Induction Heated Roll Support Shaft Layout for Small-Diameter Power Feed
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Solution Overview
Problem
Conventional induction heated roll apparatuses with small-diameter rollers face limitations in supplying sufficient electric power due to thin lead wires, restricting heating temperature and increasing the risk of deflection and contact between the roller body and induction heating mechanism.
Innovation Solution
The support shaft supporting the induction heating mechanism is positioned on the inner peripheral surface of the roller body via bearings, allowing for a larger diameter and reducing deflection, with a nonmagnetic support shaft and optional magnetic shield and spacer members to manage thermal deformation and cost effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the support shaft is positioned inside the drive shaft, then the structure is compact, but the support shaft diameter is reduced limiting power supply capacity
Solution Approach 1:
The support shaft is repositioned from the radial dimension (inside the drive shaft) to the axial dimension (supported by the roller body at both ends). This dimensional change allows the support shaft to achieve a larger diameter without increasing the overall device footprint, thereby resolving the contradiction between structural compactness and power supply capacity.
2Adaptability or versatility
If the roller body has small diameter and long length, then it meets heat treatment requirements, but deflection of induction heating mechanism increases causing contact risk
Solution Approach 1:
By repositioning the support shaft to be supported by the roller body at both ends along the axial direction, the bearing spacing is significantly reduced. This dimensional reconfiguration provides effective span support that counteracts deflection in long, small-diameter roller bodies, reducing the risk of contact between the roller body and induction heating mechanism.
Solution Approach 2:
The support shaft is preliminarily positioned and fixed by bearings at both ends of the roller body before operation. This preliminary positioning prevents excessive deflection and potential contact during the heat treatment process, ensuring reliable operation for long, small-diameter roller bodies.
3Power
If the lead wire diameter is increased for small-diameter rollers, then power supply is sufficient, but the support rod becomes too thin to accommodate it
Solution Approach 1:
The support shaft is repositioned to a location where it can achieve a larger diameter (supported by the roller body rather than the drive shaft). This dimensional change provides sufficient internal space to accommodate thicker lead wires, allowing adequate power supply capacity without compromising the support structure.
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 configuration ensures sufficient power supply to the induction heating mechanism, reduces deflection and contact risks, and enhances mechanical strength while maintaining cost-effectiveness by using standard bearings with optional spacers.
Implementation Method 1
an induction heating mechanism that is provided inside the roller body and allows the roller body to inductively generate heat
Implementation Method 2
the support shaft is rotatably supported on an inner peripheral surface at the both ends of the roller body via a bearing
Data Source
AI summary
In order to supply sufficient electric power to an induction heating mechanism even with a small-diameter roller, an induction heated roll apparatus includes a roller body having a hollow cylindrical shape, a drive shaft provided at each of both ends of the roller body and rotatably supported, an induction heating mechanism that is provided inside the roller body and allows the roller body to inductively generate heat, and a support shaft that extends from both ends of the induction heating mechanism and supports the induction heating mechanism. The support shaft is rotatably supported on an inner peripheral surface at both ends of the roller body via a bearing.