Patent Grant
9333546
The present invention relates to a roller leveler for flattening a metal sheet or plate having a cut-sheet form and a metal sheet flattening method.
In the process of manufacturing a metal sheet, such as a steel sheet, the metal sheet is subjected to rolling and cooling steps, in which the metal sheet undergoes deformation, such as warping and/or waving. Accordingly, in order to remedy the deformation, such as warping and/or waving, and thereby to flatten the metal sheet, a roller leveler, which includes a plurality of leveling rolls disposed on upper and lower sides in a staggered state, is used (for example, Patent Document 1).
The roller leveler is configured to pass a metal sheet to be flattened between the lower rolls and the upper rolls, while pushing the upper rolls toward the lower rolls or pushing the lower rolls toward the upper rolls, to repeatedly apply bending to the metal sheet, and thereby to planarize the warping and/or waving of the metal sheet. At this time, the pressing amount of the respective rolls of the roller leveler is suitably set to bend the metal sheet at a yield ratio preferably of 0.7 or more.
[Patent Document 1]
Jpn. Pat. Appln. KOKAI Publication No. 2009-255148
When a conventional roller leveler is used to flatten a metal sheet having a cut-sheet form, the driving force for passing the metal sheet depends on the torque of the leveling rolls. In order to flatten a thin metal sheet made of a material with a larger yield stress, the diameter of the rolls needs to be small. This brings about a problem such that, if it is arranged to ensure the pressing amount necessary for the flattening, the torque of the work rolls becomes insufficient to pass the metal sheet.
This is because, in order to apply a sufficient pressing amount, drive shafts connected to drive the leveling rolls need to have a diameter smaller than that of the rolls. For this reason, when the leveling rolls have a small diameter to flatten a thin metal sheet, which is made of a material with a larger yield stress, their torque inevitably becomes small. In this case, the torque may be smaller than the value necessary for passing the metal sheet if it is arranged to ensure the yield ratio necessary for flattening the metal sheet.
In light of this problem, conventionally, when flattening is performed on a metal sheet having a small thickness and a large yield stress, it is necessary to restrictively set the pressing amount of the leveling rolls to a value that enables the sheet passing even by the torque of the leveling rolls. Consequently, there may be a case where the metal sheet is not sufficiently flattened.
The present invention has been made under the circumstances, and an object of the present invention is to provide a roller leveler and a metal sheet flattening method, which can sufficiently flatten a metal sheet having a small thickness and a large yield stress.
In order to solve the problem mentioned above, the present invention includes the following aspects.
According to a first aspect of the present invention, there is provided a roller leveler for flattening a metal sheet having a cut-sheet form, the roller leveler including: a plurality of leveling rolls disposed in a staggered state on upper and lower sides of a pass line of the metal sheet to be flattened and configured to rotate to sandwich and flatten the metal sheet while passing the metal sheet therethrough; a hydraulic pressing cylinder configured to press the metal sheet via the leveling rolls; a drive unit configured to rotate the leveling rolls to pass the metal sheet; and a pinch roll unit disposed on one side of a leveling roll array area, in which the leveling rolls are disposed along the pass line of the metal sheet, and having a pair of pinch rolls configured to pinch the metal sheet and apply a drawing force thereto, wherein the roller leveler is configured to cause the pressing cylinder to press the metal sheet via the leveling rolls with a pressing amount necessary for flattening the metal sheet while passing the metal sheet between the leveling rolls by a driving force applied by the drive unit and the drawing force applied by the pinch rolls.
