Synchronized Feed Rolls Without Gear Backlash for Sheet Handling
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Solution Overview
Problem
Existing sheet material feeding apparatuses face issues with accuracy and maintenance costs due to gear backlash and wear, as well as the need for high-capacity motors to lift rolls, and slow speed adjustments in air-supplied systems.
Innovation Solution
A sheet material feeding apparatus with synchronized motor-driven rolls, a vertically movable roll support, and an eccentric cam system that allows for precise control and adjustment of roll position without gears, using elastic members to reduce inertial forces and horizontal runout, and a control device for synchronized rotation and speed control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gears are used to transmit driving force from the first drive motor to the second feed roll, then the second feed roll can be driven in conjunction with the first driven feed roll, but gear backlash deteriorates stopping accuracy of the second feed roll and causes deterioration of accuracy of feed length
Solution Approach 1:
The patent replaces the mechanical gear transmission system with an electronic control system. Two independent drive motors (first drive motor and second drive motor) directly drive the first and second rolls respectively, without mechanical connection. A control device coordinates the operation of both motors to achieve synchronized rotation, eliminating gear backlash and wear while maintaining synchronization reliability.
Solution Approach 2:
The control device serves multiple functions: it independently controls the first drive motor and second drive motor, coordinates their rotation speeds to maintain synchronization, and adjusts the second roll's position. This multi-functional control approach replaces the specialized gear transmission mechanism while achieving the same synchronization goal without its drawbacks.
2Reliability
If gears are used to transmit driving force, then the second feed roll can be driven in conjunction with the first driven feed roll, but teeth of drive gear and driven gear wear over time causing backlash to increase and requiring large maintenance costs
Solution Approach 1:
The patent eliminates the mechanical gear transmission system entirely, replacing it with electronically controlled independent motors. This substitution removes the wear-prone gear teeth that require lubrication and maintenance, while the electronic control system maintains synchronization reliability without mechanical contact between moving parts.
Solution Approach 2:
The independent motor system with electronic control requires no external lubrication or mechanical maintenance. The control device automatically coordinates the motors to maintain synchronization, and the system is self-sufficient without requiring periodic gear lubrication or tooth inspection that would be necessary with mechanical gear systems.
3Ease of operation
If the force generating actuator lifts the movable roll support to release the workpiece, then the workpiece can be released from between the rolls, but a motor with large capacity is required as the force generating actuator
Solution Approach 1:
The patent separates the drive function and the release function into independent systems. The drive function is handled by the two independent motors that directly drive the rolls, while the release function is achieved by independently controlling the motors to stop rotation, allowing the workpiece to be released without requiring a separate high-capacity lifting actuator.
Solution Approach 2:
The workpiece clamping and release is achieved through periodic control of the drive motors. The motors rotate to clamp and feed the workpiece, then stop rotation to release it. This periodic on-off control of the drive motors provides the clamping and release function without requiring a continuously operating high-capacity lifting actuator.
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 solution achieves high-speed, high-accuracy sheet material feeding with reduced maintenance costs, improved accuracy, and the ability to clamp or release materials synchronously with processing operations, using a smaller motor capacity and eliminating gear wear.
Implementation Method 1
elastic members to reduce inertial forces and horizontal runout
Implementation Method 2
a cam piston that is movable horizontally as well as engaging with the cam bearing so as to move the roll support member vertically when the cam piston moves horizontally
Implementation Method 3
an eccentric cam that rotates so as to move the cam positon horizontally; and in that the eccentric cam is configured to perform an adjustment of a rotation thereof including a stop of rotation halfway
Data Source
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AI summary
A sheet material feeding apparatus includes a first roll 106, and a second roll 108 arranged vertically below first roll 106, to feed a sheet material clamped between the first roll 106 and the second roll 108. The sheet material feeding apparatus further includes a first motor 102 provided with a rotatable first motor shaft 104 coupled to the first roll 106, and a second motor 103 provided with a rotatable second motor shaft 105 coupled to the second roll 108. The first motor shaft 104 and the second motor shaft 105 rotate at substantially the same rotation speed to allow the first roll 106 and the second roll 108 to rotate in synchronization with each other.