Continuing the theme of the previous post, we now turn to an even stickier bit of wishful thinking. That is, the desire/hope/wish/belief/etc that winding defects can be cured (to everyone’s satisfaction) or at least noticeably remedied by changing the winder TNT (Tension, Nip, Torque) curves. Here we have the blessing (not!) of not just one knob but perhaps as many as three knobs. Here we have the blessing (not!) of not just a setpoint, but possibly taper and even curves to play with. Here we have the blessing (not!) of the teachings and writings of machine builders and experts alike; pay attention to winder programming. All we have to do is to get back to where we were on Tuesday when they weren’t running any defects. (In my problem solving course, I call this the fallacy of the Sweet Spot).
Unfortunately, with winders we literally have an infinite number of combinations of three knobs positions taken three at a time and then a further iteration on curve shapes. Unfortunately, we may get stuck beyond the length of our career, trials might go on to the heat death of the universe; especially if we add new products and conditions and constraints. Unfortunately, the machine builders have given us knobs and the admonition to use them; but no specifics for any defect. Unfortunately, most winding defects are not largely affected by tension, nip and/or torque curves. Certain types of roll edge offsets, have no tightness sensitivity. Certain types of starring, have no practical tension sensitivity. Most gage related defects such as bagginess (caused by gage bands), corrugations, ridges and others may have have little practical tightness sensitivity. Even loose defects, such as a loose core caused by winding on a wet core, may have little practical tightness sensitivity. Even tight defects, such as caused by film shrinkage, may have little practical practical winding tightness sensitivity.
So, again we recognize getting stuck in the same way; we’ve been playing with the knobs for a while now and life is still not CONSISTENTLY good. So, again we get unstuck in the same way; go to school on Critical Thinking in Converting to think outside the (control) box. So again we get unstuck by going to school on Winding Machines, Mechanics and Measurements.