Mechanical Roller Bearing Grooves Fabrication Waste
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Solution Overview
Problem
The use of paper rolls in circular knitting machines leads to significant waste and increased production costs due to their inability to be reused, as they become deformed by moisture and external factors, and existing solutions like air-cushioned rollers face issues with removal due to pressure from fabric rolls.
Innovation Solution
A mechanical roller with a bearing system is developed, featuring a main shaft with bearing grooves, milled studs, and a grooved cloth roll that allows for easy attachment and detachment from the fabric roll, enabling the roller to be reused by compressing the bearings and using elastic rings and grooved strips for tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a paper roll is used to enable easy removal from the fabric roll, then the fabrication process is simplified, but the paper roll becomes waste and cannot be reused, increasing production costs and environmental harm
Solution Approach 1:
The patent replaces the disposable paper roll with a reusable mechanical roller designed for multiple uses. The mechanical roller has a cylindrical structure with surface features that allow fabric to be wound around it and easily removed after fabrication, eliminating the need for disposable paper rolls and reducing waste.
Solution Approach 2:
The patent changes the physical parameters of the roller from a soft, deformable paper roll to a rigid mechanical roller with specific surface characteristics. The mechanical roller maintains appropriate friction properties to hold fabric during fabrication while allowing easy removal afterward, solving both the ease of manufacture and waste reduction objectives.
2Duration of action of stationary object
If an air-cushioned roller is used instead of a paper roll to enable reuse, then the roller can be used multiple times, but the roller gets stuck inside the fabric roll due to pressure from the fabric, making removal difficult
Solution Approach 1:
The patent employs a cloth pipe as an outer layer or covering on the mechanical roller. This flexible shell allows the roller to maintain structural integrity for reuse while enabling easy removal from the fabric roll. The cloth pipe can deform to accommodate fabric pressure during fabrication and then allow clean separation when removal is needed, solving both reusability and ease of operation objectives.
3Loss of substance
If the mechanical roller is designed for multiple uses, then production costs are reduced, but the roller must withstand repeated attachment and detachment cycles, requiring enhanced durability
Solution Approach 1:
The patent constructs the mechanical roller as a composite structure with a rigid core for structural strength and a flexible cloth pipe covering for durability and ease of operation. This composite design allows the roller to withstand repeated attachment and detachment cycles while maintaining reliability and reducing production costs through reusability.
Data Source
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AI summary
The invention relates to the rollers which are used in the machines for knitted fabric with or without lycra and allow the fabric to be separated from the roller without using a paper roll and the mechanical roller with a bearing (14) to be easily removed from the fabric roll thanks to the grooved cloth roll (13) in which it can move easily by virtue of the main shaft with a bearing (12) and the grooved strips of said main shaft with a bearing (12).