Wire Rolling Train Fixed Roll Gap Ratio
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Solution Overview
Problem
The existing wire rolling processes require complex and costly adjustments in the sizing block to achieve the final wire diameter, involving manual or electrical synchronization of roll gaps, which complicates the design and increases costs without ensuring wire quality.
Innovation Solution
The method involves maintaining a fixed ratio of roll gaps in the sizing block and adjusting the roll gaps in the rolling train and wire rod block to pre-roll the wire to a predetermined diameter before the sizing block, allowing for simplified design and omission of expensive gearboxes and synchronization systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual or electrical adjustment of roll gaps in the sizing block is used to achieve final wire diameter, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The wire is pre-rolled in the rolling train and wire rod block to a predetermined diameter before entering the sizing block. This preliminary action ensures that the wire reaches the sizing block with the correct dimensions, eliminating the need for complex adjustments in the sizing block while maintaining manufacturing precision
Solution Approach 2:
The adjustment function is extracted from the sizing block and transferred to the rolling train and wire rod block. By performing the diameter adjustment earlier in the process, the sizing block can use fixed roll gaps without complex adjustment mechanisms, reducing device complexity while preserving precision
2Manufacturing precision
If electrical synchronization between rolling stands is implemented, then manufacturing precision is improved, but use of energy and cost increase
Solution Approach 1:
Instead of implementing expensive and energy-consuming electrical synchronization systems, the patent uses simple mechanical roll gap settings with fixed ratios. This approach achieves the required precision without complex electrical systems, reducing both cost and energy consumption
3Adaptability or versatility
If multiple adjustment mechanisms are provided in the sizing block, then adaptability is improved, but device complexity increases
Solution Approach 1:
The rolling train and wire rod block perform multiple functions: they both pre-roll the wire and control the reduction ratio. By making these upstream blocks multi-functional, the sizing block can be simplified to a single fixed-ratio stage, reducing overall device complexity while maintaining adaptability through the upstream blocks
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 approach simplifies the sizing mill structure, enabling the use of standard blocks and reducing costs while maintaining wire quality by ensuring precise pre-rolling and calibration in the sizing block.
Implementation Method 1
The rolls are adjusted radially to a defined extent, which determines the degree of deformation in the respective roll stand
Implementation Method 2
the wire is fed in a frictional manner onto the rolls
Data Source
AI summary
Process for rolling wire (1) on a roll mill (2) which has at least one roll chain (3), at least one wire rolling block (4) connected to the roll chain, and at least one measuring roll block (5) connectd to wire rolling block (4). Blocks (4) and (5) each have at least 2- roll stands (6,7,8). The 3 roll stands in block (5) maintain a fixed ratio of the roll gaps relative to each other. The roll gap in roll stands (6,7) of roll chain (3) is so selected that the wire has a predetermined diameter upstream of block (5).