DUAL-STAGE MULTI-ROLL LEVELER AND METAL STRIP MATERIAL FLATTENING METHOD

Abstract

Dual-stage multi-roll leveler embodiments of the general inventive concept include independent sets of first stage work rolls and second stage work rolls, with each set of work rolls including one or more upper work rolls disposed above one or more lower work rolls. An adjustable but equal entry side-to-exit side gap is present between the upper and lower work rolls of each work roll set. An exemplary dual-stage leveler removes shape defects and coil set and/or curl from a moving strip material through a combination of work roll gap adjustment and first and/or second stage work roll bending. Because there is no feathering out of work roll penetration in either stage, differential roll speed and the problems associated therewith are eliminated.

Claims

1. A dual-stage multi-roll leveler for flattening a moving strip material, comprising: a framework defining a work envelope having a material entry side and a material exit side; a first leveling stage including a driven first stage work roll set located within the work envelope to receive the strip material through an entry side thereof, the first stage work roll set including a plurality of upper work rolls disposed above a plurality of lower work rolls with a uniform entry side and exit side gap therebetween; a second leveling stage including a driven second stage work roll set disposed within the work envelope and located downstream of the first stage work roll set so as to receive the strip material therefrom, the second stage work roll set being independent from the first stage work roll set and including a plurality of upper work rolls disposed above a plurality of lower work rolls with a uniform entry side and exit side gap therebetween; a gap adjusting mechanism configured to uniformly adjust the gap between the upper and lower work rolls of the first stage and second stage work roll sets; and a work roll bending mechanism configured to uniformly bend the upper work rolls or the lower work rolls of the second stage work roll set; wherein a lack of feathering out of work roll penetration eliminates any possible torque windup due to differential roll speed.

2. The leveler of claim 1, wherein the first stage work roll set is operative to remove shape defects from the strip material, and the second stage work roll set is operative to remove coil set from the strip material.

3. The leveler of claim 1, wherein the gap adjusting mechanism comprises a plurality of powered jack screw assemblies.

4. The leveler of claim 3, wherein the plurality of powered jack screw assemblies are coupled together for concurrent and equivalent movement.

5. The leveler of claim 1, wherein the second stage work roll bending mechanism is selected from the group consisting of an adjustable wedge assembly and a plurality of vertically-oriented cylinders.

6. The leveler of claim 5, wherein the adjustable wedge assembly includes: a plurality of individually displaceable wedges, the wedges configured to act on each upper work roll or each lower work roll to the same degree; and a plurality of actuators for selectively and controllably displacing the wedges.

7. The leveler of claim 1, further comprising a material guide disposed between the first stage work roll set and the second stage work roll set, the material guide adapted to direct strip material exiting the first stage work roll set into the second stage work roll set.

8. The leveler of claim 1, further comprising a drive system for rotationally driving the upper work rolls and/or the lower work rolls of the first stage work roll set and the second stage work roll set.

9. The leveler of claim 8, wherein the drive system includes a first drive motor that is coupled to driven work rolls of the first stage work roll set, and a second drive motor that is coupled to the driven work rolls of the second stage work roll set.

10. The leveler of claim 8, wherein the drive system includes a single drive motor that is coupled to both the driven work rolls of the first stage work roll set and the driven work rolls of the second stage work roll set, in a manner that allows the driven work rolls of each stage to be driven at different rotational speeds.

11. The leveler of claim 10, wherein the drive system includes a drive belt assembly that employs a drive belt rotating first stage and second stage pulleys of dissimilar diameter, such that the driven work rolls of the second stage work roll set will rotate at a greater velocity than the driven work rolls of the first stage work roll set.

12. A dual-stage multi-roll leveler for flattening a moving strip material, comprising: a framework defining a work envelope having a material entry side and a material exit side; a first leveling stage including a driven first stage work roll set located within the work envelope to receive the strip material through an entry side thereof, the first stage work roll set including a plurality of upper work rolls disposed above a plurality of lower work rolls with a uniform entry side and exit side gap therebetween; a second leveling stage including a driven second stage work roll set disposed within the work envelope and located downstream of the first stage work roll set so as to receive the strip material therefrom, the second stage work roll set being independent from the first stage work roll set and including a plurality of upper work rolls disposed above a plurality of lower work rolls with a uniform entry side and exit side gap therebetween; a gap adjusting mechanism configured to uniformly adjust the gap between the upper and lower work rolls of the first stage and second stage work roll sets; a work roll bending mechanism configured to uniformly bend the upper work rolls or the lower work rolls of the first stage work roll set; and a work roll bending mechanism configured to uniformly bend the upper work rolls or the lower work rolls of the second stage work roll set; wherein a lack of feathering out of work roll penetration eliminates any possible torque windup due to differential roll speed.

13. The leveler of claim 12, wherein the first stage work roll set is operative to remove shape defects from the strip material, and the second stage work roll set is operative to remove coil set from the strip material.

14. The leveler of claim 12, wherein the gap adjusting mechanism comprises a plurality of powered jack screw assemblies.

15. The leveler of claim 14, wherein the plurality of powered jack screw assemblies are coupled together for concurrent and equivalent movement.

16. The leveler of claim 12, wherein the first stage and second stage work roll bending mechanisms are selected from the group consisting of an adjustable wedge assembly and a plurality of vertically-oriented cylinders.

17. The leveler of claim 16, wherein the adjustable wedge assembly includes: a plurality of individually displaceable wedges, the wedges configured to act on each upper work roll or each lower work roll to the same degree; and a plurality of actuators for selectively and controllably displacing the wedges.

