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Application of taper control in coiling of flexible packaging materials
Time: 2014-05-30 Source: Packaging Frontier Reading: 13737 times
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Wenzhou Junchuan Machinery Equipment Co., Ltd.

Abstract: During the rewinding process of coils used in the flexible packaging industry, the winding core of the flexible packaging coiling material is generally wrinkled due to improper setting or control of the winding taper. Based on the characteristics of different forms of taper input and output for a large number of equipment, ZhuoJi has calculated different taper calculation and representation methods, and thus has come up with a method for the correct use and control of taper tension to reduce material waste and improve product quality.

The algorithm of tension taper of different equipment manufacturers is almost different, but the ultimate goal is the same: as the diameter of the roll changes, the surface tension of the roll is reduced to avoid the core deformation or wrinkling during the central winding process. This is also the purpose of controlling the winding taper.

Due to different calculation methods, there is no uniform standard for tension taper, which brings certain difficulties to both the user and the equipment operator. Different equipment has formulated different process standards, which also brings a lot of inconvenience to flexible packaging enterprises in the process of practical application.

Under the premise that there is no industry standard, each design developer uses different methods to achieve taper control according to their hobbies and programming techniques and habits. By comparing various calculation methods, this paper counts several commonly used equipment tension taper input control methods and analyzes them separately, so that the majority of users have a deeper understanding of their equipment taper control, so as to correctly set the relevant parameters , And used to analyze and troubleshoot when the winding effect is poor.

I. Analysis of taper control of different equipment manufacturers

The taper needs to be controlled by entering the corresponding taper parameters. These parameters are obtained by different taper calculation methods. At present, there are basically three kinds of taper calculation methods for various equipment manufacturers, as shown in Table 1.

Note: "●" indicates the parameters that must be entered;

"○" means that the system automatically calculates the input or the taper calculation parameters imported by the system developer in advance (no operator input required);

"×" indicates parameters that are not required for this taper calculation method;

"F preset tension & F small": refers to the "target tension" or "initial tension" when we need a small roll diameter;

"F large": refers to the tension required when the diameter of the roll is large, such as the maximum diameter of the roll is Φ600mm, which is the tension value outside the roll of material;

"D small": the initial diameter of the taper, that is, the diameter at which the taper begins to decay, or the diameter at which the taper calculation is started;

"D large": the end diameter of the taper, or the maximum diameter;

"K (tension taper)": Taper or slope, generally expressed as a percentage or as a decimal point (In the second taper control method in Table 1, K is hidden, although the size of K or There is no direct input of the taper value, but it is still attenuated in proportion);

"D1 tension taper compensation": Only in the first algorithm, the parameters of taper compensation are used;

“D Real-time”: The real-time diameter of the winding. This data is very critical. It is usually calculated by a program instead of manual input. There are many methods for calculating the material diameter, which are not described here in detail.

"F real-time": It is based on the instantaneous winding diameter, the motor torque (surface tension acting on the material), which is what we usually call the tension.

Because the equipment manufacturer does not adopt a uniform unit standard and a uniform taper calculation method, this also brings a lot of trouble to the user, especially when making the process sheet, different equipment process data must be formulated according to different equipment. The equipment using unit brings a lot of trouble, and it is also the fundamental reason that the technical department of this industry has no way to compile the process data of the equipment to the production process sheet. In this way, if you are not familiar with the equipment, you will have a high reject rate.

Analysis of various taper calculation methods

1, F real time = F preset × {1-K [1- (D small + D compensation)] / (D real time + D compensation)} Non-linear taper

In this method, the taper value can be obtained by inputting the two variables of the preset tension F & F small and K (tension taper). This method is relatively simple and belongs to the non-linear taper calculation method. It can obtain various winding effects. By inputting the required initial tension F preset tension & F small and taper K (tension taper), different taper outputs can be obtained according to different winding diameters and changes.

Example: The initial tension F = 250N, the diameter unit is mm, and the taper is 20%. According to calculation method 1, the tension values of different coil diameters are obtained. As shown in Table 2:

According to the results in Table 2, the tension change trend is obtained:

The above data shows that the taper curve is a non-linear taper curve. This non-linear taper curve can be adjusted by adjusting the input taper compensation. Figure 2 shows the coiled taper curve when the taper compensation is set to 500:

Modifying the taper compensation value can obtain different winding curves, but as a user, there is usually no understanding of the size setting of this compensation data, so equipment users generally do not set this parameter, and this compensation coefficient is usually As a system parameter, the engineer defaults to "0". The aforementioned non-linear taper has been widely adopted recently. The larger the D compensation, the closer it is to linearity, and the decreasing rate decreases.

2.F real time = F small-(F small-F large) × (D real time-D small) / (D large-D small) typical linear taper

The input variables for this calculation method are F preset tension & F small, F large, D small, and D large. The application is more common.

Column: Initial tension F0 = 250 N, F large = 208.17N, D small = 98mm, D large = 600mm, get the tension value of different roll diameter, as shown in Table 3.

The tension change trend generated based on the data in the above table is shown in Figure 3:

The above taper calculation method is widely used, intuitive, and easy to understand. When the enterprise uses it, it only needs to set the minimum coil diameter and the maximum coil diameter and the corresponding maximum tension and minimum tension values, and then the parameters for controlling the taper can be obtained.

3, F real time = F small-F small × K × (D real time-D small) / (D large-D small linear taper

This is an earlier method of taper. The difference from the second method is that you do not need to enter the tension value for large rolls, but enter the taper value, as shown in Table 4:

The tension trend generated according to the data in Table 4 is shown in Figure 4:

Through the above three kinds of taper calculation methods, we can understand the parameters that need to be adjusted when the taper decreases.

The decreasing gradient is related to the input parameters. Different parameter inputs will have different taper values. Enterprises should have an understanding of existing equipment taper calculation methods in order to obtain correct and suitable taper values for themselves.

If the user wants to know the existing method of calculating the taper of the winding device, there are two ways: One way is to compare the above three calculation methods according to "Table 1". Each calculation method has a corresponding taper parameter input option. Then I know which calculation method my equipment uses, so I know how to control the taper; the second way is to directly consult the equipment manufacturer.

Third, the conclusion

After the user has mastered the three taper calculation methods described above, the user can correctly input the parameters required to control the taper. At the same time, companies should also pay attention to the following issues: closed-loop tension modes are all marked with mechanical units, and the tension units are "N" and "kg"; if "%" is used as the tension unit, the open-loop tension mode is generally used. Although there is a mechanical unit for the winding tension of the slitting device, the winding tension is generally adopted in the open loop method. The taper calculation method is the same, but the tension value is calculated and simulated, not the actual tension. It has some special characteristics, so it is rarely used as closed-loop control, which should be paid attention to.

Taper notation has the following types: "%" and decimals less than 1, and some directly enter the integers from "1 to 100" for representation. No matter which notation is adopted, readers should convert it to proportions to perform understanding.

In order to obtain the ideal winding effect, it is necessary to do the following:

1.The equipment tension must be calibrated, and the actual output value is consistent with the instrument display, which is conducive to process monitoring;

2. The sensitivity error of the tension sensor used for checking feedback is ≤ 5N; the filtering time should be <1S; if it is a swing lever control method, the swing lever must be checked flexibly. The inspection method is: remove the connection between the low-friction cylinder and the pendulum, and manually check whether the pendulum can swing freely and flexibly; the low-friction cylinder is directly related to the tension, but it needs to be inspected by professionals, otherwise the airbag inside the cylinder will be damaged .

3. After the above conditions are met, entering the correct taper parameters will significantly improve the winding effect and control loss.

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