Winding-

Caliper effects on wound roll density

Scott A. Baum and David R. Roisum

In two tria& a new analyzer for roll densip showed that an erratic response
was attributable to thepaper caliper instead of any problem with the winder.

The roll density analyzer has proven to be a useful tool

1. The configuration for the conventional density analyzer equipment
for winding diagnostics. It is automated and easy to use, is shown in solid lines, and the option for correcting caliper is shown
and it is highly sensitive to changes in the wound roll. One in Dhantom.
limitation has been that density analyzers have been too
sensitive to changes in web caliper, making it difficult to Con chuck
determine if fluctuations in the density profile were Counter
reflecting changes in winding or web caliper, or both. timer board
Consequently, a new density analyzer has been developed
to incorporate measurements of web caliper.

Development of the density analyzer

I
Properties that have been monitored for quality control L . 1

for decades are basis weight, caliper, and web density in

an unloaded condition. Low densities of less than 0.01 lb/
in.5 are desired for tissue and toweling in which bulk (the connected to an LVDT (linear variable displacement
inverse of density) and absorbency are important.
transducer) for measuring radial deformation as addition-
Conversely, high densities of more than 0.042 lb/in.3 are
al layers were added during winding (1).However, this
typical for lightweight coated grades in which the sheet
crude device gave density only at a single data point as
is filled with clays and other materials to provide a dense
a function of added wraps and was not suitable for
and smooth printing surface.
production measurements.
Density can be calculated from basis weight and caliper
In the 1970s, the term “density)’ began to appear as
as:
synonymous with “wound-in-tension))in literature about
p = b/c (1) winding. This usage appeared in an article in 1970 by
Shvetsov, who compared the density of wound rolls to the
where unstressed density of the parent material (2).He defined
a density index as:
p = density, kg/m3 (lb/in.a)
b = basis weight, or grammage, kg/m2 (Ib/in.*) density index = p/po (2)

c = caliper, m (in,). where

p = rewound roll density, kg/m3 (lb/in.3)
Long before the density analyzer instrument was PO = unstressed material density, kg/m3 (lb/in.3).
invented, the density of a web material was found to
increase with increasing z-direction loading. In particular, Shvetsov found this density ratio to vary from 0.80 to
high wound-in tensions produced high interlayer pres- 1.09 for more than 600 rolls of paper tested from several
sures and, consequently, an increase in density that could mills and proposed this measure be used for roll quality
be discerned with careful measurements of roll diameter control. A similar approach is used to estimate the amount
and weight. In 1967, Ul’yanov patented a density meter of air wound into rolls of impermeable material such as
consisting of a tab inserted between layers of the roll and plastic film. In 1979, Hewinson obtained a US. patent for
a winding machine design that was claimed to control
wound roll density at a predetermined value by winding
Baum is research and development engineer, Beloit inside a loop of belt that controlled the circumference of
Corp. Research Center, 1165 Prairie Hill Rd., Rockton, the rewinding roll (3).
111. 61072-1595. Roisum is senior research scientist, However, it was not until 1980 that the first practical
Kimberly-Clark Corp., 2100 Winchester Dr., Neenah, measurement method for density became available, with
Wis. 54956 the invention of a computerized roll density analyzer. This
July 1991 Tappi Journal 123
 development was headed by Eriksson of the Swedish 2. Noncontactingpneumatic servo c&ipor gauge
Newsprint Research Center and was funded by a
consortium of three corporations (4-6). Since then, many
machinery builders and paper companies have developed
~

