Vertical winder handle the winding of wide materials

Vertical winders handle the winding of wide-width materials mainly in the following ways:

1. Enhanced mechanical structure design

Wide-width reel and support: For the winding of wide-width materials, first of all, a suitable wide-width reel is required. The length of the reel must be able to accommodate the width of the material, and its structural strength needs to be enhanced to withstand the greater weight and tension brought by the wide-width material. The reel is usually made of high-strength metal materials and may have structures such as reinforcing ribs inside. At the same time, the support structure at both ends of the reel is also more robust and stable, generally supported by large bearings and sturdy frames to ensure that the reel will not bend or shake during the winding process, and ensure that the wide-width material can be evenly wound on the reel.

Wide guide roller system: Wide materials require wider and more precise guide rollers to guide them. The length of the guide roller should match the width of the material, and its surface should maintain a high degree of flatness and finish to prevent the material from wrinkling or deviating due to problems with the guide roller surface during transmission. The installation accuracy of the guide rollers must be extremely high, and the parallelism error between them must be controlled within a very small range, so that the wide material can smoothly enter the reel in the correct direction for winding when passing through the guide rollers. In addition, the guide rollers may be equipped with multiple auxiliary supports to prevent deformation due to their own excessive length, which will affect the winding of the material.

2. Advanced tension control strategy

Partition tension control: Since wide-width materials may be uneven in the width direction, simple overall tension control may cause uneven material winding. Therefore, partition tension control technology is adopted. Multiple areas are divided in the width direction of the material, and each area has an independent tension sensor and adjustment device. For example, by setting different tension control areas on both sides and the middle of the material, the tension is accurately adjusted according to the actual situation of the material in each area, so that the material can be subjected to appropriate tension in the entire width, thereby ensuring the flatness and tightness of the winding.

Dynamic tension compensation: During the winding process, as the diameter of the reel increases, the tension of each part of the wide material will change. The dynamic tension compensation system monitors and calculates these changes in real time. According to the parameters such as the reel diameter, material width and winding speed, the tension at different positions is automatically adjusted to ensure that the wide material can maintain a stable tension state at all stages of winding, avoiding material deformation or uneven winding due to uneven tension.

3. Accurate correction and alignment measures

Multi-sensor edge detection and correction: To address the problem of uneven edges on wide-width materials, multiple edge detection sensors are used on both sides and edges of the material. These sensors can accurately monitor the position changes of the edge of the material in real time. Once the edge deviation of the material is detected, the control system will immediately start the correction mechanism. By adjusting the angle or position of the guide roller, the material is realigned in the width direction. At the same time, the correction system must react quickly to adapt to the rapid deviation of wide-width materials during high-speed winding to ensure the neatness of the winding.

Vision-assisted alignment system: Some high-end vertical winders are equipped with vision-assisted alignment systems. The camera takes real-time photos of wide-width materials, and image recognition technology analyzes the material's texture, pattern, or markings to determine whether the material is aligned in the width direction. This vision-based system can provide more comprehensive material alignment information, and combined with edge detection sensors, it can more accurately control the winding alignment of wide-width materials and ensure winding quality.

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