Three-Roller Device for Seamless Pipe Wall Thickness Accuracy
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Solution Overview
Problem
Conventional seamless steel pipe manufacturing processes involve complex equipment layouts and multiple steps, leading to error accumulation and reduced accuracy in wall thickness, which affects the production of high-accuracy seamless steel pipes.
Innovation Solution
A three-roller device with unequal diameters, rotatable around their axes, and guide plates, combined with a plug for one-step wall reduction and uniformation, promoting forward movement and limiting the billet within a forming space to improve accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hot rolled seamless steel pipe mill machine is used with multiple forming processes, then the production process can be completed, but the equipment layout becomes complex and errors accumulate making final product unable to meet specification requirements
Solution Approach 1:
The patent combines multiple forming processes (wall reduction and extension) into a single integrated device with three rollers. The first roller performs wall reduction while the second and third rollers perform extension simultaneously, eliminating the need for separate equipment and reducing error accumulation from multiple forming steps.
Solution Approach 2:
The device segments the forming process into distinct functional zones within a single integrated structure. The three rollers are positioned at different locations along the billet to perform different functions (wall reduction at the first roller, extension at the second and third rollers), allowing complex forming to be achieved through coordinated simple actions.
2Manufacturing precision
If seamless steel pipe continuous rolling mill works in continuous assembly line, then production efficiency is maintained, but equipment fatigue and wear occur making wall thickness accuracy hardly improved
Solution Approach 1:
The device enables continuous production by performing wall reduction and extension simultaneously in one passing through three rollers. The billet continues moving forward without interruption while all forming operations are completed in a single continuous action, maintaining productivity while improving precision.
Solution Approach 2:
The device performs preliminary wall reduction at the first roller before the billet enters the extension zone at the second and third rollers. This preliminary action prepares the billet for subsequent extension, ensuring accurate wall thickness control before the final forming stage.
3Manufacturing precision
If multiple forming processes are used to manufacture seamless pipes, then the production can be completed, but the production line becomes long and errors accumulate in each step
Solution Approach 1:
The patent merges wall reduction and extension processes into a single compact device. The three rollers are arranged in close proximity, with the first roller for wall reduction and the second and third rollers for extension, all operating simultaneously on the billet in one location rather than requiring a long production line with separate equipment.
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 device enhances the accuracy and production efficiency of seamless pipes by reducing error accumulation and improving the rolling process, allowing for high-accuracy wall reduction and uniformation in a single step.
Implementation Method 1
The three rollers are rotatable around their own axis... driving the billet to move forward spirally along the rolling line
Implementation Method 2
wall reduction and uniformation... the billet is rolled through the wall reduction and uniform process under the joint action of the three rollers and the plug
Data Source
AI summary
A device for high-accuracy wall reduction and uniformation includes: three rollers, three guide plates, and a plug. The three rollers are circumferentially evenly distributed along a rolling line which is a straight line of the moving direction of a billet being rolled. The three rollers are of unequal diameter rotating structure and each roller has a small end and a big end; three small ends of the three rollers are located at a first end of the device, and three big ends of the three rollers are located at a second end; and the three rollers are rotatable around their own axis. Each guide plate is disposed between every two adjacent rollers. The three guide plates rotatably abut against the three rollers, and are circumferentially evenly distributed along the rolling line. The plug is disposed in a forming space formed by the three rollers and three guide plates.