Patent Application
20180117652
This disclosure relates generally to metal sheet or plate leveler polishers, and more specifically relates to apparatuses and methods for polishing the work rolls of a leveler.
Levelers, such as hot levelers, are commonly used in metal sheet and plate mills, namely hot rolling mills for producing metal sheets or plates.
Conventionally, a leveler is polished by bracing the leveler in an open position, in which top portion 42 of the leveler is raised (e.g., with a roll nest support car). An operator would physically crawl into the open leveler and use a hand grinder power tool to grind-polish the work rolls. This process is potentially dangerous and inefficient, as operators could possibly be injured while polishing the work rolls. Likewise, the extent to which the work rolls are consistently and qualitatively cleaned varies from operator to operator, or upon the mechanical condition of the grinding equipment, as well as whether or not a region on the work rolls is completely accessible to the operator attempting to polish the work rolls. Uniformity in the polishing operation can vary not only relative to the accessibility of the work roll region, it can vary as a function of the amount of time and pressure invested by the operator. The lack of uniformity can affect the resulting condition of the work rolls, and, in turn, the quality of the leveled metal sheet or plate.
More automated approaches have been utilized. One such technique, disclosed in Chinese Pat. No. CN205183384 calls for the use of a concave-shaped steel-bristle brush for cleaning a work roll.
Alternatively, Japanese Pat. No. JP200605193 discloses the use of a cleaning member that includes an inflatable air bladder that reciprocates along the length of a work roll, while the work rolls are rotated, to clean them.
The present invention has as its objectives, the goal of efficiently, effectively and safely cleaning the work rolls to ensure the quality of the metal sheets or plates being processed by the leveler itself.
These and other objectives and advantages will become apparent in view of the following disclosure, including the drawings and claims.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
One aspect of the present invention is directed to an apparatus for polishing the work rolls of a metal sheet or plate leveler where each work roll has a work roll circumference, as well as a work roll length, determined along its longitudinal axis. The leveler includes a frame, a series of upper work rolls and a series of lower work rolls. In one embodiment, the polishing apparatus includes upper and lower polishing platforms, one platform containing the polishers for polishing the upper work rolls and the other lower platform containing the polishers for polishing the lower work rolls of the leveler. The upper work rolls of the leveler are arranged in a first series and the lower work rolls of the leveler are arranged as a second series. In another embodiment, as described hereinbelow, the polishing apparatus utilizes a single platform with polishers that are fixed in position, as integrated onto each side of the platform.
The polishing unit comprises at least one polisher configured for engaging and polishing at least one of the work rolls from the series of upper and lower work rolls in the leveler, when that respective work roll is rotated. In that embodiment, the polisher is configured to engage and polish at least the substantial entire length of that one or more work roll of the leveler, as the work roll is rotated. Further, the at least one polisher comprises a substantially rigid concave pan having an abrasive material positioned therewithin for exposure of the abrasive material to the respective work roll, upon engagement of the polisher with the work roll and further, upon rotation of the work roll within the substantially rigid concave pan.
In some embodiments of the invention the at least one polishing unit comprises at least two polishers, a first polisher configured to engage at least one work roll in the upper series of work rolls, and a second polisher configured for engaging at least one work roll in the lower series of work rolls. In these embodiments, the first and second polishers are configured to polish the respective upper and lower work rolls simultaneously as the respective work rolls rotate simultaneously, while in engagement with the abrasive material within each of the first and second polishers.
In some preferred embodiments of the invention, the at least one polishing unit comprises a first series of upper polishers corresponding in number to the number of work rolls in the series of upper work rolls, together with a second series of lower polishers corresponding in number to the number of work rolls in the series of lower work rolls. In these embodiments, the first series of polishers are configured to simultaneously engage and/or polish each of the work rolls in the series of upper work rolls respectively, while the second series of polishers are configured to simultaneously engage each of the work rolls in the series of lower work rolls respectively. In these embodiments further, all of the first and second series of polishers are operably configured to polish the respective series of upper and lower work rolls as all of the work rolls simultaneously rotate, while engaged with the respective ones of the first and second series of polishers.
In some versions of the invention, all of the series of upper polishers are operably positioned on the upper platform, and all of the series of lower polishers are operably positioned on the lower platform, with the polishers on the upper platform being exposed for polishing the lower circumferential surfaces of the series of upper work rolls and the polishers in the lower platform being exposed for polishing the upper circumferential surfaces of the series of lower work rolls.
