Heating roller and heating system

Abstract

The application belongs to the technical field of industrial heating, and particularly relates to a heating roller and a heating system. The heating roller comprises a roller body, a heater, a plurality of temperature measuring resistors and a driving mechanism. The roller body comprises a roller shell and a first cavity. The heater comprises a framework and a plurality of heating components. The framework is arranged in the first cavity, and the plurality of heating components are arranged on the framework in an axial direction. The plurality of temperature measuring resistors are arranged on the roller body in an axial direction, and each temperature measuring resistor corresponds to a heating component. The driving mechanism is connected with the roller body. Different regions of the roller shell are heated by the plurality of heating components, and the temperatures of the different regions of the roller shell are collected by the plurality of temperature measuring resistors, so that the heating power of the corresponding heating component can be adjusted, and the segmented and uniform heating of the roller shell is realized. The segmented heating can ensure and improve the heating power of each region, so that the heating power of the entire heating roller can be improved. The segmented temperature collection can ensure the accuracy of temperature collection of each region, and facilitate control and adjustment, so that the uniformity of the roller surface temperature can be improved.

Description

Technical Field

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

[0002] With the rapid development of modern electronic technology and continuous breakthroughs in the performance of high-quality power electronic devices, electromagnetic induction heating technology has moved from theory to large-scale industrial application. Currently, electromagnetic induction heating rollers, with their advantages of non-contact heating, fast thermal response, and high thermal efficiency, are widely used in continuous production lines requiring precise temperature control, such as textiles, papermaking, printing, and film processing. However, the single-machine heating power of existing electromagnetic induction heating rollers is limited, making it difficult to meet the thermal energy requirements of large heating rollers with a diameter ≥0.4m and a length ≥1m, as well as the requirements for uniform surface temperature. Furthermore, when the target temperature reaches above 400℃, insufficient heating power can easily lead to slow heating or even failure to reach the process temperature. Summary of the Invention

[0003] This application aims to provide a heating roller and heating system, which greatly improves the heating power of the heating roller, can meet the heat energy requirements of large hot rollers, and greatly improves the surface temperature and surface temperature uniformity of the hot roller.

[0004] The first aspect of this application provides a heating roller, comprising: a roller body including a roller shell and a first cavity; a heater including a frame and a plurality of heating components, the frame being disposed within the first cavity of the roller body, the plurality of heating components being spaced apart along the axial direction of the roller body on the frame for partitioned heating of the roller shell; a plurality of temperature measuring resistors being spaced apart along the axial direction on the roller body, each temperature measuring resistor corresponding to one of the heating components for monitoring the temperature of the portion of the roller shell corresponding to the heating component; and a drive mechanism connected to the roller body for driving the roller body to move.

[0005] In an optional embodiment of this application, the roller body includes: a roller shell with multiple openings, each opening housing at least one of the temperature-sensing resistors; a central body disposed within the roller shell and forming a second cavity, wherein one axial end of the central body is connected to the roller shell and together with the roller shell forms the first cavity; and a roller shaft disposed within the second cavity and cooperating with the central body. The surface of the roller shaft that mates with the central body is a conical surface. At least a portion of the driving mechanism is disposed within the roller shell and connected to the roller shaft to drive the roller body to move.

[0006] In an optional embodiment of this application, the heating assembly includes: a heating core fixedly disposed on the frame, and the heating core having a receiving groove; and a heating coil disposed in the receiving groove.

[0007] In an optional embodiment of this application, the heating roller further includes a rotary temperature transmitter, which includes: a resolver rotor plate with a first coil and a processor, the processor being connected to the plurality of temperature measuring resistors, and the resolver rotor plate being connected to the drive mechanism; and a resolver stator plate with a second coil, the second coil being used to connect to a power supply.

[0008] In an optional embodiment of this application, the resolver rotor board is further provided with: a plurality of temperature measuring circuits connected to the processor, and each of the temperature measuring circuits is connected to a corresponding temperature measuring resistor; and an auxiliary circuit connected to the first coil.

[0009] In an optional embodiment of this application, the heating core is composed of multiple layers of sheet-like structures with interlayer insulation.

