Shim Pack Handling for Faster Rolling Mill Roll Changeovers
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Solution Overview
Problem
The changeover of backup rolls in a rolling mill stand is time-consuming due to the need for individual handling and transportation of shims, which are prone to adhesion and require multiple crane movements, posing safety risks.
Innovation Solution
Assembling shims into packs at a remote location, using a carrier element with centering and securing means, and transporting them as a unit to reduce crane trips and adhesion, facilitated by a device with screws and a base plate design to overcome adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If individual shims are transported and installed separately, then each shim can be precisely positioned, but the changeover time increases significantly and crane movements multiply
Solution Approach 1:
Multiple individual shims are merged into a single shim pack assembly that is transported and installed as one unit. This combining approach maintains the precision positioning capability while dramatically reducing the number of separate crane movements and installation steps required, directly addressing the time loss issue.
Solution Approach 2:
The shims are pre-assembled into packs with positioning features and fastening mechanisms before transportation. This preliminary preparation ensures that when the shim pack arrives at the installation location, it can be quickly positioned and secured without requiring separate positioning operations for each individual shim, thereby reducing changeover time while maintaining precision.
2Measurement precision
If multiple individual shims are handled separately, then each shim can be independently positioned, but the complexity of logistics and crane operations increases
Solution Approach 1:
The logistics system is simplified by merging multiple separate shim handling operations into a single shim pack transportation and installation operation. This reduces the complexity of logistics coordination and crane scheduling while maintaining the ability to precisely position each shim within the pack through pre-installed positioning features.
Solution Approach 2:
The shim pack design incorporates universal positioning features and fastening mechanisms that work across different installation locations and configurations. This multi-functionality allows the same pack structure to be used for various shim arrangements, simplifying the logistics system and reducing the need for location-specific customization.
3Ease of manufacture
If shims are stacked individually, then they can be stored separately, but adhesion forces cause difficulty in disassembly and create safety risks
Solution Approach 1:
Multiple shims are merged into a single integrated pack structure with interlocking features and fastening mechanisms. This merging eliminates the adhesion problems between separate stacked shims while maintaining storage flexibility. The unified structure ensures safe handling and disassembly as a single unit, removing the safety risks associated with individual shim handling.
Solution Approach 2:
The shim pack introduces an intermediary structure between individual shims, using fastening elements and positioning features to hold shims together in a controlled manner. This intermediary structure prevents direct adhesion between shim surfaces while maintaining easy storage and retrieval capabilities, and ensures safe disassembly through controlled release mechanisms.
4Measurement precision
If individual shims are transported by crane, then each shim can be delivered to the correct location, but the number of crane movements increases up to 30 trips
Solution Approach 1:
Multiple individual shim deliveries are merged into a single crane operation that transports an entire shim pack at once. This combining approach maintains accurate delivery to the correct location through pre-configured pack positioning features while dramatically improving productivity by reducing crane trips from up to 30 to just one or a few operations.
Solution Approach 2:
The shims are pre-assembled into packs with identification and positioning features before transportation. This preliminary preparation ensures that when the shim pack is delivered by crane, it can be accurately positioned and quickly identified at the destination, maintaining delivery accuracy while eliminating the need for multiple separate crane trips.
Data Source
AI summary
A method relates to providing shims for backup and/or work rolls of a rolling mill stand. The shims are required when changing over rolls. The method comprises the steps of: a) assembling at least one shim, preferably at least two or three shims, into an shim pack at a first location remote from the rolling mill stand; b) transferring the shim pack into a carrier element at the first location; c) transporting the carrier element together with the shim pack from the first location to the location near the rolling mill stand; d) removing the shim pack from the carrier element at the location near the rolling mill stand; e) using the shims when changing over rolls.