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Metal Expanding Lug Shafts
Metal Expanding Lug Shafts
The DG-2000 Metal Air Shaft is a pneumatic expanding lug shaft designed for unwind and rewind applications. When inflated, expanding lugs securely grip the inside of the core to support reliable roll handling throughout production.
Designed for long-term durability and easy maintenance, the DG-2000 combines a metal shaft body with Double E Group's proprietary bladder technology, diamond-pattern gripping lugs, and a quick-change journal system. These design features help provide dependable core gripping while simplifying maintenance and reducing the production downtime associated with servicing the shaft.
DG-2000 shafts are configured around the requirements of the application. Core diameter and material, roll weight and dimensions, web speed, tension, shaft dimensions, and machine configuration are among the factors considered when specifying the appropriate shaft design.
The DG-2000 Metal Air Shaft is designed to support safe, efficient operation throughout its service life. Reliable core gripping, durable construction, and serviceable components help support dependable production while simplifying routine shaft maintenance.
Designed with the user in mind, the DG-2000 incorporates Double E Group’s proprietary lightweight bladder technology and quick-change journal system to simplify service and help limit costly production downtime.
Together, these components create a durable, serviceable air shaft designed for reliable core gripping and efficient maintenance. DG-2000 shafts are then configured around the core, roll, machine, and operating requirements of each application.
The DG-2000 is a pneumatic expanding shaft that uses compressed air to activate its internal bladder. As the bladder inflates, the lugs expand outward to grip the inside of the core, securely holding the roll during operation. When the shaft is deflated, the lugs retract to release the core for roll removal or changeover.
This design allows the DG-2000 to provide reliable core gripping for both unwind and rewind applications while maintaining a straightforward pneumatic operating principle.
The DG-2000 is designed to provide the durability and gripping performance required for demanding unwind and rewind applications while remaining straightforward to maintain. Its metal construction, proprietary bladder technology, and serviceable journal design work together to provide a dependable expanding shaft that can be configured around the requirements of the application.
Conventional rubber bladder materials can stretch during repeated inflation and deflation, increasing the potential for abrasion and premature failure. The DG-2000 uses Double E Group’s proprietary corded bladder material, designed to resist stretching, abrasion, and punctures. The bladder material also allows the lugs to collapse when the shaft is deflated without requiring individual lug-return springs, eliminating additional wear points that can contribute to bladder failure.
DG-2000 gripping lugs are available with steel, aluminum, or hard-rubber gripping surfaces to accommodate different application requirements. Double E Group’s diamond-pattern surface increases the lug contact area within the core to provide reliable gripping performance.
Rather than using a tapered press-fit journal connection, the DG-2000 uses a close-tolerance fit, deep journal insertion, and high-strength flathead fasteners. Journals can be removed with a hex wrench when service is required, allowing the bladder to be changed in minutes. By comparison, press-fit journal designs may require a hydraulic press and heat for removal.
Depending on the requirements of the application, Double E Group also offers the DLB-2000 Carbon Fiber Core Shaft as an alternative to traditional metal shaft construction. Every component of the DLB-2000 is engineered to solve challenges converters face every day, including heavy shafts, excessive deflection, difficult handling, bladder failures, and lost production time.
Its lightweight carbon fiber construction reduces shaft weight while maintaining strength and rigidity, making shafts easier to handle while reducing deflection and roll bounce. Greater stiffness also supports higher critical speeds for demanding unwind and rewind applications.
DLB-2000 Carbon Fiber Core Shafts are available in both expanding lug and through-shaft designs to meet different application requirements.
Selecting the appropriate core shaft requires consideration of the complete application. DG-2000 Metal Air Shafts are engineered around the requirements of the machine, roll, material, and operating conditions. Rather than selecting a shaft based on a single factor such as roll weight or speed, Double E Group considers these operating requirements together when determining the appropriate shaft design.
Key application information includes:
Evaluating these operating conditions together allows the shaft construction, dimensions, journals, and other design requirements to be matched to the application. Proper shaft specification helps support reliable performance, efficient roll handling, and safe operation within the shaft's intended use.
Engineered specifically for the converting industry, ShaftSafe® is the first, real-time air pressure monitoring system for Double E Group and Convertech air shafts and bladder chucks
ShaftSafe® Features:
The correct DG-2000 configuration depends on the complete requirements of your application. Factors such as core size and material, roll weight and dimensions, web speed and tension, shaft dimensions, machine configuration, and unwind or rewind position are evaluated together to determine the appropriate core shaft design.
Double E Group can review your application requirements and help specify a DG-2000 for your equipment and operating conditions.
Yes. DG-2000 Metal Air Shafts are configured to fit the requirements of our customer’s machine and application. Shaft dimensions and journals can be designed around the existing equipment, while the overall shaft configuration is determined using factors such as core size, roll requirements, operating conditions, and machine setup.
If you are replacing an existing shaft, Double E Group can use your machine and application information to help determine the appropriate DG-2000 configuration.
To properly specify a DG-2000 Metal Air Shaft, Double E Group will need information about your existing equipment, roll, core, and operating conditions. Helpful application details include core inside diameter and material; maximum and minimum roll weight, width, and diameter; shaft dimensions and support separation; web speed and tension; machine type; and whether the shaft will be used in an unwind or rewind position.
Information about your brake or drive configuration, roll handling method, available air pressure, and any problems with your current shaft can also help determine the appropriate design.
Download the DG-2000 brochure & specification form
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