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

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

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 Michael Schröder 2

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 Michael Schröder 3

Centre Conventional Unwind Shaft Michael Schröder

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 Michael Schröder

MODERN TYPE UNWIND PANTOM AXES Michael Schröder

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 Michael Schröder

NEW TYPE OF UNWIND PHANTOM AXES WITH SPLICER KNIFE POSITION ON THE TURRET Michael Schröder

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 Michael Schröder

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 Michael Schröder 10

LIFTING BY CRANE FOIL UNWINDER Michael Schröder 11

FILM UNWINDER LIFTING BY LIFTING CARRIAGE Michael Schröder 12

CONVENTIONAL REEL HANDLING WITH LIFTING TABLE REMOVE EMPTY CORE REEL PREPARATION POSITION Michael Schröder 13

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 Michael Schröder 14

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 Michael Schröder 15

NEW METHOD FOR REEL HANDLING REEL PREPARATION BY TURNABLE FLOOR V-TABLE IN ADVANCE WAITING POSITION REMOVE EMPTY CORE LIFTING TABLE AUTOMATIC HEIGHT ADJUSTMENT Michael Schröder 16

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 Michael Schröder 17

UNWINDING OF SENSITIVE MATERIAL AS FOIL AND THIN FILM � IMPORTANT DESIGN FEATURE FOR SUCCESSFUL UNWINDING PROCESS Michael Schröder 18

UNWINDING PROCESS KINIFE PNEUMATIC PASTER ROLL PNEUMATIC SERVO CARRIAGE DRIVE Michael Schröder 19

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 Michael Schröder 20

WEB GUIDING AND TRANSFER DESIGN FEATURES • IDLER ROLL – DIAMETER (160-200 mm) – ROLL DESIGN CRITERIA Rt 3-5 my – DISTANCE ROLL TO ROLL – WRAP ANGLE • PASTER ROLLER – MATERIAL AND SURFACE • WEB TENSION CONTROL Michael Schröder 21

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 Michael Schröder 22

SPLICE SEQUENCES KNIFE CUT TAPE PREPARATION CONTACT WITH BUMP ROLLER REEL ACCELERATION/ SPEED MATCH Michael Schröder 9

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 Michael Schröder

SPLICE SEQUENCES COMPRESSED AIR PIPE WITH NOZZLES KNIFE CUT CONTACT WITH BUMP ROLLER TAPE PREPARATION REEL ACCELERATION/ SPEED MATCH Michael Schröder

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 Michael Schröder

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 Michael Schröder 27

Time for One Roll Revolution Line Speed versus Roll Diameter 1.0 0.9 Line speed 300 m/min Line speed 600 m/min 0.8 Time (seconds) Line speed 900 m/min 0.7 0.6 0.5 0.4 0.3 0.2 – 0.1 0 0 0,25 0,5 0,75 1,0 1,25 1,5 – New Roll Diameter (meter) Michael Schröder 28

Required Repeatability of Paster Roll Engagement 0.50 0.45 Line speed 300 m/min 0.40 Line speed 600 m/min Time (seconds) Line speed 900 m/min 0.35 0.30 0.25 0.20 0.15 0.10 0.05 0.00 0 0,25 0,5 0,75 1,0 1,25 1,5 New roll diameter (meter) Michael Schröder 29

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 Michael Schröder 30

Tail length variation versus Knife repeatability 0.2 0.18 300 m/min 0.16 600 m/min 0.14 Time (sec) 0.12 900 m/min 0.10 0.08 0.06 0.04 0.02 0 0 5 10 35 40 45 50 55 60 65 70 15 20 25 30 Tail length variation (cm) Michael Schröder 31

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 Michael Schröder 32

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 Michael Schröder 33

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 Michael Schröder 34

THANK YOU FOR YOUR ATTENTION Michael Schröder 35