Web 101SM – What is Web Handling?

Introduction

SM

©2010
David Roisum, Ph.D.
Finishing Technologies, Inc. 1.1
 Sections
• Introduction
• Rollers
• Tension Control
• Wrinkling/Spreading
• Winding

1.2
 What is a Web?
 Long  Thin  Flexible

• All webs follow the same laws of physics

• If we know the physics, we know the behavior 1.3
 Web Materials
• Paper
• Film
• Foil
• Nonwovens
• Textiles
• Other
• Combinations

1.4
 Web Products
Industries Household Examples
• Aerospace • Books & Magazines
• Agriculture • Clothing
• Automotive • Currency
• Building Products • Garbage Bags
• Medical Products • Insulation
• Packaging • Potato Chips
• Printing • Writing Paper
1.5
 What is Web Handling?
• Art and Science of
• Getting a Web through a Machine
• As Fast/Wide as Possible and with
• Minimum Waste

• Why?

1.6
 Why Study Web Handling?
• Fast/Wide - Productivity
• Minimum Waste – Yield
• Its all about Money !!
Web
Handling

1.7
 Examples Web Handling Waste
• Baggy Webs
• Curl
• Length & Width (dimension)
• Registration (location)
• Web Breaks
• Winding Defects
• Wrinkling
• etc
1.8
 Major Topic Areas
• Web Handling • Web Converting
– Rollers (3) – Slitting
– Tension Control (2) – Winding
– Nip Control (2)
– Temperature/Moisture • Other
Effects and Control
– Material Properties
– Guiding (Path Control)
– Physical Properties
• Wrinkling – Problem Solving
– Wrinkle Cause/Cure – etc
– Spreading
1.9
 What We Will Not Study Here
Web Manufacturing Web Converting
Forms web Changes web
• Film Extrusion • Coating
• Paper Making • Laminating
• Textile Weaving • Printing
• etc • Sheeting
• etc

Web Handling Preserves web’s properties 1.10

 “A month in your plant

is worth an hour in the Library”

-Bell Labs saying

or

1.11
 Books by Dr. Roisum
• 1994 – The Mechanics of Winding
• 1996 – The Mechanics of Rollers
• 1998 – The Mechanics of Web Handling
• 2000 – Web Words
• 2002 – Critical Thinking in Converting
• 2006 – Web101SM CD
• 2007 – Winding Machines, Models and
Measurements
– Coauthored with Dr. J. Keith Good.

• TAPPI PRESS, tappi.org, (770) 446-1400

• David Roisum, drroisum@aol.com, roisum.com
• 920-725-7671 phone, 920-312-8466 cell
• http://www.webhandlingblog.com/
1.12
 Other Books TAPPI PRESS
• Roll and Web Defect Terminology, 2nd Ed.
by Duane Smith 2007
• Anthology of Winding by Jan Gronewold
2000
• Winders the Complete Guide by Jan
Gronewold 1998.
• Winding by Ken Frye 1990
• Tension Control by Kee Shin 2000
• Converting for Flexible Packaging by
Adolph Miller 1994

• TAPPI PRESS, tappi.org, (770) 446-1400

1.13
 Books Other
• Coating and Drying Defects by Edgar Gutoff and Edward Cohen, 2nd Ed., Wiley-Interscience,
2006. (call 800-225-5945)
• Modern Coating and Drying Technology. by Edgar Gutoff and Edward Cohen, 2nd Ed., Wiley-
Interscience, 1992. (call 800-225-5945)*
• Web Processing and Converting Technology and Equipment by Donatas Satas, Van Nostrand
Reinhold, 1984*
• The Plastic Film and Foil Web Handling Guide by William Hawkins, CRC PRESS, 2003
• Coating, Converting and Specialty Processes by Michael Kocurek and Michael Kouris, TAPPI
PRESS, 1990
• Rubber Roller Group Handbook by the Rubber Roller Group 2000
• Application of Statistical Process Control to Roll Products by Paul Frost, PJ Assoc 1991. (call 617-
471-3798)*
• Rotogravure and Flexographic Printing Presses by Herbert Weiss, Converting Technology Co,
1985*
• Control Systems for Web Fed Machinery by Herbert Weiss, Converting Technology Co, 1983*
• Technically Speaking by Herbert Weiss, Converting Technology Co, 1978*
• Coating and Laminating Machines by Herbert Weiss, Converting Technology Co, 1977*
• Science and Technology of Surface Coating by BN Champman, Academic Press, 1974*
• Coating Equipment and Processes by George Booth, Lockwood NY, 1970*
• Drying Principles and Practice by RB Keely, Pergamon Press, 1972*

