Double-Sided Transcription Roll Apparatus Motor Posture Control
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Solution Overview
Problem
Existing sheet/film manufacturing techniques face issues with gear marks (horizontal stripes) due to torque ripples, which affect the quality and optical characteristics of the produced sheets/films, and require maintaining the posture of the motor's rotation axis constant to prevent pattern displacement and gear mark occurrence.
Innovation Solution
The implementation of a sheet/film manufacturing apparatus with a first and second roll, each driven by a motor, and a power transmission mechanism that includes an intermediate shaft member and shaft couplings to maintain the posture of the second roll's motor constant, allowing for adjustment of the second roll's position along the shaft direction to prevent gear marks and pattern displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a direct-drive mechanism is used to eliminate gear marks, then gear marks are prevented, but the motor's rotation axis posture may change causing pattern displacement
Solution Approach 1:
A posture correction mechanism is introduced as an intermediary between the direct-drive motor and the roll. This mechanism includes a motor shaft coupling and a roll shaft coupling that can rotate relative to each other, allowing the motor shaft to maintain a constant posture while still driving the roll. The intermediary couplings absorb the rotational deviations, preventing both gear marks and pattern displacement.
Solution Approach 2:
The system transitions from a rigid direct coupling to a dynamic coupling system that can adapt its configuration. The motor shaft coupling and roll shaft coupling are designed to rotate relative to each other, enabling the system to dynamically adjust and maintain the motor shaft posture constant while accommodating variations in roll position and orientation.
2Manufacturing precision
If precision control motors with reducers are used to control roll rotation, then optical characteristics improve, but torque ripples occur causing gear marks
Solution Approach 1:
The invention extracts and removes the reducer component from the drive system. By using a direct-drive mechanism without gear reducers, the source of torque ripples is eliminated. The system achieves the necessary speed control through motor control alone, avoiding the harmful gear marks that would otherwise be generated by the reducer's gear meshing.
3Manufacturing precision
If the second roll position is adjusted along the shaft direction, then pattern alignment is achieved, but the motor posture changes causing gear marks
Solution Approach 1:
The motor shaft coupling acts as an intermediary that decouples the position adjustment of the second roll from the motor shaft posture. When the second roll is adjusted along the shaft direction for pattern alignment, the coupling mechanisms absorb the positional changes without transmitting them to the motor shaft, thereby maintaining constant motor posture and preventing gear marks.
Data Source
AI summary
An apparatus includes a first roll and a second roll on each of which a pattern is formed, a first motor and a second motor to rotate the respective rolls, a shaft direction supporting mechanism to support the second roll along a shaft direction and an axial position adjusting mechanism configured to move the shaft direction supporting mechanism along the shaft direction. The posture of the rotating shaft of the second motor is maintained constant at all times, and the second roll is moved in the shaft direction along the first roll, thereby adjusting the positions of both patterns on the first roll and the second roll along the shaft direction.