Curved Bar Expander

Curved Bar Expander System – Abhisara International

System Components:

  1. Tension Controller
    • Monitors and regulates material tension.
    • Adjusts tension in response to roll diameter changes.
  2. Air Filter
    • Ensures the pneumatic system operates with clean air.
    • Maintains system efficiency and prevents contamination.
  3. Electronic-Pneumatic (E-P) Converter
    • Translates electrical signals from the tension controller into pneumatic pressure.
    • Adjusts air pressure based on voltage signals proportional to roll diameter.
  4. Sensor Collar and Proximity Sensor
    • Mounted on the roll stand’s arm to detect rotational proximity.
    • Provides data on roll diameter to the tension controller.

Operation Process:

  1. Sensor Monitoring
    • Proximity sensor detects rotations and position of the sensor collar on the roll stand’s arm.
    • Information used to monitor and adjust roll diameter.
  2. Signal Transmission
    • Proximity sensor sends signals to the tension controller.
    • Tension controller adjusts voltage output based on roll diameter.
    • Maximum roll diameter triggers maximum voltage to the E-P converter.
  3. Voltage and Pressure Adjustment
    • Decreasing roll diameter proportionally reduces voltage to the E-P converter.
    • E-P converter translates voltage changes into air pressure adjustments.
    • Lower voltage results in reduced air pressure, thus decreasing brake pressure.

Features:

  • Proportional Type Design: Adjusts tension proportionally to roll diameter changes, ensuring consistent tension.
  • No Need for Load Cell or Dancer Roll Mechanisms: Simplifies system and reduces additional component requirements.
  • Low Roll Diameter Detection: Automatically detects and adjusts for low roll diameters.

Benefits of Using Automatic Tension Control:

  • Automatic Brake Pressure Reduction: Maintains consistent tension as roll diameter decreases.
  • Simplified Threading Procedure: Reduces the need for manual adjustments, maintaining consistent tension.
  • Automatic Stopping: System halts the sheeter when minimum roll diameter is reached, preventing material waste and damage.

Specifications:

  • Maximum Roll Width: 100 inches (2540 mm)
  • Maximum Roll Diameter: 84 inches (2134 mm)
  • Pneumatic Requirements: 75 PSI (7 kPa)
  • Customizable Specifications: Adjustable to meet customer-specific needs.

How It Works:

  • Yarn Tension Measurement: The ATC (Automatic Tension Control) sensor unit continuously measures yarn tension.
  • Signal Processing: ATC operator unit receives signals and adjusts motor and gearbox.
  • Brake Adjustment: Automatically adjusts the flex-brake on the weft-feeder to maintain stable yarn tension.

Abhisara International Curved Bar Expander system ensures efficient and consistent tension control in manufacturing processes, enhancing product quality and reducing manual intervention.