${row.name}, Scenario ${b ? "B" : "A"}: ${fmt(row[key])} ${unit}

45:["$","title",null,{"children":"Rolling Process Dashboard | Anaphite | Observable"}] 4d:Tc10f,const notebookInitialState = {"scenarios": {"single": {"a": {"speeds": [10.0, 15.0, 20.0, 25.0, 30.0, 35.0], "gaps": [245.0, 195.0, 145.0, 105.0, 65.0], "lengths": [null, null, null, null, null], "passes": [{"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}], "measuredGsm": [505.0, 355.0, 251.0, 188.0, 188.0], "densities": [2.31, 2.3, 2.3, 2.3, 2.48], "interpolation": "stage", "incomingDensity": 2.4, "incomingGsm": null}, "b": {"speeds": [12.0, 18.0, 24.0, 30.0, 36.0, 42.0], "gaps": [245.0, 195.0, 145.0, 105.0, 65.0], "lengths": [null, null, null, null, null], "passes": [{"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}], "measuredGsm": [505.0, 355.0, 251.0, 188.0, 188.0], "densities": [2.31, 2.3, 2.3, 2.3, 2.48], "interpolation": "stage", "incomingDensity": 2.4, "incomingGsm": null}}, "double": {"a": {"speeds": [10.0, 15.0, 20.0, 25.0, 30.0, 35.0], "gaps": [100.0, 80.0, 60.0, 50.0, 40.0], "lengths": [null, null, null, null, null], "passes": [{"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}], "measuredGsm": [null, null, null, null, null], "densities": [2.31, 2.3, 2.3, 2.3, 2.3], "interpolation": "stage", "incomingDensity": 2.4, "incomingGsm": null}, "b": {"speeds": [12.0, 18.0, 24.0, 30.0, 36.0, 42.0], "gaps": [90.0, 70.0, 50.0, 40.0, 30.0], "lengths": [null, null, null, null, null], "passes": [{"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}], "measuredGsm": [null, null, null, null, null], "densities": [2.31, 2.3, 2.3, 2.3, 2.3], "interpolation": "stage", "incomingDensity": 2.4, "incomingGsm": null}}, "two": {"a": {"speeds": [10, 15], "gaps": [100, 80, 60, 50, 40], "lengths": [null, null, null, null, null], "passes": [{"left": 10.0, "right": 15.0, "gap": 100.0, "length": null}, {"left": 10.0, "right": 15.0, "gap": 100.0, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}, {"left": 10, "right": 15, "gap": 100, "length": null}], "measuredGsm": [null, null, null, null, null, null, null, null, null, null, null, null], "densities": [2.31, 2.3, 2.4, 2.4, 2.4, 2.4, 2.4, 2.4, 2.4, 2.4, 2.4, 2.4], "interpolation": "stage", "incomingDensity": 2.4, "incomingGsm": null}, "b": {"speeds": [10, 15], "gaps": [90, 70, 50, 40, 30], "lengths": [null, null, null, null, null], "passes": [{"left": 12.0, "right": 18.0, "gap": 90.0, "length": null}, {"left": 12.0, "right": 18.0, "gap": 90.0, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}, {"left": 12, "right": 18, "gap": 90, "length": null}], "measuredGsm": [null, null, null, null, null, null, null, null, null, null, null, null], "densities": [2.31, 2.3, 2.4, 2.4, 2.4, 2.4, 2.4, 2.4, 2.4, 2.4, 2.4, 2.4], "interpolation": "stage", "incomingDensity": 2.4, "incomingGsm": null}}}, "settings": {"density": 2.4, "diameterMm": 200.0, "foilUm": 16.0}, "layout": {"mode": "single", "count": 2, "selected": 2, "directions": ["lr", "rl", "lr", "rl", "lr", "rl", "lr", "rl", "lr", "rl", "lr", "rl"]}}; const modes = { two: {name: "2R · Repeated passes", rollers: 2, description: "One physical nip, used repeatedly. Set each pass independently; the default direction alternates left → right, then right → left."