Upload
trinhphuc
View
213
Download
0
Embed Size (px)
Citation preview
Michael Schröder 2
IMPORT FOR PRODUCTIVITY• HIGH PRODUCTICVITY
MINIMUM REST MATERIAL ON THE COREIMPORTANT VALUE BUT:CAN BE REDUCED WITH NEW PLC AND FAST CPU´SCLOSE CORE TOLERANCES CAN IMPROVE AMOUNT OF WASTE
SPLICE RELIABILTYCAUSE MACHINE STOPS WITH A LOT OF WORK TO RESTART AND THREADING OPERATION IS: DEPENDING ON REEL PREPARATION QUALITY AND UNWINDDESIGN
Michael Schröder 3
DIFFERENT TYPE OF UNWINDS DEPENDS ON:
Substrate and Materials:Board and heavy paper 150 – 400 g/m2Light paper 20- 120 g/m2Foil Al 5,5 my to 7 myFilm 12 – 50 my
Speeds:Low speed up to 350 m/minHigh speed over 500 m/min
Michael Schröder
CONVENTIONAL TYPE OF UNWIND
• CHARACTERISTIC OF THIS UNWIND
CENTRE CROSS BEAMSIZE OF UNWIND NEED A LOT SPACELONG WEB PATH FROM ROLL TO ROLL
USE FOR MAINLY FOR BOARDHEAVY PAPERLOW SPEED
Michael Schröder
MODERN TYPE UNWIND
• CHARACTERISTIC OF UNWIND
PHANTOM CROSS BEAMCOMPACT DESIGNMORE RIGID THAN THE CENTRE BEAM DESIGNSHORT WEB PATH FROM ROLL TO ROLL
USE FOR MAINLY FOR ALL MATERIAL TYPES HEAVY AND LIGHT WEB MATERIALSLOW AND HIGH SPEED
Michael Schröder
NEW TYPE OF UNWIND AND SPLICER
• CHARACTERISTIC OF UNWIND
PHANTOM CROSS BEAM
KINFES ON THE TURRETCUTTING POINT FAR AWAY FROM THE NIPWEB MATERIAL TIHGHTENED UP FOR SPLICE BETWEEN SHORT DISTANCE
USE FOR MAINLY FOR ALL MATERIAL TYPES HEAVY AND LIGHT WEB MATERIALSLOW AND HIGH SPEED
Michael Schröder 10
REEL-HANDLING IMPORTANT FOR FAST SPEED OPERATION
THIN FOIL IS TAKEN INTO THE UNWIND WITH OVERHEAD CRANE CYCLE TIME IS NOT CRITICAL
FILM MATERIAL IS PREFERRED HANDLED BY LIFTING DEVICE CYCLE TIME IS NOT CRITICAL
THICK WEB MATERIAL WITH SHORT CYCLE TIME NEEDS MOST AUTOMATION FOR REEL HANDLING
CYCLE TIME IS VERY CRITICAL
Michael Schröder 13
CONVENTIONAL REEL HANDLING WITH LIFTING TABLE
REMOVE EMPTY CORE
REEL PREPARATION
POSITION
Michael Schröder 14
REEL PREPARATION &CYCLE TIME
NECESSARY ACTION• REMOVE EMPTY CORE 30 s• MOVE, LIFT AND CHUCK NEW REEL 60 s • SPLICE PREPARATION 90 s• INDEXING APPROX. 90 DEGREE 20 s• ACCELERATION OF NEW REEL 20 s• TRANSFER WAITING AND ACTING 60 s• INDEXING APPROX. 90 DEGREE 20 s
• TOTAL TIME 300 s
Michael Schröder 15
CYCLE TIME
CONSIDERING CYCLE TIME OF 5 MINUTESPREPARATION TIME IS LEFT APPROX.
