FEEDROLL STRIPPER

FIELD OF THE DISCLOSURE

The present disclosure relates to devices and methods for material transport in a production process.

BACKGROUND

In a production process, a feedroll assembly is used to feed material into a downstream production element, such as a granulator or mill. A motor drives rollers in the feedroll assembly that aid in transporting the material to the downstream production element. The speed at which the rollers are driven may be varied to change the rate at which material is output from the feedroll assembly. Additionally, a distance between the rollers may be varied to accommodate different thicknesses of material. Together, the speed and distance of the rollers controls the rate of material fed into the downstream production element.

BRIEF DESCRIPTION OF THE DRAWINGS

Objects, features, and advantages of the present disclosure will become apparent upon reading the following description in conjunction with the drawing figures, in which:

FIG. 1 shows a side view of a feedroll assembly with a fixed stripper and a movable roller in a first position.

FIG. 2 shows a side view of the feedroll assembly of FIG. 1 with the movable roller in a second position.

FIG. 3 shows a side view of an improved feedroll assembly having a movable roller assembly with a stripper.

FIG. 4 shows an isometric view of the improved feedroll assembly of FIG. 3.

FIG. 5 shows an exploded view of the improved feedroll assembly of FIG. 3.

FIG. 6 shows an isometric view of the movable roller assembly of FIG. 3.

FIG. 7 shows an exploded view of the movable roller assembly of FIG. 6.

FIG. 8 shows a guide slot of the improved feedroll assembly of FIG. 3.

FIG. 9 shows the movable roller assembly of the improved feedroll assembly of FIG. 3 in a first position.

FIG. 10 shows the movable roller assembly of the improved feedroll assembly of FIG. 3 in a second position.

FIG. 11 shows a view of the improved feedroll assembly of FIG. 3 arranged within a production system.

FIG. 12 shows a flowchart of a method of operating the improved feedroll assembly of FIG. 3.

DETAILED DESCRIPTION

Various example embodiments will now be described more fully with reference to the accompanying drawings in which only some example embodiments are shown. Specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments, however, may be embodied in various different forms, and should not be construed as being limited to only the illustrated embodiments. Rather, the illustrated embodiments are provided as examples so that this disclosure will be thorough and complete, and will fully convey the concepts of this disclosure to those having ordinary skill in the art. Accordingly, known processes, elements, and techniques, may not be described with respect to some example embodiments. Unless otherwise noted, like reference characters denote like elements throughout the attached drawings and written description, and thus descriptions will not be repeated. The present invention, however, may be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.

It will be understood that, although the terms first, second, and the like may be used herein to describe various elements, components, regions, layers, and/or sections, these elements, components, regions, layers, and/or sections, should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments of the present disclosure. As used herein, the term “and/or,” includes any and all combinations of one or more of the associated listed items. The phrase “at least one of” has the same meaning as “and/or”.

Spatial and functional relationships between elements (for example, between modules) are described using various terms, including “connected,” “engaged,” “interfaced,” and “coupled.” Unless explicitly described as being “direct,” when a relationship between first and second elements is described in the above disclosure, that relationship encompasses a direct relationship where no other intervening elements are present between the first and second elements, and also an indirect relationship where one or more intervening elements are present (either spatially or functionally) between the first and second elements. In contrast, when an element is referred to as being “directly” connected, engaged, interfaced, or coupled to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between,” versus “directly between,” “adjacent,” versus “directly adjacent,” and the like).

When an element is referred to as being “on,” “connected to,” “coupled to,” “adjacent to,” or “proximate to” another element, the element may be directly on, connected to, coupled to, adjacent to, or proximate to the other element, or one or more other intervening elements may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” “directly coupled to,” “directly adjacent,” or “immediately adjacent to” another element there are no intervening elements present.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments of the disclosure. As used herein, the singular forms “a,” “an,” and “the,” are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the terms “and/or” and “at least one of” include any and all combinations of one or more of the associated listed items. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Expressions such as “at least one of,” when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list. Also, the term “exemplary” is intended to refer to an example or illustration.

