High-temperature high-speed heating roller and heating roller system

Abstract

This application relates to the field of industrial heating technology, and more specifically to a high-temperature, high-speed heating roller and a heating roller system. The heating roller includes: a roller body, comprising a roller shell, a central body located within the roller shell, and a roller shaft cooperating with the central body; one axial end of the central body is connected to the roller shell and together with the roller shell forms a first cavity; a heater, disposed within the first cavity, for partitioned heating of the roller shell; a drive mechanism, connected to the roller body, for driving the roller body to move; a first channel portion for containing a first cooling medium, at least partially disposed on the drive mechanism, for conveying the first cooling medium to the drive mechanism; and a second channel portion for containing a second cooling medium, for conveying the second cooling medium to the heater and the drive mechanism. The heating roller of this application, by providing the first and second channel portions and other components, achieves effective cooling of the heating roller under extreme operating conditions of superimposed high temperature of 400°C and high speed of 9000 rpm.

Description

Technical Field

[0001] This application relates to the field of industrial heating technology, and more particularly to a heating roller and a heating roller system. Background Technology

[0002] With the application of new-generation high-performance synthetic fibers, special films, and other high-end materials, the process conditions required for producing these materials are becoming increasingly stringent, typically requiring extreme conditions such as high temperature (up to 400℃) and high speed (up to 9000rpm). However, existing electromagnetic heating and heat transfer oil technologies suffer from systemic defects under these extreme conditions, including poor temperature control accuracy, uneven temperature control, insufficient cooling of bearings and coils leading to overheating failure, structural instability, and lag in control response, making long-term stable operation impossible. Summary of the Invention

[0003] This application provides a heating roller, comprising: a roller body including a roller shell, a central body located within the roller shell, and a roller shaft cooperating with the central body, wherein one end of the central body in the axial direction of the roller body is connected to the roller shell and together with the roller shell forms a first cavity; a heater disposed within the first cavity for partitioned heating of the roller shell; a drive mechanism connected to the roller body for driving the roller body to move; a first channel portion for receiving a first cooling medium, at least partially disposed on the drive mechanism to deliver the first cooling medium to the drive mechanism; and a second channel portion for receiving a second cooling medium, wherein a portion of the second channel portion is disposed between the heater and the central body to deliver the second cooling medium to the heater, and another portion of the second channel portion is disposed on the drive mechanism to deliver the second cooling medium to the drive mechanism.

[0004] In one embodiment, the drive mechanism includes: a housing comprising a bearing seat, a motor housing, and a rear cover connected in sequence, wherein the bearing seat is partially disposed within the roller body, the motor housing is connected to the roller body, and the rear cover is disposed on the end side of the drive mechanism away from the roller body; a motor shaft disposed within the housing and connected to the roller shaft along the axial direction to drive the roller shaft to rotate; a motor comprising a motor rotor and a motor stator, wherein the motor rotor is connected to the motor shaft, and the motor stator is disposed within the motor housing and located outside the motor rotor; a first bearing disposed between the motor shaft and the bearing seat; and a first cooling sleeve disposed between the motor stator and the motor housing, wherein a first cooling channel is formed between the first cooling sleeve and the motor housing, and the first cooling channel communicates with the first channel portion to cool the motor stator.

[0005] In one embodiment, the heating roller further includes a protective cover partially disposed on the outside of the motor housing and a rear plate disposed on the protective cover away from the roller body end. The first channel portion includes: a first liquid inlet section, one end of which is disposed on a through hole in the rear plate for receiving the first cooling medium; a first cooling section disposed inside the motor housing and communicating with the first cooling channel and the first liquid inlet section; and a first liquid outlet section communicating with the first cooling section through the first cooling channel. The first liquid outlet section and the first liquid inlet section are disposed opposite each other in the axial direction, and one end of which is disposed on a through hole in the rear plate.

[0006] In one embodiment, the heating roller further includes a second cooling sleeve disposed in the first cavity and located between the heater and the center portion, and a second cooling channel is formed between the second cooling sleeve and the heater, the second cooling channel communicating with the second channel portion to cool the heater.

[0007] In one embodiment, the bearing housing is provided with an annular groove, and the second channel portion includes: a second liquid inlet section, one end of which is disposed away from the roller body on a through hole in the rear plate for receiving the second cooling medium; a second cooling section disposed on the roller shell and communicating with the second liquid inlet section and the annular groove for cooling the first bearing; a third cooling section disposed within the second cooling sleeve and communicating with the second cooling section and the second cooling channel for cooling the heater; and a second liquid outlet section communicating with the annular groove and the second cooling channel, one end of which is disposed away from the roller body on a through hole in the rear plate and is axially opposite to the second liquid inlet section.

[0008] In one embodiment, the first cooling channel is a spiral cooling channel; and / or the second cooling channel is a spiral cooling channel.

[0009] In one embodiment, the roller body further includes multiple resistors disposed within the roller shell for collecting temperature data of the roller shell in the corresponding sections of the roller shell. The heating roller also includes a resolver temperature transmitter disposed on the rear cover. The resolver temperature transmitter includes: a resolver rotor plate connected to the drive mechanism, the resolver rotor plate having a first coil and a processor, the processor being connected to the multiple resistors to process the temperature information to obtain a temperature signal; and a resolver stator plate having a second coil, the resolver stator plate being configured to receive the temperature signal and output it externally through magnetic coupling between the second coil and the first coil.

[0010] In one embodiment, the drive mechanism further includes a second bearing disposed outside the motor shaft and located on the rear cover, the second bearing being sealed to the motor housing and the motor shaft; and / or the resolver temperature transmitter is provided with a sealing layer.

[0011] This application provides a heating roller system, characterized in that it includes the heating roller and temperature control module described above. The temperature control module includes: a temperature control board connected to the refractive temperature transmitter of the heating roller, used to acquire temperature signals of different zones of the roller shell; and an inverter circuit connected to the temperature control board and the heater of the heating roller, used to control the heating power applied by the inverter circuit to the heater corresponding to the different zones of the roller shell according to the temperature signals of the different zones.

