Web 101.

78SM – When to Move, How Close to Move

Guidelines for Allowable Roller
Misalignment

©2013
David Roisum, Ph.D.
Finishing Technologies, Inc. 77.1
Why is Alignment So Important?
Affects the Web:
• Flatness: Bagginess and apparent Bagginess
• Position: Path and Registration (e.g. Printing)
• Runnability (Web Breaks)
• Winding: Roll Quality
• Wrinkles
• Costs money if standards are:
– Too loose or
– Too tight
77.2
 Two Views of Alignment
• Mechanical • Web Handling
– Level – In-plane (bending)
– Square • Path control
• Web breaks
– Common Centerlines
• Wrinkles
– Out-of-plane (twisting)
• Web damage/breaks at
edges
• Center wrinkle
– Offset Centerlines
• Guide runs off center
• Web runs off center 72.3
 Hand Tools - Types

40-400 microns / meter

Pi Tape

Figures Courtesy of Oasis Alignment Services 72.4

 Hand Tool - Limitations
• Level
– At best good to 0.001”/foot (100 microns per meter)
– (Optics can be 20X tighter)
• Square 2 3

– There is no squaring tool

1 4
– Parallelism Problems
• Doesn’t help square vertical spans (1-2 and 3-4)
• Accumulation of error
• Level and Square
– Large Tendency to Sloppiness
72.5
 Hand Tool – Application

• Step 1 – I might have • Step 2 – Verify working

an alignment related hypothesis that problem
problem might be exacerbated by
– Path Control misalignment
• Printer Registration – Level by level
• Wound Roll Edge – Parallel by Pi Tape
– Web Breaks
– (Diagonal) Wrinkling
• Step 3 – Align rollers
using precision tooling
– That specific area or
72.6
– Entire machine
 Optical Tooling

Similar to surveying equipment, but > 10X more precise

Figures Courtesy of Oasis Alignment Services 72.7
 Baseline Installation
• Alignment means
– Establishing ‘offset centerline’ for alignments
– Look for ‘monuments’ (small plugs) in floor

Figure Courtesy of Oasis Alignment Services 72.8

 Centerline Survey
• Alignment means
– Level,
– Square, AND
– Middle of Rollers on Same Centerline

Figure Courtesy of Oasis Alignment Services 72.9

 Squaring With Optics
• Precision Square w.r.t. Baseline
• Uses a pair of TTS
• Precision right angles

Figure Courtesy of Oasis Alignment Services 72.10

Other High Tech Alignment Tools

Laser Trackers Coordinate Measuring

Total Station
Laser Shaft Alignment
The standard for motor Gyro – Fast setup and
to roller alignment position readout
Gyroscope

Figures Courtesy of Oasis Alignment Services 72.11

Alignment Details - Preparation
• $$$ for Downtime • Design for Service
• Machine Builder (alignability)
– Standards & Instructions
– Alignability – Individual rollers
• Maintenance easily moved
– Remove Excess Rollers – Preserve Level
– Roller Maintenance Dowel Pin
• Shear ledge
– Dowel/Mark
• Jack bolts
• Align Crew Shear Ledge

– Plug Lines • Match Drilled

– Report with before & after readings Frames?
Dunn, Jim M. Precision Alignment of Winders. Tappi J., vol 79, no 6, pp 67-71, June 1996
Williams, Fritz (OASIS). Alignment Methods and Best Practices for Cost Effective Alignment
of Production Equipment. AIMCAL AWEB, Charlotte, May 7-10, 2006 72.12
 Alignment Challenges
• Bearing Housings • Alignment
– At an angle – No line of sight
– Bolt bound designs (e.g., match – Flimsy floors
drilled frames) – Hand tools
– No shear ledge
• Procedural
• Rollers - General – Lack of guidance
– Flimsy frames • Which rollers
– Flimsy foundations • How close