When a component, device, element, or the like of the present disclosure is described as having a purpose or performing an operation, function, or the like, the component, device, or element should be considered herein as being “configured to” meet that purpose or to perform that operation or function.

This disclosure provides a feedroll assembly having a movable roller assembly with stripper. This disclosure also provides a system and method that utilize the disclosed movable roller assembly.

In one example of a production process or material transport system, upstream material, such as a sheet of polymer or other production material, is passed to an input of the feedroll assembly. In one instance, the material may be a waste stream from the production process. In another instance, the material may be original bulk material. The feedroll assembly receives the material and transports it through an output of the feedroll assembly to a downstream production element, such as a granulator, mill, shredder, or any other variation of a size reduction machine, including another feedroll system. A granulator, for example, may break down the material so that the material may be recycled. Other downstream production elements are possible.

In many instances, feedroll assemblies may have at least two rollers that material is fed between as the material passes through the feedroll assembly to downstream production elements. Material passing through a feedroll assembly may adhere or stick to one or more of the rollers. In some cases, the material may wrap around a roller and create a jam in the feedroll assembly. A device (a stripper, blade, scraper, and the like) may be positioned near one or all of the rollers to prevent this wraparound problem. The stripper stops the material from wrapping around the roller and guides the material through an output of the feedroll assembly.

In some cases, one roller of the feedroll assembly may be fixed (i.e., stationary relative to a housing of the feedroll assembly) and another roller may be movable. The distance between the rollers may be varied, for example, based on a thickness of the material to pass between the rollers or a feed rate through the feedroll assembly (i.e., the rate at which the material is fed between the rollers and through the feedroll assembly). The distance between the rollers may be adjusted by moving (e.g., translating) one roller (the movable roller) away from another roller (the fixed roller). In one case, as described in more detail below with regard to FIGS. 1 and 2, the stripper adjacent the movable or moving roller is fixed in the feedroll assembly. In this case, as the moving roller moves, the distance between the rollers changes, as does a distance between the moving roller and the fixed stripper. As the distance between the fixed stripper and the moving roller increases, the material is more likely to bypass the stripper, wraparound the roller, and jam the feedroll assembly.

To address the above problems, the stripper corresponding to the moving roller may move in addition to the roller, such that the distance between the moving roller and the associated stripper may be maintained. In one example, the moving roller and stripper may move together and have a fixed relationship. The moving roller and the stripper may be secured to a common chassis that moves both elements together. In this case, the moving roller and stripper secured to a common chassis may be referred to as a movable roller assembly. In another example, the movable roller and stripper are independently movable and/or controllable.

It is to be understood that elements and features of the various representative embodiments described below may be combined in different ways to produce new embodiments that likewise fall within the scope of the present teachings.

FIG. 1 shows a side view of a feedroll assembly 100. The feedroll assembly 100 includes a first roller 102 and a second roller 104. Material may be inserted into the feedroll assembly 100 and pass between the first roller 102 and the second roller 104 in a downstream direction (e.g., the direction of arrow A). The first roller 102 may rotate but otherwise is fixed to an enclosure or housing 118 of the feedroll assembly 100. The second roller 104 may rotate and translate relative to the housing 118. As shown in FIG. 1, the second roller 104 is in a first position, where the second roller 104 is proximate or positioned closely (i.e., directly adjacent) to the first roller 102. A rotational surface of the first roller 102 and/or the second roller 104 may contact the material and advance the material through the feedroll assembly 100.

The feedroll assembly 100 may include a first stripper 106 and a second stripper 108. The first stripper 106 and second stripper 108 may be located adjacent or proximate to the rotational surface of the first roller 102 and second roller 104, respectively. The first stripper 106 may be secured to the housing 118 by a first securing member 110, and the second stripper 108 may be secured to the housing 118 by a second securing member 112. While the feedroll assembly 100 is in use (e.g., as material is being fed into the feedroll assembly 100), the first securing member 110 and the second securing member 112 hold the first stripper 106 and the second stripper 108, respectively, in place on the housing 118. In other words, the first and second securing members 110, 112 secure the first and second strippers 106, 108 to the housing, either directly or indirectly.

