FIELD
This disclosure relates generally to metal leveler polishers, and more specifically to apparatuses and methods for the localized or spot polishing of the work rolls of a metal sheet or plate leveler.
BACKGROUND
Levelers, such as hot levelers, are commonly used in steel mills, namely hot rolling mills for producing steel sheets or plates. They can also be used on leveling aluminum, bronze, and other metals. FIG. 1 illustrates a typical leveler 100 from the operator side. As shown in FIG. 1, the leveler usually includes moveable upper work rolls 60 and stationary lower work rolls 62. The metal plate enters the leveler from entry side 64 of the leveler, passes between the upper and lower working rolls, and then leaves the leveler through exit side 66. The rolling and cooling processes of the leveler reduce remaining flatness errors and residual stresses of the sheets or plates passing therethrough. However, as a result of passing metal sheets or plates through the rollers, under substantial compressive forces on the steel, particles tend to collect on the work rolls working the metal, which could cause vibrations of the sheet and degradation in the quality of subsequently leveled plates. Thus, the polishing and cleaning of the work rolls is crucial for the effectiveness and quality of the metal product passing through the levelers.
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 dangerous and inefficient, as operators could easily 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, but it can also 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 passing therebetween.
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, in order to clean them.
U.S. Pat. No. 10,279,383, the entirety of which is hereby incorporated herein by reference, discloses an apparatus and method for safely and efficiently polishing the work rolls of a metal sheet or plate leveler. As described in the various embodiments set forth in the '383 patent, the apparatus includes a support and one or more polisher assemblies to be inserted between the upper and lower work rolls of the leveler, for simultaneously polishing the upper and/or lower work rolls of the leveler during the rotation of the work rolls.
SUMMARY
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 all of the 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.
Various embodiments described herein are directed to an apparatus for localized or spot polishing or cleaning the work rolls of a metal leveler, the leveler having a series of upper work rolls and a series of lower work rolls. In one or more preferred embodiments, the apparatus includes a spot polisher frame, an airbag or other device for repositioning the polisher, and a polisher including an abrasive surface configured to radially polish a portion of one of the upper work rolls or one of the lower work rolls. The apparatus further includes a polisher arm. The polisher is attached to a first end of the polisher arm. The apparatus further includes a second end of the polisher arm hingedly connected to the spot polisher frame. The airbag is configured to inflate and deflate with air. While the airbag is inflated with air, the polisher is at a first position, and while the airbag is deflated, the polisher is at a second position. The first position is farther from the spot polisher frame than the second position.
Various embodiments described herein are directed to an apparatus for polishing the work rolls of a metal plate or sheet leveler, such as a steel leveler, the leveler having a series of upper work rolls and a series of lower work rolls. The apparatus includes a spot polisher frame and a plurality of polisher arms each having a first end and a second end. The second end of each of the plurality of polisher arms are hingedly connected to the spot polisher frame at one of a plurality of hinges. The apparatus further includes a plurality of airbags, each one of the plurality of airbags located at the first end of one of the plurality of polisher arms, respectively. The apparatus further includes a plurality of polishers, each comprising an abrasive surface configured to polish one of the upper work rolls or one of the lower work rolls, one of each of the plurality of polishers being attached to one of the plurality of polisher arms. Each of the plurality of airbags is configured to inflate and deflate with air. When each of the plurality of airbags is inflated with air, the plurality of polishers are oriented at a respective first position to enable polishing. When each of the plurality of airbags is deflated, the plurality of polishers are oriented at a respective second position-retracted from their polishing positions. The same holds true for an alternative polisher-arm translation element, such as a mechanical device operated by an electric motor, in lieu of an airbag.
Various embodiments described herein are directed to a method for polishing work rolls of a metal plate or sheet leveler, such as a steel leveler, the leveler having a series of upper work rolls and a series of lower work rolls. The method includes inserting a spot polisher into the metal sheet or plate leveler while the airbags of the spot polisher are deflated. The method further includes inflating the airbags, such that only some or all of the polishers of a plurality of polishers of the spot polisher, move into contact with selected ones, or all of the upper and lower work rolls. The method further includes rotating the series of upper work rolls and the series of lower work rolls, such that the one or more polishers rub abrasively against a portion of the selected upper and lower work rolls. The method further includes, after the inflating of the airbags and the rotating of the work rolls, deflating the airbags such that the one or more polishers move out of contact with the series of upper work rolls and the series of lower work rolls. The method further includes removing the spot polisher from the metal sheet or plate leveler while the respective airbags are deflated. In using a preferred embodiment of the invention, the polishers of the spot cleaner extend forwardly from the overall work roll (pan-type) polisher unit described in U.S. Pat. No. 10,279,383. That type of work roll polisher unit comprises polishers with concave pans that generally clean and polish the work rolls, without localized or spot cleaning capabilities that address the specific polishing or cleaning needs beyond the general, uniform polishing of the work rollers, across their entire longitudinal dimension.