18. The leveler of claim 12, further comprising a material guide disposed between the first stage work roll set and the second stage work roll set, the material guide adapted to direct strip material exiting the first stage work roll set into the second stage work roll set.

19. The leveler of claim 12, further comprising a drive system for rotationally driving the upper work rolls and/or the lower work rolls of the first stage work roll set and the second stage work roll set.

20. The leveler of claim 19, wherein the drive system includes a first drive motor that is coupled to driven work rolls of the first stage work roll set, and a second drive motor that is coupled to the driven work rolls of the second stage work roll set.

21. The leveler of claim 19, wherein the drive system includes a single drive motor that is coupled to both the driven work rolls of the first stage work roll set and the driven work rolls of the second stage work roll set, in a manner that allows the driven work rolls of each stage to be driven at different rotational speeds.

22. The leveler of claim 21, wherein the drive system includes a drive belt assembly that employs a drive belt rotating first stage and second stage pulleys of dissimilar diameter, such that the driven work rolls of the second stage work roll set will rotate at a greater velocity than the driven work rolls of the first stage work roll set.

23. The leveler of claim 12, wherein the first stage work roll bending mechanism is selectively operable and the second stage work roll bending mechanism is selectively operable, such that the leveler is operable with first stage work roll bending, second stage work roll bending, or a combination of first stage and second stage work roll bending.

24. A method for flattening a moving strip material, comprising: providing a first leveling stage including a driven first stage work roll set to receive the strip material through an entry side thereof, the first stage work roll set including a plurality of upper work rolls disposed above a plurality of lower work rolls with a uniform entry side and exit side gap therebetween; providing a second leveling stage including a driven second stage work roll set disposed within the work envelope and located downstream of the first stage work roll set so as to receive the strip material therefrom, the second stage work roll set being independent from the first stage work roll set and including a plurality of upper work rolls disposed above a plurality of lower work rolls with a uniform entry side and exit side gap therebetween; providing a gap adjusting mechanism configured to uniformly adjust the gap between the upper and lower work rolls of the first stage and second stage work roll sets; associating a work roll bending mechanism with the upper work rolls or the lower work rolls of the first stage work roll set; associating a work roll bending mechanism with the upper work rolls or the lower work rolls of the second stage work roll set; using the gap adjusting mechanism as needed to set a uniform gap between the upper and lower work rolls of the first stage and second stage work roll sets; selectively operating the work roll bending mechanism associated with the first stage work roll set to produce work roll bending within the first leveling stage when desired; and selectively operating the work roll bending mechanism associated with the second stage work roll set to produce work roll bending within the second leveling stage when desired; wherein flattening of the strip material is facilitated by work roll bending in one or both of the first leveling stage and the second leveling stage; and wherein a lack of feathering out of work roll penetration eliminates any possible torque windup due to differential roll speed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In the following descriptions of the drawings and exemplary embodiments, like reference numerals across the several views refer to identical or equivalent features, and:

[0022] FIGS. 1A-1D illustrate several shape defects common to metal strip material;

[0023] FIG. 2 depicts an exemplary upper and lower set of work rolls of a known shape-correction leveler design;

[0024] FIG. 3A depicts an exemplary technique for correcting a center buckle shape defect using a known shape-correction leveler;

[0025] FIG. 3B depicts an exemplary technique for correcting an edge wave shape defect using a known shape-correction leveler;

[0026] FIG. 4 and FIG. 5, in combination, help to illustrate the problem of differential roll speed on a known multi-roll shape-correction leveler;

[0027] FIG. 6 represents a commonly used shape-correction leveler drive scheme where all of the leveler work rolls are driven at the same speed;

[0028] FIG. 7 is a side view of one exemplary embodiment of a dual-stage multi-roll leveler according to the general inventive concept, having work roll bending capability with respect to the lower work rolls of the first stage work roll set;

[0029] FIG. 8 is a schematic representation of the movement of a strip material through the work rolls of the exemplary dual-stage multi-roll leveler of FIG. 7;

[0030] FIG. 9 is a side view of one exemplary embodiment of a dual-stage multi-roll leveler according to the general inventive concept, having work roll bending capability with respect to the lower work rolls of the second stage work roll set;

[0031] FIG. 10 is a side view of one exemplary embodiment of a dual-stage multi-roll leveler according to the general inventive concept, having work roll bending capability with respect to the lower work rolls of both the first stage work roll set and the second stage work roll set;

[0032] FIG. 11 is one exemplary embodiment of a work roll-containing cassette module that may be utilized in an exemplary dual-stage multi-roll leveler;

[0033] FIG. 12 depicts one exemplary drive scheme for a dual-stage multi-roll leveler;

[0034] FIG. 13 depicts an alternative exemplary drive scheme for a dual-stage multi-roll leveler; and

[0035] FIGS. 14A-14C represent the exemplary dual-stage multi-roll levelers depicted in FIG. 7 and FIGS. 9-10, where alternative embodiments of work roll bending mechanisms have been installed thereto.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0036] The aforementioned problem of differential roll speed on a multi-roll leveler of typical, known design, is illustrated via the combination of FIGS. 4-6. Particularly, when the rolls of a multi-roll shape-correction leveler are all driven together at the same speed (see FIG. 6) with a feathering out of work roll penetration (see FIG. 4), the entry rolls attempt to push the strip material being leveled through the exit rolls, while the exit rolls resist such movement.

