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NovaStar, Slitter Rewinder, 1600mm Width, 500 m/min, with Second Unwinder and Splicing System

Description

  1. Overview
    1. Rewinder machine for nonwoven rolls: up to 1600 mm diameter at unwinder and 1600 mm at rewinder.
    2. The workstation offers easy access to the tension control area as well as the trimming area; this way, any modification on the material measurements can be done safely.
    3. The workstation will deliver modules of rolled material with specific density, and separated from each other in order to keep operation conditions within required quality controls.
  2. Technical Characteristics
    1. Material type: nonwoven
    2. Material minimum: 150 gsm
    3. Material maximum: 180 gsm
    4. Tension maximum: 2 pli
    5. Speed: 500 meters per minute
  3. Unwinder
    1. Maximum width: 1600 mm
    2. Maximum diameter: 1600 mm
    3. Minimum width: 420 mm
    4. Maximum weight: 600 kgs
    5. Core id: 3 in
    6. Central unwinding system supported by a 3 in steel expansion shaft.
    7. Tension control system that works through a pneumatic disk brake with a replaceable pads system.
    8. Pivotable roller system whereby tension may be modified on one end to reduce tension difference on material if necessary.
    9. Safety chuck has a mechanical movement system for shaft insertion.
    10. Ultrasonic or laser sensor for real measuring of roll diameter; this information will help to keep a specific tension on material during all the process.
  4. Rewinder
    1. Maximum width: 1600 mm
    2. Maximum diameter: 1600 mm
    3. Minimum width: 100 mm
    4. Maximum weight per shaft: 600 kgs
    5. Core id: 3 in
    6. Peripheral rewinder for nonwoven; this system has a couple of main rollers where the material roll is formed.
    7. Linear guides for compaction through which a nip is obtained on the material.
    8. Transmission based on a vectorial-type motor adapted to a cycloidal reducer.
    9. Transmission has a mechanical torque control system to control the torque differential between main rolls.
    10. 3 in expansion shaft where the cardboard cores will be inserted and the material rolls will be formed.
  5. Cutting
    1. Longitudinal shear cut system guarantees clean and safe trimming at every module.
    2. Cutting system adapted to the main transmission guarantees an over speed that may be regulated according to the material during every stage of process.
    3. Pneumatic activation knives will allow a fast modification of the cutting measurements.
    4. Roller located at an easy access area for the operator to be able to make changes on the cutting width safely.
    5. Counter knives are assembled to the roller by 3 setscrews that fix their position on the roller.
    6. Counter knives have two faces, so when the first face has an important wear, it will be removed from the roller and the new face will be placed instead; this will extend the lifespan of this important component.
    7. Shear cut knives: there is an adjustment mechanism to place them on the counter knife and to adjust the cutting load accurately.
    8. Counter knives are supported towards the roller in order to obtain a cutoff.
    9. Speed on this system is an over speed in relation to that of the material, in order to generate a clean cut.
    10. Longitudinal shear cut: pneumatic activation.
    11. Counter knives roller with 3 support planes for the counter knives; 120° displacement from each other.
    12. 3 slitters are included.
  6. Fabric Opening System
    1. Based on a variable curvature system by a center knob and it is a bar-type system.
    2. Knob is there to control the curvature of the bar where material slides through.
    3. Sliding bar is made out of an ultra low friction material in order to generate a smooth sliding of material without any tension added; this will reduce wrinkles in a significant way.
  7. Automatic Tension System
    1. Open loop automatic tension control system with a sensor for diameter measuring.
    2. By this system, a real value of diameter is obtained at the rewinder.
    3. Pressure of pneumatic brake varies during process.
  8. Manual Positioning (Optional)
    1. Based on the position control of the counter knives.
    2. Module is positioned at a desired cutting parameter and the counter knife will physically come across it.
    3. Real position of module will be shown on a screen that operator will be constantly supervising.
    4. Screen will show the real measurements of the carriage in relation to the last one or as an absolute reference.
    5. Operator will be able to reset the measurement once the counter knife is replaced and will repeat this process every time a counter knife is positioned.
    6. A display will show the desired position in millimeters or inches.
    7. This system can show measurement in either absolute or increasing way.
    8. Position tolerance: +/- 0.30 mm.
    9. Positioner is installed on a support that will be located on the rewinder benches; therefore, there will be an easy access to system and an easy repetition of positioning process.
  9. Unloading Roll Table
    1. A hydraulic pivotable table will have as main function the unloading of finished rolls that then will be located on floor level.
    2. This system will eject the roll and then it will be received at the pivoting table for an efficient unloading.
    3. Unloading table will also work as a protection for the operator.
    4. This equipment will have security curtains at front to keep operator from entering the rewinding area.
    5. There will be an emergency stop button or wire where operator works and will also have physical protection with security switches at cutting area.
  10. Control
    1. Hmi central control system with touch screen to program the operation cycle and all the material characteristics.
    2. Operator will have access to all operation parameters in order to be able to make changes on the equipment operation conditions, and therefore obtain material rolls with specific densities.
    3. Transmission: vectorial moto reducer with 1000:1 torque.
    4. Digital meter counter with display and automatic stop at defined distance.
  11. Documents Included
    1. Operation manual
    2. Maintenance manual
    3. Safety manual
    4. Electric diagrams
    5. Control system manual
    6. Plc backup
  12. Requirements
    1. Electric: 15 kw, 440 vac, tri phase.
    2. Pneumatic: 6 bar - 60 lts./min.
  13. Ducts and Wiring
    1. Ducts and wires running from utilities sources to the control panel and from the control panel to the machine will be at customer costs and must be done according to the instructions shown in our diagrams.
  14. Additional Unwinder with Splicing Table
    1. Second unwinder, same as described in the beginning.
    2. 3 in steel expansion shaft.
    3. Table to make the splicing of the material and the change to the new roll.
    4. The splice must be made at zero speed.