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 hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
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.
FIG. 1 shows an elevated front view of a metal sheet or plate leveler;
FIG. 2 shows a perspective view of one embodiment of the present apparatus for polishing a metal sheet or plate leveler, which includes upper and lower platforms for supporting a plurality of polishers, including a polishing unit and stationary table support, together with the concave pans of the series of upper work roll polishers, according to various embodiments of the disclosure;
FIG. 3 shows an elevated front view of the polisher apparatus of FIG. 2, sharing both series of upper and lower polishers according to various embodiments of the disclosure;
FIG. 4 shows an elevated front view of the polishing apparatus in its orientation position, enabling its insertion into an open leveler, according to various embodiments of the disclosure;
FIG. 5 shows an elevated front view of one embodiment of the polisher apparatus in its polishing position within the leveler, according to various embodiments of the disclosure;
FIG. 6 shows a fragmented cross-sectional view of an embodiment of a polisher;
FIG. 7 shows an elevated front view of another embodiment of the polisher apparatus positioned prior to engagement of its polishers with the work rolls, in which the polisher unit relies upon a single unitary platform for supporting both its upper and lower polishers, all of which polishers can be brought into contact with all the work rolls respectively, upon lowering of the top of the leveler;
FIG. 8 shows a perspective view of one embodiment of the present apparatus for spot polishing a metal sheet or plate leveler, which shows a spot polisher assembly extending forwardly from the work roll polisher unit of FIG. 2, according to various embodiments of the disclosure;
FIG. 9 shows a perspective view of one embodiment of a spot polisher assembly for spot polishing a metal sheet or plate leveler, according to various embodiments of the disclosure;
FIG. 10 shows an elevated front view of one embodiment of a spot polisher assembly for spot polishing a metal sheet or plate leveler, according to various embodiments of the disclosure;
FIG. 11 shows a top plan view of one embodiment of a spot polisher assembly for spot polishing a metal sheet or plate leveler, according to various embodiments of the disclosure;
FIG. 12 shows a bottom plan view of one embodiment of a spot polisher assembly for spot polishing a metal sheet or plate leveler, according to various embodiments of the disclosure;
FIG. 13A shows a cross-sectional view of one embodiment of a spot polisher assembly for spot polishing a metal sheet or plate leveler, taken along line A-A of FIG. 11, and looking in the direction of the arrows, according to various embodiments of the disclosure;
FIG. 13B shows an elevated side view of one embodiment of a polisher arm for spot polishing a metal sheet or plate leveler, taken along line B-B of FIG. 11, and looking in the direction of the arrows, while the polisher arm is retracted, according to various embodiments of the disclosure;
FIG. 13C shows an elevated side view of the polisher arm of FIG. 13B while the polisher arm is in an extended position, according to various embodiments of the disclosure;
FIG. 13D shows a perspective view of the polisher arm of FIG. 13B in its unextended position of FIG. 13B, according to various embodiments of the disclosure;
FIG. 14 shows a perspective view of a spot polisher assembly for spot polishing a metal sheet or plate leveler attached to a pan leveler polisher as the spot polisher assembly is initially inserted into a metal sheet or plate leveler, according to various embodiments of the disclosure;
FIG. 15 shows a perspective view of a spot polisher assembly for spot polishing a metal sheet or plate leveler attached to a pan leveler polisher when the spot polisher assembly is fully inserted within a metal sheet or plate leveler, according to various embodiments of the disclosure;
FIG. 16 shows a cross-sectional perspective view of a spot polisher assembly for spot or localized polishing of a metal sheet or plate leveler, as attached to a pan leveler polisher, while positioned within a metal sheet or plate leveler, according to various embodiments of the disclosure;
FIG. 17A shows a perspective view of a spot polisher assembly for spot polishing a metal sheet or plate leveler attached to a pan-type leveler polisher, while inserted within a metal sheet or plate leveler, with polishers within the spot polisher assembly extended to contact and polish the leveler work rolls, according to various embodiments of the disclosure;
FIG. 17B shows a perspective view of a spot polisher assembly for spot polishing a metal sheet or plate leveler attached to a pan leveler polisher while inserted within a metal sheet or plate leveler, with the polishers of the spot polisher assembly retracted to not contact leveler rolls, according to various embodiments of the disclosure;
FIG. 18 shows a perspective view of a grinding stone for a spot polisher, according to various embodiments of the disclosure;
FIG. 19 shows a top plan view of a grinding stone for the spot polisher of FIG. 18, according to various embodiments of the disclosure; and
FIG. 20 shows an elevated side view of a grinding stone for the spot polisher of FIG. 18, according to various embodiments of the disclosure.
