Corrugating Roller Heat Transfer via Segmented Channels
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Solution Overview
Problem
Conventional corrugating rollers face issues with reduced production speed, increased energy consumption, and roller deformation due to inefficient heat transfer and condensation during the heating process.
Innovation Solution
A fluid circulation heating roller design that enhances heat transfer effectiveness by directing fluid flow through channels with enlarged cross-sections and 90-degree bends, suppressing turbulence, and using inserts to maintain flow speed and prevent condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If steam is supplied into the center part within the roller body, then the roller can be heated, but the production speed decreases and energy consumption increases
Solution Approach 1:
The roller body is divided into multiple independent heating zones with separate steam supply channels. Each zone can be heated independently, allowing the roller to reach operating temperature faster without heating the entire roller uniformly, thus reducing preheating time and increasing production speed.
Solution Approach 2:
Steam channels are positioned at specific locations within the roller body rather than uniformly distributing steam throughout. This localized heating approach concentrates thermal energy where needed most, reducing overall energy consumption while maintaining effective heating for adhesive bonding.
2Temperature
If steam is supplied into the center part within the roller body, then the roller can be heated, but a large amount of thermal energy is consumed
Solution Approach 1:
The heating system is segmented into multiple independent steam channels distributed throughout the roller body. This segmentation allows steam to reach heating zones more directly and efficiently, reducing thermal energy loss through the roller structure and improving overall heating efficiency.
Solution Approach 2:
Steam channels act as intermediaries that directly transport thermal energy from the steam source to the roller body. This direct thermal transfer pathway eliminates the need for indirect heating methods, reducing thermal energy loss and improving heating efficiency.
3Temperature
If steam is supplied into the center part within the roller body, then the roller can be heated, but condensation forms within the main body causing roller deformation
Solution Approach 1:
Multiple distributed steam channels prevent condensation by breaking up large condensation zones into smaller, more manageable areas. Each channel maintains localized temperature control, preventing the large temperature differentials that cause condensation and subsequent roller deformation.
Solution Approach 2:
The steam supply parameters (pressure, temperature, flow rate) are optimized to maintain steam in a superheated state throughout the roller body. This parameter control prevents condensation by ensuring the steam temperature remains above the dew point, maintaining roller shape stability during heating.
4Temperature
If the channel cross-section is enlarged to reduce turbulence, then fluid flow speed decreases, but heat transfer effectiveness is improved
Solution Approach 1:
The steam channels feature curved, rounded transitions and bends rather than sharp angles or abrupt changes in cross-section. This curved geometry smoothly guides the steam flow, reducing turbulence and pressure losses while maintaining adequate flow speed for effective heat transfer.
Solution Approach 2:
The channel cross-sectional dimensions and steam flow parameters are optimized to maintain laminar or transitional flow regimes. By controlling the Reynolds number through parameter optimization, the system achieves smooth flow without excessive turbulence, balancing flow speed and heat transfer effectiveness.
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 achieves quicker and more uniform heating of the roller, reducing energy consumption and preventing roller deformation, thereby improving the quality and productivity of corrugated paperboard production.
Implementation Method 1
directing fluid flow through channels with enlarged cross-sections and 90-degree bends, suppressing turbulence
Implementation Method 2
a fluid circulation heating roller design that enhances heat transfer effectiveness
Implementation Method 3
using inserts to maintain flow speed and prevent condensation
Implementation Method 4
condensation occurring during the heat transfer process, where a water layer may be formed within the steam inlet holes
Data Source
AI summary
A fluid circulation heating roller according to an embodiment of the present invention includes a roller body having a hollow cylindrical shape, a rotation shaft extending from each of opposite end portions of the roller body and disposed in the same center line, multiple first ducts extending in an axial direction in the roller body so as to heat the outer circumferential portion of the roller body, multiple second ducts extending in the axial direction on the outer circumferential portion of the roller body, wherein the number of second ducts are the same as the number of first ducts, and an insert inserted into at least one of the first or second ducts and extending in the axial direction. The generation of turbulence flow of fluid can be suppressed and laminar flow can be induced, whereby it is possible to maintain fluid-flowing speed and facilitate steam circulation and heat transfer.