Patent Application
20130048773
1. Field
Embodiments of the present invention relate to rolling mill laying heads and more particularly to replaceable wear elements for guide ring shrouds in laying heads.
2. Description of the Prior Art
Rolling mill laying heads form moving rolled elongated material into a series of helical continuous loop rings. Those rings may be further processed downstream by bundling them into coils of any desired number of helical turns. Known laying heads are described generally in U.S. Pat. Nos. 5,312,065; 6,769,641; and 7,011,264, the entire contents of all of which are hereby incorporated by reference as if fully contained herein.
As described in these patents rolling mill laying heads include a rotating quill that discharges the elongated material into a radially outwardly flared section, where it is received in the entry end an elongated hollow structure, such as for example a hollow tubular laying pipe. The laying pipe or other elongated hollow structure has a curved intermediate portion that is surrounded by the quill's flared section and an end portion that projects radially outwardly from and generally tangential to the quill's rotational axis. The rotating quill and the laying pipe hollow elongated structure in combination conform the rolled material into a helical curved shape. The laying pipe or other substitute hollow elongated structure may be replaced with one of a different profile and/or diameter in order to reconfigure the laying head to accommodate different dimensioned rolled material.
Further helical profiling of the rolled material is accomplished in a rotating helical guide that includes troughs for receiving the rolled material about its outer circumference. The helical guide described in U.S. Pat. No. 6,769,641 is of segmented, sector-shaped, modular rim construction with the circumferential troughs formed within the rim sectors. When it is desired to reconfigure the laying head to accommodate different dimensioned rolled material all of the rim sectors are changed out with another set having different trough profile and/or helical pitch needed to coil the new material. Whenever a specific trough segment becomes worn in service use, its entire rim sector structural member is replaced with a new one.
A generally annular ring or shroud, also commonly referred to as an end ring or guide ring, has a guide surface that circumscribes the laying pipe discharge end and helical guide, so that the elongated material is confined axially and radially as it is discharged in now fully coiled configuration to a conveyor belt for subsequent bundling and other processing. A pivoting tripper mechanism, including one or more tripper paddles, may be positioned at approximately the six o'clock or bottom position of the end ring/shroud distal the quill. Varying the pivot attack angle of the tripper mechanism relative to the ring/shroud inner diameter surface is useful to control elongated material coiling, for example to compensate for varying elongated material plasticity thickness, composition, rolling speed and cross sectional structure. The tripper paddle top surface is a control surface that is in rubbing contact with the elongated rolled material as it passes through the laying head to the discharge conveyor structure. That rubbing contact in turn causes wear or ablation of the paddle. In the past the tripper mechanism had to be separated from the laying head in order to remove and replace the end ring.
The end ring or shroud needs periodic replacement. Its inner diameter guide surface is also a wear surface that is in rubbing contact with the elongated rolled material as it passes through the laying head to the discharge conveyor structure. The rubbing contact in turn causes wear or ablation of the ring internal guide surface. Often the wear pattern about the end ring is not uniform. Under many circumstances it is found that wear proximal the six o'clock position on the ring and the tripper mechanism is more pronounced than in other circumferential portions of the ring. From a wear resistance point of view it is desirable to form the ring wear surface from relatively hard steel and further desirable to perform further surface hardening and heat treatment, but such wear treatment steps must be balanced with ease and cost of ring fabrication.
The ring/shroud structure often is fabricated from steel sheet that is rolled into a generally annular plan form having a straight cylindrical or frusto-conical, outwardly flaring circumferential walls in the axial dimension. Additional reinforcement flanges, rings and gussets are added to the annular ring. Design trade-offs require compromises between ring material wear resistance properties and fabrication ease/cost. Harder steel grades are generally more difficult to fabricate into rolled annular shapes. Post-fabrication heat treatment and other hardening processes may deform a fabricated end ring. Alternatively, if it is desired to form portions of the end ring with castings, they are more difficult to surface harden than comparable fabricated components.
In the past the only recourse to repair a worn guide end ring/shroud wear surface was to remove and replace the entire end ring with a new one. Excluding the worn wear surface, the remainder of the end ring is otherwise functionally and structurally sound for continued service. Due to the massive end ring structure and how it interoperates with the other laying head components, guide ring replacement is expensive and requires extended laying head downtime during the replacement service operation.