• * Rare or out of print

1.14
 Magazines and Organizations
• Magazines
– Converting Magazine - convertingmagazine.com
– Paper Film Foil Converter - pffc-online.com
• Organizations
– AIMCAL Assoc of Industrial Coaters and Laminator - aimcal.org
– CEMA Converting Equipment Mfg Assoc
– ICE (Int’l Converting Exhibition) was CMM (Converting
Machinery and Materials)
– TAPPI - tappi.org
– WHRC Web Handling Research Center - engext.okstate.edu
• Consultants
1.15
 Software
• Top Web
– TopWeb is the only comprehensive software available for web handling. It was launched in 2000 by
Rheologic Ltd, a spin-off company from Leeds University. Its sister program TopCoat models coating
processes. Both are available by downloading from www.rheologic.co.uk, or on CD by request, and can be
tried free for 30 days. Since its launch, TopWeb has added several new features, including new modules on
lamination, web path and bowed rollers.
• WINDaROLL
– There are no more complete winding models available to the general public than WINDaROLL that is
included with the book Winding Machines, Mechanics and Measurements by Dr Keith Good and Dr David
Roisum. This book si published by DEStech and marketed by www.tappi.org. While there are more
powerful models written by Dr Good and his students, they are only available to members of the Web
Handling Research Center.
• Other
– Dover Flexo Electronics: www.dfe.com/calcMenu.html; Forces on load cells from tension and wrap angles
– FMS: www.fms-ag.ch/e/downloads; Forces on load cells from tension and wrap angles
– Magpowr: www.magpowr.com/application_software.asp; Forces on load cells from tension and wrap angles
– CAC: www.converteraccessory.com/ss/tqrpmhp.htm; Motor and clutch torque and horsepower
– Magpowr: www.magpowr.com/application_software.asp; Motor and clutch torque and horsepower
– Tidland: www.tidland.com/erg_calculator.asp; Ergonomic shaft configurator
– Composite Can and Tube Institute: http://cctiwdc.org/media/coreguidelines.xls; Core material and thickness
from roll size and weight
– Stanford Products: www.stanfordproductsllc.com/roll.htm; Roll dimensions, weight, slitter knife positions
– This list with permission from Dr. Dilwyn Jones. Web Experts Go Online. AWEB2006.

1.16
 Websites
• Black Clawson: www.bc-egan.com; Winding, slitting, unwind, splicing
• Converter Accessory Corp.: www.converteraccessory.com; Spreading, wrinkling, web handling
• Converting Magazine www.convertingmagazine.com “Web Works” by Dave Roisum
• Dienes: www.dienescorp.com: Slitting
• Dover Flexo Electronics: www.dfe.com; Load cells, brakes, tension control
• Finishing Technologies: www.roisum.com; one stop shopping by Dr Roisum for web handling
• Metso Covers: www.metsocovers.com; Technical Bulletins on roll covering, nips “Up and
Running” articles on efficiency, productivity, profitability, quality, safety.
• Metso Paper: www.metsopaper.com (under News and Info)
• Paper Film Foil Converter Mag: www.pffc-online.com; “Web Lines” by Tim Walker
• Rockwell Automation www.rockwellautomation.com Electric Drives section
• Siemens: http://automation.usa.siemens; Motors and drives
• Tidland: www.tidland.com; Slitting
• Webex: www.webexinc.com; Rollers, web path

• This list with permission from Dr. Dilwyn Jones. Web Experts Go Online. AWEB2006.

