Quick-Change Forming Roller for Plastic Fiber Bundles
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Solution Overview
Problem
Existing methods for cross-sectional shaping of plastic fiber bundles are inefficient, requiring frequent changes of molding rollers, which is time-consuming, and lack precise control over cooling and shaping, especially for varying cross-sectional requirements.
Innovation Solution
A device with a quick-change forming roller system, featuring rotary couplings for cooling and adjustable positioning of multiple forming rollers in a triangular arrangement, allowing for precise shaping and cooling of plastic fiber bundles with minimal downtime for roller changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional molding rollers are used for cross-sectional shaping, then shaping function is provided, but downtime increases when changing rollers for different cross-sections
Solution Approach 1:
The molding roller surface is made dynamically adjustable through a system of adjustable molding elements that can be repositioned along the roller circumference. This allows the roller to adapt to different cross-sectional shapes without requiring physical replacement of the roller, thereby reducing downtime while maintaining shaping versatility.
Solution Approach 2:
The molding roller is segmented into multiple independent molding elements arranged around the circumference. Each element can be independently adjusted or replaced, allowing flexible configuration for different cross-sections. This segmentation enables quick reconfiguration without replacing the entire roller, reducing changeover time.
2Manufacturing precision
If multiple molding rollers are arranged in sequence, then shaping function is enhanced, but device complexity increases
Solution Approach 1:
Multiple molding rollers are merged into a single integrated unit with a common support structure and drive mechanism. This consolidation maintains the shaping precision provided by multiple rollers while reducing the overall complexity of the device by eliminating redundant support structures and synchronization mechanisms.
Solution Approach 2:
The molding roller system is designed with universal functionality to handle various cross-sectional shapes through adjustable molding elements. This multi-functionality reduces the need for multiple specialized rollers, simplifying the overall device structure while maintaining high shaping precision across different applications.
3Volume of moving object
If forming rollers are made compact, then device size is reduced, but cooling effectiveness may be compromised
Solution Approach 1:
The cooling channels are nested within the hollow core of the forming rollers, allowing cooling fluid circulation inside the roller structure itself. This nested arrangement provides effective cooling throughout the roller volume without increasing the external dimensions, maintaining compactness while ensuring thorough cooling of the plastic fiber bundles.
Solution Approach 2:
A hydraulic cooling system using liquid coolant is integrated into the forming rollers through internal channels. The liquid cooling medium flows through the roller structure, providing efficient heat removal from the contact surface with the plastic fiber bundles. This hydraulic approach achieves effective cooling within a compact roller design.
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 effective and precise cross-sectional shaping with improved roundness and cooling of plastic fiber bundles, reducing downtime for roller changes and accommodating various cross-sectional shapes, enhancing the quality and efficiency of the shaping process.
Implementation Method 1
rotary couplings on the front side, via which liquid media, in particular for cooling, are passed through the forming roller
Data Source
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AI summary
The invention relates to a device for cross-sectionally forming a plurality of plastic strands guided parallel to one another over at least one rotatable forming roller (18, 19, 20), wherein the forming roller is provided on its surface with a plurality of parallel circumferential forming recesses in which the cross-section of the plastic strands can be formed according to the cross-sectional shape of the forming recesses, wherein preferably three identical forming rollers (18, 19, 20) are arranged transversely to the running path of the plastic strands for successive forming of the plastic strands, wherein the plastic strands are between a pair of two successive forming rollers (19, 20) on a first side of the plastic strands and a third forming roller (18) which is arranged on the second side of the plastic strands in the running direction of the plastic strands between the first (19) and second forming roller (20) of the pair of forming rollers.are guided and the forming rollers are mounted in lateral guide plates by means of quick-change devices.