DETAILED DESCRIPTION
Reference will now be made in detail to the various embodiments, examples of which are illustrated in the accompanying drawings. While the embodiments will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the various embodiments. On the contrary, this description is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the claims. Furthermore, in the detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments. However, it will be clear to one of ordinary skill in the art that the various embodiments 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 various embodiments.
Generally speaking, various embodiments provide for apparatuses and methods for safely and efficiently polishing the work rolls of a metal sheet or plate leveler, such as a steel sheet or plate leveler, for example, hot leveler 100 as shown in FIG. 1. Leveler 100 is made up of top portion 42, which can be raised and lowered, and bottom portion 43, which is typically stationary. In particular, FIGS. 1-7 describe a polishing unit 20 that may be used to polish all rollers of leveler 100 simultaneously and preferably, may also polish the entire length of all of the work rollers of leveler 100 simultaneously. In this way, general overall polishing of the rollers may occur more quickly and efficiently.
In various instances, however, more intense focused polishing or cleaning of rollers may be required at various portions of the rollers of a metal sheet or plate leveler (e.g., where one or more of the rollers has been damaged, has a barb or other portion of rolled metal or contaminants sticking to the roller, etc.). Accordingly, described herein with respect to FIGS. 8-20 is an improved spot polisher for cleaning or polishing more difficult to remove portions of an overall work roller-before or after polishing unit 20 generally polishes all of the rollers simultaneously. In various embodiments, an operator of a leveler may notice a defect at a particular point along a lateral location along the work roller of a leveler, and may therefore identify that spot cleaning of the roller(s) of a leveler should be performed. In various embodiments, all rollers at that lateral location of the rollers may be radially cleaned and polished, such that it is not necessary to identify the particular roller that is causing the defect in the steel sheet or plate exiting the leveler. Alternatively, one specific region of one work roller can be addressed—at the discretion of the operator. In various embodiments, as shown in the figures and as discussed herein, a spot polisher as discussed with respect to FIGS. 8-20 may also be attached to, and protrude from, the front of a pan-type leveler polisher as such pan-type leveler polisher itself is discussed with respect to FIGS. 1-7. In this way, a spot polisher may first be inserted between the work rollers of a leveler to spot clean/polish one or more lateral locations along the rollers, and then the spot polisher may be fully pushed out the other end of the leveler so that the pan leveler may be used to positioned between the upper and lower work rollers—to polish the entire length of the rollers. After using the pan-type leveler polisher, the entire assembly including the pan polisher/leveler and the spot polisher may be removed jointly, simultaneously, so that the leveler with freshly polished/leveler rollers at both the localized level, and the overall general level, may be used to further process sheets and/or plates of steel or other metal.
Apparatus 200, as shown in FIG. 2, may include polishing unit 20 and stationary table support 11 where polishing unit 20 may be moved and inserted at a position between (and/or removed from) the opposing series of work rolls 45, 44 (e.g., upper work rolls 45 and lower work rolls 44, as shown in FIG. 1) of leveler 100, from the operator side of the leveler. Polishing unit 20 may include multiple polishers 22 on its top and bottom surfaces, and thus is capable of polishing a plurality of work rolls 45 of leveler 100 during the rotation of work rolls 45, while each of polishers 22 engages and polishes at least the majority of the operable longitudinal length of a corresponding work roll of the leveler. Further, the polishing unit may include one or more internal expandable elements, such as air bags 28, between upper and lower platforms 24, 26 of polishing unit 20 (as shown in FIG. 3), to allow polishing unit 20 to be expanded within leveler 100, thereby causing polishers 22 (e.g., abrasive material and pads) to contact and polish the rotating work rolls 60, 62 (as such work rolls are shown in FIG. 17A). In some embodiments, the polishing unit simultaneously contacts and polishes all of the upper and/or lower work rolls during the polishing process, as shown in FIG. 5. After the polishing process, the expandable element may be retracted to enable the retraction of platform 24 proximate to platform 26, to enable polishing unit 20 and, if desired, apparatus 200 in its entirety, to be removed from proximity with the leveler.
