a comparison of different unwinds and splice · pdf file¾close core tolerances can...

A COMPARISON OF DIFFERENT UNWINDS AND SPLICE SYSTEMS

Michael Schröder10, 7723

Michael Schröder 2

IMPORT FOR PRODUCTIVITY• HIGH PRODUCTICVITY

MINIMUM REST MATERIAL ON THE COREIMPORTANT VALUE BUT:CAN BE REDUCED WITH NEW PLC AND FAST CPU´SCLOSE CORE TOLERANCES CAN IMPROVE AMOUNT OF WASTE

SPLICE RELIABILTYCAUSE MACHINE STOPS WITH A LOT OF WORK TO RESTART AND THREADING OPERATION IS: DEPENDING ON REEL PREPARATION QUALITY AND UNWINDDESIGN

Michael Schröder 3

DIFFERENT TYPE OF UNWINDS DEPENDS ON:

Substrate and Materials:Board and heavy paper 150 – 400 g/m2Light paper 20- 120 g/m2Foil Al 5,5 my to 7 myFilm 12 – 50 my

Speeds:Low speed up to 350 m/minHigh speed over 500 m/min

Michael Schröder

Conventional UnwindCentre Shaft

Michael Schröder

CONVENTIONAL TYPE OF UNWIND

• CHARACTERISTIC OF THIS UNWIND

CENTRE CROSS BEAMSIZE OF UNWIND NEED A LOT SPACELONG WEB PATH FROM ROLL TO ROLL

USE FOR MAINLY FOR BOARDHEAVY PAPERLOW SPEED

Michael Schröder

MODERN TYPE UNWIND PANTOM AXES

Michael Schröder

MODERN TYPE UNWIND

• CHARACTERISTIC OF UNWIND

PHANTOM CROSS BEAMCOMPACT DESIGNMORE RIGID THAN THE CENTRE BEAM DESIGNSHORT WEB PATH FROM ROLL TO ROLL

USE FOR MAINLY FOR ALL MATERIAL TYPES HEAVY AND LIGHT WEB MATERIALSLOW AND HIGH SPEED

Michael Schröder

NEW TYPE OF UNWIND

WITH SPLICER

PHANTOM AXES

KNIFE POSITION ON THE TURRET

Michael Schröder

NEW TYPE OF UNWIND AND SPLICER

• CHARACTERISTIC OF UNWIND

PHANTOM CROSS BEAM

KINFES ON THE TURRETCUTTING POINT FAR AWAY FROM THE NIPWEB MATERIAL TIHGHTENED UP FOR SPLICE BETWEEN SHORT DISTANCE

USE FOR MAINLY FOR ALL MATERIAL TYPES HEAVY AND LIGHT WEB MATERIALSLOW AND HIGH SPEED

Michael Schröder 10

REEL-HANDLING IMPORTANT FOR FAST SPEED OPERATION

THIN FOIL IS TAKEN INTO THE UNWIND WITH OVERHEAD CRANE CYCLE TIME IS NOT CRITICAL

FILM MATERIAL IS PREFERRED HANDLED BY LIFTING DEVICE CYCLE TIME IS NOT CRITICAL

THICK WEB MATERIAL WITH SHORT CYCLE TIME NEEDS MOST AUTOMATION FOR REEL HANDLING

CYCLE TIME IS VERY CRITICAL


FOIL UNWINDERLIFTING BY

CRANE


FILM UNWINDER

LIFTING BY LIFTING CARRIAGE


CONVENTIONAL REEL HANDLING WITH LIFTING TABLE

REMOVE EMPTY CORE

REEL PREPARATION

POSITION


REEL PREPARATION &CYCLE TIME

NECESSARY ACTION• REMOVE EMPTY CORE 30 s• MOVE, LIFT AND CHUCK NEW REEL 60 s • SPLICE PREPARATION 90 s• INDEXING APPROX. 90 DEGREE 20 s• ACCELERATION OF NEW REEL 20 s• TRANSFER WAITING AND ACTING 60 s• INDEXING APPROX. 90 DEGREE 20 s

• TOTAL TIME 300 s


CYCLE TIME

CONSIDERING CYCLE TIME OF 5 MINUTESPREPARATION TIME IS LEFT APPROX.

90 SECONDS DEPENDING ON THICKNESS OF WEB MATERIAL AND LINE SPEED

BECAUSE SPLICE PREPARATION QUALITY IS IMPORTANT, TIME NEED TO BE IMPROVED


NEW METHOD FOR REEL HANDLING

WAITING POSITION

LIFTING TABLE

REEL PREPARATION BY TURNABLE FLOOR

V-TABLEIN ADVANCE

AUTOMATIC HEIGHT

ADJUSTMENT

REMOVE EMPTY CORE


ADVANTAGE WITH NEW METHOD

MORE TIME FOR REEL PREPARATION REEL PREPARATION INDEPENDENT OF UNWIND CYCLE TIME ENOUGH TIME TO PREPARE QUALITY PREPARATION

PRE-PREPARATION OF NUMBER OF REELS ARE POSSIBLE


UNWINDING OF SENSITIVE MATERIAL AS FOIL AND THIN FILM

IMPORTANT DESIGN FEATURE FOR SUCCESSFUL UNWINDING PROCESS


UNWINDING PROCESS

KINIFEPNEUMATIC

PASTER ROLL PNEUMATIC

SERVO CARRIAGE

DRIVE


PASTER ROLL DURING UNWINDING PROCESS

PASTER ROLL IS KEPT IN CONSTANT DISTANCE TO THE UNWINDING REELTAKE OFF LINE FROM THE MATERIAL IS KEPT UNIFORM TO PREVENT WEB BREAK DURING UNWINDING PROCESS


