Rolling Stand for Slotted Pipe Forming
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Solution Overview
Problem
Existing systems for continuous forming of longitudinally slotted tubes often result in markings and instabilities due to uneven distribution of rolling forces, which are exacerbated by vibrations and large roller diameters.
Innovation Solution
A system with roll stands arranged one behind the other, featuring a roll carrier with three or more rollers that are freely mounted and adjustable relative to each other, allowing for even distribution of rolling forces and minimizing the risk of vibrations and markings by averaging the forces into the roll stand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If large roller diameters are used in conventional rolling stands, then the rolling force is concentrated on fewer contact points, but this causes vibrations and markings on the product surface
Solution Approach 1:
The rolling process is segmented into multiple sequential rolling stands, each with one or more rollers. By dividing the total rolling force into multiple contact points along the material flow path, the system distributes the mechanical stress more evenly, reducing both vibrations and surface markings on the formed tube.
Solution Approach 2:
Each rolling stand is equipped with independently adjustable rollers that can be positioned to apply rolling force at specific locations. This allows optimization of the rolling force distribution across different sections of the tube, preventing concentration of force that causes markings while maintaining stability.
2Stability of the object's composition
If rollers are fixed in position on the rolling stand, then the structure is simple and stable, but this prevents even distribution of rolling forces and causes instabilities
Solution Approach 1:
The rollers are mounted on movable supports that allow them to adjust their position dynamically during operation. This dynamic capability enables the rollers to self-align and distribute rolling forces evenly across the material, improving stability without requiring complex active control systems.
Solution Approach 2:
The roller support structure is designed to automatically adjust and balance the rolling forces through its mechanical design. The system self-regulates the force distribution without requiring external intervention or complex control mechanisms, achieving stable rolling while maintaining structural simplicity.
3Device complexity
If only one or two rollers are arranged in sequence per rolling stand, then the device complexity is reduced, but this prevents adequate distribution of rolling forces and amplifies material irregularities
Solution Approach 1:
The rolling stand is segmented into multiple roller units arranged in sequence along the material flow path. Each roller contributes to the progressive forming of the tube, distributing the rolling force over multiple contact points and preventing the amplification of surface irregularities that occurs with fewer rollers.
Solution Approach 2:
Multiple rollers are combined within a single rolling stand structure, allowing them to work together in parallel to distribute the rolling force. This merging of multiple rolling elements into one integrated unit achieves better surface precision while avoiding the need for multiple separate stands.
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 configuration significantly reduces the risk of vibrations and instabilities, allowing for smoother material processing and the avoidance of markings by distributing the rolling forces evenly across the material, enabling the use of smaller rollers without compromising the cross-sectional area.
Implementation Method 1
The local contact pressure of the rolls supported by the roll support, or of the rolls successively acting on the flat material, can be distributed as evenly as possible across the flat material
Data Source
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AI summary
The invention relates to a method and an installation for continuously moulding longitudinally slotted pipes from a flat material, in which markings in the material can be minimised or avoided if the rolling forces of at least two rolls acting successively on the flat material are introduced centered into the roll stand and/or the two successively acting rolls are able to align freely relative to one another.