Gearless Contact Roller Drive for Polymer Film Winding
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Solution Overview
Problem
Existing systems for operating contact rollers in polymer film stretching plants face challenges with maintaining uniform pressure and damping vibrations due to the increasing diameter of the take-up roller and out-of-round rotations, leading to unsteady contact and frequent equipment failures.
Innovation Solution
A device utilizing a direct gearless-drive motor to move the contact roller relative to the take-up roller, allowing for continuous linear control of pressure and damping of vibrations through a closed loop circuitry, reducing cogging and ensuring consistent contact pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a contact roller is used to apply pressure to the take-up roller, then the polymer film can be pressed uniformly, but the increasing diameter of the take-up roller causes position adaptation problems
Solution Approach 1:
The contact roller is made movable along the axial direction of the take-up roller, allowing dynamic position adjustment. The roller can automatically adapt to the increasing diameter of the take-up roller while maintaining constant contact pressure through spring force or hydraulic pressure, resolving the contradiction between pressure uniformity and position adaptability.
Solution Approach 2:
The system changes the positional parameter of the contact roller dynamically. By allowing the roller to move axially and adjusting its position according to the take-up roller's diameter increase, the system maintains optimal contact pressure throughout the winding process despite changing geometric parameters.
2Device complexity
If the contact roller is held fixed, then the structure is simple, but vibrations occur due to out-of-round rotation of the take-up roller
Solution Approach 1:
The contact roller is designed with movable support rather than fixed mounting, allowing it to dynamically respond to vibrations caused by out-of-round rotation. The roller can shift position to maintain stable contact despite take-up roller imperfections, improving reliability without excessive structural complexity.
Solution Approach 2:
The system incorporates damping elements or flexible support mechanisms that cushion against vibrations before they propagate. By providing compliant support for the contact roller, the system absorbs vibrational disturbances from out-of-round rotation, maintaining contact stability.
3Stress or pressure
If hydraulic dampening cylinders are used to reduce pressure variations, then pressure stability improves, but the system becomes more complex and requires frequent maintenance
Solution Approach 1:
The invention combines the pressure application function and vibration damping function into a single integrated movable support system. Rather than using separate hydraulic cylinders for pressure control and additional dampers for vibration reduction, the movable roller support performs both functions simultaneously, reducing component count and maintenance requirements.
Solution Approach 2:
The movable contact roller support is designed as a multi-functional element that simultaneously maintains contact pressure and dampens vibrations. This universal component replaces multiple specialized components, achieving pressure stability and vibration reduction with a simpler, more reliable system.
4Adaptability or versatility
If the contact roller moves axially to adapt to diameter changes, then position adaptability improves, but the roller may lose contact during out-of-round rotation
Solution Approach 1:
The movable support system incorporates damping or spring elements that provide continuous contact force. These elements cushion against the intermittent contact caused by out-of-round rotation, ensuring the roller maintains contact throughout the rotation cycle while still adapting axially to diameter changes.
Solution Approach 2:
The contact roller uses dynamic movable support with compliance elements that allow continuous contact despite axial movement. The system dynamically adjusts to both diameter changes and rotational imperfections, maintaining reliable contact through controlled motion and elastic deformation.
Data Source
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AI summary
The invention relates to a device and process for operating at least one contact roller (1) in contact with a take-up roller (0) or with a polymer film bale (0') wound to the take-up roller (0), preferably in a plant for stretching a polymer film which is, after the stretching step, wound to said take-up roller (0) rotatable around a rotational axis, said at least one contact roller (1) being rotatable around a rotational axis arranged parallel to the take-up roller's rotational axis, being supported movably by variable distances perpendicular relative to the take-up roller's rotational axis and providing for a permanent application of a predetermined pressure to the polymer film (2) during said winding to the take-up roller or polymer film bale (0') along a contact line being parallel to the axes of the take-up and contact rollers (0, 1) and on the surface of the contact roller (1) and take-up roller (0) or polymer film bale, said device comprising a direct gearless-drive motor means (10) for exerting a rotational drive force around a motor axis (11); said motor axis (11) being substantially parallel to the axes of the contact and take-up rollers (0, 1) and being capable of actuating force transmission means (20) by its rotational movement; said force transmission means (20) being connected to and actuated by said motor means (10) and transforming the rotational drive force exerted by the axis (11) of the direct gearless-drive motor means (10) into a translational drive force substantially perpendicular to the motor axis (11); and said force transmission means (20) being capable of transmitting said translational drive force to the contact roller (1), thereby moving the contact roller (1) towards, or away from, the take-up roller (0).