Stretch Rolling Unit With Workpiece Rotation for Rolling Gripping Ends

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Solution Overview

Problem

Conventional stretch rolling methods and units face inefficiencies due to the inability to roll gripping ends, leading to poor material utilization and unstable process initiation, requiring high power input and excessive machine width.

Innovation Solution

A stretch rolling method and unit design that allows for rolling of gripping ends without reversing roll direction, utilizing a flywheel drive and eliminating direct high-power drives, with a gripping device capable of rotating the workpiece to access both ends, reducing machine width and enhancing material utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If conventional stretch rolling methods are used with one end of the workpiece not rolled, then the rolling process can be initiated, but material utilization is poor and there is a non-rolled gripping end

Engineering Contradiction:

Improvematerial utilizationVSAvoidmanipulator requirement

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

Instead of having one end of the workpiece remain unrolled as in conventional methods, the invention inverts the approach by enabling both ends to be rolled through workpiece rotation between passes, eliminating the non-rolled gripping end and improving material utilization

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention introduces dynamic rotation of the workpiece between rolling passes, transforming the static conventional process into a dynamic one where the workpiece orientation changes to enable rolling of both ends, thereby eliminating waste material

Inventive Principle:

Principle #15Dynamics

2Productivity

If direct drive is used for roll reversal between passes, then rolling can continue, but high power input is required

Engineering Contradiction:

Improvecontinuous rollingVSAvoidpower input

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

Instead of reversing the roll direction to continue rolling, the invention inverts the approach by rotating the workpiece 180 degrees between passes, allowing the rolls to maintain their rotation direction while still enabling continuous processing of both workpiece ends

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention introduces a rotation device as an intermediary mechanism between rolling passes, which rotates the workpiece without requiring the rolls to reverse direction, thereby eliminating the need for high-power direct drives for roll reversal

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If two manipulators are used for workpiece handling and longitudinal movement, then gripping ends can be managed, but machine width becomes very great

Engineering Contradiction:

Improveworkpiece handlingVSAvoidmachine width

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The invention makes the gripping device multi-functional by enabling it to grip different ends of the workpiece through rotation, eliminating the need for separate manipulators for each end, thereby reducing machine width while maintaining ease of operation

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention merges the functions of multiple manipulators into a single gripping device combined with a rotation mechanism, consolidating workpiece handling and orientation control into one integrated system that reduces the overall machine footprint

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If roll direction reversal is implemented between passes, then both ends can be accessed, but complex switchable gear mechanisms are required

Engineering Contradiction:

Improveboth ends accessibilityVSAvoidgear mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Instead of reversing roll direction through complex gear mechanisms, the invention inverts the approach by rotating the workpiece itself, allowing both ends to be accessed while maintaining simple, constant roll rotation direction

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention extracts the direction reversal function from the roll drive system and relocates it to a separate workpiece rotation device, eliminating the need for switchable gear mechanisms in the roll drive while still enabling both ends accessibility

Inventive Principle:

Principle #2Taking out (Extraction)

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 design increases material utilization, stabilizes the rolling process, reduces machine size and power requirements, and enables efficient production of finished parts like railroad axles with improved tolerances and surface quality, significantly reducing cycle time.

Implementation Method 1

a stretch rolling unit (10) comprising two stretching rolls (20) that can be driven in opposite directions, having at least two passes (21, 22) and at least one gripping device (30), wherein the stretching rolls (20) can be set into rotation by way of a flywheel (40)

Methodology Applied

Scientific EffectFlywheel: Flywheel

Data Source

PatentUS11498116B2Stretch rolling method and stretch rolling unit

Publication Date: 2022.11.15 SMS GROUP GMBH

AI summary

A stretch rolling method and a stretch rolling unit can roll out any gripping ends and uses the narrowest possible installation space. In the stretch rolling method, a workpiece is successively fed to at least two passes of a stretch rolling unit of a gripping device, wherein the workpiece is rotated by 180° about an axis of rotation lying perpendicular to the main direction of extent of the workpiece between the first pass of the two passes and the second pass of the two passes.