COMPONENT WITH WEAR INDICATOR

Description

[0001] The invention relates to a component for use in printing machines or paper and substrate processing machines, wherein the component comprises at least a first region made of a first material with first physical properties, and wherein the at least one first region comprises a functional surface which is in contact with a web-shaped or sheet-shaped substrate and is subject to wear, wherein the at least one first region comprises at least one second region, wherein adjacent to or spaced from the functional surface at least one second region is at least partially enclosed by the first region.

[0002] In printing presses or paper or substrate processing machines, such as folding units integrated into printing presses, folding devices operating separately from printing presses, stackers, or other devices that process web- or sheet-like substrates in folded or unfolded form, certain components come into contact with the substrate to be processed, such as paper, in such a way that a relative movement occurs between at least one functional surface of a component and the substrate. Such functional surfaces are subject to wear, as the relative movement between the functional surface and the substrate moving on it wears away at least one functional surface over a longer or shorter period of time.Although relatively wear-resistant coatings are known from the state of the art, some of these are also susceptible to paint shedding or entail high manufacturing costs.

[0003] If functional surfaces are subject to significant wear, the geometry in the area of ​​the functional surface of the component changes, so that either the functionality of the component and thus of the entire component is no longer fully ensured, or the wall thicknesses and cross-sections are reduced due to corresponding wear, so that heavily worn parts can also break.

[0004] On the one hand, a variety of wear-resistant or wear-inhibiting coatings are known from the state of the art. However, due to the high relative speeds of up to 20 meters per second, especially on very abrasive substrates, these usually only delay wear. As soon as such a wear-inhibiting coating is at least partially worn away, the material, which is relatively soft compared to the coating, wears just as quickly. Therefore, it is impossible for the operator or maintenance personnel to determine when a level of wear has been reached at which, based on experience, functionality, performance, or operational reliability is impaired.

[0005] EP 3 222 568 B1, DE 20 2016 101 668 U1, or DE 20 2016 106 362 U1 disclose brake brushes with brush trimmings in which, to indicate wear of the brush trimmings, the brush body at least partially has at least one projection which extends beyond the trimming surface with a projection height equal to the thickness of the trimmings. When the projection begins to wear, the operator or maintenance personnel recognizes that brushes with correspondingly worn trimmings must be replaced to ensure unrestricted functionality.

[0006] However, such projections are generally completely unsuitable for functional surfaces without brush trimming that are in contact with substrates due to the risk of damage to the substrate.

[0007] DE 10 2008 040 600 A1 discloses a roller with a shell surface made of a wound profile which forms grooves open to the outside, wherein elevations with a defined effective diameter are introduced into the grooves from the outside in order to detect the degree of wear.

[0008] EP 1 338 539 A2 discloses a strip cable in a folding machine which is subject to wear, wherein for automatic wear detection the strip cable has either an insert applied to the surface or an insert incorporated into the strip with different properties compared to the strip cable material, so that changes can be detected by removal or exposure of the insert.

[0009] The invention is therefore based on the object of creating a solution with which the reaching of wear levels or wear limits can be easily determined without the aid of aids.

[0010] The object is achieved by a component according to claim 1. The component according to the invention is characterized in that the at least one second region is designed as a cavity.

[0011] This type of design has the advantage of detecting whether a component's functional surface has reached a critical level of wear without the need for additional equipment. Furthermore, it is also possible to provide the operator with information about varying degrees of wear, allowing appropriate replacement parts to be procured in a timely manner.

[0012] By using new manufacturing processes, particularly those known as additive manufacturing or 3D printing, it is possible to produce such components quickly, cost-effectively, and, in the case of the introduction of material in the second regions, without compromising the mechanical strength properties. However, components according to the invention are not necessarily limited to an additive manufacturing process; however, various configurations of such a component are undoubtedly predestined for the 3D printing process due to the fundamental homogeneity of the mechanical properties.

[0013] According to the invention, the second area is designed as a hollow space. When a functional surface becomes worn, the second area is exposed. Since such small hollow spaces on the functional surface do not cause problems, it is also possible to visually determine whether a corresponding degree of wear has occurred.