An actuator 114 (such as a linear actuator) may be fixed to the housing 118. The actuator 114 may be coupled directly or indirectly to the second roller 104 (e.g., via one or more elements disposed between the actuator 114 and the second roller 104). A horizontal or lateral position of the second roller 104 may be set and adjusted by the actuator 114.

A motor 116 may be coupled directly or indirectly to the first roller 102 and/or the second roller 104 (e.g., by a transmission, gearing, or other elements disposed therebetween) and may be configured to drive rotation of the first roller 102 and/or the second roller 104. The motor 116 may be coupled or secured to the housing 118.

FIG. 2 shows the second roller 104 in a second position different from the first position shown in FIG. 1. By operation of the actuator 114, the second roller 104 may move between the first position shown in FIG. 1 and the second position depicted in FIG. 2, or to an intermediate position between the first position and the second position. When the second roller 104 is in the first position, the second roller 104 is proximate to the first roller 102. When the second roller 104 is in the second position, the second roller 104 is spaced apart from the first roller 102. By changing the position of the second roller 104, the distance between the first roller 102 and the second roller 104 is also changed. The distance may be changed so that the feedroll assembly 100 may accommodate material of different thickness.

Additionally or alternatively, the distance may be changed during operation of the feedroll assembly 100 (e.g., by changing the position of the second roller 104 with the actuator 114) to control or accommodate, for example, the feed rate of material into a downstream production element (e.g., a granulator) or to respond to a changing thickness of material input to the feedroll assembly 100 (e.g., due to upstream changes in the production process). However, in the embodiment of FIGS. 1 and 2, because the second stripper 108 is fixed to the housing 118 by the second securing member 112, the second stripper 108 remains stationary while the second roller 104 translates between positions.

As a result, in positions other than fully closed (i.e., the first position), there is a distance or separation between the second stripper 108 and the second roller 104. When the distance or gap between the second stripper 108 and the second roller 104 increases or expands, the material input to the feedroll assembly 100 is more likely to bypass the second stripper 108, wraparound the second roller 104, and jam the feedroll assembly 100.

FIGS. 3, 4, and 5 show a side view, an isometric view, and an exploded view, respectively, of an improved feedroll assembly 200. The feedroll assembly 200 may be part of a production or manufacturing system (e.g., a material handling or transport system within a factory). The feedroll assembly 200 may perform material handling and advancement of production media through the production/manufacturing system.

The feedroll assembly 200 includes a first roller 202 and a second roller 204. Material input to the feedroll assembly 200 passes between the first roller 202 and the second roller 204 in a downstream direction (e.g., the direction of arrow A of FIG. 3). The first roller 202 may rotate but otherwise is fixed to an enclosure or housing 218 of the feedroll assembly 200. The second roller 204 may also rotate, but is movable in relation to the housing 218. In this regard, the first roller 202 and the second roller 204 are both rotatably coupled to the housing 218. A rotational surface of the first roller 202 and/or the second roller 204 may contact the material and advance the material through the feedroll assembly 200 to downstream production or manufacturing components.

The feedroll assembly 200 may include a first stripper 206 and a second stripper 208. The first stripper 206 and second stripper 208 may be located adjacent or proximate to the rotational surface of the first roller 202 and second roller 204, respectively. The first stripper 206 may be secured to the housing 218 by a first securing member 210. While the feedroll assembly 200 is in use (e.g., as material is being fed into the feedroll assembly 200), the first securing member 210 holds the first stripper 206 in place on the housing 218.

The feedroll assembly 200 may include a support structure or chassis 220, as shown and described in more detail below with regard to FIGS. 4 and 7. The chassis 220 may be slidably coupled to the housing 218. The chassis 220 may be translatable relative to the first roller 202 that is fixed to the housing 218. The second roller 204 may be rotatably coupled to the chassis 220. The second stripper 208 may be fixedly coupled to the chassis 220. The second roller 204, which is rotatably coupled to the chassis 220, translates with translation of the chassis 220. As a result, the second roller 204 is translatable relative to the first roller 202. In this regard, the second roller 204 is movable independently of the first roller 202 via a translation of the chassis 220 between different positions within the housing 218. In a first position, the second roller 204 may be disposed proximate or adjacent to the first roller 202. As shown in FIGS. 3 and 4, the second roller 204 is in a second position, where the second roller 204 is spaced apart from the first roller 202.

