Nat. Volatiles & Essent.

Oils, 2021; 8(5): 2995-3007

Automatic Paper Slitter and Rewinding Machine

1V. Parvathi Priya, 2R. Mukunth

1
Department of Robotics and Automation Engineering
PSG College of Technology, Coimbatore-641 004, India
[email protected]

2
Department of Robotics and Automation Engineering
PSG College of Technology
Coimbatore-641 004, India
[email protected]

Abstract

Nowadays, automation plays a key role in all over the industries. Due to the demand of using paper is growing day
by day, efficiency and quality is need to be improved in the process of paper mill. Although, paper making involves the
use of several different processes and machines. The slitter-rewinder is an essential part of any paper mill. Unwinding of
large, main freshly produced rolls from paper making machine, cutting it into smaller length, and rewinding it to smaller
rolls for delivery is the job of a slitter-rewinder machine. Any issue with the slitter-rewinder, which is one of the production
process in the paper mill, will cause entire mill to shut down. This paper explains how the various stages in the process is
converting the manually operating rewinding and slitter machine into fully automated rewinding and slitter machine. The
basic concept uses load cell based tension controller, nip reliving rider roll using PID proportional valve, HMI, and PLC to
carry out the process. The main idea is to automate the process to avoid paper breakage and bring in optimal time
management and quality rewinding.

Keywords—Automation, Rewinder, Slitting machine, PLC, HMI, Paper mill.

I. INTRODUCTION

It is a challenging task to increase productivity and efficiency in most of the leading paper mills
in Southeast Asia. This makes the paper mills to retrofit its slitter-rewinder by incorporating the
latest technology. The main aim of this upgradation is to improve quality of the roll, which
improves the machine speed to its maximum level and to eliminate frequent shutdowns. Most of
the paper mill manufacturers are running with the drive systems of 25 to 30 years old. As number
of components had become obsolete, repairing and maintenance of the drive system in the slitter-
rewinder is more expensive and could not be replaced. Existing old hardwiring control and
mechanical unit which hold the thyristor assembly for control in the machine shows the signs of failure
and breakdown at some points and issues in power modules.
The automatic slitter-rewinder is the most sophisticated machine in mill machinery, with
many motors and controls. Tension, which decides the consistency of the paper rolls, is at the core
of this machine's operation. To ensure precise slitting, and proper roll density profiles, precise and

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consistent forces must be applied in the process. Except for nip power, the output of the drives is
largely responsible for the roll's consistency. The winder must operate as a synchronised
mechanism, maintaining precise speed-torque control during continuous cyclic operation of stop
to full speed and back to zero speed.
The overall objective includes converting the manually operating Rewinding and Slitter
machine into fully automated Rewinding and Slitter machine. For automating the process, load
cell-based tension controller, NIP reliving Rider roll using PID proportional valve, HMI, and PLC is
used.

II. LITERATURE SURVEY

“Design of a paper slitting and rewinding machine for a developing country”, Zimbabwe by
Tawanda Mushiri et al. [1], discusses how to design an economic slitting and rewinding machine that
focuses on small and medium businesses. Present issue is that such machines are very expensive on
the market which makes the small and medium business in developing countries cannot afford it.
“Design and Analysis of Paper Cutting Machine works on Geneva Mechanism”, by Vijay
Kumar et al. [2], conducted a study of mechanism incorporating a Geneva wheel and a gear train to
achieve intermittent motion is presented in paper. Position, velocity and acceleration are compared.
Reduce extreme jerk of Geneva wheel is used to find the non-circular motion of the gear pair. The
Geneva drive is an indexing mechanism that converts continuous motion to intermittent motion,
allowing the paper to be moved in-between cutting intervals. It describes the cutting operation using
a crank-lever mechanism. The cutter return to its original position by means of spring effect.
“Advanced Paper Cutting Machine using ARM7”, by SS Lavhate [3], proposed that the
designed system will be an automated smart length measurement device. It includes a rotary
encoder, proximity switches, motor, and an embedded design that includes a microcontroller circuit
and other components. The device serves as the control circuit for a paper cutting machine that can
cut a variety of materials including paper, plastic, thin film, leather, and nonferrous metal slices. The
paper cutting industry uses this system and demonstrates the contribution to a low-cost solution in
manufacturing.
Patent US4422588A [4], titled “Slitter-rewinder system” a slitter and a drum type rewinder
are part of a slitting and rewinding system and method. The core-cutter comprises a tool magazine
for storing cores. For severing a selected core into widths according to the setting of the slitter
knives, a transversely programmable movable core slitter was provided. The sections of slit core are
received by a core transporter, which transports them to the winder drums while also moves the
winded roll out of winding position. The paper web severing and adhesive application device cuts
the web from the winder and applies adhesive strips to the back's tail and lead corners.

