Keeping It in Line
A look at today's cost-cutting web-handling technologies.
TODAY'S PRESS OPERATORS don't have to be the fiddling wizards of yesteryear's press rooms. As technology continues to improve, operators have less tinkering to do in order to keep the web in register and maintain the appropriate tension control than compared to even a few years ago.
Automatically adjusting edge detectors and rolls designed to mitigate web-troubling deflection, to name just a couple, make an operator's job that much easier. But even with the most advanced technology available, do all printers and converters need top-of-the-line web handling equipment?
"If you define top-of-the-line equipment as expensive or loaded with superfluous features—bells and whistles for which most converters have absolutely no need—the answer would be no. But, if you define top-of-the-line equipment with words like simplicity, dependability, versatility, and efficiency, the answer would be a resounding yes," said Robert Duffy, president of Airtech Converting Equipment.
However, that's not to say that investing in new web-handling equipment when the time comes isn't a good idea, said Jim Edmondson, president of Pyramid Creative Group, Inc., a B2B marketing communications firm that represents such companies as Webex Inc. and AccuWeb, Inc.
"There are lots of converting operations with machinery held together with twist ties and duct tape. While those companies are able to put product out the door, they are historically not the ones that survive the long haul, as changing materials and application technologies emerge within our ever-changing world," Edmondson said. "If one looks closely at the larger, industry-leading converters and web processors, you are more likely to find organizations that routinely investigate and apply new and/or custom web-handling solutions and technologies found in today's leading-edge machinery and components. In the end, everything is relative. If your customers will remain forever loyal and happy with the product being provided, and no additional revenues or profits are of interest, why change? The fact is, however, most corporations are driven to achieve more."
To help printers and converters stay competitive, web-handling equipment manufacturers add to their product portfolios regularly. The following are a few of the latest additions:
AC motor brake tension control
ABB Inc.
www.abb.com
The Pressductor® load cell design, together with innovative tension electronics, creates a complete range of features and benefits to achieve reliable and consistent web tension control. The technology features an unwind AC motor brake and tension rewind with taper and diameter calculation. Other advantages include no pads or air, meaning no maintenance; tension control at zero speed through acceleration and deceleration; seamless switch from brake to motor assistance; no dust or noise; and a high return on investment through energy recovery.
Auto-adjusting edge detectors
AccuWeb, Inc.
www.accuweb.com
WideArray™ Edge Detectors are designed for converters that run varying web widths and have historically used mechanical devices to move the edge detectors for each changeover. The unit automatically detects web edges passing through its 18.4˝-wide detection range. When positioned on opposite sides of the web in a center guiding mode, its detection range allows operators to change the point or web width on the fly, speeding makeready time by eliminating manual adjustment or mechanical edge-sensing devices.
Air-powered web alignment
Airtech Converting Equipment
www.airtech.us
Airtech's 100 percent air-powered web alignment system run entirely on plant air and uses only approximately 1.0 cfm at a standard operating pressure of 5 psi. The system is easy to install and requires no technical start-up assistance. It's also dependable, never needing routine or scheduled maintenance and is perfect for dusty production conditions. The air-powered system is ideal for "x-proof" applications and it requires no modifications when changing to translucent, clear, opaque, dark, or reflective materials.
Between unit camera upgrades
eltromat
www.eltromat.com
eltromat now offers an upgrade to its register controls with between-unit cameras. Cameras see the printed image just the way a human would, thus eliminating any offsets due to scanning. Any remaining fine tuning is rapidly done since the operator can immediately see the result of any correction with the between-unit cameras. Other advantages of between-unit camera-based register controls are small micromarks, less trim, and the ability to read extremely low contrasted colors on difficult substrates.
New digital narrow web guide
Erhardt + Leimer Inc.
www.erhardt-leimer-us.com
The new compact DRS 22 digital narrow web guide system can be easily integrated into any machine design. This CE-approved design is the fastest guide in its class with an adjustable correction speed up to 3.5˝ per second. Either an infrared or ultrasonic edge or color line sensor detects the position of the web. The digital controller is integrated into the pivoting frame and adjusting the control parameters is simple thanks to the user-friendly operator controls.
Advanced digital camera sensor
Fife Corp.
www.fife.com/dac
The DAC-004 digital camera sensor enables converters to guide a wide range of difficult-to-sense materials from nonwovens to steel, and includes innovative new software to simplify set up and operation. The DAC-004 sensor uses a total of 7,450 pixels and can sense up to four edges of material web width with a high resistance to contamination, dust particles, oil, vapors, and water. The technology has the ability to connect via analog or digital fieldbus network connectivity, and runs in a variety of applications from armless rewinding, center, edge, and line guiding to web width measurement.
Perma-Tork and Sofstep online
MAGPOWR
www.magpowr.com
Perma-Tork® permanent magnet clutches and brakes, and Sofstep® magnetic particle clutches and brakes are now available for ordering online at www.magpowr.com/order. MAGPOWR customers can now re-order existing Perma-Tork and Sofstep products that have already been specified for their application at any time and receive order confirmation within one business day. Perma-Tork clutches and brakes are capable of producing highly accurate, dependable torque, using high energy, multi-pole magnets to establish lines of magnetic force that retard the motion of the center rotating disc and deliver smooth, precise control. Sofstep clutches and brakes provide smooth controllable torque for power transmission and tension applications.
Web guide with CMOS cameras
Menzel, Inc.
www.menzelus.com
The Menzel Vision System is an image processor for pattern guiding to monitor, slit, and guide webs. The technology uses CCD and the newest high-speed CMOS cameras to detect a wide variety of edges, lines, patterns, and print marks on running webs. The system offers web guiding at a high level of precision; width measurement and constant check/reports; web guiding using clear web edges; pattern guided process control; and minimized use of hardware. The Menzel Vision System is also flexible and easy to install and can be integrated into existing systems.
Compact web guide controller
North American Manufacturing Co., Ltd.
www.namfg.com
The new H6420 web guide controller combines a convenient operator touch pad with a robust pulse width modulated drive in one compact package. The web guide controller operates on a 24 VDC power supply within an IP55 rated water and dust-resistant housing. Used in conjunction with SimPlex™ sensors and actuators, the web guide controller provides precise web position control for edge guide, center guide, or line following applications. The H6420's small size enables maximum installation flexibility.
Zero deflection roll
Webex Inc.
www.webexinc.com
The ZDR (Zero Defection Roll) is used to effectively counteract undesirable web or nip forces that tend to deflect rolls and result in undesirable web performance. ZDR rolls are a custom solution ideal for film casting and calendaring operations where consistent profiling over a range of external pressures is important. Proper application can eliminate variation in web thickness resulting from uneven nip profiles.
By Kate Sharon
Associate Editor