[0014] Preferred developments of the invention will become apparent from the dependent claims and the following description. Various embodiments of the invention are explained in more detail, without being limited thereto, with reference to the drawings. Herein: Fig. 1 an exemplary representation of a component comprising an exemplary functional surface and a plurality of second regions Fig. 2 an exemplary representation of a component comprising an exemplary functional surface and a second region Fig. 3a a plan view of the Fig. 2 shown component in a first embodiment Fig. 3b a plan view of the Fig. 2 shown component in a second embodiment Fig. 3c a plan view of the Fig. 2 shown component in a third embodiment Fig. 4 a component according to the invention in a sectional view with a second area formed over its extent with a variable distance to the functional surface Fig. 5 a sectional view of the in Fig. 4 shown component

[0015] Fig. 1 shows an exemplary component 1, which comprises a first area 2 and, for example, a functional area 4. It is pointed out at this point that all Figuren 1 bis 5 corresponding components 1 used in printing machines or paper or substrate processing machines are shown only schematically. Such components 1 used in practice usually have complex geometries with more than just one flat functional surface 4. Furthermore, the components shown in the Fig. 1 bis 5 For reasons of simpler and more understandable representation, the components 1 shown only have a single functional surface 4, although the present invention also fundamentally comprises parts with a plurality of functional surfaces 4.

[0016] The Fig. 1 The symbolically represented component 1 is only shown with a first region 2 formed from a first material, which forms the functional surface 4 in contact with a substrate not shown. Even if in none of the Figuren 1 bis 5 a component 1 is shown which comprises an additional third region, for example a third region made of a third material and designed to receive or mount the first region 2, to which the first region 2 is connected, the present invention also comprises components 1 in which, for example, the first region 2 is made of a first material such as plastic, which are connected to a third region (not shown) made of a third material such as steel or aluminum for fastening in the substrate-processing machine.

[0017] The Fig. 1 The component 1 illustrated by way of example comprises a first region 2 made of a first material. The first region 2 comprises at least one functional surface 4 in contact with a web-shaped or sheet-shaped substrate, which is subject to wear due to its contact with the substrate to be processed.

[0018] The Fig. 1 is a sectional view of the component 1 with a cutting plane arranged perpendicular to the functional surface 4 and thus allows an insight into the component 1 according to the invention.

[0019] Like this one in Fig. 1 As can be seen from the sectional view of the component 1 shown, the first region 2 comprises a plurality of second regions 3, which are at least partially enclosed by the first region 2 and are arranged adjacent to or at a distance from the at least one functional surface 4.

[0020] The first region 2 thus comprises a first second region 3-1, which essentially directly adjoins the functional surface 4 or is only very slightly spaced from the functional surface 4. The first region 2 further comprises a second second region 3-2, which is spaced slightly further from the functional surface 4 by the distance a1 than the first second region 3-1, and a third second region 3-3, which is spaced slightly further from the functional surface 4 by the distance a2 than the second second region 3-2. As can be seen from the sectional view through the component 1, the second regions 3-1, 3-2 and 3-3 are at least partially enclosed by the first region 2.

[0021] The inventive in Fig. 1 The component 1 shown thus comprises a first region 2 and a plurality of second regions 3, wherein at least two second regions 3 have a different distance a from the functional surface 4.

[0022] Although in Fig. 1 While an embodiment with three second regions 3-1, 3-2, 3-3 is shown by way of example, the present invention is possible with any number of second regions 3, for example also with only one second region 3.

[0023] If the functional surface 4 wears, the component thickness d decreases and the functional surface 4*, which deviates from the original position, at least partially intersects a second area 3, in the exemplary representation according to Fig. 1 the functional surface 4* created by wear initially cuts the first second area 3-1.

[0024] Thus, at least a second area 3, in this example the Fig. 1 This is initially the first second area 3-1, with corresponding wear of at least one functional surface 4 at least partially a component of the functional surface 4 or 4* shifted in position.

[0025] The same applies if the Fig. 1 functional surface 4 shown does not wear evenly, but for example in the left area of ​​the Fig. 1 The functional surface 4 shown wears more than the remaining area. In this case, the first second area 3-1 also becomes the first of the second areas 3 to become part of the functional surface 4 or 4*.

[0026] In an exemplary embodiment, the at least one second region 3 consists of a second material with second physical properties. This second material of the second region 3 differs in at least one property from the first material from which the first region 2 is made.

[0027] In an exemplary embodiment, the second material of the at least one second region 3 has second physical properties that differ from the first properties of the first material of the first region 2, in that the second material has different optical properties and / or a different reflection behavior. This means, for example, that due to the reflection of other wavelength ranges of visible light, the at least one second region 3 has a different color than the material of the first region 2.

[0028] Using the example of Fig. 1 In the embodiment shown, it is also possible that not all second regions 3-1, 3-2, 3-3 have the same color and thus the same optical properties, but that at least one of the second regions 3-1, 3-2, 3-3 has a color that differs from the remaining second regions 3-1, 3-2, 3-3, or that each of the plurality of second regions 3-1, 3-2, 3-3 has a different color.

