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Jennerjahn - Definit

Definitions of machine parts and procedures.

Acceleration Time Time is takes the winder to go from zero speed to top speed.
Autolaoder - Section of a slitter/rewinder used to automatically load cores or mandrel shafts into the winding station before winding material on them. This can describe a pick-and-place device for loading loose cores or an escapement mechanism that releases mandrel shafts.
Auto Tuck A mechanism that automatically tucks tails after the tail blow sequence is complete.
Backstand See Unwind Stand.
Backup This term generally refers to the process of moving the web in the reverse direction at the start of the rewind cycle. This movement shortens and/or eliminates the material that is folded during the tucking sequence.
Banana Roll See Bowed Roller.
Bluing Roll marking damage that occurs when ink capsules in paper are activated.
Both Machine operating mode used to describe a fully automatic cycle that includes both winding rolls and sealing the loose tails.
Bottom Knives See Female Knives.
Bowed Roller A curved roller
Caliper Thickness of the paper. The value can varies depending to the type of material being wound.
Cant The offset angle of the male knife that provides a sharp slitting contact point.
Catwalk See Walkway.
Center Winder Type of winder that drives the roll from the center using a shaft.
Core Chuck Mechanism used to clamp cores during winding sequence.
Core Offset Difference between the edge of the core and the edge of the paper on a finished roll. Generally more pronounced on narrow width rolls.
Core Plug Plastic cap in the end of a core that the core chuck clamps against.
Core Tolerance / Stack-up Accumulated distance on core shaft that causes core offset.
Coreless Special operation that allows product winding without cores.
Counter Balance Pneumatic adjustment that allows precision control of the rider roll force on both sides of the web.
Cycle Time The time it takes to finish on complete machine cycle.
Dancer Web tension controlling idler mechanism used in conjunction with the brake.
Dancer Relief Lower pressure setting that the dancer toggles to when not in the winding mode.
Dead Idler Shaft An idler that rotates around a stationary shaft.
Deceleration Rate Measure of how fast the winding speed decreases. Measured in feet per second squared or meters per second squared.
Deceleration Time Time is takes the winder to go from top speed to zero speed.
Diagnostic Screen Operator interface screen used to monitor the status of inputs and outputs on the machine.
Diameter Bypass Machine setting that allows slow speed winding for spreader and knife set-up.
Diameter Control Machine setting used to wind to a specified finished diameter.
Differential Over speed Speed differences between rear and front bedrolls used to keeps the web tight during winding.
Drive Electrical device used to manipulate electricity to control the speed
Drum Tuck When starting a rewind roll with the traditional tucked start
Dual Web Special setup that permits two narrow parent rolls to be rewound at one time.
Durometer The measure of rubber hardness on covered rolls. (Usually Durometer of 80)
E/P electro Pneumatic Converter Device that converts an electrical signal to a pneumatic output. It is used to control the brake relative to the dancer.
Edge Guiding Method of monitoring and moving the position of the web based on the location of the edge of paper.
Eject Conveyor See Exit Conveyor.
Elevation View Engineering print that details the side view of the machine including the height.
Encoder Device that converts a rotation input into an electrical signal.
End-of-Roll Warning Ink mark applied to web near the end of the winding cycle.
Exit Conveyor This is a conveyor
Female Knives Name for the knife blades used to slit the web. The female knives contact the male knives to create a shear cut.
Female Knife Shaft Spacer Steel or composite material stacked with female knives to space to the desired cut widths.
Flow Control Adjustable flow restriction device to change actuation speeds. They are generally mounted in the pneumatic actuator ports.
Footage Control Programmable setting that controls winding distance.
Fold-Less Start This describes the process of starting a rewind roll without folding the material.
Glue Applicator Mechanism that applies small beads of adhesive to the finished roll tails at desired locations.
Grease Manifold Multiple zerk bays located at the back of the side cabinets.
Horton Brakes Pneumatically activated brakes to slow and stop the unwind rolls.
Imaging Thermal product marking that occurs when heat or friction contacts the roll.
Ink Reservoir Tank used to holds end of roll warning signal ink.
Interweave Roll characteristic when edges of adjacent rolls overlap during winding.
Jumbo Roll This is the relatively large roll of material used to feed the rewinder. This roll is loaded onto an unwind stand. The material is then unwound to create the finished rewind rolls.
Kickout See Riderroll Eject.
Limit Switch Mechanical switch that activates when a physical contact is made.
Line Guiding Method of monitoring and moving the position of the web based on the location of a printed line paper.
