Winding: Machines, Mechanics & Measurements
This trademarked and award-winning course by David Rosium has been taken by about 5,000 students! The Winding Introduction covers the fundamentals of winding. This course is essential for anyone working with winding machines or wound roll product.
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This course is designed for operators/technical people responsible for most any type of winding machines or wound roll product. The only prerequisite is a some technical aptitude and enough job experience to be familiar with the parts of your machines, basic functions and common web/roll defects. However, it would be helpful to have the Web Handling and Converting course first as this provides solid foundation for the Winding Course.
What you will learn:
• Eliminate winding defects
• Know whether your defect is manufacturing or winding related or both
• Select and use the proper type of winder and settings for your product
• Design and maintain winding machinery
• Design and maintain winder control systems for tension, nip and torque
• Design and manufacture webs for more reliable winding
• Troubleshoot a variety of web, winding and operational issues
• Understand why the winding world does what it does
Winding is found at the end of web manufacturing, roll-to-roll converting, and rewinding. Without much exaggeration, winding makes web manufacturing possible by providing a convenient place to store the web between process steps. In this introductory module, we will describe winding machines, mechanics and measurements. Be certain that you are familiar with the topics in modules 1-12 before beginning the winding modules.
21 Cores, Core Shafts and Chucks
In this module we describe the foundation of wound rolls which may be cores, mandrels or nothing at all in some cases. Next, we describe how to hold the roll rock steady via core shafts or chucks.
22 Winder Types
Winders can be built in many ways. However, most fall within six types. The turret and pope reel are continuous winders that follow most web manufacturing lines as well as high productivity roll-to-roll converting. The duplex and two-drum winders cut larger parent rolls into smaller shipping rolls. Finally, two specialty winders include the slipped core winder and the gap winder. This module covers the application, limitations and design highlights for each of these types.
Here rewinder productivity is measured and predicted using models. Other factors affecting productivity are also discussed including Human-Machine-Interaction. Some automation is discussed here as well as in the Extra module.
24 Mechanical and Electrical Issues
Winders are first and foremost, web handling machines. Thus, attention to rollers, tension and nip control, spreading and wrinkling are subjects that also apply here. However, winders have many issues that are more demanding, unusual or even unique. These include mechanical issues such as vibration and spreading. However, electrical issues are even more concerning. Every single drive motor on a winder is much more complicated than anything found upstream. There may be more PLC power on the winder than the entire rest of the plant or mill combined.
25 Winding Theory
The understanding of winding defects and stresses in a wound roll has evolved together. It began as the observation that the tightness/hardness of the wind mattered for some defects. Then it was found that good roll structure helped with a few more defects. However, the science of calculating stresses allow us to predict many defects and understand many more.
26 Wound Roll Defects
This module covers many of the 100 defects that are found on wound rolls. How they are formed, causes and cures are discussed in some detail.
27 Roll Quality Measurement
There are at least a dozen commercial roll quality instruments on the marketplace. While many are based on roll hardness, other measurement principles can also be useful for certain problems and products. Design and application are discussed in detail.
28 Roll Quality Inspection
Your eyes are and will always be the most useful roll quality instrument. Here we discuss several wound roll defects that are visual that have not been discussed in the earlier modules.
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All told you have more than 1,000 pages and more than ½ million words! All are searchable and keyworded. These documents cover must-know subjects of web-handling, rollers, tension and nip control, wrinkling, spreading, slitting, guiding, converting operations such as printing, coating, laminating, heating and cooling as well as industrial problem solving techniques of a wide variety. If you need to go beyond my own writings, you will find that the RoisumLibrary indexes nearly everything else ever written in the web handling areas.
An unpublished book that followed Critical Thinking in Converting (TAPPI PRESS, 2002).
This spreadsheet has sheets for my personal works including books, conference papers, Web Words columns, Web Wise columns, WebHandling Blog, Web101 teaching modules and Web201 YouTube clips. All are dated and keyworded and searchable. Merely click on the appropriate tab at the bottom to navigate between the various databases.
Defines some 1,000 technical words used in our web-industries including aliases.
A keyworded and searchable list of some 4,000 articles, books, conference papers, columns, theses and other published material by the famous, infamous and not so famous authors of web handling related material. This is most everything ever published on web-handling subject except for patents.
37 of my columns from AIMCAL’s Converting Quarterly. Fair use with attribution here would include my name as well as AIMCAL.
190 of my columns from the now deceased Converting Magazine
An emergency help guide with links that you are welcome to share as you like.
Winding: Machines, Mechanics and Measurements
Winding is one of the oldest of the web handling sciences. However, it is also one of the most misunderstood. All too often the winder is blamed for waste, because it is the first chance to get a good look at the product, when the problem may be that the web quality is not adequate for winding period. There are several classes of winder such as center, centerwind with layon roller, surface wind and center surface wind. The winder class tells you which of the TNT’s (Tension, Nip and Torque) are available to tighten the wound roll. Also, there are many types of online winders such as turrets and reels, offline winders such as two drums and duplex, and niche winders such as gap and differential. An introduction to some of the common wound roll defects is also covered.
Winding is a 1-2 day course depending on which modules are taken. However, the web handling sections above are prerequisite. If you only want a general overview, module 20 should be enough. If you work with winders or winder problems regularly, you may wish to take other modules as fits your needs.
Videos in this module