In some embodiments of the invention, the upper and lower platforms bearing the upper and lower series of polishers are separable from one another, while in other embodiments the upper and lower platforms are integrated into a single platform with an upper surface bearing the upper polishers and a lower surface bearing the lower polishers. In those embodiments in which the upper and lower platforms, together with the first and second series of polishers respectively are selectively movable relative to each other, the upper and lower platforms are capable of being repositionable; from an orientation position in which the upper and lower platforms are substantially adjacent each other to permit both the alternative introduction and retraction of the apparatus into and from a position within the open leveler, between the respective series of upper and lower work rolls—to a polishing position in which the upper and lower platforms are extended to reposition the first and second series of polishers respectively into an operable engagement with respective ones of the series of upper and lower work rolls, to enable the polishing of the work rolls upon their simultaneous rotation, while the leveler is in its open position.
In yet other embodiments, the upper and lower platforms, together with the first and second series of polishers respectively, are restrainably fixed relative to each other where each of the series of polishers are positioned upon the top and bottom of a single integrated platform. In this embodiment, the upper work rolls of the leveler engage with the respective series of upper polishers upon movement of the top of the leveler, together with its series of upper work rolls downwardly, toward the series of upper polishers, to establish contact between the lower circumferential portions of the upper work rolls and the abrasive material within each of the concave pans comprising the upper polishers on the upper surface of the platform. Likewise, in these embodiments, each of the series of lower polishers on the bottom surface of the one platform is configured for engagement with respective ones of the series of lower work rolls, upon the continued spring-loaded movement of the platform downwardly—as a result of the continued downward movement of the top of the leveler to prompt its lower polishers towards contact with the series of lower work rolls in the bottom portion of the leveler. This downward movement will establish contact between the upper circumferential positions of the lower work rolls and the abrasive material within each of the concave pans positioned within the lower polishers on the integrated platform. In these embodiments the apparatus utilizes all of the work rolls in the series of upper work rolls to be configured to be brought into operational engagement with the polishers in the upper platform initially, while all of the work rolls in the series of lower work rolls are subsequently engaged upon the spring-loaded movement of the platform, as the top of the leveler continues to be lowered. The polishing of the work rolls in both the upper and lower series of work rolls may take place simultaneously after engagement has been achieved through the lowering of the top of the leveler, upon the rotation, and polishing of all of the work rolls. Through the structure and operation of this embodiment, all of the work rolls in both series of the upper and lower work rolls can be polished simultaneously.
In these preferred embodiments, regardless of whether the positions of the upper and lower platforms are repositionable relative to each other or are restrainably fixed in position to each other, the series of upper work rolls, as well as the series of lower work rolls are contemplated as being capable of being withdrawn from each other to enable the “opening” of the leveler, and for insertion of the polishing apparatus into position and alignment with the respective polishers and work rolls, as well as out of the polishing positions aligned with the upper and lower work rolls, upon completion of the polishing operation. The upper work rolls can then be raised and lowered at will to reposition the work rolls themselves for use in their capacity of metal sheet or plate leveling.
In some preferred embodiments of the invention, the substantially rigid concave pan comprises a substantially rigid, metallic pan assembly in which the abrasive material comprises a substantially abrasive surface positioned within the substantially rigid concave pan as a lining, for positioning, alignment and engagement with the respective one of the work rolls. In these embodiments, the abrasive surface of the lining comprises an abrasive paper or other material substrate capable of bearing the exposed abrasive surface while providing a layer of firm rubber backing behind the abrasive surface. Further, in these embodiments, the substantially rigid concave pans and abrasive materials positioned therewithin are configured for alignment and engagement with the work rolls, and to further conform to the circumferential shape of the exposed portion of the work roll to equivalently distribute the exposure and engaged pressure of the abrasive material to the exposed circumferential portion of the respective work rolls upon which the polishers are engaged, and serve to polish upon rotation of the respective work rolls. Further, as there remains a degree of flexibility in the concave pans in some embodiments, the pans will possess a degree of flex to “self-adjust” about the circumference of the work roll to more fully, favorably and efficiently expose the work rolls, upon engagement with the polishers, to a consistent degree of pressured engagement and polishing efficiency with the abrasive material positioned within the concave pans. In many of these preferred embodiments, the first and second series of polishers positioned within the first and second platforms are configured to most efficiently, simultaneously polish the series of upper work rolls and the series of lower work rolls respectively to further enhance the efficiency of the apparatus over the use of single polisher elements—well beyond the efficiency and potential safety exposure of an individual laborer attempting to polish the work rolls manually with portable handheld power equipment.