[0012] In one embodiment, the heating roller system further includes: a protection resistor disposed within the roller body for acquiring temperature data of the roller shell; and a temperature protection module comprising a temperature detection board connected to the protection resistor and the temperature control board. If the temperature detection board detects that the temperature acquired through the protection resistor exceeds a preset threshold, it triggers an over-temperature protection signal and sends the over-temperature protection signal to the temperature control board, thereby enabling the temperature control board to control the heating power applied by the inverter circuit to the heaters corresponding to different zones of the roller shell.

[0013] The heating roller provided in this application has at least one of the following beneficial effects: by conveying cooling medium to the drive mechanism through the first channel and to the heater and drive mechanism through the second channel, effective cooling of the heating roller is achieved under the extreme conditions of superimposed high temperature of 400℃ and high speed of 9000rpm. This effectively solves the problems of overheating, lubrication failure and lifespan of the bearing system under the extreme conditions of superimposed high temperature of 400℃ and high speed of 9000rpm. The heating roller and heating roller system provided in the embodiments of this application can meet the requirements of the new generation of high-performance chemical fibers for the combined operation of 400℃ and 9000rpm, achieving an axial temperature difference of ≤±1℃ on the roller surface, thereby improving product quality, significantly extending equipment life (actual measurement data proves that it can ensure continuous operation for more than 40,000 hours under harsh conditions), and greatly improving production efficiency (reducing production line downtime due to failure). Attached Figure Description

[0014] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 A cross-sectional schematic diagram of a heating roller provided in an exemplary embodiment of this application; Figure 2 This is a schematic diagram of the structure of a heating roller system provided in an exemplary embodiment of this application; Figure 3 A schematic diagram of the structure of a heating roller system provided in another exemplary embodiment of this application; Figure 4 A schematic diagram of the structure of a heating roller system provided in yet another exemplary embodiment of this application; Figure 5 A temperature measurement curve provided in an exemplary embodiment of this application; The following are the labeling elements in the figure: 100. Heating roller; 10. Roller body; 11. Roller shell; 12. Central body; 13. Roller shaft; 14. First cavity; 16. Flange; 17. Protective resistor; 20. Heater; 30. Drive mechanism; 31. Housing; 311. Bearing housing; 312. Motor housing; 313. Rear cover; 32. Motor shaft; 33. Motor; 331. Motor rotor; 332. Motor stator; 34. First bearing; 35. First cooling jacket; 36. Second bearing; 40. First channel section; 41. First liquid inlet section; 42. First cooling section; 43. First liquid outlet section; 50. Second channel section; 51. Second liquid inlet section; 52. Second cooling section; 53. Third cooling section; 54. Second liquid outlet section; 60. Protective shield; 70. Back plate; 71. Through hole; 72. Through hole; 73. Through hole; 74. Through hole; 80. Second cooling jacket; 90. Resolver temperature transmitter; 91. Resolver rotor plate; 92. Resolver stator plate; 1000 Heating roller system; 200 Temperature control module; 210 Temperature control board; 220 Inverter circuit; 300 Temperature protection module; A. Axial direction. Detailed Implementation

[0015] The above are merely embodiments of this application and are not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

[0016] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on the other component or there may be an intervening component. When a component is considered to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terminology, "upper," "lower," "left," "right," and similar expressions used in this application's specification are for illustrative purposes only and do not represent the only possible implementation.

[0017] Furthermore, the terms "first," "second," "third," and "fourth" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first," "second," "third," or "fourth" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0018] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature and the second feature are in indirect contact through an intermediate medium. Furthermore, "above," "over," and "on top" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0019] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in this application is for the purpose of describing particular embodiments only and is not intended to be limiting of this application. The term "and / or" as used in this application includes any and all combinations of one or more of the associated listed items.

[0020] Many electromagnetic induction heating and thermal oil heating solutions, when simultaneously meeting the extreme conditions of 400℃ high temperature and 9000rpm high speed, have at least the following systemic defects: industrial frequency induction heating has low thermal efficiency, is bulky, and the temperature is difficult to exceed 300℃; thermal oil heating has large thermal inertia (temperature rise and fall are measured in hours), the oil is prone to carbonization above 300℃, and the high temperature seal and rotary joint wear are severe under high speed, posing a risk of leakage, and is only suitable for medium and low speed applications; although ordinary high frequency electromagnetic heating can reach 6000-7000rpm, in environments above 300℃, the life of coil insulation materials (temperature resistance 220-250℃) and bearing lubrication (failure above 150℃) decreases sharply, and there is a lack of effective cooling, so the speed cannot be stably reached 9000rpm.

[0021] Specifically, under extreme conditions of 400℃ high temperature and 9000rpm high speed, the centrifugal force, convection, and radiation caused by high-speed rotation make it difficult to maintain the uniformity of roller surface temperature within ±2℃. Uneven heat distribution will seriously affect product quality. Since ordinary grease begins to decompose above 150℃ and completely fails above 300℃, the difference in thermal expansion coefficients between the inner and outer rings and rolling elements of the bearing leads to changes in clearance, affecting rotational accuracy. Furthermore, existing air-cooling or simple water-cooling systems cannot effectively remove the large amount of frictional heat generated by high-speed rotation. Therefore, the bearing system overheats and fails due to high-temperature grease decomposition, uneven thermal expansion, and insufficient cooling. At a roller surface temperature of 400℃, the upper limit of the operating temperature of the induction coil insulation material (such as polyimide, mica, etc.) is 220-250℃. In a 400℃ environment, it will rapidly age and carbonize, causing insulation failure, short circuit, and burnout. The roller body deforms excessively due to the superposition of thermal deformation and centrifugal force, disrupting dynamic balance and reducing material strength by 30%-50%. Since the time it takes for the roller to rotate one revolution is about 6.7ms at a high speed of 9000rpm, the temperature sampling and control cycle must be less than 6.7ms to effectively control the heating roller. The traditional PID control algorithm (Proportional-Integral-Derivative Control Algorithm) cannot meet the requirement of a control cycle of less than 6.7ms at 9000rpm. Temperature fluctuations cannot be compensated in time, the control system response is lagging, and ultimately the equipment cannot achieve long-term stable and reliable operation.