similar instruments. Today, there are many different Connector

kinds of density analyzers in use on paper mill reels, LVDT
winders, rewinders, and unwinds throughout the world.
Some of these density analyzers are based on portable
personal computers, while others a r e permanently
mounted in benchboards or control cabinets.
While the density analyzer may not be the most common
method of measuring roll structure, its performance is by Reference chamber
far the best documented in the pertinent literature. Control chamber
Eriksson showed the effect of torque, nip, and tension on
wound-in density, the relationship between wound-in and
wound-off density of the roll after long-term storage, and
the effect of wrap sample size (4-6). McDonald showed the
correlation between roll hardness and density, the effect Nozzle
of calendering (caliper) on density, and the effect of torque
on density (7). Odell’s study was the most complete,
detailing the effects of the paper machine, the effects of Work piece
torque, nip pressure, tension, speed, and acceleration, the
Reference
effect of splices, and the effect of the winder set location
on the parent reel to the density profile at the winder (8).
Similar studies were performed by others (9-12).
The density analyzer is popular because it has most of
the attributes of an ideal roll structure measurement system
(13). These attributes include profiling with respect to
diameter for setting up programs for torque, nip pressure,
and winding tension. Furthermore, the analyzer has
recording capabilities, it performs nondestructive testing,
it is easy to use, and its cost is moderate. Perhaps the two
greatest advantages are that it has relatively high resolution
of changes in roll structure and that it can be implemented the roller encoder, and the diameter of the wound roll can
for automated on-line production measurements. be calculated from the ratio of the pulses of the roll and
However, since its invention, most of the improvements roller encoders. These measurements are used to calculate
in the density analyzer have been enhancements rather density (4-7, 14) using Eq. 3:
than fundamental changes in design. Previous improve-
ments have included faster computers, higher count p = (26 n2ppr) / [d (pi - pi-l)l (3)
encoders, and a better coupling of encoders to the rotating
roll and roller. Caliper cross-sensitivity has been recog- where
nized as a problem (7, 8), but its detrimental effects on p = roll density, kg/m3 (lb/h3)
instrument utility have not been dealt with until recently.
Because the early density analyzers were undesirably b = basis weight, kg/m2 (lb/in.2)
sensitive to changes in web caliper, it was not easy to n = roll rotation per sample, revolutions
determine if fluctuations in the density profile reflected
changes in winding or in web caliper, or both. p p r = roller encoder pulses per revolution
Consequently, a new density analyzer has now been d = roller diameter, m (in.)
developed that supplements the roll diameter and footage
pi = roller encoder pulses for sample i
measurements with web caliper measurements. Now the
changes in the wound roll can be distinguished as to the pi-l = roller encoder pulses for sample i - 1.
caliper effects and the roll structure effects caused by the
winder. Additionally, this redesign of the density analyzer All of the terms in Eq. 3 can be measured with extreme
has improved the measurement sensitivity. accuracy except one, the basis weight 6. Previously, the
basis weight was assumed to be constant, but it actually
varies as a result of fluctuations in web manufacturing.
Principle of operation Thus, there was no method for separating web effects (b)
Figure 1 shows the original configuration of the density from winding effects (pi - pi-& Consequently, it was risky
analyzer. It consists of a winding or unwinding roll, a roller to diagnose a problem as to its source.
traveling a t web speed, incremental rotary encoders One approach to determining basis weight for Eq. 3
attached to the axes of the roll and the roller, pulse might be to use information from the basis weight
counters, and a microcomputer. The length of web wound scanners on the paper machine. However, there is no
into a roll can be calculated from counting pulses from mechanism for “aligning” basis weight data to winder
124 July 1991 Tappi Journal
3. Diameter vs. caliper, conventional density, and-caliper-corrected
The nozzle is designed such that the back pressure,
density for copy paper calendered with the stack loading decreased developed by the discharging supply air, varies with the
stepwise gap between the sensing orifice and paper web. This back
pressure controls the servo mechanism, maintaining a
4.5 I 1 gap of 0.003 in. between the nozzle and paper. Thus,
changes in the caliper of the paper cause the nozzle to
displace accordingly.
Mechanical displacement of the nozzle sensed by the
LVDT is converted to a proportional voltage by signal
conditioning of the output. Frequency response is rated
I at 30 Hz for amplitude variations up to 0.004 in. The gauge
2.5
0 10 20 30 can resolve displacements as little as 5 x in. at a
0.045 1 1
frequency response up to 30 Hz.
Caliper information from two gauges is monitored by
the density program using an analog interface circuit
board, as Fig. 1 shows. The program and signal condi-
tioning units are designed for processing the displacement
of each gauge head separately or the average of both gauge
heads. Web caliper is sampled at a rate of 18 Hz, and the
0.025 I 1 average during the sample period is used for density
0 10 20 30
calculations to compensate for caliper variations, which
affect the diameter change of a winding roll.

-
Gauge calibration is performed using a precision feeler
gauge. However, because the web beneath the sensing
-. head is under loading from both web tension and nozzle
pressure, the readings may need to be corrected to an
unloaded condition, which for linear elastic materials is:

