Modular Press Section Frame Design for Web Forming Machines
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Solution Overview
Problem
Current frame designs for press sections are highly individualized, leading to longer design, calculation, and manufacturing times, resulting in higher production costs, as they cannot be reused across different machines, except for rare 'sister machines' built in small quantities.
Innovation Solution
A frame for web forming machines comprising frame side elements, intermediate and upper cross machine direction beams, rectangular nip frame modules, and support arms, allowing for standardized construction that supports inclined pairs of nip rolls and enables secure maintenance positions, reducing space requirements and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual frame designs are used for each press section, then the frame can be optimized for specific machine requirements, but the design, calculation, and manufacturing time increases, resulting in higher production costs
Solution Approach 1:
The frame is divided into modular components including side frames, cross beams, and press nip units that can be independently designed and manufactured. These modules can be reused across different machine configurations, reducing overall design and manufacturing time while maintaining adaptability to specific machine requirements.
Solution Approach 2:
Standardized frame modules are designed to serve multiple functions and be applicable across different press section configurations. The universal modules can be adapted to various machine types through standardized connection interfaces, eliminating the need for complete redesign for each machine while preserving optimization capabilities.
2Adaptability or versatility
If individual frame designs are used for each press section, then the frame can be tailored to specific needs, but production costs increase due to longer design and manufacturing cycles
Solution Approach 1:
The frame structure is segmented into standardized modules that can be manufactured independently using consistent processes. This segmentation enables economies of scale in production while allowing customization through different module combinations, thereby reducing overall manufacturing costs.
Solution Approach 2:
Standardized frame modules are designed with adjustable parameters such as length, positioning, and connection configurations that can be modified to meet specific machine requirements without requiring complete redesign. This parameter adjustment capability maintains customization while leveraging standardized manufacturing processes to control costs.
3Productivity
If standardized frame modules are used, then production time and costs are reduced, but the ability to optimize for specific machine requirements may be limited
Solution Approach 1:
The frame is constructed from discrete standardized modules that can be independently optimized and then assembled into machine-specific configurations. This segmentation allows both efficient standardized production and flexible optimization for specific requirements through modular assembly.
Solution Approach 2:
The modular frame design enables dynamic adaptation where standardized modules can be reconfigured, added, or removed based on specific machine requirements. This dynamic assembly approach maintains high production efficiency while preserving the ability to optimize frame characteristics for different applications.
4Strength
If cantilevered frame construction is used in cross machine direction, then structural support is provided, but space for rolls and felts between side frames is reduced
Solution Approach 1:
Instead of using a cantilevered construction where beams extend from one side frame, the invention uses cross beams that connect between both side frames. This inverted approach provides structural support through distributed loading while maximizing the available space between side frames for rolls and felts.
Data Source
Figure 1
Figure 2
AI summary
There is provided a frame (1) for a web forming machine. This frame comprises frame side elements (2) which extend in machine direction and beams which extend between the frame side elements in cross machine direction. The frame side elements (2) comprise a rectangular nip frame module (21) adapted to support an inclined pair of nip rolls (11, 12) and an upper connection beam (22) located above the nip frame module (21) and connected to the nip frame module (21). At least one intermediate cross machine direction beam (3a) is provided which connects the nip frame modules (21). Also, at least one upper cross machine direction beam (3b) connects the upper connection beams (22). Furthermore, insertion units (4) are provided in the rectangular nip frame modules (21).