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Differential Shafts: Working Principle and Application
A differential shaft, also known as a friction shaft or air-controlled rewinding shaft, is primarily used in slitting machines for rewinding and special unwinding processes. It operates by controlling the friction torque through compressed air, ensuring smooth and consistent operation.
The structure of a differential shaft consists of a mandrel and multiple sets of friction rings (also called differential rings). These rings can slide independently, allowing the torque to be controlled either through central pressure or lateral transfer pressure. This ensures that each coil is rewound under constant tension, resulting in a uniform and neatly stacked roll from the inner to the outer diameter.
Slitting machines are designed to divide a large material roll into several smaller coils. Maintaining precise tension during this process is crucial, as it directly affects the production rate and the transverse uniformity of the final product.
During the process, material thickness variations can lead to accumulated errors in the diameter of each coil. This can cause fluctuations in tension and speed, leading to uneven winding and potential damage to the material. Differential shafts help overcome these issues by accurately controlling the tension on each roll. The friction rings slide at a specific friction torque, compensating for any speed differences and maintaining consistent performance.
Depending on the material type, slitting width, thickness, and tension requirements, selecting the appropriate differential shaft can significantly improve the overall performance. Using a differential shaft enhances the automation level of the slitting machine, reduces manual intervention, improves speed control, and increases rewinding accuracy.
Especially for expensive materials such as tinsel, battery separators, and special papers, the use of a differential shaft greatly improves efficiency and reduces costs, making it an essential component in high-precision slitting applications.