[0037] Exemplary dual-stage multi-roll leveler (hereinafter dual-stage leveler for brevity) embodiments described herein are able to overcome the aforementioned problems associated with differential roll speed in a novel and efficient manner. Schematic side views of several such exemplary dual-stage levelers 100, 600, 700 appear in FIG. 7 and FIGS. 9-10.

[0038] As shown in FIG. 7, one exemplary dual-stage leveler embodiment 100 has an entry side 105 and an exit side 110, with material flow occurring in an entry-to-exit direction as indicated by the arrow. Typically, and as would be familiar to one of skill in the art, strip material to be flattened is fed from a coil into the entry side 105 of the dual-stage leveler 100.

[0039] The exemplary dual-stage leveler 100 also includes a frame 115, with which is associated an upper and lower platen 120, 125. A working envelope 130 is defined between the platens 120, 125 and the entry side 105 and exit side 110 of the dual-stage leveler 100.

[0040] Disposed within the working envelope 130 of the exemplary leveler 100 is a first, entry side leveling stage (first stage) 135 and a separate second, exit side leveling stage (second stage) 140, each of which includes its own set 135a, 140a of work rolls. As previously explained, the terms first, entry side, second, and exit side are intended to indicate only the order in which the provided independent sets of work rolls will contact the strip material as it passes through the leveler. No other meaning is to be implied.

[0041] The first stage 135 includes a work roll set 135a comprising a plurality of upper work rolls 145 disposed above a plurality of lower work rolls 155. Likewise, the second stage 140 also includes a work roll set 140a comprising a plurality of upper work rolls 150 disposed above a plurality of lower work rolls 160.

[0042] While the first stage work roll set 135a is shown to have a total of nine work rolls and the second stage work roll set 140a is shown to have a total of five work rolls in the exemplary dual-stage leveler embodiment 100 of FIG. 7, it is to be understood that different numbers of first stage work rolls and second stage work rolls may be utilized in other dual-stage leveler embodiments. Likewise, while the work rolls 145, 155 of the first stage work roll set 135a and the work rolls 150, 160 of the second stage work roll set 140a are shown to be the same diameter in the exemplary dual-stage leveler 100 of FIG. 7, it should be understood that in other dual-stage leveler embodiments the works rolls of one leveler stage and the work rolls of the other leveler stage(s) may have dissimilar diameters.

[0043] The upper work rolls 145, 150 and the lower work rolls 155, 160 of the exemplary dual-stage leveler 100 are arranged in a substantially parallel relationship between the entry side 105 and exit 110 side of the leveler, with the longitudinal axis of each work roll oriented substantially perpendicular to the direction of travel of the strip material that will be passed through the leveler. As described in more detail below, the upper work rolls 145 and the lower work rolls 155 of the first stage work roll set 135a cooperate to remove strip material shape defects during leveler operation, while the upper work rolls 150 and the lower work rolls 160 of the second stage work roll set 145a will cooperate primarily to remove coil set and/or induced curl from the strip material during leveler operation.

[0044] The upper work rolls 145, 150 and/or the lower work rolls 155, 160 of the first and/or second stage work roll sets 135a, 140a may be supported by a corresponding set of backup rolls, such as the exemplary backup rolls 165, 170 shown to support the upper work rolls 145, 150 in FIG. 7. The backup rolls are disposed in flights, such that two backup rolls support each work roll. It may also be possible to eliminate the backup rolls in other embodiments.

[0045] The first and second leveler stages 135, 140 also include support bearings 185 that function to support the work rolls 145, 150, 155, 160whether directly or through associated backup rolls. In the exemplary dual-stage leveler 100 of FIG. 7, the first stage work roll set includes six upper support bearings and six lower support bearings, while the second stage work roll set includes five upper support bearings and three lower support bearings. The number of bearings present in a given leveler embodiment will depend on the number of work rolls and/or backup rolls present and, therefore, the number of bearings used may be different in other leveler embodiments.

[0046] A gap adjusting mechanism is provided to adjust the space between the platens 120, 125 of the exemplary leveler 100 and, consequently, the gap between the upper work rolls 145, 150 and lower work rolls, 155, 160 of the first stage and second stage work roll sets. The gap between the upper work rolls 145, 150 and the lower work rolls 155, 160 of the first stage and second stage work roll sets is provided to allow metal strip material to pass therethrough during leveler operation.

[0047] In some embodiments, the gap adjusting mechanism of a dual-stage leveler embodiment may be configured for independent adjustment of the platen spacing along the entry and exit sides of the leveler. In other exemplary embodiments, the gap adjusting mechanism may be configured such that operation thereof will simultaneously adjust both the entry side and exit side platen spacing. In any case, the initial setting and subsequent adjustment of the platen spacing occurs in a manner that maintains parallelism between the platens 120, 125 and, consequently, an equal gap between the upper and lower work rolls 145, 155 of the first stage work roll set 135a and the upper and lower work rolls 150, 160 of the second stage work roll set 140a.

[0048] In the exemplary dual-stage leveler 100 of FIG. 7, the gap adjusting mechanism is comprised of pairs of vertically oriented entry side and exit side jack screw assemblies 190, 195. The entry side and exit side jack screw assemblies 190, 195 may be geared or otherwise connected and/or controlled so that parallelism between the platens 120, 125 and an equal gap between the upper and lower work rolls of the first stage work roll set 135a and second stage work roll set 140a will be maintained during operation of the jack screw assemblies. As would also be familiar to one of skill in the art, one or more electric motors (or another type of motor) may be utilized to drive the jack screw assemblies 190, 195. It is also possible that the motor-driven jack screw assemblies 190, 195 may be replaced with hydraulic cylinders or other suitable actuating devices in other embodiments.