Accordingly, embodiments of the present invention include a selectively replaceable guide ring wear element body for a laying head end ring that is installed within the inner diameter of the end ring. The wear element body, when installed in the guide ring forms a guide surface for the elongated material that is constrained within the ring. When the wear element body is deemed to require replacement, the old one is removed from the end ring inner diameter and replaced with a new one. A plurality of wear element bodies may be installed about one or more portions of the end ring inner diameter and they form the guide surface. Size, configuration and material properties of the wear element bodies may vary for different portions within the ring guide guide surface within the end ring inner diameter. For example, a wear element body intended for installation in the six o'clock position within the ring guide inner diameter may have harder material properties or greater thickness than those for other portions of the ring guide, and/or may be adapted for quicker removal and reinstallation than for other portions of the ring guide. Some portions of the end ring may not have replaceable wear elements while other circumferential portions incorporate replaceable wear elements. Another type of wear element embodiment of the present invention is a tripper paddle forming a tripper mechanism control surface. The wear element bodies within the end ring inner diameter and the tripper paddles are replaceable external the end ring without removing the tripper mechanism from the laying head.
Another exemplary embodiment includes a selectively replaceable guide ring wear surface for a laying head guide ring, including a wear element body having a curved inner surface defining at least a portion of the guide surface that is oriented within the ring inner diameter. The wear element body has an outer surface having a profile conforming to the guide ring inner diameter that is adapted for mated coupling with the guide ring inner diameter. The wear element body also has an engagement surface adapted for mating engagement with a fastening element that is also coupled to the end ring. When the wear element body is engaged with the fastening element and end ring, it forms a portion of the guide ring wear surface within the end ring inner diameter. In some embodiments the guide ring and/or its replaceable wear surface include clearance notches to facilitate tripper paddle replacement and clearance for tripper functional operation. The wear element surfaces may be replaced without removing the tripper mechanism from the laying head system.
Another exemplary embodiment includes a method for selectively replacing a guide ring wear surface defined within the inner diameter of a laying head guide ring, by providing a wear element body having a curved inner surface defining at least a portion of the guide surface and an outer surface having a profile conforming with the guide ring inner diameter that is adapted for mated coupling with the guide ring inner diameter, and an engagement surface adapted for mating engagement with a fastening element that is coupled to the end ring. The wear element body, when engaged with the fastening element and end ring, forms a portion of the guide ring wear surface. The method further provides mating the wear body outer surface with a corresponding surface of the end ring inner diameter. After the mating step the method provides for fastening the fastening element to the end ring and the wear body engagement surface, thereby forming at least a portion of the end ring wear surface within the wear body inner diameter.
Another exemplary embodiment includes a laying head system for coiling hot rolled elongated material, comprising a quill rotating about an axis, for discharging elongated material there from. A pipe support is coaxial with the quill rotational axis. An elongated hollow member, such as a laying pipe, is coupled to the pipe support, for passage of elongated material there through. The laying pipe has a first end generally aligned with the quill rotational axis for receiving elongated material discharged from the quill, and a second end radially spaced from the rotational axis for discharging elongated material generally tangentially relative to the rotational axis. The system also includes a generally annular end ring coaxial with the quill rotational axis, for guiding elongated material discharged from the laying pipe second end into a continuous coil that is in turn discharged from the end ring. The guide ring has an inner diameter radially and axially circumscribing the laying pipe second end and further defines respective axial sides proximal and distal the quill. A pivoting tripper is coupled to the end ring along the distal side by a pivotal axis that is generally tangential to the end ring inner diameter, for selectively orienting the elongated material coil discharged from the end ring by varying pivotal angle between the tripper and the end ring. The tripper mechanism has a tripper control surface that in cooperation with the adjoining end ring guides discharged elongated material onto the awaiting conveyor into a formed loop. The guide ring of this system also has a selectively replaceable guide ring wear surface wear element body lining the end ring inner diameter, having: a curved inner surface defining at least a portion of the guide surface; and an outer surface having a profile conforming with the guide ring inner diameter that is adapted for mated coupling with the guide ring inner diameter. The wear surface element body also has an engagement surface. A fastening element engaged with the wear surface element body engagement surface and the end ring, couples the wear element body to the end ring, so that wear surface element body curved inner surface forms a portion of the guide ring wear surface within the end ring inner diameter. The tripper mechanism control surface is a tripper paddle that is selectively replaceable external the end ring. The tripper mechanism does not have to be removed from the laying head in order to replace the wear element body or tripper paddle.
