Heated Roller Fabrication
Weather you call them heated rollers or chill rollers they are interchangeable during fabrication. A heated roller is attached to a heat unit that sends a hot fluid, usually hot oil, into the spiral baffled roller that is engineered to turn that hot oil into a consistent temperature profile across the face of the roll. In the case of a chill roll, which includes the same style spiral baffled inner wrappings and engineered to provide the maximum chilling performance to the surface of the outer shell of the roll.
For this discussion we will call them heated rollers. We look at a design of a heated roller and work with the customer to determine the parameters required for their process. Parameters are what the substrate requirements of the process are. Usually the roll speed and wrap angle tells us where we want to go. Now engineers look at a fabrication design and enter all these parameters from multiple disciplines into powerful software called Computational Fluid Dynamics (CFD). CFD uses thermal and fluid dynamics while incorporating Chemical Engineering, Motion Sciences, and Metallurgical Principals all into one complex engineering equation. This generates a crystal clear result of what how the roll will perform in the equipment it is being run.
Changes can then be made to the heated roller by changing internal wrap angles of spirals. Roll size can be increased or decreased as well. Then by entering these changes into the CFD equation will demonstrate how the temperature is going to change across the roll face. Fluid flow rate, turbulence data, fluid pressure are the sub factors are responsible for changing the heated roller output of temperature across the face of the roll.
Benefits of CFD in Heated Roller Design
- A complete color coded map of the outer roll surface
- Accuracy and certainty the roll will perform correctly
- “Just right design” helps keep pumps and heaters from being oversized when they are not needed
- Productivity increase as the roll can keep up its necessary output
Today heated rollers can be designed to eliminate over engineering or eliminate some rolls completely which translates into tremendous savings for converting machinery costs. Save forever on operating costs with fewer heated rollers. Heat transfer rollers that are designed properly save money in original cost and increased production efficiency. Forever put an end to the “Too Much” or “Not Enough” dilemma !