Web Guide Steering Roller with Two Degrees of Freedom
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Solution Overview
Problem
Existing guide systems fail to simultaneously control the transverse position and angular orientation of a moving web, particularly for wide, thin webs, leading to positioning errors and wrinkles.
Innovation Solution
A web guide apparatus with a steering roller that has two degrees of freedom, allowing it to pivot and translate, combined with an array of position sensors and actuators to accurately control the web's lateral position and angular orientation using a general solution for lateral dynamics, enabling precise positioning and orientation control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a passive guide system (crowned roller or tapered roller with flange) is used, then the transverse position of the web can be controlled, but the web edge buckles or wrinkles develop because the system cannot effectively control wide, thin webs
Solution Approach 1:
The patent transitions from static passive guide rollers to a dynamic active guide system where the positioning roller can move laterally in response to real-time web position feedback. The roller mount includes a motor-driven positioning mechanism that dynamically adjusts the roller position to correct web deviations without contacting the web edge, thereby preventing buckling and wrinkles while maintaining precise transverse control.
2Manufacturing precision
If a typical active guide system with single-degree-of-freedom positioning is used, then transverse position control can be achieved, but angular orientation of the web cannot be controlled at the same location
Solution Approach 1:
The patent extends the control system from one degree of freedom (lateral position only) to two degrees of freedom by adding angular orientation control. The positioning roller mount incorporates both lateral translation capability and rotational capability, allowing independent control of web position and angle at the same location through coordinated actuation of the positioning mechanism.
3Manufacturing precision
If multiple positioning guides are used to control both position and angle, then control capability is improved, but device complexity increases with multiple guides and zero-backlash mechanisms
Solution Approach 1:
The patent consolidates multiple functions into a single multi-functional positioning roller assembly. The roller simultaneously performs transverse positioning and angular orientation control through its two-degree-of-freedom mount, eliminating the need for separate positioning guides and complex zero-backlash mechanisms while achieving the same control objectives with reduced system complexity.
Data Source
AI summary
An apparatus for steering a web, including a web path having at least one steering roller and an exit roller, each having a mount; wherein the steering roller(s) each have an axis of rotation and wherein the mounts for the steering roller(s) can pivot those axes with a total of two degrees of freedom. An array comprising a plurality of sensors for monitoring the position of the web is present connected to a controller so as to determine the position and angular orientation of the web. The controller adjusts the pivot(s) of the mount(s) so as to control the angular orientation and the lateral position of the web at a particular point along the web path.