Electronic Nip Adjustment and Pressure Measurement on Pull Station

A method of controlling a converting line having a pull station, wherein the pull station comprises a top continuous loop and a bottom continuous loop, the top continuous loop and the bottom continuous loop are adapted to receive a plurality of webs in a vertically stacked arrangement at an entrance of the pull station and convey the stacked arrangement of webs between the top and bottom continuous loops through a discharge of the pull station, the top continuous loop being disposed on a frame, the method comprising:

• providing a frame actuator operatively connected to the frame that supports the top continuous loop of the pull station;
• enabling a sensor of the frame actuator to sense a position of the frame actuator;
• providing a stop that is configured to engage the frame and prevent movement of the top continuous loop toward the bottom continuous loop;
• providing a stop actuator that is configured to adjust the position of the stop;
• enabling a stop load sensor of the stop actuator to sense a load applied against the load sensor when the frame engages the stop;
• configuring a processor associated with a controller of a control of the converting line to determine a distance measurement between the top continuous loop and the bottom continuous loop based upon the actuator position sensor;
• configuring the processor to determine a force imparted to the plurality of webs based on the stop load sensor, the weight of the frame and the top continuous loop, and a force imparted to the top continuous loop by the frame actuator as the plurality of webs are conveyed from the entrance of the pull station to the discharge of the pull station;
• and
• enabling the controller to generate signals for controlling the pull station based upon at least one of the distance and force measurements.

A method of controlling a converting line having a pull station, wherein the pull station comprises a top continuous loop and a bottom continuous loop, the top continuous loop and the bottom continuous loop are adapted to receive a plurality of webs in a vertically stacked arrangement at an entrance of the pull station and convey the vertically stacked arrangement of webs between the top and bottom continuous loops through a discharge of the pull station, the top continuous loop being disposed on a frame, the method comprising:

• providing a frame actuator operatively connected to the frame that supports the top continuous loop of the pull station;
• sensing a position of the frame actuator;
• adjustably setting a minimum distance between the top continuous loop and the bottom continuous loop;
• imparting a force to the top continuous loop with the frame actuator;
• sensing a load applied by the frame to the pull station;
• determining a distance measurement between the top continuous loop and the bottom continuous loop based upon the position of the frame actuator;
• configuring the processor to determine a force imparted to the plurality of webs based on the load applied by the frame actuator to the pull station, the weight of the frame and the top continuous loop, and the force imparted to the top continuous loop by the frame actuator as the plurality of webs are conveyed from the entrance of the pull station to the discharge of the pull station;
• and
• enabling the controller to generate signals for controlling the pull station based upon at least one of the measurement of the distance and the measurement of the force imparted to the plurality of webs.