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Solution Overview
Problem
Existing segmented rollers face issues with unpredictable material web influencing due to elastic profiles, leading to fatigue fractures and reduced service life, along with unwanted noise and vibrations, as the profile movement is not accurately controlled and is prone to deceleration and impact.
Innovation Solution
Designing the profile to be shear-resistant and incorporating an elastic lip on the roller body or profile to ensure secure, vibration-free displacement, with optional separate elastic lips for enhanced stability and noise reduction, and using spacers for additional stabilization and progressive spring effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastic profiles are used to allow displacement, then the profile can move along the groove, but this leads to transverse movements, impacts, vibrations, and unpredictable material web influencing
Solution Approach 1:
A spacer is introduced as an intermediary element between the profile and the groove walls. This spacer mediates the interaction by providing controlled contact points that prevent transverse movements and impacts while still allowing longitudinal displacement, thus eliminating vibrations and ensuring predictable material web influencing
Solution Approach 2:
The spacer changes the geometric parameters of the groove-profile interface by introducing controlled gaps and contact points. This modifies the displacement characteristics to eliminate unwanted transverse movements while maintaining the necessary longitudinal flexibility for material web control
2Manufacturing precision
If profiles are made shear-resistant to prevent deformation, then positioning accuracy improves, but this increases susceptibility to fatigue fractures from oscillatory movements
Solution Approach 1:
The spacer acts as a cushioning element that absorbs and dampens oscillatory movements before they can transmit full stress to the shear-resistant profile. This beforehand cushioning prevents the development of fatigue fractures while maintaining the positioning accuracy provided by the shear-resistant profile design
3Ease of operation
If free space is provided between groove and profile for displacement, then profile mobility is enabled, but this causes the profile to hit the groove, generating noise and vibrations
Solution Approach 1:
The spacer serves as an intermediary that fills the free space between the profile and groove walls in a controlled manner. It enables profile mobility through the intended displacement path while preventing harmful contacts that generate noise and vibrations
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
This solution allows for precise and reproducible material web control, reducing fatigue fractures, noise, and vibrations, thereby extending the service life and improving the accuracy of material web handling.
Implementation Method 1
at least one lip (20) which is elastically deformable when the at least one spring (8) engages in the at least one groove (9)
Implementation Method 2
at least one sliding element with an elastic lip or at least one elastic lip with a sliding function on at least one roller body (2) and/or on at least one profile (7)
Data Source
Figure 1
Figure 2~3
AI summary
A segmented roller (1) has a roller body (2) which is rotatably mounted about an axis (3). The roller body (2) has grooves (9) on its outer surface into which springs (8) of profiles (7) engage. These profiles (7) grip the web (5) directly or indirectly. To increase the service life and improve the mechanical properties of the profiles (7), the profiles (7) are designed to be shear-resistant and have elastic lips (20). These elastic lips (20) are deformed when the spring (8) engages the groove (9).