WEB GUIDING AND TRANSFER DESIGN FEATURES

• IDLER ROLL– DIAMETER (160-200 mm)– ROLL DESIGN CRITERIA– DISTANCE ROLL TO ROLL– WRAP ANGLE

• PASTER ROLLER– MATERIAL AND SURFACE

• WEB TENSION CONTROL

Rt 3-5 my


SPLICE SEQUENCES WITH DIFFERENT SPLICER DESIGNS

CONSIDERATION FOR MOST CRITICAL THIN MATERIALS WITH DIFFERENT RESULTS

1. SPLICE SEQUENCE ON THE HIGH SPEED UNWIND2. SPLICE SEQUENCE ON NEW CONVENTIONAL

SPLICER

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KNIFE CUT

REEL ACCELERATION/SPEED MATCH

CONTACT WITH BUMP ROLLER

TAPE PREPARATION

SPLICE SEQUENCES

Michael Schröder

RESULTS OF SPLICE

SPLICE CUT AND END TAIL FAR AWAY FROM THE NIP POINT BETWEEN NEW REEL AND TAPESAFE WAY OF SPLICE FOR THE SPLICE FROM TOPOVERLAP WILL BE WITH CERTAIN LENGTHTHIN MATERIAL WILL FALL DOWN IN UNDEFINED WAY AFTER CUTCUT CAN BE DONE AFTER THE NIP WITH THE BUMP ROLLER IS CLOSED

Michael Schröder

KNIFE CUT

REEL ACCELERATION/SPEED MATCH

CONTACT WITH BUMP ROLLER

TAPE PREPARATION

SPLICE SEQUENCES COMPRESSED AIR PIPE WITH NOZZLES

Michael Schröder

RESULTS OF SPLICESPLICE CUT AND END TAIL CLOSE TO THE NIP POINT BETWEEN NEW REEL AND TAPEEND TAIL NEED TO BE BLOW AWAY FOR SPLICE FROM TOP, DUE TO INSURE THAT THE END TAIL NOT RUNNING INTO THE NIPOVERLAP CAN BE VERY SHORTCUT CAN BE DONE AFTER THE NIP WITH THE BUMP ROLLER IS CLOSED


SPLICE RELIABILITY DEPENDS ON

PASTER ROLL SPEED AND GRIP TO THE REEL SURFACETO BE ACHIEVED BY SHOCK ABSORBER OR PNEUMATIC DAMPER

KNIFE SPEED AND CONFIGURATION


–

–0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

1,51,251,00,750,50,250

New Roll Diameter (meter)

Tim

e (s

econ

ds)

Line speed 300 m/min



Time for One Roll RevolutionLine Speed versus Roll Diameter


Required Repeatability of Paster Roll Engagement

0.000.050.100.150.200.250.300.350.400.450.50

1,51,251,00,750,50,250

New roll diameter (meter)

Tim

e (s

econ

ds)

Line speed 300 m/minLine speed 600 m/minLine speed 900 m/min


SHORT OVERLAP TAIL LENGHT IMPORTANT

LONG OVERLAP COULD CAUSE PROBLEMS IN THE EXTRUSION LAMINATOR ENTRY AND NIPLONG OVERLAP NOT ALLOWED IN PRINTING MACHINES

• SOLUTION :SHORT OVERLAP CAN BE CREATED BY CLOSE ARRANGEMENT OF PASTER ROLL AND KNIFE ONLY


Tail length variation versus Knife repeatability

00.020.040.060.080.10

0.120.140.160.18

0.2

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70

Tail length variation (cm)

Tim

e (s

ec)

300 m/min

600 m/min

900 m/min


NEXT STEP FOR CONVENTIONAL SPLICER

REQUIRED SPLICING SPEED CONTINUE TO BE INCREASED BY: ACTUATION FOR KNIFE AND PASTER ROLL WITH VIA SERVO DRIVE INSTEAD OF PNEUMATIC CYLINDERSPEEDS CAN BE ADJUSTED AND FIXED IN AUTO-SPLICER SEQUENCE


DEVELOPMENT FOR FUTURE SPLICER

BUTT SPLICER OPERATION WITHOUT FESTOON

• WHY?FESTOON CAUSE TENSION PROBLEMS AND TRANSFER STRESS TO THE WEB MATERIALPROBLEMS WITH THINNER MATERIALSSPACE AND HIGH COST REQUIREMENT FOR THE FESTOON


NEW BUTT SPLICER

DESIGN FEATURES

SPLICE SPEED UP TO 800 M/MINNEWEST DRIVE TECHNOLOGYAUTOMATIC CUT INDEPENDENT FROM SPEED THROUGH THE RUNNING AND EXPIRING WEB IN ONE TIMESPLICER DESIGN FOR THIN AND THICK WEB MATERIALS AS FILM UP TO 350 G/M2 BOARDAUTOMATIC DISPOSAL OF THE END TAILTAPE ON BOTH SIDES OF THE WEB TO INSURE SAFE TRANSFER WITH FULL LINE SPEED


THANK YOU FOR YOUR ATTENTION

a comparison of different unwinds and splice · pdf file¾close core tolerances can...

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