The web guide system is mainly applied to the lateral deviation control of the coil materials, which can control various reel materials on a production line. The automatic web guide system is simple to operate, easy to install and has fast response speed, strong anti-interference, high-precision web guiding.
The coils are on a long and fast production line, as the speed, tensile, the nonuniform material thickness and all kinds of mechanical damage, resulting in moving and unidirectional deviation, causing the machining operation of the middle section not easy to cooperate, resulting in the loss of many materials and the difficulty of subsequent processing. The automatic web guiding system can solve these problems, which can always keep the edge postilion of the web always be neat and consistent. Web guide control can make steel, corrugated paper, textile, printing, labeling, non-woven fabric processing and other much more industries realize automated control.
A typical automatic web guide system which is a closed-loop system, includes a web guiding controller, a web guide sensor, a web guide framework, and a driver. The sensor detects the difference between the detection value of the edge or the line and the set value, and converts it into a proportional signal through the PLC controller. The driver realizes the web guide. It has three guiding methods, including edge position control, line control and center control.
Technical Parameters Of Automatic Web Guide System
1. Support photoelectric sensor, ultrasonic sensor, CCD sensor.
2. Intelligent detection sensor parameters, no need for calibration sensors in most situations.
3. Automatic stroke measurement, not any mechanical switch needed.
4. Adopts variable PI adjustment algorithm, high precision, fast responding, with smaller error.
5. Super high response speed of 500 microseconds.
6. Analog sensor signal adopts 16-bit AD sampling.
7. Adopts the FIR digital wave filter, with strong anti-interference ability and more stable signals.
v8. DC servo motor pushing the ball screw9.Support Simplified Chinese, Traditional Chinese, English, three languages.
10. User-friendly operation, fast and easy.
11. Support MODBUS and PLC operation.
High-precision Automatic Web Guide System
The precision of the web guide system is defined as the position accuracy of the web just coming out of the probe. The accuracy of the web guiding system is determined by three factors, including the deviation of the invasive web, the accuracy of the web guiding system itself, the installation accuracy of the web guide machine.
The automatic web guide system is a controller of tracking edge or printed line of the working material to perform high-precision differential and swing, which is composed of large-scale industrial integrated circuits, with strong anti-interference ability, high reliability and long service life. The lateral web offset in the transmission is detected by the photoelectric sensor, and the electrical signal proportional to the offset will be sent to the controller. After power amplification, it is sent to the motor to make it rotate forward, stop or reverse and the motor shaft end is connected with a lead screw. The screw drives the roller to move the rolling roller in the rolling rail to move laterally in the offset direction, thereby reaching the purpose of the automatic web guide. The signal is being firmly measured and the high-precision of the web offset is the premise of automatic web guiding.
Wide Applications Of Automatic Web Guide System
An automatic web guide system can be widely used for various coils such as web films, non-woven fabric, woven fabrics, on a production line.
Applicable industries: printing, packaging, paper, non-woven fabric, lithium battery, rubber tire, metallurgy.
Applicable coils: wrapping materials, such as roll paper, film, metal foil, film, leather, non-woven fabric, woven fabric, etc.
Applicable equipment: print packaging, flexo printing machine, gravure printing machine, label printing machine, slitting machine, coating machine, composite machine, die cutter, blown film machine, etc.
The automatic web guide system is an integrated high-tech product with a wide range of applications, It has the characteristics of fast responding speed, high accuracy, long service life and high stability. It is essential in the coil material production line.
The tension controller is a high-precision instrument with digital, automatic control for web tension. It can be widely used in tension control of the printing, packaging, paper, textile and dyeing industries. Web tension controller adopts the CPU of 16-bit or 32-bit, with high speed, high precision, high reliability.
Why Choose The Automatic Tension Controller
A typical tension control system is mainly composed of a tension controller, a tension reader, a tension sensor, a magnetic powder brake, and a clutch. Depending on the loop, it can be divided into types of open loop, closed loop or free ring. According to the monitoring method of different coils, it can be divided into types of ultrasonic, floating roller, tracking arm. The stability of tension control has directly affected the quality of the slitting products. If the tension is insufficient, it will generate drift in the raw materials moving and the finished paper wrinkle will appear after the rewinding. If the tension is large, the raw material is easily broken, so that the finished products will appear more broken ends after the rewinding.
The Performance Of The Automatic Tension Controller
The tension controller refers to the durable control of the tension performance when the feedstock is stored on the device. This control is required to be valid for any operating speed of the machine, including the deceleration, acceleration, and uniform speed of the machine. Even in emergency parking conditions, it should be guaranteed that the parties are not damaged.The automatic tension controller is a control instrument that can directly set the tension value of the controlled machine, then directly output the signal of the tension sensor as a tension feedback value, after the proposed bias, outputting to the PID controller for disposal. Then input to the core executive agency to control and finally arrives the purpose of a small bias.