[0010] In an optional embodiment of this application, the heating roller further includes: a first cooling sleeve, fitted between the central body and the frame, for cooling the heater; and a second cooling sleeve, fitted between the first cooling sleeve and the drive mechanism, for cooling the drive mechanism.

[0011] In an optional embodiment of this application, at least one of the first cooling jacket and the second cooling jacket is provided with a spiral cooling channel.

[0012] In an optional embodiment of this application, the drive mechanism includes: a housing, partially disposed within the roller body; a motor shaft, disposed within the housing; a bearing, disposed between the motor shaft and the housing; a motor rotor, connected to the motor shaft; and a motor stator, disposed within the housing and located outside the motor rotor and connected to the housing.

[0013] A second aspect of this application provides a heating system comprising the heating roller described above and a control module. The control module includes a temperature controller and a power supply. The temperature controller is configured to control the supply voltage of the power supply based on the temperature signal collected by each of the temperature sensing resistors, thereby adjusting the heating power of the corresponding heating component. For example, the supply voltage of the power supply may be a high-frequency pulse voltage.

[0014] In summary, the solution provided in this application has at least the following beneficial effects: In the heating roller provided in this application, multiple heating components heat different areas of the roller body, and multiple temperature-sensing resistors collect the temperature of different areas of the roller shell. This allows for the adjustment of the heating power of the corresponding heating components based on the collected temperatures of different areas, thereby achieving segmented and uniform heating of the roller shell. Segmented heating ensures and improves the heating power of each area, thus increasing the overall heating power of the heating roller. Segmented temperature acquisition ensures the accuracy of temperature data collection for each area, facilitating control and adjustment, and improving the uniformity of the roller surface temperature. Therefore, the heating roller of this application can meet the thermal energy requirements and surface temperature uniformity requirements of large heating rollers, and can raise the roller surface temperature to over 400°C, making it suitable for continuous production lines requiring precise temperature control, such as those in textiles, papermaking, printing, and film processing. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of the specific embodiments of this application, the drawings used in the specific embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the structure of the heating roller provided according to an embodiment of this application; Figure 2 for Figure 1 An enlarged view of circle A in the image; Figure 3 for Figure 1 An enlarged view of circle B in the image; Figure 4 This is a schematic diagram of the structure of the resolver rotor plate of the resolver temperature transmitter provided according to an embodiment of this application; Figure 5 This is a schematic diagram of the structure of the resolver stator plate of the resolver temperature transmitter provided according to an embodiment of this application; Figure 6 This is a schematic diagram of the heating system provided according to an embodiment of this application.

[0017] The attached icons are numbered as follows: 00. Heating system; 100. Heating roller; 10. Roller body; 11. Roller shell; 12. Center body; 13. Roller shaft; 14. First cavity; 15. Opening; 16. Second cavity; 20. Heater; 21. Frame; 22. Heating assembly; 221. Heating core; 222. Heating coil; 223. Receiving slot; 30. Temperature measuring resistor; 40. Drive mechanism; 41. Housing; 411. Front housing; 412. Rear housing; 413. Rear cover; 42. Motor shaft; 43. Bearing; 44. Motor rotor; 45. Motor stator; 50. Resolver temperature transmitter; 51. Resolver rotor plate; 511. First coil; 512. Processor; 513. Temperature measurement circuit; 514. Auxiliary circuit; 515. Infrared transmitting circuit; 52. Resolver stator plate; 521. Second coil; 522. Infrared receiving module; 60. First cooling jacket; 70. Second cooling jacket; 80. Protective cover; 90. Fan; 110. Heavy-duty connector; 120. Temperature protection plate; 130. Terminal block; 140. End cover plate; 150. Flange; 200. Control module; 210. Temperature controller; 220. Power supply; C. Axial direction. Detailed Implementation

[0018] To make the above and other features and advantages of this application clearer, the application is further described below with reference to the accompanying drawings. It should be understood that the specific embodiments given herein are for the purpose of explanation to those skilled in the art and are exemplary only, not restrictive.

[0019] The terms "first" and "second" in the specification and claims of this application may explicitly or implicitly include one or more of the features. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0020] Currently, heating rollers mainly include steam heating rollers and electromagnetic heating rollers. Steam heating rollers require external steam sources, steam pipes, valves and other structures to achieve heating, while electromagnetic heating rollers require electromagnetic induction structures to achieve heating.