FIG. 2 illustrates polishing apparatus 200 in accordance with various other embodiments. Apparatus 200 includes apparatus table 11 with support leg 10. Stationary apparatus table 11 balances and supports polishing unit 20 movably positioned thereon, to enable polishing unit 20 to reciprocate into and out of leveler 100 while the leveler is in its open position, with upper work rollers 45 separated from lower work rollers 44. A user may operate and control the movement of polishing unit 20 relative to table 11, optionally by motor 12 (such as an air motor), with its controls and valves 12(a) thereby moving polishing unit 20 into and out of a leveler 100. Further, polishing unit 20 may include one or more polishers 22, on each of its top and bottom platforms 24, 26. Each polisher 22 is shaped and sized to align with, engage and receive corresponding work roll 60, 62 of leveler 100 (see FIG. 17A). As shown in FIG. 2, polishers 22 comprise substantially rigid concave pans 22(a), each supporting an abrasive surface or abrasive lining 22(b), or a combination of a firm rubber backing 22(b) and an abrasive paper 22(c), as shown in FIG. 6. As such, during the polishing process, multiple work rolls of the leveler may simultaneously be polished by abrasive surfaces.
FIG. 3 shows a side view of general pan-type polishing unit 20, to illustrate the structures and components of this embodiment in more detail. Specifically, platforms 24 and 26 are shown in their retracted orientation position in FIG. 3. In this embodiment, upper work roll polishers 22 on platform 24 are configured to be extended away from the lower work roll polishers 22 on lower platform 26. The separation of the two platforms making up polishing unit 20 enables polishing unit 20 to be inserted between the series of upper work rolls 45 in moveable leveler top 42 and the lower work rolls 44 in stationary leveler bottom 43, within metal sheet or plate leveler 100. Once the series of upper work rolls 45 have been retracted away from the stationary series of leveler lower work rolls 44 in stationary leveler bottom 43, the leveler assumes its open position shown in FIG. 1.
Also shown in FIG. 3 are air bags 28 for extending platform 26 away from platform 24, upon activation of the air bags, such as also by air motor 12 and air motor control 12(a), shown in FIG. 2, or by a separate air motor. The shape of the concave pans making up polishers 22 is shown in FIG. 3, together with the abrasive linings 22(a) in each such pan, as detailed in FIG. 6, showing a close-up of the polisher structure. As shown in phantom in FIG. 3, as an alternative to air motor 12, an electric motor 47, together with motor control 47(a), can be utilized to extend apart upper platform 24 from lower platform 26 to engage work rolls 60, 62 when the work rolls are in their open position, through electric motor 47 rotating of motor gearing 48, also shown in phantom. Platform lock lever 30 is also shown in FIG. 3, together with polishing unit 20 locating lock pins 32—which enable the alignment of the polishers 22 with respective ones of work rolls 60, 62, through cooperation of pins 32 with apertures in top portion 42 of leveler 100. As shown in FIGS. 4 and 5, locating lock pins 32 specifically cooperate with aligned apertures in leveler top 42 to maintain the polishers in alignment with their respective work rolls, both immediately prior to and during both the locating and polishing operations.
As shown in FIG. 4, polishing unit 20 includes upper platform 24 and lower platform 26, where upwardly-facing polishers 22 are positioned on the top surface of upper platform 24 and downwardly-facing polishers 22 are positioned on the bottom surface of lower platform 26. In the illustrated embodiment, upper platform 24 includes five concave polishers, and lower platform 26 includes six concave polishers, such that each polisher 22 corresponds to one of the eleven work rolls 44, 45 of leveler 100, as shown in FIG. 1. Polishing unit 20 may also include one or more expandable elements 28 positioned between upper portion 24 and lower portion 26. Expansion and retraction may be orchestrated by expandable air bag 28, by hydraulic or pneumatic pistons, or by an electric motor 47, or the like. When apparatus 200 is in use, expandable element 28 causes polishers 22 to contact and polish rotating work rolls 45 and 44. When apparatus 200 is not in use, it is desirable to retract expandable element 28, so as to bring upper platform 24 and lower platform 26 closer together—to reduce the profile of apparatus 200 and, in turn, enable the entire polishing apparatus to be removed from its position between the two series of work rollers, 45 and 44. Polishing unit 20 may include rollers and levers 30 to hold the upper and lower portions together when apparatus 200 is not in use.
