From mechanical design to intelligent control: the technological evolution of modern slitter rewinders

As the core equipment of papermaking, film, foil and other industries, the technological evolution of modern slitting and rewinding machine has experienced a leapfrog development from traditional mechanical design to intelligent control. The following is an analysis of this evolution process from key technical nodes:

First, laying the foundation of the mechanical design stage (mid-20th century)

1. Infrastructure innovation

◦ The double take-up shaft design is used to achieve continuous production, and the mechanical tension control system (such as heavy hammer lever, friction brake) ensures the basic tension stability.

◦ The slitting tool has been developed from a round blade to an adjustable spiral knife, and the cutting accuracy has been improved to the ±0.5mm level.

2. Material and power upgrades

◦ The high-carbon steel gear transmission system replaces cast iron parts, and the bearing life is increased by 3 times; The AC asynchronous motor realizes multi-stage speed regulation through a mechanical gearbox.

Second, electrification and Automation Transformation (1980s-2000s)

1. PLC control revolution

◦ After the introduction of Siemens S7 series PLC, the logic control program was realized, and the failure rate was reduced by 40%. The PID algorithm enables the tension control accuracy to reach ±1N.

2. Application of sensing technology

◦ Ultrasonic or laser caliper monitors the coil diameter in real time, and cooperates with the magnetic particle brake to form a closed-loop control, and the speed is increased to 600m/min.

3. HMI human-computer interaction

◦ The touch screen interface replaces the button panel, which can store 100+ sets of process parameters, and the changeover time is reduced by 70%.

Third, intelligent breakthrough stage (2010 to present)

1. Digital Twin and Simulation

◦ ANSYS mechanical dynamics simulation optimizes roll train layout and reduces vibration amplitude by 25%; Virtual commissioning shortens the R&D cycle by 30%.

2. AI core technology innovation

◦ Deep learning vision systems (e.g., Halcon+CNN) implement:

▪ Micron-level defect detection (sensitivity 0.1mm²)

▪ Automatic pitch compensation (dynamic adjustment±0.05mm)

◦ Reinforcement learning algorithm optimizes winding parameters and reduces material loss by 15%.

3. IIoT architecture

◦ 5G+OPC UA implementation:

▪ 500+ sensor data collection in milliseconds

▪ Cloud-based PHM system predicts bearing failures (92% accuracy)

4. New drive concept

◦ Direct drive servo motors (e.g., Kollmorgen DDR) eliminate mechanical transmission, with a positioning accuracy of ±0.01° and a 20% reduction in energy consumption.

Fourth, the future direction of technology

1. Interdisciplinary integration

◦ Metamaterial rollers (graphene coating) reduce inertia by 30%

◦ Quantum sensors enable tension monitoring at the nanometer level

2. Autonomous decision-making system

◦ The digital brain calculates 10^6 slitting schemes in real time

◦ Blockchain traces the full life cycle data of each volume of material

Comparison of typical cases

This evolution process shows that the slitting and rewinding machine has developed from a single processing equipment to a comprehensive system integrating mechanical precision engineering, intelligent algorithms, and industrial Internet, and continues to promote the expansion of flexible manufacturing boundaries.