[0021] Steam heating rollers typically require steam to be supplied to the roller surface via a rotary joint. Based on the installation and heating methods of steam heating rollers, existing steam heating rollers generally suffer from the following problems: The installation of steam heating rollers is complex and requires a large area due to the need for external steam sources (such as boilers), pipes, and valves; the heating effect is severely affected by unstable steam sources, making it impossible to achieve the required process temperature and uniform surface temperature; steam heating rollers primarily control heat and overall internal temperature through pressure, which cannot achieve precise temperature control; and steam leakage is prone to occur, increasing the risk of safety accidents.

[0022] Although electromagnetic induction heating rollers have advantages such as non-contact heating, fast thermal response, and high thermal efficiency, the limited heating power of existing electromagnetic induction heating rollers makes it difficult to meet the thermal energy requirements of large heating rollers with a diameter ≥0.4m and a length ≥1m, as well as the requirements for uniform surface temperature of the heating rollers. Furthermore, when the target temperature reaches above 400℃, insufficient heating power can easily lead to slow heating or even failure to reach the process temperature.

[0023] Therefore, this application provides a heating roller that employs a multi-segment high-frequency induction heating method, improving the roller surface temperature, heating power, and temperature uniformity. This meets the requirements for large-scale heating rollers and can be widely used in continuous production lines requiring precise temperature control, such as those for textiles (e.g., aramid, carbon fiber), papermaking, printing, and film processing. Of course, it is not limited to this; the heating roller can also be applied to any other system requiring heating and temperature control.

[0024] Figure 1 This is a schematic diagram of the structure of the heating roller provided according to an embodiment of this application. Figure 2 for Figure 1 An enlarged view of circle A in the image. Figure 3 for Figure 1 An enlarged view of circle B in the image; See Figures 1 to 3 The heating roller 100 may include a roller body 10, a heater 20, a plurality of temperature measuring resistors 30, and a drive mechanism 40.

[0025] The roller body 10 (also referred to as a guide disc) has a first cavity 14 for mounting a heater 20, enabling the heater 20 to heat the roller shell 11 of the roller body 10. The roller body 10 can be a columnar structure to roll under the action of the drive mechanism 40, thereby achieving heating and rolling of the object being heated. The length of the roller body 10 can be selected according to the application scenario; for example, the length of the roller body 10 can be less than 1m, equal to 1m, or greater than 1m, and this application does not limit it in this way.

[0026] Since 40Cr is a high-quality alloy structural steel with good hardness, toughness, wear resistance, weldability, certain corrosion resistance and easy processing, the roller body 10 can be made of 40Cr alloy steel, which can significantly reduce the deformation of the roller body 10 at high or ultra-high temperatures.

[0027] The heater 20 may include a frame 21 and multiple heating components 22. The frame 21 is disposed within the first cavity 14 of the roller body 10 and is used to mount the multiple heating components 22 and provide support for the multiple heating components 22. In actual use of the heating roller 100, the frame 21 is fixed to an external fixed bracket by a flange.

[0028] Multiple heating components 22 are spaced apart along the axial direction C of the roller body 10 on the frame 21 for zoned heating of the roller shell 11. Specifically, each heating component 22 can be fixed to the frame 21 by bolts. The multiple heating components 22 divide the roller shell 11 into multiple areas, and each heating component 22 heats a corresponding area.

[0029] Specifically, the number of heating components 22 can be two, three, four, five, six, eight or more, and the number of heating components 22 can be set based on the length of the roller body 10.

[0030] Multiple temperature-sensing resistors 30 are spaced apart along the axial direction C on the roller body 10, for example, inside the roller shell 11. Each temperature-sensing resistor 30 corresponds to a heating element 22 and is used to monitor the temperature of the portion of the roller shell 11 corresponding to the heating element 22. Specifically, the temperature-sensing resistor 30 can be a platinum resistance thermometer or other sensors used for measuring temperature.

[0031] The drive mechanism 40 is connected to the roller body 10 and is used to drive the roller body 10 to move so as to heat and roll the object to be heated.

