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0 What is Web Handling?

Timothy J. Walker, TJWalker + Associates Inc.


164 Stonebridge Road, Saint Paul, MN 55118 tjwalker@tjwa.com www.webhandling.com 651.686.5400

TJWA Inc., Copyright 2012

www.webhandling.com

What is Web Handling?


The process technology of transporting and storing thin, flexible materials.

A web is any flexible, continuous material where:


Length >> Width >> Thickness Webs include papers, films, foils, non-wovens, textiles, and laminates.

Thickness

Width

Length

TJWA Inc., Copyright 2012

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Web Handling Processes


Makers:
Coating, Extrusion, & Paper and Film-Making

Converters: Slitting,
Die-Cutting, & Laminating

Controls!
Critical to successful web handling.

TJWA Inc., Copyright 2012

www.webhandling.com

TJWA Inc., Copyright 2012

www.webhandling.com

Part 1
Tension Control Based on Material and Process Requirements

+ Web Properties
Know your webs mechanical and frictional properties.

+ Tension Control
Understand what controls tension in your process.
TJWA Inc., Copyright 2012 www.webhandling.com 5

Part 2

Web Support: Rollers and Air Flotation

+ Roller Design
Design rollers for driving, idling, and nipping applications Why is roller parallelism important?

+ Traction
Understand when webs slip on rollers.
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Part 3

Nipped Rollers Systems and Lamination

+ Roller Design
Design rollers for driving, idling, and nipping applications Why is roller parallelism important?

+ Traction
Understand when webs slip on rollers.
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Part 4
+ Web Guiding
What cause a web to shift laterally? What web guide is best for a process?

+ Wrinkling
What causes web wrinkles? What eliminates wrinkles?
Day 2, AM

Lateral Control of Guiding, Wrinkling, & Spreading Processes

TJWA Inc., Copyright 2012

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Part 5
+ Winders
What winder design is best for a product?

+ Winding and Roll Structure


What determines the pressure inside a wound roll?
Day 2, PM

Winding Process Understanding and Improvement

TJWA Inc., Copyright 2012

www.webhandling.com

Part 1: Solutions w/ Web Tensioning


1A 1B 1E

1C
Tension: Too High or Too Low Tension: Varies Over Time Tension: MD Variations Tension: Slit Strands

1D

MD = Machine Direction

Tension: TD Variations

TD =
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Transverse Direction
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Part 2: Solutions with Imperfect Webs


Cambered and Baggy Webs Non-Flat Webs

Cambered Webs

Baggy Webs

Curled Webs

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Part 3: Solutions with Slipping/Shifting Webs


3A: MD Slip Between Web and Driven or Idler Rollers
3C: Web TD Shifts or Slips Laterally on Rollers

MD Slip on Rollers

TD Slip/Shift on Rollers

3B: MD Slip Between Layers in a Rolls

3D: TD Shift or Misalignment of Layers in a Rolls

MD Slip in Rolls
TJWA Inc., Copyright 2012
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TD Error in Rolls
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Part 4: Solutions with Buckled Webs


In Spans On Rollers In Rolls

Buckled Buckled Web in Between Spans Rollers

TD Buckles On Rollers

TD Buckles in Rolls

MD Buckles On Rollers

MD Buckles Rolls

TJWA Inc., Copyright 2012

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Four Basic Principles of Webs

Stress and Strain

Shape Stiffness

Parallel Entry Rule

Crossweb Tension Variations

TJWA Inc., Copyright 2012

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What Does the Web Feel?


1. Spans:
End Tensioning

2. Rollers:
Straining to Conform

3. Nips:
Under Pressure

4. Other External Forces (air flow, coatings)


5. Internal Forces (length variations, shrinkage,
viscoelastic recovery)
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Spans: End Tensioning


Tensioning from Rollers:
Runout, Straightness, Eccentricity, Level, Tram

Web path length variations Stretch (strain) variations

Tension (stress) variations


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Rollers: Straining to Conform


The web stretches, attempting to conform to the rollers shape.
Diameter variations
Speed variations Stretch (strain) variations Tension (stress) variations

TJWA Inc., Copyright 2012

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Nips: Under Pressure


Nips create the highest pressures on the web. Nips variations can create BIG pressure variations.
Diameter variations
Alignment variations Loading variations

Hardness variations Deflection variations


Product thickness variations
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