Modular Web-Handling Machine Blocks for Roller Alignment
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Solution Overview
Problem
Roll-to-roll processes face challenges in maintaining web parallelism between rollers to prevent wrinkles and defects, requiring precise alignment that is difficult and costly to set up, especially for short production runs or experimental setups.
Innovation Solution
The use of modular, reconfigurable blocks with precision alignment points allows for quick and direct mounting of shaft-mounted web-contacting devices, eliminating the need for separate alignment procedures, ensuring rollers are in tram and level without further adjustment, maintaining parallelism to within 0.004 radians.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment procedures with optical, laser, mechanical, or inertial equipment are used to set up web-contacting devices, then roller parallelism precision is improved (within 0.0005 radian or 0.0001 radian), but setup time and equipment cost increase significantly
Solution Approach 1:
The web handling machine is divided into modular reconfigurable blocks, each with integrated precision alignment features. This segmentation allows individual modules to be pre-aligned and then assembled together, eliminating the need for comprehensive alignment procedures on the entire machine.
Solution Approach 2:
Precision alignment points and bores are pre-positioned during module fabrication. This preliminary action ensures that when modules are assembled, the web-contacting devices are automatically aligned to the required precision (within 0.004 radian) without requiring subsequent alignment adjustments.
2Manufacturing precision
If elaborate alignment equipment is used to achieve high precision roller parallelism, then web handling quality is improved, but equipment cost increases
Solution Approach 1:
The modular blocks are designed with self-aligning features including precision bores and alignment points that automatically guide shaft mounting to the correct position and orientation. This self-service alignment eliminates the need for external optical, laser, or inertial alignment equipment.
Solution Approach 2:
Complex optical, laser, or inertial alignment systems are replaced with a mechanical solution based on precision-machined alignment points and bores in the modular blocks. This mechanical substitution achieves the required alignment precision through design rather than measurement and adjustment.
3Adaptability or versatility
If adjustable roller mounts with separate alignment procedures are used, then roller parallelism can be adjusted, but setup complexity and time increase
Solution Approach 1:
The functions of roller mounting and precision alignment are merged into a single integrated solution. The modular blocks contain both the mounting structure and the precision alignment features (bores and alignment points) as one unit, eliminating the need for separate adjustment procedures.
Solution Approach 2:
The design transitions from adjustable parameters requiring alignment procedures to fixed precision parameters built into the modular block geometry. The alignment points are positioned at precise locations during manufacturing, changing the approach from adjustment to inherent precision.
Data Source
AI summary
A web-handling machine frame, at least partially built from reconfigurable interconnected blocks having precision alignment points. From such blocks, modular equipment web-handling lines for web-handling operations can be constructed ad hoc with their shaft mounted web-contacting devices in tram without the need for separate alignment procedures.