Staggered Roller Scale Breaker with Recoiler Tension

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Solution Overview

Problem

Existing methods for removing scale from sheet metal surfaces are inefficient in creating a serpentine path and applying sufficient tension to effectively break scale, limiting the processing of various sheet metal thicknesses and requiring frequent setup adjustments.

Innovation Solution

A descaling apparatus with a staggered arrangement of rollers creating a serpentine path and applying tensile force from a recoiler to break scale, allowing for a range of sheet thicknesses to be processed with minimal setup adjustments, using a combination of rollers and secondary surface finishing cells for thorough scale removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If existing methods are used to remove scale from sheet metal surfaces, then scale removal is achieved, but the methods are inefficient in creating a serpentine path and applying sufficient tension, requiring frequent setup adjustments

Engineering Contradiction:

Improvescale removal efficiencyVSAvoidsetup adjustment time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The roller system is segmented into multiple individually adjustable rollers arranged in a serpentine configuration. Each roller can be independently positioned to create the optimal wrap angle for scale breaking, allowing the system to handle various sheet thicknesses without complete reconfiguration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The roller positions are made dynamically adjustable through individual adjustment mechanisms on each roller. This allows the serpentine path geometry to be adapted for different sheet metal thicknesses while maintaining the tension and wrap angle necessary for effective scale removal, reducing setup time.

Inventive Principle:

Principle #15Dynamics

2Force

If existing methods apply tension to break scale, then some scale removal occurs, but insufficient tension is applied to effectively break scale across various thicknesses

Engineering Contradiction:

Improvetension force applied to sheet metalVSAvoidability to process various sheet thicknesses

Core Design Contradiction:

ForceVSAdaptability or versatility

Solution Approach 1:

Different rollers in the serpentine arrangement can be positioned to create locally optimized wrap angles and tension distribution. This allows the system to apply appropriate tension force for effective scale breaking while adapting to various sheet thicknesses through localized geometric adjustments.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system changes geometric parameters (roller positions, wrap angles, serpentine path configuration) to optimize the tension force applied to the sheet metal. By adjusting these parameters, the apparatus can effectively process various sheet thicknesses with appropriate tension force for scale removal.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If frequent setup adjustments are made to accommodate various sheet thicknesses, then adaptability is improved, but processing time and productivity are reduced

Engineering Contradiction:

Improveability to process various sheet thicknessesVSAvoidprocessing throughput

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The serpentine roller arrangement with individual adjustment capabilities serves multiple functions: it can process various sheet thicknesses, create optimal wrap angles for different materials, and maintain consistent tension force. This multi-functionality reduces the need for frequent setup changes while maintaining high productivity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The solution effectively breaks scale from sheet metal surfaces across various thicknesses with reduced setup time and frequency, ensuring thorough scale removal and improved surface texture.

Implementation Method 1

subjecting the processed sheet metal to tension from a recoiler

Methodology Applied

Scientific EffectTension: Tension

Implementation Method 2

passing the sheet metal through a plurality of rollers having a staggered arrangement generating a serpentine path of the sheet metal through the rollers and a wrap angle sufficient to break scale from the sheet metal

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS8707529B2Method and apparatus for breaking scale from sheet metal with recoiler tension and rollers adapted to generate scale breaking wrap angles

Publication Date: 2014.04.29 THE MATERIAL WORKS

AI summary

A metal processing apparatus comprises a scale breaker apparatus having a plurality of rollers positioned in a staggered arrangement and engaging first and second surfaces of sheet metal. The staggered arrangement creates clearances between the rollers of the first and second surface rollers sufficient to enable the sheet metal to conform to a portion of an outer periphery of at least one of the rollers while passing between the first and second surface rollers under a tensile force. The metal processing apparatus further comprises a recoiler adapted to coil the length of sheet metal. The recoiler subjects the sheet metal passing through the scale breaking apparatus to a tensile force sufficient to conform the sheet metal to a portion of the outer periphery of at least one of the rollers with a wrap angle sufficient to break scale from the sheet metal.