Additionally, the second stripper 208 is secured or coupled to the chassis 220, such that a surface of the second stripper 208 is adjacent to a surface of the second roller 204. In this way, the second stripper 208 is configured to be secured in a static relationship relative to the second roller 204 that is rotatably coupled to the chassis 220. The second stripper 208, the second roller 204, and the chassis 220 may collectively be part of a movable roller assembly 230 and are shown together in FIGS. 4, 6 and 7, discussed below. By way of the static relationship between the second roller 204 and the second stripper 208, movement of the chassis 220 effecting a change in the distance between the first roller 202 and the second roller 204 (e.g., during operation of the feedroll assembly 200) does not result in a change in a distance between the second roller 204 and the second stripper 208. The chassis 220 maintains the fixed relationship between the second roller 204 and the second stripper 208. Moving the second roller 204 and second stripper 208 in this way allows for accommodating variations in material thickness. This type of translation also allows the second stripper 208 to maintain proximity to the second roller 204 to prevent thinner cross section materials from wrapping around the second roller 204 and causing jams, while also helping to guide the material to the discharge end (i.e., output) of the feedroll assembly 200.

Referring to FIGS. 4 and 7, in one embodiment, the chassis 220 may include a frame portion 222, side or end plates 224, and at least one support gusset 225. In one example, the frame portion 222 may include two support beams or support plates 223 extending along the direction of the second roller 204 between two side or end plates 224, where each side or end plate 224 is located proximate to respective ends of the second roller 204. In this example, two support gussets 225 may span between the two support plates 223 to connect and stabilize the two support plates 223. While two support plates 223 and two support gussets 225 are shown in the Figures, an additional number of support plates 223 and support gussets 225 may be used. In one example, a single support gusset 225 may be used. The support plates 223 may be connected, coupled, or affixed to the side or end plates 224 and support gussets 225 in any number of ways, such as by welding or fastening using nuts and bolts, screws, rivets, and the like. In one instance, all the components of the chassis 220, including the frame portion 222 (i.e., the two support plates 223), the end plates 224, and the support gussets 225 may be integrally formed as one unit.

The second stripper 208 may be fixedly coupled to the frame portion 222 of the chassis 220. More specifically, the second stripper 208 may be fixedly coupled to a support plate 223 of the frame portion 222. The second stripper 208 may be sized to correspond to the size of the support plate 223. For example, the second stripper 208 and the support plate 223 may be the same length, such that both extend along the length of the second roller 204 between the side or end plates 224. In one case, the second stripper 208 may be fixedly coupled to the chassis 220 in one or more positions. The second stripper 208 may be fixed to the frame portion 222 of the chassis 220 in a first position with a first distance between the second roller 204 and the second stripper 208. The second stripper 208 may additionally or alternatively be fixed to the frame portion 222 of the chassis 220 in a second position with a second distance between the second roller 204 and the second stripper 208. The second stripper 208 may be fixed in the first position or the second position based on a thickness of material input to the feedroll assembly 200 or a dimension or extent of the second stripper 208. For example, as the second stripper 208 experiences wear and deterioration over time from operation of the feedroll assembly 200, the second stripper 208 may be fixed in a different position to maintain a desired static relationship between the second stripper 208 and the second roller 204 during operation of the feedroll assembly 200.

As shown in FIG. 7, one or more second securing members 212 (a bolt, screw, rivet, fastener, etc.) may fixedly couple or otherwise secure the second stripper 208 to a support plate 223 of the frame portion 222 of the chassis 220. In one case, the support plate 223 provides for, is dimensioned for, or otherwise is configured for the second securing members 212 to fix the second stripper 208 to the support plate 223 in the first position and/or the second position. The support plate 223 may, in one example, include one or more voids, recesses, cavities, or spaces through which the second securing members 212 are at least partially disposed. In one case the support plate 223 includes a single space configured to allow a second securing member 212 to fix the second stripper 208 in the first position and/or the second position. Additionally or alternatively, the support plate 223 may include a plurality of spaces configured to allow the second securing members 212 to fix the second stripper 208 in the first position and/or the second position.