FIGS. 4-5 illustrate polishing unit 200 inserted within leveler 100. Polishing unit 200 is inserted from the operator side of leveler 100 (e.g., towards the longitudinal orientation of the work rolls). To ensure that polishing unit 200 is securely positioned within leveler 100, especially during the polishing process, locating and locking pins 32 are utilized to locate and lock polishing unit 200 into leveler top 42 of frame 34 of the leveler, with the respective polishers 22 and work rolls 45, 44 aligned for engagement and polishing. Entry and exit aprons 36 are placed on the entry and exit sides of leveler 300, to allow for even elevation for insertion of polishing unit 200. As shown in FIG. 4, before the polishing process, expandable elements 28 are in their contracted state (i.e., not inflated), and upper platform 24 and lower platform 26 are locked together in their respective positions. In the illustrated embodiment, eleven polishers 22 are positioned proximate to each of the respective eleven work rolls 45, 44 in metal sheet or plate leveler 100. As shown in FIG. 5, during the polishing process, expandable elements 28 may be extended (e.g., inflated) and adjusted. As such, the polishers in polishing unit 200 are extended to engage and contact the upper and/or lower work rolls of leveler 100, and thus polishers 22 can polish the work rolls when the work rolls commence rotation. After the polishing process, expandable elements 28 may be retracted and polishing unit 20 may then be removed from the leveler by itself, or as part of the extraction of overall apparatus 200.
FIG. 6 displays the three primary layers of an embodiment of the present polishers, such as polishers 22, namely concave pan 22(a), resilient liner backing 22(b), and abrasive material 22(c).
In one embodiment, as shown in FIG. 7, platforms 24 and 26 are integrated into one unitary platform 27, in which the upper and lower polishers 22 do not extend and retract from one another. In this embodiment, platform 27 is spring loaded relative to polishing unit 20 at spring coils 37. Engagement of polishers 22 with work rolls 60, 62 is accommodated by lowering leveler top 42 after the polisher unit has been inserted into the open leveler. In this embodiment, upper work rolls 60 in leveler top 42 engage and press upper polishers 22 on the top of platform 27, and, in turn, lower polishers 22 on the bottom of platform 27 into aligned engaged contact with lower work rolls 62 in leveler bottom 43. In this embodiment, the abrasive material 22(c) within the substantially rigid tray 22(a) of polisher 22 are thicker or otherwise more resilient, to accommodate the force which leveler top translates downwardly, to provide a tolerable range of polisher-on-work-roll pressures.
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 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 (e.g., 580 feet per minute). 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 (e.g., to no more than 10 psi) 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 fully 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, out of the leveler, and/or the vicinity of the leveler.
FIG. 8 shows a perspective view of one embodiment 800 of the present apparatus for spot polishing a metal sheet or plate leveler, which includes a spot polisher assembly 70 operably affixed to the forward-most end of pan leveler polisher 20. In particular, FIG. 8 shows pan leveler polisher 20 as described herein in FIG. 4 attached to spot polisher 70 on table support 11, as shown in FIG. 2. Embodiment 800 shows pan leveler 20 and spot polisher 70 not yet being positioned within a metal sheet or plate leveler, between its upper and lower sets of working rollers. As shown, in a preferred embodiment, spot polisher assemble 70 may be attached directly to one end of a general pan leveler polisher, though the invention contemplates spot polisher assembly 70 as comprising a separate work roller polisher apparatus on its own.
FIG. 9 shows a perspective view of one embodiment of spot polisher assembly 70 for spot polishing a metal sheet or plate leveler. The spot polisher 70 includes polisher arms 74, to which polishers 72 with abrasive surfaces for spot polishing rollers are attached. Spot polisher 70 also includes airbags 76 that enable polisher arms 74 to move from a non-engaging retracted position to an extended engaging position, and back to a non-engaging position, so that polishers 72 may alternatively come into contact with, or be removed from contact with, the work rollers of a metal sheet or plate leveler to spot polish the rollers, and then be retracted from its position therefrom, as shown in FIGS. 14 and 17B.
FIG. 10 shows a front view of one embodiment of spot polisher assembly 70 for the localized of spot polishing of a metal sheet or plate leveler. In the view of FIG. 10, airbags 76 are not inflated, so that the polishers 72 are not extended into a position to contact the work rollers of a metal sheet or plate leveler. In this way, the profile/height of spot polisher assembly 70 is minimized enough to easily fit and move assembly 70 between the rollers of a metal sheet or plate leveler (e.g., rollers 60 and 62 of metal sheet or plate leveler 100) as shown in FIG. 14FIG. 17B.
