Created on 06.02
How Roll Diameter Changes Affect Tension Control
During rewinding, roll diameter continuously increases. As the roll grows, speed decreases while inertia increases.
Without proper compensation, diameter changes can cause:
- loose winding
- excessive tension
- wrinkles
- slipping
- poor roll quality
Why Does Roll Diameter Affect Tension?
Tension is directly related to torque and roll diameter.
When torque remains constant:
- larger diameter → lower tension
- smaller diameter → higher tension
Therefore, tension must be continuously adjusted as the roll grows.
Common Problems Caused by Diameter Changes
1. Tension Reduction
As diameter increases, winding tension may gradually decrease, resulting in loose rolls.
2. Uneven Multi-Roll Rewinding
Different rolls often develop different diameters, creating tension differences between rolls.
3. Tension Fluctuation During Acceleration and Deceleration
Changes in diameter and inertia can create unstable tension during speed changes.
Solutions
Automatic Tension Control
Use sensors and control systems to compensate for diameter changes in real time.
Taper Tension Control
Gradually reduce tension as the roll diameter increases to improve winding quality.
Differential Slip Shafts
Slip shafts help balance tension and compensate for roll diameter differences in multi-roll rewinding.
Accurate Diameter Monitoring
Modern systems use encoders and automatic calculations to track roll diameter continuously.
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