1.17
 Buyer’s Guides
• AIMCAL Sourcebook: www.askaimcal.org/source
• Converting Magazine Buyers Guide: http://sourcebook.cahners1.com/Conv
• Converting Resource Find A Supplier: www.convertingresource.com/bguide
• Flexonet Directory: http://flexonet.com/DIR/dir_main.html
• GlobalSpec: www.globalspec.com
• Label and Narrow Web Buyers Guide:
www.labelandnarrowweb.com/buyers.php
• Paper Film and Foil Converter Buyers Guide: http://buyersguide.pffc-
online.com
• PPMA Products and Services Directory: www.packcentre.info
• TAPPI Buyers Guide: www.tappi.org
• The Labels Directory: http://www2.worldoflabels.com/ind_suppliers.htm

• This list with permission from Dr. Dilwyn Jones. Web Experts Go Online.
AWEB2006.

1.18
 Basic Definitions
• MD – Machine Direction
• CD – Cross Direction a.k.a.
TD – Transverse Direction
• ZD – Z Direction
• Bagginess – aka camber,
flatness, layflat etc
• Drive – a system of
components making up a
tension control system
• Nip – Pressure between two
rollers (or roller and wound
roll)
• Roll – coil or wound roll
• Roller – rotating cylinder to
transport web
• Sheet – web that is cut to
length
• Slitter – cutting component
• Web – long, thin flexible
material
• Wrinkle – a web that is not
dead flat
1.19
Web 101.02SM – Foundations of Web Handling
Roller Intro

SM

©2010
David Roisum, Ph.D.
Finishing Technologies, Inc. 2.20
 Rollers ARE Important to Web
• Web’s ‘Universe’ is rollers and
the spans between rollers

2.21
 Rollers are NOT Mysterious
• Effects are Basic and mostly Predictable
• Rollers only do 5 things to the web

2.22
 Mechanics of Rollers
• Where equations, recipes, worked out
examples and references are found
• TAPPI PRESS, tappi.org, (770) 446-1400
• Dr Roisum, 1996
• Details given as MOR pp xx

2.23
 1 - Rollers Change Web Tension:
Symbol Key
Idler

Driven

M M M

Tension Driven Rollers

Tension rise > braking
Tension drop > motoring
Web Handling > Train Translation Idler Rollers
Motor > Engine Tension Rise,
Roller > Car (Inertia + Friction) except during decel
Web > Coupling (Tension) 2.24
 2 - Rollers Change Web Path:
• Physics: • Explains • Can Cause
• Normal Entry Law: – Guides – Web Breaks
– Web enters a roller in – Roller Misalignment – Slack Web
traction at a right – Spreaders – Wrinkles
(normal) angle – etc – etc

Traction

2.25
 Rollers also Change:
3 Wrinkles
– Decrease – spreading and flattening
– Increase – imprecise or intolerant rollers
4 Temperature
– Heated
– Cooled
5 Web Processes
– Calender, coat, laminate, print, etc.

2.26
Web/Roller Interaction Modes
Flotation
Ovens
Vr ≠ Vw Pans, Turnbars
Flattening, spreading

Sliding
Vr ≠ Vw Pans, Turnbars
Flattening, spreading

Traction
Vr = Vw MOST WEB COMPONENTS!

