Systematic Solutions For The Problems Of Deviation And Saw Jamming In Paper Roll Slitting Process

In papermaking, packaging, printing, etc., the steady operation of paper roll slitting machines directly affects production efficiency and finished product quality. However, the deviation and jagged teeth in the process of operation of equipment often cause waste of materials, equipment downtime and even safety accidents. Based on industry practice cases and technical principles, this paper systematically analyzes the root causes of these problems from four dimensions:mechanical structure, material properties, control logic and operation specification,and puts forward corresponding solutions.

1.Dynamic Calibration of roller systems
Roller is the core part of paper conveyance, its installation accuracy directly affects the straightness of sectioning. The case of a new energy battery film manufacturer shows that when the levelness error of a the slitting rollers exceeded 0.05 mm/m, the probability of material deviation in high-speed slitting increases threefold. Solutions include:

• Regular Levelness Testing: Dynamic balance testing of guide and sectional rolls is conducted monthly using laser interferometer or electronic leveller to ensure error does not exceed 0.02 mm/m.
• Bearing maintenance: Check bearing clearance every 500 working hours, replace worn bearings, and apply high-temperature lubricating grease (e.g. Molykote X-5-1) to reduce friction.
• Cylinder surface cleaning: weekly use of isopropyl alcohol-soaked non-woven cloth to clean the surface of the drum oil and paper debris, to prevent adhesion caused by deviation.

2.Precise Adjustment of the Cutting Tool System
The condition of the tool directly affects cutting performance and stress distribution of the paper. In one case involving a packaging enterprise, a 2° deviation in the angle of the blade increased transverse stress on the paper by 40%. Specific measures include:

• Blade mounting calibration: use angle gauge to ensure blade parallelism error margin ≤ 0.1° and blade tooth depth error is less than 0.05 mm.
• Dynamic tension compensation: Install pressure rod behind blade and adjust pressure in real time using a pneumatic cylinder pressure sensor (range: 0-10 bar) to ensure uniform paper clamping.
• Saw Blade Tension Optimization optimization: the belt sawing machine should gradually adjust the tension adjustment knob until the blade vibrates freely without sliding, vibration frequency is 50 – 80 Hz.

1.Paper quality control
Raw material defects are a potential cause of bias. In one printing house case, the error rate increased by 65% when the roll width deviation exceeded ± 2 mm. Solutions include:

• Supplier Screening: Require supplier to provide paper rolls motion balance test report to ensure end pulses runout ≤1 mm.
• Preprocessing Techniques: Topical paper rolls with excess moisture content (>12%) to 48 hours of constant temperature and humidity were treated and ionizing air bars (output voltage ±7 kV) were installed to eliminate electrostatic charge on charged paper rolls.
• Matching Slitting Parameters: Adjust the tangent speed according to the weight of the paper (g/m2), e.g.:
• Under 60 g/m2: cutting speed ≤150 m/min
• 60–120 g/m2: cutting speed 80–120 m/min;
• 120 g/m2 +: cutting speed ≤60 m/min

2.Upgraded Deviation Correction Systems
For ultra-thin materials (e.g., 0.01 mm PET film), multi-stage deviation correction devices are required:

• Unwinding End: PID PID control algorithms to install Install ultrasonic deviation correctors (detection accuracy ±0.05 mm) to adjust paper roll position in real time.
• Slitting Section: Using a laser positioning systems (resolution 0.01 mm) and closed-loop feedback control, the tangent line is kept parallel to paper edges.
• Rewinding End Each end (core) is controlled using a differential axis tension control system with independent torque control for each卷芯 (core) to prevent end from being dislocated.Practical application shows that the system can reduce deviation rates from 3.2% to 0.05%.

1. Closed loop tension control

Tension fluctuations is the main cause of deviation. In one case, the probability of deviation increased by 70% when tension fluctuated more than 15% of the set range. Solutions include:

• Sensor Calibration: Sensitivity of tension sensors is tested monthly using standard weights (e.g., 5 kg 10 kg) to ensure an error margin ≤ ± 0.5%.
• PLC Parameter Optimization: Adjust PID parameters material elastic modulus (E), for example:

Low Elastic Material (E < 1 GPa): P = 0.8, I = 0.2, D = 0.1
(E ≥ 1 GPa): P = 0.5, I = 0.3, D = 0.2

• Speed Gradient Control: Acceleration / deceleration using the S-curve (acceleration ≤2 m/s2) during acceleration phase to prevent inertial bias.

1.Equipment Inspection system
Establishment of a three-tier inspection system:

• Daily checks: Validation of pneumatic component pressure values (0.4–0.6 MPa), photoelectric sensor cleanliness and emergency shutdown switch response time (≤0.2 s).
• Weekly maintenance: cleaning tool debris, checking chain tension (action: 2–3 mm), lubricating guide rails (using lithium based grease).
• Monthly Upkeep: replace air filters, calibrate encoder resolution (≥1000 pulses/revolution), and test safety light curtain function.

2.Standardized Operation Training
Development of standard operating procedures, including:

• Paper Loading: use forklift auxiliary positioning device to ensure consistency between paper roll center and equipment ≤ 1 mm.
• Parameter setting: Retrieves preset parameters from the material library and prohibits manual modification of key parameters, such as tension setting points.
• Emergency response: Develop a saw-blocking contingency plans, including power outage procedures, tool removal lists and safety equipment (e.g., anti-cutting gloves, safety goggles).

Conclusion:
Solving deviation and jagged tooth of paper roll slitting machines requires coordinated solution at mechanical, material, control and operation levels. By implementing dynamic calibration, parameter adaptation, intelligent control and standardization management, the stability and production efficiency of the equipment can be significantly improved. Enterprises should set up preventive maintenance system and use digital tools to optimize data-driven decision making and ultimately achieve both quality and profit improvement.