Attention! Operators of process lines, including pickling, tin plating, hot dip and electro-galvanizing, cleaning, and annealing lines:
By installing the Winkle Roll Force Assemblies, you can now accurately load the contact surfaces of your rolls. This results in longer service life for all deformable roll covers, including rubber, fiber, cloth, and brush rolls.
The Winkle Roll Force Assemblies simplify and out-perform other methods used to maintain the proper force applied by rollers and brushes to their work surfaces. The Winkle Roll Force Assembly accounts for varying roll load as the rolls wear, load due to the weight of the roll, changes in strip thickness, bends in the product from looping pits, and welded seam, all while maintaining a consistent force applied to the work surface. Older methods such as springs and pneumatic or hydraulic cylinders do not adapt to all these issues as the Roll Force Assembly does.
The styles of Roll Force Assemblies and the loading forces available are very extensive. If you do not see a unit in the preceding chart that meets your needs, please contact us with your design requirements.
In the past, the choices for adjusting of rolls and brushes were manually adjustable springs or pneumatic and hydraulic cylinders.
Applications such a wringer rolls used manually adjustable springs. This presented the problem of varying roll load (or nip pressure) as the rolls wore. Constant adjustment of springs was required and because no simple, accurate means was available to indicate the true force being applied to the roll, the optimum force for roll life was rarely obtained.
Changes in strip thickness, bends in product from looping pits, and welded seams present additional problems for springs and cylinders. The change in spring force increases as the strip tries to force the roll against the spring, thus creating higher nip pressure and the opportunity for roll failure.
A second means to adjust nip roll force was through the use of cylinders. By applying a known pressure to the cylinder, a known force was thought to be applied to the roll. This system does not account for the weight of the roll; therefore, the downward directed roll weight was adding to the cylinder force, creating excess nip pressure and early roll failure or excessive brush wear.
Cylinders can be regulated, but excess pressure must first be created to overcome the spring setting of the regulator. The friction of the seals on the piston and rod add additional drag force on the cylinder and do not respond quickly to strip conditions. The harsh environment causes corrosion on the cylinder bore and rod, further decreasing reaction time and adding to the detrimental affects to the roll.
The Roll Force Assemblies solve all of these problems.
The air pressure to the upper air bellows is regulated to create an upward force which just balances the downward weight of the roll. The air pressure to the lower air bellows can be adjusted to give an accurate nip force (pound force per lineal inch of roll). Air regulators automatically vent excess air and compensate for increases in strip thickness.
Momentary force fluctuations due to bends in material or welds are absorbed by the elastic nature of the Roll Force Assembly and the reaction time is not slowed as with friction created by seals on a piston and rod. The Roll Force Assembly is not subject to atmospheric corrosion which takes its toll on finely finished surfaces such as piston rods and internal cylinder bores.
Winkle Roll Force Assemblies have performed for years in many metal processing plants with exceptional results. Now you may add them to your lines for improved product quality for pickling, plating, annealing, or any roll or brush nip application. Customers report significant savings in repair to roll covering, roll grinding, and new rolls. Contact us today with your application.
STANDARD CONTROL PANEL
The control panel here depicts an example of our standard operator's panel which has switches completely wired to terminal strips and all air controls tubed to panel bulkhead fittings. Just connect control power, your plant air, and the outlets to the Roll Force Assembly connection ports and you're ready to operate!
All controls are clearly labeled and operating instructions are provided on the cabinet face plate. The pressure gauges provided give a precise indication of the inlet pressure and settings selected.
We can accommodate modifications for your specific requirement or add equipment or sensors for recording and/or control. Contact us with your specific needs.
STEERING CONTROL PANEL
In addition to the controls from our standard panel, we can also provide a steering panel which incorporates the additional controls to adjust the roll force load on each side of the line independently. This has been proven effective when roll set up has a tendency to cause the strip to drift to one side of the line. This system can be used to offset the additional load imparted by the drive spindle on brush rolls to obtain even force across the strip for improved quality and longer brush life.
STRIP EDGE SENSING DEVICE
The Roll Force System can be incorporated with a strip edge sensing device for dynamic steering assistance. (Please note we offer this equipment only as an assist in steering. Badly hooked ends or wedge shaped strip often requires the need to mechanically position roll or rolls to correct strip path. The addition of the Roll Force System to the mechanical system can correct small deviations to the strip path, decreasing the frequency and amplitude of mechanical adjustment for smoother steering control.)