[0022] Therefore, this application provides a heating roller that achieves precise and uniform temperature control, as well as structural stability and energy efficiency, under extreme conditions of high temperature and high speed. Figure 1 The illustrated embodiment provides a heating roller 100, which may include at least a roller body 10, a heater 20, a drive mechanism 30, a first channel portion 40, and a second channel portion 50.

[0023] Reference Figure 1 The roller body 10 includes a roller shell 11, a central body 12 located within the roller shell 11, and a roller shaft 13 that cooperates with the central body 12. One end of the central body 12 along the axial direction A of the roller body 10 is connected to the roller shell 11 and together with the roller shell 11 forms a first cavity 14. The roller shell 11 is a shell structure and has a receiving cavity for fitting around the outside of the central body 12. Specifically, the cooperation between the roller shaft 13 and the central body 12 may include providing a cavity within the central body 12 and placing the roller shaft 13 within that cavity. In some examples, the roller shell 11 may also be referred to as a guide disc.

[0024] Heater 20 is disposed within the first cavity 14 for zoned heating of the roller shell 11. Specifically, heater 20 can be implemented using various possible heating structures. In one possible implementation, heater 20 may include a frame and multiple heating components. The frame can be disposed within the first cavity 14 of the roller body 10 for mounting and supporting the multiple heating components. The frame can also be fixed by flange 16. Multiple heating components are spaced apart on the frame along the axial direction A of the roller body 10 for zoned heating of the roller shell 11. Specifically, each heating component can be fixed to the frame by bolts. The multiple heating components can divide the roller shell 11 into multiple regions, with each heating component heating a corresponding region. The number of heating components can be two, three, four, or more, and the number of heating components can be set based on the length of the roller shell 11.

[0025] In one possible implementation, the heating roller 100 employs a multi-segment high-frequency induction heating method. The heating assembly may include a heating core and a heating coil (e.g., an induction coil). The heating core is fixedly mounted (e.g., bolted) to a frame, and the heating core forms a receiving groove, in which the heating coil is disposed. Specifically, the heating core may be a U-shaped structure to form a U-shaped receiving groove, and the heating coil is formed by winding wire within the U-shaped receiving groove. In one example, the winding can be completed using a winding machine to manufacture the multi-segment heater for the high-frequency heating roller. The winding machine may have functions such as speed regulation, counting, and alarm to ensure the consistency and stability of the high-temperature resistant wire winding for the heater. The heating core is a magnetic core made of inductive magnetic material. The heating coil is used to connect to an AC power source (e.g., 8~20kHz). When the high-frequency AC power supplied by the AC power source passes through the heating coil, an alternating magnetic field with rapidly changing direction is generated inside and outside the heating coil. At this time, by utilizing the high magnetic permeability of the heating core, the magnetic flux can be greatly increased and the magnetic field can penetrate the roller shell 11, thereby generating a strong eddy current inside the roller shell 11. The eddy current interacts with the material resistance of the roller shell 11 (e.g., it can be made of metal material or composite alloy material) to generate Joule heat, thereby achieving the heating of the roller shell 11.

[0026] The first channel portion 40 is used to contain the first cooling medium and is at least partially disposed on the drive mechanism 30 to deliver the first cooling medium to the drive mechanism 30. Specifically, the cooling medium includes, but is not limited to, liquid media, such as water, oil, and coolant.

[0027] The second channel portion 50 is used to receive the second cooling medium. A portion of the second channel portion 50 is disposed between the heater 20 and the central portion 12 to deliver the second cooling medium to the heater 20, and another portion of the second channel portion 50 is disposed on the drive mechanism 30 to deliver the second cooling medium to the drive mechanism 30. In some embodiments, the second cooling medium may be the same as or different from the first cooling medium, depending on the actual application scenario.

[0028] The drive mechanism 30 is connected to the roller body 10 and is used to drive the roller body 10 to move.

[0029] In some embodiments, see Figure 1 The drive mechanism 30 may include a housing 31, a motor shaft 32, a motor 33, a first bearing 34, and a first cooling jacket 35.

[0030] The housing 31 may include a bearing housing 311, a motor housing 312, and a rear cover 313 connected in sequence. The bearing housing 311 is partially disposed inside the roller body 10, the motor housing 312 is connected to the roller body 10, and the rear cover 313 is disposed on the end of the drive mechanism 30 away from the roller body 10. The bearing housing 311, partially disposed inside the roller body 10, can accommodate a portion of the motor shaft 32 and the first bearing 34. The rear cover 313 can accommodate and connect the motor stator 332, and can cover the end of the motor shaft 32 away from the roller body 10.

[0031] The motor shaft 32 is housed within the housing 31 and connected to the roller shaft 13 along axial direction A to drive the roller shaft 13 to rotate. It should be noted that the connection method between the roller shaft 13 and the motor shaft 32 is not specifically limited, as long as the motor 33 can transmit rotational power to the roller shaft 13. As an example, the roller shaft 13 and the motor shaft 32 can be integrally cast or machined to form a continuous, integral shaft; alternatively, they can be machined into separate roller shafts 13 and 32, and then coaxially fixed using a detachable method, including but not limited to couplings, key connections, and screw fastening.