III. METHODOLOGY

Hierarchy processes required for the development of various modules of an Automatic high-speed
rewinding and slitter machine. Fig.1 shows the methodology flow chart of the paper slitter rewinder.

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Fig.1. Methodology Flow Chart

Retrofitting of Rewinder-Slitter starts with removing the required PLC panel wirings and
connected in spare DI in new control desk via relay board and tested. S7- Profinet communication
established in S7-1500 PLC and check all handshaking signals to control the rewinder operation like
commands and feedback signals. Switch on the old 6RA70 DC drive and check the operation in no
load. Required PLC Program in both S7-1500 PLC was developed and downloaded. HMI Screens
modified as per the requirements and downloaded. Rider and Core Chuck operation tested. Paper
passed into the machine and check the operation in manual tension control and Rider manual Nip
releaving state was done. Run the rewinder in both manual / auto mode and check the operation. All
machine side interlocks in PLC program was updated and tested. Machine runs continuous up to 400
MPM and there is no fault observed.

IV. PARTS OF PAPER REWINDER AND SLITTER

A. Load cell for tension controller

The load cells on the machine's unwind section were replaced with Mitsubishi Tension
Controller LE7-40GU-L modules, which were chosen based on device specifications and it is direct
physical contact with frame. Mitsubishi's latest load cells, comes with pre-calibrated for an
application, which decreases friction and tension control. Fig.2 shows load cell mounted on a
machine.

Fig.2. Load Cell

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B. I2P valve
A current to pressure transducer is used to convert a 4 to 20mA analogue signal into a
proportional linear pneumatic value of 3 to 15 psi. The function of I2P is to convert an analogue
output from a control device into a specific, repeatable pressure value for pneumatic valve control.
An electrical signal from a controller is received form an I2P transducer and generate a
proportional output in the pneumatic form for controlling the control valve. The system is attached
to the wall and a pipe stand, or valve actuator. They are directly mounted on valve actuator and this
mechanism withstand the vibrations. To minimize vibrations, the system is often placed remotely on
instrument pipe stands. Fig.3 shows the I2P valve inside the Circuit.

Fig.3. I2P Valve

C. Pneumatic unwinder brake

It is important to use processes that ensure process consistency and excellent semi-finished or
finished product quality in order to maximize the production cycle. The most important parameter is
the web tension. To prevent any material breakage as well as ripples that can cause defects on the
final product, it is critical that the correct tension value remains constant in all work phases by using
high-quality clutches and brakes. In open or closed loop tension control regulation systems, the
brakes and clutches are mounted on roll stands, winders, and unwinders.
Pneumatic brakes are the perfect solution for unwinders, slitters, and rewinder machines –
the high torque ratio is needed for effective tension control both during the tensioning process and
during emergency stops. In this situation, the pneumatic brakes must operate at lower
temperatures in order to maintain continuous web tension control at any line speed while also
reducing part wear and dust emissions in the workplace. By meeting these objectives, the brakes
lead to a higher degree of environmental compliance and operator protection, as well as an
improvement in system performance and a decrease in maintenance times and costs. Fig. 4 shows
Unwinder Brake of the unwinder.

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Fig.4. Unwinder Brake

D.Master Control via HMI

SIEMENS KTP700 HMI panel screen is developed to optimise the profile and quality of the roll
during auto stop, product recipes, numeric and graphical set-points, permissive, complete analysis in
conjunction with the drives. SIEMENS KTP700 HMI shown in Fig.5 shows an complete and simple
interface that combines the control equipment with drive hardware and results in less complex
device with improved performance. It's much simpler to troubleshoot and manage.