– Loose mounting – Not enough time

• Rollers – Specific • Special
– Pivoting / translating – Foil
– Skewable – Close packed rollers
– Curved axis (bowed spreaders) – Narrow rollers (wheels)
– Segmented 72.13
 Two Views of Alignment
• Mechanical • Web Handling
– Level – In-plane (bending)
– Square • Path control
• Web breaks
– Common Centerlines
• Wrinkles
– See Web101.72
– Out-of-plane (twisting)
– Roller Alignment -
• Web damage or breaks at
Mechanics edges
• Center wrinkle
– Offset Centerlines
• Guide runs off center
• Web runs off center 73.14
 In-Plane Bending
• a.k.a, i.e.
– Not parallel
– Not trammed
• THE MOST
SERIOUS RISK
– Path Control
– Web breaks
– Wrinkling
– etc
73.15
 In-Plane Bending: Stresses-Strains
• 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 – Path Change
– etc

Tract ion

73.16
 Out-of-Plane Twisting
• a.k.a, i.e.
– Twist
• Very Tolerant
– Difficult to Overstress
Pi vot Pt
– No path change
2 3
• Applications:
– Displacement Guide 2 3 Sensor

– Some Dual Spreaders

Twist
L1

L2
Correction Span
1 4

73.17
Out-of-Plane Twisting: Stresses-Strains

• No Path Change
• High Stresses at Edges
• Center MD Bagginess/Wrinkle possible

73.18
 Emergency Alignment
• Wrinkles are found at roller #3 and cause the
web to break
• Question: Which roller (1-4) should be moved
in which direction (horizontal, vertical, other)?
2 kle
Wrin 3
Hint:
Dryer
1 4

Ctr
Unwind Winder 73.19
 Smart Alignment
• Which rollers and directions is alignment most
needed ?
– Level – easy
– Square – requires optics

73.20
 Two Views of Alignment
• Mechanical • Web Handling
– Level – In-plane (bending)
– Square • Path control
• Web breaks
– Common Centerlines
• Wrinkles
– Out-of-plane (twisting)
• Web damage or breaks at
edges
• Center wrinkle
– Offset Centerlines
• Guide runs off center
• Web runs off center 73.21
 Current Art/Craft/Science
• Paper Industry: 0.002” or 0.005 inch
0.003” per 100” width, 0.005”
maximum 125 micron
• Converting Industry: 0.001”
/ foot
• Most Common By Far:
nothing whatsoever

• Models for wrinkling and web

breaks
• Despite decades of research,
most everyone is getting the
answer wrong
Commercial tolerances
that are relatively easy to
achieve with a bit of care77.22
 In-Plane Bending
• a.k.a, i.e.
– Not parallel
– Not trammed
• THE MOST
SERIOUS RISK
– Path Control
– Web breaks
– Wrinkling
– etc
77.23
 In-Plane Bending: Stresses-Strains
• 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 – Path Change
– etc

Tract ion

77.24
 Out-of-Plane Twisting
• a.k.a, i.e.
– Twist
• Very Tolerant
– Difficult to Overstress
Pi vot Pt
– No path change
2 3
• Applications:
– Displacement Guide 2 3 Sensor

– Some Dual Spreaders

Twist
L1

L2
Correction Span
1 4

77.25
 Practical Alignment
• One number for maximum allowable

• Worst case for a machine or plant

– In-plane bending (versus out-of-plane, level and
square)
– Material (thin, high modulus)
– Machine (short spans, short L/W span ratios)
– Rollers (traction)

• With Practical Exceptions such as 77.26

 Calculation Based
• For Each + t, E
Critical/Typical

Web Tension
Flat
Roller, Web and Wrinkled
Align
Direction
– Path Control
– Web Breaks (Critical
Angle to Inside Edge Slack
Slackness)
Misalignment Angle
– Wrinkling (Critical Gehlbach, Lars S. and Good,
Angle to Diagonal J.K and Kedl, Douglas M.
Prediction of Shear Wrinkles in
Shear Wrinkle) Web Spans. Tappi J., vol 72, 77.27
no. 8, pp 129-134, Aug 1989
TopWeb – Roller Align etc