Function Of The Automatic Tension Controller For Unwinding And Rewinding
In the control industry, in some strip-shaped and line-shaped products, tension control is required to achieve production requirements. The general tension controller also has a volume extent function, which is generally applied to the down coiler equipment, with unwinding and winding types. The tension controller also has a taper adjustment function that can be sent directly to the winding taper on some processes inside the controller.
Fully automatic tension control is the actual tension value of the material, measured by the tension sensor directly, and then converts the tension value into a tension signal feedback to the tension controller. Through the comparison of this signal and the pre-set tension value, calculates the control signal. The automatic control execution unit makes the tension value is equal to the pre-set tension value, to achieve a stable purpose for tension control. A fully automatic tension controller is an advanced tension control method.
The fully automatic tension controller measures the actual tension of the coil materials and automatically adjusts the tension value of the coil according to pre-set tension value through the PID algorithm. It has extremely high accuracy tension control, suitable for applications where have high requirements for the accuracy of the tension controller.
How To Solve The Malfunction Of The Automatic Tension Controller
1. The automatic tension controller adopts the AC 185-264V power supply. After the current is switched on, if the tension controller does not work, check if the power supply is connected correctly or whether the fuse is abnormal.
2.If the display signal is incorrect, can re-set the correct signal range. Check the route and the tension sensor whether there is a signal fault or replace the tension sensor.
3.If the tension controller has no signal output, usually there is a connection problem, so check whether the signal output connection is correct, then turn off the voltage for ten seconds and then switch on.
4.If the tension controller signal output is unstable, check whether the roller, bearing and magnetic powder clutch, brake, or driver have an abnormality. Replace the tension sensor or re-calibrate the signal range.
For more information, please visit the article page of high-precision automatic tension controller
Once there is not an alignment of the coils, it will cause errors in the subsequent steps and the material wasting or the downtime of the machine. Therefore, when processing the web, the web guiding is necessary for the offset and it is widely used in a bonding machine, a printing machine, a coater, a paper machine, a dyeing machine, etc, which has various requirements for the winding and rewinding processes. An all-in-one web guiding system refers to the technical operation of the coils to keep the edge of the coil neat and consistent during spraying, printing, die-cutting, lamination, slitting, or other coil winding processes. Its wide applications have brought huge benefits to the coil industries. The all-in-one system has automated industries such as corrugated paper, textile, printing, labels, papermaking, plastic film, building materials, tires, and non-woven corrugated paper processing.
The Work Principle Of All-in-one Web Guiding System
The high-precision, high-speed, and high-efficiency coil automatic processing has high requirements for the lateral position of the controlled coil. Equipped with a high-performance automatic web guide system is the key to improving coil production capacity and output. The coil will shift laterally during moving, unwinding and rewinding. Therefore, the web guiding system can be installed in the above three positions for controlling the coil to pass through the designated position accurately.
All-in-one web guide machine adopts high-speed microprocessor, digital, modular and intelligent circuit design. The advanced programming, user-friendly interface, high-performance components and complete circuit protection design, make the system run continuously and stably. The response time of the control system is less than 0.01 seconds and the accuracy of the system itself can reach 0.01mm. During the coil winding process, the web guide sensor detects the position of the edge or line to pick up the deviation signal of the edge or line position.
Then the position deviation signal of the web guiding machine is sent to the web guide controller for logical operation. After the judges and processes of the control unit, it will control the drive motor to skew the web to the correct position.
The Functions & Advantages Of All-in-one Web Guiding System
The high-performance web guide system has a fast response time, high-speed CPU calculation and can support ultrasonic sensors, photoelectric sensors, CCD sensors for the different response of coils. It has the advantages of simple and practical operation, ball screw, high precision, low noise, maintenance-free, long service life, flexible installation.
Center compensation deviation web guiding can quickly guide the high-frequency feed errors. It integrates operation and control technology with a highly compact web guide. The guiding system has an innovative sensor detection real-time display and a real-time feedback system for system detection information.
The all-in-one system is driven by a brushless DC servo motor and precision ball screw, with compact structure, good mechanical rigidity, low inertia, high precision, suitable for high-speed and high-precision web guide in coil processing.
Three Detection Methods Provided By All-in-one Web Guiding System
The All-in-one web guiding system provides three different detection methods, which include edge detection, line tracking, or alignment detection. The drive system is driven by a brushless motor and the drive stroke is strictly proportional to the coil offset. The system can also be used in conjunction with different sensors to meet the needs of different coils, such as ultrasonic sensors, photoelectric sensors, CCD sensors, etc. The microcomputer digital controller provides precise control for the various functions of the guide system.
Daily Maintenance Of All-in-one Web Guiding System
1.Alignment: Tools, workpieces and accessories should be placed neatly. The web guiding system should be equipped with thorough protection equipment.
2. Cleaning: Cleaning inside and outside including all sliding surfaces, guidelines, gears, racks, etc, ensuring all parts will not leak oil, water, air, or electricity.
3. Lubricating: Refuel and change oil timely. The oil quality meets the requirements. Oil tanks, oil guns, oil cups, lumps, tubes should clean and keep complete.
