Calender Cylinder Heating Core with Segmented Air Inlets

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing heating systems for calender cylinders, such as those using diathermic oil and infrared heaters, face challenges in air circulation control, cable passage, and thermal dilation accommodation, leading to inefficiencies and maintenance costs.

Innovation Solution

A heating device with a core cylinder and a coaxially arranged cylinder for supporting infrared heating elements, featuring an air inlet, partition for cable and air separation, and sliding motion to accommodate thermal dilation, ensuring optimal air distribution and cable passage within the rotating calender cylinder.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If infrared heaters are supported by a core cylinder fixed inside the rotating calender cylinder, then heating effectiveness is improved and costs are reduced, but air circulation control becomes difficult and cable passage is interfered with

Engineering Contradiction:

Improveheating effectivenessVSAvoidair circulation control

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The core cylinder is segmented into multiple sections along its length, with each section having independent air inlet openings. This segmentation allows different regions of the core cylinder to have controlled air flow, improving air circulation while maintaining structural support for the heating elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Air inlet openings are introduced as intermediary structures that facilitate air flow between the external environment and the interior of the core cylinder. These openings act as mediators to enable controlled air circulation without compromising the fixed support structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If the core cylinder is fixed to support infrared heating elements, then structural stability is improved, but thermal dilation cannot be accommodated

Engineering Contradiction:

Improvestructural stabilityVSAvoidthermal dilation accommodation

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The core cylinder is designed with dynamic characteristics that allow it to expand and contract thermally while maintaining its fixed support function. The segmented structure with air inlet openings enables the cylinder to accommodate thermal dilation through controlled deformation without losing structural stability.

Inventive Principle:

Principle #15Dynamics

3Temperature

If diathermic oil heating system is used, then heating capability is achieved, but device complexity and maintenance costs increase

Engineering Contradiction:

Improveheating capabilityVSAvoidsystem complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The complex diathermic oil heating system is extracted and replaced with a simplified direct infrared heating system. The infrared heaters are directly mounted on the core cylinder, eliminating the need for oil circulation pumps, heat exchangers, and associated control systems, thereby reducing device complexity while maintaining heating capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical diathermic oil circulation system is replaced with an electromagnetic infrared heating system. Infrared heaters convert electrical energy directly to thermal radiation, substituting the mechanical oil circulation mechanism with a more compact and maintenance-free electromagnetic heating approach.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If diathermic oil is used for heating, then heating uniformity is achieved, but precision and control along cylinder length are reduced

Engineering Contradiction:

Improveheating uniformityVSAvoidtemperature control precision

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The core cylinder is divided into multiple sections with independent air inlet openings, allowing each section to have localized control over air flow and heat distribution. This enables different regions of the calender cylinder to be heated with precise temperature control, achieving both heating uniformity and precision along the length of the cylinder.

Inventive Principle:

Principle #3Local quality

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

The solution provides reliable, cost-effective, and precise heating with improved air circulation and thermal adaptation, reducing maintenance needs and enhancing heating uniformity along the cylinder length.

Implementation Method 1

cylinder adapted to support a plurality of infrared heating elements (4)

Methodology Applied

Scientific EffectInfrared radiation: Infrared Radiation

Implementation Method 2

core cylinder has an inlet for the passage of air which is adapted to make air flow and gather inside said core cylinder

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

fixing of the heating element supporting cylinder with respect to the core cylinder must consider thermal dilations

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20220386421A1Heating device for calender cylinders

Publication Date: 2022.12.01 PHT - PETRELLI HEATING TECH SRL

AI summary

A heating device for calender cylinders, comprising a core cylinder arranged coaxially in a cylinder adapted to support a plurality of heating elements; the core cylinder and the cylinder adapted to support the heating elements are configured to be accommodated in a fixed manner within a rotating calender cylinder; the core cylinder has an inlet for the passage of air which is adapted to make air flow and gather inside the core cylinder.