Referring to FIG. 5, the first roller 202 and second roller 204 are shown in an exploded view, separated from the housing 218, actuator 214, and motor 216. As shown in FIG. 5, the feedroll assembly 200 further includes drive components 215, such as drive sprockets/pulleys/gears/wheels and a belt, that drive the rotation of the first roller 202 and second roller 204. Other drive components may be used to rotate the first and second rollers 202, 204.

FIG. 6 shows an isometric view of the movable roller assembly 230. As shown in FIG. 6 and described above in connection with one embodiment, the location of the second stripper 208 may be adjusted so that the second stripper 208 is just touching the second roller 204 (e.g., the surface of the roller). The second securing members 212 may be tightened to secure the second stripper 208 in this arrangement.

Referring to FIG. 7, the movable roller assembly 230 may also include a roller drive assembly 300 coupled to the second roller 204. The roller drive assembly 300 may be in communication with the motor 216 and be configured to allow the second roller 204 to rotate by way of the motor 216. As shown in FIG. 7, the movable roller assembly 230 may have a roller drive assembly 300 located at each end of the second roller 204. In one example, the, or each, roller drive assembly 300 may include a roll hub 302, ring drive 304, bushing 306, and end plate 308. In one embodiment, the roll hub 302 and second roller 204 may be press fit together. Other types of connection are possible. As shown in FIG. 7, the ring drive 304, bushing 306, and end plate 308 may be coupled together, and also coupled to the roll hub 302, using screws, bolts, or other types of fasteners. In this regard, the second roller 204 is coupled or secured to the chassis 220 by way of the roller drive assembly 300.

As shown in FIG. 7, the side or end plates 224 have a proximate end 224a and a distal end 224b opposite the proximate end 224a. The proximate end 224a may be substantially U-shaped and configured to receive or otherwise engage a respective roller drive assembly 300, discussed above. The distal end 224b may include a portion having a hole or opening therein. The hole or opening may be configured to accommodate a linkage bushing and/or a guide pin 227, discussed below.

As shown in FIG. 8, the housing 218 may include one or more guide slots 226. The guide slots 226 may be a void, a recess, a cavity, or a space disposed in the housing 218 or a component of the housing 218. The movable roller assembly 230, including the chassis 220, may be slidably coupled to the housing 218 via the guide slots 226 and configured to translate along the guide slots 226. As shown in FIG. 8, the housing 218 may include a first guide slot 226a and a second guide slot 226b. In one example, the chassis 220 is slidably coupled to the housing 218 via the first guide slot 226a by way of a first guide pin 227a and the second roller 204 is slidably coupled to the housing 218 via the second guide slot 226b by way of a second guide pin 227b. The first guide pin 227a and second guide pin 227b are sized appropriately to be accommodated in the first guide slot 226a and second guide slot 226b, respectively. The first guide pin 227a may be a protruding member that protrudes outward from a surface of the chassis 220 into the first guide slot 226a. In some cases, the first guide pin 227a may be a bolt with a nut/washer combination at the end. The second guide pin 227b may also be a bolt with a nut/washer combination that protrudes from the roller drive assembly 300 at the end of the second roller 204. While shown in the figures as bolts, other types of guide pins 227 are possible. In another example, take-up bearing assemblies (e.g., set of take-up bearings moveable along a rail system) may be used in conjunction with the first and second guide slots 226a, 226b to accommodate movement of the movable roller assembly 230.