Log Eject Conveyor See Exit Conveyor.
Magazine Staged area for cored shafts in the autoloader.
Male Knives Set of fixed knives that work in combination with the female knives to slit the web using a shear cut.
Mandrel Cap Steel cap inserted on the mandrel that holds the cores tight.
Mandrel Cap Remover Mechanism that removes and returns the cap to the operator.
Mandrel Shaft Shaft used to hold core as the web is wound around the cores.
Manifold Group of air valves combined into an assembly with a common air supply.
Mill Roll See Jumbo Roll.
Mill Roll Footage Counter Counter that continually measures footage of the unwind roll.
Mill Roll Shutoff System that stops the machine cycle when minimal material is left on the unwind jumbo roll.
Multi-Ply Process of combining 2 or 3 plies of material into a single roll.
Nip Roll - A special idler used to pinch (nip) the web against another idler or winding drum. The nip roller is used to hold and/or isolate web tension by not allowing the web to move in a reverse direction. The nip roller is generally mounted in such a way as to be opened for machine webbing.
Over speed Speed differences between rear and front bedrolls used to keeps the web tight during winding.
Pack Force The downward force applied to the rewind roll. This force is used to control hardness of the finished roll.
Packing Table Table installed at end of exit conveyor to allow accumulation of finished rolls.
Panelview Interactive graphic monitor where various setting are made.
Pivot Sensor Sensor used in conjunction with the brake to sense the relative position of the dancer.
Plan View Engineering prints detailing the aerial view of the machine.
PLC Programmable Logic Controller; Central machine processing unit.
PLI Pound per linear inch; Web tension measurement.
Proximity Sensor Magnetic sensor that senses presence.
Quick Dump Valve Hand valve used to release air pressure from the dancer cylinders.
Rack and Pinion Gear combination used on the rider roll and autoloader to insure consistent even motion.
Rebuild Term used to describe a used machine that has be remanufactured and updated.
Retrofit Modification made to a piece of machinery.
Rewind The processor or device used to wind a web based material into a new finished roll. The finished roll is generally smaller than the roll the material was unwound from.
Rewind Drum - The large shaft used to drive the web in surface winding equipment. Generally this shaft if covered with a layer to rubber to improve traction on the web. In a three drum surface winder there are two winding drums and one riderroll or top roller. These drums drive the web and hold the finished roll in position during the wind.
Rewind Station Section of the machine used to wind the web into a finished roll. This includes the three winding drums on a surface winder. This includes the winding shaft on a center winder.
RGA Return Goods Authorization; Jennerjahn Machine reference number when making a warranty claim.
Riderroll (Top Roll) - This is a shaft that rests onto of the rewind roll while it is being wound. It is used to apply torque to the surface of the rewind roll. This torque causes the layers of the roll to tighten as the roll is wound. This roll can also be used to apply pack force to the rewind roll. This also controls the hardness of the finished roll.
Riderroll Eject Name for the process used to transfer a finished roll form the rewind station to the seal station by rotating the riderroll drum in reverse.
Riderroll Kickout See Riderroll Eject.
Riderroll Support Rollers Rollers that provide positive support for rider roll during the winding cycle.
Roll Process Line (RPL) Refers to secondary equipment used to process the finished rolls as they exit the rewinder. This can include roll separation
Running Time Amount of time it takes the machine to complete the winding portion of a cycle.
Safety Interlock Safety device used to lock a guard door in the closed position to prevent access to a hazardous area.
Seal Only Seal Only refers to an operation mode in which the machine only seals a set of previously wound rolls. The rewind functions of the machine are locked out.
Seal Station Section of machine used to attach the loose end of a finished roll. Sealing methods include glue and adhesive labels.
Set-up Time Time required to ready the machine when changing from one product to another.
Shaftless Unwind Type of unwind stand that suspends the jumbo roll between a pair of chucks.
Shear Cut Slitting method where two knives overlap to provide a cut.
Single Ply Machine capable of running only one sheet of material.
Single Preset Counter Electronic device used to create the line speed ramps and control length of material.
Skew Process of pivoting the jumbo roll or an idler shaft to tighten or loosen the web on one side. This process evens out the tension across the web and reduce wrinkles.
Slitter Only Machine operating mode used to describe a cycle that include only winding rolls.
Slitter/Rewinder Equipment used to cut a web into strips in the direction of the web and wind it into rolls.
Spreader Bar Bar used to hold the web separators. Usually it is located prior to the winding drums.
