I. Tension Control: Ensuring materials are wrinkle-free, stretch-free, and deformation-free. High-precision materials are generally thin, soft, and easily stretched. Tension fluctuations can lead to uneven winding, wrinkling, or even material breakage.
A fully closed-loop tension control system is essential. This system uses tension sensors to provide real-time data feedback, and the controller dynamically adjusts the winding and unwinding torque to achieve tension accuracy within ±0.5%.
Variable frequency drive + taper tension control technology is recommended. This automatically reduces tension as the roll diameter increases, avoiding the "tight inside, loose outside" phenomenon.
For ultra-thin materials (such as 0.01mm-level optical films), it is recommended to choose a model with integrated servo drive for faster response and more precise control.
II. Correction Accuracy: Ensuring edge alignment and interlayer consistency. Accumulated micron-level offsets can lead to failures in subsequent slitting or laminating processes, especially significant in multi-layer composite processes.
The correction system should achieve a positioning accuracy within ±0.1mm; high-end models can achieve dynamic correction capability of ±0.05mm. A closed-loop structure employing photoelectric or ultrasonic edge detection combined with servo motor-driven frame adjustment forms a millisecond-level response chain of "scanning-calculation-correction."
Supporting multi-station alignment correction (before unwinding, during slitting, and before rewinding) further improves overall alignment.
III. Hydraulic Cylinder Synchronization Accuracy: Determining Core Stress Uniformity
For rewinders with double-sided support, asynchronous movement of the hydraulic cylinders on both sides will cause core tilting and uneven pressure, directly affecting the neatness of the roll end face.
Traditional synchronization errors in the industry are generally around 10mm, while high-precision equipment can control them within 0.3mm, achieving a leap from "passive resistance" to "active coordination."
The implementation path includes: introducing high-precision displacement sensors and pressure compensation devices to construct an intelligent closed-loop synchronization system, maintaining stability even under off-center load conditions.
It is recommended to prioritize models with this technical solution, especially suitable for winding wide-width (>1m) or high-rigidity materials.
IV. System Integration and Automation Level: Ensuring Process Stability High-precision production requires reduced human intervention, relying on system-level collaborative control to maintain parameter consistency.
The control system should be based on a PLC + touchscreen architecture, supporting functions such as parameter preset, fault interlock protection, and fixed-length shutdown.
Integrate a multi-segment closed-loop control network (such as PROFIBUS-DP bus) to coordinate the synchronous operation of paper ejection, traction, slitting, and rewinding units.
Optional modules such as dust removal, static electricity removal, and CCD detection can be added to improve cleanliness and quality control capabilities.