By following or sliding along the guide slots 226, the movable roller assembly 230, including the chassis 220, the second roller 204, and the second stripper 208, moves relative to the first roller 202. In one example, both of the guide slots 226 are linear. In another example, the first guide slot 226a is arcuate and the second guide slot 226b is linear. Other guide slot 226 shapes are possible. Together, the guide slots 226 and guide pins 227 facilitate stability of the movable roller assembly 230 through its linear motion (i.e., translation). In one embodiment, the first guide slot 226a and second guide slot 226b may be combined to form a single continuous guide slot 226 having an arcuate portion to accommodate the first guide pin 227a and a linear portion to accommodate the second guide pin 227b.

Referring to FIG. 9, an actuator 214 (such as a linear electronic, hydraulic, or pneumatic actuator) may be fixed to the housing 218. The actuator 214 may be coupled directly or indirectly to the second roller 204 (e.g., via one or more elements disposed between the actuator 214 and the second roller 204, such as the chassis 220). A horizontal or lateral position of the second roller 204 may be set and adjusted, as discussed above, by the actuator 214. As shown in FIG. 9, the movable roller assembly 230 is in a first position, where the second roller 204 is proximate to the first roller 202.

Also as shown in FIG. 9, a motor 216 may be coupled directly or indirectly to the first roller 202 and/or the second roller 204 (e.g., by a transmission, gearing, or other elements disposed therebetween, such as the drive components 215 discussed above) and drive rotation of the first roller 202 and/or the second roller 204. The motor 216 may be coupled or secured to the housing 218, either directly or indirectly.

FIG. 10 shows the movable roller assembly 230 in a second position different from the first position shown in FIG. 9. As discussed above, the movable roller assembly 230, including the chassis 220, may move relative to the first roller 202 that is fixed to the housing 218. When the movable roller assembly 230, including the chassis 220, is in the first position, the movable roller assembly 230, and thus the chassis 220, is proximate to the first roller 202. When the movable roller assembly 230, including the chassis 220, is in the second position, the movable roller assembly 230, and thus the chassis 220, is spaced apart from the first roller 202. Because the second roller 204 and the second stripper 208 are secured to the chassis 220, movement of the chassis 220 (e.g., from the first position to the second position, from the second position to the first position, or to another position between the first position and the second position) causes a corresponding movement of the second roller 204 and the second stripper 208. The movable roller assembly 230 may be set or adjusted to any position between the first position shown in FIG. 9 (fully closed position) and the second position shown in FIG. 10 (fully open position).

FIG. 11 illustrates a view of the improved feedroll assembly 200 of FIG. 3 arranged within a system 400, such as a production or manufacturing system. The system 400 includes an improved feedroll assembly 200, an actuator 214, and a motor 216. The feedroll assembly 200 of the system 400 of FIG. 11 may include a first roller 202 coupled to a housing of the feedroll assembly 200. The first roller 202 of the feedroll assembly 200 may be designed and configured the same as the first roller 202 disclosed and described above with regard to FIGS. 3 and 4.

The system 400 also includes a movable roller assembly 230. The movable roller assembly 230 may be designed and configured the same as the movable roller assembly 230 disclosed and described above with regard to FIGS. 3-10. For example, the movable roller assembly 230 may include a chassis 220, a second roller 204 coupled to the chassis 220, and a stripper coupled to the chassis 220, such that a surface of the stripper is adjacent to a surface of the second roller 204. The movable roller assembly 230 may be slidably coupled to the housing and translatable relative to the first roller 202. The chassis 220, second roller 204, and stripper may be designed and configured the same as the chassis 220, second roller 204, and second stripper 208 disclosed and described above with regard to FIGS. 3-10.

The system 400 also includes an actuator 214 configured to adjust a position of the movable roller assembly 230. The system 400 also includes a motor 216 configured to adjust rotation of the first roller 202 and the second roller 204. The actuator 214 and motor 216 may be designed and configured the same as the actuator 214 and motor 216 disclosed and discussed above with regard to FIGS. 3, 5, 9, and 10.

In one embodiment, the second roller 204 is movable independently of the first roller 202 via a translation of the movable roller assembly 230. In other words, the movable roller assembly 230 may be movable between a first position and a second position. When the movable roller assembly 230 is in the first position, the second roller 204 is proximate to the first roller 202, as shown in FIG. 11. When the movable roller assembly 230 is in the second position, the second roller 204 is spaced apart from the first roller 202.

