Traverse in india, Traverse Unit
  • Traverse Unit
  • Traverse Unit Specification
  • Salient Features
  • Applications
  • Principle of Operation
  • Selection Of Traverse Unit
  • Operation Guide
  • Optional Accessories
  • Traverse Assembly
  • Vertical Traverse Assembly
  • Maintenance
  • Ordering Information
  • Dimension Details

TRAVERSE UNIT

Rollring Traverse Units

Rollring Traverse units are linear drives, which converts constant speed rotation of a plain round shaft into variable speed, variable stroke, automatic reciprocating motion without changing the direction rotation of shaft. Used in any application where a constant speed rotation of a shaft needs to be converted to automatic reciprocating motion with instantaneous reversal, Infinitely variable linear speed and variable stroke length.

This is a unique method of converting rotary motion into linear reciprocating motion on the principle that contact pressure created between a correctly dimensioned ring and shaft enables significant forces to be transmitted. The linear speed directly related to the angle of contact between the ring and shaft.

The Reversal is automatic and instantaneous. Linear speed (Traverse Pitch) is very finely variable by flick of a lever on the dial. Traverse stroke length infinitely variable along the length and is limited only by the shaft length.

TRAVERSE UNIT SPECIFICATIONS
Model Shaft dia mm Style : Number of Rolling rings Maximum Side thrust FrrKg Max Pitch hmm Max-imum shaft RPM Maximum linear speed Meters / Minute Drive Torque required without load Kg-Cm Weight Kg
HT1 10 3 5 4 2000 8 0.25 0.5
HT2 15 3 9 9 2000 18 0.3 1.1
4RR15 15 4 18 9 2000 18 0.5 1.31
HT3 20 3 14 17 1500 25.5 0.3 2
4RR20 20 4 28 17 1500 25.5 0.6. 2.5
HT22 22 3 14 17 1500 25.5 0.3 2
4RR22 22 4 28 17 1500 25.5 0.6 2.5
HT3N 30 3 21 28 1000 28 1.2 3.2
4RR30 30 4 42 28 1000 28 2.5 4
HT4 40 3 38 30 750 22.5 3.5 6.6
4RR40 40 4 76 30 750 22.5 4.5 7.5
HT5 50 3 58 36 500 18 7.5 9.9
4RR50 50 4 116 36 500 18 13 11.3
HT6 60 3 100 50 350 17.5 10 15.7
4RR60 60 4 200 50 350 17.5 16 18.5
HT8 80 3 150 68 300 20.4 32 32
4RR80 80 4 300 68 250 17 37 38.7

* h max = linear movement of traverse unit per rotation of shaft at setting 10 on the dial

Traverse system

SALIENT FEATURES

  • Proven System
  • Absolute minimum maintenance
  • Two Years Warranty
  • Automatic and Instantaneous reversal
  • Variable linear speed with constant speed and unidirectional rotation of shaft.
  • Variable stroke length
  • Finely adjustable Linear speed by flick of a lever.
  • Seventeen models of Traverse units with a side thrust ranging from 5 Kg to 300 Kg and shaft diameter ranging from 10 mm to 80 mm.
  • Two models for each shaft in four rolling ring and three rolling ring design.
  • Traverse unit with four rolling rings are heavy duty models with double the side thrust comparing to three rolling ring models with only minor change in dimensions .
  • Zero backslash and Highly Efficient Transmission of Motion
  • Used in Horizontal and Vertical applications
  • Very Low drive torque requirement
  • Traverse unit can be easily modified from clockwise direction of rotation to anti clockwise direction rotation of shaft
  • Pneumatically operated reversal mechanism for bidirectional rotation of shaft
  • Maximum linear speed limited only by maximum shaft rpm
  • No limitation on minimum shaft speed. Can be operated at very low speed
  • Minimum stoke lengthpossible is approximately equal to diameter of shaft.
  • Maximum travel length limited only by shaft sag.
  • Shaft supplied up to a length of 4 meters * ( 20 mm and above )
  • Separate drive not necessaryfor winding applications
  • Automatic synchronization between bobbin speed and traverse linear speed
  • Free movement lever for positioning.
  • Heavy loads ,can be traversed with Guide carrier
  • Traverse assembly supplied as per customer requirements.
  • Service and Repair facility
  • Spares available ex stock