[0032] The motor 33 may include a motor rotor 331 and a motor stator 332. The motor rotor 331 is connected to the motor shaft 32, and the motor stator 332 is disposed within the motor housing 312 and located outside the motor rotor 331. Specifically, the motor rotor 331 of the drive mechanism 30 may be a permanent magnet, brushless structure, and the drive mechanism 30 may be a permanent magnet synchronous motor (e.g., a synchronous spindle motor with a permanent magnet rotor). The motor 33 may, for example, use rare-earth magnetic materials. In some embodiments, the speed achieved by the permanent magnet synchronous motor can reach 24,000 rpm. In this embodiment, the motor shaft 32 may also use a permanent magnet synchronous motor spindle to drive the motor 33, eliminating mechanical components such as connectors, reducers, and encoders, achieving a compact design, and possessing various advantages such as high power density, extremely high speed, extremely high torque, and energy saving compared to asynchronous motors. The smooth and precise spindle motor can ensure very accurate rotational precision at extremely high speeds.

[0033] The first bearing 34 can be disposed between the motor shaft 32 and the bearing housing 311. The first bearing 34 can be sleeved on the outside of the motor shaft 32 for connecting the motor shaft 32 and the housing 31. In some embodiments, the drive mechanism 30 may include a bearing system, which may include the first bearing 34 and the second bearing 36. The first bearing 34 and the second bearing 36 are respectively disposed at both ends of the motor shaft 32. Each component of the heating roller 100 can be machined using a high-precision CNC machine tool to ensure that the mating dimensions, runout, and other indicators meet the design requirements. For example, the coaxiality of the first bearing 34 and the second bearing 36 is less than 0.01 mm, so that the runout and other indicators of the assembled heating roller 100 meet the requirements when operating under the extreme conditions of superimposed high temperature of 400℃ and high speed of 9000rpm. The first bearing 34 and the second bearing 36 can use polyamide cages, so that the bearings can withstand the ultimate speed of 12000rpm (12,000 revolutions per minute).

[0034] A first cooling jacket 35 can be disposed between the motor stator 332 and the motor housing 312, and a first cooling channel is formed between the first cooling jacket 35 and the motor housing 312. The first cooling channel communicates with the first channel portion 40 to cool the motor stator 332. In some embodiments, the first cooling jacket 35 can be a stator potting water cooling jacket. The water temperature and water flow rate in the first cooling jacket 35 can be set according to the actual application scenario, for example, the water temperature is set to 20-30℃ and the water flow rate is set to 1-2L / min. In some embodiments, the first cooling jacket 35 can be configured to be connected to at least one of the motor housing 312 and the motor stator 332.

[0035] In some embodiments, the heating roller 100 further includes a protective cover 60 partially disposed on the outside of the motor housing 312 and a rear plate 70 disposed on the side of the protective cover 60 away from the end of the roller body 10.

[0036] The first channel section 40 includes a first inlet section 41, a first cooling section 42, and a first outlet section 43. The end of the first inlet section 41 furthest from the roller body 10 is disposed on a through hole 71 in the rear plate 70 for receiving a first cooling medium. The first cooling section 42 is disposed within the motor housing 312 and communicates with the first cooling channel and the first inlet section 41. The first outlet section 43 communicates with the first cooling section 42 through the first cooling channel. The first outlet section 43 and the first inlet section 41 are arranged opposite each other in the axial direction A, and the end of the first outlet section 43 furthest from the roller body 10 is disposed on the through hole 72 in the rear plate 70.

[0037] Specifically, the first cooling medium (e.g., water) can be introduced into the first inlet section 41 through the through-hole 71, such as... Figure 1 As shown by the arrows, the liquid enters the first cooling section 42, the first cooling channel and the first liquid outlet section 43 in sequence. The liquid is discharged outward through the through hole 72 in the first liquid outlet section 43, thereby cooling the motor stator 332 of the drive mechanism 30.

[0038] In some embodiments, the heating roller 100 further includes a second cooling sleeve 80 disposed in the first cavity 14 and located between the heater 20 and the center portion 12, and a second cooling channel is formed between the second cooling sleeve 80 and the heater 20. The second cooling channel communicates with the second channel portion 50 to cool the heater 20.

[0039] In some embodiments, at least one of the first cooling channel and the second cooling channel may be a spiral cooling channel. In some embodiments, both the first cooling channel and the second cooling channel are configured as spiral cooling channels. Based on the spiral cooling channel, when the cooling medium flows in along the spiral direction, it can form a forced swirling flow. Compared with a straight flow trajectory, this spiral flow trajectory significantly increases the contact path and turbulence degree between the cooling medium and the inner walls of the first and second cooling channels, effectively disrupting the boundary layer and thus significantly improving the heat transfer coefficient between the wall and the cooling medium. The centrifugal force generated by the spiral flow will cause the cooling medium to be uniformly distributed in the circumferential direction, making the circumferential and axial temperature fields in the first and second cooling channels more uniform, thereby achieving uniform heat dissipation for the motor stator 332 and the heater 20.

[0040] In some embodiments, the bearing housing 311 is provided with an annular groove, and the second channel portion 50 includes a second liquid inlet section 51, a second cooling section 52, a third cooling section 53, and a second liquid outlet section 54.

[0041] The second inlet section 51, located away from the roller body 10, is positioned on the through hole 73 of the rear plate 70 to receive the second cooling medium. The second cooling section 52, located on the roller shell 11, communicates with the second inlet section 51 and the annular groove to cool the first bearing 34. The third cooling section 53, located inside the second cooling sleeve 80, communicates with the second cooling section 52 and the second cooling channel to cool the heater 20. The second outlet section 54 communicates with the annular groove and the second cooling channel; the end of the second outlet section 54, located away from the roller body 10, is positioned on the through hole 74 of the rear plate 70 and is axially opposite to the second inlet section 51 along axis A.

[0042] Specifically, the water temperature and flow rate in the second cooling jacket 80 can be set according to the actual application scenario. For example, the water temperature can be set to 20-30℃ and the water flow rate can be set to 1-2L / min.

