Accurately sizing rollers to your application is crucial for optimal performance of web handling machines. Manually processing these calculations can be time-consuming; however, Maxcess is changing that by introducing the newest upgrade to the WINertia™ roll deflection calculator, making it more streamlined than ever.
If you’ve used the WINertia™ Deflection Calculator in the past, you know how this powerful tool simplifies the process and gives you engineering and deflection calculations effortlessly. The best part is, it’s free! No purchase required.
What the WINertia™ Deflection Calculator Can Do for You
The WINertia™ Deflection Calculator is an exclusive, web-based engineering tool developed by the Maxcess brand, Componex. It allows users to input key parameters, such as web load, wrap angle, and web width, to calculate deflection in both idler rolls and shafts. Users can also compare different roll and shaft sizes in seconds using intuitive drop-down menus.
What’s New in the Updated WINertia™ Deflection Calculator?
We’ve listened to your feedback and made meaningful improvements to streamline your workflow:
- Refreshed Interface – A cleaner layout makes it easier to enter data and interpret results.
- Improved Accuracy – Updated formulas ensure you get more precise performance calculations.
- Expanded Options – Now reflects the latest WINertia™ idler roll configurations & selections.
Whether you’re quoting a system, designing a web path, or simply checking specs, the updated calculator helps you make informed decisions faster.
How to Use the WINertia™ Deflection Calculator
- Open the calculator.
- Choose Roll or Shaft mode.
- Enter wrap angle, span / roll face length, web width & tension (lbf).
- Select roll & shaft diameters from the drop-downs.
- Hit Calculate – review deflection, inertia & weight, then click Submit for a Quote to contact Maxcess experts.
Built for Engineers, Designed for Speed
We know time is critical, and this tool is built to save it. The updated WINertia™ Deflection Calculator continues to offer the same reliability you expect, with added usability and clarity that make your job easier.
“The WINertia™ Deflection Calculator was built to give users the kind of fast, accurate engineering data they need to make informed roll and shaft decisions,” says Tony Frasier, Precision Rolls Specialist at Componex. “It’s part of our mission to help customers enhance machine performance with smarter solutions.”
Why Roll Deflection Matters
The Cost of Excess Deflection
Roll deflection can significantly hinder the performance of your web handling machines because it directly impacts tension control, web tracking, and product quality. So, how do you reduce roll deflection?
Simple Ways to Reduce Deflection
The easiest way is to increase the diameter of the roller. According to Componex experts, OD is king!
For example, increasing the roll diameter from 3” to 4” can more than double the area moment of inertia (from 2.4 to 5.0), significantly improving strength without adding excessive weight.
WINertia™ tubing, like 4×3, delivers even higher performance, with an inertia value of 6.9 and only a modest increase in weight. See the ISO 16281 standard for calculation methodology.
For web paths where trapped air causes wrinkles, switching to a WINertia™ AV Air-Vent Idler lets the air escape and keeps the web flat.
Support the Roll with the Right Shaft
While many engineers focus on roll sizing, shaft deflection is just as significant. Undersized shafts increase misalignment between the shaft and bearing, leading to higher bearing friction and a greater risk of premature bearing failure.
The WINertia™ Deflection Calculator helps determine whether your shaft configuration is sufficient for your application. It even considers bearing compatibility, such as the difference between standard radial bearings (which allow up to 0.25° misalignment) and WINertia™ self-aligning bearings, which accommodate up to 2°.
Need more strength? The calculator makes it easy to explore options, such as upgrading from a 4×2 tube to a 4×3 version. A 1.5” shaft, for example, is five times stronger than a 1.0” shaft, critical information when planning for longer spans or heavier loads.
Componex also offers tubular shafts for use in load cells and other applications where dead weight is problematic.
Try the WINertia™ Deflection Calculator Today
Maxcess is proud to make the WINertia™ Deflection Calculator available to the entire industry. It’s just one more way we are helping our customers handle webs better, faster, and smarter with our tension-control solutions. Check out the updated calculator today and see the improvements for yourself – use the WINertia™ Deflection Calculator now or talk with a Maxcess application engineer.
WINertia™ Deflection Calculator Frequently Asked Questions (FAQs)
What inputs does the WINertia™ Calculator need?
Wrap angle, web width, web tension, roll face length, roll diameter, shaft diameter & material modulus.
How accurate are the results compared to FEA?
For standard WINertia™ tubes the tool matches finite-element models within ±5 % across spans < 120 in.