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Staff -- Converting Magazine, 7/1/2003

Lightweight strip shafts

SRT model strip shafts are lightweight yet durable alternatives to traditional metal strip shafts, says co. Unique aluminum body extrusions remove all excess weight from the shaft while performing well in lightweight and/or low tension applications. They are available in various diameters with brass air valves for corrosion resistance, custom-made steel journals, aircraft-grade aluminum bodies, high-performance bladders, and rugged gripping elements. These strip shafts are available in diameters starting at 1 in. Double E Co., 508/588-8099, fax: 508/580-2915, www.doubleeusa.com

Retrofit kit for web guiding

A new retrofit kit upgrade package for web guiding includes all the current controls needed to convert older A9 guiding systems to today's technology. Upgrading to the co.'s CDP-01 controllers gives added flexibility and control over web guiding setup. Advanced setup features automatically determine and set guide polarity, guide point, and system gain. Built for demanding web-guiding applications, this controller also provides the flexibility to add features like remote operation or multidrive versions to control multiple actuators. You can continue to use the servo motor/actuator and/or guiding structure you are currently using. Available for both electromechanical and electrohydraulic operations, the CDP-01 upgrade kit can be configured for line, edge, or center guiding applications. Fife Corp., 800/639-3433, www.fife.com/retrofit

Single-side corona-treat station

The new blown film split box features continuous trouble free operation; open design for easy webbing; easy roll removal; removable electrode; stainless steel segments; track resistant high voltage insulators; and friction free dead shaft roll bearings—all provided as standard equipment. Corrosion resistant components are said to eliminate unnecessary down time for loosening corroded segments or replacing rusted hardware. Operator controls via manual air valve or microprocessor diagnostics with PLC control depending on the application. Pillar Technologies, 262/367-3060, fax: 262/367-3206, www.pillartech.com

Ultrasonic tension control

VERSATEC is an ultrasonic tension control said to work well with upgrades and retrofits. VERSATEC bolts onto an existing machine making it easy to upgrade from manual to automatic unwind/rewind. Standard outputs are available to control AC or DC drives or pneumatic brakes via current-to-pressure transducer. An internal power amplifier for control of magnetic-particle brakes and clutches can also be used. In unwind applications, the Stop Multiplier feature of the VERSATEC increases torque during machine stops, providing smooth stops and helping prevent slack webs. In rewind applications, the Taper Tension feature prevents telescoping rolls by reducing tension as the roll diameter increases. MAGPOWR, 800/MAGPOWR, www.magpowr.com/retrofit

Inverter

The new 3G3RV AC inverter features a new high-slip braking function for intermittent braking applications that shortens motor stopping time by one-third without using braking resistors. In addition to the 3G3RV's standard rotational auto-tune, a new static auto-tune function eliminates the need for motor rotation to determine and set parameters. With the 3G3RV, the co. has provided a built-in RS485/422 Modbus communications protocol and made available optional cards for DeviceNet and Profibus. Omron Electronics LLC, 847/755-7057, fax: 847/843-8087, www.idmcontrols.com

Airshaft & chuck system

The new COR-LOK® airshafts and chucks feature a freshly engineered tubing (bladder) design contoured to match the geometry of the co.'s unique, spiraled shaft body. Compared to previous designs, the economical new contoured tubing allows increased gripping power, a longer tubing life and exceptionally easy replacement, states co. The new COR-LOK airshaft and chuck systems also offer several air valve options intended to match virtually any plant requirements. To fully inflate, they require only 90 to 120 psi. Converter Accessory Corp., 800/433-2413, fax: 610/863-7818, www.handleyourweb.com

Defect tracking system

RollCode defect tracking system, when signaled by an operator, or by input from any automatic inspection device, places a flag on the moving web to mark defects. RollCode records the location and interacts with downstream process equipment to automatically stop the equipment at the flagged location. The defective material can then be spliced out. The roll information can be stored on a LAN, the RollCode website, or printed on bar coded label. Novation, Inc., 610/837-5026, fax: 610/837-9938, www.novation.com

