A simple device for rewinding rolls of fabrics. Cutting of roll materials
In the age of high technology, a person strives to keep up with the times, inventing new types of products needed in different areas activities. Our company has been an active participant in the market for the production of self-adhesive materials for a long time and does not stand aside from the process of introducing innovations. Therefore, we improve production, organize the release of new types of products, and provide new types of services.
We are ready to provide material rewinding services And finished products from the original roll to rolls of smaller diameter. Rewinding paper, cardboard, film, foam, nonwoven, foil and other various roll materials.
The glue application line is one of the most important pieces of equipment in our company. Applying glue is the main purpose of this type of equipment, but it is important to note that its technical characteristics allow rewinding of rolls with the largest winding. The line is equipped program management, and this makes it possible to control the length and density of winding roll materials and the quality of the finished product.
Our rewinding capabilities
Principle rewinding of roll materials on the line of gluing is that the source material is fixed on the unwinding shaft and, having passed through the system of shafts, is wound on the winding shaft. Rewinding in a role on this line allows you to work with materials that have the following characteristics:
Unwinding web width – up to 1500 mm
The maximum diameter of the roll on winding is 1000 mm
Main types of rewound materials: paper, cardboard, film, foamed and non-woven materials, foil and other roll materials
Technical characteristics of the types of products rewound on the line
1. Single and double sided PP film:
BORR, width - from 1050 to 1250 mm, winding - up to 500 m
2. Polyester films:
PET, width - from 1050 to 1270 mm, winding - up to 300 m
3. Aluminum foil tapes:
MA, finished product width - 1050 mm, winding - up to 1500 m
LMA, finished product width - 1050 mm, winding - up to 500 m
MK, finished product width - 1060 mm, winding - up to 1000 m
MTL, width - 800 mm, winding - up to 1200 m
MCA, width - 1050 mm, winding - up to 900 m
4. Foamed rubber tape.
Jumbo roll width - 1000 mm, winding - up to 180 m (depending on the thickness of the material)
5. Tape based on polyurethane foam (PPU), polyethylene foam (PPE):
PPU, jumbo roll width - from 1000 to 1050 mm, winding - up to 120 m (depending on the thickness of the material)
PPE, jumbo roll width - from 1000 to 1050 mm, winding - up to 450 m (depending on the thickness of the material)
6. Double-sided tape based on polyethylene foam (PPE).
Jumbo roll width - from 500 to 1050 mm, winding - up to 450 m (depending on the thickness of the material)
Rewinding of self-adhesive materials
aim rewinding of self-adhesive materials is to obtain rolls of the required winding length. The principle of operation on the rewinder is that the source material is fixed on the unwinding shaft and, passing through the auxiliary shafts, is wound onto a cardboard spool. Machine for rewinding roll materials equipped with a program control that allows you to control the length and density of the winding.
Specifications materials used on the rewinding machine
Unwinding web width – up to 1400 mm
Maximum material weight - up to 700 kg
The maximum diameter of the roll on unwinding is 1000 mm
The maximum diameter of the roll on winding is 300 mm
Rewinding and cutting webs of paper, film, foil or non-woven materials is required for compact storage, ease of transportation, subsequent processing and use of materials.
For winding rolls, rewinding and cutting machines are used, which wind the web layer by layer onto a sleeve or directly onto a shaft. The drive of the machine during winding stretches the web and this tension creates pressure inside the roll, directed along the radius to the center of the roll and proportional to the tension expressed in units of force per web width, and inversely proportional to the radius. This pressure in turn holds the layers together and provides friction between them. The friction between the layers will be proportional to the area of contact and the coefficient of friction of the material. It is it that transfers the moment of rotation from the shaft (sleeve) to the upper layers of the roll and creates tension in the web during winding. The friction prevents the layers from slipping and thus keeps the shape of the roll during transport and storage.
Web tension
Each canvas has irregularities in the transverse or longitudinal directions, while visually the canvas looks “baggy”. By applying tension to the canvas, we strain it and remove these unevenness and the canvas becomes more even. Then, under tension, the web becomes stiffer and this helps to eliminate sagging, for example, between the shafts. Finally, the tension creates friction between the layers after winding and helps to find out how many meters have been wound in a certain period of time (knowing the speed, thickness and width of the material).
Figure 1. Main parameters of slitting machines
How to determine the correct web tension? According to practice, it is set as a maximum tension equal to 15-20% of the value corresponding to the breaking force of the material. For 90% of cases, the allowable tension lies in the range of 50-550 N/m, and in 95% of cases, in the range: 20 to 2000 N/m. You can agree or not with the given quantitative estimates, but this is the practice, and this will help when choosing a machine drive.
