Reinforced Ironing Roll Assembly for Rigid Lightweight Construction
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Solution Overview
Problem
Existing methods for manufacturing ironing rolls with heatable chests are time-consuming, labor-intensive, and expensive, particularly for large industrial designs, often resulting in insufficient rigidity and stability due to the use of heavy central shafts and complex constructions.
Innovation Solution
The ironing roll design features a casing with releasably connected reinforcement elements, including first and second teeth of varying heights, allowing for simple and rapid mounting while ensuring rigidity without a heavy central shaft, using a snap connection mechanism between the casing and reinforcement elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a heavy central shaft is used to ensure rigidity, then the ironing roll achieves sufficient rigidity for large industrial applications, but the weight and manufacturing complexity increase significantly
Solution Approach 1:
The ironing roll is divided into multiple independent segments: a cylindrical casing and separate reinforcement elements. The casing is made from thin-walled standard tubes (10-12mm thickness) that are perforated and then reinforced with discrete elements positioned at specific locations. This segmentation allows the roll to achieve rigidity through strategic reinforcement rather than through overall heavy construction, significantly reducing weight while maintaining structural integrity.
Solution Approach 2:
Reinforcement elements are applied locally at critical positions within the casing rather than uniformly throughout. The reinforcement elements have varying heights (first and second teeth of different heights) that are welded to the casing at specific locations to provide targeted structural support. This local reinforcement approach achieves the necessary rigidity only where needed, avoiding the weight penalty of a uniformly heavy construction.
2Reliability
If traditional manufacturing methods with complete welding of plates are used, then the ironing roll achieves structural integrity, but the manufacturing time and labor intensity increase significantly
Solution Approach 1:
Standard tubes with wall thicknesses of 10-12mm are manufactured in advance with perforations already formed. These pre-prepared tubes serve as the basis for the ironing roll casing, eliminating the need for time-consuming on-site plate welding and perforation work. The reinforcement elements are also prepared separately before final assembly, allowing parallel preparation of components that are then quickly assembled together.
Solution Approach 2:
The invention combines multiple components (casing, reinforcement elements with varying tooth heights, bearing arrangements) into a unified assembly that achieves structural integrity through their integrated configuration rather than through extensive welding. The reinforcement elements are welded to the casing at strategic positions, and the bearing arrangements are mounted on the reinforcement elements, creating a structurally sound assembly through component integration rather than monolithic construction.
3Strength
If standard tubes with thick walls are used, then the ironing roll achieves sufficient strength, but the transportation cost and difficulty increase
Solution Approach 1:
Instead of using uniformly thick-walled tubes throughout, the invention uses standard tubes with wall thicknesses of 10-12mm that are easier to transport and handle. The necessary strength is achieved locally through the addition of reinforcement elements with varying heights that are welded to the casing at critical positions. This approach maintains strength requirements while significantly improving transportation ease compared to using uniformly thick-walled custom tubes.
4Volume of moving object
If the ironing roll is designed for large industrial applications with diameters of 0.3m and more, then the working capacity increases, but the manufacturing complexity and cost increase
Solution Approach 1:
Large ironing rolls with diameters of 0.3m and more are constructed by segmenting the structure into a cylindrical casing and separate reinforcement elements. The casing is made from standard tubes that are perforated and then reinforced with discrete elements at critical positions. This segmentation allows large-diameter rolls to be manufactured using standard components and simplified assembly procedures, reducing manufacturing complexity and cost compared to constructing large rolls as monolithic structures.
Solution Approach 2:
The reinforcement elements serve multiple functions: they provide structural reinforcement, support bearing arrangements, and maintain the rigidity of the thin-walled casing. The bearing arrangements mounted on the reinforcement elements handle both rotational support and positioning functions. This multi-functionality reduces the overall complexity of the design by having components perform multiple roles rather than requiring separate dedicated structures for each function.
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 design enables the manufacture of a more rigid, cost-effective, and less labor-intensive ironing roll suitable for large industrial applications, using thinner materials and reducing manufacturing time and complexity.
Implementation Method 1
the second teeth being welded on in the corresponding slots of the aforementioned casing
Data Source
Figure 1~3c
AI summary
The invention relates, on the one hand, to an ironing roll (1) for an ironing device which is provided with a heatable chest, the ironing roll (1) being provided with a casing, and the ironing roll (1) comprising one or more reinforcement elements (3a, 3b, 3c) which are provided to be connected to the casing and which extend, once connected to this casing, within the casing, the aforementioned reinforcement elements (3a, 3b, 3c) being provided to be releasably connected to the casing. On the other hand, the invention relates to an ironing device, comprising an ironing roll with a casing and a heatable chest, the ironing device comprising an ironing roll (1) according to the invention.