Mill roll analysis system

• US 7,249,004 B2
• Filed: 02/28/2003
• Issued: 07/24/2007
• Est. Priority Date: 02/28/2003
• Status: Expired due to Fees

• Current Assignee: NCCM Co. LLC
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Almquist, Eric G., Lindeman, David D.
• Primary Examiner(s): Knight; Anthony
• Assistant Examiner(s): STEVENS, THOMAS H
• Application Number:
  US10/376,727
• Publication Number:
  US 20040172223A1
• Time in Patent Office: 1,607 Days
• Field of Search: 703/1, 72/141
• US Class Current: 703/1
• CPC Class Codes: B21B 2265/00 Forming parameters
• CPC Class Codes: B21B 2267/00 Roll parameters
• CPC Class Codes: G06F 2111/02 CAD in a network environment, e.g. collaborative CAD or distributed simulation
• CPC Class Codes: G06F 2111/04 Constraint-based CAD
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: Y10T 29/49544 Roller making

Abstract

A mill roll analysis system is described that includes a user interface module, a structural analysis engine, and an analysis control script. The user interface module receives mill roll design data from a remote user via a computer network. The analysis control script automatically directs the structural analysis engine to define and evaluate an appropriate analytical model for the mill roll design based on the mill roll design data. The mill roll analysis system presents an intuitive web-based interface for capturing the mill roll design data, and may present predefined mill roll applications and mill roll types for selection for the user. As a result, the remote user need not be familiar with the underlying analytical modeling techniques, which may be highly-complex by nature. Consequently, a user may utilize the system to evaluate and improve mill roll design in order to achieve increased product performance.

Claims

1. A system comprising:

a user interface module that receives input data from a user via a computer network, wherein the input data defines a mill roll design;

a structural analysis engine; and

an analysis control script to automatically direct the structural analysis engine to define and evaluate an analytical model for the mill roll design based on the input data, wherein the definition and evaluation of the analytical model for the mill roll includes computing displacement values or stress values or stress values for the mill roll defined by the mill roll design.

2. The system of claim 1, further comprising an input processing module to process the input data supplied by the user, and to create a temporary operating environment for the structural analysis engine to evaluate the analytical model.

3. The system of claim 2, wherein the input processing module processes the input data and generates a parameter input file in a format suitable for processing by the structural analysis engine.

4. The system of claim 2, wherein the input processing module selects the analysis control script from a plurality of analysis control scripts as a function of the input data, wherein each of the analysis control scripts directs the structural analysis engine to define and evaluate a different analytical model.

5. The system of claim 4, wherein the input processing module creates a scratch directory for use as the temporary operating environment, and copies the selected analysis control script into the scratch directory.

6. The system of claim 1, wherein the analysis control script conforms to a scripting language for invoking the structural analysis engine.

7. The system of claim 1, wherein the user interface module presents a network-based user interface to receive the input data from the user.

8. The system of claim 7, wherein the user interface includes an input area that presents a set of predefined mill roll applications for selection by the user, and the analysis control script directs the structural analysis engine to automatically define and evaluate the analytical model based on the selected mill roll application.

9. The system of claim 8, wherein the user interface module dynamically updates the user interface based on the selected mill roll application to contain one or more input fields for specifying at least a strip width and a strip thickness for metal to be processed by the mill roll.

10. The system of claim 8, wherein the set of predefined mill roll applications includes Bridle, Deflector, Hold-Down, Ironing, Pinch/feed, Tension and Wringer.

11. The system of claim 7, wherein the user interface module presents graphical representations of the mill roll applications to assist the user selection.

12. The system of claim 7, wherein the user interface includes an input area that presents a set of predefined mill roll orientations for selection by the user and facilitates selection of a mill roll orientation by the user, and the analysis control script directs the structural analysis engine to automatically define and evaluate the analytical model based on the selected mill roll orientation.

13. The system of claim 7, wherein the user interface includes an input area that presents a set of predefined mill roll coverings for selection by the user and facilitates selection of a mill roll orientation by the user, and the analysis control script automatically directs the structural analysis engine to define and evaluate the analytical model based on the selected mill roll covering.

14. The system of claim 7, wherein the user interface includes an input area that presents a set of predefined mill roll profiles for selection by the user, and the user interface module dynamically updates the user interface based on the selected profile to contain one or more input fields for specifying a minimum diameter and a maximum diameter for the mill roll.