[0049] As should be understood from the foregoing description, the feathering out of work roll penetration common to known multi-roll levelers is eliminated in an exemplary dual-stage leveler design. Consequently, as shown in the exemplary dual-stage leveler 100 of FIG. 7, the entry gap 175a and exit gap 175b between the upper and lower work rolls 145, 150 of the first stage work roll set 135a will be equal, as will the entry gap 180a and exit gap 180b between the upper and lower work rolls 150, 160 of the second stage work roll set 140a.

[0050] As briefly mentioned above, shape defect removal is further accomplished in the first stage of the exemplary dual-stage leveler embodiment 100 of FIG. 7 by way of uniformly bending the first stage work rolls to selectively elongate or otherwise selectively deform at least certain sections of the strip material being flattened. Work roll bending may be performed on the upper work rolls 145 and/or lower works rolls 155 of the first stage work roll set 135a of an exemplary dual-stage leveler. In the exemplary dual-stage leveler embodiment 100 of FIG. 7, only the lower work rolls 155 of the first stage work roll set 135a are subject to such bending.

[0051] Work roll bending in an exemplary dual-stage leveler according to the general inventive concept may be achieved by any one or more of several techniques. In the case of the exemplary dual-stage leveler 100 embodiment of FIG. 7, work roll bending is accomplished by way of an adjusting wedge assembly 200 that lies subjacent to the lower work rolls 155 of the first stage work roll set 135a. The adjusting wedge assembly 200 may be comprised of a plurality of individual adjusting wedges whose positions may be selectively adjusted by way of corresponding actuators 205 to impart the desired work roll bending. For example and without limitation, the adjusting wedge assembly 200 may be configured and may operate as represented in FIG. 7, such that all of the lower work rolls 155 of the first stage work roll set 135a will be locally bent (i.e., work roll penetration will be adjusted) by a like amount during movement of a given wedge.

[0052] In previous multi-roll leveler designs, the upper crown or the wedge assembly of the leveler must tilt to provide deep entry roll penetrationresulting in little exit roll penetration and an overall work roll penetration profile that feathers out from the entry side to the exit side of the leveler. Because of such work roll penetration feathering, this traditional leveler design and setup creates the differential roll speed and undesirable internal torque windup described above. In contrast, when an exemplary dual-stage leveler is configured as described herein, such as in the case of any of the exemplary levelers 100, 600, 700, there is no feathering out of work roll penetration and no resulting differential roll speed and/or undesirable internal torque windup as is common with known multi-roll levelers.

[0053] In the exemplary dual-stage leveler 100 of FIG. 7, uniform penetration of the work rolls 145, 155 across the first stage work roll set may be produced by a combination of gap adjustment using the jack screw assemblies 195, 200 and roll bending using the wedge assembly 200, while uniform penetration of the work rolls 150, 160 across the second stage work roll set 140a is produced exclusively through gap adjustment using the jack screw assemblies.

[0054] As a result of equal entry side and exit side work roll penetration within each leveler stage, as described above, the rotational speed of the entry and exit work rolls of each leveler stage will be the same (i.e., equal to the surface speed experienced by the inside bend radius of the strip material being processed). Differential roll speed is, therefore, eliminated by such a design, as is any associated internal torque windup within each stage. The lack of internal torque windup allows all of the torque applied to each work roll to be utilized for working the strip material, and the applied torque will be substantially equally distributed to each of the work rolls within a given stage (although the first and last work roll will may experience slightly less torque due to a lesser material wrap angle). Also, the lack of internal torque windup allows for a very predictable and manageable torque distribution.

[0055] As can be further observed in FIG. 7, and as schematically indicated in FIG. 8, proper location of the support bearings 185 in the dual-stage leveler 100 results in a space 210 between the exit side of the first stage work roll set and the entry side of the second stage work roll set. Strip material exiting the work rolls of the first work roll stage must traverse this space 210 in order for the unrestrained leading end thereof to reach the work rolls of the second work roll stage. As indicated in FIG. 8, the strip material 215 may also be somewhat upwardly-directed in an area 220 near the first work roll stage work roll set as a result of an up-curl imparted by the work rolls 145, 155 thereof. Strip material may alternatively be somewhat downwardly-directed upon exiting the first work roll stage work roll set due to down-curl, in embodiments where the first work roll stage work rolls are arranged such that the most downstream work roll is an upper work roll (e.g., if the upper and lower work roll configurations 145, 155 are reversed). To help ensure proper initial engagement of the moving strip material 215 with the second stage work roll set, the exemplary dual-stage leveler 100 may include a guide 225, deflector assembly, threading plate, or some other mechanism for ensuring that the leading end of the strip material 215 is directed into the gap between the work rolls 150, 160 of the second work roll stage work roll set.

[0056] An even better understanding of the operation of the exemplary dual-stage leveler 100 of FIG. 7 may be gained by reference to FIG. 8, where it can be observed that when the strip material 215 is passed through the dual-stage leveler 100 in the indicated material flow direction, the work rolls 145, 155 of the first stage work roll set 135a will engage the strip material to remove shape defects from the strip material as explained above. That is, work roll penetration and bending in the first leveler stage are controlled and directed such that the strip material 215 is caused to wrap partially around at least some of the work rolls 145, 155 of the first stage work roll set 135a so as to elongate or otherwise deform at least certain areas of the strip material as necessary to remove shape defects present therein. Likewise, work roll penetration in the second leveler stage is simultaneously such that the work rolls 150, 160 of the second stage work roll set 140a will engage the strip material 215 in a manner by which any remaining coil set is removed from the strip material, as also explained above. The second work roll stage work roll set is also operative to remove any curl (see below) or other undesirable shape characteristics imparted to the strip material by the first stage work roll set 135a.

