Segmented Braking Rollers for Filter Rod Pneumatic Conveying
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Solution Overview
Problem
Existing conveyor devices for filter rods in the tobacco processing industry face issues with operational reliability and gentle treatment, particularly due to the transfer of kinetic energy between filter rods during braking, leading to undefined speeds and wear of resilient elements in passive braking systems.
Innovation Solution
The implementation of a receiving device with two pairs of braking rollers, where the first pair is upstream of the second pair, both pairs having the same peripheral speed, ensuring simultaneous engagement and gentle deceleration, and potentially using suction rollers for effective speed imposition, thereby reducing wear and increasing service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single pair of braking rollers is used to brake filter rods, then the device complexity is reduced, but the operational reliability deteriorates due to undefined speeds when filter rods collide during braking
Solution Approach 1:
The braking device is segmented into two pairs of braking rollers (first pair and second pair) arranged in sequence in the conveying direction. This segmentation allows the filter rod to be braked in stages, with each pair providing a controlled braking action. The first pair reduces the speed of the incoming filter rod, and the second pair provides additional braking to ensure the filter rod reaches a defined speed before entering the acceleration device, thereby eliminating speed undefinedness and improving operational reliability.
2Ease of manufacture
If resilient elements are used in passive braking devices, then the braking action is simple, but the service life deteriorates due to wear of the resilient elements
Solution Approach 1:
The invention replaces the passive resilient elements with an active braking system using two pairs of driven braking rollers. Instead of relying on resilient elements that wear out, the braking action is achieved through controlled rotation of the braking rollers at specific speeds. This mechanical substitution eliminates the wear problem associated with resilient elements while maintaining effective braking functionality, thereby extending the service life of the braking device.
3Speed
If filter rods are braked with high speed reduction, then the braking effectiveness is improved, but the gentleness of treatment deteriorates causing potential damage to filter rods
Solution Approach 1:
The braking process is segmented into two stages using two pairs of braking rollers. The first pair performs initial speed reduction from the high incoming speed, and the second pair completes the braking to reach the defined speed. This staged approach distributes the speed reduction across multiple contact points, preventing sudden high-force impacts that could damage the filter rods while still achieving effective braking.
Solution Approach 2:
The first pair of braking rollers acts as a cushioning stage before the second pair. By reducing the speed in the first stage, the kinetic energy of the filter rod is partially dissipated, so that when the filter rod contacts the second pair, the remaining energy is lower. This beforehand cushioning prevents excessive force application that could damage the filter rods while maintaining braking effectiveness.
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 configuration ensures safe, gentle, and efficient transport of filter rods by maintaining defined speeds and reducing wear, thus enhancing operational reliability and extending the service life of the braking device.
Implementation Method 1
a braking device that brakes the filter rods... the braking device comprising two pairs of braking rollers
Implementation Method 2
an acceleration device that accelerates the filter rods... an acceleration device that accelerates the filter rods in the longitudinal axial conveying direction
Implementation Method 3
conveyor device for transporting filter rods in the tobacco processing industry that are conveyed with compressed air
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a receiving device (15) of a conveying device (1, 2) for transporting filter rods (6 - 6") conveyed by compressed air for the tobacco processing industry, wherein the receiving device (15) comprises a braking device (31, 32) that decelerates the filter rods (6 - 6") and an acceleration device (33) that accelerates the filter rods (6 - 6"), the acceleration device (33) being arranged downstream of the braking device (31, 32) in a conveying direction (17) of the filter rods (6 - 6"). The invention is characterized in that the braking device (31, 32) comprises at least two braking devices configured to actively decelerate the filter rods. Furthermore, the invention relates to a corresponding method for conveying filter rods (6 - 6") conveyed by compressed air for the tobacco processing industry.