APPLICATIONS

Used in any application requiring linear reciprocating motion with automatic and instantane-ous reversal, finely adjustable stroke length, finely variable linear speed with constant speed and unidirectional rotation of the shaft.

Traverse Units are used for winding very fine fiber optic wires to heavy gauge cables / steel wire ropes. Traverse units can be used to wind material of any shape - Round, Flat, Hexagonal Tube, Hose and Material Rubber / Plastic Hoses and Pipes, P.P strap, M.S / Stainless steel strip, Chain, Rectangular Conductors, Flats, Filaments, Ribbon, Tapes, Foils and for winding any material of any shape and size.

Seventeen models of traverse units are available to choose for shaft dia 10 mm to 80 mm Traverse assembly of various designs and fittings with shaft length up to 4000 mm manufactured against customer requirements.

Application Areas

1. Wire and Cable Industries

2. Steel, Aluminium, Copper, Plastic and Rubber Industries.

3. Textile Industries

4. Plastic industries

5. Transformer Manufacturing Industries:

For layer winding of wire and rectangular conductor in LV, HV and Cross over coil winding machines

6.Automobile Industries,Glass / mirror Industries

For Spray Painting / coating

7. Surface treatment

Metal spraying

8. Rubber Industries

For Stock Blender, Rubber mixing

9. Sequential Feed / Positioning Devices

10. Paper / card board industries

For coating , Testing and spraying

11. Material handling and packaging

12. Tyre Manufacture

13. Measuring / Testing

14. Glass / Mirror industries Coating, spraying and painting

15. Linear drives

PRINCIPLE OF OPERATION

Rollring Traverse Units are positive drives which converts constant speed rotation of a shaft to variable speed and variable stroke reciprocating motionwith automatic and instantane-ous reversal without changing direction of shat rotation. The Rollring drive performs similar to a lead screw but has the added advantage of an infinitely variable pitch and stroke length without any electrical drives and controls.

This is a unique method for converting rotary motion into linear reciprocating motion on the principle that contact pressure created between a correctly dimensioned rolling rings and shaft enables significant forces to be transmitted. The linear speed is directly related to the angle of contact between the rolling rings and shaft.

The Reversal is automatic and instantaneous without any electrical control sys-tems.Linear speed is infinitelyvariable withspeed setting dial. Stroke length is infinitely ad-justable.

Traverse assembly

Rolling ring traverse

SELECTION OF TRAVERSE UNIT

Traverse unit model is selected considering the side thrust “F” required for traversing, Weight of assemblies mounted on traverse unit, tension in the material to be traversed, Maximum stroke length (Travel length), Maximum Linear speed etc.

For calculation, a model need to be pre selected by approximately estimating required force considering all the forces acting on the traverse unit – Weight of assembly mounted , Tension in the material to be traversed , Max travel length, Linear speed, Shaft sag, Frictional load etc.

Suitability of the modelpre selected is verified by calculation as given below.

F = 0.25 m x v + F r + F z + 0.12 m× g +F w

The value of side thrust F so calculated should be less than rated side thrust of traverse unit pre selected
F < F rr.

Frr :Rated side thrust of the traverse unit pre selected If the required side thrust F calculated is higher than that of the traverse unit pre selected Frr, higher size unit needs to be selected. Select a higher size traverse unit and verify the suitability as above.

Related Units

m = weight to be Traversed in Kg (Weight of the traverse unit + Weight of assembly mounted directly on the unit).