0 10 20 30
DIAMETER

where

UR = , loading induced by nozzle pressure, kg/m2 (lb/in.2)

density samples to the required accuracy of a couple of
feet, Since it is prohibitively expensive to equip winders m = stress induced by web tension, kg/m2 (Ib/in.2)
with their own basis weight scanners, this approach was ER = roll radial modulus ( z direction for the paper), kg/m2
not a practical alternative. (Ib/in.2)
We find an alternative approach in Eq. 1,which shows
us that density, basis weight, and caliper are coupled. ER = roll tangential modulus (machine direction for the
Thus, it might be more economical to obtain the caliper paper), kg/m2 (Ib/h2)
than to measure basis weight. Combining Eqs. 1 and 3 MT = Poisson ratio.
yields a caliper-corrected density formulation:
Corrections for highly nonlinear materials require
P =( 2 ~ ‘ ~P P T/) [d (Pi - ~ i - d l (4) “backing down” the stress-strain curve. The magnitude
where of the correction depends on the x-direction stiffness of the
grade and can be from as little as 1%for paperboard grades
po = mean unstressed density of the material measured in to more than 10%for bulky grades.
the test lab.
Benefits of caliper corrected density
Using this equation, we can measure web fluctuations
through changes in caliper. The result is an improvement For the purpose of discerning the effect of caliper
in performance. Changes in density in unstressed material variations on the monitoring of wound roll density, tests
are relatively small in comparison to changes in basis were run on two rolls manufactured with severe caliper
weight or caliper for web materials such as paper. (Density gradients. Each roll was a 47-1b/3000 f t 2 basis weight copy
changes are essentially independent of basis weight or paper calendered on Beloit Research’s pilot calender.
caliper for other web materials such as films and foils.) The calender nip pressure for each roll was adjusted
to give a desired test caliper profile. Roll A was calendered
On-line caliper measurement using three different nip pressures decreased stepwise,
which resulted in the staircase caliper profile shown in
On-line determinations of paper caliper were made using the top graph of Fig. 3.Roll B was calendered with a ramp
a noncontacting pneumatic servo gauge head. As Fig. 2 function first increasing and then decreasing and then
shows, the gauge uses a pneumatic servo follower nozzle increasing for stack loading. The resulting caliper profile
connected to a LVDT displacement transducer. is shown in Fig. 4 in the top graph. After calendering,
July 1991 Tappi Journal 125
 the rolls were wound on the pilot winder for both 4. Diameter vs. caliper, conventional density, and caliper-corrected
conventional and caliper-corrected determinations of roll density for copy paper calendered with the stack loading increased
density. Because paper caliper was the variable of interest, and decreased gradually
the rolls were wound with constant torque (55% front
4.5 1 1
drum), nip pressure (5 pli), and tension (2 pli).
The conventional density readings for the stair-stepped
Roll A is shown in the center graph of Fig. 3. As shown,
the conventional density profile mirrors the caliper of the
incoming sheet. In other words, low caliper yields high
density, and vice-versa. However, the shape of the caliper
profile is not known for conventional density. Thus, one 2.5
might be tempted to conclude that something was amiss 0 10 20 30 40
with the winding of the roll, when in fact the erratic
response was almost entirely due to the paper. By contrast,
the caliper-corrected density shown in the bottom graph
of Fig. 3 yields a nearly uniform profile, eliminating all
of the density offsets produced by the more uniform paper
caliper from programming of the winder for the constant
torque, nip pressure, and tension profiles.
Similarly, the conventional density profile for the 0.025 I I
0 10 20 30 40
ramped Roll B given in Fig. 4 (center) mirrors its incoming
caliper profile. Again, without the caliper-corrected density
E 0.045
I- -.
profile given in Fig. 4 (top), one might be tempted to adjust ti=
K c3 0.040
winding profiles to compensate for a problem that has its a
source in the web. With caliper measurement, however, &5 0.035
we can distinguish web problems from winder problems. &Z
2 5 0.030
io
Radial compression a
u 0.025
Admittedly, the two examples are somewhat artificial 0 10 20 30 40
because real web caliper profiles are not as exaggerated. DtAMETER
Therefore, let us take a third example, in which caliper
profiles are as obtained from a mill. Additionally, we will
use this example to illustrate an alternative approach to
caliper-corrected density. This measure is termed “radial yields a fine profile of over 1000 data points for a roll of
compression” and is calculated as: typical size.
Though radial compression and caliper-corrected
Radial compression, % = 100%x [2nCi - (Di- Di-1)1/(2 n a) (6) density profiles have the same shape and measurement
In this expression, the term 2 n c is the expected diameter resolution as in the bottom graph in Fig. 5, the radial
increase of the winding roll if the web were wound without compression profile has several potential advantages.
stress, which is simply twice the current caliper times the These include:
number of wraps per sample. The term Di - Di-I is the 1. All inputs to the equation are measured by the
measured diameter change during a sample period. The instrument, whereas the density approach requires an
numerator is the difference between the expected input of basis weight (or unstressed density) from lab
diameter increase and the measured diameter increase. testing.
If the roll is wound at a high tension, it will not grow as 2. Radial compression is a simpler calculation.
quickly as at a low tension because the z-direction pressure 3. Radial compression is zero for a zero wound-in tension.
decreases the thickness of the web inside the roll.
The top graph of Fig. 5 shows a caliper profile for an 4. Radial compression yields values in more self-evident
NCR paper of 31 lb/3000 ft2 that was sent to Beloit units (% vs. kg/m2).
Research for customer trails. For measuring the resolution 5. Radial compression is a fundamental roll structure
of the new instrument, the roll was wound with a sharp measurement closely related to radial strain.
stepwise drop in tension from 4 pli to 1 pli at a diameter
of 20 in. As the center graph of Fig. 5 shows, the resulting Conclusions
density profile does indeed exhibit the expected drop in
roll structure at 20 in. even without caliper information In conventional density analyzers, basis weight is assumed
(which was used in the equation as a constant). However, to be constant for the calculations, despite the fact that
if the measured on-line caliper is used in the calculation, basis weight varies considerably for the manufacture of
the winding profile stands out more clearly (bottom graph, real webs. If the density principle is extended to also
Fig. 5). Indeed, the resolution of the instrument has measure caliper, several advantages are realized. First,
increased for real web winding by more than an order it is possible to distinguish web problems from winding
of magnitude if caliper information is used. Thus, it is not problems, which aids in diagnostics. Second, with caliper
unusual to obtain wrap counts smaller than 20, which correction, the noise of the density profiles decreases, so