Fig.5. HMI Panel

The paper mills have the problem with product length and diameter was solved by the automatic
stopping function. Permissive and diagnostic pages helped operators keep the winder running
smoothly and cut down on service calls to maintenance. The recipe system made it possible for
operations to easily set up orders while maintaining product continuity.

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V. WORKING OF SLITTER REWINDING MACHINE

A paper slitter rewinding machine is a retrofitting machine that cuts the main large paper roll
into small rolls that can be used for other purposes. Fig. 6 shows basic components of a slitter
rewinder of paper machine.

Fig.6. Basic Components of Slitter-Rewinder

The paper slitter rewinding machine consists of:

1) Unwinding stage
2) Slitting stage
3) Rewinding or winding stage

A. Unwinding stage
This stage contains a stand to unwind, which is used to load and secure the main roll of paper.
The roll would be held in place by the stand, which causes it to rotate around its central axis. The
two extended ends of a shaft are clamped which retain the rolls that runs the entire length of the
rolls on bearings in backside stand, or each with mechanical gripping elements on both ends of the
roll by inserting two chucks that extends in order to hold it. Big inertial forces are encountered when
unwinding heavy rolls at first, which can cut the paper. Guided unwinds are used to brake as required
so that the material's precise tension during the process is maintained.

B. Slitting Stage
The slitting of webs into several small slits takes place during slitting point. The paper which is
unwound is then carried over to a series of spread rollers and slitter head after leaving winding point.
The slitter head is used to cut the web. The slitter head contains a series of rotating knives or razors.
Depending on unit type, the required width of the slit is set in manual or automatic by adjusting
knives position on the slitter head. There are rollers in front of the slitter head that which makes the
sheet straight and ensures cuts in good quality.

C. Rewinding Stage
In this stage, rewound of rolls into required diameter of small cores is done in the rewind
stand from slitter head. Factors like wound material and roll hardness, influence type of winder that
is used in the specified situation. After slitter head, the rollers split the slit parts when they join the
winding. It prevents the roll range of the sheet weaving back and forth in-between adjacent rolls.

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VI. DESIGN STAGES

A. Surface winder two drum design

Webs line speed are known and it helps in determining the speed of assumed diameter and
surface diameter. The calculations of required torque by the electric motor used to run the surface
drum was done. The required torque is the product of the surface drum radius and overall tension
at the surface of surface drum in the web. As seen under various design phases, losses and other
design factors were also taken into account. Fig.7 shows the assembly of drum in retrofitted slitting
and rewinding machine.

Fig.7. Drum

B. Slitting system rotary shear design

First, the standard size of 8” diameter bottom knife was chosen. Fig.8 shows the rotary shear
of the paper slitting and rewinding machine.

Fig.8. Rotary Shear

Several calculations were performed using this diameter value to decide the appropriate size
of top knife to maintain right configurations such as arch movement, penetration depth, and centre
distance between the top and bottom knives during normal machine working conditions. When
calculating strength needed to move the slitter head, overall force acting on top and bottom knives
was considered.

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C. Unwind section design

Unwind stage shows design of unwind centre. The motor selection that would drive the unwind
stand is done. Fig. 9 shows the unwind stage of slitting and rewinding machine.

Fig.9. Unwind Section

D. Final Assembly
All the component in the machine slitter is assembled with reference to the assembly
drawing. Fig.10 shows the final assembly drawing the machine.

Fig.10 Slitter-Rewinder Assembly

TABLE I. MACHINE COMPONENT OF 3D ASSEMBLY

Part number Part Name

1, 2 Surface drums
3 Traction roll
4 Straightening roller
5 bearing
6 Top knife
7 Top knife shaft
8 Bottom knife
9 Bottom knife shaft
pulley

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10 Unwind core
11 Bottom knife shaft
12 Unwind core chuck
13 Unwind stand
14 Main frame base
15 Load cell unit stand
16 Load cell
17 Slitter head/ surface
drum electric drive
motor
18 Electric motor stand
19 and 20 Surface drum pulley
21 ‘V’ belt
22 Surface winder stand

Table 1 shows the final 3D assembly showing machine components.

