Technical Roll Polymer Fiber Sensor Retrofit
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Solution Overview
Problem
Existing roller systems in the paper industry face complexity in manufacturing and retrofitting sensors, which are costly and difficult to integrate during real-time operation, especially due to high thermal loads and the inability to retrofit existing rollers with sensors.
Innovation Solution
A technical roller design featuring an empty tube that can be retrofitted with a polymer fiber sensor, allowing for easy installation of a sensor system after the roller's manufacture, using a polymer-based optical fiber to record parameters like temperature and pressure, and a detection device for data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are permanently integrated into the roller during manufacturing, then parameter detection capability is achieved, but manufacturing complexity increases and thermal stress during coating application becomes very high
Solution Approach 1:
The sensor system is segmented into separate components: the empty tube is integrated into the roller during manufacturing, while the polymer fiber sensor is installed separately afterward. This segmentation allows the roller to be manufactured without complex sensor integration, reducing manufacturing complexity while maintaining parameter detection capability.
Solution Approach 2:
The empty tube is prepared in advance during roller manufacturing, creating a pre-configured pathway for later sensor installation. This preliminary action enables simple integration of the detection system without requiring complex modifications during the coating application process, avoiding thermal stress on sensors.
2Reliability
If sensors are permanently integrated into the roller during manufacturing, then parameter detection capability is achieved, but the ability to retrofit existing rollers with sensors is lost
Solution Approach 1:
By separating the tube structure from the sensor component, the system allows existing rollers to be retrofitted with sensors through simple insertion into the pre-formed empty tube, without requiring complex integration procedures or specialized manufacturing processes.
3Ease of manufacture
If the empty tube is arranged outside the roller core, then production cost is reduced, but the distance from the roller surface increases
Solution Approach 1:
The polymer fiber sensor utilizes optical principles (light transmission and reflection) rather than mechanical contact, allowing accurate parameter detection even when positioned in the empty tube outside the roller core. This eliminates the need for the sensor to be in direct contact with the roller surface while maintaining measurement precision.
4Measurement precision
If the empty tube has a small inner diameter to fit the polymer fiber tightly, then parameter detection precision improves, but the difficulty of inserting the polymer fiber increases
Solution Approach 1:
The empty tube is designed with flexible material properties that allow it to be slightly expanded during polymer fiber insertion, then contract to provide tight contact for precise measurement. This flexibility resolves the contradiction between easy insertion and precise detection.
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 simplifies the manufacturing process, enables cost-effective production, and allows for the retrofitting of sensors, improving parameter recording and data transmission while reducing the risk of damage to the sensor during installation.
Implementation Method 1
a polymer fiber to be inserted into the empty tube. Such a polymer fiber serves as a sensor for detecting various parameters, particularly temperature and pressure
Implementation Method 2
a detection device that is designed to couple light into the polymer fiber and to detect reflected light from the polymer fiber as a measured value
Data Source
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AI summary
The invention relates to a technical roll, in particular for paper manufacturing, having an elongate roll core (12) and at least one first covering (14) which is provided on the roll core (12), wherein an empty duct (20, 22) is provided, which is suitable for receiving a polymer fibre (30) and extends over the length of the roll (10) such that the polymer fibre can be introduced at one end of the empty duct. The invention also relates to a technical roll having a polymer fibre and to a method for introducing the polymer fibre into an empty duct. The invention lastly relates to the use of a polymer-based optical waveguide as a sensor in a technical roll.