Doctoring Salvage Rewinder with Web Guiding System, badly Wounded Rolls are a very big issue in Converting Industry.
After printing the roll in Rotogravure Machine, Flexo Printing Machine, etc., bad Rolls need to be wounded correctly with the help of Salvage Rewinder to reduce the wastage of the material.
KEW Manufactures all types of Doctoring Salvage Rewinding Machine with perfect Edge Guiding System to correct the badly wounded rolls.
Our Company’s machine helps to reduce the wastage of the laminate roll by perfectly winding the bad rolls and removing the old wasted rolls and making the roll new. Also Manufacturer of Unwind Trolley with Web Guiding System
Web Guiding Salvage Rewinding Process Machinery Manufacturer:
Our machine sets the standard for machines of this size. It incorporates the latest Total Tension Control System with closed-loop tension feedback to ensure it produces finished reels of the highest quality.
The machine has been specifically designed to process tension sensitive substrates. The cantilevered design allows easy loading and unloading of reels.
The machine is reversible to allow the print direction to be corrected without the need to unload and re-load the roll.
Typical uses of Web Guiding Salvage Rewinding Machine:
- Inspection
- Defect Removal
- Roll profile correction
- Spooling
- Trimming
- Slitting
The Converter Guide 4 Digital web guiding system is simple to set up, and utilizes AC Servo technology, with encoder feedback to give the ultimate web guiding performance.
With a rewinding machine the finish roll edge profile is sometimes controlled by the guider therefore this is a key area of the machine.
The guider corrects at speeds up to 50mm per second. The controls for the guider are fully integrated with the machine controls.
Technical Specifications of Web Guiding Salvage Rewinding Machine:
- Electronic of the film Photocell sensor for an edge.
- Electronic 0 5 HP AC Motor.
- Electrical Panel Board to Operate the complete Unit.
- Hydraulic Cylinder Adjuster Oil Pipe.
- Speed of Unit 250/min
- Variation of the film Winding is 0.5
- HYDRO -PNEUMATIC Web Aligner Unit.
- 0.5 H.P. Motor
- Air Pipe 5 Mtr.
- Oil Pipe 5 Mtr.
- Sensor 1 pcs
- Adjuster 1 pcs.
- Air Filter 1 pcs.
- Oil Filter 1 pcs.
- Hydraulic Cylinder size 6 strock 1 pcs
- High speed - 600 m/min
- Simple to set up and operate
- Short web path
- Digital web guiding
- Lay-on rollers to ensure air-free winding
- Comprehensive on-screen diagnostics
- Reversible operation - X2 will slow down and stop at end of the reel and will rewind automatically
- Ability to rewind and stop when defect detected
- Optioning trim slitting
- Closed-loop tension control
- Recipe system to ensure repeatability.
- The short distance between rollers
- Ethernet-based OPC server allowing access to machine parameters by SCADA or other management systems
- Robust design with heavy-duty frames
- Only high-quality components from global suppliers
- Touch screen control interface
- Internet-based real-time remote diagnostics
- No Hydraulics
- Operator friendly safety system compliant with EN13418
- Low maintenance
- Worldwide support
- X2 Salvage Rewinder Features
- Auto-reverses to detected defects
- Shaftless or shafted winding
- Driven or braked unwind
- Optional splice table
- Digital web guiding
- Optional shear, razor, or crush cut trim slitting
- Optional spreader roller
- Customized center-module for customers’ processes
Why is a web guiding system needed?
Web material transported within converting machines will not always track straight. A web guiding system is required for proper alignment of the material.
A variety of factors such as poor quality raw materials, material property variations in raw materials, improper machine alignment, improperly maintained machines, environmental conditions, and processing conditions, cause lateral web misalignment as they are transported in the converting machines/lines.
Lateral variations due to poor quality of raw material include telescoped rolls, poorly wound rolls with lateral misalignment, cambered webs, raw material with web thickness variations, etc.
Even if the raw materials are perfect, process variations in speed and tension might cause changes in traction that steer the web improperly.
Finally, roller misalignment, changes in roller drag, and air entrainment between the web and roller can cause lateral misalignment.
Aligning the flexible web material over the rollers during transport within the manufacturing process is critical to most converting applications.
Often, wastes such as wrinkling, creasing, misregistration, and at times web breaks are attributed to web alignment issues during transport. Reducing these wastes improves the productivity of the manufacturing process.
What is a web guiding system and where is it needed?
Web guiding system is also referred to as web guides or lateral guides. These devices are used in aligning the flexible material roll-to-roll converting machines.
As the name suggests, the device guides the material to the desired position. Web guides are used in different locations within the manufacturing machines based on the process requirement.
Web guides in the intermediate processing areas are called intermediate web guides. Web guides used at the entry or exit of the manufacturing machines are terminal web guides.
Intermediate web guides are typically used before or after a process where material positioning is required; web guides at the end of a long oven or at the entry of a coating or printing process are common locations for intermediate web guiding.
Unwind guides are used to position the material coming off a material roll at a correct location within the machine while a rewind guide is used to wind rolls with good roll edge quality.
No matter where the web guide is used, the function of the device is to ensure proper alignment of the material within the machine or on a material roll.
How does a web guiding system work?
As the flexible material is transported over rollers, the web tends to align itself perpendicular to the axis of rotation of the rollers.
This is called the normal entry rule and this is the reason for web misalignment when the rollers in a converting machine are not aligned properly.
Web guides that align the material use the same normal entry principle. By deliberately changing the axis of rotation of the guide roller, the web guides steer to a different position.
Several types of web guides are used to align the web; the difference is in the way the axis of rotation of the roller is changed.
What are the components of a web guiding system?
Web guides are often electromechanical devices that automatically control the edge or the centerline position of the web within the machine.
There are three main components of a web guide:
- sensor
- controller
- guide mechanism
The sensor is the vision of the system used to sense the actual/current position of the web material. Different types of sensors are used to measure the lateral position of the web material.
The type of sensor is usually based on the type of web material and the processing application. The position information from the sensor is then sent to a controller which is the brain to the guiding system.
The controller processes the sensor information and determines the required corrective action for the guide mechanism in order to guide the material to the required position.
The controller then commands the actuator, which is part of the guide mechanism, to physically steer the web material to the desired location.
Typically the controller is electronic hardware; electrical and pneumatic controllers are seldom seen in practice today.
The web guiding system is essentially an automatic control device that constantly corrects the position of the web-based on the sensor measurement.
The effectiveness of this control system is dependent on all three main components of the guiding system. If anyone of the components is faulty the overall guiding system will be ineffective.
Choosing the Best Web Guiding System for your Operation:
As we search for the most appropriate equipment for our operation, we are faced with the task of selecting from myriad options based on technical data and specs.
Through these data, measurements of accuracy, precision, linearity, and resolution, manufacturers are trying to present the benefits of their products based on the device’s performance profile.
However, sometimes what appears to be the best offer, based on what looks to be the best technical data, might not really be the best.
The technical data can even be irrelevant information when considering performance. See performance indicators relevant to your system and how to apply this information to your applications.