[0057] Another exemplary dual-stage leveler embodiment 600 is depicted in FIG. 9. The exemplary leveler 600 is similarly constructed and operates in a manner similar to the exemplary dual-stage leveler 100 shown in FIG. 7, except that in this leveler embodiment 600, work roll bending capability is incorporated into the second leveler stage as opposed to the first leveler stage in the leveler 100 of FIG. 7. Consequently for purposes of clarity, only leveler components relative to a description of the differences between the exemplary leveler 600 of FIG. 9 and the exemplary leveler 100 of FIG. 7 are shown in FIG. 9.

[0058] As with the exemplary dual-stage leveler 100 of FIG. 7, the exemplary dual-stage leveler embodiment 600 of FIG. 9 includes within a working envelope thereof a first, entry side leveling stage (first stage) 605 and a separate second, exit side leveling stage (second stage) 610, each of which includes its own set 605a, 610a of work rolls. The first stage work roll set 605a comprises a plurality of upper work rolls 615 disposed above a plurality of lower work rolls 620. Likewise, the second stage work roll set 610a comprises a plurality of upper work rolls 625 disposed above a plurality of lower work rolls 630. The upper work rolls 615, 625 and the lower work rolls 620, 630 of the exemplary dual-stage leveler 600 are again arranged in a substantially parallel relationship between the entry side and exit side of the leveler, with the longitudinal axis of each work roll oriented substantially perpendicular to the direction of travel of the strip material that will be passed through the leveler.

[0059] In the exemplary dual-stage leveler 600 of FIG. 9, shape defect removal by the first stage work roll set 605a is accomplished exclusively through work roll penetration produced by gap adjustment using a gap adjusting mechanism such as the jack screw assemblies described above with respect to the leveler 100 of FIG. 7. In contrast, removal of coil set and/or induced curl from the strip material by the second stage work roll set 610a is accomplished by a combination of gap adjustment and uniform roll bending using, for example, a wedge assembly 635 like or similar to that described above with respect to the exemplary leveler 100 of FIG. 7. Although the functionality of the first stage and second stage of the exemplary leveler 600 is essentially reversed from that of the exemplary leveler 100, the penetration of the work rolls 615, 620 of the first stage work roll set 605a into the strip material being leveled and the penetration of the work rolls 625, 630 of the second stage work roll set 610a into the strip material being leveled is still uniform across the respective first and second stages. Likewise, the entry gap 640a and exit gap 640b between the upper and lower work rolls 615, 620 of the first stage work roll set 605a will be equal, as will the entry gap 645a and exit gap 645b between the upper and lower work rolls 625, 630 of the second stage work roll set 610a. Consequently, the feathering out of work roll penetration common to known multi-roll levelers is again eliminated by the design of the exemplary dual-stage leveler 600, which eliminates any problems associated with differential roll speed and/or undesirable internal torque windup as is common with known multi-roll levelers.

[0060] Yet another exemplary dual-stage leveler embodiment 700 is depicted in FIG. 10. The exemplary leveler 700 is similarly constructed and operates in a manner similar to the exemplary dual-stage leveler 100 shown in FIG. 7, except that in this leveler embodiment 700, work roll bending capability is incorporated into both the first leveler stage and the second leveler stage, as opposed to only the first leveler stage in the leveler 100 of FIG. 7. Consequently for purposes of clarity, only leveler components relative to a description of the differences between the exemplary leveler 700 of FIG. 10 and the exemplary leveler 100 of FIG. 7 are shown in FIG. 10.

[0061] As with the exemplary dual-stage leveler 100 of FIG. 7, the exemplary dual-stage leveler embodiment 700 of FIG. 10 includes within a working envelope thereof a first, entry side leveling stage (first stage) 705 and a separate second, exit side leveling stage (second stage) 710, each of which includes its own set 705a, 710a of work rolls. The first stage work roll set 705a comprises a plurality of upper work rolls 715 disposed above a plurality of lower work rolls 720. Likewise, the second stage work roll set 710a comprises a plurality of upper work rolls 725 disposed above a plurality of lower work rolls 730. The upper work rolls 715, 725 and the lower work rolls 720, 730 of the exemplary dual-stage leveler 700 are again arranged in a substantially parallel relationship between the entry side and exit side of the leveler, with the longitudinal axis of each work roll oriented substantially perpendicular to the direction of travel of the strip material that will be passed through the leveler.

[0062] In the exemplary dual-stage leveler 700 of FIG. 10, shape defect removal by the first stage work roll set 705a may be accomplished by work roll penetration produced by gap adjustment using a gap adjusting mechanism (such as the jack screw assemblies described above with respect to the leveler 100 of FIG. 7), by uniform roll bending using, for example, a wedge assembly 735a like or similar to that described above with respect to the exemplary leveler 100 of FIG. 7, or by a combination of gap adjustment and uniform roll bending. Similarly, removal of coil set and/or induced curl from the strip material by the second stage work roll set 710a may be accomplished by work roll penetration produced by gap adjustment using a gap adjusting mechanism (such as the jack screw assemblies described above with respect to the leveler 100 of FIG. 7), by uniform roll bending using, for example, a wedge assembly 735a like or similar to that described above with respect to the exemplary leveler 100 of FIG. 7, or by a combination of gap adjustment and uniform roll bending.

