Example Development

 


Web
Quality

Production
Quality

OEM Machine
/Component Development

Proof
-of-
Concept

Interleaving winding - enable noncontact film winding 


 x
Cardboard core torque transmission - low cost core

x

Induction heated knurling - one-sided film edge knurling


x
Film separation/peeling - new product development x



Layon roller study - high speed paper and film winding
x


Roller surface - high speed conveyance

x

Bowed roller - web spreading
x


Anti-wrinkle and web spreading - paper, film, foil

x


Airbar clearance - reduce film edge contamination


x

Reverser clearance - eliminate web contamination


x

Weave - minimize film lateral oscillations

x


Hybrid turnbar/rollers - wrinkle free product


x

Track off - elevated temperature on film
x


Winding product & process - verify predictive models
x
  x

 


Example Projects continued...


Web Quality

  • Developed a film separation/peeling process to enable defect free production of a low cost coextruded multi-layer thermal receiver product. 
  • Created roll winding first principles model that clarify the impact of product and process parameters on wound roll induced web non-planarity due to web thickness non-uniformity. 

Production Quality

  • Optimized layon roller process and design parameters to achieve improved web and roll quality by conducting high speed process studies on paper and PET webs.
  • Implemented bowed and anti-wrinkle rollers in numerous locations to eliminate wrinkling concerns upstream of critical processes such as gravure coaters and nip drives.

OEM Machine/Component Development

  • Developed and evaluated a low cost gudgeon for use on an existing winder chuck to enable replacement of a conventional film core with a low cost cardboard core in a continuous film coating operation. 
  • Generated roller traction first principles model that accounts for roller surface roughness and profile and used the model to develop low cost options for achieving reliable slip free roller conveyance at high speeds.
  • Developed and applied air reverser web clearance models to the design of hole patterns for a large number of production machines.

Proof-of-Concept

  • Developed and implemented an web edge interleaving process to enable noncontact film winding.
  • Designed, developed and implemented an induction heating edge knurling process for improved wound roll and web quality and increased web coating width.
  • Utilized Optimation's MCF to develop and demonstrate robust conveyance components and a web path system to enable wrinkle-free conveyance of new product in an existing production machine.
  • Provided winding and conveyance machine commissioning for a new copper foil manufacturing facility for winding optimization, enhanced process understanding, elimination of conveyance defects, and increased speed capability.