Tension controller

The WebHandlere3 is a digital tension controller capable of bringing precise, automatic closed-loop web control to web presses and converting machinery, says co. The WebHandler 3 controls output to a tensioning component such as a pneumatic brake, clutch or DC drive. Setup, adjusting web tension, changing selections, and viewing controller status can be accomplished with the intuitive, six-key touch-pad interface and clear text prompts from the large, backlit LCD display. Features include touch panel set-up and calibration, automatic compensation for speed and roll diameter changes, soft start, storage and recall of multiple job setups, and serial access via PC workstation or laptop using the included WH3_link Windows-based software. Dover Flexo Electronics, 603/332-6150, fax: 603/332-6150, www.dfe.com

UV processor

This co. introduces the Optimum series UV processor. This unit is said to be suitable for installation on coating lines from 10 to 110 in. Space requirement in the web direction is only 3 ft. Additional benefits include improved adhesive performance and faster cure rate, reports co. With the Optimum UV Processor, UV laminating adhesive is applied directly to the substrate and immediately nipped to the laminating film. UV adhesive is cured instantly as the laminated substrate passes through the processor. This system allows the converter to complete finishing in-line or run roll-to-roll. Prime UV Systems, 630/681-2100, fax: 630/681-0022, www.primeuv.com

Lightweight shafts

The new Ultra-lightweight GX shafts are constructed using a specially designed aluminum extrusion, providing a strong, durable alternative to composite shafts, reports co. Available for 3 and 6 in. core sizes, each GX shaft is built to meet the exact specifications of the environment where it will be used. The co.'s engineers develop the optimum balance of strength and shaft weight for each order, based upon the specific application requirements. Tidland Corp., 800/426-1000, www.tidland.com/retrofit

Analog controllers

The X-3100ce tension controller, the D-3100ce dancer controller and the DTI-3100ce dancer controller with tension indication form this co.'s new and improved family of analog controllers with digital parameter handling. These System 3000™ controllers were developed to provide accurate, repeatable tension control on all types of web processing machinery, reports co. New features include: transferable memory card, RS-232 interface to computer or PLC and direct on-board DeviceNet and Profibus DP fieldbus connections. The Montalvo Corp., 800/226-8710, fax: 800/644-5097, www.montalvo.com

Dancer control system

This microprocessor based controller is designed for high precision and easy operation, featuring PC based setup and calibration to eliminate potentiometer adjustments. The co.'s closed-loop dancer control system features the RSD100 digital dancer position controller, EN50 electro-pneumatic transducer, DPS 30 or 60 dancer position sensor, and power supply. The RSD 100 interfaces with a brake, clutch or motor drive to provide stable web tension through adjustments in dancer arm position. Dancer position sensors measure the rotational movement of a dancer arm. The EN50 electro-pneumatic transducer allows the RSD to interface directly with air engaged brakes/clutches. The RSD system is completely automatic in operation and works to maintain constant and consistent tension by compensating for roll-diameter changes, egg-shaped rolls, and other tension disturbances. Nexen Group, 651/286-1054, www.nexengroup.com

Controllers & motors

The compact ECODRIVE Cs series introduces a new generation of system-compatible AC servo drives in the 100 to 750 watt power range, with 230VAC single-or three-phase power input. Most units are just 2.17 in. wide, 7.17 in. high and 6.69 in. deep. The ECODRIVE Cs product range also includes four new motor sizes that feature the same compact dimensions. The motors include options for a built-in holding brake, keyed output shaft and absolute feedback that eliminate referencing. Bosch Rexroth Corp., 847/645-3774, fax: 847/645-6201, www.boschrexroth-us.com

Clutches & brakes

SensiFlex® pneumatic tension control clutches and brakes can be used on both unwinds and rewinds. They are said to feature smooth performance throughout the converting process. The unique, patent pending SensiFlex actuator engages the clutch or brake at low air pressures and reacts to slight air pressure adjustments providing a wider range of available torque output than comparable pneumatic models. Mach III Clutch Inc., 859/291-0849, fax: 859/655-8362, www.machiii.com