[0032] In the heating roller 100 of this application, multiple heating components 22 heat different areas of the roller shell 11, and multiple temperature measuring resistors 30 collect the temperature of different areas of the roller shell 11. This allows for adjustment of the heating power of the corresponding heating components 22 based on the collected temperature of different areas, thereby achieving segmented and uniform heating of the roller shell 11. The segmented heating method ensures and improves the heating power of each area, thus increasing the overall heating power of the heating roller 100. The segmented temperature collection method ensures the accuracy of temperature collection in each area, facilitating control and adjustment, thereby improving the uniformity of the roller surface temperature of the heating roller 100. Therefore, the heating roller 100 of this application can meet the thermal energy requirements (such as heating power requirements of 100kW or more) and the requirements for uniform surface temperature of large heating rollers with a diameter ≥0.4m and a length ≥1m, and can raise the roller surface temperature of the heating roller 100 to over 400℃. It is suitable for continuous production lines requiring precise temperature control, such as textiles (e.g., aramid, carbon fiber), papermaking, printing, and film processing.

[0033] In some embodiments, see Figures 1 to 3 The roller body 10 may include a roller shell 11, a central body 12, and a roller shaft 13.

[0034] The roller shell 11 has a shell structure and a receiving cavity, which is fitted onto the outside of the central body 12. Multiple openings 15 are formed on the wall of the roller shell 11, and at least one temperature measuring resistor 30 is disposed in each opening 15. The temperature measuring resistor 30 can be disposed on the wall of the roller shell 11.

[0035] Specifically, each opening 15 may contain one, two, three, four, or more temperature measuring resistors 30; this application does not limit this. For example, the roller shell 11 has two openings 15, and each opening 15 contains four temperature measuring resistors 30.

[0036] It should be noted that, regardless of the number of temperature measuring resistors 30 and the number and position of openings 15, multiple temperature measuring resistors 30 are arranged sequentially along the axial direction C of the roller body 10, so that each area of ​​the roller shell 11 of the roller body 10 corresponds to one temperature measuring resistor 30.

[0037] The central body 12 is disposed inside the roller shell 11 and forms a second cavity 16, which is used to install the roller shaft 13. One end of the central body 12 on the axial direction C 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 first cavity 14 is provided with a heater 20, which is used to heat the roller shell 11.

[0038] The roller 13 is disposed within the second cavity 16 and is connected to the central body 12. Specifically, the roller 13 is disposed within the second cavity 16 and is interference-fitted with the inner wall of the second cavity 16 to achieve the connection between the roller 13 and the central body 12. The surface of the roller 13 that mates with the central body 12 is a conical surface.

[0039] It should be noted that the second cavity 16, also known as the center hole, corresponds to the roller 13, and the inner wall surface of the second cavity 16 on the center body 12 is also a conical surface. The taper of the conical surface can be designed according to requirements; for example, the taper can be 1:20, the surface roughness can reach 0.8μm, and the diameter of the second cavity 16 can be 100mm. Furthermore, to ensure the fit between the roller 13 and the center body 12, the conical surface on the center body 12 and the conical surface on the roller 13 need to be ground using a precision tapered measuring tool to ensure a tight fit between the mating surfaces after assembly.

[0040] At least a portion of the drive mechanism 40 is disposed within the roller housing 11 and connected to the roller shaft 13 to drive the roller body 10 to rotate via the roller shaft 13.

[0041] In this embodiment, the temperature measuring resistor 30 is placed on the wall of the roller shell 11 to ensure measurement accuracy. At the same time, the surface of the center body 12 that mates with the roller shaft 13 is set as a conical surface to facilitate the installation and disassembly of the two.

[0042] In some embodiments, see Figure 1 and Figure 2 The heating component 22 may include a heating core 221 and a heating coil 222.

[0043] The heating core 221 is fixedly mounted (e.g., bolted) on the frame 21, and the heating core 221 forms a receiving groove 223, in which the heating coil 222 is arranged. Specifically, the heating core 221 can be a U-shaped structure to form a U-shaped receiving groove 223, and the heating coil 222 is formed by winding wire in the U-shaped receiving groove 223.

