Modular Web Roller Assembly for Scalable Printer Reconfiguration
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Solution Overview
Problem
Existing continuous web printers are not scalable or modular, requiring custom mounting of printheads and rollers, making it difficult to adjust the number of printheads or change the web path geometry, which is time-consuming and expensive.
Innovation Solution
A modular roll bar assembly that can be removably attached to the imaging device main frame, allowing for adjustable web path geometry and printhead support, with integrated web tension measurement and thermal control systems to optimize web tension and temperature management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If continuous web printers are designed with custom mounted printheads and rollers to suit particular user needs, then the printer can be optimized for specific printing requirements, but the device becomes non-scalable and difficult to modify for different configurations
Solution Approach 1:
The printer is divided into modular components including removable roll bar assemblies, interchangeable printhead modules, and standardized mounting interfaces. Each roll bar assembly can be independently removed and replaced to change web path geometry or accommodate different printhead configurations without affecting other parts of the system.
Solution Approach 2:
The standardized mounting interfaces and universal roll bar design allow the same structural components to serve multiple functions and accommodate various printhead types and configurations. A single base platform can support different web path geometries and printhead arrangements through interchangeable modular components.
2Adaptability or versatility
If custom mounting is used to accommodate different numbers of printheads or change web path geometry, then specific printing requirements are met, but reconfiguration becomes time-consuming and expensive
Solution Approach 1:
The system transitions from fixed custom mounting to dynamic reconfigurable mounting where roll bar assemblies can be quickly removed and repositioned along the printer frame. Standardized interfaces enable rapid exchange of modular components without requiring time-consuming custom fabrication or complex assembly procedures.
3Reliability
If tension bars or rollers are placed in the feed path to remove slack from the web, then the web remains taut without breaking, but the web path geometry becomes fixed and non-adjustable
Solution Approach 1:
Roll bar assemblies are pre-configured with integrated tension control mechanisms and can be positioned in advance at optimal locations along the web path. The modular design allows tension bars and rollers to be pre-assembled with adjustable mounting features that maintain web tension while accommodating future reconfiguration needs.
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
Enables scalable and modular printer platforms that can accommodate multiple printhead configurations and web path changes, improving flexibility and reducing the time and cost associated with reconfiguring the printer setup.
Implementation Method 1
A load cell is operably coupled to the support frame and configured to generate a signal indicative of a down force applied to the support frame. A controller is operably coupled to the load cell to receive the signal and to correlate the down force applied to the support frame indicated by the signal to a tension measurement value for the continuous web.
Implementation Method 2
The assembly includes a temperature control system configured to heat or cool the plurality of roll bars to a predetermined temperature.
Implementation Method 3
The assembly includes a temperature control system configured to heat or cool the plurality of roll bars to a predetermined temperature.
Data Source
AI summary
A modular roll bar assembly for use in a continuous web imaging device includes a plurality of roll bars and a support frame configured to operably support the plurality of roll bars such that the plurality of roll bars define a web path having a non-linear shape with an entrance end and an exit end. The entrance end is configured to receive a substantially continuous web of substrate material, and the plurality of roll bars is configured to guide the continuous web past the exit end. A load cell is operably coupled to the support frame and configured to generate a signal indicative of a down force applied to the support frame. A controller is operably coupled to the load cell to receive the signal and to correlate the down force applied to the support frame indicated by the signal to a tension measurement value for the continuous web.