This is a national stage of PCT application No. PCT/FI00/00885, filed on Oct. 10, 2000. Priority is claimed on that application and on patent application No. 19992214 filed in Finland on Oct. 13, 1999.
The present invention relates to a calender for surface-treating a moving web of paper or board.
The invention also relates to a construction suited for mutual mounting of calender rolls.
Different types of calenders are used for improving the smoothness and surface profile of manufactured sheet of paper or board. One of the concurrent calender types is the soft-nip calender comprising at least two calender nips operating in succession along the sheet travel, whereby each nip is formed by a soft roll and a hard roll mounted to rotate on each other. Today, the soft roll is generally surfaced with a polymer coating, while the hard roll is a heatable roll made from cast iron. The different types of rolls are mounted as an alternating succession in a vertical stack thus forming successive nips, whereby either side of a running web travels alternately over a soft roll, a hard roll and so on, thus making both sides of the sheet maximally equal after the surface-treatment. The calender rolls, particularly the soft roll, undergo wear during the use, thereby invoking a need of scheduled replacement. Today, two different techniques of roll replacement are used. In one arrangement, the old roll with its bearing housings is elevated away from its operating position by means of an overhead hoist. Herein, either the upper roll must always be removed before the lower roll can be replaced or, alternatively, the roll stacks must be askewed from a vertical plane in order to facilitate a sideways obliquely performed lifting of the lower roll away from its normal position under the upper roll. Also in vertically aligned roll stacks it is possible to implement the removal of the lower roll to take place in a sideways direction by first shifting the lower roll laterally away from under the upper roll. In this type of a construction, the frame of the calender stack must be open at least in the direction of the lower roll removal.
When the construction is such as to allow the lower roll to be removed only after the removal of the upper roll, the roll replacement operation becomes extremely clumsy, particularly if the upper roll is a heatable roll, as is the case inevitably always for the second nip, because the roll connections such as those of the heating medium circulation must be disconnected during the removal of the roll. In a roll replacement system with a sideways shifting arrangement of the rolls, sufficient free space must be reserved for the movement of either roll. Such servicing space for roll replacement requires more footprint about the calender. As the roll diameters in modern papermaking machines are large, the headroom for roll replacement may be as large as two meters per roll and, since a calender always has at least two calender nips, the need of lateral footprint may be up to four meters for a two-nip calender. Obviously, this kind of roll mounting is not possible in such machinery rebuild operations wherein a soft-nip calender must be fitted to replace an outdated machine calender. During machinery rebuild, it may be necessary to relocate various units of the papermaking machinery and increase the length of the machine, which is expensive. Also in new factory projects, a machine of a larger overall length increases costs due to larger footprint, among other factors. Another drawback of a large lateral roll change space is that the web must travel as open draw over the roll change space, because this portion of machinery cannot be equipped with auxiliary devices. Long, open web draws increase the risk of web breaks and complicate web tail threading.
It is also possible to replace the lower roll of a calendar nip by way of elevating the upper roll apart from the lower roll and then moving the lower roll with its bearing housings aside supported by a roll transfer carriage, whereupon the roll can be replaced. This arrangement is hampered by the large lateral space required about the roll and its need for a dual set of roll handling equipment, whereby the lift must be complemented with at least two transfer carriages, which makes this construction costly.
Attempts have been made to reduce the space requirement of the calender in the machine direction of the web travel by way of, e.g., locating the calender frames of two successive roll nips, the frames having one open side, in a back-to-back disposition of the frames by their closed sides, whereby the web travel between the successive nips is maximally minimized. While this arrangement needs a smaller layout footprint, a problem arises from the roll replacement operations that now must be performed on opposite sides of the calender frame thus still needing as much roll change headroom as in any other conventional calender.
Other objects and features of the present invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are intended solely for purposes of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims.
It is an object of the present invention to provide an entirely novel type of calender construction capable of overcoming the problems of the prior art techniques described above.
The goal of the invention is achieved by way of disposing two successive calender nips so that the mutual distance between the lower rolls of the successive nips is smaller than the mutual distance between the upper rolls of the nips, whereby the rolls of the nips as seen from their ends are disposed in a V-shaped configuration.