2.27
 Laws and Behaviors
• Are Different for Each of The Modes
• Must Know Mode By

– Calculation of traction Design

– Measurement
• Hand/Roller Tachometers
• Lasers

– Observation
• Blueing, patina, machining marks Troubleshoot
2.28
 Mixing Modes Rule
• OK to have different modes in a machine
– e.g. can have floating dryer and tracking rollers
on same line
• Not OK to change modes on any particular
element
– And time
– Any place across width

2.29
 Mixing Modes > Δ Tension
• Changing Modes causes a Tension Upset
Tracking Sliding Floating

T1 T2

T1 T2 T1 T2

T2/T1 < e^(µθ) = e^(µθ) =1

Note >> Web travels left to right in all of my figures

2.30
 Mixing Modes > Δ Position
• Changing Modes causes a Path Upset
Traction

Sliding

Floating

2.31
 Normal Entry Law > Web Path
• A web seeks a right angle entry to
a roller in traction

Traction

2.32
 Roller Diameter Taper or Nip
Pressure Variation and Web Path

Traction

Sliding

2.33
 Baggy Web and Web Path
• Web arcs away from baggy side when slack
• Web arcs toward baggy side under tension
– More offset in traction than sliding
Unwind Roller

Sliding
Less

Baggy Edge
Traction
2.34
More
 Roller Design Rules:
• ’10 Commandments of
Web Machine Design’

4.35
Use Fewest Number of Rollers
• Rollers Begin with badness I
– Rollers and attachments cost money
– Take up space
– Increase time to do cleanup, maintenance,
threading and troubleshooting
– Challenge tension and path control
– If you make a mistake or are unlucky - can
increase web defects such as wrinkles

4.36
 Roller Count Rationale
• Minimum roller count is KISS Rule of
Design (Keep It Simple Stupid) applied to
Web Handling
• Can judge skill of designer by how few
rollers and roller styles are used for
machine

4.37
Rollers Should Not
Deflect Excessively else:
• Increases wrinkling II
• Increases variability at a nip
• Increases vibration

4.38
 Deflection Details - Forces
• Rollers Deflect Due to Forces of:
Roller’s own Weight

Web’s Tension

Nip
4.39
 Deflection Details - Standards
• Class B: 0.00015” per inch of face or

About the thickness

of a human hair

More Info: MOR ch 3 4.40

 Sizing Roller Diameter
• Not too $mall, not bigger than nece$$ary
– Engineering Calculations
– Slenderness (width / diameter) Rule of Thumb
• 10-15 for nipped rollers
• 15-20 for unnipped rollers
• Roller Diameter Sizing Criteria
– Deflection (determines most rollers)
– Critical Speed (very fast)
– Stress (mostly journals)
– Traction (with adhesion)
– Heat Transfer (heat/chill rollers)
4.41
Do Not Allow Web to
Slip on Roller else:
• Loss of tension control III
• Loss of path control
• Web marking
• Roller Wear

4.42
Limit Tension Differences
Across Rollers else
• Loss of Traction Risks IV
• Floppy web on low tension side
• Yield or break on high tension side Symbol Key
Idler

Driven

M M M

Tension
4.43
Rollers Should Be
Rigidly Mounted else:
• Alignment is lost V
• Noise is increased
• Vibration is increased
• Wear is increased

4.44
 Mounting Details - Standards
• Clearance should not
be detectable by
hand
• Clearance and
compliance should
not exceed a
hairsbreadth

4.45
Rollers Should Be
Aligned else:
VI
• Registration Problems
• Web Bagginess
• Web Breaks
• Wrinkling

4.46
 Alignment Details - Types
• In-Plane (Bending)
– a.k.a.: Parallel or Tram
– Most serious by far
– Can be detected by eye
– Walking diagonal shadows
– Can be measured with a flat tape
• Out-of-plane (Twisting)
– a.k.a.: Skew
– Most benign
– Harder to detect
More Info: MOR ch 12 4.47
 Alignment Details - Detecting
• Visually
– Walking diagonal shadows
– Floppy edge one span
• Hand Tools
– Flat Tape
(Parallel)
– Tramming Stick
(Parallel)
– Precision Level
4.48
 Alignment Details - Correcting
• About a hairsbreadth
• Seldom possible with
hand tools, need
• Theodolite or laser