These and other embodiments can be achieved in accordance with the present invention by a laying head system for coiling hot rolled elongated material, including a quill rotating about an axis, for discharging elongated material there from. A pipe support is coaxial with the quill rotational axis. A hollow elongated member, such as a laying pipe, is coupled to the pipe support, for passage of elongated material there through. The laying pipe has a first end generally aligned with the quill rotational axis for receiving elongated material discharged from the quill, and a second end radially spaced from the rotational axis for discharging elongated material generally tangentially relative to the rotational axis. In this system a generally annular end ring is coaxial with the quill rotational axis, for guiding elongated material discharged from the laying pipe second end into a continuous coil that is in turn discharged from the end ring. The annular end ring/shroud has an inner diameter radially and axially circumscribing the laying pipe second end, and defines respective axial sides proximal and distal the quill, as well as an axially inset notch. The inset notch further defines a notch face surface. This embodiment includes a pivoting tripper coupled to the end ring along the distal side by a pivotal axis that is generally tangential to the end ring inner diameter. The tripper selectively orients the elongated material coil discharged from the end ring by varying pivotal angle between the tripper and the guide surface. The tripper has a tripper control surface inset within and abutting the end ring notch that in cooperation with the adjoining notch face guides discharged elongated material into a formed loop. The guide ring/shroud of this system embodiment has a selectively replaceable guide ring wear surface wear element body having a curved inner surface defining at least a portion of the guide surface and notch face. The wear element body also has an outer surface having a profile conforming to the guide ring inner diameter that is adapted for mated coupling with the guide ring inner diameter, as well as an engagement surface. In this system embodiment a fastening element is engaged with the wear surface element body engagement surface and the end ring, for coupling the wear element body to the end ring, so that wear surface element body curved inner surface forms a portion of the guide ring wear surface.
The features of the present invention embodiments may be applied jointly or severally in any combination or sub-combination by those skilled in the art. Further features of embodiments of the present invention, and the advantages offered thereby, are explained in greater detail hereinafter with reference to specific embodiments illustrated in the accompanying drawings, wherein like elements are indicated by like reference designators.
The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
After considering the following description, those skilled in the art will clearly realize that the teachings of the present invention can be readily utilized in rolling mill laying heads and more particularly to replaceable wear elements for guide ring shrouds in laying heads. The present invention facilitates selective rapid and efficient replacement of worn portions of guide ring shrouds by removing and replacing modular wear body elements without the need for replacing the entire guide ring.
Referring generally to
The laying head system 30 includes a generally horn shaped quill 50 that rotates about an axis. A hollow laying pipe 60 has a generally helical axial profile of increasing radius, with a first end 62 that that is aligned with the rotational axis of quill 50 and receives elongated material discharged from the quill. The laying pipe 60 has a second end that is spaced radially outwardly from and generally tangential to the quill 50 rotational axis and thus discharges the elongated material generally tangentially to the rotating quill. The laying pipe 60 is coupled to a pipe support 70 that is in turn coupled coaxially to the quill 50, so that all three components rotate synchronously about the quill rotational axis. Quill 50 rotational speed is selected based upon, among other factors, the elongated material M structural dimensions and material properties, advancement speed S, and desired coil diameter.
In this embodiment, as elongated material M is discharged from the laying pipe second end 64, it is directed into a ring guide 80 having guide rim segments 82 into which are formed a guide trough channel 84 having a helical pitch profile, such as that described in commonly owned U.S. Pat. No. 6,769,641. As the elongated material M is advanced through the ring guide 80 it is conformed into a continuous loop helix.
As stated in the '641 patent, the segmented ring guide enables relatively easy reconfiguration of the ring guide helical pitch to accommodate different elongated materials by changing the rim segments 82 without disassembling and replacing the entire ring guide 80. Alternatively, a laying head system may be constructed with a solid structure ring guide or no ring guide at all.
As previously noted, the elongated material M is configured into a continuous looped coil as it rides within the ring guide 80 helical trough channel 84. Ring guide 80 is coupled to the pipe support 70 and rotates coaxially with the quill 50. The helical trough 84 advancement rotational speed is harmonized with the elongated material M advancement speed S, so there is little relative linear motion speed between the two abutting objects and less rubbing wear of the trough 84 surfaces that contact the coiling material.