According to a second aspect of the present invention, there is provided a roller leveler for flattening a metal sheet having a cut-sheet form, the roller leveler including: a leveling unit that has a plurality of leveling rolls disposed in a staggered state on upper and lower sides of a pass line of the metal sheet to be flattened and configured to rotate to sandwich and flatten the metal sheet while passing the metal sheet therethrough, a hydraulic pressing cylinder configured to press the metal sheet via the leveling rolls, and a drive unit configured to rotate the leveling rolls to pass the metal sheet; a first pinch roll unit and a second pinch roll unit respectively disposed on opposite outsides of a leveling roll array area, in which the leveling rolls are disposed along the pass line of the metal sheet, each of the first and second pinch roll units having a pair of pinch rolls configured to pinch the metal sheet and apply a drawing force thereto; and a control system configured to control flattening of the metal sheet, wherein the control system is configured to perform control such that the metal sheet is passed through the leveling roll array area in a first direction oriented from the first pinch roll unit toward the second pinch roll unit, in a state where the metal sheet is not pressed or in a state where the metal sheet is pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; then, when a leading end of the metal sheet reaches the second pinch roll unit, the pressing amount given by the pressing cylinder is increased to a value necessary for flattening the metal sheet, and a drawing force in the first direction is applied by the second pinch roll unit to the metal sheet to pass the metal sheet; then, when a tail end of the metal sheet has passed through the leveling roll array area, a feed direction of the metal sheet is changed from the first direction to a second direction opposite to the first direction; then the metal sheet is passed through the leveling roll array area in the second direction, in a state where the metal sheet is not pressed or in a state where the metal sheet is pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; and then, when the tail end of the metal sheet reaches the first pinch roll unit, the pressing amount given by the pressing cylinder is increased to a value necessary for flattening the metal sheet, and a drawing force in the second direction is applied by the first pinch roll unit to the metal sheet to pass the metal sheet.
According to a third aspect of the present invention, there is provided a roller leveler for flattening a metal sheet having a cut-sheet form, the roller leveler including: a leveling unit that has a plurality of leveling rolls disposed in a staggered state on upper and lower sides of a pass line of the metal sheet to be flattened and configured to rotate to sandwich and flatten the metal sheet while passing the metal sheet therethrough, a hydraulic pressing cylinder configured to press the metal sheet via the leveling rolls, and a drive unit configured to rotate the leveling rolls to pass the metal sheet; a pinch roll unit disposed on one outside of a leveling roll array area, in which the leveling rolls are disposed along the pass line of the metal sheet, and having a pair of pinch rolls configured to pinch the metal sheet and apply a drawing force thereto; a metal sheet reversing mechanism disposed on the other outside of the leveling roll array area, and configured to turn the metal sheet to reverse positions of leading and tail ends thereof; and a control system configured to control flattening of the metal sheet, wherein the control system is configured to perform control such that the metal sheet is passed through the leveling roll array area from a metal sheet reversing mechanism-side of the leveling unit, in a state where the metal sheet is not pressed or in a state where the metal sheet is pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; then, when a leading end of the metal sheet reaches the pinch roll unit, the pressing amount given by the pressing cylinder is increased to a value necessary for flattening the metal sheet, and a drawing force is applied by the pinch roll unit to the metal sheet to pass the metal sheet; then, when a tail end of the metal sheet has passed through the leveling roll array area, the metal sheet is transferred into the metal sheet reversing mechanism and the metal sheet is turned to reverse positions of the leading end and the tail end thereof; then, the metal sheet thus reversed is passed through the leveling roll array area from the metal sheet reversing mechanism-side, in a state where the metal sheet is not pressed or in a state where the metal sheet is pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; and then, when the leading end of the metal sheet reaches the pinch roll unit, the pressing amount given by the pressing cylinder is increased to a value necessary for flattening the metal sheet, and a drawing force is applied by the pinch roll unit to the metal sheet to pass the metal sheet.
According to a fourth aspect of the present invention, there is provided a roller leveler for flattening a metal sheet having a cut-sheet form, the roller leveler including: first and second leveling units arrayed along a pass direction of the metal sheet, and each having a plurality of leveling rolls disposed in a staggered state on upper and lower sides of a pass line of the metal sheet to be flattened and configured to rotate to sandwich and flatten the metal sheet while passing the metal sheet therethrough, a hydraulic pressing cylinder configured to press the metal sheet via the leveling rolls, and a drive unit configured to rotate the leveling rolls to pass the metal sheet; a pinch roll unit disposed between the first leveling unit and the second leveling unit, and having a pair of pinch rolls configured to pinch the metal sheet and apply a drawing force thereto; and a control system configured to control flattening of the metal sheet, wherein the control system is configured to perform control such that the second leveling unit is set in a state where the metal sheet is to be not pressed or in a state where the metal sheet is to be pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; then the metal sheet is passed, toward the second leveling unit, through a first leveling roll array area of the first leveling unit, in which the leveling rolls are disposed, in a state where the metal sheet is not pressed or in a state where the metal sheet is pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; then, when a leading end of the metal sheet reaches the pinch roll unit, the pressing amount given by the pressing cylinder of the first leveling unit is increased to a value necessary for flattening the metal sheet, and a drawing force is applied by the pinch roll unit to the metal sheet to pass the metal sheet; then, when a tail end of the metal sheet reaches the pinch roll unit, the first leveling unit is set in a state where the metal sheet is to be not pressed or in a state where the metal sheet is to be pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; and then the pressing amount given by the pressing cylinder of the second leveling unit is increased to a value necessary for flattening the metal sheet, and a drawing force is applied by the pinch roll unit to the metal sheet to pass the metal sheet toward the first leveling unit.
