Feed Roll System

Feed Roll System – Abhisara International

System Components:

  1. Feed Roll Stand
    • Provides a stable base for the roll.
    • Designed to accommodate varying roll sizes and widths.
  2. Tension Controller
    • Monitors and adjusts the material tension during the feed process.
    • Ensures consistent tension for optimal material handling.
  3. Air Filter
    • Maintains clean air supply to the pneumatic system.
    • Prevents contamination and ensures system efficiency.
  4. Electronic-Pneumatic (E-P) Converter
    • Converts electrical signals from the tension controller into precise pneumatic pressure.
    • Adjusts air pressure to control roll tension accurately.
  5. Proximity Sensor and Sensor Collar
    • Mounted on the roll stand’s arm to detect the number of rotations.
    • Provides real-time data on roll diameter to the tension controller.

Operation Process:

  1. Sensor Monitoring
    • Proximity sensor detects the rotational movement and position of the sensor collar on the roll stand’s arm.
    • Provides continuous monitoring of roll diameter.
  2. Signal Transmission
    • Proximity sensor sends rotational data to the tension controller.
    • Tension controller adjusts voltage output based on the roll’s diameter.
    • Maximum roll diameter triggers maximum voltage to the E-P converter.
  3. Voltage and Pressure Adjustment
    • As the roll diameter decreases, the voltage sent to the E-P converter reduces proportionately.
    • The E-P converter translates voltage changes into corresponding air pressure adjustments.
    • Lower voltage results in decreased air pressure, reducing brake pressure on the roll stand.

Features:

  • Proportional Type Design: Adjusts tension proportionally based on roll diameter, ensuring consistent material tension.
  • No Need for Load Cell or Dancer Roll Mechanisms: Simplifies the system, reducing the need for additional components.
  • 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 the roll diameter decreases.
  • Simplified Threading Procedure: Reduces the need for manual adjustments, ensuring consistent tension throughout the process.
  • Automatic Stopping: The system halts the feed process when a minimum roll diameter is reached, preventing material waste and potential damage.

Specifications:

  • Maximum Roll Width: 100 inches (2540 mm)
  • Maximum Roll Diameter: 84 inches (2134 mm)
  • Pneumatic Requirements: 75 PSI (7 kPa)
  • Customizable Specifications: System specifications can be tailored to meet customer-specific requirements.

How It Works:

  • Tension Measurement: The ATC (Automatic Tension Control) sensor unit continuously measures the material tension.
  • Signal Processing: The ATC operator unit receives the tension data and adjusts the motor and gearbox accordingly.
  • Brake Adjustment: The flex-brake on the feed roll system is automatically adjusted to maintain stable and consistent material tension.

Abhisara International’s Feed Roll System ensures efficient and consistent tension control, enhancing product quality and reducing the need for manual intervention in various manufacturing processes.