Stationary end ring 90 has an inner diameter that is coaxial with the quill 50 rotational axis and circumscribes the laying pipe 60 second end 62 as well as the ring guide 80. The end ring 90 counteracts centrifugal force imparted on the elongated material M as it is discharged from the laying pipe 60 second end 62 and advances along the ring guide 80 helical trough channel 84 by radially restraining the material within the end ring inner diameter guide surface. High relative speed between the advancing elongated material M and the stationary end ring 90 causes rubbing wear on the end ring inner diameter guide surface.
Referring to
Referring to
The guide end ring 90 embodiment shown in
Referring to
As is shown in
In this exemplary embodiment in order to provide clearance for pivoting motion of the tripper mechanism 150 the lower annular split ring wear element 112 has respective left, bottom and right clearance notches 122, 124, 126 that abut the corresponding annular support ring notches 94, 96, 98. Inclusion of tripper mechanism clearance notches in either the wear element body 110 or the ring 90 or both is optional when practicing the present invention.
The wear element body 110 upper and lower annular split ring wear elements 112, 114 include a fastener engagement surface 130 that is adapted, for mating engagement with a fastening element, so that the wear body is rigidly coupled to the end ring 90. Referring to
Alternative ways to couple the wear element body 112 and the end ring 90 are shown in
Another alternative way to couple the wear element body 112 to the end ring 90 is by use of a clamp mechanism 141, including a clamp screw 142 and clamp nut 144. Rotating the clamp nut increases clamping force FS between the wear element 112 and the annular support ring. When wear element body 112 replacement is necessary it is removed by loosening the clamping mechanism 141. Similarly, the
Any combination of the exemplary wear body 110 coupling mechanisms may be utilized in an end ring 90. For example, if it is contemplated that one or more sections of wear body 110 will be changed more frequently than other sections, it may be advantageous to utilize the clamping screw or hydraulic cylinder wear element body retention mechanisms of
An alternative embodiment of wear element body 110′ is shown in
Another alternative embodiment of end ring 90′ is shown in
Use of replaceable wear element bodies 110, 110′ also facilitates optimization of wear properties and fabrication efficiency within an end ring 90 or 90′. Wear element bodies can be constructed of a relatively harder material and/or heat treated to a greater hardness than the end ring 90 structural elements, such as the annular support ring 92. Generally it is more difficult to fabricate components from harder material, and heat treatment processes increase risk of work piece distortion. By practicing the present invention the end ring 90 structural components, such as the annular support ring 92, can be constructed of a softer steel and/or castings to ease their fabrication. Harmoniously, the wear elements 110 can be constructed of a harder, potentially costlier material, and/or given additional heat or other surface treatment than necessary for the purely structural support elements. For example, a wear element can be constructed of cold rolled 1020 series steel, then heat treated. Risk of heat treatment distortion can be reduced by using multiple sector-shaped wear elements within an end ring, so that small individual element distortion variations do not impede final assembly of the wear ring. Alternatively, wear elements 110 can be constructed of a harder material, such as AR 800 series steel, that while relatively more difficult to fabricate than milder steel, only comprise a relatively small portion of the effort needed to fabricate a complete end ring 90, 90′.
As shown in
The end ring 90 and tripper mechanism 150 also facilitate rapid replacement of worn tripper paddles 152, 154, 156 without the need to remove the tripper actuator mechanism from the end ring. For example, center tripper paddle 152 is coupled to center tripper actuator mechanism 153 by removable fasteners 158 (e.g., machine screws and nuts). The paddle 152 along its pivot axis is oriented proximal the undercut ring bottom notch 96 and wear element body bottom notch 124 formed respectively in the annular support ring 92 and wear element body 112 (see
The present invention facilitates relatively easy field repair and maintenance of a laying head system 30 by combination of one or more of modular replaceable laying pipe 60, helical ring 80 rim segments 82, end ring 90 wear element bodies 110 and tripper mechanism 150 paddles 152, 154, 156. The laying head system does not require total disassembly in order to replace any of these modular components. More particularly, the laying pipe 60 can be replaced without disassembling the entire quill structure 50, the pipe support 70, helical ring 80 or end ring 90. Rim segments 82 can be jointly or severally replaced without removing the entire helical ring 80 structure. Similarly, wear element body 110 segments, such as 112, 114, 112′ or 112A-N′ and tripper paddles 152, 154, 156 can be removed from the laying head 30 discharge end 34 without removing the entire end ring 90 structure or the tripper mechanism 150.