According to a fifth aspect of the present invention, there is provided a roller leveler including: a plurality of leveling rolls disposed in a staggered state on upper and lower sides of a pass line of a metal sheet to be flattened and configured to rotate to sandwich and flatten the metal sheet while passing the metal sheet therethrough; a plurality of backup rolls that back up the plurality of leveling rolls on the upper and lower sides; a pair of roll frames that support the leveling rolls and the backup rolls on the upper and lower sides, respectively; a pair of frames that support the pair of roll frames on the upper and lower sides, respectively; a hydraulic pressing cylinder configured to press one of the pair of frames to press the metal sheet via one of the roll frames and the leveling rolls; a drive unit configured to rotate the leveling rolls; a plurality of hydraulic crowning cylinders arrayed along a width direction perpendicular to a pass direction of the metal sheet between one of the frames configured to be pressed by the pressing cylinder and a corresponding one of the roll frames; a pinch roll unit disposed on one side of a leveling roll array area, in which the leveling rolls are disposed along the pass line of the metal sheet, and having a pair of pinch rolls configured to pinch the metal sheet and apply a drawing force thereto; and a control system configured to control flattening of the metal sheet, wherein the control system is configured to perform control such that the pressing cylinder presses the metal sheet via the leveling rolls with a pressing amount necessary for flattening the metal sheet while the metal sheet is passed between the leveling rolls by a driving force applied by the drive unit and the drawing force applied by the pinch rolls, and wherein the control system is configured to obtain lateral deflection amounts of the pair of frames, to calculate necessary tightening amounts of the respective hydraulic crowning cylinders necessary for compensating for the deflection amounts, and to control tightening of the respective hydraulic crowning cylinders based on the necessary tightening amounts.
In the fifth aspect, it is preferable that the control system be configured to calculate necessary tightening amounts of the respective hydraulic crowning cylinders necessary for compensating for compressive deformation of the pressing cylinder, the hydraulic crowning cylinders, the pair of roll frames, the backup rolls, and the leveling rolls based on information on the compressive deformation, and to control tightening of the respective hydraulic crowning cylinders based on a total value of the necessary tightening amounts necessary for compensating for the compressive deformation and the necessary tightening amounts necessary for compensating for the deflection amounts of the pair of frames.
According to a sixth aspect of the present invention, there is provided a metal sheet flattening method of flattening a metal sheet having a cut-sheet form in a roller leveler, which includes a plurality of leveling rolls disposed in a staggered state on upper and lower sides of a pass line of the metal sheet to be flattened and configured to rotate to sandwich and flatten the metal sheet while passing the metal sheet therethrough, a hydraulic pressing cylinder configured to press the metal sheet via the leveling rolls, a drive unit configured to rotate the leveling rolls to pass the metal sheet, and a pinch roll unit disposed on one side of a leveling roll array area, in which the leveling rolls are disposed along the pass line of the metal sheet, and having a pair of pinch rolls configured to pinch the metal sheet and apply a drawing force thereto, the method including: causing the pressing cylinder to press the metal sheet via the leveling rolls with a pressing amount necessary for flattening the metal sheet, while passing the metal sheet between the leveling rolls by a driving force applied by the drive unit and the drawing force applied by the pinch rolls.
