U-Shaped Frame Connector for Roller Press Weight Reduction
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Solution Overview
Problem
High-pressure roller presses face challenges with heavy machine frames that complicate handling, transportation, and maintenance, particularly in areas with limited infrastructure, necessitating a reduction in weight and complexity while maintaining stability.
Innovation Solution
A U-shaped connecting element is used between top and bottom frame elements to manage forces, eliminating the need for bolts, rivets, and screws, allowing for a one-piece design with welded connections, and incorporating rails for bearing movement to facilitate easier assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the machine frame is made heavy to ensure stability and withstand high forces, then the stability and load-bearing capacity are improved, but the handling and transportation become more difficult
Solution Approach 1:
The machine frame is divided into separate components (first frame element, second frame element, and connecting elements) that can be manufactured and transported independently. These segmented parts are assembled on-site to form the complete stable structure, allowing each component to be lighter and easier to handle while maintaining overall frame stability when assembled.
Solution Approach 2:
The connecting elements are designed with specific geometric configurations (such as triangular or rectangular cross-sections) that provide structural rigidity through dimensional geometry rather than relying solely on material thickness. This allows for optimized weight distribution and structural efficiency, reducing overall frame weight while maintaining stability.
2Strength
If traditional connection methods (bolts, rivets, screws) are used in the machine frame, then the structural strength is improved, but the manufacturing complexity and weight increase
Solution Approach 1:
The connecting elements are designed as integrated components that combine multiple functions into a single piece. These elements merge the roles of structural support, connection, and reinforcement into unified components, eliminating the need for separate bolts, rivets, or screws. The integrated design reduces the number of parts and assembly steps while maintaining connection strength through optimized geometric forms.
Solution Approach 2:
The connecting elements utilize composite construction techniques combining different materials or material layers to achieve optimal strength-to-weight ratio. This may include using high-strength alloys in critical load-bearing sections and lighter materials in less stressed areas, or employing composite material structures that provide both strength and reduced complexity.
3Productivity
If the machine frame is designed as a single integrated piece, then the manufacturing efficiency is improved, but the maintenance and repair become more difficult
Solution Approach 1:
The machine frame is segmented into modular components that can be independently manufactured, transported, and assembled. This modularity allows for faster on-site assembly compared to monolithic construction while enabling easier maintenance and repair by allowing access to and replacement of individual components without dismantling the entire frame structure.
Solution Approach 2:
The frame design incorporates adjustable and reconfigurable connecting elements that can be dynamically assembled or disassembled based on operational needs. This dynamic design allows the frame to be quickly configured during manufacturing and easily adjusted or repaired during maintenance operations, balancing manufacturing efficiency with maintenance accessibility.
4Productivity
If the connecting element uses welded connections only, then the production speed increases, but the ease of maintenance decreases
Solution Approach 1:
The connecting elements are designed as separate, standardized components that can be pre-fabricated using welded connections for efficient production, then assembled using simpler connection methods on-site. This segmentation allows the high-speed welded manufacturing of individual components while enabling easier assembly and maintenance through the modular nature of the segmented design.
Solution Approach 2:
The connection method is optimized by changing the parameters of the connecting elements themselves - designing them with features that allow for rapid assembly and disassembly mechanisms. This may include incorporating interlocking geometric features, standardized fastening interfaces, or other design modifications that enable quick maintenance operations while the components themselves can be efficiently manufactured through welding.
Data Source
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AI summary
The invention relates to a machine frame (20) for a high-pressure roller press (10) for receiving the rollers (31, 32) in the bearings (33, 34, 35, 36) of said press, comprising at least one first frame element (41) below the rollers (31, 32), at least one second frame element (42), wherein at least one connecting element (43, 44) is provided for connecting the at least one first frame element (41) to the at least one second frame element (42). According to the invention, the at least one connecting element (43, 44) has a U-shaped design forming two limbs (45, 46, 47, 48). As a result, the frame can be designed with smaller dimensions and in one piece, because no releasable connections are necessary in said configuration of the machine frame. Said design saves weight and makes handling easier.