Web Processing System Tension Control via Dancer Roller
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Solution Overview
Problem
Web fluttering due to disturbances like drive motor vibration and wind causes tension variations, hindering higher-precision printing in web processing systems.
Innovation Solution
A web processing system with two rollers rotating in phase and a dancer system that includes guide rollers, a dancer roller, and an actuator device to suppress web tension variations by maintaining a reference tension between the rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two rollers rotate at the same phase while being in contact with a web, then printing precision is improved, but web tension variation increases due to disturbances like motor vibration and wind
Solution Approach 1:
A dancer roller is introduced as an intermediary element between the two printing rollers. The dancer roller can move freely in the web thickness direction and is connected to a tension detector and actuator. This intermediary device detects tension variations caused by motor vibrations and wind, then uses the actuator to adjust the dancer roller position, thereby suppressing tension variations and maintaining stable web tension during high-precision printing
Solution Approach 2:
A tension detector continuously monitors the web tension between the two printing rollers and provides feedback to a control system. The control system processes this tension information and adjusts the dancer roller position via an actuator to maintain constant tension. This feedback mechanism enables real-time compensation for tension variations caused by disturbances while maintaining the rollers' synchronized rotation for high-precision printing
2Stability of the object's composition
If a dancer system with actuator is added to suppress tension variation, then web tension stability is improved, but device complexity increases
Solution Approach 1:
The dancer roller serves as a simple intermediary mechanical element that can move freely in the web thickness direction. By positioning this single movable roller between the two printing rollers and connecting it to a tension detector and actuator, the system achieves tension control without requiring complex multi-component mechanisms. The dancer roller's simple structure minimizes added complexity while effectively suppressing tension variations
Solution Approach 2:
The dancer roller system is designed to automatically detect and correct tension variations without requiring external intervention. The tension detector continuously monitors web tension, and the actuator automatically adjusts the dancer roller position to maintain constant tension. This self-service capability stabilizes web tension during printing operations without requiring additional complex control systems or manual adjustments
Data Source
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AI summary
A web processing system (102) which includes a first plate cylinder (24) and a second plate cylinder (34) that are configured to rotate at the same phase while being in contact with a web (4) which continuously exists along a movement passage and a dancer system (40) for suppressing a tension variation of the web (4) between the first plate cylinder (24) and the second plate cylinder (34).