Flat Leads in Perforated Roll Shells for Sensor Protection
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Solution Overview
Problem
Existing sensing systems in fiber web machines are cumbersome and costly to install due to the need for drilling through holes in the roll shell, which can damage sensors and require complex drilling patterns, leading to uneven perforation and increased manufacturing time.
Innovation Solution
The use of flat leads with a wider width than the diameter of the through holes allows for easier and more reliable installation of sensing systems, enabling them to travel freely around the roll shell without breaking, even when coinciding with holes, and the inclusion of sensors between flat leads protects them from damage during drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional round leads are used in sensing systems, then the leads can be easily routed through holes, but the leads are vulnerable to damage during drilling and require complex drilling patterns
Solution Approach 1:
The patent uses flat ribbon-like leads instead of traditional round wires. These flat leads have sufficient mechanical strength to withstand the drilling process while maintaining flexibility for routing. The flat geometry provides a larger cross-sectional area that resists breaking during hole drilling, eliminating the need for complex drilling patterns or special protective measures.
2Ease of manufacture
If sensors are positioned around through holes, then the sensing system can be integrated into the roll shell, but the sensors are at risk of damage during the drilling process
Solution Approach 1:
The patent positions the sensors on the roll shell surface before the drilling operation occurs. By completing sensor placement beforehand, the sensors are protected from damage during the subsequent drilling of through holes. The flat leads accommodate this sequencing by maintaining electrical connectivity without requiring the sensors to be positioned within the hole paths.
3Productivity
If blind drilled holes are used for the sensing system, then the drilling work becomes easier and faster, but the through hole perforation becomes uneven
Solution Approach 1:
The patent applies different hole drilling strategies to different regions of the roll shell. Through holes are drilled in areas where they are needed for structural or functional purposes, while blind holes are used specifically for the sensing system locations. This localized approach allows optimized drilling for each region without compromising overall manufacturing precision or productivity.
4Manufacturing precision
If multiple drilling patterns are used for the sensing system, then the sensing system can be precisely positioned, but the manufacturing process becomes more time-consuming and error-prone
Solution Approach 1:
The patent employs a universal drilling pattern that serves both the structural requirements of the roll shell and the positioning requirements of the sensing system. The flat leads are designed to accommodate standard drilling patterns without requiring specialized multi-pattern drilling sequences, thereby reducing manufacturing time while maintaining precise sensor placement through proper lead routing and connection techniques.
Data Source
AI summary
A perforated roll (10) of a fiber web machine includes a roll shell (19), holes (13) extending through the roll shell, and a sensing system (14) arranged in the roll shell. The sensing system (14) includes at least one pair of leads (16), to which one or more sensors (15) have been connected. At least one pair of leads is composed of flat leads (17.2, 17.2), which are arranged in the roll shell side by side. A prefabricated sensor sheet (26) may be prepared for a perforated roll of a fiber web machine, such that holes may be drilled therethrough to communicate with the roll shell holes (13).