How to prevent slippage?
Low friction materials need more force to prevent slippage. The layers near the core have a more limited area of contact than the layers on top of the roll. And narrow rolls will have a smaller area of contact between the layers than wide rolls and will require more tension.
What is the Buildup Factor?
The buildup factor is the ratio of the outside diameter of the core to the final diameter of the roll.
For webs with relatively good lateral compressibility and a high coefficient of friction, this ratio can easily be achieved in the order of 10. Those. on a 152mm sleeve, you can wind a roll with a diameter of 1520mm without difficulty and on almost any machine. But for materials with a poor combination of low modulus in the longitudinal direction, high radial stiffness, low coefficient of friction and poor flatness, difficulties begin already at a ratio of 3-4. This is one of the objective difficulties of winding 76.2mm rolls of large diameters onto cores. If you change the winding shafts to larger ones in diameter, it will be easier to work.
What is Poisson's Ratio?
When we apply tension to the fabric in one direction, it changes its shape and tends to become thinner in the other two directions. Poisson's ratio is a parameter that characterizes these changes.
The law states that for most materials the ratio is within 0.3%. For example, a PET sheet 1200 mm in width under tension stretches by 1% along. Poisson claims that this will shrink the canvas by 0.3%, which is about 3.6mm. This is important if you want to cut the exact width.
Young's modulus
Young's modulus is the tangent of the slope of the sample elongation versus applied stress curve.
Knowing the Young's modulus of the materials being wound is important if you are faced with various materials, choose a new machine or want to solve a problem. Each material has its own value of Young's modulus and this parameter determines the behavior of the material on the rewinding and cutting machine, and whether the machine is suitable for this material or not.
The range of changes in the value of Young's modulus in the reference literature is very large. If you are working with a polyester web at 0.2% elongation, then changing the roll diameter by 0.1% at its diameter of 76mm does not significantly affect the process, but if you work with an aluminum foil web at 0.02% elongation with the same change in roll diameter, then rather Total good result will not work. When winding tape on shafts or using spreader rolls with soft surfaces, the allowable level of change in Young's modulus of the material must be calculated. Relatively large changes in the diameter of the rollers can lead to web slippage and poor wrinkle removal efficiency.
Another example of checking shaft alignment. For example, you have three sheets of PE, PET and aluminium foil with Young's moduli, respectively, 100, 500 and 10000, with the same web tension, elongations of 1, 0.2 and 0.01% will be given. If the alignment error is 0.1 mm on a shoulder of 1000 mm, i.e. 0.01%, then for PE this is almost not noticeable, because. it turns out 1% + -0.005%, but for aluminum 0.01% + -0.005% will be noticeable and very. Practice shows that the alignment of the shafts, acceptable for most materials, except for foil, is: 0.15-0.17 mm per meter.
How to calculate the length of the canvas in a roll?
Imagine a roll as a cylinder that you are looking at from the end. The entire end area is occupied by a wound material with a thickness T. Then, according to the formula for the area of a circle, we get Pi (Pp2 -Pg2) \ T \u003d Length. Conversely, if you know the thickness and length of the material, then the radius or its diameter can be predicted. It is important to remember that by unwinding the web, you will relieve tension and the web will become shorter. Here the Young's module will come to the rescue to explain to the customer - with a length of 100 m and a stretch of 1%, the customer will miss a whole meter.
How not to make a mistake in the weight of the roll?
Physicists have a quantity they call density or weight per unit volume. You can forget for a moment that we have a sleeve, and there is a void in it, and only then the material is wound.
Let our roll be a cylinder filled with water with a density equal to 1. Its volume, multiplied by 1, will give the maximum weight of the roll for evaluation. Why maximum? Because the density of PE is close, but less than 1 (0.992-0.996) and all other materials are also less than unity. Plus, when winding in a roll, there will always be layers of air, which will make it lighter. Usually interested in the maximum possible weight, and it can be quickly determined. For papers and cardboards, take the density equal to 0.72-0.76, for coated papers - 0.76-0.82.
The roll weight is required for the operator to communicate with drive specialists. Otherwise, they may misjudge the moment of inertia and problems will begin.
Central type rewinders
Center rewinders are the most common type of rewinders. It is so called because the moment of rotation is communicated by the drive to the roll from the central shaft.
Central type machines must ensure that the material is wound or unwound according to certain rules, or, as they say, with a certain profile of the moment of force. Rewinding takes place at a constant linear speed of the web, i.e. the formula is as follows: motor rotation in rpm = linear speed of the web in m m min X gear ratio and \ Pi, 2 and roll radius in m.
