Segmented Creping Pressure Control Across Sheet Width
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Solution Overview
Problem
Existing creping machines fail to satisfactorily process all types of sheet materials due to limitations in pressure distribution, leading to quality control issues and reduced efficiency, particularly when dealing with fabrics having varying basis weight profiles.
Innovation Solution
A creping machine with independently adjustable pressure application areas across the width of the sheet material, allowing for customized pressure profiles based on measured thickness, enabling precise control of creping pressure and eliminating the need for shims.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a constant pressure is applied across the sheet material using a single pressure plate, then the device complexity is reduced, but the manufacturing precision and quality control deteriorate due to inability to accommodate varying basis weight profiles
Solution Approach 1:
The pressure plate is divided into multiple independently controllable pressure application areas (at least three zones: first, second, and third areas) that can be adjusted separately. This segmentation allows different pressures to be applied to different regions of the sheet material, accommodating varying basis weight profiles without requiring complex manual adjustments or shims.
Solution Approach 2:
The pressure application system transitions from a static constant pressure plate to a dynamic system where pressure can be independently adjusted in different zones. This enables real-time adaptation to material variations, improving creping precision while maintaining operational simplicity through automated or semi-automated pressure control.
2Manufacturing precision
If shims are used to adjust pressure on one side to compensate for basis weight variations, then the manufacturing precision improves, but the device complexity increases and quality control problems arise due to marks and defects
Solution Approach 1:
Instead of using physical shims to adjust pressure locally, the pressure plate is segmented into multiple independently controllable zones. This allows electronic or mechanical control systems to adjust pressure in specific areas without physical additions that could cause defects or marks on the material.
Solution Approach 2:
The mechanical shim adjustment system is replaced with a controlled pressure application system using multiple pneumatic or hydraulic actuators that can independently adjust pressure in different zones. This substitution eliminates the need for physical shims that cause quality defects while providing precise pressure control through a more sophisticated but cleaner mechanism.
3Productivity
If increased pressure is applied to the edges of the pressing member, then the productivity is improved for some paper products, but the adaptability deteriorates for fabrics with varying basis weight profiles
Solution Approach 1:
The pressure application areas are segmented into at least three independently controllable zones across the width of the sheet material. This segmentation provides flexibility to adjust pressure profiles for different material types - enabling increased edge pressure for paper products to maintain productivity while allowing customized pressure distributions for fabrics with varying basis weight profiles.
Solution Approach 2:
Different pressure levels can be applied to different local areas of the sheet material based on specific requirements. For paper products, higher pressure at edges can be maintained for productivity, while for fabrics with heavier edges, the system can reduce edge pressure and increase center pressure, optimizing performance for each material type locally rather than using a uniform approach.
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 machine achieves a 10-15% increase in capacity, reduces quality defects, and allows for higher processing speeds while improving control over the creping process, especially for fabrics with varying basis weight profiles.
Implementation Method 1
pressing means for pressing a length of sheet material against the driving device extending across the width of the driving device
Implementation Method 2
the pressing means is a pressure plate associated with a pneumatic cylinder designed to apply a substantially constant pressure
Implementation Method 3
a retarding member which can be an inclined surface that deflects the driven sheet away from the drum and, by retarding the driven sheet, causes it to crepe
Data Source
AI summary
A machine for creping sheet material such as paper, textiles, metal foils, or plastic, comprises a driving drum, and a pressing plate for pressing a length of sheet material against the drum to drive the material lengthwise in the machine direction, and a retarding member arranged to contact the lengthwise-driven sheet material to cause it to crepe. The pressing plate has a plurality of pressure application points or areas distributed across the width of the sheet material on the drum, the pressure application points or areas being associated with pneumatic cylinders for applying different pressures to different parts of the material across its width according to a given pressure profile. The pneumatic cylinders can be arranged in groups to provide an adjustable pressure profile across the material wherein the pressures applied at the opposite edges of the material and at intermediate parts of the material are adjustable independently of one another. A machine retrofitted according to the invention operates at increased speed with less defects and higher efficiency.