Three-Roller Tube Rolling Mill Without Intermediate Furnace
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Solution Overview
Problem
Existing rolling systems for tubular bodies are hindered by the need for intermediate heating furnaces, which complicate management, lead to decarburization and oxidation issues, and increase production costs due to complex configurations and large dimensions.
Innovation Solution
A rolling mill system that integrates mandrel rolling and calibration rolling into a single line without an intermediate furnace, using a second section of rolling stands with 120° rotation axes and at least one motorized vertical axis roller, simplifying the process and reducing system length by approximately 70 meters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heating furnace is used between rolling lines, then the tubular bodies can be heated to required temperature, but the system dimensions increase and management complexity increases
Solution Approach 1:
The patent combines the heating function with the rolling process by using the heat generated during deformation itself, eliminating the need for a separate heating furnace. The rolling process serves dual purposes: shaping the tubular bodies and providing the necessary thermal energy through mechanical work conversion.
Solution Approach 2:
The heating furnace, which causes space occupation and management issues, is completely removed from the system. The heating function is extracted from a separate thermal processing step and integrated into the mechanical rolling process through energy conversion.
2Temperature
If a heating furnace is used between rolling lines, then the tubular bodies can be heated to required temperature, but the management complexity increases due to tube accumulations and decarburization
Solution Approach 1:
Heating and rolling operations are merged into a single continuous process. The tubular bodies are heated in-line during transfer between rolling stands, eliminating the need for separate heating furnace operations and associated management of tube accumulations and quality control.
Solution Approach 2:
The heating process occurs continuously during the rolling operation itself, maintaining continuous production flow without interruptions for furnace loading/unloading or tube accumulation management. The thermal processing is integrated into the mechanical working sequence.
3Manufacturing precision
If traditional three-rollers stands are used, then calibration rolling can be performed, but the stand replacement operation becomes complex
Solution Approach 1:
The rolling stand is divided into modular components that can be independently replaced. The rollers are designed as separate, interchangeable units mounted on a common support structure, allowing individual roller replacement without affecting the entire stand assembly or requiring complex disassembly procedures.
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 reduces production costs, minimizes temperature loss, and simplifies the handling and management of tubular bodies, while improving the quality of the final product by reducing thickness tolerances and eliminating intermediate accumulations and scale formation.
Implementation Method 1
three motorized-rollers rolling stands, each rotating about a rotation axis which is inclined by 120° with respect to the axes of the other rollers
Implementation Method 2
a first section for rolling on mandrel defined by a first plurality of rolling stands arranged in sequence along a rolling axis
Data Source
AI summary
The present invention relates to a multi-stand rolling mill for tubular bodies. The rolling mill comprises a first section for rolling on mandrel defined by a first plurality of rolling stands arranged in sequence along a rolling axis. According to the invention, the rolling mill also comprises a second rolling section without mandrel, arranged downstream of said first section, which comprises a second plurality of stands arranged in sequence along said rolling axis. Each stand of said second section comprises three rollers having rotation axes which are arranged at 120° from one another. The rotation axes for each stand are rotated by 180° with respect to corresponding rotation axes of an adjacent stand. According to the invention, at least one stand of said second section comprises a motorized roller having a vertical rotation axis.