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1、,Low inertia carbon fiber rollers:低惯量碳纤维辊：,a big step in the performance of coating, laminating and printing machines是涂布机、覆膜机、印刷机性能上的一大进步,Why carbon fibre rollers为什么是碳纤维辊,Carbon fibre composite rollers are used since many years in many converting applications in the fields of tissue, non-woven, pape
2、r and plastic film.多年来，碳纤维复合材料辊已经在纸巾、非织造、造纸和塑料薄膜领域得到了应用。In those fields due to the line speed and the width of the web simply there is no way to use other types of material to build the rollers.They could not have sufficient mechanical characteristics to guarantee the performance of the line.在这些领域中，
3、由于卷筒纸速度和宽度原因，根本无法使用其它材质制造的辊子，因为它们没有足够的机械性能来保证生产线的整个性能指标。,Why carbon fibre rollers为什么是碳纤维辊,This is due to the unique characteristics of the carbon fiber composite which can have very high stiffness (up to twice that of steel) and very low density(5 times lower than steel).这是由于碳纤维复合材料的独特特性，它具有非常高的刚度(高
4、达钢的2倍)和极低的密度(比钢低5倍)。,500,1500,2000,2500,35003000,4000,00.00,10.00,20.00,30.00,40.00,Resistance,50.0060.00Stiffness/Weight,Steel1000alloys,Aluminum alloys,High Resistance Carbon Composites (UD),Standard Carbon Composites(UD),High Modulus Carbon Composites (UD),What is carbon fiber composite什么是碳纤维复合材料
5、,A high performance carbon fiber composite is usually composed by an epoxy matrix reinforced with many different types of carbon fibers depending from the performance requests of the component.根据不同的性能要求，高性能碳纤维复合材料通常是由不同类型的碳纤维和环氧树脂基体组成。PAN fibers聚丙烯晴基纤维High resistance and toughnessRt up to 7000 MPa E
6、 230-300 Gpa高强度和韧性抗拉强度可达7000Mpa模量230-300GpaPITCH fibers 沥青基纤维Very high modulus but fragileRt up to 3400 MPa E up to 930 Gpa非常高的模量但是很脆抗拉强度可达3400Mpa模量可达930Gpa,At least 90% of the use all over the world of carbon fibers is related to PAN fibers.全世界至少有90%的碳纤维使用的是聚丙烯腈基纤维。Nevertheless, in roller industry
7、PITCH fibers are very important since the stiffness and lightness are more interesting than resistance.然而，在辊行业中，沥青纤维是非常重要的，因为刚度和轻质特性比强度更有意义。Very long and fast rotating rollers, have a high content of PITCH fibers to increase the longitudinal elastic modulus of the whole tube up to values of nearly 3
8、00 GPa (1.5 times the steel).对于长度很长和转速很高的辊，使用高含量的沥青纤维制造，以增加整个管的纵向弹性模量，模量值高达近300 GPA（钢的1.5倍）。,Carbon rollers summary of the advantages碳辊-优势汇总,Higher speed and lower weight更高的转速和更低的重量Carbon rollers for converting machines usually have twice the critical speed of the corresponding steel rollers, with a
9、 weight that is 10-15 times lower.转换机上碳辊的临界转速通常是相应钢辊的两倍，但其重量比钢辊低10至15倍Wider formats更宽的幅度Due to the stiffness and lightness of carbon the film working formats can become wider and increase production.因为碳辊轻质高强的特性，薄膜的加工幅度可以更宽，增加产量。Lower starting time更低的启动时间Thanks to the lower inertia the plant starting
10、 time can be overwhelmingly lower with a better efficiency in production.由于惯性较低，装置启动时间可大大降低，生产效率更高Many rollers dont need to be powered很多导辊不需要动力Often metal rollers, due to the weight and lightness of the film they carry, need to be powered and controlled by complex electronic systems to avoid stretch
11、 or damages. The lightness of carbon allows to eliminate motors, electronic drivers, control systems etc. 由于所需带动薄膜的重量和轻质原因，为了避免拉伸或损坏，金属导辊通常需要由复杂的电子系统来驱动控制。碳辊的轻质就可以不需要电机、电子驱动器、控制系统等。,Carbon rollers summary of the advantages,Better precision in load cells负载单元的精度更高Dancing rollers and load cell rollers,
12、 if made of carbon fibre, form a lower tare weight. This means the actual film tension can be read with greater precision and quickness from smaller load cells.如果由碳纤维材质制成，那么摆动的辊子和负载的辊子就会形成较低的重量。也就意味着实际的薄膜张力可以通过更小的负载单元来读取更精确和更快的速度。Possibility of diameter reduction直径减小的可能性With carbon fibre the diamete
