Patent ID: 7344105

Claim:
A method of controlling the winding of a web material about a spool, the method comprising steps of: a) providing a web material, b) providing a spool about which the web material may be wound, c) providing a desired nip load, d) determining a first-side force set point according to at least the desired nip load, e) applying a first-side force to the spool with a first-side primary engaging element, f) supporting the web material with a rotating reel, g) forming a nip between the spool and the reel, h) passing the web material through the nip, i) winding the web material around the spool forming a wound roll, j) determining a first-side force analog value, k) determining a first-side force error value according to the first-side force analog value and the first-side force set point, l) determining a radius of the wound roll, m) determining a first-side force-control-loop gain according to the radius of the wound roll, and n) adjusting the first-side force to reduce the first-side force error value according to the first-side force control loop at a response rate, wherein the first-side force-control-loop gain at least partially determines the response rate.