A web guiding system is a mechanism used in many industries, including printing, packaging, and textiles, to offer accurate alignment and control of a moving web or continuous material during industrial processes.
Various sensors and detectors are used by the web guiding system to precisely determine the location and alignment of the web material being processed. These sensors and detectors play an important role in providing feedback to the control system, which then modifies the guiding mechanism to keep the web in the proper position.
Ultrasonic sensors
Ultrasonic web guide sensors use high-frequency sound vibrations to determine the position and distance of objects. They can determine the position of the web edge by creating ultrasonic waves and monitoring how long it takes the waves to bounce back after impacting the web substance. Ultrasonic sensors are often used in edge guiding systems to enable precise and non-contact web edge detection.
Vision sensors
Using cameras and image processing algorithms, vision sensors photograph online content and analyse its placement and alignment. They can detect web elements such as edges, lines, and patterns and send real-time data to the control system for web directing changes. Vision sensors are incredibly versatile, and they can be used in edge, centre, and combination guiding systems.
Infrared sensors
Using infrared light, the infrared web guide sensor detects the presence and position of things. They can be employed in web guiding systems to identify the web edge by emitting infrared light and measuring the light's reflection or transmission when it comes into contact with web material. Infrared sensors are useful in applications where the web material is transparent or translucent, such as in the plastic film and glass industries.
Capacitive sensors
Capacitive sensors work by detecting changes in capacitance caused by the proximity of objects. They can determine the position of the web material by measuring capacitance changes when it comes into touch with the sensor. Capacitive sensors are commonly used in centre guiding systems to detect the position of the web material in relation to the centerline.
Laser sensors
Laser sensors use laser beams to measure distances and positions precisely. They can be employed in web guiding systems to precisely establish the position of the web edge by emitting laser beams and detecting the beams' reflection or scattering from the web substance. Laser sensors are suited for applications that require high precision and resolution.
Load cells
Load cells are used to calculate the tension or stress on a web material. By placing them in the web route, they can supply input to the control system for tension control and web guiding modifications. To keep the web material tensioned and aligned, load cells are frequently used in web tension control devices such as brakes and clutches.
Types Of Web Guiding System
Edge Guiding
Edge guiding is the most common type of web guiding mechanism, in which the web edge guiding system modifies the location of the web material based on the detection of one or both web edges. Edge guiding systems detect the position of the web edge(s) and make adjustments to keep the web aligned along the desired path. Edge guiding systems can contain actuators such as steering rollers or guide rails to physically move the web material to the desired place.
Center Guiding
The technique of sensing the position of the web material's centerline and altering the guiding mechanism is known as centre guiding, also known as line guiding or line following. In centre guiding systems, sensors or detectors are often employed to measure the location of the web material in relation to the centerline and then make adjustments to keep the web aligned along the centerline. Centre guiding systems might contain actuators such as center-driven rollers or adjustable guide bars to centre the web material.
Role Of Actuators In The Web Guiding System
Web guide actuators are important components of a web guiding system because they physically change the position of the web material in response to data from sensors or detectors. Actuators are devices that convert electrical, hydraulic, or pneumatic signals from the control system into mechanical motion in order to move or control the position of the web material.
Steering Rollers
Steering rollers, also known as dancer rollers or idler rollers, are commonly used in edge guiding systems. They are supported by adjustable arms or brackets that can be moved horizontally or vertically to guide the web material. The position of the steering rollers is changed based on feedback from sensors or detectors to keep the web material in the appropriate area.
Guide Rails
Guide rails are solid structures or bars put parallel to the web route in edge guiding systems. They can be changed horizontally or vertically to direct the web information. The location of the guide rails is adjusted based on feedback from sensors or detectors to keep the web material aligned along the desired path.
Center-Driven Rollers
Center-driven rollers are used in centre guiding systems to direct the web material down the centerline. They are powered by a motor and can be adjusted horizontally based on sensor or detector feedback to centre the web material. The speed of the center-driven rollers is controlled by the control system in order to maintain proper web material alignment.
Adjustable Guide Bars
Adjustable guide bars are used in centre guiding systems to guide the web material along the centerline. They are stiff bars that can be adjusted horizontally or vertically based on sensor or detector data to centre the web material. Adjustable guide bars are typically installed on both sides of the web material and can be altered independently to maintain proper alignment.
Pneumatic or Hydraulic Actuators
Pneumatic or hydraulic actuators are utilised in web guiding system to provide accurate and strong control of the web material. Using pressurised air or hydraulic pressure, they generate mechanical motion and change the location of the web material. Pneumatic or hydraulic actuators can be used in conjunction with other types of actuators, such as steering rollers or guide rails, to achieve the desired guiding performance.