Industry 4.0
Vol. 10 (2025), Issue 5, pg(s) 166-169

DOMINANT TECHNOLOGIES IN “INDUSTRY 4.0”

Industry 4.0-Focused Dynamic Tension Control in Wet Wipe Production: Development of Automatic Braking and Accumulation System

  • 1 KANSAN R&D Center, Izmir, Turkiye
  • 2 KANSAN R&D Center, Izmir, Turkiye; Ege University, Department of Mechanical Engineering, Izmir, Turkiye

Abstract

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.

Keywords

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