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Blown Film Technology
Published in Nicholas P. Cheremisinoff, Elastomer Technology Handbook, 2020
There is a secondary nip, either as a part of the winder or just prior to the film entering the winder. This secondary nip provides the tension control point necessary as part of the winder operation. The main functions of a winder are to guide the film evenly into the roll form and to provide tension control on the film to produce evenly wound rolls. The winder must apply enough tension to make a roll that will not telescope when handled, and it must not apply so much tension to the film as to cause crushed cores or center roll bagginess. Tensions on center drive winders are generally tapered from the core to the outer wraps to compensate for the change in diameter of the roll. On a surface winder, the compensation is automatic because of the drive mechanism. When tensions are being adjusted on a winder, it must be kept equal to or less than 1/2 of 1% of the film secant modulus to avoid excessive stress in the film. One reason for the low value of recommended tension is that the film is not totally at equilibrium by the time it is wound into the roll. Dimensional changes occur as the film crystallizes or cools; these dimensional changes also induce stresses. Both Loonsbury12 and Knitter9 have produced recent discussions about winders that offer insight into important design parameters. Winding technology is an area of study that has received more attention in the paper industry than in the film industry, but one can learn the principals from paper and apply them to film. One major difference between the two materials is that the elasticity of films is much greater and has to be considered in the winding theory.
Manufacture of Pressure-Sensitive Products
Published in István Benedek, Mikhail M. Feldstein, Technology of Pressure-Sensitive Adhesives and Products, 2008
Winders are constituents of web-handling equipment in paper, film, and metal processing industries. Unwinder web-tension control is a main parameter. The coating and lamination quality are strongly affected by the winding, coating, lamination, web control, unwinding, and machine control [23]. Winding tension is a control parameter for (tackified) self-adhesive films (SAFs) also (see Applications of Pressure-Sensitive Products, Chapter 7), where the winding tension influences the pressure in the roll and the diffusion (migration) of viscous components in the carrier for SAF. Winding tension depends on the hardness of the film and must be adjusted on the winder. The fine control of the web tension was first required by the coating of soft PVC films and developed later for thin protective films. In this case, a two-component regulating system is used. The first component regulates the torque, and the second acts as feedback. Unwind reel diameter is controlled, and torque is regulated proportionally. A sensitive dancer roll measures the tension. For common films the lowest web tension is generally about 20 N, and it should not exceed 10 N for thin plastic films. Common winding machines used for blown-film manufacture do not fulfill such requirements (because of the excentricity of the roll); here, forces of 200–300 N may appear. A surface/center rewinder allows the production of hard or soft rolls with laminates up to 200 g/m2. Winding machines with a web-tension regulation of 50–200 g/mm2 and web tensions of 0.1 to 10 kN are common. For blown films, the maximum winding speed is situated at 20–140 m/min; for cast films the speed is 120–400 m/min and for biaxially oriented films, it is 280–350 m/min. Horizontal surface winders are relative inexpensive, but have limitations on the width of the rolls that can be wound on small-diameter paper cores. Multidrum surface winders have been developed to allow winding large-diameter, wide rolls on small-diameter cores. Although more expensive, they allow each roll to be slit in line and shipped directly to the customer without rewinding.
Application of the Internet of Things in the textile industry
Published in Textile Progress, 2019
Hitesh Manglani, George L. Hodge, William Oxenham
Saurer Schlafhorst’s Plant Control System (PCS) is a web-based system accessible from the browser at any place and time. The PCS philosophy is said to be E3: Energy, Economics, and Ergonomics. This system, like the other four, gathers data online and prepares different level reports for the mill, groups of machines, or individual machines or spinning positions. Saurer, in July 2018, presented Autoconer X6 their winding system with the Bobbin Cloud material-flow system based on radio frequency identification (RFID) technology [148]. In addition to claimed lower energy consumption (up to 20% lower compared to Autoconer X5) and increased production system (up to 6% higher compared to Autoconer X5), it demonstrates linking of ring spinning machine to winders using RFID technology. This RFID linkage, along with integrated online quality monitoring system SPID, takes the level of machine networking and process automation in PCS to a higher level. Saurer is developing its technology center in Arbon, Switzerland, where the focus is on the formula “E3 + I,” where I stands for ‘Intelligence’. Saurer provided PCS up until 2019, which was rebranded as Senses at ITMA 2019 and divided into three modules of Senses Maintenance, Senses Workforce, and Senses Data Transfer. The original parent company of Saurer was Oerlikon, which, as recently as ITMA ASIA + CITME 2018, showcased IoT based AIM4DTY solution in their human-made fiber segment as discussed earlier in the section.