Suction Roll Sensor Embedding and Drilling Sequence
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Solution Overview
Problem
Suction rolls in papermaking machines face challenges in integrating pressure and temperature sensors due to the drilling of holes, which can damage the sensors and disrupt their positioning, and existing solutions may not be optimal for all roll covers.
Innovation Solution
A sensing system with sensors embedded in the polymeric cover of the roll, featuring apertures through which through holes extend, and centering members to maintain sensor position, along with a two-segment lead routing path and optional counterbores or conductive mesh leads to enhance signal quality and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sensors are embedded in the polymeric cover prior to drilling holes, then sensor positioning can be controlled, but the drilling process will damage the sensors and signal carrier
Solution Approach 1:
The patent segments the hole formation process into two distinct stages: (1) forming recesses in the polymeric cover at sensor locations using a first drilling operation, and (2) forming through-holes in the metallic shell at non-sensor locations using a second drilling operation. This segmentation allows sensors to be embedded in the cover first, then recesses are drilled around them, preventing damage to sensors and signal carrier while maintaining precise positioning.
2Stability of the object's composition
If holes are drilled after the polymeric cover is applied and cured, then the cover structure is complete, but the drilling will damage embedded sensors and signal carrier
Solution Approach 1:
The patent applies preliminary action by forming recesses in the polymeric cover before drilling the through-holes in the metallic shell. The recesses are created at the sensor locations while the sensors are already embedded in the cover, establishing a protective cavity that prevents subsequent drilling operations from damaging the sensors or signal carrier.
3Loss of information
If optical fiber is used as signal carrier, then signal transmission is achieved, but the minimum bending radius requirement makes routing between holes difficult
Solution Approach 1:
The patent extracts the signal carrier routing problem from the constrained space between holes by extending the through-holes through the polymeric cover to exposed locations on the outer surface. This allows the optical fiber signal carrier to be routed externally along the surface of the roll rather than being forced to navigate tight bends between internal holes, eliminating bending radius constraints and simplifying the routing path.
4Adaptability or versatility
If the polymeric cover shifts during curing, then manufacturing flexibility is maintained, but sensor and signal carrier positions become unpredictable
Solution Approach 1:
The patent implements feedback by using alignment markers positioned on the metallic shell that are visible through the polymeric cover during the drilling operation. These markers provide real-time positional reference information, allowing the drilling equipment to adjust and compensate for any cover shift that occurred during curing, thereby maintaining precise hole placement relative to sensor locations despite manufacturing variations.
Data Source
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AI summary
An industrial roll, comprising: a substantially cylindrical shell having an outer surface and an internal lumen; a polymeric cover circumferentially overlying the shell outer surface, wherein the shell and cover have a plurality of through holes that provide fluid communication between the lumen and the atmosphere; and a sensing system comprising: a plurality of sensors embedded in the cover, the sensors configured to sense an operating parameter of the roll and provide signals related to the operating parameter, wherein at least some of the sensors include an aperture, and wherein some of the through holes of the cover extend through respective apertures of the sensors; a plurality of centering members inserted through the apertures of the sensors and into the through holes, each of the centering members having an internal bore that permits fluid communication between the lumen and the atmosphere; and a processor operatively associated with the sensors that processes signals provided by the sensors.