Rotary Knife and Emboss Application

The equipment in this application decoiled oil absorbent mat into an embossing machine that would emboss a logo into the mat. The web would then enter a tension roll system to maintain tension with a pinch roll/rotary knife system to cut mat to programmed lengths. The pinch roll for both the emboss machine and the rotary knife machine is VFD controlled with an attached encoder that acts as the master to the embosser and rotary knife. The embossed logo had a requirement to be positioned in the center of the sheared web. This application required complex math algorithms to calculate custom position camming (PCAM) profiles to synchronize the embosser with the rotary knife to maintain logo positioning and accurate web length. The application also required a complex homing process to ensure the cutting tool or embosser did not contact the web unless the pinch roll is in motion. In order to maintain the emboss location, there was a requirement of a tensioning system between the embosser and rotary knife. This system required complex process algorithms to adjust and maintain the appropriate amount of tension while the web was in acceleration, deceleration, or at speed. This application required complex motion algorithms and processes to ensure length accuracy and superior quality.