Roller With Pneumatic Pressure Control
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Solution Overview
Problem
Existing rollers for applying contact pressure to material webs, such as in tire manufacture, face challenges in adapting to non-flat surfaces and ensuring consistent pressure distribution due to the reliance on heavy discs and complex non-stick coatings, which can fail under conditions like rubber dust interference.
Innovation Solution
A roller design featuring a hollow axle with internally controlled pneumatically or hydraulically adjustable pressure, allowing discs to move radially and apply pressure independently of gravity, using a separating layer like spring steel comb plates to transmit force effectively and prevent sticking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If heavy discs are used to generate contact pressure through gravity, then sufficient contact pressure is achieved, but the device complexity and disc weight increase
Solution Approach 1:
The patent employs a hollow roller axle with internal pneumatic or hydraulic pressure to generate contact pressure on material webs. Pressure media (gas or liquid) is introduced into the hollow axle, which then transmits this pressure radially outward to the discs, enabling contact pressure generation independent of gravity and disc weight.
Solution Approach 2:
The invention replaces the traditional gravity-based mechanical pressure generation system with a fluid pressure-based system. Instead of relying on the weight of heavy discs acting under gravity, the system uses pneumatic or hydraulic pressure to generate and control contact pressure, allowing for lighter disc construction.
2Reliability
If complex non-stick coatings are applied to prevent disc sticking, then sticking is prevented, but manufacturing complexity and cost increase
Solution Approach 1:
The patent introduces a separating layer as an intermediary between the discs and the material webs. This separating layer, which can be in the form of foil or sheet material, prevents direct contact and potential sticking between the discs and the material, as well as between adjacent discs, thereby reducing the need for complex non-stick coatings on the discs themselves.
3Adaptability or versatility
If discs are made movable radially to adapt to surface contours, then adaptability improves, but device complexity increases
Solution Approach 1:
The discs are designed to move radially on their own without complex external actuation mechanisms. The internal pressure within the hollow axle automatically causes the discs to move radially outward or inward based on the pressure level, allowing the discs to self-adjust to surface contours of the material webs without requiring additional control systems for each disc.
Solution Approach 2:
The hollow roller axle serves multiple functions: it provides structural support for the discs, contains the pressure media for generating contact pressure, and enables radial movement of the discs through internal pressure variation. This multi-functionality reduces the need for separate mechanisms for each function, thereby reducing overall device complexity.
4Ease of operation
If fixed contact pressure is used, then simplicity is maintained, but adaptability to different production parameters is reduced
Solution Approach 1:
The contact pressure is made dynamic and adjustable during operation. The internal pressure within the hollow axle can be varied by controlling the pressure media flow, allowing the contact pressure to be adjusted according to different production requirements, material types, and process parameters, transforming a static system into a dynamic one.
Solution Approach 2:
The system allows for changes in operating parameters, specifically pressure, during operation. By adjusting the internal pressure of the hollow axle, the contact pressure can be modified to suit different production conditions, material properties, and quality requirements, providing operational flexibility without requiring fundamental design changes.
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 consistent and adjustable contact pressure across varying web surfaces without relying on disc weight, reducing the risk of sticking and allowing for lighter, cheaper disc construction, thus enhancing operational flexibility and reducing material costs.
Implementation Method 1
The contact pressure of the discs can be applied or controlled pneumatically or hydraulically
Implementation Method 2
The contact pressure of the discs can be applied or controlled pneumatically or hydraulically
Implementation Method 3
The separating layer can be applied directly to the hose... in particular of spring steel comb sheet metal
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The roller (1) has a hollow roller shaft (2) at which a set of radially movable disks (3) are provided. The disks pneumatically or hydraulically exert contact pressure on a material web. The disks are controlled by internal pressure inside the roller, where the internal pressure is spatially directed towards the disks. A roller inner body has a tubular separating layer (5) surrounding a tube (4) of the body and provided between the tube and the disks. The separating layer is directly applied on the tube. Sides of the tube are closed by stoppers (6).