[0043] Specifically, the second cooling medium can be introduced into the second inlet section 51 through the through hole 73, such as... Figure 1 As shown by the arrows, the liquid enters the second cooling section 52 and the third cooling section 53 respectively. It flows into the annular groove through the second cooling section 52 to cool the first bearing 34, and flows into the second cooling channel through the third cooling section 53 to cool the heater 20. Then, it flows into the second outlet section 54, and is discharged outward through the through hole 74, thereby achieving the cooling of the heater 20 and the first bearing 34.

[0044] The structure of the first channel section 40 and the second channel section 50 of the heating roller 100 effectively cools the heater 20 of the roller body 10 and the bearing 34 and motor 33 of the drive mechanism 30, thereby ensuring long-term reliable operation of the roller body 10 under ultra-high speed rotation (speed at least 9000 rpm). Furthermore, the bearing system of the drive mechanism 30 can also employ oil-air lubrication, for example, mixing a small amount of lubricating oil with a high-speed airflow to lubricate the bearings. Oil-air lubrication can be achieved using compressed air and a small amount of lubricating oil. In some embodiments, the drive mechanism 30 integrates water cooling and circulating lubrication of the built-in bearing housing.

[0045] In some embodiments, the second cooling channel is configured as a spiral cooling channel, which may be a spiral cooling water channel between the heating coil frame and the second cooling jacket 80 to achieve cooling of the heating coil. In some embodiments, the second cooling channel achieves active cooling of the heating coil.

[0046] In some embodiments, the roller body 10 further includes a plurality of resistors disposed inside the roller shell 11 for collecting temperature data of the roller shell 11 in the partitions corresponding to each resistor. The heating roller 100 also includes a resolver temperature transmitter 90 disposed on the rear cover 313. The resolver temperature transmitter 90 includes a resolver rotor plate 91 and a resolver stator plate 92.

[0047] Specifically, the resistor includes a temperature-sensing resistor. In some embodiments, the heating roller 100 may further include multiple temperature-sensing resistors. These multiple temperature-sensing resistors may be spaced apart along an axial direction A within the roller shell 11, with each resistor corresponding to a heating element for monitoring the temperature of the portion of the roller shell 11 corresponding to that heating element. The multiple heating elements can heat different areas of the roller shell 11, and the multiple temperature-sensing resistors can respectively collect the temperature of different areas of the roller shell 11. Therefore, the heating power of the corresponding heating element can be adjusted using the collected temperatures of different areas, thereby achieving segmented and uniform heating of the roller shell 11.

[0048] Specifically, the temperature-sensing resistor can be a platinum resistance thermometer (e.g., PT100) or other sensors used for temperature measurement. Multiple openings can be formed in the wall of the roller shell 11, and at least one temperature-sensing resistor can be installed in each opening to detect the temperature of corresponding sections of the roller shell 11. For example, the temperature-sensing resistor can be installed on the wall of the roller shell 11. One or more openings can be formed in the bearing housing 311 to detect the temperature of the first bearing 34. At least one temperature-sensing resistor can be installed in the motor stator 332 of the drive mechanism 30 to detect the temperature of the motor 33.

[0049] Specifically, each opening may contain one, two, three, four, or more temperature measuring resistors; this application does not limit this.

[0050] The resolver rotor plate 91 is connected to the drive mechanism 30, for example, to the motor shaft 32. The resolver rotor plate 91 is equipped with a first coil and a processor. The processor is connected to multiple resistors to process temperature information and obtain temperature signals. Specifically, the processor is connected to multiple temperature-sensing resistors to process the temperature signals collected by the resistors. The processor can be an STM32 processor. The resolver rotor plate 91 is connected to the drive mechanism 30 and moves together with the roller 10 under the action of the drive mechanism 30.

[0051] The resolver stator plate 92 is equipped with a second coil. The resolver stator plate 92 is configured to receive temperature signals and output them externally through the magnetic coupling between the second coil and the first coil. Specifically, the second coil is used to connect to a power supply so as to power the resolver rotor plate 91 using the magnetic coupling between the first coil and the second coil. The resolver stator plate 92 is also configured to receive temperature signals processed by the processor and output them externally.

[0052] In this embodiment, there is no physical contact between the first and second coils, resulting in no friction or wear during long-term use, ensuring long-term reliability and meeting the requirements for stable long-term operation of the heating roller 100, significantly reducing maintenance costs. Furthermore, the magnetic coupling between the first and second coils supplies power to the resolver rotor plate 91, eliminating speed limitations (stable power supply is possible from tens to tens of thousands of revolutions per minute), making it particularly suitable for high-speed heating rollers. In addition, by embedding a high-performance processor in the resolver rotor plate 91 to process and transmit data collected from multiple temperature-sensing resistors, the coil power can be adjusted in real time, thereby improving the temperature control accuracy of the roller body 10 and the uniformity of the roller surface temperature.

[0053] In some embodiments, the resolver rotor plate 91 may also be provided with one or more temperature measuring circuits, rectifier circuits, filter circuits, and voltage regulator circuits. One or more temperature measuring circuits may be connected to the processor, and each temperature measuring circuit is connected to a corresponding temperature measuring resistor. The temperature measuring circuit 513 may use a reference resistor connected in parallel with the temperature measuring resistor to achieve temperature measurement. The rectifier circuit is connected to the first coil and is used to rectify the voltage signal coupled to the first coil. The filter circuit is connected to the rectifier circuit and is used to filter the rectified voltage signal. The voltage regulator circuit is connected to the filter circuit and multiple temperature measuring circuits and is used to regulate the voltage signal after filtering by the filter circuit, thereby supplying power to the multiple temperature measuring circuits. The voltage signal coupled to the first coil, after being processed by the rectifier circuit, filter circuit, and voltage regulator circuit, can obtain a DC voltage signal, thereby providing a stable voltage signal for the multiple temperature measuring circuits.

[0054] In some embodiments, the resolver rotor plate 91 may also be provided with an infrared emitting circuit, which is used to convert the temperature signals corresponding to each temperature measuring circuit after processing by the processor into light signals. The resolver stator plate 92 may be provided with an infrared receiving module, which is used to receive the light signals generated by the infrared emitting circuit and output them to the outside.

