Three-Roll Rolling Stand With Eccentric Bushings for Better Roundness
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Solution Overview
Problem
Existing rolling stands for metal tubes, bars, or wires often produce material with insufficient roundness due to the star-shaped arrangement of rolls, and their positioning and adjustment mechanisms are not flexible enough for modular use within a rolling block, hindering efficient production and maintenance.
Innovation Solution
A rolling stand with a hexagonal housing and three rolls arranged in a star shape, allowing for adjustable radial distance via eccentric bushings, enabling flexible positioning and modular use with both manual and remote adjustment options, and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If three rolls are arranged in a star shape in a rolling stand, then the device complexity is reduced, but the roundness of the rolled material becomes insufficient
Solution Approach 1:
The rolling process is segmented into multiple passes through multiple rolling stands, where each stand performs a portion of the rounding operation. The first rolling stand with three rolls creates a triangular cross-section, and subsequent rolling stands with different arrangements (Y-arrangement and anti-Y-arrangement) progressively round the material by contacting different portions of the cross-section.
Solution Approach 2:
The rolling stands are arranged in a periodic sequence with alternating Y-arrangement and anti-Y-arrangement configurations. This periodic alternation allows different portions of the material cross-section to be contacted in successive passes, progressively improving roundness while maintaining the simplicity of each individual stand.
2Manufacturing precision
If rolling stands are arranged sequentially to improve roundness, then the roundness of rolled material is enhanced, but the number of rolling stands increases
Solution Approach 1:
Each rolling stand is designed with universal characteristics that allow it to perform multiple functions depending on its position in the sequence. The stands can be configured in different arrangements (Y or anti-Y) and can handle materials of different sizes, reducing the need for specialized equipment for each rounding pass.
Solution Approach 2:
The rolling stands incorporate adjustable components such as eccentric bushings that allow dynamic adjustment of roll positions and radial distances during operation. This dynamic adjustability enables each stand to adapt to different material sizes and rounding requirements, reducing the total number of stands needed.
3Ease of repair
If rolling stands are made modular for easy replacement, then the ease of repair is improved, but the positioning flexibility within the rolling block is reduced
Solution Approach 1:
The rolling stands are designed as modular units with standardized interfaces and universal mounting features that allow them to be easily replaced while maintaining positioning flexibility. Each stand contains all necessary components (rolls, bearings, adjustment mechanisms) as integrated modules that can be quickly swapped without affecting the overall system configuration.
Solution Approach 2:
The stand housing is designed with symmetric bearing surfaces and mounting features that create equipotential conditions for installation in different orientations and positions within the rolling block. This allows modular stands to be easily replaced while maintaining the same positioning flexibility as the original configuration.
4Adaptability or versatility
If the radial distance of rolls is adjustable via eccentric bushings, then the adaptability for different die sizes is improved, but the device complexity increases
Solution Approach 1:
The eccentric bushing adjustment mechanism is designed to be self-contained and self-explanatory, requiring minimal external equipment or complex procedures for operation. The mechanical eccentric design naturally provides the adjustment function through simple rotation, making the system self-sufficient for size changes without requiring additional motors, sensors, or control systems.
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
Enhances the roundness of the rolled material and reduces the number of required rolling stands by allowing universal use within a rolling block, improving production efficiency and facilitating easy maintenance.
Implementation Method 1
the three roller shafts are mounted in bearing bores of the stand housing by means of eccentric bushings in such a way that a radial distance of the rollers to the rolling axis is adjustable
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2A~2B
AI summary
The present application relates to a rolling stand (1) for rolling metallic bars, wires or tubes along a rolling axis (19), comprising a stand housing (10) whose outer surface, viewed along the rolling axis, has at least six side surfaces (14.1-14.6) of equal length arranged rotationally symmetrically around the rolling axis, wherein two side surfaces (14.1, 14.4, 14.2, 14.5, 14.3, 14.6) form a pair of side surfaces (14.1-14.6) lying parallel to each other, and three rolls (20.1-20.3) mounted on a roll shaft, surrounding the rolling axis (19) in a star shape, which together form a caliber (21). The three roller shafts are mounted in bearing bores of the frame housing (10) by means of eccentric bushings so that a radial distance of the rollers (20.1-20.3) to the roller axis (19) is adjustable.