With a minimum radius, the rotation speed should be maximum. With an increase in the radius or diameter of the roll, it is necessary to reduce the rotation speed in order to maintain a constant linear speed. If at the same time if the tension is constant, then the moment T \u003d tension times the radius. As the radius increases, the moment should increase. There are machines where there is no need to maintain a constant linear speed of the web.
It is important to remember that winding and unwinding are under direct control of the speed of the shaft in the center of the roll. When winding, the speed decreases with increasing radius, and when unwinding, the speed increases with decreasing radius.
Tension control
On machines, tension control is organized using circuits. feedback. First of all, you need to determine what is better to control, speed or torque. Then select the type of circuit: open or closed. Then decide on the type of sensor to organize feedback in a closed loop. For example, it can be a ballerina or a shaft with strain gauges.
An open loop means that we have almost no feedback, and we just set some limit parameter. For example, on the force of the unwind brake. Thus, the tension parameter is never measured in an open loop. This is a cheap method, and it is used if it is important for your process to control the constancy of speed, length or time factors, i.e. measured scalar parameters.
In closed circuits, a so-called PID controller is used. The PID controller (proportional-integral-derivative controller) is a device in a feedback control loop. Used in systems automatic control to form a control signal in order to obtain the required accuracy and quality of the transient process. The PID controller generates a control signal that is the sum of three terms, the first of which is proportional to the difference between the input signal and the feedback signal (error signal), the second is the integral of the error signal, and the third is the derivative of the error signal. But this is for machine gunners. It is important for operators that the machine understands what is happening and directly measures the set parameter. Often errors occur due to failures in PID controllers or their incorrect tuning. If a static deviation appears, then look for the problem in the integral part of the PID, and if the desired value walks around the given one, then in the differential part of the PID.
Vector or scalar drive
In both cases, we are talking about frequency converters, although the terms "vector" and "scalar" are inaccurate in relation to their characteristics. We are talking about an alternating current parameter, which means that the use of the term "scalar" is generally unacceptable.
From the course of elementary physics, it is known that a scalar quantity is such a quantity, each value of which (unlike a vector) can be expressed by one (real) number, as a result of which the set of scalar values \u200b\u200bcan be depicted on a linear scale (scale - hence the name). With scalar (frequency) control, harmonic currents of the motor phases are formed, which means that the control maintains a constant ratio of the maximum motor torque to the resistance torque on the shaft. That is, when the frequency changes, the voltage amplitude changes in such a way that the ratio of the maximum motor torque to the current load torque remains unchanged. An important advantage of the scalar method is the possibility of simultaneous control of a group of electric motors. The scalar control method allows for easy adjustment, even when using the factory settings.
Vector control is a method of controlling synchronous and asynchronous motors, not only by generating harmonic phase currents (voltages), but also by providing control of the rotor magnetic flux (torque on the motor shaft). Vector control is used when it is necessary to obtain an extended frequency control range, this allows you to significantly increase the control range, control accuracy, and increase the speed of the electric drive. This method provides direct control engine torque. Such control systems are more modern and more expensive. They are typical for high-end rewinding machines.
How is web speed measured?
In most cases, the principle of measuring the number of revolutions of a shaft with zero slip and a known long circle is used. Velocity = 2 Pi RPM Radius. The length is simply determined by multiplying the speed by the time. On expensive machines, drive shafts, tachometers or linear encoders are installed to measure the speed of rotation of the shafts, as well as magnetic, inductive and / or optical sensors on cheaper models. In any case, it is important to ensure the tension of the web and its grip in the shaft. Remember, measurements on stretched and loose webs will give a difference proportional to the degree of elongation under tension.
What is the angle of coverage of the load cell shaft by the cloth?
The wrap angles recommended by the manufacturers are always large, i.e. over 45 degrees. But everything is relative. High tension web and light shaft can work at low wrap angles, which will be less than 45 degrees. But when working with canvases at low tensions, the wrapping angle should be as large as possible. Also, check that the measurement direction vector is perpendicular to the force of gravity.
Which ballerina is correct?
First of all, in order for a shaft to be called a ballerina, it must dance easily, i.e. practically fly and nothing should interfere with him. Reduce shaft inertia, weight, friction where possible, compensate for gravity and pneumatic effects, use predominantly horizontal systems, increase shaft signal, ensure 180 degree draper coverage and sufficient length of draper arms before and after the shaft. Check it all out on your machine. The ballerina is sensitive to the folds of the fabric, it is difficult to adjust it correctly, which leads to changes in the tension of the fabric, does not respond well to rapid changes in tension, and does not measure tension directly.