V(meter/sec)=Maximumlinear speed

t(Sec) = Reversal Time( Reffig . 6)

Fr(Kg) = Frictional Force (Applicable when the associated assemblies are mounted on a separate independent carriage and coupled to the traverse unit)

g = Acceleration due to gravity (9.81 m/sec2)

Fz= Additional Forces acting on the traverse (if any)

Fw(kg)= Force Acting related to winding tension.

Fw

C (mm) = Travel length.

T (Kg) = Tension in the material to be wound.

B (mm) = Distance from previous support position.

Compare the side thrust calculated with maximum side thrust available on the traverse unit pre selected. Select the model or choose a different model based on the above calculations. Recheck the force again as above if different model is selected

WINDING / SPOOLING APPLICATION

Select suitable model of Traverse unit considering the maximum winding tension, weight of assembly mounted on the traverse unit, Max linear speed, travel length, Distance between capstan or last guide to traverse.

When the distance between capstan / last guide to traverse is short, the forces acting on traverse unit will be more and higher size model may be necessary.

Load carrier is required for the following applications:-

1. When Tension / twisting forces are more on the material to be traversed

2. When heavy guide assembly needs to be traversed

3. When there is large over hang of the guide assembly.
In such conditions a load carrier with linear bearings, supported on two number shaft is necessary for mounting the guide assembles.

Suggesting suitable model

1. Maximum travel length or maximum width of bobbin used
2. Size of the material to be traversed
3. Material
4. Max Tensile strength of the material / approximate winding tension
5. Max linear speed
6. Distance from capstan or last guide to traverse
7. Application – Vertical or Horizontal
8. Maximum Weight of assembly to be traversed
9. Requirement of Load carrier
10. Any other information

OPERATION GUIDE

1. Assembling traverse unit on the shaft

Set pitch on the traverse unit to maximum and insert one end of the shaft in to the traverse unit and rotate the shaft. When shaft is rotated in correct direction the bearing end of the Reversal lever points towards the direction of travel. Traverse unit will move on to the shaft like a nut.

Do not push the unit or use force. Traverse unit can be removed from the shaft similarly. Shaft ends may be chamfered to prevent damage to rolling rings during installation.

linear drives

2. Max insertion depth of mounting screws

Four threaded holes are provided on the traverse unit for mounting assembly to be traversed

Please ensure that the length of bolt used does not exceed insertion depth N and penetrate inside the box. Refer fig 4 and dimension “N“ for maximum insertion depth for each model.

Traverse

3. Direction of shaft rotation and how to modify traverse unit to suit required direction of rotation of shaft.

Traverse units are normally supplied “Top towards“ for clockwise direction of rotation of shaft, unless specified.

Traverse unit can be easily modified to suit anticlockwise direction of rotation of shaft “top away” simply by altering the position of reversal mechanism Refer fig 5.

Procedure : The reversal mechanism is removed and refitted with a 180 degree turn of the reversal lever

a. Remove striker plate, reversal Lever, springs and release lever of the reversal mechanism by loosening the allen head bolt on the release lever.
b. The striker plate is refitted on opposite side
c. The release lever is refitted with 180 degree turn
d. Refit springs and release lever
e. Ensure that lug of springs is not bend while refitting
f. Please lubricate springs with grease / oil

Pneumatically Operated Reversal MechanismIn applications such as winches where shaft need to be operated in clockwise as well as anti-clockwise direction pneumatically operated reversal mechanism can be used.

4. Pitch Setting

Pitch can be varied from near zero to maximum specified value. For adjusting the pitch pointer is shifted on the dial as required. Position 10 is the max pitch, h max.

Pitch setting position 1 and below should be avoided for accuracy. Accuracy of pitch and side thrust will be low below position1. For obtaining fine control of pitch, the speed reduction between bobbin shaft to traverse shaft is to be increased.

Recommended speed reduction between spool shaft to traverse shaft

dr - Traverse shaft drive pulley, ds- spool shaft drive pulley.