According to a seventh aspect of the present invention, there is provided a metal sheet flattening method of flattening a metal sheet having a cut-sheet form in a roller leveler, which includes a leveling unit that has a plurality of leveling rolls disposed in a staggered state on upper and lower sides of a pass line of the metal sheet to be flattened and configured to rotate to sandwich and flatten the metal sheet while passing the metal sheet therethrough, a hydraulic pressing cylinder configured to press the metal sheet via the leveling rolls, and a drive unit configured to rotate the leveling rolls to pass the metal sheet, and a first pinch roll unit and a second pinch roll unit respectively disposed on opposite outsides of a leveling roll array area, in which the leveling rolls are disposed along the pass line of the metal sheet, each of the first and second pinch roll units having a pair of pinch rolls configured to pinch the metal sheet and apply a drawing force thereto, the method including: passing the metal sheet through the leveling roll array area in a first direction oriented from the first pinch roll unit toward the second pinch roll unit, in a state where the metal sheet is not pressed or in a state where the metal sheet is pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; then, when a leading end of the metal sheet reaches the second pinch roll unit, increasing the pressing amount given by the pressing cylinder to a value necessary for flattening the metal sheet, and applying a drawing force in the first direction by the second pinch roll unit to the metal sheet to pass the metal sheet; then, when a tail end of the metal sheet has passed through the leveling roll array area, changing a feed direction of the metal sheet from the first direction to a second direction opposite to the first direction; then passing the metal sheet through the leveling roll array area in the second direction, in a state where the metal sheet is not pressed or in a state where the metal sheet is pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; and then, when the tail end of the metal sheet reaches the first pinch roll unit, increasing the pressing amount given by the pressing cylinder to a value necessary for flattening the metal sheet, and applying a drawing force in the second direction by the first pinch roll unit to the metal sheet to pass the metal sheet.
According to an eighth aspect of the present invention, there is provided a metal sheet flattening method of flattening a metal sheet having a cut-sheet form in a roller leveler, which includes a leveling unit that has a plurality of leveling rolls disposed in a staggered state on upper and lower sides of a pass line of the metal sheet to be flattened and configured to rotate to sandwich and flatten the metal sheet while passing the metal sheet therethrough, a hydraulic pressing cylinder configured to press the metal sheet via the leveling rolls, and a drive unit configured to rotate the leveling rolls to pass the metal sheet, a pinch roll unit disposed on one outside of a leveling roll array area, in which the leveling rolls are disposed along the pass line of the metal sheet, and having a pair of pinch rolls configured to pinch the metal sheet and apply a drawing force thereto, and a metal sheet reversing mechanism disposed on the other outside of the leveling roll array area, and configured to turn the metal sheet to reverse positions of leading and tail ends thereof, the method including: passing the metal sheet through the leveling roll array area from a metal sheet reversing mechanism-side of the leveling unit, in a state where the metal sheet is not pressed or in a state where the metal sheet is pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; then, when a leading end of the metal sheet reaches the pinch roll unit, increasing the pressing amount given by the pressing cylinder to a value necessary for flattening the metal sheet, and applying a drawing force by the pinch roll unit to the metal sheet to pass the metal sheet; then, when a tail end of the metal sheet has passed through the leveling roll array area, transferring the metal sheet into the metal sheet reversing mechanism and turning the metal sheet to reverse positions of the leading end and the tail end thereof; then, passing the metal sheet thus reversed through the leveling roll array area from the metal sheet reversing mechanism-side, in a state where the metal sheet is not pressed or in a state where the metal sheet is pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; and then, when the leading end of the metal sheet reaches the pinch roll unit, increasing the pressing amount given by the pressing cylinder to a value necessary for flattening the metal sheet, and applying a drawing force by the pinch roll unit to the metal sheet to pass the metal sheet.
According to a ninth aspect of the present invention, there is provided a metal sheet flattening method of flattening a metal sheet having a cut-sheet form in a roller leveler, which includes first and second leveling units arrayed along a pass direction of the metal sheet, and each having a plurality of leveling rolls disposed in a staggered state on upper and lower sides of a pass line of the metal sheet to be flattened and configured to rotate to sandwich and flatten the metal sheet while passing the metal sheet therethrough, a hydraulic pressing cylinder configured to press the metal sheet via the leveling rolls, and a drive unit configured to rotate the leveling rolls to pass the metal sheet, and a pinch roll unit disposed between the first leveling unit and the second leveling unit, and having a pair of pinch rolls configured to pinch the metal sheet and apply a drawing force thereto, the method including: setting the second leveling unit in a state where the metal sheet is to be not pressed or in a state where the metal sheet is to be pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; then passing the metal sheet, toward the second leveling unit, through a first leveling roll array area of the first leveling unit, in which the leveling rolls are disposed, in a state where the metal sheet is not pressed or in a state where the metal sheet is pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; then, when a leading end of the metal sheet reaches the pinch roll unit, increasing the pressing amount given by the pressing cylinder of the first leveling unit to a value necessary for flattening the metal sheet, and applying a drawing force by the pinch roll unit to the metal sheet to pass the metal sheet; then, when a tail end of the metal sheet reaches the pinch roll unit, setting the first leveling unit in a state where the metal sheet is to be not pressed or in a state where the metal sheet is to be pressed by the pressing cylinder with a pressing amount small enough to allow the metal sheet to be passed by the drive unit; and then increasing the pressing amount given by the pressing cylinder of the second leveling unit to a value necessary for flattening the metal sheet, and applying a drawing force by the pinch roll unit to the metal sheet to pass the metal sheet toward the first leveling unit.
