Pivotable Feed System for Rubber Web Pre-Crosslinking
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Solution Overview
Problem
The integration of irradiation chambers into extruder lines for pre-crosslinking rubber webs is hindered by high maintenance costs, leading to production downtimes, and not all webs require pre-crosslinking, necessitating a solution to minimize interruptions and allow for flexible handling of material webs.
Innovation Solution
A device with a pivotable feed and transport system allows the extruded material web to bypass the irradiation chamber during maintenance, eliminating the need for production interruptions and enabling diversion to a second chamber or direct spooling for interim storage, thus avoiding offline irradiation and maintenance-related downtimes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an irradiation chamber is integrated into the extruder line for pre-crosslinking, then pre-crosslinking capability is improved, but maintenance costs and production downtimes increase
Solution Approach 1:
The feed device and transport device are made pivotable, allowing dynamic switching between the irradiation chamber path and the bypass conveyor path. This enables the system to adapt its configuration based on whether pre-crosslinking is needed or maintenance is being performed, resolving the contradiction between having pre-crosslinking capability and maintaining production continuity.
Solution Approach 2:
The bypass conveyor acts as an intermediary element that provides an alternative material transport path around the irradiation chamber. This mediator allows material to flow continuously through the system even when the irradiation chamber is under maintenance or when pre-crosslinking is not required, thus maintaining productivity while preserving the option for pre-crosslinking.
2Productivity
If the irradiation chamber is integrated immediately after extrusion, then pre-crosslinking efficiency is improved, but maintenance complexity increases
Solution Approach 1:
The material transport system is segmented into multiple independent paths: one through the irradiation chamber and another through the bypass conveyor. The feed device and transport device serve as segmentation points that can direct material along different routes. This segmentation reduces maintenance complexity by allowing the bypass path to operate independently when the irradiation chamber requires maintenance.
3Productivity
If a bypass conveyor is added to allow continuous operation during maintenance, then production continuity is improved, but device complexity increases
Solution Approach 1:
The feed device and transport device serve multiple functions: they can direct material either through the irradiation chamber for pre-crosslinking or through the bypass conveyor for continuous operation during maintenance. This multi-functionality justifies the added complexity by providing versatile operational capabilities that resolve the contradiction between production continuity and system simplicity.
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 solution allows continuous operation of the extruder line during maintenance, reduces production downtimes, and enables efficient handling and storage of pre-crosslinked material webs without adhesion or dimensional instability, improving operational efficiency and flexibility.
Implementation Method 1
transport webs of material extruded from rubber mixtures into irradiation chambers and to pre-crosslink them superficially there by means of electron beams
Data Source
Figure 1
Figure 2
AI summary
Device for transporting and optionally pre-mixing a web of material (14) extruded from a rubber compound, comprising: - an irradiation chamber (1') with an electron beam source (4), - a conveyor belt (6) arranged at the irradiation chamber (1') with a load section (6a) passing through the irradiation chamber (1'), - a bypass conveyor (7) arranged below the irradiation chamber (1'), - a feed device (8) arranged in front of the irradiation chamber (1') with respect to the transport direction (Pi), which can be pivoted into a position leading to the conveyor belt (6) and a position leading to the bypass conveyor (7), and - a discharge device (9) arranged behind the irradiation chamber (1') with respect to the transport direction (P1), which can be pivoted into a position leading to the conveyor belt (6) and a position leading to the bypass conveyor (7).