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Nonwovens
2014
David Roisum, Ph.D.
Finishing Technologies, Inc.
INDA 2014
80.1
What is a Web?
Long
Thin
Flexible
80.2
Wrinkling
Wrinkle Cause/Cure
Spreading
Other
Material Properties
Physical Properties
Problem Solving
80.3
Baggy Webs
Curl
Length & Width (dimension)
Registration (location)
Web Breaks
Winding Defects
Wrinkling
etc
80.4
Winding
Different defect set
Different winder settings
Different quality measure
80.5
Web-to-roll
Paper machine
Film extrusion
Foil mill
Textile loom
etc
Roll-to-roll
(Slitter) Rewinder
Manufacturing such as
Calendering
Coating
Laminating
Metallizing
Printing
etc
Salvage (Rewinder)
80.6
M1
Tension
Ni p
Center Wind w
Layon Roller
M1
Tension
Ni p
Surface Wind
M2
Tension
Ni p
Center- Surface
Wind Tension
M1
( M1+ M2)
M2
80.7
Tight
Center Wind
M
1
Tension
Nip
Center Wind w
Layon Roller
M
1
Tension
Nip
Surface Wind
M
2
Tension
Nip
Center-Surface
WindTension
M
1
(M1+ M2)
M
2
Centerwind range is
from min to max web
tension
Layon roll nip adds
additional tightness
Surface wind cant get
as loose because of
required nip
Center-Surface has
widest range
Tightness
Centerwind Torq.
Diff.
80.8
Index
Layon Roller
f er
s
n
t r a ho w n
d
n
a
tS
Cut No
Turret
Spindle A
Turret Mech
80.9
Core(shaft) support
Upsets at bottom of roll
Surface wind class
Reel Mech
80.10
Drum
View
From
Top
Duplex Mech
80.11
Wound Roll
Drums
Shaftess or Shafted
Surface wind class
Very Durable
Very Productive
Two Drum Mech
Programmed Nip
80.12
Tension
Ni p
M2
M1
80.13
Tension +
Nip +
Torque
WIT +
Mat erial
propert ies
Wound Roll:
WIT,
tight ness,
hardness,
Stresses, etc
80.14
Programmed Nip
Cam
PLC
Calculation
Lookup table
Outside
Core
Outside
Core
Roll Wgt
Drum Nip
Outside
How
Looser Finish
Core
Structure a roll
Compensate for geometry
Compensate for gravity
All of the above
Tight Start
Geometry Compensation
Roll Structure
80.17
30
Actual
Actual
20
P
ro
10
10
gr
am
20
me
22.9
7.8
30
40
80.19
Flat spots
Out-of-Round
Telescoping
Etc.
Blocking
Core Crush*
Corrugations
Gage Bands > Bag
Tin Canning, etc.
80.20
What
Tight Start
Smooth Transition
Looser Finish
How
T,N, T or WIT
Core
Outside
Current Roll Diameter
10
30 Roll
10 Roll
-10
20 Roll
40 Roll
Outside
-20
-30
Core
-40
0
10
15
20
Radial Position (in)
25
Pressure is highest
at core
Without taper,
pressure is
roughly level
through most of
the roll
S-shaped pattern is
the trend common
to most winding
situations
80.22
80.23
Position
OD
Core
Position
OD
Core
Caliper
Pressure
80.24
Winding Pressure
80.25
80.26
26.27
Diameter
OD
Min
Core
Sideguards
Living with waste
WIT
Operational
Change Web
Increase web-web friction for torque induced
Increase density for nip induced
Core diameter increase
Max
Roll diameter decrease
80.29
Telescoping Case IV
More formally known as Progressive Outward Dishing
During Winding (most commonly a 2 Drum)
Multiple rolls wound on same axis grow in width due to
Interlayer pressure and
Poisson effect
Diagnostics
No J-line motion needed
Rolls wider above core than at outside
Progressive outward roll edge pattern
Remedies
Winding Minimum winding tightness (T, N and T)
Increase spreading of multiple rolls wound same axis
Web or roll product design
80.30
Web Moved
Rol l Moved
Tensi on,
Wr ap
Wi dt h Var
Sl i t t er Moved
Wri nkl e at Sl t r
80.32
Unwinding
The size of the diameter variation that might do this could be as little as 1/1,000
The web gage variation that caused this diameter variation could easily be below the
threshold of ordinary web measurements and controls
Roisum, David R. The Secrets of a Level Process and Product. Various venues, 2001.
80.33
Corrugation Description
A.K.A. Ropes, Chain Marks, Tin Can
Narrow annular band, wrinkles at an angle
Caused by Winding
A caliper-varying product
Tight, especially with nip
80.34
Corrugation Mechanics
Web
Gage
Profile
Wound
Roll
Diamet er
Profile
Small diameter
sped up by nip
against roller
80.35
80.36
Observe
Symmetry of (angle between) points
Symmetric natural
Asymmetric unnatural often a blow
or squeeze due to handling
Gage Variation
Intentional
Coating short of edges
Unintentional
Rough handling
Tightness
Core
Outside
Current Roll Diameter
Air Buckles
Asymmetric pattern
Blow
Squeeze
80.38
80.39
80.40
Winding Books
Roll and Web Defect Terminology by Duane
Smith 1995, 2007
Winding Machines, Mechanics and
Measurements Dr Keith Good and Dr David
Roisum 2007
Winding by Ken Frye 1990
The Mechanics of Winding by David Roisum
1994
Winders the Complete Guide by Jan Gronewold
1998.
Anthology of Winding by Jan Gronewold 2000
TAPPI PRESS, tappi.org, (770) 446-1400
80.41
Questions?
Answers:
David Roisum, Ph.D.
http://www.webhandlingblog.com/
http://www.roisum.com
drroisum@aol.com
920-725-7671 office
920-312-8466 cell
80.42