}, single: {name: "6R single sided", rollers: 6, description: "Powder enters nip 1. The film follows the rollers through nips 2–4, then meets the foil at nip 5 to form a single-sided electrode."}, double: {name: "6R double sided", rollers: 6, description: "Powder enters nips 1 and 5. Two films follow mirrored routes through nips 2 and 4, then meet the foil at nip 3 to coat both sides."} }; function defaults(mode, b = false) { return { speeds: mode === "two" ? [10, 15] : (b ? [12,18,24,30,36,42] : [10,15,20,25,30,35]), gaps: b ? [90,70,50,40,30] : [100,80,60,50,40], lengths: b ? [11,10.5,9.5,8.5,7.5] : [12,11.5,10,9,8], passes: Array.from({length:12}, (_, i) => ({left: b ? 12 : 10, right: b ? 18 : 15, gap: b ? 90 : 100, length: b ? 11 : 12, direction: i % 2 ? "rl" : "lr"})) }; } function nipCalculation(left, right, gapUm, contactMm) { if (![left,right,gapUm].every(Number.isFinite) || left < 0 || right < 0 || gapUm <= 0 || left + right <= 0) { return {valid:false, shearRate:NaN, residenceTime:NaN, shearStrain:NaN}; } const deltaU = Math.abs(right - left) / 60; const meanU = (left + right) / 120; const shearRate = deltaU / (gapUm * 1e-6); const residenceTime = Number.isFinite(contactMm) && contactMm >= 0 ? contactMm * 1e-3 / meanU : NaN; return {valid:Number.isFinite(residenceTime), shearRate, residenceTime, shearStrain:shearRate * residenceTime}; } function stages(mode, count = 2) { if (mode === "two") return Array.from({length:count}, (_, i) => ({index:i, name:`Pass ${i+1}`, role: i === 0 ? "Film formation / first pass" : "Film re-pass", branch:"Repeated passes"})); const roles = mode === "single" ? ["Powder → film", "Film working", "Film working", "Film working", "Film + foil → electrode"] : ["Left powder → film", "Left film working", "Two films + foil → electrode", "Right film working", "Right powder → film"]; return (mode === "double" ? [0,1,4,3,2] : [0,1,2,3,4]).map(index => ({index, name:`Nip ${index+1}`, role:roles[index], branch:mode === "double" ? (index < 2 ? "Left film" : index > 2 ? "Right film" : "Lamination") : "Single film"})); } function results(mode, state, count) { return stages(mode,count).map(stage => { const p = state.passes[stage.index]; return {...stage, ...nipCalculation(...(mode === "two" ? [p.left,p.right,p.gap,p.length] : [state.speeds[stage.index],state.speeds[stage.index+1],state.gaps[stage.index],state.lengths[stage.index]]))}; }); } // Loading is dry film mass per area in g/m², excluding foil. function fitLine(points) { const clean = points.filter(p=>Number.isFinite(p.gap) && p.gap>0 && Number.isFinite(p.gsm) && p.gsm>0); if(clean.length<2) return {ok:false,reason:"Add at least two valid points at different gaps."}; const n=clean.length, x=clean.reduce((s,p)=>s+p.gap,0)/n, y=clean.reduce((s,p)=>s+p.gsm,0)/n; const xx=clean.reduce((s,p)=>s+(p.gap-x)**2,0); if(xx===0) return {ok:false,reason:"Use at least two different set gaps."}; const slope=clean.reduce((s,p)=>s+(p.gap-x)*(p.gsm-y),0)/xx, intercept=y-slope*x; const residual=clean.reduce((s,p)=>s+(p.gsm-(slope*p.gap+intercept))**2,0), total=clean.reduce((s,p)=>s+(p.gsm-y)**2,0); return {ok:true,slope,intercept,n,r2:total>0 ? 