Induction Heated Roll Cooling via Journal Flange Apertures
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Solution Overview
Problem
Existing induction heated roll apparatuses face limitations in cooling performance due to pressure losses in the cavity between the journal shaft portions and the supporting shaft of the induction heating mechanism, and the introduction of atomized cooling media can lead to vaporization before reaching the roller main body, hindering efficient heat capture.
Innovation Solution
The apparatus features a hollow roller main body with induction heating mechanism and a cooling mechanism that includes intake and discharge apertures on the journal flange portions, bypassing the cavity between the journal shaft and supporting shaft, and a mist supply mechanism to increase humidity and specific heat of the gas, enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gas cooling is used through the cavity between journal shaft portions and supporting shaft, then cooling function is provided, but pressure loss occurs and cooling performance deteriorates
Solution Approach 1:
The invention extracts the gas flow path from the problematic cavity between journal shaft portions and supporting shaft. Instead of forcing gas through this restricted space, the design provides direct gas flow paths through the roller main body structure, eliminating the pressure loss bottleneck while maintaining the cooling function.
Solution Approach 2:
The invention changes the dimensional approach of gas flow by introducing multiple aperture locations (first and second end sides in axial direction, and lateral surfaces) rather than relying on a single linear path through the constrained cavity. This multi-dimensional gas flow distribution improves cooling effectiveness without suffering from pressure loss.
2Temperature
If atomized cooling medium is introduced through supporting shaft, then cooling is provided, but vaporization occurs before reaching roller main body reducing efficiency
Solution Approach 1:
The invention uses gas as an intermediary cooling medium that flows directly through apertures in the roller main body, bypassing the supporting shaft pathway. This direct gas flow mechanism delivers cooling effectively without the vaporization problems that occur when atomized cooling medium travels through the supporting shaft.
3Volume of moving object
If journal shaft portion outer diameter is reduced to accommodate larger shell portion, then roller main body size increases, but cavity cross-sectional area decreases limiting cooling capacity
Solution Approach 1:
The invention segments the gas flow paths into multiple independent channels through apertures distributed at different locations (axial ends and lateral surfaces). This segmentation allows the cooling system to bypass the need for a large continuous cavity, enabling effective cooling even when the cavity cross-sectional area is reduced by smaller journal shaft portions.
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 improves cooling performance by increasing gas flow rate and efficiently capturing vaporization latent heat, while preventing high-temperature gas from contacting bearings, thus extending their lifespan and ensuring uniform temperature distribution.
Implementation Method 1
an induction heating mechanism causes circumferential wall portions of the roller main body to emit heat using an induced current
Implementation Method 2
emit heat using an induced current
Implementation Method 3
efficiently capturing vaporization latent heat
Implementation Method 4
capturing vaporization latent heat
Data Source
AI summary
An induction heated roll apparatus includes a roller main body, an induction heating mechanism, and a cooling mechanism. The induction heating mechanism heats the roller main body, while the cooling mechanism cools the roller main body and/or the induction heating mechanism using a cavity portion between the roller main body and the induction heating mechanism. The cooling mechanism has intake apertures and discharge apertures that are formed in a journal flange portion and communicate with the cavity portion, a suction mechanism that suctions a gas in the cavity portion through the discharge apertures, and a mist supply mechanism that supplies mist to the intake apertures.