15. The system of claim 7, wherein the user interface includes an input area to select at least one of a hollow shaft or a solid shaft for the mill roll design, and the user interface module dynamically updates the user interface based on the selected shaft to contain one or more input fields for specifying at least an inner diameter or an outer diameter for the shaft, and at least one of inner length or an outer length of the shaft.

16. The system of claim 7, wherein the user interface includes at least one input area to define one or more of a number of actuating cylinders that engage the mill roll, whether the cylinders are of push type or pull type, a pressure delivered to the cylinders, an efficiency for the cylinders, and a mechanical advantage achieved by the cylinders.

17. The system of claim 7, wherein the user interface includes at least one input area to define at least one of a line tension or a wrap angle for the mill roll.

18. The system of claim 1, wherein the user interface includes input areas to specify at least one of a type of gudgeon for a shaft for the modeled mill roll, a number of steps in the gudgeon, a stub diameter for the gudgeon, a stub length for the gudgeon, a fillet radius for the gudgeon, a step diameter for the gudgeon, a bearing diameter for the gudgeon and a bearing length for the gudgeon.

19. The system of claim 1, further comprising an execution module invoked by the input processing module, wherein the execution module initiates operation of the structural analysis engine and directs the structural analysis engine to operate in accordance with the analysis control script.

20. The system of claim 19, wherein the execution module directs the structural analysis engine to evaluate the model to compute analytical output data including the displacement values and stress values.

21. The system of claim 19, wherein the execution module processes the analytical output data to produce an analysis report in a format viewable by the user.

22. The system of claim 21, wherein the format includes at least one of hypertext markup language (HTML) format or a portable document format (PDF).

23. The system of claim 21, wherein the execution module communicates the analysis report to the user via an electronic mail (email) message.

24. The system of claim 21, wherein the structural analysis engine computes values representing stresses and deflections in the shaft, and the analysis control script formats the analysis report to highlight any of the calculated values that exceed a respective limit value.

25. The system of claim 24, wherein the computed values include at least one of a maximum shaft displacement, a maximum shaft stress, a maximum compressive stress, a maximum tensile stress, a maximum contact pressure, and a bearing load.

26. The system of claim 21 wherein the execution module generates the analysis report to include at least one recommendation for modifying the input data.

27. A method comprising:

receiving input data from a user via a computer network, wherein the input data defines a mill roll design;

invoking an analysis control script to automatically direct a structural analysis engine to define and evaluate an analytical model for the mill roll design based on the input data, the definition and evaluation of the analytical model including a computation of at least a displacement value or a stress value for the mill roll defined by the mill roll design; and

communicating an analysis report to the user that contains analytical results from the structural analysis engine.

28. The method of claim 27 further comprising:

processing the input data supplied by the user to generate a parameter file for the structural analysis engine; and

creating a temporary operating environment for evaluation of the analytical model.

29. The method of claim 27, wherein invoking an analysis control script comprises selecting the analysis control script from a set of analysis control scripts as a function of the input data, wherein each analysis control script directs the structural analysis engine to define and evaluate a different model.

30. The method of claim 27, wherein the analysis control script conforms to a scripting language for invoking the structural analysis engine.

31. The method of claim 27, further comprising presenting a network-based user interface to receive the input data from the user.

32. The method of claim 31, further comprising:

presenting the user interface to include a set of predefined mill roll applications for selection by the user, and

automatically directing the structural analysis engine to define and analytical model based on the selected mill roll application.

33. The method of claim 31, further comprising dynamically updating the user interface based on the selected mill roll application to contain one or more input fields for specifying a strip width and a strip thickness for metal to be processed by the mill roll.

34. The method of claim 32, wherein the set of predefined mill roll applications includes Bridle, Deflector, Hold-Down, Ironing, Pinch/Feed, Tension and Wringer.

35. The method of claim 32, further comprising presenting graphical representations of the mill roll applications to assist the user selection.

36. The method of claim 31, further comprising:

presenting the user interface to include a set of predefined mill roll orientations for selection by the user, and

automatically directing the structural analysis engine to define and evaluate the analytical model based on the selected mill roll orientation.