[0063] As with the exemplary dual-stage leveler 100 of FIG. 7 and the exemplary dual-stage leveler 600 of FIG. 9, the penetration of the work rolls 715, 720 of the first stage work roll set 705a of the exemplary leveler 700 of FIG. 10 into the strip material being leveled and the penetration of the work rolls 725, 730 of the second stage work roll set 710a into the strip material being leveled is again uniform across the respective first and second stages. Likewise, the entry gap 740a and exit gap 740b between the upper and lower work rolls 715, 720 of the first stage work roll set 705a will be equal, as will the entry gap 745a and exit gap 745b between the upper and lower work rolls 725, 730 of the second stage work roll set 710a. Consequently, the feathering out of work roll penetration common to known multi-roll levelers is again eliminated by the design of the exemplary dual-stage leveler 700, which eliminates any problems associated with differential roll speed and/or undesirable internal torque windup as is common with known multi-roll levelers.

[0064] Each of the exemplary dual-stage levelers 600, 700 shown in FIGS. 9-10 may incorporate previously described features of the exemplary dual-stage leveler 100 of FIG. 7. For example and without limitation, the levelers 600, 700 may utilize a leveler frame and platens, a gap adjustment mechanism, a roll bending wedge assembly or assemblies, back up rolls, support bearings and/or a material guide that is similar to or the same as that described above with respect to the exemplary dual-stage leveler 100 of FIG. 7. Similarly, the exemplary dual-stage levelers 600, 700 shown in FIGS. 9-10 may include a number of works rolls and/or a work roll diameter that is different from that shown, whether in the first stage, the second stage, or both stages thereof.

[0065] In some exemplary dual-stage leveler embodiments, such as the dual-stage leveler 100 shown in FIG. 7, the work rolls and position control hardware (e.g., wedges, actuators) may be built into the leveler. For example, the work rolls may be mounted in roll frames that are secured to the leveler platens in a manner that does not provide for easy removal, and the wedge actuators may be mounted to the leveler frame, etc., and may be mechanically coupled to the corresponding wedges for pushing or pulling movement thereof.

[0066] Alternatively, the work rolls of a dual-stage leveler embodiment may be provided as part of a removable cassette assembly. One such exemplary cassette assembly 300 is represented in FIG. 11. As shown, the exemplary cassette assembly 300 is divided into a removable upper and lower cassette subassembly 305, 310.

[0067] The upper cassette subassembly 305 includes an upper sub-platen 315 that is adapted for releasable affixation to the upper platen of an associated dual-stage leveler (e.g., to the upper leveler platen 120 in FIG. 7). An upper cassette work roll retention frame 320 is located subjacent to the upper sub-platen 315 and is adapted to retain upper work rolls 325, 330 of respective first stage and second stage work roll sets. The upper cassette work roll retention frame 320 may be further adapted for retention of first stage and second stage upper backup rolls 335, 340, bearings, and/or a variety of other work roll-related components.

[0068] In a similar manner to the upper cassette subassembly 305, the lower cassette subassembly 310 includes a lower sub-platen 355 that is adapted for releasable affixation to the lower platen of an associated dual-stage leveler (e.g., to the lower leveler platen 125 in FIG. 7). A lower cassette work roll retention frame 360 is located superjacent to the lower sub-platen 355 and is adapted to retain lower work rolls 345, 350 of respective first stage and second stage work roll sets. The lower cassette work roll retention frame 320 may be further adapted for retention of first stage and second stage lower backup rolls 365, 370, bearings, and/or a variety of other work roll-related components.

[0069] In the same manner as described with respect to the exemplary dual-stage leveler 100 of FIG. 7, the upper work rolls 325 and the lower work rolls 345 define a first stage work roll set and the upper work rolls 330 and the lower work rolls 350 define an independent second stage work roll set of the exemplary cassette assembly 300. The exemplary cassette assembly may include any of the other features associated with the first and second stage of the exemplary dual-stage leveler 100 of FIG. 7. For example, and without limitation, the cassette assembly 300 may include an infeed director 375, and a guide 380, deflector assembly, threading plate, or some other means for ensuring that the leading end of the strip material fed into the cassette assembly is directed into the gap between the work rolls 330, 350 of the second work roll stage work roll set.

[0070] The exemplary cassette assembly 300 may further include a wedge assembly 385 that, in this embodiment, is a part of the lower cassette subassembly 310. The wedge assembly 385 may include a plurality of individual and selectively movable wedges as previously described in regard to the aforementioned wedge assembly 200 of FIG. 7. In the case of this exemplary cassette assembly 300, however, a first set of actuators 390 is provided for moving the wedges in a penetration-increasing direction, and a second set of actuators 395 is provided for moving the wedges in a penetration-decreasing direction.

[0071] The dual-actuator design of this exemplary cassette embodiment allows the first set of actuators 390 to remain mechanically disconnected from the associated wedges, which facilitates installation and removal of the cassette assembly 300 to/from a dual-stage leveler. To further facilitate installation and removal of the cassette assembly in such an embodiment, the actuator stroke of the first set of actuators 390 may also be longer than the maximum wedge travel distance so as to allow for a gap between the pistons of the actuators 390 and a contacting surface of the wedges when the actuator pistons are withdrawn. The first set of actuators 390 may be mounted, for example, to a frame portion of an associated dual-stage leveler or to another structure in sufficiently close proximity thereto.