More Alignment Tools 4.49

Rollers Should Be Round
else:
• Registration Problems
• Web Bagginess
• Web Breaks
• Wrinkling

4.50
 Roundness Details - Types
• Radial Runout
– Most common concern
– Easy to detect
• Dial indicator
• Barring product nip
• Vibration
• Diameter Variation
– Most serious for product damage
– Far more fussy than alignment
– Increases with wear 4.51
 Roundess Details - Standards
• 0.1 – 1.0 hairsbreadths
• Check runout with dial
indicator
• Check diameter variation
with micrometer

4.52
Web 101.05SM – Foundations of Web Handling
Tension Control

©2010
David Roisum, Ph.D.
Finishing Technologies, Inc. 5.53
 Why is Tension So Important?
Affects the Web:
• Flatness: Bagginess & Curl
• Geometry: Length, Width and Thickness
• Position: Path and Registration
• Runnability (Web Breaks)
• Winding: Roll Quality
• Wrinkles

5.54
 What is Tension?
• Force : rope, string, wire, struts
• Force / width : webs
• Force / width / thickness : engineer’s stress

es
ch
In
40
=
W

F = 20 lbs

Tension = F/W = 20 lbs / 40 inches

Tension = 0.5 lb/in = 0.5 PLI
5.55
 Tension Control Elements
• Tension sensor (load cell or dancer)
• Tension actuator (motor or brake)
• Tension controller (drive, PLC or black box)

M
• Tension setpoint
• Tension quality
Controller

• Tension control strategy Load Cell

• Rollers and other mechanical elements

5.56
 The 1-2-3’s of Setting Tension
1. Starting point based on literature, machine
builder guidelines or experience

2. Let the web tell you based on frequency of

high and/or low tension defects as a result.
If mostly high tension defects > reduce tension
If mostly low tension defects > increase tension

3. If both high and low tension defections >

Economic Optimization
5.57
 1 - Tension Setpoint Guidelines
• Common Materials
– Machine Builder Recommendations
– TAPPI
– Literature
• Jones, John P. Determining tension Values, Converting Mag, Nov 89
• Any Material
– 0.5-1.0 PLI per mil of thickness
– 10-25% of MD Tensile Strength
– Best tension is approx. proportional to strength or gage
NewTension/OldTension = NewGage/OldGage
– If your practice is different from above, find out why
• Example: Newsprint 3 mils thick and 10 PLI strong
– By thickness rule 1.5-3.0 PLI
– By strength rule 1.0-2.5 PLI
– Industry standard 1-3 PLI 5.58
 2a - Too MUCH Tension
• Necking (ductile or rubbery materials)
• Web Breaks (brittle materials)
• Wrinkles (some types)
• Wound Roll Defects
– Blocking
– Core crush type 1, etc

• Ten$ion Dependent:
– Cu$tomer complaint$
– Rejectable wa$te
– Downtime$

5.59
 2b - Too LITTLE Tension
• Bagginess
• Flutter
• Web path changes
• Printer misregister
• Wrinkles (some types)
• Wound Roll Defects
– out-of-round, telescope, etc

• Ten$ion Dependent:
– Cu$tomer complaint$
– Rejectable wa$te
– Downtime$ 5.60
 How to Measure Tension
• Web Sag
– MOR pp 21

• Air backpressure
• Performance Curves
– Mechanical Brake Current/Pressure
– Motor Amperage

• Dancers that are calibrated

• Load Cells are Best !!
5.61
 What is a Load Cell?
• Roller mounted on a (electronic) force gage
• Roller force feeds back to motor torque control

M
Controller
Load Cell
5.62
 What is a Dancer?
• Roller on a pivoting arm
• Arm position sensor feeds motor control speed