[0029] Thus, based on the color of the exposed second areas 3, it is possible to determine the degree of wear of the functional surface 4 of the component 1 during the inspection.

[0030] At the Fig. 1 In the example shown, for example, the first second region 3-1 could be made of a white-colored material, so that after a corresponding period of operation, initial wear of the functional surface 4 formed by the, for example, black-colored material of the first region 2 can be recognized.

[0031] For example, if the second second area 3-2 is colored yellow, progressive wear can be detected when the yellow-colored second second area 3-2 becomes visible, even though, for example, the functionality of component 1 is still fully guaranteed at this stage. However, exposing the yellow-colored second second area 3-2 may be accompanied by a recommendation to stock a corresponding component 1 or to check inventory levels.

[0032] If, for example, the third second area 3-3 is colored red, then upon visibility of the red-colored third second area 3-3, severely advanced wear can be detected, at which, for example, the functionality of component 1 is only guaranteed for a limited time and / or to a limited extent. Thus, exposing the red-colored third second area 3-3 can be associated with the recommendation to replace a corresponding component 1 or at least to check its functionality and / or to schedule a replacement of component 1 at least within a certain period of time.

[0033] According to the invention, the at least one second region 3 is designed as a cavity.

[0034] In particular, by means of additive manufacturing processes, also referred to as 3D printing, it is possible, due to the process, to produce such cavities with small dimensions and a precisely defined geometric shape and arrangement also with respect to the functional surface 4, even if the second region 3 designed as a cavity is completely enclosed by the first region 2.

[0035] Such a second area 3 designed as a cavity can, as for example in Fig. 1 shown, be completely enclosed in the first area 2.

[0036] Although not in Fig. 1 As shown, it is also possible, in the case of a plurality of second regions 3, to design at least one second region 3, for example the first second region 3-1, as a hollow space and to design at least one further second region 3, for example the second second region 3-2 and the third second region 3-3, with a second material different from the first material of the first region 2 or with several different second materials.

[0037] Although in Fig. 1 only a sectional view of the component 1 is shown, at least one second area 3 or the one second area 3 according to the illustration in Fig. 3a be completely enclosed by the first area 2.

[0038] It is also possible that at least one second area 3 or the one second area 3 extends up to at least one boundary surface 5 as shown in Fig. 3b suffices.

[0039] Furthermore, it is possible that at least one second region 3 or the one second region 3 extends from a first outer boundary surface 5 of the component 1 to a second, preferably to the second outer boundary surface 5 opposite the first outer boundary surface 5 according to the illustration in Fig. 3c suffices.

[0040] In the case of a plurality of second regions 3, a combination of all the aforementioned configurations of the second regions 3 is possible, provided that the shape and function of the component 1 permits this.

[0041] Fig. 2 shows comparable to Fig. 1 also a sectional view through a component 1 according to the invention, in which the second region 3 extends to at least one boundary surface 5 of the component 1 or of the first region 2 which differs from the at least one functional surface 4.

[0042] In the Fig. 2 In the example shown, the first region 2 comprises only a second region 3, which is spaced a1 from the functional surface 4 and has a triangular cross-section in the sectional plane.

[0043] Although not in Fig. 2 shown, it is also possible that the second area 3 is only minimally spaced from the functional area 4 or essentially borders on it.

[0044] Although not in Fig. 2 As shown, it is also possible for the first region 2 to have a plurality of second regions 3. This plurality of second regions 3 can either extend entirely to at least one boundary surface 5, or at least one second region 3 extends to an outer boundary surface 5 and at least one further second region 3 is completely enclosed by the first region 2.

[0045] In Fig. 2 a special case is shown in which the at least one second region 3 extends to a boundary surface 5 of the component 1 or the first region 2 opposite the at least one functional surface 4.

[0046] The Fig. 3a bis 3c each show a top view of the Fig. 2 component 1 shown in section, although in a different design.

[0047] Although in Fig. 2 only a sectional view of the component 1 is shown, at least one second area 3 or the one second area 3 according to the illustration in Fig. 3a extend exclusively to the boundary surface 5 opposite the functional surface 4.

[0048] It is also possible that at least one second area 3 or the one second area 3 extends up to at least one boundary surface 5 as shown in Fig. 3b suffices.

[0049] Furthermore, it is possible that at least one second region 3 or the one second region 3 extends from a first outer boundary surface 5 of the component 1 to a second, preferably to the second outer boundary surface 5 opposite the first outer boundary surface 5 according to the illustration in Fig. 3c suffices.