According to a tenth aspect of the present invention, there is provided a metal sheet flattening method of flattening a metal sheet having a cut-sheet form in a roller leveler, which includes a plurality of leveling rolls disposed in a staggered state on upper and lower sides of a pass line of a metal sheet to be flattened and configured to rotate to sandwich and flatten the metal sheet while passing the metal sheet therethrough, a plurality of backup rolls that back up the plurality of leveling rolls on the upper and lower sides, a pair of roll frames that support the leveling rolls and the backup rolls on the upper and lower sides, respectively, a pair of frames that support the pair of roll frames on the upper and lower sides, respectively, a hydraulic pressing cylinder configured to press one of the pair of frames to press the metal sheet via one of the roll frames and the leveling rolls, a drive unit configured to rotate the leveling rolls, a plurality of hydraulic crowning cylinders arrayed along a width direction perpendicular to a pass direction of the metal sheet between one of the frames configured to be pressed by the pressing cylinder and a corresponding one of the roll frames, and a pinch roll unit disposed on one side of a leveling roll array area, in which the leveling rolls are disposed along the pass line of the metal sheet, and having a pair of pinch rolls configured to pinch the metal sheet and apply a drawing force thereto, the method including: causing the pressing cylinder to press the metal sheet via the leveling rolls with a pressing amount necessary for flattening the metal sheet, while passing the metal sheet between the leveling rolls by a driving force applied by the drive unit and the drawing force applied by the pinch rolls; and obtaining lateral deflection amounts of the pair of frames; calculating necessary tightening amounts of the respective hydraulic crowning cylinders necessary for compensating for the deflection amounts; and controlling tightening of the respective hydraulic crowning cylinders based on the necessary tightening amounts.
In the tenth aspect, it is preferable that the method include calculating necessary tightening amounts of the respective hydraulic crowning cylinders necessary for compensating for compressive deformation of the pressing cylinder, the hydraulic crowning cylinders, the pair of roll frames, the backup rolls, and the leveling rolls based on information on the compressive deformation; and controlling tightening of the respective hydraulic crowning cylinders based on a total value of the necessary tightening amounts necessary for compensating for the compressive deformation and the necessary tightening amounts necessary for compensating for the deflection amounts of the pair of frames.
In the present invention, it is preferable that the metal sheet to be flattened be a steel sheet having a thickness of 2.0 to 25.4 mm and a yield stress of 400 to 1,800 MPa.
Embodiments of the present invention will now be described with reference to the accompanying drawings.
In this specification, the term “press down” is intended to include not only a case where the pressure is applied downward as shown in
On the side opposite to the upper leveling rolls 6 with respect to the pass line of the metal sheet P, a plurality of lower leveling rolls 8 are disposed and supported by a lower roll frame 10 disposed therebelow. A plurality of lower backup rolls 9 are disposed between the respective leveling rolls 8 and the lower roll frame 10 to back up the lower leveling rolls 8. The lower backup rolls 9 are each formed of a short body and supported by the lower roll frame 10 along the axial direction of the lower leveling rolls 8. The lower roll frame 10 is disposed on the lower frame 3. In place of the pressing cylinders 4 for pressing the upper leveling rolls 6, pressing cylinders for pressing the lower leveling rolls 8 may be used.