Static Electrical buildup that occasionally can occur on the web of certain products.
Surface Winder Type of winder that winds material along the external surface of a set of winding drums.
Tab Adhesive label used to seal the loose end of a finished roll of material. The labels are placed on a bar using the tabber unit.
Tab Plate Aluminum plate that tabs are placed on prior to insertion on the roll tails.
Tabber Unit Device used to dispense adhesive labels onto a bar before being used to seal the loose end of a finished roll. Programming controls the placement of the labels on bar.
Tail Loose end of the web after it has been separated from the previous rewind roll. The tail may be the width of the entire web or it can be slit into many narrower strips.
Tail Blow Device that blows cut tails over the cored mandrel shaft prior to tucking.
Tail Cutter Device used to separate the finished rewind roll from material web by moving a cutting device across the web. The type of cutter can vary depending on the type of material.
Tail Index Refers to the time it takes the seal station to index the finished roll to wind up the tails.
Taper Tension Process used to control roll structure by reducing the amount of web tension as the rewind roll diameter increases. This produces a finished roll that is harder in the center than on the outside.
Taper Torque Process used to control roll structure by reducing the amount of torque applied to the rewind roll as the diameter increases. This produces a finished roll that is harder in the center than on the outside.
Tension Unit of force that the web experiences during non-regulated dancer pressure. Can be measured in total force on the web or in weight per unit of web width.
Top Knife See Male Knives.
Torque Controller Electronic device that controls the amount of torque applied by the riderroll based on operator variables
Trim This term refers to the strip of material that is removed from the edge of the web. It can also be used as a verb to refer to the process of removing this trim.
Trim Blower The fan used to transfer the waste trim from where it is slit to a holding area. The fan may also be used to chop up the trim.
Tuckless Start See Fold-Less Start.
Unwind Stand Stand used to support the jumbo roll while it is unwound. The unwind can also be used to guide the material into the winder.
Walkway Elevated platform used to access areas blocked by the web path.
Web Refers to material that is threaded through the machine or other series of shafts.
Web Separators Steel deviators located prior to the bedrolls that spread the web to eliminate interweave.
Wrap-up Detection Series of sensors used to shut down the equipment if material wraps around any of the winding drums.
Set up Testto prove proper knowledge of the following Successfully change the machine over from one product to the other
Female Knife Shaft set up
Male Knife Shaft set up
Spreader set up
Autoloader set up
Rewind chuck setup
Tuck Retain Setup
Tuck Setup
Core Hopper Setup
Rewind Mandrel Set Up
Tabber Setup
Gluer Setup
Footage torque and Accel / Decel Setup
Brake Puck setup
Tail tuck length (long or short) set up
Roll Processing Line Set Up
Examples of Trouble Shooting Tests
Skew Adjust to the point of wrinkles. Tech should be able to recognize baggy edge and correct.
Bowed Roller Adjust so that spread is insufficient. Tech should be able to readjust for good spread.
Brake Puck Selector Move to incorrect position. Tech should be able to recognize a too little or too much brake condition.
Dancer Pressure Turn to minimal to produce slow response or loose wind. Tech should be able to recognize incorrect web tension condition.
Pivot Sensor Physically move pivot sensor to incorrect position.
Tension Controller Change gain up or down. - Tech should be able to recognize too hot or too sluggish dancer reaction.
Tension Controller Change dancer position. Tech should be able to recognize too little or too large dancer stroke for given acell and decell conditions or simply recognize wrong dancer position during changeover.
Overspeed Pully Change to minimum overspeed or underspeed. - Tech should recognize poor winding condition and check for overspeed as possible cause.
Torque Adjust to minimal to create loose wind. - Tech should recognize poor winding condition and check torque as possible cause.
Rewind chucks Create enough missalignment to negatively influence the roll starts - Tech should recognize poor winding condition and check chucks as possible cause.
Kick Out Torque Adjust too high or too low in create an issue. Tech should recognize and correct.
Vacuum Sensor / Vacuum Cups Adjust one or the other to create vaccum losses.
Bottom Limit Adjust bottom limit so that it is not made when rider roll is resting on the cores.
Tuck Sensor Adjust so that the tuck extend is not met.
Roll In Seal Bed Roll Sensor Adjust this to and incorrect position.
Rewind Chucks Create a loose condition where cores can move side to side to create coning at the start.
Unwind Shaft Arms Lower these. This will create a issue with the diameter sensor and select the incorrect number of brake puck incorrect accell rate and incorrect decel rate.