In one embodiment, the stripper of the movable roller assembly 230 may be configured to be secured in a static relationship relative to the second roller 204. For example, the chassis 220 of the movable roller assembly 230 may include a frame portion, where the stripper is fixedly coupled to the chassis 220 by the frame portion. In this regard, the stripper maintains its proximity to the second roller 204 to prevent materials from wrapping around the second roller 204 and causing jams inside the feedroll assembly 200.

The system 400 may also include at least one a guide slot disposed in the housing of the feedroll assembly 200. In one embodiment, the movable roller assembly 230 is slidably coupled to the housing via the guide slot and configured to translate along the guide slot. In one example, the housing of the feedroll assembly 200 may include two guide slots. In this example, one guide slot may be arcuate, and one guide slot may be linear, where the arcuate guide slot is configured to receive or accommodate a guide pin coupled to the chassis 220 and where the linear guide slot is configured to receive or accommodate a guide pin coupled to the second roller 204. The guide slot or slots, including the arcuate guide slot and the linear guide slot, as well as the guide pins, may be designed and configured the same as the first guide slot 226a, the second guide slot 226b, the first guide pin 227a, and the second guide pin 227b disclosed and discussed above with regard to FIG. 8. As discussed above, take-up bearing assemblies may be used to allow for translation of the movable roller assembly 230.

The system 400 of FIG. 11 may also include a first process element 402 upstream of the feedroll assembly 200 and a second process element 404 downstream of the feedroll assembly 200. FIG. 11 shows a view of the feedroll assembly 200 arranged with the first (i.e., upstream) process element 402 and the second (i.e., downstream) process element 404. In one example, the upstream or first process element 402 may be a manifold. The upstream process element 402 may feed material into the feedroll assembly 200. In other words, material may be input into the feedroll assembly 200 from the first process element. In one example, the upstream process element 402 receives the material from another process element such as a cutter or press.

In another example, material to be processed can also be fed from a roll that was collected from a manufacturing process. The roll can either be pulled in by the feedroll assembly 200 itself or assisted by a roll feeding mechanism that rotates the roll of material at a variable rate to limit slipping and stress of the feedroll assembly 200. The disclosed movable stripper design is advantageous with deep draw plastic items, such as containers and cups, since the rollers need to translate to such an extreme degree to accommodate these items.

The downstream or second process element 404 receives the material from the feedroll assembly 200. In other words, the material is output from the feedroll assembly 200 to the second process element 404. The downstream process element 404 may be, for example, a granulator or grinder. The rate at which the material is input to the downstream process element 404 may be controlled by adjusting the speed at which the first roller 202 and the second roller 204 rotate. The rotational speed of the first roller 202 and second roller 204 may be controlled by varying an output of the motor 216. For example, a variable frequency drive (VFD) motor controller may be used. Changing gearing ratios may also be used to adjust the feedroll feed rate of material into the downstream process elements 404 for particular applications.

The distance between the first roller 202 and the second roller 204 may be controlled by the actuator 214 translating the movable roller assembly 230, including the chassis 220. In this way, the downstream process element 404 may operate at an efficient setpoint (e.g., such as a setpoint rotational speed) while the material feed is controlled by the feedroll assembly 200. Disposing the stripper on the chassis 220 (e.g., so that the second roller 204 and the stripper maintain a fixed relationship) reduces the likelihood that material clings, adheres, or sticks to the second roller 204 and thereby accumulates in the feedroll assembly 200. As a result, the production process may be operated for a longer time without stopping to perform maintenance on the feedroll assembly 200. In this way, the efficiency of the production process increases.

