Stencil printer having controllable tension device for a stencil wiper assembly and method of controlling tension

1. A stencil printer comprising:

a stencil;

a material applicator to apply material on the stencil; and

a stencil wiper assembly to selectively wipe the stencil, the stencil wiper assembly having a quick-change material module comprising

a supply roller to receive a roll of material,

a take-up roller to receive used material,

a drive to move the material across the stencil from the supply roller to the take-up roller, and

a controllable tension device configured to vary a tension of the material when driving the material from the supply roller to the take-up roller, the controllable tension device including a brake mechanism configured to apply a pre-determined tension to the supply roller, the brake mechanism including a disk secured to a shaft of the supply roller and a caliper assembly configured to apply a braking force on the disk, wherein the caliper assembly includes

a first housing positioned on one surface of a frame member of the web-material supply module,

a second housing positioned on an opposite surface of the frame member, and

a piston that moves within a chamber formed within the first housing.

2. The stencil printer of claim 1 , wherein the caliper assembly includes a pneumatic brake caliper that is coupled to a controller to control the tension of the supply roller.

3. The stencil printer of claim 1 , wherein the piston is moved within the chamber of the first housing by an application of fluid provided by a fitting secured to the first housing and in fluid communication with the chamber.

4. The stencil printer of claim 1 , wherein the caliper assembly further includes a first friction puck positioned in the chamber of the first housing and movable by the piston toward the disk when assembled.

5. The stencil printer of claim 4 , wherein the caliper assembly further includes a second friction puck positioned within a chamber of the second housing, the first friction puck being positioned next to the piston within the first housing and movable by the piston to selectively engage an outboard surface of the disk, and the second friction puck being fixed within the second housing and configured to engage an inboard surface of the disk.

6. The stencil printer of claim 1 , wherein the controllable tension device further includes a first encoder associated with a shaft of an idler roller of the web-material supply module, a second encoder associated with the supply roller, and a controller coupled to the first encoder and the second encoder, the controller being configured to count a rotation of the first encoder and to count a rotation of the second encoder to determine a ratio between the rotation of the first encoder and the rotation of the second encoder, and to use this information to determine a diameter of the supply roller.

7. A web-material supply module of a stencil wiper assembly for wiping a stencil of a stencil printer, the module comprising:

a supply roller to receive a roll of material;

a take-up roller to receive used material; and

a drive to move the material across the stencil from the supply roller to the take-up roller; and

a controllable tension device configured to vary a tension of the material when driving the material from the supply roller to the take-up roller, the controllable tension device including a brake mechanism configured to apply a pre-determined tension to the supply roller, the brake mechanism including a disk secured to a shaft of the supply roller and a caliper assembly configured to apply a braking force on the disk, wherein the caliper assembly includes

a first housing positioned on one surface of a frame member of the web-material supply module,

a second housing positioned on an opposite surface of the frame member, and

a piston that moves within a chamber formed within the first housing.

8. The module of claim 7 , wherein the caliper assembly includes a pneumatic brake caliper that is coupled to a controller to control the tension of the supply roller.

9. The module of claim 7 , wherein the caliper assembly further includes a first friction puck positioned in the chamber of the first housing and movable by the piston toward the disk when assembled, and a second friction puck positioned within a chamber of the second housing, the first friction puck being positioned next to the piston within the first housing and movable by the piston to selectively engage an outboard surface of the disk, and the second friction puck being fixed within the second housing and configured to engage an inboard surface of the disk.

10. The module of claim 7 , wherein the controllable tension device further includes a first encoder associated with a shaft of an idler roller of the web-material supply module, a second encoder associated with the supply roller, and a controller coupled to the first encoder and the second encoder, the controller being configured to count a rotation of the first encoder and to count a rotation of the second encoder to determine a ratio between the rotation of the first encoder and the rotation of the second encoder, and to use this information to determine a diameter of the supply roller.

11. A method for controlling tension of a supply roller within a web-material supply module of a stencil wiper assembly designed to wipe a stencil of a stencil printer, the method comprising:

moving the material between a supply roller and a take-up roller, moving the material being achieved by a motor coupled to the take-up roller to drive a rotation of the take-up roller; and

controlling a tension of the material when driving material from the supply roller to the take-up roller by a controllable tension device including a brake mechanism configured to apply a pre-determined tension to the supply roller, the brake mechanism including a disk secured to a shaft of the supply roller and a caliper assembly configured to apply a braking force on the disk, wherein the caliper assembly includes

a first housing positioned on one surface of a frame member of the web-material supply module,

a second housing positioned on an opposite surface of the frame member, and

a piston that moves within a chamber formed within the first housing.