In view of the low slitting efficiency of ribbons (thermal transfer ribbons, barcode ribbons, etc.), the automatic high-speed slitting machine can increase the production capacity by more than 50% through the following technical solutions, while ensuring the slitting accuracy and material integrity:
First, pain points and challenges of ribbon slitting
1. Material Properties:
◦ Multi-layer structure (PET substrate + coating + ink), easy to delaminate or warped edges.
◦ Sensitive to tension, too much will be pulled off, too small will cause uneven winding.
2. Traditional Questions:
◦ Long downtime for manual roll change and limited slitting speed (typically ≤ 100m/min).
◦ Edge burrs and slitting dust contaminate the ink layer.
Second, the core solution of automatic high-speed slitting machine
1. Ultra-high-speed slitting module
◦ Laser Slitting/Air Knife Technology:
◦ Non-contact cutting to avoid damage to the ribbon coating caused by mechanical friction (especially suitable for wax-based/mixed-based ribbons).
◦ The cutting speed can reach 300~500m/min, which is 3 times faster than the traditional blade slitting.
◦ Dynamic Dust Collection System:
◦ Negative pressure adsorption + ionic air cleaning, slitting and removing debris at the same time to prevent contamination of the coil.
2. Fully automatic roll change and splicing
◦ Double-station winding + pre-loaded paper core:
◦ The servo-driven inflatable shaft automatically switches, and the roll change time is reduced from 3 minutes to 0 seconds.
◦ Equipped with a static eliminator to avoid film adhesion.
◦ Intelligent splicing technology:
◦ The ultrasonic sensor detects the diameter of the coil and triggers the splicing preparation in advance, and the success rate of splicing ≥ 99.9%.
3. Ribbon tension control
◦ Three-stage closed-loop tension:
◦ Unwinding (magnetic particle brake) + slitting (floating roller feedback) + winding (servo motor), tension fluctuation ≤± 0.5N.
◦ Preset tension curves for different ribbon types (resin-based/wax-based) and automatically adjust.
4. High Precision Web Guiding (EPC)
◦ Infrared + CCD dual sensor:
◦ Infrared detection of the edge of PET substrate, CCD identification of ink coating pattern, deviation correction accuracy ± 0.1mm.
◦ Anti-shake algorithm, suitable for high-speed operation of ribbon thin materials.
Third, comparative data for efficiency improvement
index | Conventional ribbon slitting machine | Fully automatic high-speed slitting machine | Lift |
Slitting speed | 80~120m/min | 250~400m/min | +150% |
Roll change efficiency | 3 min/roll | 0 sec (fully automatic) | 100% |
Yield | 85%~90% | ≥98% | +10%~13% |
Capacity per day (8 hours) | 400~500 km | 900~1200 km | +50%~80% |
Fourth, the special optimization of ribbon slitting
1. Environmental Control:
◦ Constant temperature and humidity module (20~25°C, RH40%~60%) to prevent carbon ribbon moisture absorption or static electricity accumulation.
2. Edge Enhancement:
◦ Infrared heated edge after slitting (optional) to reduce the risk of coating peeling.
3. Dust-free guide rollers:
◦ Carbon fiber or silicone coated guide rollers to avoid scratching the ink layer.
5. Expansion of intelligent functions
• AI Defect Detection:
◦ Scan the ribbon coating uniformity online and automatically mark pinholes, bubbles and other defects.
• MES system docking:
◦ Slitting data (length, width, batch) is automatically uploaded to the factory management system to trace the whole production process.
• One-click changeover:
◦ Memorize the parameters of different ribbon specifications (e.g. 4.5mm/6mm/8mm), and the switching time is < 1 minute.
6. Applicable Scenarios
• Barcode ribbons: TTR, TTK and other thermal transfer ribbon slitting.
• Special ribbons: high-temperature resin-based ribbons, washed standard ribbons.
• Other sensitive films: release films, conductive films.
Through a fully automated design, high-speed slitting technology and ribbon-specific adaptation solutions, the machine can significantly increase production capacity and reduce losses. If you need to further customize the solution (e.g. ultra-narrow slitting or anti-oxidation needs), specific parameters are available!