For a high-accuracy web guide system, not only you should consider the ability of web guiding, but also consider the characteristics of the coil and its movement on the machine.
The Web Offsets Which Affect The Accuracy Of Web Guide System.
Driver limits
The driver has a limit in the web guide system. All web guide systems can correct the position offset within a certain range, and this range should less than the drive limit. Most drivers have a limit of +/-75 mm. If the enter position of the web is shifted by more than 75 mm, the system will be stopped because of the movement to the limit position, and the positional offset for the portion of more than 75 mm cannot be corrected.
Instant position offset
When the lateral position offset occurs in a short period of time, this offset is known as an instant position offset which is usually occurred because the shorter length of the web is r or the high-speed web. It may also be caused by materials, machines, or process changes, for example, due to the unmembacted web switching bonding. Because this positional offset is immediate, the lateral speed of this positional offset is infinite, which is called the most challenging positional offset and the web guide system is impossible to have an infinite tracking speed. In order to improve the efficiency of the web guiding, the instant offset.
The offset of the steady-state
The offset of the steady-state is usually caused by the deviation between the web and the reel, the reel and the flat gas shaft, the discharge rack and the subsequent process centerline. Further, during the transmission process, the offset of the steady-state is also occurred due to the non-parallel guide roller, the uneven diameter guide roller, or the external force, such as the airflow. There’s not a horizontal moving speed in the offset of the steady-state. Therefore, as long as the driving limit of the actuator driver is larger than the distance of the coil offset of the steady-state, this type of offset does not affect the accuracy of the web guide system.
Web
In addition to the offset of instant position and steady-state, the web also produces progressive lateral position offset, which may be caused by various reasons, such as the non-neat or inclined side of the coil, the movement of the loose roller, the sliding or sticky milling of the web in the roller, the work conditions of the machine or process for example that the tension, speed, lubrication, or temperature change will interfere with the mechanism of the coil transmission.
Web guide system itself
The web guide system may also cause the web offset. If the control loop is not adjusted well and the blind zone of the probe is too large, or the driver is loose, then the web guide system will cause the offset of the web. There are several important indicators for web guide system installation, which include calibration width, winding angle, the position of the swing center and the direction of swing.
Conditions & Features The Web Guide System Should Satisfy For The Highest Accuracy
Usually, the precision of 0.3 mm can meet most of the applications, which is also the accuracy that most of the web guide system can achieve with general settings. But to achieve 0.1 mm or higher accuracy, coil, web guide machine, and equipment must meet some requirements.
Conditions of the web guide system and coils should satisfy
1. The input of the web offset is a type offset of the steady-state.
2. The input of the web offset ranges within the driver limit.
3. Prouch, rebound, or probe of the connector is small enough.
4. The initial push power of the driver is large enough.
Features of the web guide system should satisfy
1. Inverse second of 40 seconds
2. The maximum lateral positional offset is less than 4 mm / second, at the speed of 25 meters/minute and the lateral offset angle is less than 6 degrees.
3. The frequency of any coil rack or the horizontal cycle is less than 6.4 Hz.
Large system gain, the quick response speed of the driver, the smallest loose connection & drivers rebounded, will do a great favor for the high-precise web guide system.
High accurate web guiding system will help greatly improve productivity and reduce production waste. As a web guide system manufacturer, the question you will be asked commonly is that what is the accuracy of your web guiding? The answer always will be doubted, because the definition of the accuracy of the web guide system varies for different people. Before learning the accuracy of the web guiding system, there’s a simple question that why the web guide system is required?
Why web guide system Is required?
The edges or center lines of the process of coating, printing, compounding, dividing, and winding, otherwise, the transverse dislocation of the coil will cause the waste or even downtime. This is why the web guide system is required. It is the technique which will always coil side is neat and consistent. Usually, the tracking method of the web guide includes three types of edge, center and line.
What determines the accuracy of web guide system
The accuracy of the web guide is determined by three factors: the deviation of the invasive web, the accuracy of the web guide system, the installation accuracy of the system. Further, the unique features of the coiling are that the deviation of the invasive web, the lateral movement or swing size of the coil, which are important factors in determining the accuracy of the web guide.
