Custom Auto Paper Take-Off Unit

About the project

I am building a new converting line and need a purpose-built, metal automatic paper take-off unit. Core dimensions are fixed: the expanding air shaft must be Ø74 mm and the web width 2 000 mm. Drive will come from an AC gear motor, so please size and specify a model that delivers smooth, adjustable unwind speed without introducing vibration. Stable web tension is critical, therefore I want a dancer-type tension rod fitted with a sensor and closed-loop, fully automatic control. All control hardware, wiring diagrams, and PLC/HMI logic (if required) should be part of the package so the unit can slot straight into the rest of my line. Directly after the take-off section I need an IR dryer with an integrated fan. It has to mount on the same frame, clear the 2 000 mm web, and deliver even drying at production speed. Please recommend lamp power, airflow, shielding, and any safety interlocks you deem necessary. Deliverables • 3D CAD model and detailed 2D fabrication drawings of the complete assembly • Motor sizing calculations and manufacturer datasheets for the AC gear motor • Control architecture, wiring diagrams, PLC/HMI program or ladder logic printout • Bill of materials with commercially available parts and suggested suppliers • Installation, alignment, and commissioning guidelines • Remote sign-off support once the machine is on my floor Acceptance criteria • Shaft diameter, web width, and mounting footprints match the figures above • Web tension remains within ±2 % of the setpoint across the full speed range • IR dryer achieves target moisture reduction without scorching at max line speed • All documentation is delivered in editable formats (STEP, DWG, PDF, and native controls files)

Skills required