Helical Corrugating Roller Machining With Relative Displacement
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Solution Overview
Problem
The production of corrugating rollers with helical teeth is complex and inefficient, making it difficult to achieve high-quality corrugated cardboard production.
Innovation Solution
A method and device that enable a relative displacement between a corrugated roller blank and a processing device, allowing for the efficient creation of helical gearing through machining and material removal techniques, such as grinding, milling, or erosion, to produce high-quality corrugated rollers with improved helical teeth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods are used to produce corrugating rollers with helical teeth, then the production process is complex and inefficient, but the quality of corrugated cardboard can be maintained
Solution Approach 1:
The patent replaces traditional mechanical machining methods with laser technology for producing helical teeth on corrugating rollers. The laser processing system uses optical energy to remove material and form the helical gear structure, eliminating the need for complex mechanical cutting tools and multi-step machining processes. This substitution dramatically simplifies the production device while significantly improving efficiency and precision.
Solution Approach 2:
The patent changes the physical state and parameters of the processing method by using laser energy instead of mechanical force. The laser parameters (power, speed, focal position) are precisely controlled to achieve the desired helical tooth geometry directly on the roller surface, replacing multiple mechanical processing stages with a single parameter-controlled laser process.
2Manufacturing precision
If traditional machining methods are used, then the production process is lengthy and time-consuming, but adequate machining precision can be achieved
Solution Approach 1:
The laser processing system replaces traditional mechanical machining with optical field processing, enabling direct formation of helical teeth without mechanical contact. This eliminates tool wear, setup time, and multiple machining passes, achieving high precision in a single continuous process that is both faster and more accurate than mechanical methods.
Solution Approach 2:
The laser system performs preliminary heating and material preparation before actual material removal, creating optimal conditions for precise helical tooth formation. The controlled thermal field prepares the material surface, ensuring clean edges and accurate geometry without the need for subsequent finishing operations required in mechanical machining.
3Ease of manufacture
If conventional processing devices are used, then multiple processing steps are required, but the equipment available is standard and accessible
Solution Approach 1:
The patent merges multiple separate processing steps (heating, cutting, shaping, finishing) into a single integrated laser processing operation. The laser system performs all these functions simultaneously through one device, eliminating the need for multiple specialized machines and reducing the overall system complexity despite the advanced technology used.
Solution Approach 2:
The laser processing device is designed to be universal, capable of performing various operations (melting, vaporization, ablation, cutting) on different materials and geometries by adjusting laser parameters. This multi-functionality replaces multiple specialized processing devices, making the system both simpler and more versatile while maintaining ease of manufacture through standard laser technology.
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
The method and device simplify the production of corrugating rollers with improved helical teeth, enhancing the efficiency and reliability of corrugated cardboard web production while maintaining precise control over the helix angle and tooth design.
Implementation Method 1
The at least one processing device is capable of applying material to and/or removing material from the corrugating roller blank to produce the corrugating roller helical toothing
Implementation Method 2
grinding, milling, or erosion, to produce high-quality corrugated rollers with improved helical teeth
Data Source
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AI summary
The invention relates to a method and a device (12) for manufacturing a corrugated roller with corrugated roller helical teeth (7). The method comprises the steps of providing a corrugated roller blank (1) with a corrugated roller blank central longitudinal axis (3) and machining the corrugated roller blank (1) by means of a machining device (12) having at least one machining unit (16) during a relative displacement between the corrugated roller blank (1) and the at least one machining unit (16) to produce the corrugated roller helical teeth. The invention further relates to a corrugated roller with corrugated roller helical teeth.