37. The method of claim 31, further comprising:

presenting the user interface to include a set of predefined mill roll coverings for selection by the user, and

automatically directing the structural analysis engine to define and evaluate the analytical model based on the selected mill roll covering.

38. The method of claim 31 further comprising:

presenting the user interface to include a set of predefined mill roll profiles for selection by the user, and dynamically updating the user interface based on the selected profile to contain one or more input fields for specifying at least one of a minimum diameter or a maximum diameter for the mill roll;

presenting the user interface to include an input area to select at least one of a hollow shaft or a solid shaft for the mill roll design, and dynamically updating the user interface based on the selected shaft to contain one or more input fields for specifying at least one of an inner diameter or an outer diameter for the mill roll.

39. The method of claim 31, further comprising:

presenting the user interface to include at least one input area to define one or more of a number of actuating cylinders that engage the modeled mill roll, whether the cylinders are of push type or pull type, a pressure delivered to the cylinders, an efficiency for the cylinders, and a mechanical advantage achieved by the cylinders; and

presenting the user interface to include input areas to specify at least one of a type of gudgeon for a shaft for the modeled mill roll, a number of steps in the gudgeon, a stub diameter for the gudgeon, a stub length for the gudgeon, a fillet radius for the gudgeon, a step diameter for the gudgeon, a bearing diameter for the gudgeon and a bearing length for the gudgeon.

40. The method of claim 27, further comprising communicating the analysis report to the user via an electronic mail message.

41. The method of claim 27, further comprising generating the analysis report to highlight any of the analytical results that exceed respective limits.

42. The method of claim 27, further comprising generating the analysis report to highlight any of the analytical results that exceed respective limits.

43. The method of claim 27, further comprising manufacturing a mill roll in accordance with the mill roll design.

44. A computer-readable medium comprising instructions to cause a programmable processor to:

present a network interface to include a set of predefined mill roll applications and a set of predefined mill roll types for selection by a user; and

automatically direct a structural analysis engine to define and evaluate an analytical model based on a selected mill roll application and a selected mill roll type, the definition and evaluation comprising, at least one of;

computing a displacement value for a mill roll;

computing a stress value for a mill roll.

45. The computer-readable medium of claim 44, wherein the instructions cause the programmable processor to communicate an analysis report to the user that contains analytical results from the structural analysis engine.

46. A system comprising:

a web browser executing on a remote computing device; and

a mill roll analysis system coupled to the remote computing device via a network, wherein the mill roll analysis system comprises;

a web server providing an operating environment for a user interface module that present a web-interface to receive input data from the remote computing device, wherein the input data defines a mill roll design, and

an application server providing an operating environment for an analysis control script and a structural analysis engine, wherein the analysis control script automatically directs the structural analysis engine to define and evaluate an analytical model for the mill roll design based on the input data, wherein the definition and evaluation of the analytical model for the mill roll design comprises computing at least a displacement value or a stress value for the mill roll defined by the mill roll design.

47. The system of claim 46, wherein the user interface module present the user interface to includes an input area that presents a set of predefined mill roll applications for selection by the user, and the analysis control script directs the structural analysis engine to automatically define and evaluate the analytical model based on the selected mill roll application.

48. The system of clam 46, wherein the web server and application server are different computing devices.

49. A method comprising:

receiving input data from a user via a computer network, wherein the input data defines a mill roll design;

invoking a structural analysis engine to evaluate an analytical model for the mill roll design based on the input data to produce analytical results, wherein the evaluation of the analytical model for the mill roll includes computing at least a displacement value or a stress value for the mill roll defined by the mill roll design, and

communicating an analysis report to the user that contains analytical results from the structural analysis engine.

50. The method of claim 49, further comprising presenting a network-based user interface to receive the input data from the user.

51. The method of claim 50, further comprising:

presenting the user interface to include a set of predefined mill roll applications for selection by the user, and

automatically directing the structural analysis engine to define and evaluate the analytical model based on the selected mill roll application.

52. The method of claim 50, further comprising:

presenting the user interface to include a set of predefined mill roll coverings for selection by the user, and

automatically directing the structural anaylsis engine to define and evaluate the analytical model based on the selected mill roll covering.

53. The method of claim 49, further comprising manufacturing a mill roll in accordance with the mill roll design.