In the embodiments of the invention in which the upper and lower platforms are repositionable relative to each other between their orientation and polishing positions, a platform translation element is positionable therebetween the upper and lower platforms which enables each of the upper and lower platforms to be extended and retracted relative to each other. In its retracted orientation position, the apparatus can be alternatively positioned for entry into the open leveler, as well as removed from the open leveler. In its extended position the upper series of polishers can be extended into engagement and polishing contact with the series of upper work rolls and, likewise, the lower platform with its lower series of polishers can be extended downwardly into their polishing position with regard to the series of lower work rolls. In at least some of these embodiments, the platform translation element comprises an air bag assembly positioned between the upper and lower platforms of the apparatus through which an air motor with valve member controls can alternatively inflate and deflate the air bag assembly to, in turn, extend and retract the positions of the upper and lower platforms respectively. In yet other such embodiments, the translation element comprises an electric motor assembly positioned between the upper and lower platforms of the apparatus, with suitable controls, to extend and retract each of the platforms relative to the other, between their orientation and polishing positions, such as through the use of a threaded drive.
In some embodiments of the invention, when the upper and lower platforms are extended to enable the simultaneous polishing of the upper work rolls and lower work rolls by the upper and lower polishers respectively, polishing occurs upon rotation of the work rolls, while engaged with the abrasive material in the polisher. In these embodiments also, after polishing, the upper and lower platforms may be retracted to enable the simultaneous reorientation of the platforms to enable repositioning of the apparatus, or at least its polishing unit, into and out of the leveler at a location between the upper and lower work rolls. Further, in these embodiments, the invention contemplates the use of locking pins for locating and locking the apparatus into its operable position within the frame of the leveler, in which the respective concave pans are aligned with the respective work rolls for engagement, polishing and disengagement. Further, in at least some of these embodiments, a closing element is utilized for locking the upper and lower platforms relative to each other in their orientation position for entry and withdrawal of the apparatus, while the apparatus is not in its polishing position. In some of these embodiments, the closing element comprises an assembly of rollers and levers.
In some of the embodiments of the invention, each of the upper and lower platform(s) cooperates with an apparatus table support, with the polishing unit containing the platform or platforms reciprocating in and out of the leveler for orientation, relative to the table support. Further, in some of the embodiments of the invention the apparatus includes a motorized assembly for removably inserting and retracting the apparatus platform or platforms (depending on the embodiment) from its/their position between respective aligned ones of the upper and lower work rolls. Regardless of whether the translation element comprises an air bag system or an electric motor, appropriate controls and switching mechanisms are contemplated in the embodiments to enable the use of the translation element—where the upper and lower platforms are separable from one another and respectively extend towards and/or retract from the aligned work rolls with which they will be exposing the abrasive materials during rotation of those work rolls. Likewise, the motorized assembly for removably inserting the apparatus between the upper and lower work rolls includes an insertion control assembly.
The invention also includes several embodiments of methods associated with the utilization of the polishing apparatus to polish the upper and lower work rolls of a metal sheet or plate leveler. In some of the embodiments of the inventive method, the method includes the steps of configuring the leveler into its open polishing position to accept the insertion and/or removal of the polishing apparatus; configuring the polishing apparatus into an orientation position to enable insertion of the apparatus into the leveler; inserting the polishing unit of the apparatus into the leveler wherein the polishing unit includes polishers configured from substantially rigid concave pans which can be simultaneously aligned for engagement with respective work rolls, to polish respective ones of the upper and lower work rolls of the leveler during the rotation of the work rolls. With this method, at least one of the polishers is configured to engage and polish substantially the entire operable length (along the longitudinal axis) of the corresponding work roll of the leveler. In these embodiments also, the steps further include extending the upper and lower polishers to engage the upper and lower work rolls of the leveler, followed by the rotation of the work rolls to enable polishing, as well as the step of simultaneously polishing all of the contacted work rolls during the rotation of those work rolls. In at least some of these embodiments also, the substantially rigid concave pans include an abrasive material, and a resilient lining between the pan and the abrasive material, for enabling the polishing of the work rolls during their rotation.