13、rs of the rollers can be reduced with many advantages in the geometrical design of the machine which can be more compact and economical.采用碳纤维可以减少导辊的直径，在机械的几何设计上具有许多优点，可以更紧凑、更经济。Reduction of surface contact减少表面接触Another advantage of smaller diameters comes by reducing the contact area between film an
14、d roller. This means there are fewer possibilities to damage the film and less interferences during its course.小直径的另一个优点是减少了薄膜和导辊之间的接触面积。这意味着损坏薄膜的可能性更小，在工作过程中受的干扰也更小。Reduction of structural loads on the machine减少机器上的结构载荷The use of carbon rollers in converting machines does not only increase working
15、speed and the width of material but reduces the loads and vibrations on the structure that can become lighter and economical with less electric power involved.在转换机器上使用碳辊不仅提高了工作速度和材料的宽度，而且减少了结构上的负荷和振动，可以在较少的电能的情况下变得更轻、更经济。,Carbon rollers in coating and laminating machines碳辊在涂布机和覆膜机上的应用,Nowadays its a
16、 normal and forced choice the use of carbon fiber rollers in plants with web widths of 2.7 m or more and speeds of at least 6-700 m/min while for lower sizes aluminum rollers are still the standard choice due to their lower cost.目前工厂中，在卷筒纸大于2.7米宽幅或者工作速度在6-700米/分钟的以上的要求条件下，碳辊的使用还是很常见的。然而在低于这些要求的情况下，由
17、于铝辊的成本较低，铝辊仍然是首要选择。,Our experience show now that even with web widths lower than 2 m the advantage of using carbon rolls is absolutely effective and can solve many problems particularly with thin films and metallized films which can be easily damaged and scratched by high tension or friction on the
18、roller.经验表明，即使卷筒纸宽度小于2米的，使用碳辊的优势还是很明显的，它可以解决许多问题，特别是薄膜和金属化薄膜很容易被导辊上的高张力或摩擦损坏和划伤问题。,Two different operating conditions两种不同的操作条件,1 - Start and stop of the machine启动和停机3 parameters have a big influence:3个参数有很大的影响The moment of inertia of the roller 导辊的转动惯量The wrapping angle of the web卷筒纸的包角The surface f
19、riction coefficient of the roller导辊表面的摩察系数,T,T,M,M = 2r T sin(/2),M = J .,Jroller moment of inertiawrapping angle,Where: T web tensionr roller radius surface friction coefficient,The most important parameter is the moment of inertia of the roller. The lighter the roller the lower the torque M needed
20、 and easier to put the roller in rotation and to accelerate.最重要的参数是导辊的转动惯量，导辊越轻，所需的扭矩越小，越容易驱动导辊转动以及加速。The carbon roller, in comparison to a classical aluminum roller which it can replace, has a moment of inertia 2.5 - 3 times lower in average.与传统的铝辊相比，碳辊的转动惯量平均降低了2.53倍。,Two different operating condi
21、tions,2 Machine operation at working speed工作转速下的机器运转The most important parameter in this phase is the bearing friction. Lower the bearing friction smaller the influence on the web.这一阶段最重要的参数是轴承摩擦。轴承摩擦力越小，对卷筒纸的影响越小Due to the small web tension with delicate films, the weight of the roller is the main
22、parameter for the bearing size and thus affects the friction. Lower weight allows smaller bearing so the friction can be further reduced.对于易损的薄膜，由于卷筒纸的张力小，导辊的自身重量是影响轴承尺寸的主要参数，从而影响摩擦力。较低的重量允许较小的轴承，因此摩擦力可以进一步减少。Moreover in many cases, due to their better vibration damping, carbon fiber rollers allow a
23、 higher durability of the bearing permitting a longer maintenance intervals in the machine.此外，在许多情况下，由于碳纤维导辊具有更好的振动阻尼，允许机器上轴承在更长间隔维护周期下，具有耐久性。,Consequences of the use of carbon rollers in start and stop of the machine使用碳辊在机器启动和停止过程中具有重要地位,Consequences of the use of carbon rollers in the normal opera
24、tion使用碳辊在正常运转中的重要地位,Herebelow it can be seen a scheme of a Nordmeccanica Duplex Combi machine以下是诺德美克覆膜两用机的一个方案,Duplex Combi HorizontalRed dots are recommended carbon fiber rollers positions红点标注处是推荐使用碳纤维导辊的位置 2014 nordmeccanica SpA,Operating applications操作应用,In a Nordmeccanica triplex laminator the f