4.Safety: The operation personnel should be familiar with the maintenance structure of the web guide system, complying with the operating procedures and reasonably use the all-in-one system with daily maintenance, carefully maintenance tools to prevent accidents.
For more information, please visit the page of why choose all-in-one web guide system.
An automatic tension controller is a high-precision, fully digital, intelligent tension controller, with more advantages and practicality in application and function. It is anti-interference, much more convenient, and stable. It has extremely high tension control accuracy, which is suitable for use in occasions that have high requirements for the accuracy of tension control.
Characteristics of automatic tension controller
1. High accuracy
The signal can be transmitted via the tension sensor, and then the output signal is processed by the intelligent PID. The actuator can be adjusted to control the changes in the diameter of the tensile scale and the appropriate coil. The output accuracy is as high as 0.1% so that the tension control is more accurate and stable.
2.Single/dual input
Receiving single or dual sensor inputting signal with automatic zeroing and calibration.
3.User-friendly interface
Adopts a full touch screen with simple operation and manual and automatic switching.
4.Strong anti-interference
Metal shell with strong anti-interference capacity without sparks.
5.Parameter password protection
Secret code setting will avoid that errors change the setting parameters.
6.Wide applications
Widely used in many industries such as paper-making, printing, packaging, textile, non-woven fabric, etc. The precision of tension control directly affects the processing quality of the product.
Automatic tension controller manufacturer - Arise
Arise, which is a leading web guide manufacturer, the products including web guiding system, web guide controller, web guide senor and more other products of web guiding & tension control, in China, with more than 10 years of experience, can provide full automatic tension controller with 32-bit or 16-bit high-precise AD sampling - T500/T1000.
In the industries of paper, printing, textile, packaging, metal and wire & cable, in order to maintain high production efficiency, a basic tension controller is essential. It has wide applications, especially in the most related coiling and unwinding industries which need a perfect web tension controller to improve production efficiency and product quality.
What Is The Tension Controller?
Tension control refers to the ability to control the tension when the raw materials are transported on the device. In the coiling industry, the tension always needed to be controlled for production requirements, and the tension controller is a type of device for tension control. It has the advantages of small error, fast responding speed, high accuracy and simple adjustment. There’re three types of tension controllers including automatic tension controllers, semi-automatic tension controllers and manual tension controllers.
The basic composition of the tension control system
A typical tension control system is mainly composed of a tension controller, a tension reader, a tension detector, a magnetic powder brake, and a clutch. According to the loop, it can be divided into open loop, closed-loop, or free ring tension control system and it can be divided into types of ultrasonic, floating roll, track arm, according to the monitoring method of different coils.
Working principle of the tension controller
The tension controller can directly set the value of the tension control, and then input the signal of the tension sensor as a feedback value. Input the error to the PID or other manipulations for dealing with, and output to the actuator to control.
The tension controller system is controlled between the units of the magnetic powder clutch and must maintain a consistent ratio at the speed, a constant tension among the materials, or controlling tension according to the specified regularity, to ensure high-efficiency productivity and superior product quality.
Why The Tension Controller Is Important In The Coiling and Unwinding Industries
In the production process of paper, textile, plastic film, wire, printing products, tape, metal strip, etc, the roll of the material or wire is crucial to the quality of the product, and constant tension control is required for this purpose, which can make the products withstand the best tension in the process of winding and remain unchanged from the beginning.
The tension controller can be widely used in various applications where tension is precisely measured, with flexible and extensive applicability. The controller compares the deviation of the tension setting value and tension measurement. The output is adjusted through the proportional integration algorithm calculation, so that the web tends to be the setting value, thereby achieving the purpose of constant tension control. Therefore, it is very important to set the appropriate value of proportional integral and stationary zone parameters for the stability of the tension system.
The stability of constant tension control is directly related to the quality of the products. If the tension is too large, the stretch deformation of the processing material will be caused. If the tension is too small, it will deform the stress between the layers of the material and the layers, resulting in the uniform unwinding, affecting the quality of processing.
The Debugging Method Of The Tension Controller
The rewinding & unwinding, or transfer of the tension controller is based on the balance of tension variation in different industries, for high-efficiency production, the debugging method of the tension controller is critical.
The debugging method of the tension controller can be done in the following steps.
1. Programming the related parameters of tension measurement.
2. Make sure the tension controller is installed and the wiring is turned on the power.
3. By manual adjustment, check the system to confirm that the tension is normal and the actuator is operating normally.
4. Ensure the installation of the tension sensor and the wiring is correct. Check whether the signal of the tension sensor is normal.
5. Adjust the PID parameters according to the operation situation for guaranteeing the balance operation of the tension control system.
6. Calibrate the 0 points and the full scale of the tension signal, and ensure the normal display of the tension.
When the tension controller is automatic and the tension is greater than the setting value, the output current value is reduced. When the tension is smaller than the setting value, the output current value increases and the current value is increased with the increased tension in the system, which is greater than the setting value, the output current decreases, and the value of the tension will be reduced, thereby recirculating, achieving automatic control.
For more professional knowledge, please visit the article page of important tension controller for the coiling industry.