[0055] In some embodiments, the housing 31 of the drive mechanism 30 may also be provided with an outer cover for housing the resolver temperature transmitter 90.

[0056] In some embodiments, the drive mechanism 30 further includes a second bearing 36, which is disposed outside the motor shaft 32 and located on the rear cover 313. The second bearing 36 may be a sealed bearing for a sealed connection with the motor housing 312 and the motor shaft 32. The first bearing 34 is provided with a sealing structure. The housing 31, the first bearing 34, the second bearing 36, and the sealing structure of the drive mechanism 30 achieve a seal, and work together with the second cooling section 52 to cool the bearings, thereby further achieving stable operation of the heating roller 100 under extreme conditions of superimposed high temperature of 400°C and high speed of 9000 rpm. For example, it can ensure continuous stable operation for more than 40,000 hours at 400°C and 9000 rpm.

[0057] In some embodiments, a sealing layer is provided on the exterior of the resolver temperature transmitter 90. Specifically, the components on the resolver temperature transmitter 90 can be protected with high-performance potting compound, which can improve its measurement accuracy and anti-interference ability in environments with high oil content and high acidity or alkali.

[0058] Specifically, the sealing layer and sealing structure can prevent high-temperature gases and dust from entering. The sealing layer and sealing structure can be achieved through the design and processing of sealing rings and structural gaps, or through other sealing mechanisms, which are not limited in this application.

[0059] In the heating roller 100 of this application, cooling medium is supplied to the drive mechanism 30 through the first channel section 40 and to the heater 20 and drive mechanism 30 through the second channel section 50, thereby achieving effective cooling of the heating roller 100 under the extreme conditions of superimposed high temperature of 400℃ and high speed of 9000rpm. This effectively solves the problems of overheating, lubrication failure, and reduced lifespan of the bearing system under the extreme conditions of superimposed high temperature of 400℃ and high speed of 9000rpm.

[0060] Reference Figures 2-3 This application embodiment also provides a heating roller system 1000, which includes a heating roller 100 and a temperature control module 200. The temperature control module 200 may include a temperature control board 210 and an inverter circuit 220.

[0061] The temperature control board 210 is connected to the resolver temperature transmitter 90 of the heating roller 100 to acquire temperature signals from different zones of the roller shell 11. Specifically, the temperature control board 210 can be connected to the resolver stator plate 92 of the resolver temperature transmitter 90. The temperature control board 210 may include a temperature controller, such as an ARM-based temperature controller.

[0062] In some embodiments, the temperature control board 210 may employ fuzzy self-tuning PID control technology to fuzzify the precise quantity of the PID control input, obtain the fuzzy control quantity through fuzzy rules and fuzzy inference, and convert it into a precise control quantity for online correction of the PID parameters. This improves the control accuracy of the heating roller 100 temperature and enables the heating roller 100 to be used flexibly under different set temperatures, speeds, room temperatures and load conditions.

[0063] Specifically, the temperature control board 210, based on the characteristics of the controlled object, the heating roller 100, and according to the system output response curve, combined with the effects and mutual influence of the three parameters P, I, and D, accurately inputs the variable deviation e and deviation change ec at different time periods. Through fuzzy rules and fuzzy inference, it performs online adaptive control of the parameters Kp, Ki, and Kd in the controlled process to obtain accurate output control quantities, so as to meet the different requirements of control parameters when e and ec are different, thereby improving the control accuracy of the heating roller 100 temperature and the surface temperature uniformity.

[0064] The inverter circuit 220 is connected to the temperature control board 210 and the heater 20 of the heating roller 100, and is used to control the heating power of the inverter circuit applied to the heater 20 corresponding to different zones of the roller shell 11 according to the temperature signals of different zones.

[0065] Reference Figures 3-4 In one embodiment, the heating roller system 1000 may further include a protection resistor 17 and a temperature protection module 300. The protection resistor 17 is disposed within the roller body 10 and is used to acquire temperature data of the roller body 10. Specifically, the protection resistor 17 may be a platinum resistance thermometer (e.g., PT100).

[0066] The temperature protection module 300 includes a temperature detection board 310, which is connected to a protection resistor 17 and a temperature control board 210. When the temperature detection board 310 detects that the temperature obtained through the protection resistor 17 exceeds a preset threshold, it triggers an over-temperature protection signal and sends an over-temperature protection signal to the temperature control board 210, so that the temperature control board 210 controls the inverter circuit 220 to increase the heating power of the heaters 20 corresponding to different sections of the roller shell 11.

[0067] Specifically, the inverter circuit 220 can be a bridge resonant inverter circuit. For example, the inverter circuit 220 may include: a rectifier bridge, a filter capacitor, an IGBT power module, an IGBT drive circuit, a resonant capacitor, and a heater coil.

[0068] In some embodiments, the heating roller 100 can be divided into multiple independent temperature control zones (e.g., 2, 4, 5 to 12, or more than 12) along the axial direction A. Each zone corresponds to a set of heating components and is equipped with an independent power control unit. The temperature control board 210 can adopt an ARM+CPLD architecture. The ARM processor runs a multi-segment decoupled control algorithm and an independent digital PID controller for each zone, while the CPLD is responsible for high-speed sampling synchronization, PWM waveform generation, and fast logic processing of the digital phase-locked loop (DPLL). The PID controller of each zone can independently calculate the heating power command required for that zone based on the real-time feedback from the corresponding zone temperature sensor (e.g., resistor, PT100), and suppress thermal interference between adjacent zones with the assistance of the multi-segment decoupled network. The multiple independent temperature control coils of the heating roller 100, combined with the adaptive predictive control algorithm, ultimately achieve a temperature control accuracy of ±0.1℃.