FIG. 11 shows a top plan view of one embodiment of spot polisher assembly 70 for spot polishing a metal sheet or plate leveler. FIG. 12 shows a bottom view of one embodiment of spot polisher assembly 70 for spot polishing a metal sheet or plate leveler. As shown in FIGS. 11 and 12, polishers 72 may be on both the bottom and top of spot polisher assembly 70 so that both the upper and lower work rolls of a metal sheet or plate leveler may be spot polished. Each of polishers 72, for example, may correspond to one of rollers 60 and 62 of metal sheet or plate leveler 100, as shown in FIGS. 17A and 17B. Similarly, polisher arms 74 may also each correspond to one of polishers 72 and one of rollers 60 and 62 of metal sheet or plate leveler 100. Further, airbags 76 may also each correspond to one of polishers 72, one of polisher arms 74, and one of rollers 60 and 62 of metal sheet or plate leveler 100. In this way, airbags 76 may be inflated or deflated to control movement of polisher arms 74 (and therefore polishers 72) into or out of contact with rollers 60 and 62 of metal sheet or plate leveler 100, as desired-either individually or collectively.
FIG. 13A shows a cross-sectional view of one embodiment of spot polisher 70 for spot polishing a metal sheet or plate leveler, taken along line A-A of FIG. 11. Airbag 76 is shown deflated and is attached on its one side to static portion 90 of spot polisher assembly 70 (e.g., part of a frame of spot polisher 70) and, on its other side, to a moveable portion of polisher arm 74. In various embodiments, airbag 76 may be attached to both of static portion 90 and polisher arm 74. In various embodiments where airbag 76 is attached to only one of static portion 90 and polisher arm 74, airbag 76 may nevertheless come into contact with one of static portion 90 and polisher arm 74 that airbag 76 is not connected to when airbag 76 is inflated—in order to cause movement of polisher arm 74 (and thereby cause movement of polisher 72 into direction C. Spot polisher assembly 70 may also include hinge 84 connecting polisher arm 74 to static portion 90 of spot polisher 70. In this way, polisher arm 74 and polisher 72 may be rotated about hinge 84 to move polisher 72 in direction C to come into contact with a portion of a work roller (e.g., when airbag 76 is inflated) and to move polisher 72 in the opposite of direction C to come out of contact with a roller, when airbag 76 is deflated, and prompted by springs 99 of FIG. 13 to retract downwardly. Polisher 72 may also be connected to polisher arm 74 at hinge 98 to enable polisher 72 to self-level itself with respect to a leveler work roller as polisher 72 is pressed up against the leveler roll for the localized polishing operation.
Airbag 76 may be fluidly connected to tubing 78, which may be fluidly connected to an air pump to control inflation and deflation of airbag 76. In the example of FIG. 13, tubing 78 may be connected to tubing 80 by a hose (not shown) such as a flexible (e.g., rubber) hose. A valve 82 may further be connected to tubing 80 to control airflow into and out of tubing 78, 80 and therefore airbag 76. In various embodiments, the tubing 80 and/or valve 82 may be connected to an air pump or some other reservoir of air (e.g., a compressed air tank) configured to cause inflation and/or deflation of air in airbag 76. A valve such as valve 82 may also be capable of releasing air from airbag 76. In various embodiments, mechanisms other than an airbag may be used in order to move polisher arm 74 and/or polisher 72. For example, hydraulics or any other system may be used to cause movement of polisher 72 so that polisher may be moved into place against a roller of a metal sheet or plate leveler and held in place under compression, as the roller rotates to spot polish the roller at a particular radial location.
In various embodiments, valve 82, an air pump, etc. may be electronically controlled either automatically or by a user via a user interface, so that airbags 76 may be inflated and/or deflated as desired for spot polishing rollers of a metal sheet or plate leveler. In various embodiments, individual airbags 76 may be individually controlled so that one or fewer than all polishers 72 are in contact with rollers of a metal sheet or plate leveler at any given time as desired. In various embodiments, airbags 76 may also be controlled altogether, simultaneously, so that all polishers 72 are either in contact with or not in contact with rollers collectively, at the same time. Likewise the spot polishers can be manually or automatically operated to move between the longitudinal locations along the work rollers, also individually or simultaneously, as desired by the operator. In various embodiments, an operator visually inspecting plates or sheets coming out of a leveler may note that defects are occurring on a top or bottom side only of a sheet or plate. In an instance where defects are occurring only on the top side, all spot polisher arms associated with upper rolls 60 may be engaged (e.g., airbags inflated), while the polisher arms associated with lower rolls 62 are not engaged (e.g., airbags are left deflated). In an instance where defects are occurring only on the bottom side, all spot polisher arms associated with lower rolls 62 may be engaged (e.g., airbags inflated), while the polisher arms associated with upper rolls 60 are not engaged (e.g., airbags are left deflated). Airbags may be inflatable and/or inflated to anywhere between 20 pounds per square inch (psi) to 80 psi, such as in increments ranging from 20 psi, 25 psi, 30 psi, 35 psi, 40 psi, 45 psi, 50 psi, 55 psi, 60 psi, 65 psi, 70 psi, 75 psi, up to 80 psi. The work rollers will be rotated to enable the spot polishing of the work rollers at varying speeds, including, for example, anywhere from 180 rotations per minute (RPM) to 230 RPM, in increments at any of 180 RPM, 185 RPM, 190 RPM, 195 RPM, 200 RPM, 205 RPM, 210 RPM, 215 RPM, 220 RPM, 225 RPM, up to 230 RPM.