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Our capabilities:
Cutting any film materials with a thickness of 20 to 500 microns
Cutting foils and nonwovens
Rewinding film materials from 6" and 3" cores
Maximum width of master rolls 1.8 meters winding length 12000 meters
Minimum cutting width 5 cm
High quality winding, operators experience over 10 years
We work with material of any complexity
Fulfillment of the order with high quality and strictly within the stipulated time
Our production is our pride. The needs of printers for laminating film in rolls of various winding widths and lengths and the desire to help our partners minimize waste when laminating products with various types of films led us to purchase the first slitter rewinder.
At the moment, production has grown into a separate line of business and we cut film not only from our own supplies and to our partners in the printing market, but also take orders for cutting almost any film materials.
The film is wound and cut to fit YOUR production capacity. Core diameter, laminating film roll length and width - of your choice
The lead time for an order depends on the quantity and characteristics of the required rolls.
Winding is made on bushings 1 and 3 inches.
Film for lamination in standard winding is always present in our warehouses.
For industrial laminators, a thin film (20-27 microns) is wound, as a rule, at 3000 meters. Dense types of PET films - depending on your wishes.
BOPP and PET film for non-industrial (office) roll laminators, wound in the following sizes:
|
Lamination film thickness in microns |
Roll length |
|
|
Glossy Transparent Laminating Film |
20, 22 |
|
|
23, 24 |
||
|
Matt Laminating Film |
20, 23, 25, 27 |
|
These standard sizes (correspondence of film thickness to footage per roll) are offered as maximum for non-industrial roll laminators, film with more winding than indicated in the table will have a roll diameter larger than the technical parameters of the laminator provide. The film of larger winding is not installed on the laminator (the diameter of the roll will be greater than the distance between the guide on which the roll is attached and the surface to be laminated provided by the manufacturers of roll laminators).
The laminating film can be any width of your choice. The maximum width of a laminate roll is 1800 mm.
All laminating film undergoes coronal processing (electrical discharge processing) and is ideal for varnishing, screen printing, embossing and creasing.
Whatever products you laminate, we can offer you a laminating film of decent quality. We value your time, your money and your nerves. As well as your own time, money and nerves. We not only select and offer mutually beneficial working conditions specifically for your company, but we fulfill them.
You can come to our office with your printed materials and test any type of film we sell on Geni-Lami roll laminators.
We have our own fleet of vehicles (cars and trucks). For large orders, delivery in Moscow is free of charge!
Device (machine) for rewinding / unwinding roll materials UPRM-1300-70-50R- this device with a manual drive is designed for rewinding / unwinding and measuring long thin roll materials (PVC films, fabrics, etc.). The machine allows you to get from one large roll several rolls of smaller diameter, the required length.
Roll rewinder calculated on the maximum weight of a roll with material (PVC films, fabrics) up to 50 kg. and the maximum diameter of the sleeve used is up to 70 mm.
The design of the device for rewinding materials in rolls simple, functional and consists of:
- giving device,
- a measuring table with a length meter implemented on a sealed electronic counter ID-2,
- receiving device.
Rewinding of rolled materials is carried out as follows: the pay-off device of the machine is a horizontal axis on which a roll with rewound material is put on. Further, the material is pulled through the measuring table of the device for rewinding rolled materials to the cutting zone, the counter is reset and the rewound material is pulled to the receiving device. The receiving device of the machine is made in the form of a frame on which the rolled material is fixed. The unwinding of the material on the device is carried out by bringing the rotation of the handle by the operator with the help of muscle strength. The machine is easy to use when rewinding roll materials.
Advantages of the device for rewinding and measuring the length of materials in rolls (PVC films, fabrics) UPRM-1300-70-50R:
- versatility, the machine makes it possible to expand the scope of its application, it is possible to rewind not only film, fabric, but also other thin roll materials;
- when rewinding roll materials, measurements are highly accurate even on short lengths.
- when the programmed length is reached, a beep sounds.
Technological characteristics.
| Parameter name | Meaning |
| Principle of operation | operator's hand on the handle |
| The maximum length of the used sleeve, mm | 1300 |
| Maximum weight of a roll with material, kg | 50 |
| The maximum diameter of the sleeve used, mm | 70 |
Version of the length gauge | |
| Measuring principle | electronic |
| Information retention time when power is off | unlimited |
| Meter supply voltage | 220V |
| Power supply frequency, Hz | 50 |
| Counter capacity | 6 bit |
| Max Speed accounts, m/s | 5 |
| Counting resolution, cm | 1 |
| Material length measurement error, % | ±0.5 |
| Overall dimensions, mm.: | |
| - giving rack | 1670x500x1000 |
| - measuring table machine for rewinding / unwinding film, fabric, etc. | 1515x580x960 |
| - reception desk | 1670x500x1000 |
If you want to rewinding of roll materials in larger volumes with greater productivity we offer