Yours truly, David Roisum, gave an hour long tutorial on Troubleshooting Baggy Webs. The premise was that the options are two: fix the bag in manufacturing or suffer. However, troubleshooting is challenging because measurements are difficult, identifying the element responsible is difficult and changing the element that is responsible is difficult. Nonetheless there is hope if you keep your wits about you and are brave. You must commit, something like kick-starting an old Harley, if you hold back even the least you may get hurt. Many people fear getting hurt so they just don’t try. Perhaps they will be inspired by the half dozen case histories illustrating how troubleshooting might be done.
Jerry Brown of Essex Systems talked about the Anatomy of a Wrinkle. He designed and built a pilot line up which he ran a latex belt. The latex was extensible enough that one can see the geometry changes on a misaligned roller which can then be removed on a concave roller.
Michael P. Bria of MEGTEC talked about Web Vibration in Flotation Dryers. He experimentally verified that the Chang vibration model was close, but did not properly account for web mass.
Brant Ross, Ph.D of MotionPort talked about Initial Application of Multi-Flexible Body Dynamics Software to Web Handling Simulation. Software such as this has been used for complex dynamic mechanism design for some time, but here it was shown to be useful for modeling of roller runout and misaligned rollers.
Andre Icso of Circonix Technologies talked about Feed Forward Algorithms in Web Conveyance Applications. To make a drive control system work well, the drive must calculated or infer as much as possible rather than rely heavily on the trimming from load cells or dancers. Static and dynamic friction, inertia, speed changes and many other upsets can be feed-forword to get the correction started sooner.
Dr. Lee Fenney Sigmala Ltd talked about Intelligent Micro Servo Control - The Future of Converting? Micro servos have many advantages over pneumatic actuators including reduced cost. Four of them are now used in one model of automatic slitters.
William Gilbert of Siemens talked about Synchronized Drive Control in Web Handling Applications. Servo and position controlled drives have revolutionized the printing and packaging industries. In addition to much more precise and flexible registration control, they can eliminate drive shafts and accelerate varying inertias more consistently.
Pierre Nader of SPN Consultants talked about Equipment Optimization - A Comprehensive Approach. This organization specializes in offsite analysis of man, machine and materials in a winding system. It does so by piping mega-amounts of data from an array of sensors to computers for analysis.
Joel Oakes of Delta Industrial talked about Optimizing Registration in Converting Equipment. Registration accuracy is determined by a number of machine factors such as encoder count, speed, tension, path length, gears, tooling accuracy and so on.
Bob Hosler of Keyence talked about Non-Contact Measurement in Web Handling Processes. Inductive, 1D and 2D lasers can be used for a wide variety of measurements such as roller runout, nip gap, web profile and thickness, vibration and so on.
Darrell Whiteside of Maxcess talked about The New Technology of Closed Loop Tension Control. Unwind tension controllers have advanced to include weightless load cell calibration, gain scheduling, out-of-round roll compensation and auto-tuning.
Mike Kordik of Beta LaserMike talked about Using Laser Doppler Velocimetry to Increase Profits and Reduce Downtime on Converting Lines. Lasers can measure web length and speed to better than an incredible 0.05% without the contact or slippage risks of conventional roller or wheel based methods.
Teach, can I excuse myself? My brain is full.
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