I. Tension Control System Problems
1. Mismatch between unwinding and rewinding tension: Inconsistent tension settings at both ends result in material being too tight or too loose.
2. Roll diameter compensation function not enabled: Speed is not adjusted in real time as the roll diameter changes, causing tension fluctuations.
3. Outdated control mode: Traditional open-loop control lacks real-time feedback, leading to lag in adjustment.
II. Tension Sensor Abnormalities
1. Sensor not calibrated or zero-point drift: Measurement accuracy decreases and signal distortion occurs after long-term use.
2. Sensor contamination or damage: The surface is covered with paper dust or oil, or the internal strain gauge is broken, causing feedback signal fluctuations.
3. Loose wiring or poor shielding: The signal is affected by electromagnetic interference, resulting in fluctuations or interruptions.
III. Mechanical System Failures
1. Guide roller parallelism deviation > 0.1mm: This leads to uneven material stress, causing misalignment or wrinkling.
2. Bearing wear or insufficient lubrication: This increases rotational resistance and affects the stability of tension transmission.
3. Uneven pressure on the pressure rollers or wear on the roller surface: This causes localized tension changes and easily leads to wrinkles.
IV. Drive and Electrical Factors
1. Slow inverter response: Ordinary inverters have inaccurate torque control at low speeds, leading to tension loss of control.
2. Motor acceleration and deceleration oscillation: Poor speed synchronization affects the tension balance of the entire line.
3. Loose electrical connections: Poor wiring contact in the PLC or controller causes signal interruption.
V. Process and Environmental Impacts
1. Differences in material properties: Using the same set of tension parameters for materials of different weights, thicknesses, or elasticities leads to poor compatibility.
2. Large fluctuations in workshop temperature and humidity: Temperature or humidity exceeding the range of 22±2℃ or 50%±5% causes material expansion and contraction.
3. Severe dust pollution: Paper dust enters the gaps between sensors or guide rollers, affecting detection accuracy and operational stability.
