Nip Roller Workshop

Timothy J. Walker
tjwalker@tjwa.com
(651) 686-5400 Office (651) 249-1121 Mobile (866) 572-3139 Fax

Kevin A. Cole
kevin.cole@optimation.us
(585) 321-2325 Office

WEBHANDLING.COM

OPTIMATION.US

AIMCAL.ORG

Nip Roller Workshop: Seminar Nip Roller System Design Nip Roller Pressure Wrinkling and Lateral Control Driving and Tensioning Lamination and Curl

TJWalker+Associates, Inc., Copyright 2009

www.webhandling.com

RP-2

Nip Roller Workshop: Labs

Lab #1 Measuring Nip Footprint and Pressure Uniformity Lab #2 Measuring Lateral Motion and Creating Wrinkles from Uneven Nipping Lab #3 Baggy Webs and Nips Lab #4 Process Speed / Feed Variations and Nips Lab #5 Curl Induced by Nip Roller Systems
TJWalker+Associates, Inc., Copyright 2009 www.webhandling.com RP-3

Nip Roller Workshop: Seminar Nip System Design: What is the best right rubber hardness and roller geometry for your process? How do you align nip rollers? What is the best way to controlling nip loads?

TJWalker+Associates, Inc., Copyright 2009

www.webhandling.com

RP-4

Nip Roller Workshop: Seminar Nip Roller Pressure: What is the pressure between nipped rollers? How is a nip footprint measured and why? How is nip pressure measured? What are the common causes of pressure variations? (and what are the remedies?)
Lab #1 Measuring Nip Footprint and Pressure Uniformity
TJWalker+Associates, Inc., Copyright 2009 www.webhandling.com RP-5

Nip Roller Workshop: Seminar Wrinkling and Lateral Control: Can uneven nip loading cause lateral shifting of the web? Why causes wrinkling at nipped rollers? What are the best remedies to prevent wrinkling at nips?
Lab #2 Measuring Lateral Motion and Creating Wrinkles from Uneven Nipping Lab #3 Baggy Webs and Nips
TJWalker+Associates, Inc., Copyright 2009 www.webhandling.com RP-6

Nip Roller Workshop: Seminar Driving and Tensioning: What are the best practices in driving nipped rollers? How does nip load change web tension or speed?
Lab #4 Process Speed / Feed Variations and Nips

TJWalker+Associates, Inc., Copyright 2009

www.webhandling.com

RP-7

Nip Roller Workshop: Seminar Laminating and Curl: What is the cause of curl in laminates? How does nipped roller system design and geometry affect curl?
Lab #5 Curl Induced by Nip Roller Systems

TJWalker+Associates, Inc., Copyright 2009

www.webhandling.com

RP-8

Nip Roller Workshop: Seminar Nip System Design: What is the best right rubber hardness and roller geometry for your process? How do you align nip rollers? What is the best way to controlling nip loads?

TJWalker+Associates, Inc., Copyright 2009

www.webhandling.com

RP-9

Important Nip System Variables

P = Pressure A = Area of cylinder N = No. of cylinders Weff = Effective Weight of nip LCYL = Length from pivot to cylinder LNIP = Length from pivot to nip Angles of arm, cylinder, roller contact - or H = Rubber indentation, the difference in covering thickness in the unnipped vs. nipped zone.

LNIP LCYL

TJWalker+Associates, Inc., Copyright 2009

www.webhandling.com

RP-10

Important Nip System Variables

D1 = diameter W1 = width tS1 = shell thickness tC1 = covering thickness EC = cover modulus/hardness n = cover Poissons ratio journals, crowning?
TJWalker+Associates, Inc., Copyright 2009 www.webhandling.com

D2 = diameter W2 = width tS2 = shell thickness tC2 = covering thickness journals, crowning?

RP-11

Calculate Nip Load

Given Machine Settings: Nip Air Pressure (psi) Convert to Process Condition: Nip Load (lbs/in)
Calc. cylinder force from pressure and area
2 FCYL ! nPA ! nP(2Trcyl )

Calc. leveraged nip force

LNIP LCYL

FNIP ! FCYL LCYL LNIP

For vertical nips, include roller weight effect

FNIP ! FCYL LCYL LNIP s WNIP

Calculate Nip Load:

N ! FNIP w
TJWalker+Associates, Inc., Copyright 2009 www.webhandling.com RP-12

Nip Force per Width (N)

Total Nip Load Force Nip Load in Force per Width

FN ! F1  F2  s Weff
w F1

N ! FN / w
F2

F1 = Force applied to side 1 of nipping roller F2 = Force applied to side 2 of nipping roller Weff = Effective roller weight on nipping load
TJWalker+Associates, Inc., Copyright 2009 www.webhandling.com RP-13

What is the Nip Width?

roller width

Is the nip width the web or roller width?

web width

tweb = web thickness

Hrubber = rubber indentation

N ! FN / wroller

N ! FN / wweb

If tweb < Hrubber Nip width is roller width.

TJWalker+Associates, Inc., Copyright 2009 www.webhandling.com

If tweb > Hrubber Nip width is web width.

RP-14

Nip System Process & Geometry Factors

Web(s): h = thickness wweb = web width Eweb = web elastic modulus

Tension & Speed: Tension control in Tension control out Nip system speed or torque control Process velocity

Geometry: Span length in Span length out Pre-nip wrap angle (on rigid or compliant roller?) Post-nip wrap angle (on rigid of complinat roller?)
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TJWalker+Associates, Inc., Copyright 2009