Calender Roller Extraction System for Faster Heated Roller Replacement
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Solution Overview
Problem
Conventional calender systems for treating web-like materials with heated rollers face challenges such as prolonged roller replacement times, safety risks for operators, and structural complexities due to cooling requirements and manual operation.
Innovation Solution
A calender system with a load-bearing frame, orthogonally positioned heatable rollers, and a drive unit allowing for controlled rotation, along with hydraulic actuators and levers to simplify roller extraction and replacement, and an internal heating fluid system to manage temperature without external cooling, enabling faster and safer roller exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cooling systems are applied to calender rollers, then the rollers can be safely replaced, but the structural and operational complexities increase and cost effectiveness decreases
Solution Approach 1:
The invention extracts and eliminates the external cooling system from the calender structure. Instead of providing cooling through the calender frame, the rollers are designed with internal cooling channels that allow coolant circulation directly within the roller bodies, thereby removing the need for complex external cooling infrastructure while maintaining safety during roller replacement
Solution Approach 2:
The rollers are designed to be self-cooling through internal channels that circulate coolant. This self-service cooling mechanism eliminates the need for external cooling systems and allows operators to safely handle and replace rollers after a short cooling period without complex cooling infrastructure
2Adaptability or versatility
If manual operations are performed to disengage rollers from the calender, then the rollers can be replaced, but the replacement time increases and operator safety risks increase
Solution Approach 1:
The invention introduces dynamic, movable components including hydraulic cylinders and levers that enable automated engagement and disengagement of rollers. The levers can be positioned in different states (engaged/disengaged) and the hydraulic system provides powered motion, transforming the static manual process into a dynamic automated one that reduces replacement time and improves safety
Solution Approach 2:
The invention replaces manual mechanical operations with an automated hydraulic system. Hydraulic cylinders powered by a pump provide the force needed to engage and disengage rollers, eliminating the need for operators to perform dangerous manual lifting and positioning tasks while significantly reducing replacement time
3Temperature
If heated rollers are used for material treatment, then the desired thermal processing is achieved, but the rollers must be cooled for extended periods before replacement
Solution Approach 1:
The invention implements preliminary cooling action through internal channels that begin cooling the rollers immediately after use. The coolant circulation system is pre-configured within the roller structure, allowing cooling to start instantly when the roller is removed from the heated position, rather than requiring extended passive cooling periods
Solution Approach 2:
The invention uses a hydraulic cooling system with pumps and channels to actively circulate coolant through the roller interiors. This hydraulic fluid circulation provides efficient heat removal, reducing the cooling time required before rollers can be safely handled and replaced
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 system reduces roller replacement time, enhances operator safety, and simplifies the calender structure, allowing for efficient and automated handling of heated rollers without waiting for them to cool down, thus improving operational efficiency and cost-effectiveness.
Implementation Method 1
The rollers (R1, R2) are heatable rollers... operating temperature of the rollers... combined action of pressure and heat
Implementation Method 2
a first hydraulic actuator (307) generating a first hydraulic force (F5)... a second hydraulic actuator (313) generating a second hydraulic force (F6)
Data Source
AI summary
Calender for the treatment of web-like materials, including a fixed structure supporting two heated rollers reciprocally arranged so as to form a nip traversable by web-like materials, where each roller has pins mounted on bearings. The structure includes two lower levers and two upper levers adapted for exerting on the bearings forces oriented according to not coinciding directions, each lever being connected with an actuator that controls its rotation around a horizontal axis to put it in a first engagement position of the respective bearing and in a second release position, such that in the second position of the levers the extraction of the rollers from the calender is allowed.