[0044] Specifically, the heating core 221 is a magnetic core (made of inductive magnetic material), and the heating coil 222 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 222, a rapidly changing alternating magnetic field is generated inside and outside the heating coil 222. At this time, by utilizing the high magnetic permeability of the heating core 221, the magnetic flux can be greatly increased and the magnetic field can penetrate the metal 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 to generate Joule heat, thereby achieving efficient heating of the roller shell 11.

[0045] In some embodiments, the heating core 221 may be formed by stacking multiple sheet-like structures (e.g., multiple thin sheets) with interlayer insulation, which can significantly block eddy current paths, reduce eddy current losses, and thus further improve heating efficiency.

[0046] In some embodiments, see Figures 1 to 3 The drive mechanism 40 may include a housing 41, a motor shaft 42, a bearing 43, a motor rotor 44, and a motor stator 45.

[0047] A portion of the housing 41 is located within the roller body 10. The motor shaft 42 is housed within the housing 41 and connected to the roller shaft 13 of the roller body 10. Bearings 43 are sleeved on the outside of the motor shaft 42 and are used to connect the motor shaft 42 to the housing 41. Two bearings 43 can be used, with each bearing 43 positioned at one end of the motor shaft 42. Furthermore, the coaxiality of the two bearings 43 is less than 0.01 mm to ensure the roller body can move freely after assembly.

[0048] The motor rotor 44 is connected to the motor shaft 42, and the motor stator 45 is disposed inside the housing 41 and located outside the housing 41 and connected to the housing 41.

[0049] To ensure accurate, stable, and efficient rotation speed, the drive mechanism 40 can be used in conjunction with a frequency converter in a one-to-one direct-drive configuration to achieve independent control of the rotation speed of the roller 10. This method offers higher control precision and is more flexible and convenient to use.

[0050] In some embodiments, see Figures 1 to 3The housing 41 of the drive mechanism 40 may include a front housing 411, a rear housing 412, and a rear cover 413 connected in sequence. A portion of the front housing 411 is disposed within the roller body 10 and houses a portion of the motor shaft 42 and a corresponding bearing 43. The rear housing 412 houses and connects to the motor stator 45, and the rear cover 413 covers the end of the motor shaft 42 away from the roller body 10.

[0051] In some embodiments, the motor shaft 42 of the drive mechanism 40 is made of 42CrMo, which can improve the mechanical properties and hardenability of the motor shaft 42, and give the motor shaft 42 a higher fatigue limit and resistance to repeated impacts. The properties of the material can also be changed through hot working. Furthermore, the motor shaft 42 can be treated with processes such as heat treatment and forging to further improve its mechanical properties and shape accuracy.

[0052] In some embodiments, the bearing 43 of the drive mechanism 40 can be a high-precision, high-load bearing, and can be double-sided sealed and self-lubricating to ensure the motor's corrosion resistance and lubrication requirements. Furthermore, the bearing 43 has a quenching hardness of not less than HRC48-53, meeting the requirements for wear resistance during long-term operation.

[0053] In some embodiments, the motor rotor 44 of the drive mechanism 40 can be a permanent magnet, brushless structure, then the drive mechanism 40 can be a permanent magnet synchronous motor.

[0054] Figure 4 This is a schematic diagram of the resolver rotor plate of the resolver temperature transmitter provided according to an embodiment of this application. Figure 5 This is a schematic diagram of the structure of the resolver stator plate of the resolver temperature transmitter provided according to an embodiment of this application.

[0055] In some embodiments, see Figure 1 as well as Figures 3 to 5 The heating roller 100 may also include a resolver temperature transmitter 50, which may include a resolver rotor plate 51 and a resolver stator plate 52.

[0056] The resolver rotor plate 51 is equipped with a first coil 511 and a processor 512. The processor 512 is connected to multiple temperature measuring resistors 30 and is used to process the temperature signals collected by the temperature measuring resistors 30. Specifically, the processor 512 can be an STM32 processor. The resolver rotor plate 51 is connected to the drive mechanism 40 so that it moves together with the roller 10 under the action of the drive mechanism 40.

[0057] The resolver stator plate 52 is provided with a second coil 521, which is used to connect to the power supply so as to use the magnetic coupling between the first coil 511 and the second coil 521 to supply power to the resolver rotor plate 51. The resolver stator plate 52 is configured to receive the temperature signal processed by the processor 512 and output it to the outside.

