Web Handling System with Dynamic Dancer Rollers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-speed production printers face challenges in handling print media due to curling and browning issues when printing stops, as existing dancer roller mechanisms fail to address these problems effectively.
Innovation Solution
A web handling system with dual dancer rollers and a stationary dryer roller configuration that moves the web forward and backward after printing stops, and engages/disengages rollers during printing and stopping to prevent curling, along with independent dancer rollers that maintain web tension and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a dancer roller mechanism is used to buffer the web and maintain web tension during printing, then web handling stability is improved, but curling and browning occur when printing stops due to isolated heat exposure
Solution Approach 1:
The dancer roller mechanism is made dynamically controllable, transitioning between engaged and disengaged states based on printing operation status. During printing, the mechanism engages to maintain web tension and stability. When printing stops, the mechanism disengages to prevent the web from contacting heated rollers, thereby eliminating curling and browning while preserving handling stability during active printing.
Solution Approach 2:
The system performs preliminary action by detecting the stop condition of the printing operation and proactively disengaging the dancer roller mechanism before significant heat exposure occurs. This preventive measure ensures the web is removed from the heated roller contact zone in advance, preventing curling and browning while maintaining stability during the printing phase.
2Stability of the object's composition
If the dancer roller mechanism remains engaged to maintain web tension, then web handling is stable, but the web continues to contact heated rollers causing curling when printing stops
Solution Approach 1:
The dancer roller mechanism transitions from a static engaged state to a dynamic state that can disengage when printing stops. This dynamic control allows the system to maintain web tension and stability during printing by keeping the mechanism engaged, while preventing heat-induced curling by disengaging the mechanism when the printing operation ceases, thus eliminating continuous roller contact.
3Temperature
If the web is cooled during printing using dancer rollers, then web temperature is reduced, but curling occurs when printing stops due to temperature variation
Solution Approach 1:
The dancer roller mechanism is dynamically controlled to disengage when printing stops, preventing the web from contacting heated rollers that cause temperature variations and subsequent curling. During printing, the mechanism remains engaged to allow controlled cooling through web movement, while preventing harmful thermal effects during idle periods.
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
Prevents curling and browning of the print media by minimizing exposure to isolated heat and maintaining web tension, ensuring smooth handling and processing even after printing cessation.
Implementation Method 1
a stationary roller to cure ink on a printed side of a web of a print medium
Implementation Method 2
A dryer, installed downstream from the printer, may assist in drying the wet ink on the web after the web leaves the printer
Data Source
AI summary
A web handling system is disclosed. The web handling system includes first dancer rollers coupled to engage and move a web of a print medium in a forward and backward direction upon stopping a printing operation and allow forward motion during the printing operation.