The definition of the accuracy of web guide system
The web guide machine is typically upstream of a critical process, and the closer the process is, thus the maximum reduction in position deviation errors when entering the critical process. As a manufacturer of web guiding, need to follow the edge, center, or line position of the coil just from the probe. So it is recommended that installing the machine in the location closest to the key process.
For more professional knowledge, please visit the article page of The accuracy of web guide system.
What is the full automatic web tension controller
The automatic web tension controller is a high-precision, multi-functional, fully digital tension controller, which is combined with a tension sensor to form a closed-loop system. By receiving the signal transmitted by the tension sensor, after the internal PID calculation processing, the actuator is adjusted to automatically control the winding or unwinding tension of the materials. It performs high-precision tension control on the coils.
The full-automatic web tension controller has a large control range, high precision, strong anti-industrial interference ability. It can be used in conjunction with tension sensors, magnetic powder brakes or clutches, electronic control converters, torque motors, and frequency converters. It is widely used for tension control in printing, packaging, textile printing and dyeing industries.
T500/T1000 Web Tension Controller
T500/T1000 web tension controller is manufactured by Arise Technology which is a professional and leading manufacturer & supplier of web guiding products and accessories including all-in-one web guide system machine, web guide controller, web guide controller, web guide sensor, tension controller, etc, in China with the latest advanced technology.
T500 web tension controller adopts 16-bit high-precise AD sampling for l us sampling time. The sensor has high signal precision and high speed. It can drive a magnetic powder brake. The controller can be connected with single/double pressure sensors.
T1000 is the first web tension controller to adopt a full touch screen. It adopts 32-bit high-precision AD sampling with 1us sampling time. The sensor provides a high precision signal with high speed and can be applied in conjunction with magnetic powder brakes, pneumatic brakes, electric motors, etc. It can be calculated automatically without a sensor.
Advantages Of T500/T1000 Web Tension Controller
1.It adopts 16-bit or 32-bit high-speed CPU with a humanized design, easy operation.
2. Using the PID algorithm without overshoot, the tension control is fast and stable.
3. Receive single/dual sensor input signals, adapt to various tension sensors
4. Dual 24V/4A output, which can directly drive two brakes/clutches.
5. It can output 0-10V, 4-20mA drive inverter or servo motor.
6. Easy installation and debugging with a simple tension calibration process.
7.Metal shell with strong anti-interference capacity without sparks
8. Parameter password protection to prevent misoperation.
9. Highly stable tension measurement.
Wiring Notices Of Automatic T500/T1000 Web Tension Controller
1. Weak wires such as the input signal wire, switch input and output terminals, the output power supply should be kept away from strong wires like the instrument power wire and power supply wire to avoid signal interference.
2. Kindly be noted that weak current terminals such as input signals, switch input and output terminals, and output power supply must not be connected to strong currents, otherwise, the entire controller will be burned.
3. Connect the tension sensor signal according to the correct wiring diagram. If you need to connect two tension sensors, you must pay attention to the polarity of the signal not to be wrong, otherwise, the displayed measurement value will be inaccurate.
4. If only a single tension sensor is connected, the input terminal which is not connected to the tension signal must be short-circuited.
Web tension controller provides a high precision control with a simple adjustment. The full automatic T500/T1000 web tension controller can ensure continuous, accurate tension control of various coil materials in all kinds of production processes.
Whether the web tension control is stable will directly affect the quality of the product. If the tension is insufficient, the coil materials will drift during operation, and the finished paper will be wrinkled after slitting and rewinding. Web tension controller refers to the instrument which can permanently control the tension of the coil materials when conveyed on the machine. This controller must be effective for any speed of the machine, including machine acceleration, deceleration and uniform speed, even in the case of an emergency stop. It should also be able to ensure that the slit is not damaged.
Why Choose Web Tension Controller?
In many industries, winding control problems are often encountered. For example, in the production process of coil materials, the unwinding and winding tension of the coil materials is very important to the quality of the product. For this reason, constant tension control is required. That is to make the product receive good tension during the winding process and keep it unchanged from beginning to end. The stability of the tension control is directly related to the quality of the slitting product. If the tension is too large, it will cause the tensile deformation of the processed material, if the tension is too small, the stress between the layers of the coiled material will be deformed, resulting in uneven winding and affecting the processing quality.
How Does The Web Tension Controller Work?
