Calender Roller Rocker Arm Angle Adjustment
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Solution Overview
Problem
Calenders face challenges in adjusting the entanglement angle during pressure treatment due to lateral forces, leading to downtime and difficulties in maintaining optimal web thickness, especially when transitioning between 'pressure' and 'gap' modes, where changes in interlocking angles affect roll gap height detection.
Innovation Solution
The calender design incorporates a rocker with a roller bearing holder and a length adjuster that allows for low-force adjustment of the entanglement angle, combined with a device for limiting pivoting and a pneumatically or hydraulically operated piston/cylinder arrangement, enabling precise adjustment of the nip height and roll gap while minimizing forces acting on the rocker arm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the rollers are interlocked to compensate for roller deflection, then the gap height uniformity is improved, but transverse forces act on the bearings preventing angle change during pressure treatment
Solution Approach 1:
The bearing arrangement is designed to be movable relative to the calender frame, allowing the roller angle to be dynamically adjusted during operation. The displacement device enables the bearing to move in a direction with a component perpendicular to the roller axis, facilitating real-time angle changes without interrupting the pressure treatment process.
Solution Approach 2:
A displacement device acts as an intermediary mechanism between the operator and the bearing arrangement. This device mediates the adjustment process by applying controlled forces to move the bearing, overcoming the transverse forces generated by roller interlocking while maintaining system stability during angle changes.
2Adaptability or versatility
If hydraulic or pneumatic pressure is used to set the roller gap, then the gap can be opened for foreign objects, but the gap height becomes difficult to control when changing interlocking angles
Solution Approach 1:
The system incorporates feedback mechanisms that monitor the actual roller gap height and provide information to the control system. This feedback loop enables real-time adjustments to compensate for changes in gap height that occur during angle adjustments, maintaining precise gap control even when the interlocking angle changes.
Solution Approach 2:
The displacement device serves multiple functions: it adjusts the roller angle during pressure treatment, enables gap opening for foreign object removal, and maintains gap height control throughout these operations. This multi-functional design eliminates the need for separate mechanisms for each operation.
3Productivity
If the rocker arm is displaced to change the entanglement angle during pressure treatment, then downtime is reduced, but forces must be overcome to move the bearing arrangement
Solution Approach 1:
The displacement device acts as a force-mediating mechanism that generates and applies the necessary forces to move the bearing arrangement during operation. By providing this intermediary force application, the system can overcome the transverse forces generated by roller interlocking without requiring manual intervention or system shutdown.
Solution Approach 2:
The system employs pneumatic or hydraulic actuation mechanisms within the displacement device to generate the forces needed to move the bearing arrangement. These fluid-based actuation systems provide sufficient force to overcome the transverse forces from roller interlocking while enabling smooth, controlled movement during continuous operation.
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 design allows for continuous adjustment of the entanglement angle during pressure treatment, reducing downtime and enabling direct detection of angle changes, ensuring optimal treatment results and maintaining defined web thickness, even during operation.
Implementation Method 1
pneumatically or hydraulically operated piston/cylinder arrangement
Implementation Method 2
pneumatically or hydraulically operated piston/cylinder arrangement
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
In a calender for the pressure treatment of a web of material (W), which has a first roller (2) with a first roller axis and a second roller (7) with a second roller axis and the first and second rollers (2, 7) are interlocking about an interlocking axis that intersects the first and second roller axes perpendicularly, at least one bearing device (9) of at least one of the rollers (2, 7) has at least one rocker arm (11) with a roller receptacle (10), and the rocker arm (11) is displaceable on the calender frame (1) in an approach direction (X) and with a directional component (R) perpendicular to the roller axis.