126 July 1991 Tappi Journal

5. Diameter vs. caliper, conventional density, and both radial 6. Eriksson, L. G., Lydig, C., Viglund, J. K., and Komulainen,
compression and caliper-correcteddensity for the NCR paper P., Svensk Papperstid. (4):86(1983).
7. McDonald, J. D. and Farrell, W. R., Pulp Paper Can. 86(9):
56(1985).
8. Odell, M. H., Symons, R. E., and Brown, G. S., APPITA 38(5):
359(1985).
9. Granlund, B., Proceedings of the First Winding Technology
Conference, Swedish Newsprint Research Center (TFL),
Djursholm, 1987, p. 167.
10. Komulainen, P., 1982 Paper Finishing and Converting
Conference Proceedings, TAPPI PRESS, Atlanta, p. 87.
2.6l . ’ 11. Komulainen, P. and Tulkki, M. ATIP Review 37(8):434(1983)
0 10 20 30 40 (in French).
12. Holmer, H., Larsson, P., Svahn, T., Westman, L., and Warner,
M., Changes in reel-density curves induced by different
winding parameters, Advances and Trends in Winding
Technology, Proceedings of the First Winding Technology
2 2
5 0.026 Conference, Swedish Newsprint Research Center (TFL),
Djursholm, 1987, p. 153.
8 0.024
I
13. Roisum, D. R., Tappi J. 71(10): 91(1988).
14. Roisum, D. R., The measurement of web stresses during roll
ap 0.022b . 10
’ 20 30 40 winding, Ph.D. thesis, Oklahoma State University, May 1990.
Received for review Sept. 6, 1990.
Accepted Dec. 12,1990.

s
i DIAMETER

that the statistical significance of diagnostics measur(

ments improves. Third, the noise reduction allows us 1
obtain wound roll structure profiles with a much fine
spatial resolution than ever before. Finally, the alternativ
measure of radial compression, which is obtained fro1
exactly the same measurements as caliper-corrected
density, holds promise for a more meaningful measure of
wound roll structure.
The principles used in these extensions to the density
approach have been carried through from laboratory
prototype to portable field analyzers. The result is a
portable personal computer hardware package with
menu-driven software than can be set up quickly on most
reels, winders, and unwinds. Consequently, one unit can
be used for many winding machines. Furthermore, the
system is designed for completely unobtrusive and
automated data acquisition. Finally, the instrument leaves
us with little reason not to monitor roll structure quality.0

Literature cited
1. Ul’yanov, V. I., Tensometric apparatus for the control of web
winding, U.S.S.R. Patent 249,929 (Nov. 30, 1967).
2. Shvetsov, Y. N., Bumazh. Prom. (6): 21(1970) (Russian).
3. Hewinson, V. K., Barlow, R., and Fogarty, E., Method and
apparatus for forming a fibrous cylindrical element, U.S.
Patent 4,146,188 (March 27,1979).
4. Eriksson, L. G., Lydig, C., Viglund, J. K., and Komulainen,
P., Measurement of paper roll density distribution, report to
the Swedish Newsprint Center (TFL), Djursholm, Sweden.
5. Eriksson, L. G., Lydig, C., Viglund, J. K., and Komulainen,
P., Tappi J. 66(1): 63(1983).
July 1991 Tappi Journal 127