Wire Rod Rolling Stands with Independent Motor Control
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Solution Overview
Problem
Conventional wire rod rolling systems face limitations in varying the reduction percentage of rolled products and controlling dimensional tolerances due to rigid speed ratios between rolling stands, requiring complex and costly mechanical transmissions with numerous motors, which leads to inefficiencies and increased downtime for diameter changes.
Innovation Solution
The wire rod rolling apparatus is designed with separate pass-line drives for oval and round section gauge rolling stands, allowing independent motor control for each rolling unit, enabling flexible adjustment of reduction ratios and precise draw control without mechanical shifts, using fewer and more efficient motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mechanical transmissions with fixed speed ratios are used to control rolling stands, then synchronous operation is achieved, but the system becomes rigid and cannot easily vary reduction percentages for different product diameters
Solution Approach 1:
The patent replaces the mechanical transmission system with fixed speed ratios and change-over gears with an electrical drive system featuring independently controllable motors for each rolling stand. This substitution eliminates the need for complex mechanical transmissions while enabling flexible variation of reduction percentages through electronic speed control, directly resolving the contradiction between adaptability and device complexity.
2Adaptability or versatility
If multiple motors with variable ratios are used to achieve flexible speed control, then adaptability improves, but the number of motors increases leading to excessive installed power and system complexity
Solution Approach 1:
The patent applies segmentation by dividing the rolling mill into multiple independently controlled zones, with each rolling stand equipped with its own motor. This segmentation enables flexible speed control for each stand to achieve variable reduction percentages while avoiding the need for a single complex multi-ratio transmission system, thus reducing the total number of motors and installed power compared to conventional approaches.
Solution Approach 2:
The patent implements dynamic speed control by equipping each rolling stand with an independently controllable motor that can adjust its speed ratio in real-time based on processing requirements. This dynamic control capability provides the needed flexibility for varying reduction percentages without requiring multiple fixed-ratio mechanical transmissions or excessive motors, resolving the contradiction between adaptability and quantity of components.
3Manufacturing precision
If fixed speed ratios are maintained between rolling stands, then mechanical transmission simplicity is preserved, but dimensional tolerances of rolling product deteriorate due to inability to control longitudinal tension
Solution Approach 1:
The patent replaces the fixed-ratio mechanical transmission system with independently controlled electrical drives for each rolling stand. This substitution enables precise control of longitudinal tension and speed ratios between stands through electronic control, significantly improving dimensional tolerances of the rolling product while avoiding the complexity of mechanical change-over gears and multiple transmission systems.
Solution Approach 2:
The patent implements feedback control by equipping each rolling stand with independent motor control that can respond to process conditions and adjust speed ratios accordingly. This feedback capability enables precise control of longitudinal tension to maintain dimensional tolerances, resolving the contradiction between manufacturing precision and device complexity by using simple independent motors with control systems rather than complex mechanical transmissions.
4Adaptability or versatility
If rolling rings with different diameters are used to produce various product diameters, then product versatility improves, but all rolling rings must be replaced for each diameter change causing production downtime
Solution Approach 1:
The patent applies parameter changes by controlling the speed ratios of independently driven rolling stands to achieve different product diameters instead of physically changing the rolling rings. By varying the speed parameters of the motors driving each stand, the system can produce various diameters with the same rolling rings, eliminating downtime for ring replacement and resolving the contradiction between versatility and time loss.
Data Source
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AI summary
A wire rod rolling plant constituted by three distinct, independent rolling units (10, 20, 30), wherein there are provided four rolling stands, arranged in oval-round- oval-round sequence, in the first two rolling units, and there are provided at least two rolling stands, in oval-round sequence, in the third rolling unit. One motor (12, 22) is provided in the first two rolling units (10, 20) for actuating the two round steps arranged in even positions and one motor (11, 21), independent from the first one, is provided for actuating the two oval steps arranged in odd positions. Two motors (31, 32), mutually independent, which actuate each rolling step respectively are provided in the third rolling unit.