Speed
Motor
Controller
Pneu Position
Cyl
Sensor
More Info: MOR pp 16-18 5.63
 What is Draw/Speed Control?
• Roller drive speed is controlled
• Open loop on web (no web tension sensor)
ε0, T0 ε1, T1 ε2, T2 ε3, T3

M M M

V2 V3
V1 ed
ed eed e
e Sp Sp
Sp

Drive Controller

5.64
 Web 101.09SM – How to Keep the Web Flat

©2010
David Roisum, Ph.D.
Finishing Technologies, Inc. 9.65
 Wrinkling
• is a Major Cause of Waste and Delay and
Customer Complaints
– Most web materials
• Paper, film, foil, nonwovens, textiles, aluminum sheet,
laminates, etc
– Most web machines
• Formers, winders, coaters, laminaters, printers, etc
• Aliases
– Baggy web, buckle, crease, foldover, gather, hard
wrinkle, soft wrinkle, pucker, trough, etc
• Is there a definition that can pull all this together?
Mechanics of Web Handling. Chapter 13. TAPPI PRESS 9.66
 Wrinkling Defined
• Any web not as flat as
– An inspection table
– Pane of glass

• Wrinkle Severity
– QA wrinkle: customer complains
– Troubleshooter wrinkle: can see shadows in
web run long before rejectable defects occur
9.67
 Wrinkling and Rollers
• Rollers are often central to wrinkling
– May be what initiates the wrinkle or
– May turn a trough into a foldover or crease
– More rollers may mean more wrinkles
– However, sometimes rollers can reduce wrinkling (spreading/flattening)
• Useful distinctions based on location
– Trough – wrinkle in a web span coming to roller
– Bulge – wrinkle crossing a roller
– Crease – wrinkle folded over on a roller Bulge Crossing Roller

9.68
Troughs Crease
 Why Web is Not Flat?
• Web has buckled in compression

• Buckling resistance increases with cube of

caliper or thickness

1 mil is 10X as wrinkle prone as 2 mil product

• Where does compression come from?

Roisum, David R. The Mechanics of Wrinkling. Tappi J., vol 79, no 10, pp 217-226, October 9.69
1996
 Wrinkling Cases
• Based on Source of Buckling Compression
• Taxonomy – ordering by appearance/character

Machine Direction (CD compression)

Diagonal Shear (Mohr’s circle compression)
Transverse Wrinkle (laminate, winding)
Baggy Web (MD tension profile variation)
Corrugation (winding nip)
Curl (laminating strain mismatch)

Roll and Web Defect Terminology, 2nd edition. TAPPI PRESS, 2007 9.70
 MD Wrinkle
• Wrinkles oriented in the MD
• May be evenly spaced at source (curtains)
• Wrinkles may coalesce irregularly at roller
• Severity: number crossing roller (0.001-100)
• Conclusion: web wants to be wider
Bulge Crossing Roller

Roisum, David R. What Causes Machine

Direction Trough Wrinkles? Converting
Magazine, Web Works column, pp 22,
March 1994. 9.71
Troughs Crease
 MD Wrinkle - Subcases
Causes Cures
Tension too high (stretchy materials) Reduce tension
Tension drop in span (stretchy materials) Maintain tension
Temperature increase (film, foil) Lower (oven etc) temperature
Moisture increase (nylon, paper) Decrease coat weight or water %
Slender roller deflection Increase roller size
Excessive roller grooving width Avoid wide grooves with thin webs
Roller groove or bump Roller maintenance, housekeeping
Improper spreading Fix spreader

Bottom Line:
Spread before wrinkles set or
Remove root cause More Info: MOWH pp 169-171 9.72
 MD Wrinkle Summary
1 – Wrinkle oriented in Machine Direction

2 – Web wants to be wider

3a – Reduce root cause

3b - Take out extra width with spreader

4a – or redesign product/process
4b – or live with wrinkles 9.73
 Diagonal (Shear) Wrinkle
• Wrinkles oriented at small angle w.r.t. MD
• Severity: angle of wrinkle
• Conclusion: something is crooked
• Examples Roller
Misalign
Corrugation Rivers &
Lakes
Material
Skew

