Wire Rod Rolling Roller Gap Control With Scraper Cleaning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In wire rod rolling processes, existing technologies face challenges in precisely adjusting the gap between rollers due to wear and the need for new dimensions, leading to issues with spark by-products adhering to the inner surfaces of forming grooves, which can result in reduced wire rod quality.
Innovation Solution
A gap adjustment device with a scraper and anti-loosening mechanism, utilizing a worm shaft and worm wheel system, along with a sensor-controlled motor to adjust the vertical height of rollers, and an oil-impregnated journal bearing to minimize friction, allowing for precise gap adjustment and removal of spark by-products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the gap between rollers is adjusted manually in conventional wire rod rolling processes, then the structure remains simple, but the adjustment precision is insufficient and cannot meet the requirements for new wire rod dimensions
Solution Approach 1:
The patent replaces the conventional manual mechanical adjustment system with an automated system comprising a laser transmitter, receiver, processor, and motor-driven adjusting mechanism. The laser-based measurement system substitutes manual gauging, while the motorized worm shaft adjustment mechanism replaces manual wheel adjustment, achieving precise gap control for different wire rod dimensions.
Solution Approach 2:
The system enables self-adjustment through automated feedback control. The laser transmitter and receiver continuously measure the gap distance, the processor compares it with the target value, and the motor automatically adjusts the roller position to maintain the desired gap, eliminating the need for continuous manual intervention.
2Measurement precision
If a conventional adjustment mechanism is used, then the device structure is simple, but the roller position cannot be precisely controlled when rollers are worn or new dimensions are required
Solution Approach 1:
The patent employs a laser measurement system to replace conventional mechanical gauges or visual estimation methods. The laser transmitter projects a beam that reflects off the roller surface to the receiver, providing precise non-contact measurement of the gap distance, enabling accurate detection of roller position even when rollers are worn.
Solution Approach 2:
The system implements closed-loop feedback control where the laser measurement continuously monitors the actual gap position, the processor compares this with the target position, and automatically commands the motor to correct any deviation, ensuring the roller gap maintains the required precision throughout operation.
3Productivity
If manual adjustment methods are employed, then the operation process is simple, but the time required for gap adjustment and scraper operation is excessive
Solution Approach 1:
The system performs self-adjustment automatically without requiring operator intervention for gap measurement and correction. The laser measurement, processing, and motor adjustment occur autonomously, significantly reducing the time needed to adjust roller gaps when wear or dimension changes occur.
Solution Approach 2:
The laser measurement system operates continuously to monitor the gap position, and the motor adjustment mechanism can make continuous fine adjustments as needed, rather than requiring periodic manual intervention. This maintains optimal rolling conditions continuously, improving productivity.
4Force
If conventional bearings are used, then the device structure is simple, but friction between the drive shaft and bearing housing is high
Solution Approach 1:
The patent employs a porous journal bearing where the bearing material contains controlled porosity that allows lubricant to be drawn into and retained within the bearing structure. This porous structure increases the lubricant reservoir capacity and ensures continuous lubrication of the drive shaft journal, significantly reducing friction compared to conventional solid bearings.
Solution Approach 2:
The bearing structure is designed with differentiated properties - the porous regions provide lubricant reservoirs while the outer shell maintains structural integrity. This local quality variation optimizes both lubrication performance and mechanical strength, reducing friction without compromising bearing capacity.
5Object-generated harmful factors
If a basic roller structure is used, then the manufacturing cost is low, but spark by-products cannot be removed from the forming groove inner surface
Solution Approach 1:
The patent extracts the spark removal function from the basic roller structure by adding a separate scraper assembly. The scraper, positioned adjacent to the roller forming groove, mechanically removes spark by-products that accumulate on the groove inner surface, preventing defects in the rolled wire rod while maintaining the simplicity of the core rolling function.
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
Enables precise adjustment of the gap between rollers, effectively removing spark by-products and improving wire rod quality by minimizing friction and preventing loosening phenomena, thus ensuring consistent wire rod production.
Implementation Method 1
a journal bearing inserted into the upper bearing housing and the lower bearing housing and in surface contact with the upper drive shaft and the lower drive shaft to minimize friction
Implementation Method 2
a sensor transmitter is disposed on the bottom surface of the upper bearing housing, a sensor receiver is disposed on the upper surface of the lower bearing housing, the sensor receiver is configured to receive a laser beam transmitted from the sensor transmitter to detect a distance between the rollers
Implementation Method 3
a worm shaft screw-coupled to inner surfaces of the through-holes formed through the upper body and the lower body, and a worm wheel engaged with an outer surface of the worn shaft
Implementation Method 4
an oil-impregnated journal bearing to minimize friction
Data Source
AI summary
A wire rod rolling roller is disclosed. In one aspect, the wire rod rolling roller includes upper and lower rollers spaced apart from each other and configured to roll a wire rod passing therebetween and upper and lower drive shafts fixedly extending through the centers of the upper and lower rollers, respectively, and configured to rotate the upper and lower rollers. The wire rod rolling roller also includes upper and lower bearing housings respectively disposed on one side of the upper drive shaft and one side of the lower drive shaft, and configured to support the upper and lower drive shafts. The wire rod rolling roller further includes a journal bearing inserted into the upper and lower bearing housings and in surface contact with the upper and lower drive shafts to minimize fiction and a gap adjustment device configured to adjust a gap between the upper and lower rollers.