Minimum to maximum Pitch range If the minimum to maximum pitch requirement ratio is above 15:1, traverse shaft should be provided with two speeds. .

5. Reversal Time:

The reversal of direction of move-ment of traverse unit is instantaneous and automatic On making contact with end limit stopper, the torsion spring on the reversal mechanism gets charged and will trigger and force the reversal once the throw over posi- tion is reached. The reversal time depends on linear speed of traverse unit. Please refer fig 6 for reversal time at various pitch settings.

Consequently when the pitch of the traverse unit or shaft speed is increased there may be slight variation in traverse stroke length and vice versa.

OPTIONAL ACCESSORIES FOR TRAVERSE UNIT

1. Free-movement lever (Disengaging Lever)

Two types of free movement lever are available. Lever provided on bottom side Type FM 1and lever provided on op side Type FM 2.

Free movement lever Type FM 1

Provided on bottom side. By turning the lever by 90 degree the traverse unit gets disengaged on the shaft and can be moved freely on the shaft. Available for all models except for model HT1

Free movement lever Type FM 2

Provided on top side. By turning lever by 90 degree, the traverse unit gets disengaged on the shaft. Not available for all four Rolling ring models and for model HT1

2. Remote Control Of Pitch

Linear speed of Traverse unit is varied with fractional hp motor mounted on the traverse unit. Available for all models with shaft dia 30 mm and above

3. Pitch Setting By Set Screws

Separate pitch setting for each direction is possible

4. Pneumatically operated Reversal mechanism

Traverse unit is suitable for clockwise as well as anti clock wise direction of rotation of shaft. The direction of travel is reversed with air cylinder mounted on the traverse unit, solenoid valve and proximity switch.

TRAVERSE ASSEMBLY

Traverse assembly consists of traverse unit, shaft, side end brackets, steady rail, reversal limit adjustments and guide assembly.

Load carrier with linear bearing and guide shafts is recommended in application traversing heavy guide assembly, excessive winding tension and when there is overhang of guides.

We supply Traverse assembly of various designs with accessories to suit requirements. Shaft length available upto 4 meter*

Traverse Assembly specifications

Traverse unit model Shaft Dia. mm Additional Length L1mm ( minimum) Side thrust at 300 rpm Kg Maximum shaft RPM Pitch at setting 10 on the dial per rotation of shaft .H max Max Linear Speedmeter/min
HT1 10 3 5 4 2000 8
HT2 15 3 9 9 2000 18
4RR15 15 4 18 9 2000 18
HT3 20 3 14 17 1500 25.5
4RR20 20 4 28 17 1500 25.5
HT22 22 3 14 17 1500 25.5
4RR22 22 4 28 17 1500 25.5
HT3N 30 3 21 28 1000 28
4RR30 30 4 42 28 1000 28
HT4 40 3 38 30 750 22.5
4RR40 40 4 76 30 750 22.5
HT5 50 3 58 36 500 18
4RR50 50 4 116 36 500 18
HT6 60 3 100 50 350 17.5
4RR60 60 4 200 50 350 17.5
HT8 80 3 150 68 300 20.4
4RR80 80 4 300 68 250 17

Traverse shaft : Shaft used should have high surface hardness, without any bend and good surface finish. Hardened hard chrome plated shafts with high surface finish are recommended.

Shaft material : C45

Heat treatment : High frequency induction hardening

Surface roughness : Polished Ra<=0.8µ; Straightness with in 50 µ per 300 mm

Shaft Sag : IIt is necessary to consider sag of the shaft for the travel length while selecting a model

Minimum Stroke Length : Minimum stroke length is approximately equal to diameter of the shaft.

Shaft drive : Separate drive is not required in most of the applications. Drive can be provided from associated assemblies and traverse linear speed will be automatically synchronized. Drive torque required is very low and separate motor is not necessary.