25、ollowing rollers have been changed 在诺德美克三层覆膜机中，以下辊子已经被更换掉with a very good quality improvement of the web.提高卷筒纸质量The rollers are indicated in red in the sketch.下图红色标注的导辊This replacement has consistently improved the rotation of the rollers with stretchable materials like PE or CPP for which very low
26、tension values are used during the process.在低张力伸缩性材料如 PE或者CPP加工过程中，更换使用碳辊大大提高了旋转速度。All the scratches disappeared after the replacement of the rollers.更换成碳辊后，所有的划痕都消失了。,We recommend, in case of replacement, to evaluate the possibility to reduce the bearing size replacing also the inner shaft with a s
27、maller one.我们建议，在更换导辊的情况下，同时评估轴承尺寸是否有减小的可能，这样芯轴就可以更用更小的来替代。,Operating applications,Other very important applications have been made completely replacing the idle rollers and guide rollers of a rotogravure printing press in which metallized OPP and PET were heavily damaged and scratched by the slippi
28、ng of the roller which cannot be put or kept in rotation by the web.其他重要应用中，在凹版印刷机上，惰辊和导向辊已经完全被碳纤维辊替代。由于辊子的打滑，而不能使卷筒纸转动或者保持旋转状态，使金属化的OPP和PET膜被严重损坏和划伤。Same operation has led to a very effective improvement in the web quality in a flexographic printing press used for delicate webs.同样的操作在柔版印刷机上的卷筒纸的质量得
29、到了非常有效的改善。,Air elimination排气Fast rollers can drag in rotation air which lifts the web, preventing the contact with the roller, reducing the rotation and creating web damages.辊筒在高速运转中，带动气体旋转，使卷筒纸抬起，防止与辊筒直接接触，减少旋转，造成卷筒纸损坏。,Carbon fiber rollers can be provided with grooves to eliminate the airand, havi
30、ng the possibility to reduce the roller diameter, can be more efficient also in this aspect in front of an aluminum roller.碳纤维辊可以用凹槽来消除空气，同时有可能减少导辊的直径，相比较于铝辊也可以更有效地使用。,Problems solution问题解决方案,Wear resistance耐磨性If a carbon fiber roller is made with a prepreg wrapping technology can be provided with a
31、 carbon fabric surface. In this case its wear resistance is by far better than the aluminum surface and even better than anodized aluminum.如果碳纤维辊是用预浸料卷管技术制成的，可以提供有碳纤维织物的表面。在这种情况下，其耐磨性远远优于铝表面，甚至优于阳极氧化铝。,The hardness also is higher that that of an aluminum roller.表面硬度也比铝辊的高。,Problems solution,Surface
32、coatings表面喷涂Carbon rollers can be provided with many different types of coatings, from rubber and elastomeric coating up to hard thermal spray coverings.碳辊可以提供多种不同类型的涂层，从橡胶和弹性涂层到硬热喷涂涂层。,In coating and laminating machines it is, for some rollers, very important to have the right covering in order to
33、avoid web sticking with the rollers. A high roughness thermal spray with a silicone sealing is confirmed as the best and durable antisticking solution and can be applied on high quality carbon rollers.在涂布机和覆膜机中，对于一些辊子来说，最重要的是表面有合适的涂层，避免卷筒纸粘在辊子表面。实际证实最佳和耐用的防粘处理是采用硅胶密封高粗糙度热喷涂方法，可获得高品质的碳辊。,Problems sol
34、ution,Comparison between a typical size aluminum roller and a carbon fiber roller一种典型尺寸铝辊和碳辊的的对比,With the same size of a relatively small roller, a carbon fiber roller can have a reduction of weight and moment of inertia of about 2.5 times with a higher stiffness. 拥有相同较小尺寸的辊子，碳纤维辊可以减轻重量和转动惯量约2.5倍，并具
35、有较高的刚度。While aluminum rollers have fixed characteristics, carbon fiber rollers can be designed to meet many different needs, so they can have much higher stiffness or can be even lighter than this here indicated. The difference comes much more evident as the size increases.虽然铝辊具有固定的特性，但碳纤维辊的可设计性可满足许
36、多不同的需要，因此它可以有更高的刚度，甚至可以比这里的更轻。随着尺寸的增大，这种差异就变得更加明显。,Notwithstanding their higher price, carbon fiber rollers can give to the machines so many advantages that its cost increase can be considered negligible in comparison to the lower material waste, better quality and higher production speed which can be achieved.尽管价格较高，但碳纤维辊可以给机器带来许多好处，相比之下，与更低的材料浪费、更好的质量和更高的生产速度相比，它的成本增加就可以忽略不计。,Conclusion结论,