FIG. 13B shows an elevated side view of polisher arm 74 of FIG. 11 for spot polishing a metal sheet or plate leveler, taken along line B-B of FIG. 11 while the polisher is retracted. FIG. 13B shows similar components to those shown in FIG. 13A, and additionally shows springs 99. Springs 99 may be one or more metal springs or may be of any other suitable material or component that stores a potential force and holds polisher arm 74 in place when airbag 76 is deflated, as shown in FIG. 13B. FIG. 13C shows an elevated side view of polisher arm 74 of FIG. 13B while polisher 72 is in its extended position to maintain contact with a work roll being radially spot-cleaned. In particular, airbag 76 is inflated in FIG. 13C such that polisher arm 74 rotates around hinge 84 to extend polisher 72, for example up into a leveler roll of a metal sheet or plate leveler as described herein. Springs 99 extend as airbag 76 is inflated, and as airbag 76 is deflated springs 99 will pull polisher arm 74 back into position to retract polisher 72 back into the position shown in FIG. 13B. FIG. 13D shows a perspective view of the polisher arm of FIG. 13B.
FIG. 14 shows a perspective view an embodiment 130 of spot polisher assembly 70 for spot polishing a metal sheet or plate leveler attached to a pan leveler immediately prior to inserting spot polisher assembly 70 into metal sheet or plate leveler 100. In particular, spot polisher 70 connected to pan-type leveler 20 is outside of metal sheet or plate leveler 100 as it is about to be inserted into metal sheet or plate leveler 100. As shown, spot polisher assembly 70 is situated closer to metal sheet or plate leveler 100 so that spot polisher 70 can be inserted first to radially spot polish one or more localized portions of the work rollers of metal sheet or plate leveler 100—prior to using pan leveler 20 to polish an entire length of rollers of metal sheet or plate leveler 100.
FIG. 15 shows a perspective view of a spot polisher assembly 70 for spot polishing metal sheet or plate leveler 100 attached to pan leveler 20 while completely inserted within metal sheet or plate leveler 100. As shown, both pan leveler 20 and spot polisher assembly 70, which is rigidly affixed to pan leveler 20, are supported by table 11 as spot polisher 70 has been fully orientated for spot polishing into metal sheet or plate leveler 100. The entire assembly (pan leveler and spot polisher 70 together) may be slid or otherwise moved across table 11 so that the assembly may be inserted into metal sheet or plate leveler 100, as desired. Table 11 may have rails along with the assembly to ensure a precision feed of both the spot polisher and the concave pan cleaner into the steel plate leveler. Steele leveler 100 may also have rails aligned with the rails of table 11, so that as the assembly is moved into metal sheet or plate leveler 100, the assembly is still supported by the rails of metal sheet or plate leveler 100, rails of table 11, or some combination of the two supports.
Linkages 94 are shown comprising the rotatable elements, gearboxes, transmissions, etc., or any combination thereof configured to rotate the work rollers of metal sheet or plate leveler 100. Linkages 94 and the rotatable elements therewithin may be configured to move so that when the rollers of metal sheet or plate leveler 100 are separated for or during cleaning, the linkages 94 and elements therein need not be disconnected from the rollers themselves to enable cleaning or polishing. When the work rollers of metal sheet or plate leveler 100 are separated for cleaning/polishing, linkages 94 may separate to create an assembly/polisher insertion space 92. Space 92 may be sufficient to fit spot polisher assembly 70 when pan-type leveler 20 is being used to clean the entire length of rollers of metal sheet or plate leveler 100—in which case spot polisher assembly 70 is pushed out of the back end of the leveler into that spatial void between the transmission linkages. Simply put, when pan leveler 20 is moved fully into metal sheet or plate leveler 100 and spot polisher 70 is no longer positioned therewithin the leveler, the dimensions of spot polisher may be such that spot polisher 70 fits within space 92 after spot polisher 70 has been pushed out the far end of metal sheet or plate leveler 100. Spot polisher assembly 70 may enter a first end of metal sheet or plate leveler for polishing, and after spot polishing, may exit out a second end while pan leveler 20 is being used for overall polishing and cleaning. Then spot polisher may re-enter the second end as pan leveler 20 is removed from the first end of metal sheet or plate leveler 100 and eventually spot polisher 70 may be removed from the first end of metal sheet or plate leveler 100 as pan leveler 20 is pulled further away from metal sheet or plate leveler 100, along table 11.