Existing end rings, whether unused or already worn through field use, can be retrofitted with replaceable guide surfaces by lining the existing annular ring inner diameter with wear element bodies, using the installation methods of the present invention. The existing ring inner diameter can be reconditioned to replace worn surfaces using known repair techniques, such as installation of replacement metal patches, weld bead build up, or by hot plasma deposition, and subsequent grinding to achieve a desired surface finish. If the existing end ring has relatively little wear a wear element body can be installed without the necessity of ring reconditioning. Pass-through apertures can be formed in the existing ring to facilitate fastening of the wear element body lining to the ring inner diameter.
A method for selectively replacing a guide surface of a guide ring of a laying head system for coiling hot rolled elongated material. The system has: a quill rotating about an axis, for discharging elongated, material therefrom; a pipe support coaxial with the quill rotational axis; and a hollow elongated member, such as a laying pipe, coupled to the pipe support, for passage of elongated material there through, the laying pipe or other hollow elongated member having a first end generally aligned with the quill rotational axis for receiving elongated material discharged from the quill, and a second end radially spaced from the rotational axis for discharging elongated material generally tangentially relative to the rotational axis. The system also has a generally annular end ring coaxial with the quill rotational axis, for guiding elongated material discharged from the laying pipe second end into a continuous coil that is in turn discharged from the end ring. The end ring further has an inner diameter radially and axially circumscribing the laying pipe second end and defines respective axial sides proximal and distal the quill. The end ring also defines an axially inset notch within its distal side. The inset notch further defines a notch face surface. A pivoting tripper is coupled to the end ring along the distal side by a pivotal axis that is generally tangential to the end ring inner diameter, for selectively orienting the elongated material coil discharged from the end ring by varying pivotal angle between the tripper and the end ring. The tripper has a tripper control surface inset within and abutting the end ring notch that in cooperation with the adjoining notch face guides discharged elongated material into a formed loop. The method for selectively replacing the guide surface comprises providing a wear element body having: a curved inner surface defining at least a portion of the guide surface and notch face; an outer surface having a profile conforming with the guide ring inner diameter that is adapted for mated coupling with the guide ring inner diameter; and an engagement surface adapted for mating engagement with a fastening element that is coupled to the end ring, the wear element body, when engaged with the fastening element and end ring, forming a portion of the guide ring wear surface. The method further comprises mating the wear body outer surface with a corresponding surface of the end ring inner diameter; and fastening the fastening element to the end ring and the wear body engagement surface, thereby forming at least a portion of the end ring guide wear surface with the wear body inner surface.
Selectively replaceable wear surfaces in a laying head system for coiling hot rolled elongated material. The system has: a quill rotating about an axis, for discharging elongated material therefrom; a pipe support coaxial with the quill rotational axis; a hollow elongated member, such as a laying pipe, coupled to the pipe support, for passage of elongated material there through. The hollow elongated laying pipe has a first end generally aligned with the quill rotational axis for receiving elongated material discharged from the quill, and a second end radially spaced from the rotational axis for discharging elongated material generally tangentially relative to the rotational axis. A generally annular end ring is coaxial with the quill rotational axis, for guiding elongated material discharged from the laying pipe second end into a continuous coil that is in turn discharged from the end ring. The end ring has an inner diameter radially and axially circumscribing the elongated hollow member laying pipe second end, and defines respective axial sides proximal and distal the quill, and an axially inset notch defined within the end ring proximal the guide surface distal side. The inset notch further defines a notch face surface. A pivoting tripper mechanism is coupled to the end ring along the guide surface distal side by a pivotal axis that is generally tangential to the end ring inner diameter, for selectively orienting the elongated material coil discharged from the end ring by varying pivotal angle between the tripper and the end ring, the tripper has a tripper control surface inset within and abutting the end ring notch, that in cooperation with the adjoining end ring inner diameter guides discharged elongated material into a formed loop. The selectively replaceable laying head wear surfaces comprise an end ring wear element body having a curved inner surface defining at least a portion of the guide surface and notch face; an outer surface having a profile conforming with the guide ring inner diameter that is adapted for mated coupling with the guide ring inner diameter; and an engagement surface adapted for mating engagement with a fastening element that is coupled to the end ring. The wear element body, when engaged with the fastening element and end ring, forms a portion of the guide ring replaceable wear surface. The selectively replaceable wear surfaces may further comprise a tripper wear element having a tripper paddle defining the tripper control surface coupled to the tripper mechanism external the end ring; and selectively removable tripper fasteners coupling the tripper paddle to the tripper mechanism, that are accessible for removal external the end ring.
Although various embodiments which incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings.