[0050] In the case of a plurality of second regions 3, a combination of all the aforementioned configurations of the second regions 3 is possible, provided that the shape and function of the component 1 permits this.

[0051] Fig. 4 shows a further embodiment of a component 1 according to the invention, in which the first region 2 comprises at least one second region 3, which forms over its extent an interface 6 facing the functional surface 4 between the at least one second region 3 and the first region 2, wherein this interface 6 has a variable distance a from the functional surface 4.

[0052] In this respect, as the wear of the functional surface 4 progresses, an increasingly larger part of the second region 3 becomes part of the functional surface 4, so that the degree of wear can be determined based on the extent to which the at least one second region 3 is exposed.

[0053] This at least one second area 3 can either have a more or less uniform height over its extension in the extension of the distance a, or it is also possible, as in Fig. 5 shown that the at least one second area 3 in the in Fig. 5 shown section plane has a variable cross-section.

[0054] Furthermore, it is possible that at least one second region 3 has a variable cross-section relative to a cutting plane parallel to the functional surface 4 depending on the distance a to the functional surface 4, as in Fig. 5 shown.

[0055] In particular, in the case of second areas 3 with a somewhat larger extension in at least one dimension, such as in Fig. 4 As shown, it is possible if at least one of these second regions 3 consists of a material composition which has different physical properties, in particular different optical properties such as different colours, depending on the distance a or a(x) to the functional surface 4.

[0056] At the Fig. 4 In the example shown, this could, for example, be implemented in such a way that the left section of the second area 3 consists of a green or white colored material, while the middle section of the second area 3 consists, for example, of yellow colored material. The right section of the second area 3 can preferably be colored red or orange, so that with a black colored material of the first area 2, for example, the degree of wear can be determined by the visibility of different colors, as described under the description of Fig. 1 already carried out, can be detected without additional measuring or aids.

[0057] Although none of the Figuren 1 bis 5As shown, at least one second region 3 can have physical properties which are detectable, preferably contactless, after the exposure of the at least one second region 3 as a result of wear of a functional surface 4.

[0058] This can be achieved, for example, by the material of at least one second region 3 exhibiting a particular optical reflection behavior, for example, in a particular frequency range of visible light. It is also possible that by implementing second regions 3 made of a metallic material into a first region 2 made of plastic, the exposure of the second region 3 made of metallic material can be detected with a capacitive sensor.

[0059] There are basically no restrictions regarding the materials that can be used for the first area 2 and the second area 3 of component 1. These can be made of known metals and / or plastics.

[0060] In conventional manufacturing of such parts, for example by drilling holes below and parallel to the wear surface, the holes can be filled with other materials, for example by inserting plastic or metal pins.

[0061] Although it is possible to manufacture a component 1 according to the invention using conventional manufacturing methods, the use of an additive manufacturing method such as 3D printing offers far greater flexibility and combinatorics in the design of the second regions 3. Furthermore, this method can be used to process numerous plastics and metals and also to combine them with one another, so that components 1 made of both plastic and / or metal can be manufactured.

Claims

1. Component (1) for use in printing machines or paper- and substrate-processing machines, wherein the component (1) comprises at least one first region (2) made of a first material with first physical properties, and wherein the at least one first region (2) comprises a functional surface (4) which is in contact with a web or sheet-shaped substrate and is subject to wear, wherein the at least one first region (2) comprises at least one second region (3), wherein adjacent to or at a distance from the functional surface (4) at least one second region (3) is at least partially enclosed by the first region (2), characterised in that the at least one second region (3) is designed as a cavity.

2. Component (1) according to claim 1, characterised in that at least one second region (3) is completely enclosed in the first region (2).

3. Component (1) according to claim 1, characterised in that at least one second region (3) extends up to a boundary surface (5) of the component (1) opposite the functional surface (4).

4. Component (1) according to claim 1, characterised in that at least one second region (3) extends to a boundary surface (5) of the component (1) opposite the functional surface (4).

5. Component (1) according to one of claims 1 to 4, characterised in that the at least one first region (2) comprises a plurality of second regions (3), at least two second regions (3) having a distance a from the functional surface (4) which differs from one another.

6. Component (1) according to one of claims 1 to 5, characterised in that at least one second region (3) has a variable distance a from the functional surface (4) over its extension to the functional surface (4) with an interface (6) facing the functional surface (4).

7. Component (1) according to one of claims 1 to 6, characterised in that at least one second region (3) has a variable cross-section relative to a sectional plane parallel to the functional surface (4) as a function of the distance a from the functional surface (4).