How are diaphragm air cylinders used in web tensioning devices?

How are diaphragm air cylinders used in web tensioning devices?

ControlAir’s Diaphragm Air Cylinders are commonly used in web tensioning devices which are used in manufacturing processes to control the tension of a flexible web material like paper, film, or fabrics as they move through various processing stages. Web tensioners utilize sensors, rollers, diaphragm cylinders, and brakes/clutches to adjust and maintain the desired tension. Ensuring consistent tension improves product quality and prevents issues like wrinkling or tearing of the web material. Web tensioners are widely used in industries such as printing, packaging, thin film applications, and textiles.

Diaphragm air cylinders play a crucial role in web tension devices by applying and controlling tension in web materials. A diaphragm air cylinder is a type of pneumatic actuator that converts fluid pressure into linear mechanical force. It consists of a cylindrical body with a rolling diaphragm sealed inside. When air pressure is applied to one side of the diaphragm, it deflects, causing the rod or piston attached to it to move in a linear direction. Their adjustable pressure and responsive low-friction characteristics make them well-suited for achieving precise tension control, contributing to the quality and consistency of web-based manufacturing processes.

Here’s how ControlAir’s Diaphragm Air Cylinders are typically utilized in web tensioning systems:

Key Functions in Web Tensioning

1. Tension Regulation:

• Role of Diaphragm Air Cylinders: These cylinders are crucial for adjusting and maintaining the correct tension on the web material. They apply a controlled force to tension rollers or dancer arms that interact with the moving web. The operator can increase or decrease the tension as required by regulating the air pressure supplied to the cylinder. This can be done with a precision pressure regulator, I/P transducer, or some other form of electronic regulator. This allows for precise tension control based on the specific requirements of the web material and the production process.
• Diaphragm Advantage: The diaphragm design provides precise and stable force output, which is essential for keeping the web material tension consistent, preventing slack or excessive tension that could lead to material damage or breakage.

2. Compensation for Variations:

• Adaptive Response: As the web material is fed through the machine, the tension can vary due to changes in speed, roll diameter, or mechanical inconsistencies. Diaphragm air cylinders can quickly and accurately adjust the force applied to the tensioning components to compensate for these variations.
• Pressure Control: By adjusting the air pressure supplied to the diaphragm cylinder, the system can fine-tune the tension applied to the web, ensuring optimal performance.

Implementation in Web Tensioning Devices

The dancer roll mechanism employs a pivoted roller, known as the dancer, which moves vertically in response to the tension of the web. A diaphragm air cylinder is connected to the dancer roll, which applies a counteracting force to uphold the desired tension level. This mechanism dynamically adjusts as the tension of the web fluctuates, with the dancer roll responding to changes and the diaphragm cylinder modifying its force output accordingly to maintain the desired tension range. Similarly, tension roller setups utilize diaphragm air cylinders to directly control the position and force of tension rollers against the web material. This direct application allows for precise regulation of contact pressure, ensuring consistent tension throughout the process. The advantages of employing diaphragm air cylinders include their ability to provide precision and stability in tension control, their quick responsiveness to changes in web speed and tension, and their durability in withstanding the demanding conditions of continuous web processing operations.

Conclusion

In summary, ControlAir’s Diaphragm Air Cylinders are integral to the effective functioning of web tensioning devices. They ensure the material being processed remains under consistent tension, thereby improving the quality and efficiency of the web handling process. By providing precise, stable, and adjustable force, these cylinders help maintain the desired tension, compensating for any variations in the process, and thereby preventing issues such as material damage or machine stoppages.

You can download our white paper to learn more about these cylinders: Diaphragm Cylinders: Virtually Frictionless and Leak-Free