E. Selection of Drives
By installation of the 6RA70 DC Drive and V90 AC drives, in conjunction with HMI, high output,
top speed performance, improved quality of rolls, less maintenance, and minimum shutdowns can be
achieved in paper mill. They have also been able to virtually remove shut downs that occurred due to
component failure.
VII. TESTING AND IMPLEMENATION

A. Stress analysis of the bottom knife

In the bottom knife, the highest von Mises tension occurs nearest to the knife is connected to the
bottom knife shaft. As a result, the design is safer. Fig. 11 and Fig.12 depicts Von Mises Stress analysis
on the top of knife under the condition of static loading.

Fig. 11. Stress Analysis Results from Solid works

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Fig. 12. Stess analysis of Knife

B. Results of Von Mises Stress Analysis

Factor of safety is assumed as N=10, The designed stress is as follows:

Overall, knife's design stress is greater than the von Mises stress. As a result, design is perfect.
The result of stress analysis shows that the yield stresses of the components is more than the
maximum Von Mises stress in the measured components. As a result, these components will not
malfunction under normal operating conditions.

C. Front Control desk

The application program was developed and commissioning was done. The drive and controller
software was devleoped, and the panel was as shown Fig.13. After a complete two-weeks of testing,
these new equipment within the contingency the mill was installed. The plant was ensured to a
seamless transition.

Fig. 13 Control Desk

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D. PLC Program
The relay ladder logic program blocks for the following functions of rewinder and slitter
machine was developed and implemented. Fig.14, Fig.15 and Fig.16 shows the sample relay ladder
logic PLC program of the machine.
Automation_Control_Desk_PR216_Rewinder/PLC_1
[CPU 1511-1 PN] / Program blocks include:
▪ Auto_Reel_Change [FC8
▪ Interlocks [FC1]
▪ Core_Chuck [FC5]
▪ Curve1_FC [FC18
▪ Curve2_FC [FC19
▪ Curve3_FC [FC21]
▪ Curve4_FC [FC21]
▪ Curve5_FC [FC21]
▪ Length_Calculation [FC10]
▪ LHS_Core_Chuck [FC6]
▪ LINE_SPEED_GEN [FC15]
▪ MOTOR SPEED CALC [FC20]
▪ Moving_Parts_MC [FC3]
▪ MTS [FC9]
▪ RCV_DATA_FROM_S7300_PLC [FC12]
▪ REWINDER_LOGIC [FC13]

Fig. 13. PLC Sample Program of Rewinder

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Fig. 15. PLC Sample Program of Auto Reel Change

Fig. 15. PLC Sample Program of Rider Roll

VIII. CONCLUSION

The paper slitter-rewinder machine was retrofitted to run automatically and it was
implemented. The Control panel was build. The drive and machine process PLC program, front end
control panel was developed and installed. The complete retrofitting machine was interfaced with
control panel and installed successfully. The machine could be run to cut paper ranges from
1189mm to 40mm with any constraints.

REFERENCES
1. Mushiri, Tawanda, Mbohwa, Charles Mashana, Godfrey, “Design of a Paper Slitting and
Rewinding Machine for a Developing Country, Zimbabwe”, IIEOPM, Detroit, Michigan, 2016.
2. Vijay Kumar U, Ghanshyam Kumar, Dharesh Bansod, Deepak Sahu, Rishabh Bendre,
Aakanksha Suryawanshi, “Design and Analysis of Paper Cutting Machine works on Geneva
Mechanism” , Vol-2 Issue-2, IJARIIE, 2016.
3. SS Lavhate, “Advanced Paper Cutting Machine using ARM7”, Vol-3, Issue-4, IJEAT, 2014
4. The patent US4422588A, “Slitter-rewinder system”, 1983.
5. Ashe Controls Ltd winding Manual, Ashe Controls Limited, 2015.

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6. Bloch, E, “ SMEs key to economic wellbeing”, 2014.

7. Burris Machine Company Manual, Inc., 2011.
8. Burris Machine Company Manual, INC.. ., 2014.
9. Paper Machine Winding Manual, Convergence Training, 2015.
10. Slitting Manual Cortape Incorporated, 2015..
11. Slitting Rewinding Machine (DC-RSM-1092/1575II) Manual. DC International Group Ltd,
2015.
12. Crush Cutting Reference Guide, Dienes Corporation, 2015.
13. Rewinder - How a Rewinder works, Jennerjahn Machine, Inc., 2015.
14. Slitting Techniques: “A Basic Guide, Parkinson Technologies Inc”, 2015.

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