Herein, the calender rolls can be connected to each other by means of pull rods adapted to connect the roll bearing housings to each other, whereby the connections to the auxiliary devices of the roll may be adapted into the roll stack so as form an integrated auxiliary equipment assembly.
The invention offers significant benefits.
By virtue of the invention, it is possible to gain a substantial reduction in the footprint occupied in the machine direction by a calender such as a soft-nip calender or the like comprising a plurality of separate roll nips.
The invention also facilitates a simple replacement of the lower rolls. The calender framework becomes extremely uncomplicated and lightweight, because the roll bearing housings are connected to each other so that the nip forces are not transmitted to the framework. Now, since the calender framework is relieved from high forces imposed thereon by the roll nips, also the calender foundations are not subjected to high stresses. Hence, a calender according to the invention is aptly suited for machine rebuilds intended, e.g., to improve the quality of the manufactured product with the help of a more efficient calender. A calender according to the invention may even be fitted to replace a single-stack machine calender in places where prior-art calender constructions could not necessarily be squeezed onto the footprint left free by a dismantled two-stack machine calender. Furthermore, the length of open web draws remains short and the number of guide rolls is smaller than in conventional calender constructions. The bearing housings of any roll pair forming a nip are connected to each other by techniques that in an uncomplicated and precise manner give the required roll fixing force also for the upper rolls, and there are provided transfer and support means for the auxiliary devices operating between the calender nips so as to permit the displacement of these devices for the time the lower rolls are being replaced. The fluid, electrical and other connections of the rolls and their auxiliary means are concentrated at the roll ends and enclosed therein, whereby the connections have enough headroom so that there is no need to disconnect them from the rolls being replaced. It is even possible to design the entire calender into an integrated unit that can be shipped to a customer and rapidly mounted on site as a replacement of an existing calender or as a part of new machinery being erected.
In the following, the invention will be examined with the help of exemplifying embodiments and by making reference to the appended drawings in which
Referring to
In the embodiment of
In the embodiment of
In
For changing the rolls, the calender according to the invention is complemented with some auxiliary means. The bearing housings 4, 5 of the upper rolls 11, 13 are mounted on guides 24 which are fixed to the frames 21 and 22 and along which the bearing housings can be slidably elevated upward away from their superimposed location above the bearing housings 3, 6 of the lower rolls 12, 14. Obviously, the guides 24 may be replaced by any other similar guidance means. The intervening units between the calender nips, such as rolls, a steam box, measurement equipment or other possible auxiliary devices can be advantageously combined into an integrated assembly 23 that is mounted to the upper roll bearing housing 5 by aligning the assembly with a keyed connection and then fixing it in place by means of bolts. Alternatively, the assembly with its auxiliary devices can be mounted on the lower roll bearing housing. In the exemplifying embodiment shown in
In this calender embodiment, the change of the upper rolls 11, 13 can be made simply by using a lift for elevating the roll away from its operating position above the lower roll bearing housing. The lower rolls 12, 14 are changed by way of disconnecting the bearing housings from each other and then lifting the upper rolls 11, 13 upward along the guides 24. Next, the bearing housings 3, 6 of the lower rolls 12, 14 are detached from the frames 21, 22, whereupon the rolls can be transferred by a lift away from the lift area remaining between the calender nips 1, 2. Prior to the lifting of the lower rolls and, advantageously, before the bearing housings are detached, the auxiliary equipment assembly 23 is detached and lowered down to keep it clear from the transfer path of the lower rolls. Obviously, the installation of a new roll takes place in a reverse order. To assure fast roll replacement, it is essential to have the connections of the upper rolls 11, 13 and the auxiliary equipment assembly 23 implemented with such dimensioning rules that these units need not be dismantled when these units must be moved aside.
In
The lower roll is replaced as follows. First, the auxiliary equipment assembly 23 situated in front of the nip is detached from the bearing housings 5, 6 and is lowered below the lower roll without any need to dismantle its connections, whereupon the bearing housings 5, 6 can be disconnected from each other. The upper roll is elevated upward under the guidance provided by the guide surfaces 24 formed on the frame 22 and is locked in place by way of, e.g., pushing a pin 36 either manually or by actuator means through the holes made to the upper part of the frame 22 and the upper part of the bearing housing 5. Resultingly, the upper roll remains resting on the pin supported by the bearing housing 5 so that the lower edge of the bearing housing 5 leans against the frame 22. The connections of the upper roll must be designed such that they permit lifting the roll into its locked position during roll change without any need for dismantling the connections. Hereafter, the lower roll bearing housings 6, as well as the connections of the roll and the mechanical drive shaft thereof, are detached from the frame 22. If there are any auxiliary devices located in front of the lower roll, such as a cleaning doctor, the auxiliary devices are rotated aside clear of the roll change transfer path either manually or using powered actuators. Subsequently, the lower roll with its bearing housings 6 can be elevated away from the area remaining between the roll nips. Obviously, the installation of a new roll takes place in a reverse order.