The upper leveling rolls 6 and the lower leveling rolls 8 are respectively provided with drive units 15 (
In the leveling unit 60, the upper frame 2 and the upper roll frame 5 are coupled with each other by a plurality of hydraulic crowning cylinders 12 disposed therebetween. As shown in
As shown in
Load cells (or hydraulic pressure converters) 23 are attached between the pressing cylinders 4 and the housing 1, and used to detect compressive deformation of the pressing cylinders 4, hydraulic crowning cylinders 12, upper roll frame 5, upper backup rolls 7, upper leveling rolls 6, lower leveling rolls 8, lower backup rolls 9, and lower roll frame 10.
A first pinch roll unit 30a including a pair of pinch rolls 31a and a second pinch roll unit 30b including a pair of pinch rolls 31b are respectively disposed on the opposite outsides of the area, in which the leveling rolls are disposed, or the leveling roll array area, along the pass line of the metal sheet P to pinch and draw the metal sheet P. The clearance between the pair of pinch rolls 31a is adjusted by a pinch roll cylinder 32a, and the clearance between the pair of pinch rolls 31b is adjusted by a pinch roll cylinder 32b. The pinch rolls 31a and the pinch rolls 31b are configured to be rotated respectively by drive units 33a and 33b each including a rotary motor to provide a drawing force to draw the metal sheet P, the material to be flattened. Further, guide rolls 34a and 34b are respectively disposed between the pair of pinch rolls 31a and the leveling roll array area and between the pair of pinch rolls 31b and the leveling roll array area.
A plurality of optical sensors 41 are disposed along the pass line between the pinch rolls 31a and 31b and they serve as a position detection mechanism to detect the position of the leading end of the metal sheet P. The optical sensors 41 are used to detect the leading end, and then a pulse generator (not shown) is used to perform tracking on the leading end of the metal sheet P.
The roller leveler 100 according to this embodiment is designed such that a control system 50 controls its respective components. The control system 50 includes a process controller having a CPU, a user interface connected to the process controller and having a keyboard and a display, and a storage section that stores recipes containing control programs (software) and process condition data recorded therein. A required recipe is retrieved from the storage section and executed by the process controller in accordance with an instruction or the like input through the user interface. Consequently, the roller leveler 100 can perform a predetermined process (operational sequence) as described later under the control of the process controller. The recipes containing control programs and process condition data that are stored in a computer readable storage medium, such as a magnetic disk (flexible disk, hard disk, etc.), an optical disk (CD, DVD, etc.), a magneto-optical disk (MO, etc.), and/or a semiconductor memory, may be used. Alternatively, the recipes may be available online, that is, may be transmitted from another apparatus through, e.g., a dedicated line, as needed.
In order to flatten the metal sheet P (i.e., to perform leveling), the control system 50 controls the penetration depth (pressing amount) of the leveling rolls 6 and 8 given by the pressing cylinders 4, controls the press timing and penetration depth (pressing amount) of the pinch roll cylinder 32a or 32b, and controls the drive units 15, 33a, and 33b, based on positional information on the metal sheet P obtained by the optical sensors 41. Further, the control system 50 receives information on the deflection of the upper frame 2 and the lower frame 3 sent thereto from the deflection detection sensors 21 and 22, or it receives, in addition to this information, information on the compressive deformation of the pressing cylinders 4, hydraulic crowning cylinders 12, upper roll frame 5, upper backup rolls 7, upper leveling rolls 6, lower leveling rolls 8, lower backup rolls 9, and lower roll frame 10 sent thereto. Then, the control system 50 uses its calculating function to calculate necessary tightening amounts of the respective hydraulic crowning cylinders 12 based on the pieces of information mentioned above, so that it controls the tightening by the respective hydraulic crowning cylinders 12 based on positional information obtained by the position detection sensors in the respective hydraulic crowning cylinders 12.
Next, an explanation will be given of an operation of the roller leveler 100 thus structured, in flattening a metal sheet P having a cut-sheet form.
When the leveling rolls 6 and 8 are used to reduce the internal stress of the metal sheet P by their driving force and flatten the metal sheet P, it is necessary to satisfy the following formula (1), where, in association with the metal sheet P, “t” (mm) is sheet thickness, E (N/mm2) is Young's modulus, δy (N/mm2) is yield stress, D (mm) is roll diameter, and η is yield ratio.
1−η=(δy·D)/(E·t) (1)
In this formula, the yield ratio is required to be 0.7 or more to sufficiently reduce the internal stress. Accordingly, it is necessary to satisfy the following formula (2).