Counter Balance Pressures Set these backwards. Tech should understand motor side requires more up pressure and recognize roll quality problem.
Web Web the machine incorrectly like opposite side of bowed roll or over a spreader tube. Tech should know web path
Seal Bed Roll Button Mismatch seal bed roll position with screen setting to cause tabs to miss.
Explain the sequence of operations for the seal only mode including what sensors must be made and in what order.
Expain the sequence of operations for the wind only mode including what sensors must be made and in what order.
Provide a list of sensors and have the tech explain the sensor's purpose within the machine's PLC program / why it is necessary for proper machine function.
Set drive to default parameters. Tech should be able to perform copycat function to restore a working set of parameters. (Also perform drive auto tune.)
Open set of motor windings to create a single phase condition. Tech should be able to locate and determine this with a simple resistance test.
Select any PB or sensor on print book. Tech should be able to locate physical location on machine. (Example - Tail cut right prox tab plate rotate etc.)
Tech should be given new panel view or panel view plus program and be able to load to HMI. Should also know how to check com settings.
If a sequence is halted midway tech should know what should happen next so as to locate what is stopping sequence.
Stop machine sequence via the program. Tech should be able to use diagnostic screens to determine which sequence failed and on which step. This is the first bit of info the controls engineer or service Tech will need. (Important)
All new machines are built with Control Logic PLC. It uses tag database. Tech should be able to locate Input/output in program. Simple test of selecting a prox switch and having Tech locate in program.
Lengthen timer so that machine waits to long to dump rolls and after dumping last set. Tech should be able to locate and modify timer presets to optimal preset.
Remove analog input wire on mill roll diameter sensor. Tech should be able to find data from analog devices such as mill roll diameter sensor or rewind diameter sensor to determine if it's a program issue or device issue & fix.
Remove enable command from drive. Tech should be able to determine if drive is enabled based on indicator status on drives.
Remove DC com wire on din connector of dancer relief valve. This will cause a wrinkle that can be hard to troubleshoot. Electrically an open common is hard to trouble shoot. (This would be extra credit on test)
Remove brake controller and install factory unit. Tech should be able to make voltage & current measurements that are necessary to install new brake controller.
Create open circuit in guard circuit or light curtain. Tech should be able to diagnose difference between guard problems or light curtain problem based on indicator status of each controller. Tech should then be able to use multimeter to determine where problem is. Tech should also be able to use diagnostic screens to reach the same conclusion.
Remove black signal wire from any prox switch. Prox will still illuminate but signal will not be present in program. Tech should be able to find page in print based on prox number. (Example - 1206 would be on page 12 and Tech should be able to find in PLC program from there.)
Install corrupt program in PLC or simply instruct Tech to load updated program. Tech should be able to select file from any source and download to PLC. Tech should also be able to upload save and email program for controls engineer to develop.
Remove all RS Linx drivers from Tech's laptop/shop computer. Tech should be able to select proper driver and cables or PLC module to connect to and go online with PLC. (This is a must)
Disable a step in a sequence (AFI). Tech should be able to use manual force page to determine if a wiring/component problem exists or if it's a problem with the program. (Example - Tail cutter won't go right tech should test from force page and see if field circuit is good. He can then determine if the program is the issue. This is a very quick way to determine how to proceed.)
Set bottom limit while rideroll is at top position. This is a fairly common problem. Tech should be able to diagnose this via diagnostic page or by findings in the PLC program.
Tech should be able to demonstrate the sequence for putting a machine in set-up mode and also to resume run.
Wiring errors at machine install can occur. +24VDC can be connected to DC and will cause a short circuit. This is common due to the close proximity on the terminal strip. Tech should be able to find this with meter instead of pulling all the wiring out.
Simulate a faulty speed potentiometer. Tech should be able to find command speed in drive with HIM module and trace back to source of problem.
Have Tech demonstrate how to find fault history on HMI then select fault and have him locate fault in PLC program.
Install new com module in drive. Tech should be able to configure com parameters through the HMI to set IP address if Ethernet/IP or Mode config if RIO.
Switch wires on tabber encoder. (This would simulate customer changing encoder cable and wiring it incorrectly.) Tech should be able to locate encoder counts and determine if correct.
Tech should be able to re-address an output in the event it becomes faulty. He should demonstrate how to do this with both RS 500 & RS 5000 if possible
Tech should demonstrate how to save program to E-Prom so that if a failure takes place it doesn't reload an older program.
Created by: mapulido
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