As mentioned earlier, the present invention relates to calender constructions in which the bearing housings of the calender rolls are connected to each other. The required nip force as well as the opening and closing of the nip are implemented by means of a mechanism acting on a deflection-compensated roll; whereby the calender frame receives only a minimal portion of the reactive forces resulting from the actuation of the nip pressure. To achieve a fast and reliable roll change and, above all, easy installation of a new roll, the connection of bearing housings to each other must be designed to be uncomplicated and such that it gives a sufficiently large and very accurately correct nip force. Obviously, the embodiment must also assure an accurate alignment of the bearing housings.
In
In
The connecting force imposed by the pull rods is easy to control to a desired value inasmuch the force generated by a contracting rod can be readily computed. The pull rod is advantageously made from steel whose thermal expansion coefficient is known precisely. Obviously, the rod may be made from any other material of a sufficiently high strength, whereby the above-mentioned locking members 31, 32, 33 can be replaced by nuts having a thread compatible with those made to the rod ends or, alternatively, other locking means can be used capable of accurately positioning the rod in its longitudinal axis direction. Instead of using a heater element, the rod may be heated by other methods such as an oven or a heating bath, but this technique requires a rapid installation sequence during which the rod may not cool down. The electrical heater element can be mounted in a permanent or removable manner.
In addition to the exemplifying embodiments described above, different modifications may be contemplated without departing from the spirit of the invention. While only a soft-nip calender is discussed above as an example of calender types, the invention can as well be applied to all such calenders that include at least two calender nips formed by two rolls. The angle between the inclined roll stacks, that is, the V-angled disposition between the adjacent roll stacks can be varied, however, not making the angle smaller that what is necessary to ensure unobstructed removal of the lower roll from below the upper roll. The required tilt angle between the rolls stacks is determined by such factors as the outer dimensions of the rolls and their bearing housings. Typically, a line drawn through the centers of the upper roll and the lower roll is inclined by 15° in regard to the vertical plane. The number of calender nips may be greater than two, whereby each two calender nip pairs needs two roll change spaces and so upward according to the increasing number of calender nips. The number of rolls in a single assembly of nips may also be larger, whereby a typical arrangement is to use three rolls in a stack. The bearing housings of the calender may be mounted using fixing means different from those described above.
The pull rod arrangement according to the invention is also applicable to single-nip calenders. These types of calenders include, e.g., low-gloss calenders and machine calenders, wherein the peripheral devices of the roll are advantageously integrated into an auxiliary equipment assembly in the manner described above.
Thus, while there have been shown and described and pointed out fundamental novel features of the present invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices described and illustrated, and in their operation, and of the methods described may be made by those skilled in the art without departing from the spirit of the present invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Substitutions of elements from one described embodiment to another are also fully intended and contemplated. It is also to be understood that the drawings are not necessarily drawn to scale but that they are merely conceptual in nature. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.
Number | Date | Country | Kind |
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19992214 | Oct 1999 | FI | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/FI00/00885 | 10/12/2000 | WO | 00 | 4/10/2002 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO01/27389 | 4/19/2001 | WO | A |
Number | Name | Date | Kind |
---|---|---|---|
3270664 | Veneman et al. | Sep 1966 | A |
3584570 | Sass et al. | Jun 1971 | A |
4211165 | Schill | Jul 1980 | A |
4375188 | Leiviskä | Mar 1983 | A |
4915026 | Halme | Apr 1990 | A |
5850785 | Vallius | Dec 1998 | A |
Number | Date | Country |
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2117970 | Apr 1995 | CA |
44 34 509 | Apr 1995 | DE |
0 666 367 | Aug 1995 | EP |