Drum Lagging Material with On-Machine Seamability to Reduce Downtime
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Solution Overview
Problem
Conventional lagging materials for corrugator machines require adhesive bonding for installation, leading to frequent machine downtime for replacement, as they need to be periodically removed and reinstalled.
Innovation Solution
A seaming apparatus and lagging material design that allows for on-machine seamability, eliminating the need for adhesives. The lagging material features a seaming area and coatings on both sides to enhance friction, enabling it to be stretched and seamed onto the drum surface without adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonding is used to install lagging material on drums, then the lagging material provides sufficient friction to prevent belt slipping, but the lagging material requires frequent machine downtime for removal and replacement
Solution Approach 1:
The lagging material is divided into multiple modular segments that can be independently installed and removed. Each segment can be separately replaced without requiring complete removal of the entire lagging system, significantly reducing machine downtime while maintaining continuous friction coverage.
Solution Approach 2:
The lagging segments are pre-assembled with friction-enhancing surfaces before installation. This preliminary preparation allows for quick installation without requiring extensive on-site preparation time, reducing the overall downtime associated with lagging replacement.
2Strength
If conventional glued lagging materials are used, then installation provides strong adhesive bonding, but replacement requires grinding, scraping, and extensive preparation taking several days
Solution Approach 1:
The adhesive bonding function is extracted and replaced with a mechanical interlocking mechanism. The lagging segments feature engagement structures that mechanically attach to the drum surface, eliminating the need for strong adhesives and their associated removal processes. This allows for simple mechanical removal without grinding or scraping.
Solution Approach 2:
The chemical adhesive bonding system is replaced with a mechanical attachment system. The lagging segments use mechanical features such as clips, lugs, or interlocking structures to attach to the drum, providing equivalent or superior strength while enabling easy removal and replacement without extensive preparation work.
3Reliability
If lagging material is designed for permanent adhesive installation, then friction performance is maintained, but the system lacks adaptability for quick replacement and reinstallation
Solution Approach 1:
The lagging system transitions from a static permanent installation to a dynamic reversible system. The modular segments with mechanical attachment features can be easily installed, removed, and reinstalled multiple times while maintaining consistent friction performance. This dynamic design provides adaptability for quick replacement without compromising reliability.
Solution Approach 2:
The attachment mechanism parameters are designed to allow for quick changes in installation state. The mechanical fastening system uses adjustable or snap-fit features that can be rapidly engaged and disengaged, enabling the lagging to transition between installed and removed states quickly while maintaining optimal friction characteristics when installed.
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 reduces machine downtime by allowing for quick and adhesive-free installation and removal of the lagging material, maintaining effective friction to prevent belt slipping throughout the process.
Implementation Method 1
a first coating on a drum-contact outer surface of the substrate, wherein the coating increases the coefficient of friction of the lagging material when the lagging material is installed onto the drum such that no adhesive is required to keep the lagging material on the drum
Implementation Method 2
a tensioning member is operably engaged with the opposed elongate members for drawing the opposed elongate members together in the machine direction (MD). Each lagging material engagement member is structured to engage a seaming area of the lagging material such that when the elongate members are drawn together, the lagging material is stretched into a seamable position
Data Source
AI summary
Disclosed are lagging materials for use on a driven cylindrical pulley or drum for an industrial machine. A lagging material can comprise a seaming element along the cross-machine direction (CD) of each of the opposing ends of the lagging material for forming a seam for seaming opposing ends of a lagging material when brought together. A lagging material can also comprise coatings that increase the Coefficient of Friction of a lagging material when the lagging material is installed onto the drum such that no additional adhesive is required to keep the lagging on the drum circumference when in operation. Also described is an apparatus for installing an on machine seamable lagging including at least two opposed elongate members, such that when the elongate members are drawn together, the lagging material is stretched into a seamable position to be installed on the drum.