[0069] In some embodiments, the inverter circuit 220 in the heating roller system 1000 can use the 540V DC obtained by rectifying three-phase 380V as the bus, with IGBT bridge resonance as the topology, and in conjunction with an independent resonant circuit, to achieve efficient and controllable high-frequency power conversion in the frequency range of 8-20kHz. Finally, together with the PID and decoupling algorithm on the temperature control board 210, it constitutes a closed-loop temperature control system with high dynamic response and high temperature uniformity.

[0070] In some embodiments, the resolver rotor plate 91 rotates at high speed with the roller body 10, transmitting the real-time temperature to the resolver stator plate 92 based on the temperature signal acquired by the temperature-sensing resistor and processed by the processor, using infrared transmission technology. The resolver stator plate 92, on the one hand, uses spatial electromagnetic induction to supply power to the resolver rotor plate 91; on the other hand, it receives the processed temperature data from the resolver rotor plate 91 via optical signals and can transmit it to the temperature control board 210 of the temperature control module 200, thereby completing multi-channel high-precision temperature control. This combination of inductive power coupling and infrared signal transmission significantly improves the anti-interference capability and measurement accuracy during temperature acquisition and control, thereby enhancing the reliability of the heating roller 100.

[0071] In some embodiments, the roller body 10 may adopt a composite structure, such as a three-layer composite structure. The three-layer composite structure may include an outer working layer, an intermediate magnetic conductive layer, and an inner support layer. The outer working layer may include a roller shell 11, which may be made of high-temperature resistant alloy steel with a hard chrome or ceramic coating and a hardness HRC≥52. In one example, the roller shell 11 may be made of 40Cr alloy steel. 40Cr is a high-quality alloy structural steel with good hardness, toughness, wear resistance, weldability, certain corrosion resistance, and ease of processing, thereby significantly reducing the deformation of the roller shell 11 at high or ultra-high temperatures, thus giving the roller body 10 better heat resistance. The intermediate magnetic conductive layer may include a heating assembly. The inner support layer may include a second cooling jacket 80, which may be made of high-strength special steel to ensure structural strength. Since a second cooling channel is formed between the second cooling jacket 80 and the heater 20, a second cooling channel, such as a spiral cooling channel, may be formed inside the inner support layer. The composite structure adopted by the roller body 10 can take into account high temperature strength, magnetic conductivity and structural stability, thus enabling the heating roller 100 to achieve stable compatibility between ultra-high temperature of 400℃ and ultra-high speed of 9000rpm.

[0072] In some embodiments, a Schenker dynamic balancer (dynamic balance grade G0.4) can be used to perform dynamic balance correction on the heating roller 100 to achieve an average vibration value of <2mm / s when the whole roller is running at a high temperature of 400°C and a high speed of 9000rpm, thereby reducing noise, improving bearing life and avoiding mechanical failure.

[0073] In some embodiments, an infrared thermometer can be used to perform non-contact temperature measurement and temperature profile distribution testing on the heating roller 100 in the heating roller system 1000, with reference to... Figure 5 In one experiment, a FLUKE high-performance infrared thermometer was used to transmit the data from the temperature control module 200 to a computer. A hardware and software temperature measurement platform was built to complete the non-contact temperature measurement and temperature curve distribution test of the roller 10, and to accurately measure the surface temperature uniformity and stability of the heating roller 100.

[0074] In this experiment, roller 10 was 0.5 meters long. (For example...) Figure 5The temperature measurement curve shown represents length (mm) on the horizontal axis and temperature (degrees Celsius) on the vertical axis. This curve demonstrates that the measured surface temperature of the heating roller 100 in the experiment reached 400±1℃. Therefore, this experiment further verifies that the surface temperature uniformity of the heating roller 100 in this embodiment can reach 1℃, the temperature control module 200 of the heating roller system 1000 has extremely high temperature control accuracy, and the heating roller 100 has extremely high temperature stability. Therefore, the heating roller 100 and heating roller system 1000 provided in this embodiment can meet the requirements of the new generation of high-performance chemical fibers for 400℃ and 9000rpm synergistic operation, and can achieve an axial temperature difference of ≤±1℃ on the roller surface, thereby improving product quality, significantly extending equipment life (actual measurement data proves that it can ensure continuous operation for more than 40,000 hours under harsh conditions), and greatly improving production efficiency (reducing production line downtime due to malfunctions).

[0075] The heating roller 100 and heating roller system 1000 according to the embodiments of this application effectively overcome the systematic defects of existing electromagnetic heating and heat transfer oil technologies under extreme working conditions of superimposed high temperature of 400℃ and high speed of 9000rpm, such as poor temperature control accuracy, uneven temperature control, insufficient cooling of bearings and coils leading to overheating failure, structural instability and control response lag. They achieve high precision, high uniformity, high energy efficiency and high reliability heating performance. Under the harsh conditions of strong coupling between stable working temperature of 400℃ and extreme speed of 9000rpm, they simultaneously achieve high precision temperature control (±0.1℃), high uniformity temperature control (±1℃) of heating roller 100, as well as high structural stability, high energy efficiency and long life of heating roller 100.

[0076] Furthermore, the heating roller system 1000 embodiment provided in the above embodiments and the heating roller 100 embodiment belong to the same concept, and the specific implementation process can be found in the heating roller embodiment, which will not be repeated here.

[0077] Although embodiments of this application have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions, and alterations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the claims and their equivalents. The above descriptions are merely preferred embodiments of this application and are not intended to limit the application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A heating roller (100), characterized in that, include: The roller body (10) includes a roller shell (11), a central body (12) located inside the roller shell (11), and a roller shaft (13) cooperating with the central body (12). One end of the central body (12) in the axial direction (A) of the roller body (10) is connected to the roller shell (11) and together with the roller shell (11) forms a first cavity (14). A heater (20) is disposed in the first cavity (14) for partitioned heating of the roller shell (11); A drive mechanism (30) is connected to the roller body (10) and is used to drive the roller body (10) to move; A first channel section (40) is used to contain a first cooling medium and is at least partially disposed on the drive mechanism (30) to deliver the first cooling medium to the drive mechanism (30); as well as The second channel section (50) is used to contain the second cooling medium. A portion of the second channel section (50) is disposed between the heater (20) and the center section (12) to deliver the second cooling medium to the heater (20). Another portion of the second channel section (50) is disposed on the drive mechanism (30) to deliver the second cooling medium to the drive mechanism (30).

