A COMPARISON OF DIFFERENT UNWINDS AND SPLICE SYSTEMS Michael - - PowerPoint PPT Presentation

A COMPARISON OF DIFFERENT UNWINDS AND SPLICE SYSTEMS Michael Schröder 10, 7723

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IMPORT FOR PRODUCTIVITY

• HIGH PRODUCTICVITY
• MINIMUM REST MATERIAL ON THE CORE
• IMPORTANT VALUE BUT:

CAN BE REDUCED WITH NEW PLC AND FAST CPU´S CLOSE CORE TOLERANCES CAN IMPROVE AMOUNT OF WASTE

SPLICE RELIABILTY

• CAUSE MACHINE STOPS WITH A LOT OF WORK TO RESTART

AND THREADING OPERATION IS: DEPENDING ON REEL PREPARATION QUALITY AND UNWIND DESIGN

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DIFFERENT TYPE OF UNWINDS DEPENDS ON:

• Substrate and Materials:

Board and heavy paper 150 – 400 g/m2

• Light paper 20- 120 g/m2
• Foil Al 5,5 my to 7 my

Film 12 – 50 my

• Speeds:

Low speed up to 350 m/min High speed over 500 m/min

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Conventional Unwind

Centre Shaft

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CONVENTIONAL TYPE OF UNWIND

• CHARACTERISTIC OF THIS UNWIND

CENTRE CROSS BEAM

SIZE OF UNWIND NEED A LOT SPACE LONG WEB PATH FROM ROLL TO ROLL

USE FOR MAINLY FOR

• BOARD

HEAVY PAPER LOW SPEED

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MODERN TYPE UNWIND

PANTOM AXES

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MODERN TYPE UNWIND

• CHARACTERISTIC OF UNWIND

PHANTOM CROSS BEAM

COMPACT DESIGN MORE RIGID THAN THE CENTRE BEAM DESIGN SHORT WEB PATH FROM ROLL TO ROLL

USE FOR MAINLY FOR

• ALL MATERIAL TYPES HEAVY AND LIGHT WEB MATERIALS

LOW AND HIGH SPEED

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NEW TYPE OF UNWIND WITH SPLICER

PHANTOM AXES KNIFE POSITION ON THE TURRET

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NEW TYPE OF UNWIND AND SPLICER

• CHARACTERISTIC OF UNWIND

PHANTOM CROSS BEAM KINFES ON THE TURRET

CUTTING POINT FAR AWAY FROM THE NIP WEB MATERIAL TIHGHTENED UP FOR SPLICE BETWEEN SHORT DISTANCE

USE FOR MAINLY FOR

• ALL MATERIAL TYPES HEAVY AND LIGHT WEB MATERIALS

LOW AND HIGH SPEED

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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

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FOIL UNWINDER

LIFTING BY CRANE

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FILM UNWINDER

LIFTING BY LIFTING CARRIAGE

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CONVENTIONAL REEL HANDLING WITH LIFTING TABLE

REMOVE EMPTY CORE REEL PREPARATION POSITION

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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

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CYCLE TIME

CONSIDERING CYCLE TIME OF 5 MINUTES PREPARATION 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

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NEW METHOD FOR REEL HANDLING

WAITING POSITION LIFTING TABLE REEL PREPARATION BY TURNABLE FLOOR V-TABLE IN ADVANCE AUTOMATIC HEIGHT ADJUSTMENT REMOVE EMPTY CORE

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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

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UNWINDING OF SENSITIVE MATERIAL AS FOIL AND THIN FILM

IMPORTANT DESIGN FEATURE FOR SUCCESSFUL UNWINDING PROCESS

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UNWINDING PROCESS

KINIFE PNEUMATIC PASTER ROLL PNEUMATIC SERVO CARRIAGE DRIVE

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PASTER ROLL DURING UNWINDING PROCESS

PASTER ROLL IS KEPT IN CONSTANT DISTANCE TO THE UNWINDING REEL

TAKE OFF LINE FROM THE MATERIAL IS KEPT UNIFORM TO PREVENT WEB BREAK DURING UNWINDING PROCESS

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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

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SPLICE SEQUENCES WITH DIFFERENT SPLICER DESIGNS

• CONSIDERATION FOR MOST CRITICAL THIN

MATERIALS WITH DIFFERENT RESULTS

• 1. SPLICE SEQUENCE ON THE HIGH SPEED UNWIND
• 2. SPLICE SEQUENCE ON NEW CONVENTIONAL

SPLICER

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KNIFE CUT

REEL ACCELERATION/ SPEED MATCH CONTACT WITH BUMP ROLLER TAPE PREPARATION

SPLICE SEQUENCES

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RESULTS OF SPLICE

SPLICE CUT AND END TAIL FAR AWAY FROM THE NIP POINT BETWEEN NEW REEL AND TAPE SAFE WAY OF SPLICE FOR THE SPLICE FROM TOP OVERLAP WILL BE WITH CERTAIN LENGTH THIN MATERIAL WILL FALL DOWN IN UNDEFINED WAY AFTER CUT CUT CAN BE DONE AFTER THE NIP WITH THE BUMP ROLLER IS CLOSED

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KNIFE CUT

REEL ACCELERATION/ SPEED MATCH CONTACT WITH BUMP ROLLER TAPE PREPARATION

SPLICE SEQUENCES

COMPRESSED AIR PIPE WITH NOZZLES

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RESULTS OF SPLICE

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

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SPLICE RELIABILITY DEPENDS ON

PASTER ROLL SPEED AND GRIP TO THE REEL SURFACE

TO BE ACHIEVED BY SHOCK ABSORBER OR PNEUMATIC DAMPER

KNIFE SPEED AND CONFIGURATION

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– –

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1,5 1,25 1,0 0,75 0,5 0,25

New Roll Diameter (meter) Time (seconds)

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

Time for One Roll Revolution Line Speed versus Roll Diameter

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Required Repeatability of Paster Roll Engagement

0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 1,5 1,25 1,0 0,75 0,5 0,25 New roll diameter (meter) Time (seconds)

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

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SHORT OVERLAP TAIL LENGHT IMPORTANT

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

• SOLUTION :

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

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Tail length variation versus Knife repeatability

0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.2 5 10

15 20 25 30

35 40 45 50 55 60 65 70 Tail length variation (cm) Time (sec) 300 m/min 600 m/min 900 m/min

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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 CYLINDER SPEEDS CAN BE ADJUSTED AND FIXED IN AUTO-SPLICER SEQUENCE

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DEVELOPMENT FOR FUTURE SPLICER

BUTT SPLICER OPERATION WITHOUT FESTOON

• WHY?

FESTOON CAUSE TENSION PROBLEMS AND TRANSFER STRESS TO THE WEB MATERIAL PROBLEMS WITH THINNER MATERIALS SPACE AND HIGH COST REQUIREMENT FOR THE FESTOON

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NEW BUTT SPLICER

DESIGN FEATURES

SPLICE SPEED UP TO 800 M/MIN NEWEST DRIVE TECHNOLOGY AUTOMATIC CUT INDEPENDENT FROM SPEED THROUGH THE RUNNING AND EXPIRING WEB IN ONE TIME SPLICER DESIGN FOR THIN AND THICK WEB MATERIALS AS FILM UP TO 350 G/M2 BOARD AUTOMATIC DISPOSAL OF THE END TAIL TAPE ON BOTH SIDES OF THE WEB TO INSURE SAFE TRANSFER WITH FULL LINE SPEED

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THANK YOU FOR YOUR ATTENTION