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Dancer roll assemblies are an excellent choice where out-of-round (egg shaped) rolls are causing tension fluctuations.


Commonly, master rolls of material are far from perfect. Often times, one major imperfection is the master (unwind) roll is just not round; it may have a flat spot from being stored laying on its face or it may just be egg shaped coming from your supplier. Flat spots and /or egg shape can cause extensive tension fluctuations as the roll is unwound and fed into your process. Chances are your converting process and product quality will suffer due to incoming tension fluctuations.

Dancer rolls operate by mechanically "storing" material within a set of moving rollers. This web storage can effectively operate as a "shock absorber" to absorb and correct tension fluctuations. By absorbing and correcting tension fluctuations, the web will then be fed into your converting process at the desired, uniform tension level, thereby maximizing your process, product quality and throughput. Proper dancer design, including enough web storage to accommodate your operating speeds and largest tension fluctuations is essential to the overall operation.

Keep in mind, however, the dancer assembly, by itself, is just one piece of a much larger puzzle. The dancer must include position feedback and a properly performing tension control system to control your brake or drive system.


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