Separate drive. Fractional horse power geared motor having output rpm to match the required maximum linear speed is recommended. Refer specification for drive torque required

Recommended Shaft Speed

Spooling / Winding Applications

In spooling or Winding application the drive to traverse shaft is provided from any shaft transmitting drive to the bobbin for automatic speed synchronization

dr =Diameter of drive pulley on traverse shaft
ds = Diameter of drive pulley on spool shaft
For layer winding application the maximum pitch required for the application is the maximum wire dia or maximum width of strip.
For accuracy it is necessary to provide speed ratio as recommended. In applications where minimum to maximum required pitch required exceeds 15:1, it is necessary to provide two speed drive to traverse shaft for accuracy of pitch.

Reversal End Limits : Reversal end limits are provided for varying the stroke length.

Side Brackets : Supports the traverse shaft on bearings.

Steady Rail : Prevents rotation of the traverse unit on the shaft.

Mounting of Assembly on the traverse unit : Four number tapped holes are provided on top side of the traverse unit for mounting. The weight of assemblies mounted on the Traverse unit may be reduced to the minimum possible.

Load Carrier : For traversing heavy assembly / assembly with long overhang / when tension in the material traversed is high, load carrier is provided.

Types of load carrier

1. Bearing mounted : A separate top mounting plate assembly with four number bearings used in conjunction with steady rail prevents the rotation of the unit on the shaft and also takes care of twisting forces and tension. Used for moderate loads and twisting forces.

2. Load carrier With Linear bearing : Guide assembly is mounted on load carrier with linear bearings supported two guide shafts.

3.With Linear Motion Systems : When heavy loads are to be traversed, a load carrier with LM blocks and rail is recommended

Protection of shaft from Dust accumulation : In very dusty and corrosive environment, a bellow type cover is used to prevent wear out and extend life of rolling rings. Non inflammable bellows are recommended in metal spraying applications.

Winding on Conical / Bi-Conical spools : For winding on conical or bi conical spools, self adjusting end stops are provided. End limit position is altered during winding as required using small motor and PLC.

Traversing the spool : Rollring Traverse is used to traverse the spool. The winder traverses the spool for a smooth and even winding. The spooled material remains perfectly in line, which elimi-nates lateral stress, pulling and the risk of deformation that is normally associated with winding flat, delicate or brittle materials that are prone to breakage, tearing and twisting. This minimizes material damage, reduce waste and result in less production interruptions. The bobbin traversing is designed for spooling fine wires, tape, lace and other material that can crease, fold or snap when traversed on to a spool.

Traverse unit will be stationary and shaft will be traversing along with associated assemblies

VERTICAL TRAVERSE ASSEMBLY

Load carrier with linear bearings and guide shaft is recommended for mounting the guide assembly. Counter weight, equivalent to the weight of traverse unit and guide assembly, may be provided to increase the efficiency.

MAINTENANCE

Lubrication

Lubrication of shaft : Apply only a very thin film of oil. Clean the shaft and spread the oil as thinly as possible. We recommend cleaning the shaft every shift in very dusty environment to prevent accumulation of dust on the shaft causing wear out of rolling rings and shaft.

Lubricate the reversal mechanism, particularly the springs with high viscosity oil SAE 90 or equivalent.

Frequency : Weekly, under normal conditions. When the operating conditions are severe like extremely dusty and corrosive environment or for high temperatures, shorter lubrication intervals is recommended.

Loss of Side Thrust : Traverse units are factory set for side thrust as per specifications. If there is any deterioration in thrust after a long period of operation due to wear out, it can be compensated by adjusting the thrust screw provided. A large slotted screw is provided at the unit bottom side (side of Reversal mechanism) can be slowly tightened. Thrust screw if over tightened will cause failure of operation of reversal mechanism. So the screw should be tightened slowly with care.

Pitch change : Please press the pointer down and change the pitch to prevent damage to the teeth on the dial.

