Roller Gap Pressure Mapping for Wide-Range Line Force Control
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Solution Overview
Problem
Existing devices for adjusting line force in the working gap of rollers with hydraulically deflection-controllable and pneumatically actuated rollers are limited by the working ranges of pneumatically/hydraulically acting ratio controllers, restricting the operational range and accuracy of line force correction.
Innovation Solution
Storing hydraulic pressures corresponding to pneumatic pressures in a data memory and using electro-pneumatic proportional valves to control the actuation, eliminating the need for pneumatic/hydraulic ratio controllers, and incorporating a pneumatically/hydraulically acting overflow valve for improved pressure control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pneumatic/hydraulic ratio controllers are used to control hydraulic pressure based on pneumatic pressure, then line force correction is achieved, but the working range is limited and the device cannot be operated in the entire linear force range
Solution Approach 1:
The patent replaces the mechanical pneumatic/hydraulic ratio controller with an electronic data storage system (EPROM) that stores pre-calculated pressure relationships. This substitution eliminates the mechanical limitations of the ratio controller while maintaining control accuracy through electronic memory and retrieval of pressure data across the entire working range.
Solution Approach 2:
The patent changes the control parameter from mechanical ratio-based pressure control to electronic data-based pressure control. By storing hydraulic pressure values corresponding to various pneumatic pressure values in the EPROM, the system can access any pressure combination within the full working range, overcoming the limited operating range of mechanical ratio controllers.
2Force
If the working gap is reduced to increase line force, then squeezing effect is improved, but the device complexity increases due to limited working range of ratio controllers
Solution Approach 1:
The patent replaces the complex mechanical ratio controller system with a simpler electronic data storage and retrieval system. The EPROM stores the relationship between pneumatic and hydraulic pressures, eliminating the need for complex mechanical ratio control mechanisms while achieving the desired line force across the entire working range.
3Manufacturing precision
If hydraulic pressure is increased to correct fish-belly profile, then uniform squeezing across web width is achieved, but the working range of ratio controllers is exceeded
Solution Approach 1:
The patent changes from mechanical ratio-based pressure control to electronic data-based pressure control. The EPROM stores hydraulic pressure values that correspond to various pneumatic pressure values, allowing the system to maintain precise pressure relationships for uniform squeezing across the entire operational range without being constrained by mechanical ratio controller limitations.
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 treatment of materials over a larger line force range with enhanced line force error correction, allowing for uniform squeezing across the web width and improved operational flexibility.
Implementation Method 1
controlling at least one electro-pneumatic proportional valve for actuating the device for adjusting the rollers
Implementation Method 2
a rotating roller shell is supported hydraulically on a crosshead passing through the roller shell
Implementation Method 3
A pneumatically actuated device is provided for closing the working gap, the pinch pressure required for the respective application being set by specifying the pneumatic actuating pressure
Data Source
Figure 1
Figure 2
AI summary
In a method for setting the linear force in the working gap of a pair of rollers which comprises at least one roller that can be hydraulically controlled in terms of its deflection and a pneumatically actuated device for adjusting the rollers, in which method the setting of the linear force is performed by presetting a pneumatic actuating pressure and adapting the hydraulic pressure in the sense of minimizing the linear force error, the hydraulic pressure values that are assigned to the pneumatic pressure values for the entire working spectrum of the pair of rollers (3) are stored in a data memory (15) and are used for activating at least one electro-pneumatic proportional valve (19, 19') to actuate the device for adjusting the rollers (1, 2) and for activating a hydraulic source (34) providing the hydraulic actuating pressure for the at least one roller that can be controlled in terms of its deflection.