77.28
 WP AbbottApp
Wrinkle Predictor AbbottApp

• ‘Wrinkle Predictor’ runs on any computer

and smartphone that has a modern browser

77.29
 Empirical
• For Each Walks
Critical/Typical ‘ Uphill’
Roller, Web and
Direction
– Wrinkling (Critical Points to
Angle) Narrow side
• Move roller while
running, observe
when diagonal
wrinkle starts
73.30
Parametric Allowable Misalignment per WP
AbbottApp

Hair'
s
Brea Misalig Misalig

Analysis:
Case Describe dth n n Tension Width Span Diameter Wrap Friction Thickness Modulus Slack Notes
microra
dians mils lbs in in in degrees mil MPSI Wrinkle

1.00 Paper Machine 60 1000 300 600 300 30 24 90 0.3 3 0.8 Wrinkle
Board
2.00 Machine 146 2433 730 3000 300 30 24 90 0.3 10 0.8 Wrinkle
Board
3.00 Rewinder 4 733 22 300 30 30 10 90 0.3 10 0.8 Slack
Paper
4.00 Rewinder 3 500 15 60 30 30 8 90 0.3 3 0.8 Both
4.01 Tension Study 4 700 21 1.5X Wrinkle
Low
tension
4.02 Tension Study 2 266 8 0.5X Slack worst
4.03 L/W Study 6 1000 30 2X Slack
Short
L/W
4.04 L/W Study 2 266 8 0.5X Slack worst
4.05 Diameter 3 500 15 3X Both
4.06 Diameter 3 500 15 0.5X Both NC

36 cases
4.07 Wrap 3 500 15 0.167X Both NC
4.08 Friction Study 3 500 15 3X Both NC
4.09 Friction Study 3 500 15 0.3X Both
Thick
Caliper
4.10 Caliper Study 2 300 9 1.2X 2X Slack Worst*
4.11 Caliper Study 2 300 9 0.8X 0.5X Wrinkle
High
Modulus mod
4.12 Study 2 333 10 1.5X Both worst

from paper,
Modulus
4.13 Study 6 1000 30 0.5X Both
low
tension,
short
Paper Worst span,
4.14 Case 1 83 2.5 30 30 15 8 90 0.3 3 1.2 Slack high mod
Paper Worst
4.15 Case 1 167 5 30 30 15 8 90 0.3 3 1.2 Both

paperboard, 11.0
0 PET Machine
12.0 PET
0 Rewinder
12.0
1 Tension Study

12.0
8

1
390

170

250
39

1.7

2.5 1.5X
50

5
100

10
30

20
24

4
90

90
0.1

0.1
1

1
0.4 Wrinkle

0.4 Slack

0.4 Slack
Low
tension

PET, PE and
2 Tension Study 0 90 0.9 0.5X 0.4 Slack worst
12.0
3 L/W Study 1 330 3.3 2X 0.4 Slack
Short
12.0 L/Q
4 L/W Study 0 90 0.9 0.5X 0.4 Slack worst
Thick
12.0 Caliper
5 Caliper Study 0 70 0.7 2X 5X Slack Worst*
12.0

AL foil
6 Caliper Study 0 170 1.7 0.2X 0.1X Slack
12.0 Modulus
7 Study 0 110 1.1 1.5X Slack
12.0 Modulus
8 Study 0 220 2.2 0.75X Slack
12.0 PET Worst worst
9 Case 0 30 0.3 2.5 10 10 4 90 0.1 1 0.6 Slack case
12.1 PET Worst
0 Case 0 130 1.3 2.5 10 10 4 90 0.1 1 0.6 Both

21.0
0 Foil Machine 1 35 3.5 50 100 30 12 90 0.3 1 10 Wrinkle
22.0 worst
0 Foil Converter 0 30 0.9 15 30 30 12 90 0.3 1 10 Sack case
22.0 worst
1 Foil Converter 0 36 1.1 15 30 30 12 90 0.3 1 10 Both case

