Backup Roll Segmentation for Fiber Chopper Maintenance
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Solution Overview
Problem
Existing choppers for chopping continuous fibers or fiber strands are productivity limiting due to surface roughness issues, leading to defects and increased maintenance downtime, as the working surface layer of the backup roll becomes worn, requiring frequent replacement and manual handling of heavy equipment.
Innovation Solution
A backup roll with a wheel having spiral grooves or ridges on its peripheral surface and a lightweight elastomeric working surface layer that can be easily replaced by unscrewing the worn layer and screwing on a new one, eliminating the need for heavy equipment handling and reducing maintenance time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire backup roll is removed to replace the working surface layer, then the working surface can be reconditioned, but the replacement process becomes cumbersome and time-consuming requiring two workers and lifting aids
Solution Approach 1:
The backup roll is divided into two separable components: the wheel and the working surface layer. The working surface layer can be independently removed and replaced without removing the entire backup roll, enabling quick reconditioning by simply unscrewing the layer and replacing it with a new one.
Solution Approach 2:
The working surface layer is designed to be dynamically replaceable through a screwing/un-screwing mechanism that allows rapid attachment and detachment. This dynamic connection enables the working surface to be quickly changed during maintenance without fixed permanent mounting.
2Device complexity
If a standard wheel is used for the backup roll, then the structure is simple, but the working surface layer becomes heavy and difficult to handle requiring bulky lifting equipment
Solution Approach 1:
The backup roll system is segmented into the wheel structure and the working surface layer. This segmentation allows the working surface layer to be designed as a separate, lighter component that can be easily handled and replaced without requiring the entire heavy backup roll to be moved or lifted.
3Productivity
If the chopper operates at high speeds exceeding 3000 FPM, then productivity increases, but the working surface layer may slip or become unstable
Solution Approach 1:
Spiral grooves or ridges are pre-formed on the wheel surface before the working surface layer is installed. These pre-formed features create corresponding engagement structures that prevent slippage and stabilize the working surface layer during high-speed operation, ensuring reliability at elevated productivity speeds.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables faster and more efficient chopping with reduced downtime, as the working layer can be replaced in under 2 minutes, preventing slippage and extending the life of the elastomeric material, thus improving productivity and reducing production costs.
Implementation Method 1
The spiral grooves or ridges on the peripheral surface of the wheel prevent slippage of the elastomeric working surface layer
Implementation Method 2
a lightweight elastomeric working surface layer that can be easily replaced
Data Source
AI summary
A method and apparatus for chopping long unwound items like fiber, fiber strands, yarn, etc. The chopper has a backup roll comprising a wheel and a working layer on the outer peripheral surface of the wheel and an engaging blade roll. The outer peripheral surface of the wheel contains spiral grooves or ridges that mate with ridges or grooves on an inner peripheral surface of the working layer such that a worn working surface can be quickly and easily unscrewed from the wheel and a new working surface can be quickly and easily screwed into place, making the job of replacing the working surface faster, easier and less costly than prior art practice.