[0058] In this embodiment, there is no physical contact between the first coil 511 and the second coil 521, 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 coil 511 and the second coil 521 supplies power to the resolver rotor plate 51, 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 512 on the resolver rotor plate 51 to process and transmit data collected from multiple temperature measuring resistors 30, the coil power can be adjusted in real time, thereby improving the temperature control accuracy of the roller shell 11 and the uniformity of the roller surface temperature.

[0059] In some embodiments, see Figure 4 One or more temperature measuring circuits 513 and auxiliary circuits 514 may also be provided on the resolver rotor plate 51.

[0060] One or more temperature sensing circuits 513 are connected to the processor 512, and each temperature sensing circuit 513 is connected to a corresponding temperature sensing resistor 30. Specifically, the temperature sensing resistor 30 can be a platinum resistance thermometer (such as PT100), and the temperature sensing circuit 513 can achieve temperature measurement by using a reference resistor connected in parallel with the temperature sensing resistor 30.

[0061] In some embodiments, the auxiliary circuit 514 may include a rectifier circuit, a filter circuit, and a voltage regulator circuit. The rectifier circuit may be connected to the first coil 511 to rectify the voltage signal coupled to the first coil 511. The filter circuit may be connected to the rectifier circuit to filter the rectified voltage signal. The voltage regulator circuit may be connected to the filter circuit and multiple temperature measuring circuits 513 to regulate the filtered voltage signal and supply power to the multiple temperature measuring circuits 513. In this embodiment, the voltage signal coupled to the first coil 511 is processed by the auxiliary circuit 514 to obtain a DC voltage signal, thereby providing a stable voltage signal to the multiple temperature measuring circuits 513.

[0062] In some embodiments, see Figure 4 and Figure 5The resolver rotor plate 51 is also equipped with an infrared emitting circuit 515, which is used to convert the temperature signals corresponding to each temperature measuring circuit 513 after processing by the processor 512 into light signals. The resolver stator plate 52 is equipped with an infrared receiving module 522, which is used to receive the light signals generated by the infrared emitting circuit 515 and output them to the outside.

[0063] In this embodiment, the resolver rotor plate 51 rotates at high speed with the roller body 10. Based on the temperature signal collected by the temperature sensing resistor 30 and processed by the processor 512, the real-time temperature is transmitted to the resolver stator plate 52 using infrared transmission technology. The resolver stator plate 52, on the one hand, uses spatial electromagnetic induction to couple the power supply to the resolver rotor plate 51; on the other hand, it receives the processed temperature data from the resolver rotor plate 51 via optical signals and can transmit it to an external temperature controller, thus 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 improving the reliability of the heating roller 100. The temperature controller can also adjust the coil power in real time, which helps to improve the temperature control accuracy of the roller shell 11 and the temperature uniformity of the roller surface.

[0064] In addition, the components of the resolver temperature transmitter 50 can be protected with high-performance potting compound, which can improve its measurement accuracy and anti-interference ability in environments with high oil and high acid and alkali.

[0065] In some embodiments, see Figure 1 and Figure 2 The heating roller 100 may also include a first cooling jacket 60 and a second cooling jacket 70.

[0066] The first cooling jacket 60 is fitted between the central body 12 and the frame 21 to cool the heater 20. The second cooling jacket 70 is fitted between the first cooling jacket 60 and the bearing 43 of the drive mechanism 40 to cool the bearing 43 of the drive mechanism 40.

[0067] During the use of the heating roller 100, a heat-conducting medium (such as pure water) can be introduced into the first cooling jacket 60 and the second cooling jacket 70. When the heat-conducting medium flows, it can carry away the heat on the heater 20 and the bearing 43 in time, thereby improving the working reliability of both under high temperature conditions, so that the heating temperature of the heating roller 100 can reach more than 400℃, ensuring its long-term stability under high temperature conditions.

[0068] In some embodiments, see Figure 1 and Figure 2 At least one of the first cooling jacket 60 and the second cooling jacket 70 is provided with a spiral cooling channel. Preferably, both the first cooling jacket 60 and the second cooling jacket 70 are provided with spiral cooling channels.