FIG. 12 shows a flowchart of a method of operating a feedroll assembly. The method of FIG. 12 may be implemented using the feedroll assembly 200 described above. In other embodiments, a different feedroll assembly may be used. For example, the method of operating a feedroll assembly may be used with a feedroll assembly 200 having a housing 218, a first roller 202 rotatably coupled to the housing 218, a support structure 220 slidably coupled to the housing 218 and movable relative to the first roller 202, a second roller 204 rotatably coupled to the support structure 220, and a stripper 208 coupled to the support structure 220, such that the second roller 204 and the stripper 208 move together with movement of the support structure 220. The acts of FIG. 12 may be implemented in the order shown but may be implemented in or according to any number of different orders. For example, act S103 may be performed prior to act S101. Additional, different, or fewer acts may be provided. For example, act S107 may be optional or omitted.

In act S101, production media is received at an input of the housing 218. The production media may be received from an upstream process element 402.

In act S103, the support structure 220 is moved based on a size of the production media. The movement of the support structure 220 is relative to and independent from the first roller 202. In this regard, the second roller 204 is movable independently of the first roller 202 via the movement of the support structure 220.

In act S105, the first roller 202 and/or the second roller 204 are rotated. The production media advances through the feedroll assembly 200 by the rotation of the rollers 202, 204.

In optional act S107, a rotational speed of the first roller 202 or the second roller 204, and/or the movement of the support structure 220 is changed or adjusted. The change or the adjustment of the rotational speed and/or the movement may be based on the size of the production media. The rotational speed and/or the movement may determine a feed rate of the production media into the downstream process element 404.

In act S109, the production media is output to a downstream process element 404.

The improved feedroll assembly described above allows movement of at least one roller relative to another roller to accommodate different size materials and to adjust or accommodate a feed rate into downstream production elements. The improved feedroll assembly also allows a stripper (blade, scraper, and the like), corresponding to the movable roller, to move along with, or in conjunction with, the movable roller to maintain a close proximity (i.e., be adjacent to) the movable roller. Allowing for movement of the stripper corresponding to the movable roller results in the stripper being able to perform its function of preventing material from sticking or adhering to the movable roller regardless of the position of the movable roller.

While one embodiment described above allows for this movement of the stripper by having the stripper and movable roller be coupled to a common chassis or support structure, other embodiments for allowing stripper movement are possible. For example, it was mentioned above that the movable roller and stripper may be independently movable and/or controllable. In this case, the movable roller and stripper may not be part of, or coupled to, the same movable component. For instance, in another embodiment, the rollers and strippers may be essentially the same as those shown and described above with regards to FIGS. 1 and 2, except that the second stripper 108 may also be independently movable. In this example, the second securing member 112 may allow for movement of the second stripper 108, such that when the second roller 104 moves away from the first roller 102, the second securing member 112 is adjusted based on the movement of the second roller 104 to maintain a close proximity between a surface of the second stripper 108 and a surface of the second roller 104.

In another embodiment, the movable roller and corresponding stripper may be connected or coupled without the use of the disclosed chassis or support structure. For instance, a stripper may be directly connected to the movable roller. In one example, respective ends of the movable roller and stripper may be joined together in a way that allows the movable roller to rotate while allowing the stripper to maintain its position relative to the movable roller. For example, a rod or bracket may extend from an end of the movable roller (i.e., from a middle, non-rotating portion of the roller) and attach to a respective end of the stripper, thereby securing the stripper in a static position relative the movable roller during movement and rotation.

In yet another embodiment, rather than using the actuator disclosed above to move (i.e., translate) the movable roller, other methods of moving the movable roller are possible. For example, the movable roller may be held in a first position (i.e., proximate the fixed roller, or “closed” position) by a spring force that is adjustable based on the material being fed into the feedroll assembly. In this case, as material thickness changes as material is fed between the rollers, the spring force allows the movable roller to move away from the fixed roller when material thickness increases (i.e., to a second or “open” position where the movable roller is spaced apart from the fixed roller) and then rebound or “spring” back to the first (i.e., closed) position when the material thickness decreases.

Although certain feedroll assemblies, systems, and methods have been described herein in accordance with the teachings of the present disclosure, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all embodiments of the teachings of the disclosure that fairly fall within the scope of permissible equivalents. Specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments of the present disclosure. This disclosure may, however, be embodied in many alternate forms and should not be construed as limited to only the embodiments set forth herein.

FEEDROLL STRIPPER

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