Project: Unwind/Rewind Converter with Lamination and Perforation Stations

For this project, the customer had requested a multi-purpose converter machine capable of handling several different webbing materials and films that span a wide range of material properties.  Machine functions include the ability to unwind large rolls to be laminated together, perforated at programmable lengths, and rewound with precise tension control.

To achieve the precise tension control demanded, the machine was built with dual tension zones.  Each zone was equipped with active servo driven rollers capable of operating in both position control or torque control depending on the material being fed through the machine.  On the rewind side, a vertical dancer with integrated closed-loop tension monitoring system was implemented to maintain precise tension control that could handle disturbances caused by rapid index acceleration/deceleration of the webbing.