FIG. 16 shows a cross-sectional perspective view of spot polisher 70 for spot polishing metal sheet or plate leveler 100 attached to pan leveler 20 while inserted within metal sheet or plate leveler 100. As shown, spot polisher 70 in FIG. 16 has its airbags (not shown) inflated such that at least some or all of polishers 72 are in contact with rollers of metal sheet or plate leveler 100—to enable localized radial cleaning, as desired.
FIG. 17A shows an elevated cross-sectional side view of spot polisher 70 for spot polishing metal sheet or plate leveler 100 attached to pan leveler 20 while inserted within metal sheet or plate leveler 100. Similar to FIG. 16, spot polisher assembly 70 in FIG. 17 has its airbags 76 inflated such that each of polishers 72 are in contact with rollers 60, 62 of metal sheet or plate leveler 100. FIG. 17 also shows how pan leveler 20 may rest on rails 96 of metal sheet or plate leveler 100 to support pan leveler 20 and, in turn, spot polisher 70. As shown in FIG. 17A, polishers 72 are also extended beyond a top and bottom edge of a frame of spot polisher 70, so that they may come into contact with rollers 60, 62. FIG. 17B shows a elevated perspective view of a spot polisher assembly for spot polishing a metal sheet or plate leveler attached to a pan leveler, while inserted within a metal sheet or plate leveler—but with polishers 72 retracted to preclude their contact with the leveler rolls. Upon comparing FIGS. 17A and 17B, it can be seen that in FIG. 17B spot polisher 70 may be easily reciprocated between the leveler rolls 60, 62 to move spot polisher assembly 70 into or out of leveler 100, while in FIG. 17A spot polisher 70 may be used to enable localized radial polishing of leveler rollers 60, 62 of leveler 100.
FIG. 18 shows a perspective view of grinding stone 140 for polisher 72 of spot polisher 70. FIG. 19 shows a top view of grinding stone 140 for spot polisher 70. The grinding stone 140 includes a top abrasive surface with angled grooves 86. A length D of grinding stone 140 may be, for example, anywhere from 3 to 15 inches, such as in increments to create grinding stone lengths of 3 inches, 4 inches, 5 inches, 6 inches, 7 inches, 8 inches, 9 inches, 10 inches, 11 inches, 12 inches, 13 inches, 14 inches, or 15 inches.
FIG. 19 shows a side view of grinding stone 140 for a spot polisher. Grinding stone 140 may further include socket 98 so that grinding stone 140 may be rotatably connected to polishing arm 74. In this way, since grinding stone 140 may be able to rotate, even slightly, with respect to polishing arm 74, this assists in the leveling/cleaning/polishing of rollers of a metal sheet or plate leveler, as the grinding stone 140 may be able to adjust to deformities of a roller to smooth them out, while self-leveling itself with respect to a surface of a roller to ensure efficient and consistent cleaning of the roller.
FIG. 20 shows an elevated side view of grinding stone 140 of FIGS. 18 and 19 for a spot polisher. A socket for a hinge connection (e.g., hinge 98 described herein and shown in FIGS. 13A-13C, 16) is also shown in FIG. 20, so that grinding stone 140 may articulate or rotate with respect to the polisher arm to which it is attached. A grinding stone may be made of any abrasive material, such as a rock or mineral, heavy duty plastic, rubber, elastomer, any other suitable material, or any combination thereof. As just one example, a grinding stone may be made from material type #4-M/B, available from R&S Processing Co., Inc. in Paramount, CA
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the various embodiments described herein. 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 various embodiments described herein. Thus, the various embodiments described herein are not intended to be limited to the embodiments shown herein but is to be accorded the widest scope possible, consistent with the principles and novel features disclosed herein.
Patent Application
20240238855
