International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

In roll-to-roll systems like wet wipe production, the synchronous and smooth unwinding of the web material with constant tension is critical for product quality and production efficiency. Traditional constant belt braking mechanisms cause tension issues due to varying bobbin diameter and friction-induced heating, leading to web undulations, stretching, and breaks in sensitive materials such as wetlace. To overcome these operational challenges, an automatically controlled braking and accumulator system has been developed. The system instantly measures product tension by monitoring web position using a laser ruler and dynamically adjusts the pneumatic brake force via a high-frequency PID algorithm updated every 5 milliseconds. Furthermore, a constant pressure pneumatic piston acts as an accumulator, balancing the web’s vertical movements and dampening instantaneous tension variations. This system, compliant with Industry 4.0 principles and based on real-time feedback, solves critical tension control problems, ensures continuity in product quality, and establishes a new concept that is a pioneering example in the global market.

Nonwoven winding machines are critical equipment where the structural integrity of the main drum directly impacts the quality and stability of the final product. This study presents the mechanical analysis and braking system design for a main winding drum (Diameter 400 mm) in a high-speed nonwoven application, driven by Finite Element Analysis (FEA) for stress minimization. The load analysis, based on the Principles of Static Equilibrium, determined the total maximum load on the drum supports, considering a maximum spool weight of 1500 kg and a nip force of 1962 N. The resultant total load applied on the supports was calculated as approximately 11.5 kN. The FEA, utilizing ST37 steel, revealed a maximum Von Mises Stress of 1.754 MPa and an extremely low maximum deflection of 0.005 mm. This confirms an optimal factor of safety (FS approx 134) and high rigidity. Furthermore, the paper addresses the safety requirement for emergency stopping from a maximum speed (omega = 50 rad/s). The minimum required braking torque was calculated as 235 Nm, while the selected COREMO PNEUMATIC CALIPER BRAKE B-2N system provides 306.8 Nm, ensuring reliable and controlled deceleration. The results validate the structural and functional design, contributing to enhanced machine performance and operational safety.