Roisum, David R. What Causes Diagonal

Shear Wrinkles? Converting Magazine,
Nip on Crown Error
Wound Roll Bagginess 9.74
Web Works column, pp 22, June 1994.
 Shear Stresses
• Push/Pull in opposite directions
• Generates compression at an angle
• ‘Indian’ Snake Bite

9.75
 Roller Misalignment
• Parallel (Tram) alignment is critical
• In-plane bending is brutal
• Wrinkle points to narrow side
Walks
• Wrinkle ‘walks’ uphill ‘Uphill’

Points to
Narrow side

9.76
 Misalignment and Tension
• Might get relief by increasing or
decreasing tension
• Will get relief by roller alignment or
caliper increase + t, E

Flat
Web Tension Align Wrinkled

More Info: Slack

MOR chapter 12
MOWH pp 172-174 Misalignment Angle 9.77
 Shear Wrinkle Strategy
• Work on Man, Machine or Material 1st ?
• Work on Machine 1st
(if you are not certain what is crooked)
– More control over machine than raw material
– Easier to get machine precise
– Fewer crooked things to check for
• Rollers are aligned
• Roller diameter does not vary across width
• Nip pressure is uniform
• Temperature is uniform

9.78
 Shear Wrinkle Summary
1 – Wrinkle oriented at slight angle

2 – Something is crooked

3 – Check machine geometry first

9.79
 Baggy Web - Appearance
• Irregular lanes or patches of tight & loose
• Classes
– Baggy edges
– Baggy lanes
– Tight lanes
– Baggy patches
• Most Troublesome
– Cause of much waste
– Difficult to troubleshoot and fix
• What can you do? See next slides >>
For More Information See:
Baggy Webs: Making, Measurement and Mitigation,. DR Roisum, 2001
Troubleshooting Baggy Webs, DR Roisum 2008 9.80
 The Badness of Baggy
• Defects
– Esthetics
– Tension variations
– Coating variations
– Slitting variations
– Winding variations
– Corona back side treat
– Path/registration errors
– Wrinkles
• Other Badness
– Hard to measure
– Hard to troubleshoot
– Hard to fix
– May have multiple
causes

9.81
 Baggy Web Summary
1 – Irregular tight and loose areas

2 – Profile of some component is not

precise enough

3 – Run and hide type problem

More Info: Baggy Webs, downloadable from roisum.com 9.82

 Web 101.10SM – Mechanics of S
P
R
E
A
D
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©2010 G
David Roisum, Ph.D.
Finishing Technologies, Inc. 10.83
 Types of spreaders
NOT Modest More Narrow Most
Web
Grooved Compliant Bowed Tandem Expander
Cover Roller Bow

Wormed Concave D-Bar Dual Bow Tenter

Roller

Pos-Z

10.84
Bowed Roller – Picture

Photo Courtesy of Spencer Johnston

More Info: MOWH pp 144-146 10.85

 Edge Pull Spreaders
• Nipped Pair of Rollers on
Each Edge
• Normal Entry Law
• Nip > High Traction >
High Spreading
• Can guide if one side
engaged at a time Traction -
Right Angle Entry

Edge Pull by CAC

More Info: MOWH pp 150 10.86
 Spiral Grooving
Swanson, Ronald P. Testing and
• Does NOT Spread Analysis of Web Spreading and Anti-
Wrinkle Devices. 4th Int'l Conf. on Web
Handling Proc., Web Handling Research
• Has fooled thousands Center, Oklahoma State Univ, June 1-4,
1997.