The tension controller is a kind of equipment that can permanently control the tension of the material belt when it is transported on the equipment. Using this equipment can well maintain the operating speed of the machine, and can not affect production in an emergency. So, how does this device work?
The web tension controller mainly works through the coil. Coil magnetostatic powder clutch and magnetic powder brake are automatic devices that can control the input current and change the output. When the coil is not energized, the input shaft rotates, the magnetic powder is pressed on the inner wall of the clamp ring under the action of centrifugal force, and the output shaft does not contact the input shaft. At this time, it is in an idle state. When the coil is energized, the magnetic powder generates a magnetic link under the action of the magnetic lines of force, so that the output shaft and the input shaft become rigid bodies and rotate, and slippage occurs when overloaded. So as to achieve the purpose of transmitting torque.
Methods Of The Web Tension Control
1. Manual Control
Constantly adjust the torque of the clutch or brake during rewinding, discharging or the process to obtain the required tension, which requires the user to check the tension of the coil materials at any time and adjust the output torque at any time. If pneumatic is used for brakes or clutches, the manual tension controller can directly select precision pressure regulators, which can save a certain amount of equipment costs, but it is only suitable for some low-speed compound machines, extruders, textile machinery and other occasions where tension control requirements are not high.
2. Semi-automatic Method
The method adopts the ultrasonic principle to automatically detect the coil diameter for adjusting the tension of the coils. The tension controller is essentially a semi-closed loop system. It can not only automatically measure the coil and control the torque output, but also has the functions of buffer start, anti-loosening and inertia compensation. The implementation cost of this scheme is low, so the method is widely used in mid-range machinery.
3. Fully automatic Method
This method is to measure the tension of the coil by a web tension sensor, and then the controller automatically adjusts the clutch or brake to control the tension of the coils. This method is a fully closed-loop tension control. In principle, this solution can reflect the change of tension in real-time, so the control accuracy is the highest. Therefore, some high-end finishing mills, high-speed slitting machines and other metallurgical applications adopt fully automatic tension controller.
Fully Automatic T500/T1000 Web Tension Controller
T500/T1000 web tension controller is manufactured by Arise Technology which is specialized in research and development, production and sale of web guiding products & accessories such as web guide sensor, web guide controller, web guide actuator, etc with advanced photoelectric, CCD, color sensitivity and ultrasonic technology. The fully automatic T500/T1000 controller provides high accurate tension control with simple & stable operation, easy installation.
After the mask machine is equipped with the web guide system, the production speed can be increased to 500 pieces/minute, and the N95 (KN95) mask machine can be increased to 3000 pieces/minute. It can perform differential and swing by tracking the edge of the working coil materials. It supports EPC which is the abbreviation of edge position control and LPC, the abbreviation of line position control, with ultra-thin melt-blown cloth custom sensors and adjustable tension.
The web guide machine uses a 940nm infrared emitter tube and imported silicon photocells to accurately detect the deviation of the melt-blown cloth. The drive system adopts low synchronization, frequency conversion speed regulation, stepping and servo motor drive. The stroke is strictly proportional to the offset of the coil materials. The servo motor drives the ball screw to precisely adjust the material deviation, and keep the edges and lines of coil materials at the designated position at any time The microcomputer digital controller provides accurate control for the various functions of the system. The machine adopts a full touch screen operation, which is simple and easy to use. The operation interface includes the languages of 8 countries, which is convenient to operate all over the world.
Professional Web Guide System Manufacturer - Arise Technology
Arise Technology, which is a professional manufacturer of the web guide system, is located in Chongqing, China, It is a high-tech enterprise specializing in the research and development, production, sales and service of high-tech industrial automation products. It focuses on the R&D and production of the web guiding system and tension control system with 15 years’ experience. Arise attaches importance to product quality, high technology and product innovation, and strives to provide advanced level products.
The products manufactured by Arise technology is simple to operate with high precision, good stability, a wide range of applications. They can track and correct the marking lines or edges of cardboard, film, aluminum foil, steel tape and other much more materials to ensure neat winding and slitting. They are widely used in packaging, film, printing, printing and dyeing, labeling, textile, steel, tire, battery and other more industries. With excellent quality products with innovative technology and professional service, the Arise web guiding products are sold all over the world and get a high reputation among customers.