[0069] Based on the spiral cooling channel, when the heat transfer medium flows in along the spiral direction, it can form a forced swirling flow. Compared with the straight flow trajectory, this spiral flow trajectory significantly increases the contact path and turbulence between the heat transfer medium and the inner wall of the cooling jacket, effectively disrupting the boundary layer and thus significantly improving the heat transfer coefficient between the wall and the heat transfer medium. At the same time, the centrifugal force generated by the spiral flow will promote the uniform distribution of the heat transfer medium in the circumferential direction, making the circumferential and axial temperature fields of the entire cooling jacket more uniform, thereby achieving uniform heat dissipation for the overall heater 20 and bearing 43.

[0070] In some embodiments, see Figure 1 and Figure 3 The heating roller 100 may further include a protective cover 80 and a fan 90. The protective cover 80 is connected to the housing 41 of the drive mechanism 40 and houses the resolver temperature transmitter 50 and the fan 90. The fan 90 can provide air cooling for the resolver temperature transmitter 50 and the motor stator 45 of the drive mechanism 40.

[0071] In some embodiments, see Figure 1 and Figure 2 The heating roller 100 may also include a heavy-duty connector 110, which is disposed on the end side of the protective cover 80 away from the roller body 10.

[0072] In some embodiments, see Figure 1 and Figure 2 The heating roller 100 may also include a temperature protection plate 120, a junction box 130, and an end cover plate 140.

[0073] In some embodiments, see Figure 1 The heating roller 100 may also include a flange 150, which is connected to the frame 21 of the heater 20 and the housing 41 of the drive mechanism 40 to fix the frame 21 and the housing 41 of the drive mechanism 40 on an external support.

[0074] This application also provides a heating system, see embodiments thereof. Figure 6 , Figure 6 This is a schematic diagram of a heating system provided in an embodiment of this application. The heating system 00 may include the heating roller 100 and the control module 200 provided in any of the above embodiments.

[0075] The control module 200 includes a temperature controller 210 and a power supply 220. The temperature controller 210 is configured to control the power supply voltage of the power supply 220 according to the temperature signal collected by each temperature measuring resistor 30, so as to adjust the heating power of the corresponding heating component 22.

[0076] In the heating system 00 of this application, multiple heating components 22 heat different areas of the roller body 10 of the heating roller 100. Through temperature sensing technology using a temperature-sensing resistor 30 and a temperature controller 210, independent control of the heating power of each heating component 22 can be achieved. This not only facilitates control and adjustment but also ensures high control precision, thereby guaranteeing and improving the heating power of each area, and consequently improving the overall heating power of the heating roller 100 and the uniformity of the roller surface temperature. Therefore, the heating system 00 of this application can meet the thermal energy requirements (such as heating power requirements of 100kW or more) and the requirements for uniform surface temperature of large heating rollers with a diameter ≥ 0.4m and a length ≥ 1m, and can raise the roller surface temperature of the heating roller 100 to over 400℃. It is suitable for continuous production lines requiring precise temperature control, such as textiles (e.g., aramid, carbon fiber), papermaking, printing, and film processing.

[0077] In some embodiments, the temperature controller 210 employs fuzzy self-tuning PID control technology to fuzzify the precise quantity of the PID control input. Through fuzzy rules and fuzzy inference, fuzzy control quantities are obtained and converted into precise control quantities for online correction of 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.

[0078] Specifically, the temperature controller 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 interactions of the three parameters P, I, and D, and corresponding to the precise input variable deviation e and deviation change ec at different time periods, performs online adaptive control of the parameters Kp, Ki, and Kd in the controlled process through fuzzy rules and fuzzy inference to obtain precise output control quantities. This satisfies the different requirements of control parameters for different e and ec, improving the control accuracy of the heating roller 100 temperature and the surface temperature uniformity (measured at ±1.5). ).

[0079] In summary, the heating system 00 of this application employs multi-segment high-frequency induction heating technology. Through temperature sensing by the temperature measuring resistor 30, the non-contact resolver temperature transmitter 50, and multi-segment independent temperature control technology, a closed-loop system is used to achieve high-precision measurement and control of the surface temperature of each heating roller in the heating system.

