applied to 3-roll or 4-roll type mandrel mills
Solution Approach 1:
The laser displacement meter-based measurement system serves as a universal reference determination method that can be applied to 2-roll, 3-roll, and 4-roll type mandrel mills. Unlike the flange contact method which only works for 2-roll configurations, the optical measurement system provides a consistent, accurate reference position determination approach across all rolling stand configurations, enabling the same control strategy to be universally implemented.
Data Source
AI summary
A rolling stand 100 in accordance with the invention is a rolling stand provided with three grooved rolls for rolling a tubular or bar shaped material to be rolled, in which three grooved rolls R21 to R23 are arranged in such a manner that an angle formed by pressing directions of any two adjacent grooved rolls of the three grooved rolls R21 to R23 comes to 120 degrees. With regard to a cross sectional shape of each of the grooved rolls R21 to R23 formed by cutting each of the grooved rolls in a plane which includes a center line of a rotating axis of each of the grooved rolls R21 to R23 and is orthogonal to a pass line of a material to be rolled, any one grooved roll R21 is provided with a first straight portion L1 extending vertically to the pressing direction in both side flange portions, and the other two grooved rolls R22 and R23 are provided with a second straight portion L2 opposing to the first straight portion L1 and extending in parallel to the first straight portion L1 in the flange portions.