[0072] The second set of actuators 395 may be mounted to the lower cassette subassembly 310. As the actuators of the first set of actuators 390 are not mechanically connected to the wedges of the wedge assembly 385 in this exemplary cassette assembly 300, said actuators do not function to retract the wedges subsequent to making a penetration-increasing movement thereof. Instead, the second set of actuators 395 is utilized to move the wedges in a penetration-decreasing direction. The actuators of the second set of actuators 395 may or may not be mechanically connected to the wedges of the wedge assembly 385.

[0073] The cassette assembly 300 is mounted within a dual-stage leveler with the upper sub-platen 315 of the upper cassette subassembly 305 releasably affixed to the upper platen of the leveler, and the lower sub-platen 355 of the lower cassette subassembly 310 releasably affixed to the lower platen of the leveler. With the cassette assembly so installed to the remainder of a dual-stage leveler, flattening of metal strip material may proceed as described above with respect to FIG. 7 and FIG. 8.

[0074] In one exemplary technique for removal of the cassette assembly 300, the upper cassette subassembly 305 is first brought substantially into contact with the lower cassette subassembly 310. Thereafter, both subassembly platens 315, 355 may be detached from the leveler platens and the entire cassette assembly 300 may be rolled or otherwise removed from the associated leveler, such as by means of a moveable cart, etc.

[0075] A roll drive system is used to drive the work rolls of a dual-stage leveler, such as but not limited to, the exemplary dual-stage leveler shown in FIG. 7 and/or FIGS. 9-10. One such exemplary drive system 400 is schematically depicted in FIG. 12. In this exemplary drive system 400, a first motor 405 is provided to drive the work rolls 410 of a first work roll set corresponding to a first stage 415 of an associated dual-stage leveler. Similarly, a second motor 420 is provided to drive the work rolls 425 of a second work roll set corresponding to a second stage 430 of the dual-stage leveler. The motors 405, 420 may be variable speed drive motors. In the exemplary drive system 400 of FIG. 10, the first motor 405 associated with the first leveler stage 415 acts as the master drive for the leveler. The second motor 420 (and second stage work rolls 425) may be operated at a different rotational speed than the first motor. For example, the second motor may be operated at a rotational speed that is slightly greater than the rotational speed of the first motor 405 (and first stage work rolls 410)depending on the strip material being processed and first stage work roll penetrationto ensure that the second stage work roll set does not impede the forward motion of the strip material after it leaves the first stage work roll set.

[0076] As would be understood by one of skill in the art, the motors 405, 420 may be coupled to respective gearboxes, such as the multi-output pinion gearboxes 435, 440 shown. Output torque from the gearboxes 435, 440 may be transferred to the work rolls 410, 425 of the respective work roll sets by way of corresponding sets of couplings 445, 450. In this exemplary embodiment, the couplings 445, 450 are flexible in nature to accommodate adjustments in work roll penetration and bending.

[0077] Another exemplary roll drive system 500 is schematically depicted in FIG. 13. In this exemplary drive system 500, a single motor 505 is provided to drive the work rolls 510 of a first work roll set corresponding to a first stage 515 of an associated dual-stage leveler, as well as the work rolls 520 of a second work roll set corresponding to a second stage 525 of the dual-stage leveler. The motor 505 may again be a variable speed drive motor.

[0078] The motor 505 is coupled to respective first stage and second stage gearboxes, such as the multi-output pinion gearboxes 530, 535 shown. In this exemplary drive embodiment, coupling of the motor 505 to the gearboxes 530, 535 is accomplished by way of a belt drive assembly 540 that includes a drive belt 545, first belt pulley 550 coupled to the motor output, and a second belt pulley 555 coupled to the input of the second stage gearbox 535.

[0079] It may again be desirable to operate the second stage work rolls 520 at a rotational speed that is slightly greater than the rotational speed of the first stage work rolls 510 (as explained above). Consequently, the first belt pulley 550 and the second belt pulley 555 of the belt drive assembly 540 may have dissimilar diameters to provide for such a difference in work roll rotational speed.

[0080] As in the roll drive system 400 of FIG. 12, output torque from the gearboxes 530, 535 of this exemplary roll drive system 500 may be transferred to the work rolls 510, 520 of the respective work roll sets by way of corresponding sets of couplings 560, 565. In this exemplary embodiment, the couplings 560, 565 are again flexible in nature to accommodate adjustments in work roll penetration and bending. A torque-limiting clutch 570 or other suitable protective element may also be provided to limit the amount of torque applied to the second stage work roll set.

[0081] It is to be understood that the roll drive systems 400, 500 of FIGS. 12-13, respectively, have been shown and described herein only for purposes of illustration. Other roll drive designs may also be used in other exemplary dual-stage leveler embodiments. For example, and without limitation, any of the various roll drive systems shown in FIGS. 7-11 of U.S. patent application Ser. No. 15/076,503 filed on Mar. 21, 2016, may be used to drive the work rolls of an exemplary dual-stage leveler.

[0082] While uniform bending of work rolls is described as being performable by a wedge assembly with respect to the exemplary dual-stage levelers 100, 600 of FIGS. 7 and 9 and by a pair of wedge assemblies with respect to the exemplary dual-stage leveler 700 of FIG. 10, it is also possible to produce uniform roll bending with other designs. One non-limiting example of an alternative uniform roll bending design is depicted in FIGS. 14A-14C, which correspond respectively with the exemplary dual-stage leveler designs shown in FIG. 7 and FIGS. 9-10. More particularly, FIG. 14A shows the exemplary leveler 100 of FIG. 7 equipped with an alternative work roll bending mechanism; FIG. 14B shows the exemplary leveler 600 of FIG. 9 equipped with an alternative work roll bending mechanism; and FIG. 14C shows the exemplary leveler 700 of FIG. 10 equipped with an alternative work roll bending mechanism.