2. The heating roller (100) as described in claim 1, characterized in that, The drive mechanism (30) includes: The housing (31) includes a bearing seat (311), a motor housing (312), and a rear cover (313) connected in sequence. The bearing seat (311) is partially disposed inside the roller body (10). The motor housing (312) is connected to the roller body (10). The rear cover (313) is disposed on the end side of the drive mechanism (30) away from the roller body (10). The motor shaft (32) is disposed inside the housing (31) and connected to the roller shaft (13) along the axial direction (A) to drive the roller shaft (13) to rotate; The motor (33) includes a motor rotor (331) and a motor stator (332). The motor rotor (331) is connected to the motor shaft (32), and the motor stator (332) is disposed inside the motor housing (312) and located outside the motor rotor (331). A first bearing (34) is disposed between the motor shaft (32) and the bearing housing (311); and A first cooling sleeve (35) is disposed between the motor stator (332) and the motor housing (312), and a first cooling channel is formed between the first cooling sleeve (35) and the motor housing (312). The first cooling channel communicates with the first channel portion (40) to cool the motor stator (332).

3. The heating roller (100) as described in claim 2, characterized in that, The heating roller (100) further includes a protective cover (60) partially disposed on the outside of the motor housing (312) and a rear plate (70) disposed on the side of the protective cover (60) away from the end of the roller body (10). The first channel portion (40) includes: The first liquid inlet section (41) is located at one end away from the roller body (10) on the through hole (71) of the rear plate (70) for receiving the first cooling medium. The first cooling section (42) is disposed inside the motor housing (312) and communicates with the first cooling channel and the first liquid inlet section (41); The first liquid outlet section (43) is connected to the first cooling section (42) through the first cooling channel. The first liquid outlet section (43) and the first liquid inlet section (41) are arranged opposite to each other in the axial direction (A). The end of the first liquid outlet section (43) away from the roller body (10) is arranged on the through hole (72) of the rear plate (70).

4. The heating roller (100) as described in claim 2, characterized in that, The heating roller (100) further includes a second cooling sleeve (80) disposed in the first cavity (14) and located between the heater (20) and the center portion (12), and a second cooling channel is formed between the second cooling sleeve (80) and the heater (20), the second cooling channel communicating with the second channel portion (50) to cool the heater (20).

5. The heating roller (100) as described in claim 4, characterized in that, The bearing housing (311) is provided with an annular groove, and the second channel portion (50) includes: The second liquid inlet section (51) is located at one end away from the roller body (10) on the through hole (73) of the rear plate (70) for receiving the second cooling medium; The second cooling section (52) is disposed on the roller shell (11) and communicates with the second liquid inlet section (51) and the annular groove to cool the first bearing (34). The third cooling section (53) is disposed inside the second cooling jacket (80) and communicates with the second cooling section (52) and the second cooling channel to cool the heater (20). The second liquid outlet section (54) is connected to the annular groove and the second cooling channel. One end of the second liquid outlet section (54) away from the roller body (10) is disposed on the through hole (74) of the rear plate (70) and is disposed opposite to the second liquid inlet section (51) in the axial direction (A).

6. The heating roller (100) as described in claim 4, characterized in that, The first cooling channel is a spiral cooling flow channel; and / or The second cooling channel is a spiral cooling channel.

7. The heating roller (100) as described in any one of claims 1-6, characterized in that, The roller body (10) also includes multiple resistors disposed inside the roller shell (11) for collecting temperature data of the roller shell (11) in the partitions corresponding to each resistor. The heating roller (100) also includes a resolver temperature transmitter (90) disposed on the rear cover (313). The resolver temperature transmitter (90) includes: A resolver rotor plate (91) is connected to the drive mechanism (30). The resolver rotor plate (91) is provided with a first coil and a processor. The processor is connected to the plurality of resistors to process the temperature information to obtain a temperature signal. The resolver stator plate (92) is provided with a second coil. The resolver stator plate (92) is configured to receive the temperature signal and output it to the outside through the magnetic coupling between the second coil and the first coil.

8. The heating roller (100) as described in claim 2, characterized in that, The drive mechanism (30) further includes a second bearing (36), which is disposed outside the motor shaft (32) and located on the rear cover (313). The second bearing (36) is sealed to the motor housing (312) and the motor shaft (32); and / or The resolver temperature transmitter (90) is provided with a sealing layer.

9. A heating roller system (1000), characterized in that, Including the heating roller (100) and temperature control module (200) as described in any one of claims 1-8, the temperature control module (200) comprising: Temperature control board (210) is connected to the resolver temperature transmitter (90) of the heating roller (100) to acquire temperature signals of different zones of the roller shell (11); The inverter circuit (220) is connected to the temperature control board (210) and the heater (20) of the heating roller (100) to control the heating power of the inverter circuit (220) applied to the heater (20) corresponding to the different partitions of the roller shell (11) according to the temperature signals of the different partitions.

10. The heating roller system (1000) as claimed in claim 9, characterized in that, The heating roller system (1000) also includes: A protective resistor (17) is provided inside the roller body (10) to obtain temperature data of the roller shell (11); Temperature protection module (300), the temperature protection module (300) includes a temperature detection board (310), the temperature detection board (310) is connected to the protection resistor (17) and the temperature control board (210), when the temperature detection board (310) detects that the temperature obtained through the protection resistor (17) exceeds the preset threshold, it triggers an over-temperature protection signal and sends the over-temperature protection signal to the temperature control board (210), so that the temperature control board (210) controls the heating power of the inverter circuit (220) applied to the heaters (20) corresponding to different sections of the roller shell (11).

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