Fabric Calender - Cutter Set Adjustment

Do you know ruchiraslk?

http://cr4.globalspec.com/thread/45014/Is-There-a-Sensor

I still think you need a roller assembly on the end of an arm which will allow lateral movement and the ability to detect the difference in stiffness between the nylon belt and the waste material.

Yes, I know Ruchiraslk

Thanks.

Is there a difference in stiffness between the "good" and the "waste" belt?

Thanks Randall

You are correct Randall,But there are thin layers in two side of the output canvas layer.

Following is the full description of this issue.

Above issue is in the calendering unit.

At the calender, compound is applied to the gap of roller 1 and 2 and roller 3 and 4. Meantime the Nylon cord is inserted to the gap between roller 2 and 3. Roller 2 and 3 rotate to their opposite directions. Hence from the other side compound applied canvas layer is taken out. Simple illustration of that calendar process is given below.

In the Fabric Calendar unit, additional compound materials from the corners are coming at the end of the calendar operation with the required fabric coding. This additional material is cut using a cutting operation from both sides. Since the two boundaries of the canvas change because of many controllable and uncontrollable factors, this cutting point is adjusted manually. Hence two machine operators continuously involve in that cutter adjusting process and feed that additional material in to the system again.

Because of quality issues we feed excess material in calender unit only.

Existing friction ratio at the calendar = 1:2

Existing friction ratio: 1:2.

Maximum speed of the 2,3 rollers: ~ 60m/min

Maximum speed of the 1,4 rollers: ~ 30m/min

Thickness of the canvas layer = nearly 1 mm

Thickness of the Excess rubber material = nearly 0.4 mm

Thickness of the Excess rubber material = nearly 60 mm (x & y value)

"Since the two boundaries of the canvas change"

So you will need a camera (or more than one) that can detect and output the geometry of the boundaries and a servo mechanism to adjust the cutter.

Where is the actual problem?

RHABE

First thanks for your reply.

The actual problem is the out put of canvas cord's edge vary in every moment.

the layer maximum speed is also 60 m/min.

we cant recognize the edge between canvas layer & thin excees rubber material clearly.

two operators do it with experience.

This post and your other identical post seem remarkably similar to this one too.

I've worked in the tire industry, and can only say that there are methods for ensuring that the calendered fabric comes out of the machine at the correct width, without there being a need for manually setting trimmers. I am not sure to what extent such trimming is proprietary, however, because my work was with one manufacturer, not many.

Is this a competition, or an effort by one manufacturer? Sorry I can't be of more help, other than to say that consistent cord spacing is critical for tire quality, and consistent cord spacing leads to consistent fabric width. Perhaps a dull hot knife could track the outer cord, in the same way that a tire builder (the person not the machine) cuts between cords in the assembly process.

Thanks Blink

This is not a competition.

I try to modification the machines.

If you can, could you please tell me what is the method use in tire industry which you had worked.(Regarding fabric calender trimmer operation)

If you can, could you please tell me what is the method use in tire industry which you had worked.(Regarding fabric calender trimmer operation)

No, I'm sorry I cannot, because I am not sure which parts are proprietary and which are not. (Also, I am not sure that I have all the details.)

What is the existing method your operators are using for detecting the fabric/edge-waste transition? By sight, thickness, flex; depending what they're going off of will determine your sensor selection criteria. Addtional info on the thickness and web-widths of the composite would be helpful. A specific response or solution for your problem will require a more specific description of your process.

Ideally the fabric web shouldn't wander much through the calender process, and a simple edge guide sensor(s) on the unwind side of your calender can be used to set the cut points for the edge trimmers.

There are a number of companies that specialize in web-handeling machine design and modification. Let me know if you'd like a specific recomendation.

Thanks Guest,

Operators do it by sight with their experience.

It is very difficult to identify when cord move with 60 m/min speed.

Nylon cord center before entering the calendering process.But with unavoidable forces nylon cord tension to both side.the edge which before entering to calendering process & the edge which leaving from calendering process is not straight.We cant neutralize those unavoidable forces.That is why we must adjust cutter set.

The output canvas have nearly 20-25 mm range also.

I hope your further consideration for it.

A couple of follow-up questions:

1. What style of cutter/slitter mechanism are you using and is it an integral part of the calender machine itself, or a stand alone slitter/cutter?

Depending on the mechanics of the cutting/slitting mechanism, could be possible to 'walk' the slitter into the edge trim material until it contacts the edge of the nylon cord, then back it off an acceptable distance? I assume there is some scrap loss for the initial threading and startup of the process.

2. Are you winding the finished material back onto a spool, or is it fed directly into another machine? I assume it must have some sort of re-centering mechanism for proper winding or feeding.

3. What manner of edge trim collection are you using? Spooling, directed to dump boxes, chopped and dumped?

4. How variable is the excess buildup on the edges? Does it change with time? More on one side than the other?

Hi Palitha,

For your problem, I agree with Rhabe. That u can use servo motor to move the cutter. And you need to add two sensors (left and right) as the input for the cutter position. Hmm, maybe u can use ultrasonic cutter or another sensor.

Good luck Palitha.