End Support Lattice Structure for Wound Roll Stability
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Solution Overview
Problem
Existing end support structures for rolls of material on tubular cores lack sufficient stability and load distribution, particularly when stacked, leading to stress concentration and potential damage during handling and storage.
Innovation Solution
The end support structure features a planar plate with a central hub and transverse ribs, forming an open lattice pattern with corrugation surfaces on both faces, which enhances strength while reducing material usage and weight, and includes undulating finger portions for easy gripping and stabilization bosses for secure stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional solid plate end supports are used, then strength and stability are sufficient, but material usage and weight are excessive
Solution Approach 1:
The solid plate end support is segmented into a lattice structure consisting of multiple ribs (radial ribs, circumferential ribs, and diagonal ribs) that form a framework. This segmentation maintains structural strength while significantly reducing material usage compared to a solid plate, directly resolving the contradiction between strength and material quantity.
Solution Approach 2:
The end support employs a lattice structure with intentional open spaces between the ribs, creating a porous-like framework. This structure provides sufficient mechanical strength through the rib network while minimizing material consumption, effectively balancing strength requirements with material reduction goals.
2Strength
If traditional solid plate end supports are used, then strength and stability are sufficient, but weight is excessive
Solution Approach 1:
The solid plate is divided into a framework of ribs that provide structural strength. By segmenting the plate into essential load-bearing ribs and removing non-essential material, the end support achieves required strength with significantly reduced weight.
Solution Approach 2:
Non-essential material is extracted from the solid plate, retaining only the critical rib structures necessary for strength. This extraction process removes excess weight while preserving the functional strength requirements of the end support.
3Ease of manufacture
If simple end support structures are used, then manufacturing is easy, but load distribution and stability are insufficient
Solution Approach 1:
The end support is segmented into multiple rib directions (radial, circumferential, and diagonal) that work together to distribute loads evenly. This segmented rib structure provides superior load distribution and stacking stability compared to simple designs, while remaining manufacturable through standard forming processes.
Solution Approach 2:
The end support incorporates ribs extending in multiple dimensions (radial, circumferential, and diagonal directions) rather than a single plane. This multi-dimensional rib arrangement enhances load distribution capability and stacking stability while maintaining manufacturability through systematic forming operations.
4Ease of manufacture
If simple end support structures are used, then manufacturing is easy, but stress concentration and damage risk increase
Solution Approach 1:
The simple solid plate is segmented into multiple ribs that distribute applied loads across many discrete load paths. This segmentation prevents stress concentration at single points, reducing damage risk while maintaining ease of manufacture through standard rib-forming processes.
Solution Approach 2:
The rib structure extends in multiple dimensions (radial, circumferential, and diagonal), creating a three-dimensional load distribution network. This multi-dimensional arrangement disperses stresses more effectively throughout the structure, enhancing reliability and damage resistance without complicating the manufacturing process.
Data Source
AI summary
An end support for supporting a roll of material wound on a tubular core is defined by a generally rectangular plate and a projecting hub member. The hub is dimensioned for insertion into a tubular core material roll. A plurality of spaced plate ribs are provided internally within the plate with at least one rib extending inwardly from each of the plate side perpendicular to the hub member. A plurality of crossing ribs are also provided and intersect with the perpendicular plate ribs and other crossing ribs to define a generally open areas lattice pattern. A plurality of corrugation surfaces are fixed to one or more of the side members, corner members, hub member, crossing ribs and plate ribs and extend into the open areas of the lattice pattern. The corrugations surfaces are alternately formed along the front and rear faces of the plate.