Torque Motor Pilger Roller Drive Eliminates Transmission Wear
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Solution Overview
Problem
Existing pilger rolling mills face challenges in achieving precise and controlled displacement of the roll stand due to high torque conversion demands, leading to energy losses, wear, and increased maintenance costs, especially when producing small diameter tubes.
Innovation Solution
The implementation of a pilger rolling mill with a torque motor that directly drives the flywheel, reducing the need for transmission components and minimizing frictional losses, allowing for precise and accurate positioning of the roll stand with reduced wear and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a transmission system is used to convert high torque to linear force in the roll stand, then the displacement control is improved, but energy losses and wear increase
Solution Approach 1:
The patent removes the transmission system (gears, belts, or other intermediate mechanical components) from between the torque motor and the flywheel. The torque motor is directly coupled to the flywheel, eliminating the transmission components that cause energy losses through friction and inefficiency. This direct coupling maintains displacement control precision while significantly reducing energy losses.
Solution Approach 2:
The patent merges the torque motor and flywheel into a directly coupled system where the motor shaft is rigidly connected to the flywheel without intermediate transmission elements. This merging eliminates the interface losses between separate components and creates a more efficient energy transmission path while maintaining the required precision through the direct mechanical connection.
2Measurement precision
If a transmission system is used to convert high torque to linear force in the roll stand, then the displacement control is improved, but wear and maintenance costs increase
Solution Approach 1:
The patent extracts and removes the transmission system components (gears, belts, bearings, lubrication systems) that are prone to wear and require maintenance. By directly coupling the torque motor to the flywheel, the system eliminates these intermediate components, thereby reducing wear and the associated maintenance requirements while preserving displacement control precision through the direct connection.
Solution Approach 2:
The direct coupling system requires less maintenance and intervention. The torque motor-flywheel direct connection eliminates the need for lubrication, adjustment, and replacement of transmission components, allowing the system to maintain its precision and reliability with minimal external service.
3Loss of energy
If a torque motor directly drives the flywheel, then energy losses and wear are reduced, but the complexity of direct high torque conversion increases
Solution Approach 1:
The patent removes the complex transmission system that would normally be required to handle high torque conversion. By directly coupling the torque motor to the flywheel, the system eliminates gears, belts, and other intermediate components, thereby reducing overall device complexity despite the high torque requirements. The torque motor is specifically selected to provide the necessary high torque directly at its output shaft.
4Force
If transmission components are used in the drive system, then torque conversion is achieved, but frictional losses increase
Solution Approach 1:
The patent merges the torque motor and flywheel into a directly coupled system, eliminating the transmission components that generate frictional losses. The direct mechanical connection allows torque to be transmitted from the motor shaft to the flywheel without the friction inherent in gears, belts, or other intermediate elements, while still achieving the required torque conversion through proper motor selection and direct coupling design.
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 solution enables precise displacement of the roll stand with high reproduction accuracy, reduces energy losses and wear, and decreases maintenance and spare part costs, enhancing the overall efficiency and reliability of the rolling process.
Implementation Method 1
a torque motor, in particular a hollow-shaft torque motor 9, which directly drives the flywheel 10 without the use of a transmission so that frictional losses are kept to a minimum
Implementation Method 2
the first end of the thrust rod 6 is fixed to the flywheel 10 in an eccentric relationship relative to the axis of rotation of the drive shaft 8, 8b so that a rotary movement of the flywheel 10 is converted into a translatory movement of the roll stand 1
Data Source
AI summary
A pilger rolling mill comprising a roll stand, a flywheel on a drive shaft which is mounted rotatably about an axis of rotation, and a thrust rod having a first end and a second end, wherein the first end of the thrust rod is fixed to the flywheel at a radial spacing from the axis of rotation and wherein the second end of the thrust rod is fixed to the roll stand so that in operation of the mill a rotary movement of the flywheel is converted into a translatory movement of the roll stand, comprising a drive motor having a motor shaft, wherein the motor shaft of the drive motor and the drive shaft are connected together in such a way that a rotary movement of the motor shaft leads to a rotary movement of the drive shaft and thus the drive motor drives the flywheel. To provide a pilger rolling mill whose drive for the roll stand exhibits no or only very little wear and which in addition permits a precise displacement of the roll stand with a high degree of repetition accuracy, according to the invention it is proposed that that the drive motor is a torque motor.