Tube Roll Assembly for Fast Axial Roll Feed Replacement
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Solution Overview
Problem
Conventional roll feeds are complex and expensive to manufacture, with rolls being bulky and difficult to replace, leading to long downtimes and inefficiencies due to their fixed configuration, which prevents simple installation or exchange of rolls.
Innovation Solution
A roll feed system with a base body and detachably connected tube rolls that can be axially removed, featuring a bearing shaft and driver for a rotationally fixed connection, allowing for easy mounting and dismounting without disassembling the entire system, reducing downtimes and improving operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rolls with fixed bearing shafts are used, then the roll structure is stable and robust, but the roll becomes bulky and difficult to replace, leading to long downtimes
Solution Approach 1:
The roll is divided into separate components: the roll body and the bearing shaft assembly. The bearing shaft can be detached from the roll body, allowing the roll body to be removed independently for replacement or maintenance without affecting the bearing shaft or requiring complete disassembly of the roll feed system.
Solution Approach 2:
The bearing shaft is extracted as a separate removable component from the roll body. This allows the roll body to be taken out independently for quick replacement while the bearing shaft remains in the system, eliminating the need to disassemble the entire roll feed when changing rolls.
2Stability of the object's composition
If bearing shafts are fixedly connected to the roll body, then the alignment is precise and stable, but the manufacture becomes complex and expensive requiring high precision and low tolerances
Solution Approach 1:
The roll is segmented into the roll body and bearing shaft assembly. Instead of requiring precise fixed connection of bearing shafts to the roll body, the bearing shaft is made removable through a receptacle interface. This reduces manufacturing complexity by eliminating the need for high-precision fixed connections while maintaining operational stability through proper receptacle design.
Solution Approach 2:
The connection between the bearing shaft and roll body is changed from fixed to dynamic/removable. The bearing shaft can be inserted into and removed from the roll body receptacle, providing both stability during operation and ease of replacement. This dynamic connection simplifies manufacturing by reducing tolerance requirements compared to fixed connections.
3Reliability
If the entire roll feed must be disassembled for roll replacement, then the roll structure is secure, but the downtime increases significantly
Solution Approach 1:
The roll feed system is segmented to allow independent removal of the roll body from the bearing shaft assembly. The roll body can be extracted through the receptacle without disassembling the bearing shaft or other components of the roll feed, enabling quick roll replacement while maintaining the security and integrity of the remaining system.
Solution Approach 2:
The roll body is extracted as a separate replaceable component through the bearing shaft receptacle. This allows the roll body to be removed and replaced independently without affecting the bearing shaft or requiring disassembly of the roll feed structure, significantly reducing replacement downtime while maintaining installation security.
4Reliability
If conventional rolls are used, then the drive torque transmission is reliable, but the number of suppliers is low and delivery times are long
Solution Approach 1:
The roll is segmented into the roll body and bearing shaft assembly, with the bearing shaft made removable. This simplified modular design reduces manufacturing complexity and allows different suppliers to produce compatible components, increasing the number of suppliers and reducing delivery times while maintaining reliable drive torque transmission through the bearing shaft connection.
Solution Approach 2:
The bearing shaft receptacle design allows universal compatibility between different roll bodies and bearing shaft assemblies. This standardization enables multiple suppliers to produce interchangeable components, increasing supply efficiency and reducing delivery times while maintaining reliable torque transmission through the standardized connection interface.
Data Source
AI summary
A roll feed includes a base body, a first tube roll having a rolling surface and a first bearing shaft, wherein the base body is configured to support the first tube roll and the first bearing shaft. The first bearing shaft and the first tube roll are configured to be detachably connected to each other for a rotationally fixed connection, wherein the base body is configured such that the first tube roll can be removed from the base body in an axial direction, wherein the axial direction is substantially parallel to an axis of rotation of the first tube roll.