– Barber Pole Optical Illusion

– Popular belief, assumption, homework failure

‘Apparent’ Motion
Rotation

More Info: MOWH pp 152 10.87

Web 101.20SM – Making a Quality Roll Product

Winding:

Machines,
Mechanics &
Measurements
©2010
David Roisum, Ph.D.
Finishing Technologies, Inc. 20.88
 Winder Classes - # Knobs
• Knobs to adjust Wound
Center Wind
Roll Tightness
Tension

– Web Tension

M1
Ni p
– Nip Center Wind w
Layon Roller
– Centerwind Torque Tension

differential

M1
Ni p
Surface Wind
– ‘s - some products are Tension

speed dependent

M2
Ni p

• Known at the TNT’s Center-Surface

Wind Tension
of winding ( M1+ M2)

M2

M1
Centerwind Torq. Diff.
( M1-M2) 20.89
 Winder Classes - Range
Tightness
Loose Tight
• Centerwind range is
Center Wind
from min to max web Tension

tension M
1

Nip
Center Wind w
• Layon roll nip adds Layon Roller
Tension

additional tightness M
1
Nip
Surface Wind
• Surface wind can’t get
Tension

as loose because of M
2
Nip
?
required nip Center-Surface
WindTension
(M1+M2)
• Center-Surface has M
2
M
1

widest range Centerwind Torq.

Diff.
20.90
 Winder Type - Turret
• Continuous production winder
• Wind one spindle, index over to new spindle
• Wide range of products and processes
Index • Core(shaft) support
Layon Roller Turret • Large rolls a challenge
• Center, Center w Layon
nsfer or Center-Surface class
d t r a hown
an tS or Gap
Cut No Spindle A Spindle B

Turret Mech 20.91

 Winder Type – Two* Drum
• Offline slitter rewinder
• *Optional 3rd roller known as Rider Roller
• Mostly paper and textiles
Rider Roller • Shaftess or Shafted
• Surface wind class
Wound Roll
• Very Durable
• Very Productive
Drums
Two Drum Mech
Programmed Nip 20.92
 TNT’s and Tightness
• Tension: makes roll
tighter Tension

• Nip: makes roll tighter, Ni p

especially soft materials

• Torque diff: makes roll
tighter (or looser)

M2

M1
Centerwind Torq. Diff ( M1-M2) 20.93
 TNT’s add up to WIT
• Wound-In-Tension is the tension in the
current outer layer of the roll WIT

Tension + Wound Roll:

Nip + WIT + WIT,
Torque Material tightness,
properties hardness,
Stresses, etc 20.94
 How Tight to Wind Roll?
• Baby Bear Theory:

• Not too tight to damage web

• Not too loose to allow roll damage

20.95
Defects by Tightness - Examples
• Loose Defects > • Tight Defects >
• Damage Roll • Damage Web
– Flat spots – Blocking
– Out-of-Round – Core Crush*
– Telescoping – Corrugations
– Gage Bands > Bag
– Tin Canning
• Defects Not affected by Tightness
– Offset core
– Wrong roll width Tight and Loose Defects 20.96
 Wound Roll Structure

T,N, T or WIT
• What
– Tight Start
– Smooth Transition
– Looser Finish Core Outside
Current Roll Diameter
• How
– Taper any of the TNT’s
• Why: reduce defects due to
– Roll Handling
– Starring
– Telescoping

20.97
 Winding Books
• Roll and Web Defect Terminology by Duane
Smith 1995, 2007
• Winding Machines, Mechanics and
Measurements Dr Keith Good and Dr David
Roisum 2007
• Winding by Ken Frye 1990
• The Mechanics of Winding by David Roisum
1994
• Winders the Complete Guide by Jan Gronewold
1998.
• Anthology of Winding by Jan Gronewold 2000

• TAPPI PRESS, tappi.org, (770) 446-1400

20.98
 Questions?

Answers:
David Roisum, Ph.D.

http://www.webhandlingblog.com/
http://www.roisum.com
drroisum@aol.com
920-725-7671 office
920-312-8466 cell 1.99