[0080] Furthermore, the heating system provided in the above embodiments and the heating roller embodiments belong to the same concept, and the specific implementation process can be found in the heating roller embodiments, which will not be repeated here.

[0081] 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.

Claims

1. A heating roller (100), characterized in that, include: The roller body (10) includes a roller shell (11) and a first cavity (14). The heater (20) includes a frame (21) and a plurality of heating components (22). The frame (21) is disposed in the first cavity (14) of the roller body (10). The plurality of heating components (22) are disposed at intervals along the axial direction (C) of the roller body (10) on the frame (21) for partitioned heating of the roller shell (11). Multiple temperature-sensing resistors (30) are spaced apart along the axial direction (C) on the roller body (10), each temperature-sensing resistor (30) corresponding to one heating element (22), used to monitor the temperature of the portion of the roller shell (11) corresponding to the heating element (22); and A drive mechanism (40) is connected to the roller body (10) and is used to drive the roller body (10) to move.

2. The heating roller (100) according to claim 1, characterized in that, The roller body (10) includes: The roller shell (11) has a plurality of openings (15), and at least one of the temperature measuring resistors (30) is provided in each of the openings (15). A central body (12) is disposed within the roller shell (11) and forms a second cavity (16), wherein one end of the central body (12) in the axial direction (C) is connected to the roller shell (11) and together with the roller shell (11) forms the first cavity (14); and A roller (13) is disposed in the second cavity (16) and is connected to the central body (12); The surface of the roller shaft (13) that mates with the central body (12) is a conical surface. At least part of the driving mechanism (40) is disposed inside the roller shell (11) and connected to the roller shaft (13) to drive the roller body (1) to move.

3. The heating roller (100) according to claim 1, characterized in that, The heating assembly (22) includes: A heating core (221) is fixedly mounted on the frame (21), and the heating core (221) has a receiving groove (223); and Heating coil (222) is arranged in the receiving groove (223).

4. The heating roller (100) according to any one of claims 1-3, characterized in that, The heating roller (100) further includes a resolver temperature transmitter (50), which includes: A resolver rotor plate (51) is provided with a first coil (511) and a processor (512), the processor (512) being connected to the plurality of temperature measuring resistors (30), and the resolver rotor plate (51) being connected to the drive mechanism (40); and The resolver stator plate (52) is provided with a second coil (521), which is used to connect to the power supply.

5. The heating roller (100) according to claim 4, characterized in that, The resolver rotor plate (51) is also provided with: Multiple temperature sensing circuits (513) are connected to the processor (512), and each temperature sensing circuit (513) is connected to a corresponding temperature sensing resistor (30); and An auxiliary circuit (514) is connected to the first coil (511).

6. The heating roller (100) according to claim 3, characterized in that, The heating core (221) is composed of multiple layers of sheet-like structures with insulation between the sheets.

7. The heating roller (100) according to claim 2, characterized in that, The heating roller (100) further includes: A first cooling jacket (60) is fitted between the central body (12) and the frame (21) for cooling the heater (20); and The second cooling jacket (70) is fitted between the first cooling jacket (60) and the drive mechanism (40) for cooling the drive mechanism (40).

8. The heating roller (100) according to claim 7, characterized in that, At least one of the first cooling jacket (60) and the second cooling jacket (70) is provided with a spiral cooling channel.

9. The heating roller (100) according to claim 1, characterized in that, The drive mechanism (40) includes: The housing (41) is partially disposed within the roller body (10); The motor shaft (42) is disposed inside the housing (41); A bearing (43) is disposed between the motor shaft (42) and the housing (41); The motor rotor (44) is connected to the motor shaft (42); and The motor stator (45) is disposed inside the housing (41) and located outside the motor rotor (44) and connected to the housing (41).

10. A heating system (00), characterized in that, The heating roller (100) according to any one of claims 1-9 and the control module (200) are included. The control module (200) includes a temperature controller (210) and a power supply (220). The temperature controller (210) is configured to control the power supply voltage of the power supply (220) according to the temperature signal collected by each of the temperature measuring resistors (30) so as to adjust the heating power of the corresponding heating component (22).

Images