90 SECONDS DEPENDING ON THICKNESS OF WEB MATERIAL AND LINE SPEED
BECAUSE SPLICE PREPARATION QUALITY IS IMPORTANT, TIME NEED TO BE IMPROVED
Michael Schröder 16
NEW METHOD FOR REEL HANDLING
WAITING POSITION
LIFTING TABLE
REEL PREPARATION BY TURNABLE FLOOR
V-TABLEIN ADVANCE
AUTOMATIC HEIGHT
ADJUSTMENT
REMOVE EMPTY CORE
Michael Schröder 17
ADVANTAGE WITH NEW METHOD
MORE TIME FOR REEL PREPARATION REEL PREPARATION INDEPENDENT OF UNWIND CYCLE TIME ENOUGH TIME TO PREPARE QUALITY PREPARATION
PRE-PREPARATION OF NUMBER OF REELS ARE POSSIBLE
Michael Schröder 18
UNWINDING OF SENSITIVE MATERIAL AS FOIL AND THIN FILM
IMPORTANT DESIGN FEATURE FOR SUCCESSFUL UNWINDING PROCESS
Michael Schröder 20
PASTER ROLL DURING UNWINDING PROCESS
PASTER ROLL IS KEPT IN CONSTANT DISTANCE TO THE UNWINDING REELTAKE OFF LINE FROM THE MATERIAL IS KEPT UNIFORM TO PREVENT WEB BREAK DURING UNWINDING PROCESS
Michael Schröder 21
WEB GUIDING AND TRANSFER DESIGN FEATURES
• IDLER ROLL– DIAMETER (160-200 mm)– ROLL DESIGN CRITERIA– DISTANCE ROLL TO ROLL– WRAP ANGLE
• PASTER ROLLER– MATERIAL AND SURFACE
• WEB TENSION CONTROL
Rt 3-5 my
Michael Schröder 22
SPLICE SEQUENCES WITH DIFFERENT SPLICER DESIGNS
CONSIDERATION FOR MOST CRITICAL THIN MATERIALS WITH DIFFERENT RESULTS
1. SPLICE SEQUENCE ON THE HIGH SPEED UNWIND2. SPLICE SEQUENCE ON NEW CONVENTIONAL
SPLICER
Michael Schröder 9
KNIFE CUT
REEL ACCELERATION/SPEED MATCH
CONTACT WITH BUMP ROLLER
TAPE PREPARATION
SPLICE SEQUENCES
Michael Schröder
RESULTS OF SPLICE
SPLICE CUT AND END TAIL FAR AWAY FROM THE NIP POINT BETWEEN NEW REEL AND TAPESAFE WAY OF SPLICE FOR THE SPLICE FROM TOPOVERLAP WILL BE WITH CERTAIN LENGTHTHIN MATERIAL WILL FALL DOWN IN UNDEFINED WAY AFTER CUTCUT CAN BE DONE AFTER THE NIP WITH THE BUMP ROLLER IS CLOSED
Michael Schröder
KNIFE CUT
REEL ACCELERATION/SPEED MATCH
CONTACT WITH BUMP ROLLER
TAPE PREPARATION
SPLICE SEQUENCES COMPRESSED AIR PIPE WITH NOZZLES
Michael Schröder
RESULTS OF SPLICESPLICE CUT AND END TAIL CLOSE TO THE NIP POINT BETWEEN NEW REEL AND TAPEEND TAIL NEED TO BE BLOW AWAY FOR SPLICE FROM TOP, DUE TO INSURE THAT THE END TAIL NOT RUNNING INTO THE NIPOVERLAP CAN BE VERY SHORTCUT CAN BE DONE AFTER THE NIP WITH THE BUMP ROLLER IS CLOSED
Michael Schröder 27
SPLICE RELIABILITY DEPENDS ON
PASTER ROLL SPEED AND GRIP TO THE REEL SURFACETO BE ACHIEVED BY SHOCK ABSORBER OR PNEUMATIC DAMPER
KNIFE SPEED AND CONFIGURATION
Michael Schröder 28
–
–0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1,51,251,00,750,50,250
New Roll Diameter (meter)
Tim
e (s
econ
ds)
Line speed 300 m/min
Line speed 600 m/min
Line speed 900 m/min
Time for One Roll RevolutionLine Speed versus Roll Diameter
Michael Schröder 29
Required Repeatability of Paster Roll Engagement
0.000.050.100.150.200.250.300.350.400.450.50
1,51,251,00,750,50,250
New roll diameter (meter)
Tim
e (s
econ
ds)
Line speed 300 m/minLine speed 600 m/minLine speed 900 m/min
Michael Schröder 30
SHORT OVERLAP TAIL LENGHT IMPORTANT
LONG OVERLAP COULD CAUSE PROBLEMS IN THE EXTRUSION LAMINATOR ENTRY AND NIPLONG OVERLAP NOT ALLOWED IN PRINTING MACHINES
• SOLUTION :SHORT OVERLAP CAN BE CREATED BY CLOSE ARRANGEMENT OF PASTER ROLL AND KNIFE ONLY
Michael Schröder 31
Tail length variation versus Knife repeatability
00.020.040.060.080.10
0.120.140.160.18
0.2
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
Tail length variation (cm)
Tim
e (s
ec)
300 m/min
600 m/min
900 m/min
Michael Schröder 32
NEXT STEP FOR CONVENTIONAL SPLICER
REQUIRED SPLICING SPEED CONTINUE TO BE INCREASED BY: ACTUATION FOR KNIFE AND PASTER ROLL WITH VIA SERVO DRIVE INSTEAD OF PNEUMATIC CYLINDERSPEEDS CAN BE ADJUSTED AND FIXED IN AUTO-SPLICER SEQUENCE
Michael Schröder 33
DEVELOPMENT FOR FUTURE SPLICER
BUTT SPLICER OPERATION WITHOUT FESTOON
• WHY?FESTOON CAUSE TENSION PROBLEMS AND TRANSFER STRESS TO THE WEB MATERIALPROBLEMS WITH THINNER MATERIALSSPACE AND HIGH COST REQUIREMENT FOR THE FESTOON
Michael Schröder 34
NEW BUTT SPLICER
DESIGN FEATURES
SPLICE SPEED UP TO 800 M/MINNEWEST DRIVE TECHNOLOGYAUTOMATIC CUT INDEPENDENT FROM SPEED THROUGH THE RUNNING AND EXPIRING WEB IN ONE TIMESPLICER DESIGN FOR THIN AND THICK WEB MATERIALS AS FILM UP TO 350 G/M2 BOARDAUTOMATIC DISPOSAL OF THE END TAILTAPE ON BOTH SIDES OF THE WEB TO INSURE SAFE TRANSFER WITH FULL LINE SPEED