31.0
0 PE Rewinder 7 3300 33 10 10 20 4 90 0.2 1 0.04 Slack
31.0 PE Rewinder worst
1 Worst Case 1 410 4.1 5 10 10 4 90 0.2 1 0.08 Slack case
31.0 PE Rewinder worst
2 Worst Case 2 990 9.9 5 10 10 4 90 0.2 1 0.08 Both case
77.31
 Paper/Paperboard - PM Winder
& Converting Rewinder
• Paper is fussier than paperboard
• Narrow converting rewinder fussier than
full width PM winder

Hair's
Bread
Case Describe th Misalign Misalign Tension Width Span Diameter Wrap Friction Thickness Modulus Slack Notes
microradi
ans mils lbs in in in degrees mil MPSI Wrinkle

1.00 Paper Machine 60 1000 300 600 300 30 24 90 0.3 3 0.8 Wrinkle
2.00 Board Machine 146 2433 730 3000 300 30 24 90 0.3 10 0.8 Wrinkle
3.00 Board Rewinder 4 733 22 300 30 30 10 90 0.3 10 0.8 Slack
4.00 Paper Rewinder 3 500 15 60 30 30 8 90 0.3 3 0.8 Both

77.32
 Converting Rewinder - Other
• Tension, Width, Span, Wrap, Friction,
Caliper, Modulus, Slack or Wrinkle
Hair'
s
Brea Tensio Diamete Frictio Thicknes
Case Describe dth Misalign Misalign n Width Span r Wrap n s Modulus Slack Notes
microrad
ians mils lbs in in in degrees mil MPSI Wrinkle

4.00 Paper Rewinder 3 500 15 60 30 30 8 90 0.3 3 0.8 Both

4.01 Tension Study 4 700 21 1.5X Wrinkle

4.02 Tension Study 2 266 8 0.5X Slack Low tension worst

4.03 L/W Study 6 1000 30 2X Slack

4.04 L/W Study 2 266 8 0.5X Slack Short L/W worst

4.05 Diameter 3 500 15 3X Both
4.06 Diameter 3 500 15 0.5X Both NC
4.07 Wrap 3 500 15 0.167X Both NC
4.08 Friction Study 3 500 15 3X Both NC
4.09 Friction Study 3 500 15 0.3X Both

4.10 Caliper Study 2 300 9 1.2X 2X Slack Thick Caliper Worst*

4.11 Caliper Study 2 300 9 0.8X 0.5X Wrinkle
4.12 Modulus Study 2 333 10 1.5X Both High mod worst
4.13 Modulus Study 6 1000 30 0.5X Both

Paper Worst
4.14 Case 1 83 2.5 30 30 15 8 90 0.3 3 1.2 Slack low tension, short span, high mod 77.33
Paper Worst
4.15 Case 1 167 5 30 30 15 8 90 0.3 3 1.2 Both
 Paper Industry Summary
• ½ Hair’s breadth good enough for most of the
rollers in the paper industry*
• ½ Hair’s breadth is the VERY tight end of
commercial tolerances
• Irony: the paper mill winder (where tight
tolerances originated) can tolerate 100X**
converting winder (which has no specs)
• * Sectional roller gaps and other special
situations excepted
• ** ‘Guide roller’ can be misaligned 300 mils 77.34
Industry Summary – Hair’s Breadth
• 100 - Board Mill • Large difference
• 50 – Paper Mill between needs and
• 1.0 – PE Convert practice in converting
• 0.5 – Paper Convert • Education
• 0.2 – Foil Convert* • Tolerance
– Few rollers
• 0.1 – PET Convert
– Slippery surfaces
– Light wrap angles
• *Walker’s foil study
indicates models are too
conservative 77.35
 Outgoing Suggestions
• Outgoing (Should • Classes
rollers be moved?) A – < 20 micro-radian
– Response to known tooling, brittle webs
misalignment problems B – 20 micro-radian
• Path
paper, metal
• Web Breaks
• Wrinkles (diagonal)
C – 100 micro-radian
converting
• Calculate or Measure
D – 1000 micro-radian
‘threshold of pain’
rubber, textiles
• Safety factor of 4-10
F - > 1000 micro-radian
– Similar to tension 77.36
web handling fail
 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
77.37