Direct drive knife

The DirEXcut™ Dual Rotary Direct Drive Knife is a high-performance cutting system designed with all off-the-shelf, readily available hardware, motors and drives. All ladder logic and drawings are provided for the machine, allowing maintenance personnel to troubleshoot the machine without extensive OEM support. The blades are helically-wrapped on dual cylinders to create a precise scissor-type cutting action across the web. Webex, Inc., 920/729-6666, fax: 920/725-9992, www.webexinc.com

Static neutralizing system

The new PerforMAX static neutralizer is an extended range, high-speed system designed to eliminate static charges even when installed up to 10 in. from the web surface, and up to 20 in. on winders. It consists of a control module and static bar. The control module monitors output at the static bar, indicates when the static bar needs cleaning and other conditions that may prevent peak performance. The range switch can be set for applications where the static bar is located less than 3 in. or greater than 3 in. away from the target material. Simco Industrial Static Control, 215/822-6401, fax: 215/822-3795, www.simco.biz

Inspection equipment

The new DC2020 is an inspection equipment system to control product quality. Common defects such as holes, dirt and coating skips are detected down to 1/64 in. at line speeds up to 6,500 fpm. The patented advanced IR-optic scheme provides discrete categorization of both hole and surface defects with whole sheet opacity monitoring. Continuous self-diagnostics ensure 100- percent real-time inspection with no dead spots or interruption in inspection. Summit Engineering, 800/368-5204, fax: 434/736-0614, www.summitengineering.com

Corona treatment system

A new family of fixed-width bare-roll corona treatment systems is designed for the narrow-web processor. These systems feature the co.'s new electrode design, which is capable of delivering much higher power densities to the web than competitive designs due to unique HVC cooling architecture. Systems are available in single- and double-side treating configurations and can be ordered with an integral power supply, or a separate power supply. Uni-Dyne® configurations are available with power ratings from 500 watts to 5,000 watts, while systems with a separate power supply have no power limitation. Corotec Corp., 800/423-0348, fax: 860/674-5229, www.corotec.com

Thermal oxidizer upgrade

Upgrading for heat-exchanger media in older regenerative thermal oxidizer (RTO) is available. The pressure drop associated with the random-packed heat-exchanger media originally used in older RTOs is said to be very high when compared to today's structured packing. By replacing the random-packed media with structured packing, the pressure drop across the unit is reduced and it's easier to pass air through the oxidizer, reports co. With this lower pressure drop, a converter's current exhaust fan will operate on a different system curve, resulting in a capacity increase of 10-25 percent, using existing exhaust fan, ductwork and process connections. MEGTEC Systems, 800/862-6943, fax: 920/339-2793,www.megtec.com

Aluminum idler rolls

A line of standard, aluminum idler rolls are said to reduce mass and rolling inertia, which makes them an obvious choice in many applications, reports co. They can be supplied with custom SealMaster, low-friction, and ER-style bearings, and are offered with a wide variety of coverings and coatings. Epoch Industries, 972/271-4295, fax: 972/278-6631, www.epochind.com

Surface treating station

This co. provides a universal surface treating station designed for processing a multitude of part shapes and sizes. The system uses a unique rotating electrode array, and has two high voltage/high frequency transformers. One transformer has a maximum output voltage of 40 kV, and the second transformer's maximum output is 22 kV. Because of the rotating electrode array and higher total voltage, the results are said to be more consistent and uniform and less set-up is required from part to part. A belt transports the parts to be surface treated through the machine. Side guides are positioned to locate the parts properly on the transport belt. The surface treating station and high voltage/high frequency electronics are capable of delivering 1,000 watts continuously. Tantec, Inc., 847/524-5506, fax: 847/524-6956, www.tantec.com

Closed loop controller

The CMGZ612 controller is designed for unwind/rewind machines or machines where multiple tension zones improve processing capability because controlling two separate tension zones in one electronic unit is said to save machine space and money. The CMGZ612 offers a two- millisecond response time, +/-10V/0-10V and 0/4-20mA outputs, and is parameter selectable for control of an unwind brake or drive, a rewind or intermediate drive. The electronic unit offers a compact housing, a 2x16 character LCD display, four indication LEDs, is programmed with only four front panel keys, and has built in filters to ensure stable control signals. FMS USA, Inc., 847/392-7872, fax: 847/392-7873, www.fms-technology.com

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