ORDERING INFORMATION

Traverse Unit

1. Model

2 . Direction of shaft rotation : Top towards or Top away
Note: Traverse unit can be very easily altered to clockwise or anti clock wise direction of rotation of shaft

3. Optional Accessories

a. Requirement of Free movement lever ( release lever ) FM1 provided on bottom side or FM2 provided on top side
b. Remote Control of Traverse pitch
c. Pitch setting by set screws
d. Reversal slow down
e. Pneumatic reversal

Traverse Assembly

1. Max Traverse stroke length or Shaft length “L” required between two side end brackets.
2. Length of Shaft extension and requirement on right side “Ra” or left side “La”.
3. Direction of shaft rotation (refer fig 3)
4. Requirement of wire guide pulley or roller
5. Requirement of Load Carrier
a. Bearing mounted
b. With linear bearing and guide shafts
c. With LM block and rail
Note: Traverse assembly is normally offered with bearing mounted load carrier unless specified.
6. Optional features / Accessories a. Bellows
b. Self adjusting end stops for bi-conical and conical spools c. Lead screw operated end stops
d. Built in speed reduction gear box e. Separate geared motor
f. Any other specific requirements

DIMENSIONS OF TRAVERSE UNIT (mm)
S. L. NO Model A B C ØD E F G H I J K L M N O Ø P Q Ø R S T U V
1 HT 1 79 2 54.5 10 12 42 11 8.5 35 12 28 40 M4 5 5 16 36.25 16 --- --- --- ---
2 HT 2 94 3 70 15 17 56 14 17.5 40 20 32 36 M5 6 6 19 48 19 32 26 44 36
3 4RR 15 115 3 70 15 17 56 14 17.5 40 20 32 36 M5 6 6 19 48 19 32 --- 40 ---
4 HT 3 120 3 87 20 23 70 18 18.5 43 32 40 70 M6 8 7 22 59.5 22 32 32 47 54
5 4RR 20 150 3 88 20 22 71 18 18.5 43 32 40 70 M6 8 7 22 59.5 22 37 --- 51.5 ---0
6 HT 22 120 3 87 22 23 70 18 18.5 43 32 40 70 M6 8 7 22 59.5 22 32 32 47 54
7 4RR 22 150 3 88 22 22 71 18 18.5 43 32 40 70 M6 8 7 22 59.5 22 37 --- 51.5 ---
8 HT 3N 143 5 103.8 30 26 87 20 18.5 59 40 50 80 M6 10 8 26 69.9 26 37 38 60 58
9 4RR 30 174 5 105.8 30 25 88 20 18.5 60 40 50 80 M6 10 8 26 71.9 30 44 --- 63 ---
10 HT 4 198 5 137.8 40 29 112 23 18.5 78 50 50 133 M12 12 10 32 92.9 32 44 44 72 77.5
11 4RR 40 198 5 137.8 40 29 112 23 18.5 80 50 50 133 M12 12 10 32 92.9 37 51 --- 76 ---
12 HT 5 232 5 157.8 50 31 130 23 28.5 79 65 90 160 M12 14 10 32 100.9 32 56 52 94 8+
13 4RR 50 232 5 157.8 50 31 130 23 28.5 81 65 90 160 M12 14 10 32 100.9 37 58 --- 88 ---
14 HT 6 280 5 184.8 60 36 150 25 28.5 127 100 80 220 M12 16 12 37 120.8 35 67 68 100 100
15 4RR 60 280 5 184.8 60 36 150 25 28.5 127 100 80 220 M12 16 12 37 120.8 40 67 --- 100 ---
16 HT 8 355 5 246.8 80 41 200 27 28 147.5 100 80 240 M12 24 14 47 165 47 75 --- 140 ---
17 4RR 80 355 5 246.8 80 41 200 27 28 147.5 100 80 240 M12 24 14 47 165 47 75 --- 140 ---

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