0.3≧(δy·D)/(E·t) (2)
This formula can be transformed into the following formula (3).
D≦0.3·(E·t)/δy (3)
Accordingly, it is necessary that the smaller the sheet thickness “t” is or the larger the yield stress δy is, the smaller the diameter of the leveling rolls is set. However, the smaller the diameter of the leveling rolls is, the smaller the torque of the leveling rolls becomes.
Accordingly, when the leveling rolls are used to flatten a metal sheet having a small thickness and a large yield stress and are given a penetration depth (pressing amount) to obtain a yield ratio necessary for flattening the metal sheet, the material to be flattened, it may become difficult to pass the metal sheet because of an insufficient torque of the leveling rolls.
According to this embodiment made in light of this problem, the pinch rolls 31a or 31b are used to apply a drawing force to the metal sheet P to assist the driving force of the leveling rolls. Consequently, it is possible to pass the metal sheet while applying the pressing amount necessary for the flattening, even when the metal sheet has a small thickness and a large yield stress.
Specifically, the sheet passing is performed as shown in
At first, as shown in
While the flattening described above is performed to the tail end of the metal sheet P, such a part of the metal sheet P which passes through the leveling roll array area at the beginning is not sufficiently flattened because it is given only a penetration depth (pressing amount) small enough to allow the metal sheet P to be passed by the driving force of the leveling rolls alone. Accordingly, when the optical sensors 41 serving as the position detection mechanism and a pulse generator (not shown) detect that the tail end of the metal sheet P has passed through the leveling roll array area, the pressing by the pinch roll cylinder 32b is dismissed to stop the drawing by the pinch rolls 31b, and the rotational direction of the leveling rolls is reversed to feed the metal sheet P toward the pinch rolls 31a, as shown in
As described above, the metal sheet P is entirely flattened when the metal sheet P is passed back and forth once. Consequently, even when the metal sheet has a small thickness and a large yield stress, it is possible to flatten the metal sheet with a high degree of accuracy to improve the flatness of the metal sheet P. However, in order to utilize this technique, the metal sheet P needs to have a length with which the necessary flattening is performed entirely over the metal sheet P by moving the metal sheet P back and forth once in the roller leveler 100. In this respect, if the metal sheet P is too short, the flattening operation in one direction is made such that flattening with the drawing by the pinch rolls becomes less than half of the metal sheet P, so the necessary flattening cannot be performed entirely over the metal sheet P by the flattening operation in the opposite direction. It is preferable for the metal sheet P having a cut-sheet form to have a length of 5 m or more. The number of back and forth motions of the metal sheet P is not limited to one, but may be two or more.
When the metal sheet used is a steel sheet, the technique described above can be suitably used to process the steel sheet having a thickness of 2.0 to 25.4 mm and a yield stress of 400 to 1,800 MPa, which has been difficult to flatten.
As described above, by utilizing the drawing force exerted by the pinch rolls, it is possible to flatten the metal sheet, the material to be flattened, with the required penetration depth (pressing amount) to attain high flatness. In this case, however, some of the components of the machine, such as the upper frame 2 and the lower frame 3, may be deflected in the width direction and, when this occurs, the penetration depth to the metal sheet varies in the width direction because of the deflection. Accordingly, in this embodiment, when it is desired to eliminate the influence of the deflection, detection values obtained by the deflection detection sensors 21 and/or 22 are used to derive the deflection amounts of the upper frame 2 and the lower frame 3. Then, the necessary tightening amounts of the respective hydraulic crowning cylinders 12 are calculated to compensate for the deflection amounts, and are used to perform a crowning correction on the upper leveling rolls 6. Consequently, it is possible to reduce the difference in the penetration depth in the width direction of the metal sheet P, the material to be flattened, which makes it possible to perform the flattening with higher flatness.