In yet other embodiments the method for polishing the work rolls of the leveler through the use of a polishing apparatus comprises the steps of: configuring the leveler in an open position; inserting the polishing unit into the leveler device wherein the polishing apparatus includes polishers on its top and bottom surfaces for simultaneously engaging and polishing the respective work rolls of the leveler during the rotation of the work rolls. In these embodiments of the method, at least one of the polishers includes a substantially rigid concave pan having an abrasive material therewithin, the pan being configured to engage and polish at least the majority of the length of the corresponding work roll of the leveler and further includes the step of juxtaposing the polishers and the upper and lower work rolls of the levelers followed by the step of rotating the work rolls to polish same within the polisher pans, after extending the polishers to further contact the work rolls during the rotation of the work rolls. In at least some of these embodiments the method further includes the step of inserting the polishers into the leveler through the use of an air motor to move the polishers as a unit relative to the table support and for inserting the polishers between the upper work rolls and the lower work rolls of the leveler. In some of these embodiments also, the method further includes the step of extending the polishers through the use of an air motor and valve to inflate and adjust internal air bags within the polishing apparatus, in order to enable the polishers to come into contact with and polish the work rolls. In at least some of these embodiments, the method further includes the step of positioning the top polishers to simultaneously contact and polish all of the upper work rolls and/or positioning the bottom polishers to simultaneously contact and polish all of the lower work rolls. In yet other preferred embodiments, the method includes the step of positioning the top and bottom polishers to simultaneously contact and polish all of the upper and lower work rolls respectively.
In yet other embodiments of the invention, the method includes the further steps of retracting the top and bottom polishers of the polishing apparatus after the polishing process, as well as removing the polishing unit of the apparatus from the leveler. In some of those embodiments, the removal of the polishers is accommodated through the use of an air or electric motor to roll the polishing unit in and out of the leveler. In the preferred embodiments of the invention, the polishers are extended into contact with the work rolls while the leveler is in its open position. In some embodiments of the invention, the polishers are brought into contact with the work rolls by at least partially closing the orientation of the work rolls located on the top portion of the leveler.
In additional embodiments of the invention, the method for polishing the work rolls in a metal sheet or plate leveler through the use of a polishing apparatus comprises the steps of: configuring the leveler into a polishing position to accept the insertion of the polishing apparatus; inserting the polishing apparatus into the leveler wherein the polishing apparatus includes upper and lower polishers restrainably positioned relative to one another on a unitary platform, said polishers being capable of being simultaneously aligned with, and engaged with, respective work rolls. In these embodiments, the polishers are configured from substantially rigid concave pans having an abrasive material positioned therewithin. In this method also the polishers can be aligned, engaged with and, accordingly, polish the work roll during the rotation of the work roll. Further, in these embodiments, the polishers are configured to engage and polish substantially the entire operable length of the corresponding work roll in the leveler by lowering the upper work rolls to eventually engage the upper and lower polishers respectively, followed by the step of rotating the work rolls to simultaneously polish the work rolls during their rotation.
The feature or features of any one embodiment may be applied to yet other embodiments even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the embodiments.
Details associated with the embodiments described hereinabove and others are described below.
The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers.
Reference will now be made in detail to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the claims. Furthermore, in the detailed description of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be obvious to one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the present invention.
Generally speaking, various embodiments of the present invention provide for apparatuses and methods for safely and efficiently polishing the work rolls of a metal sheet or plate leveler for example, hot leveler 100 as shown in
Apparatus 200, as shown in
Also shown in
As shown in
In an alternative embodiment of the invention, as shown in
As an exemplary operating process, a user may first check the leveler and make sure that it is prepared and ready to be polished. For instance, the user should verify that all metal sheets or plates have passed the hot leveler onto the cooling bed, and should turn off cooling water to leveler rolls. Next, the user will configure the leveler into its fully open position before inserting the polishing unit. The user can then insert or push the polishing unit into the leveler. After the polishing unit is inserted and aligned, the user can adjust the gap between the work rolls and begin rotating the work rolls at a desired speed. During the rotation of the work rolls, the user may then further enlarge and adjust the extendable element distance within the polishing unit (e.g., by a valve), so that the polishers sufficiently contact and polish the rotating work rolls under suitable contact pressure. For instance, in embodiments in which the expandable units are air bags, the user may inflate the air bags by using valve control 12(a) located on the operator side, while continuing to rotate the work rolls, while they engage with the polishers of the polishing unit (e.g. for about 5 minutes for each setting). During this process, the user may inspect and verify that the polishers (especially those corresponding to the entry and exit rolls) are appropriately contacting the work rolls, and adjust the pressure of the air bags according to the desired roll pressure, as well as in response to temperature and noise. After the polishing process, the user can retract the expandable element(s) of the polishing unit, while the work rolls are still rotating. Then, the user may set up the leveler in the full open position again and stop the rotation of the work rolls. Finally, the user may remove the polishing unit and/or the polishing unit and the apparatus as a whole, from out of the open leveler, and/or the vicinity of the leveler.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
