Thin Film Roll Gap Control Using Counterweight and Gravity
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Solution Overview
Problem
Existing thin film member forming devices using hydraulic servo actuators face instability in roll gap control, particularly when the load applied to the rolls is insufficient, leading to backlash and difficulty in maintaining a stable gap, especially when the rolls are vertically arranged or during power failures.
Innovation Solution
A thin film member forming device with a roll gap adjusting mechanism and a roll opening mechanism, where the rolls are arranged with rotation axes parallel to each other at an angle between 0° and 90°, allowing for precise control of the gap by adding loads to narrow or expand it using the self-weight of the movable roll and the bearing, and an auxiliary mechanism to bypass hydraulic fluid flow during power failures, ensuring the rolls can be opened to prevent resin accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a hydraulic servo actuator is used to adjust the roll gap, then the roll gap can be controlled with high precision, but the control becomes unstable when the pressing load is insufficient
Solution Approach 1:
The invention introduces a counterweight mechanism that applies a predetermined load to the movable roll in the vertical direction. This counterweight compensates for insufficient pressing load during horizontal roll gap adjustment, preventing servo pump reversal and backlash. The counterweight ensures the servo actuator operates within its stable control range while maintaining precise roll gap control capability.
Solution Approach 2:
The invention applies a preliminary load through the counterweight mechanism before actual roll gap adjustment begins. By pre-loading the movable roll vertically, the system ensures sufficient pressing force is available during subsequent horizontal adjustment operations, eliminating the instability that occurs when load is insufficient.
2Device complexity
If the rolls are arranged vertically to utilize self-weight for pressing, then the structure is simplified, but the hydraulic servo actuator cannot maintain stable control due to load fluctuations
Solution Approach 1:
The invention separates the vertical load-bearing function from the horizontal gap adjustment function. The counterweight handles vertical loading while the servo actuator focuses on horizontal positioning. This segmentation allows each component to optimize its specific function without interference from load fluctuations in the other direction.
Solution Approach 2:
The counterweight mechanism provides a stable predetermined vertical load that compensates for the instability caused by vertical roll arrangement. This counterbalancing force ensures the servo actuator receives consistent loading conditions during horizontal adjustment, maintaining control stability despite the simplified vertical structure.
3Adaptability or versatility
If the servo pump operates in reverse to adjust the roll gap when load is insufficient, then the roll gap can be adjusted, but backlash occurs and control stability is lost
Solution Approach 1:
The counterweight prevents the servo pump from needing to reverse by providing sufficient preliminary vertical load. This unidirectional operation eliminates backlash in the servo mechanism while maintaining full adjustment capability through controlled horizontal movement of the movable roll.
Solution Approach 2:
By applying preliminary vertical load through the counterweight before adjustment operations, the system ensures the servo pump operates only in the forward direction during gap adjustment. This preliminary loading prevents reverse operation and associated backlash, maintaining manufacturing precision throughout the adjustment range.
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
The solution stabilizes the roll gap adjustment and ensures continuous operation by maintaining the necessary load for forming thin films, even when the rolls are vertically arranged, and allows for prompt opening during power failures to prevent damage from resin accumulation.
Implementation Method 1
the hydraulic servo actuator adjusts the roll gap in the following manner... the piston rod of the cylinder is pressurizing the rolls
Implementation Method 2
adding a load in a direction to expand the gap to the second bearing, according to a pressing force towards the reference roll produced by self weights of the movable roll and the second bearing
Data Source
AI summary
A thin film member forming device includes a reference roll fixedly disposed while being rotatably supported by a first bearing member, a movable roll disposed movably with respect to the reference roll while being rotatably supported by a second bearing member, a roll gap adjusting mechanism which adjusts a gap between the reference roll and the movable roll and a roll opening mechanism which expands the gap. The roll gap adjusting mechanism adds a load in a direction to narrow the gap to the second bearing member, and the roll opening mechanism adds a load in a direction to expand the gap to the second bearing member.