[0083] In FIG. 14A, reference numbers indicating the same elements as in FIG. 7 have been retained, while new reference numbers are provided for the alternative work roll bending mechanism and components thereof. Certain non-relevant reference numbers have also been omitted from FIG. 14A for the purpose of clarity.

[0084] As shown, the exemplary dual-stage leveler 100 is constructed and operates as described above with respect to FIG. 7, except that the wedge assembly 200 provided for uniformly bending the lower work rolls 155 of the first stage work roll set 135a has been replaced with a work roll bending mechanism 800 comprising a plurality of work roll bending cylinders 805. The work roll bending cylinders 805 are vertically oriented such that the piston rods 810 thereof (or elements affixed thereto) will exert an indirect bending force on the lower work rolls 155 when the piston rods are caused to be extended from the cylinders.

[0085] As would be understood by one of skill in the art, the quantity and arrangement of the work roll bending cylinders 805 may vary based on the specific design of the first stage work roll set 135a. In any case, the work roll bending mechanism 800 and its plurality of work roll bending cylinders 805 will cause a uniform bending of the lower work rolls 155 of the first stage work roll set 135a.

[0086] In FIG. 14B, reference numbers indicating the same elements as in FIG. 9 have been retained, while new reference numbers are provided for the alternative work roll bending mechanism and components thereof. Certain non-relevant reference numbers have also been omitted from FIG. 14B for the purpose of clarity.

[0087] As shown, the exemplary dual-stage leveler 600 is constructed and operates as described above with respect to FIG. 9, except that the wedge assembly 635 provided for uniformly bending the lower work rolls 630 of the second stage work roll set 610a has been replaced with a work roll bending mechanism 825 comprising a plurality of work roll bending cylinders 830. The work roll bending cylinders 830 are vertically oriented such that the piston rods 835 thereof (or elements affixed thereto) will exert an indirect bending force on the lower work rolls 630 when the piston rods are caused to be extended from the cylinders.

[0088] As would be understood by one of skill in the art, the quantity and arrangement of the work roll bending cylinders 830 may vary based on the specific design of the second stage work roll set 610a. In any case, the work roll bending mechanism 825 and its plurality of work roll bending cylinders 830 will cause a uniform bending of the lower work rolls 630 of the second stage work roll set 610a.

[0089] In FIG. 14C, reference numbers indicating the same elements as in FIG. 10 have been retained, while new reference numbers are provided for the alternative work roll bending mechanism and components thereof. Certain non-relevant reference numbers have also been omitted from FIG. 14C for the purpose of clarity.

[0090] As shown, the exemplary dual-stage leveler 800 is constructed and operates as described above with respect to FIG. 10, except that the wedge assembly 735a provided for uniformly bending the lower work rolls 720 of the first stage work roll set 705a has been replaced with a work roll bending mechanism 850 comprising a plurality of work roll bending cylinders 855 and the wedge assembly 735b provided for uniformly bending the lower work rolls 730 of the second stage work roll set 710a has been replaced with a work roll bending mechanism 875 comprising a plurality of work roll bending cylinders 880. The work roll bending cylinders 855 of the first stage work roll bending mechanism 850 are vertically oriented such that the piston rods 860 thereof (or elements affixed thereto) will exert an indirect bending force on the first stage lower work rolls 720 when the piston rods are caused to be extended from the cylinders. Similarly, the work roll bending cylinders 880 of the second stage work roll bending mechanism 875 are vertically oriented such that the piston rods 885 thereof (or elements affixed thereto) will exert an indirect bending force on the second stage lower work rolls 730 when the piston rods are caused to be extended from the cylinders.

[0091] As would be understood by one of skill in the art, the quantity and arrangement of the first stage work roll bending cylinders 855 may vary based on the specific design of the first stage work roll set 705a. Likewise, the quantity and arrangement of the second stage work roll bending cylinders 880 may vary based on the specific design of the second stage work roll set 710a In any case, the work roll bending mechanisms 825, 850 and the plurality of work roll bending cylinders 855, 800 associated therewith will cause a uniform bending of the lower work rolls 720, 730 of the respective first stage and second stage work roll sets 705a, 710a.

[0092] Dual-stage leveler embodiments, such as those described and shown herein, overcome the problems of differential roll speed and resulting internal torque windup that are inherent to known multi-roll leveler designs. Such dual-stage leveler embodiments may also produce other benefits. For example, because all of the work rolls in a given stage of an exemplary dual-stage leveler may be subjected to equal penetration and bending, a larger differential (bending/flattening) path can be achieved with fewer work rolls. Thus, it may be possible to achieve a differential path through a dual-stage leveler with fewer work rolls than would be required to achieve a comparable differential path through a traditional multi-roll leveler. Further, since the problems associated with differential roll speed are eliminated by an exemplary dual-stage leveler, it may be possible to plunge (penetrate) the work rolls of a given leveler stage deeper into the strip material being processed, which should correspondingly produce a greater percent yield of the material with less torque required from the work roll drive system.

[0093] While certain embodiments of the invention are described in detail above, the scope of the invention is not considered limited by such disclosure, and modifications are possible without departing from the spirit of the invention as evidenced by the following claims: