Stage Roll Cartridge Replacement for Faster Corrugator Changeover
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Solution Overview
Problem
The complexity and increased manufacturing cost of corrugating roll unit replacement systems in cardboard sheet manufacturing due to the need for multiple types of corrugating roll units and complicated structures.
Innovation Solution
A corrugating roll unit replacing apparatus with a replacement carriage that moves along guide rails, connected by a locking hook and drive device, allowing for easy removal and mounting of corrugating roll units without requiring a movement unit on the transporting carriage, thus simplifying the structure and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the stage roll unit is replaced by disassembling and reassembling multiple components, then the replacement precision can be maintained, but the replacement time increases significantly
Solution Approach 1:
The stage roll unit is divided into a cartridge component and a hub component that can be independently handled. The cartridge component contains the stage roll and bearing assembly as an integrated unit, allowing it to be replaced as a single module rather than disassembling multiple fasteners and components, thus reducing replacement time while maintaining precision through standardized interfaces
Solution Approach 2:
The bearing assembly is pre-installed onto the stage roll within the cartridge component during manufacturing or maintenance periods. This preliminary assembly means that during operational replacement, the entire pre-assembled cartridge can be quickly swapped out without needing to assemble bearing and roll on-site, significantly reducing replacement time while ensuring proper alignment and precision
2Loss of time
If the stage roll unit is designed as a single integrated component, then the replacement time is reduced, but the manufacturing complexity and cost increase
Solution Approach 1:
The stage roll unit is segmented into two main components: the cartridge (containing the stage roll and bearing assembly) and the hub. This segmentation allows each component to be manufactured and assembled separately using standard processes, reducing overall manufacturing complexity while enabling quick replacement by swapping the cartridge as a single unit, thus achieving fast replacement without excessive manufacturing complexity
Solution Approach 2:
The bearing assembly is nested within the cartridge component, which itself is attached to the hub. This nested structure allows the complex bearing and roll assembly to be contained within a simpler cartridge housing, reducing the apparent complexity during replacement operations while maintaining the integrated functionality needed for quick swapping
3Stability of the object's composition
If the stage roll unit uses multiple fasteners and components, then the structural stability is improved, but the replacement process becomes more complex and time-consuming
Solution Approach 1:
The stage roll unit is segmented such that the cartridge (containing stage roll and bearing) forms a self-contained module that attaches to the hub through a simplified interface. This segmentation maintains structural stability within the cartridge while simplifying the interface with the hub, allowing the cartridge to be replaced as a single unit without complex fastening operations, thus improving ease of operation while preserving structural integrity
Solution Approach 2:
The stage roll and bearing assembly are merged into a single cartridge component that functions as one integrated unit. This merging ensures that the structural relationship between the roll and bearing is maintained (preserving stability) while eliminating the need to handle multiple separate fasteners and components during replacement, significantly simplifying the replacement process
Data Source
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AI summary
Provided are a device and a method for replacing a stage roll unit. This stage roll unit replacement device (100) for performing work for replacing a stage roll unit (40) between a single facer (15) and a stage roll unit transporting cart (110) is provided with: a replacement cart (101) that can move in an X-direction in which the stage roll unit (40) is replaced; a moving device (102) that can move the replacement cart (101) in the X-direction; and a connection device (103) that connects the replacement cart (101) and the stage roll unit (40).