In addition to the necessary tightening amounts of the respective hydraulic crowning cylinders 12 necessary for compensating for the deflection amounts of the upper frame 2 and the lower frame 3, the necessary tightening amounts of the respective hydraulic crowning cylinders 12 for compensating for the compressive deformation may be calculated based on the information on compressive deformation obtained via the load cells (or hydraulic pressure converters) 23 attached between the pressing cylinders 4 and the housing 1, that is, the information on compressive deformation of the pressing cylinders 4, hydraulic crowning cylinders 12, upper roll frame 5, upper backup rolls 7, upper leveling rolls 6, lower leveling rolls 8, lower backup rolls 9, and lower roll frame 10, and the total value of the two sets of the necessary tightening amounts may be used to perform a crowning correction on the upper leveling rolls 6. This makes it possible to further reduce the difference in the penetration depth in the width direction of the metal sheet P, the material to be flattened, making it possible to perform the flattening with much higher flatness.
Japanese Patents No. 3443036 and No. 3726146 disclose crowning correction of this type in detail, the entire contents of which are incorporated by reference herein.
Next, an explanation will be given of another embodiment of the present invention.
This roller leveler 200 includes: a leveling unit 60 having a structure the same as that of the former embodiment; a single pinch roll unit 30 disposed on one outside of the leveling roll array area along the pass line of the metal sheet and having a structure the same as that of the pinch roll units 30a and 30b of the former embodiment; and a metal sheet reversing mechanism 70 disposed on the other outside of the leveling roll array area of the leveling unit 60 and configured to turn the metal sheet P to reverse positions of its leading end and tail end.
The metal sheet reversing mechanism 70 includes a plurality of transfer rolls 71 for transferring the metal sheet P and a support frame 72 that supports the transfer rolls 71. The metal sheet reversing mechanism 70 further includes a rotating mechanism 73 configured to rotate the metal sheet present on the transfer rolls 71, along with the transfer rolls 71 and the support frame 72, so as to turn the metal sheet P to reverse positions of its leading end and tail end.
The leveling unit 60 and the pinch roll unit 30 are the same in structure as the leveling unit and the pinch roll unit of the former embodiment, so the reference symbols thereon are omitted.
Next, with reference to
At first, the metal sheet P is fed from that side of the leveling unit 60 adjacent to the metal sheet reversing mechanism 70 into the leveling roll array area toward the pinch roll unit 30 (
Next, an explanation will be given of still another embodiment of the present invention.
This roller leveler 300 includes a leveling unit 60a and a leveling unit 60b arrayed along the pass direction of the metal sheet P, each of which has the same structure as that of the former embodiment. A single pinch roll unit 30 is disposed between the leveling units 60a and 60b and has the same structure as that of the pinch roll units 30a and 30b of the former embodiment.
The leveling units 60a and 60b and the pinch roll unit 30 are the same in structure as the leveling unit and the pinch roll unit of the former embodiment, so the reference symbols thereon are omitted.
Next, with reference to
At first, the second leveling unit is set in a state where the metal sheet is to be not pressed or in a state where it is to be pressed by the pressing cylinders with a penetration depth small enough to allow the metal sheet to be passed by the drive unit. In this state, the metal sheet is passed, toward the second leveling unit, through the first leveling roll array area, in which the leveling rolls of the first leveling unit are disposed, in a state where it is not pressed or in a state where it is pressed by the pressing cylinders with a penetration depth small enough to allow the metal sheet to be passed by the drive unit (
According to the embodiments of the present invention, the drawing force by the pinch rolls is added to the driving force of the leveling rolls to pass the metal sheet between the leveling rolls, so that the metal sheet is passed even when the torque of the leveling rolls is insufficient to pass the metal sheet for flattening. Consequently, even when the metal sheet has a small thickness and a large yield stress, it is possible to pass the metal sheet while applying a penetration depth necessary for the flattening, thereby improving the flatness of the metal sheet. Further, in addition to this, the crowning correction in the width direction may be performed to further improve the flatness of the metal sheet.
The present invention is not limited to the embodiments described above, and it may be modified in various manners. For example, in the embodiments described above, the machine has a structure designed to press (press downward) the upper rolls of the leveling rolls toward the lower rolls, but it may be modified to press (press upward) the lower rolls toward the upper rolls. Further, the present invention should be construed to encompass arrangements obtained by omitting some of the components of the embodiments described above, as long as they do not depart from the scope of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-038047 | Feb 2011 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2012/052533 | 2/3/2012 | WO | 00 | 8/23/2013 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2012/114853 | 8/30/2012 | WO | A |
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| Number | Date | Country | |
|---|---|---|---|
| 20130327109 A1 | Dec 2013 | US |