1-residual/total : null,min:Math.min(...clean.map(p=>p.gap)),max:Math.max(...clean.map(p=>p.gap)),twoPoint:n===2}; } function calibrationModel(c) { if(c.method!=="equation") return fitLine(c.points); if(!Number.isFinite(c.slope)||!Number.isFinite(c.intercept)) return {ok:false,reason:"Enter slope and intercept."}; if ((c.min!==null&&c.min!==undefined&&(!Number.isFinite(c.min)||c.min<=0)) || (c.max!==null&&c.max!==undefined&&(!Number.isFinite(c.max)||c.max<=0)) || (Number.isFinite(c.min)&&Number.isFinite(c.max)&&c.max0&&c.max>=c.min; return {ok:true,slope:c.slope,intercept:c.intercept,n:null,r2:null,min:range?c.min:null,max:range?c.max:null}; } function predictLoading(c,gap,measured=null) { if(measured!==null && measured!==undefined) { if(!Number.isFinite(measured)||measured<=0)return {ok:false,value:NaN,source:"Invalid measured loading"}; return {ok:true,value:measured,source:"Measured",extrapolated:false}; } // A single measurement is usable at its recorded gap, but does not define a gap-response curve. if(c.method!=="equation") { const exact=c.points.filter(p=>Number.isFinite(p.gap)&&p.gap>0&&Number.isFinite(p.gsm)&&p.gsm>0&&Math.abs(p.gap-gap)<1e-9); if(exact.length)return {ok:true,value:exact.reduce((sum,p)=>sum+p.gsm,0)/exact.length,source:"Calibration measurement",extrapolated:false}; } const m=calibrationModel(c); if(!m.ok || !Number.isFinite(gap) || gap<=0) return {ok:false,value:NaN,source:"Uncalibrated"}; const value=m.slope*gap+m.intercept; if(value<=0||!Number.isFinite(value)) return {ok:false,value:NaN,source:"Non-positive prediction"}; return {ok:true,value,source:m.n===2 ? "Two-point fit" : m.n ? "Regression" : "Entered equation",extrapolated:m.min!==null&&(gapm.max),rangeUnknown:m.min===null}; } function geometricContact(diameterMm,incomingUm,gapUm) { if(![diameterMm,incomingUm,gapUm].every(Number.isFinite)||diameterMm<=0||incomingUm<=0||gapUm<=0) return {ok:false,length:NaN,reason:"Missing or invalid geometry input"}; const reduction=(incomingUm-gapUm)/1000, radius=diameterMm/2; if(reduction<=0) return {ok:false,length:NaN,reason:"Incoming stack is no thicker than the gap"}; if(reduction>=2*radius) return {ok:false,length:NaN,reason:"Reduction is outside the rolling-geometry model"}; return {ok:true,length:Math.sqrt(radius*reduction-reduction*reduction/4),reason:""}; } // Fill only between original available anchors; never recursively promote estimates to anchors. function interpolateLoadings(loadings,gaps,method="gap") { const anchors=loadings.map((l,i)=>l.ok?i:null).filter(i=>i!==null); return loadings.map((load,i)=>{ if(load.ok||method==="none"||load.source!=="Uncalibrated")return load; const left=anchors.filter(j=>jj>i); if(left===undefined||right===undefined)return load; const x=method==="stage"?i:gaps[i], a=method==="stage"?left:gaps[left], b=method==="stage"?right:gaps[right]; if(![x,a,b].every(Number.isFinite)||a===b)return {...load,source:"Interpolation unavailable: equal or invalid anchor gaps"}; const fraction=(x-a)/(b-a); if(fraction<0||fraction>1)return {...load,source:"Gap outside neighbouring anchors; not interpolated"}; const value=loadings[left].value+(loadings[right].value-loadings[left].value)*fraction; if(!Number.isFinite(value)||value<=0)return load; return {ok:true,value,source:`Interpolated by ${method==="stage"?"nip position":"set gap"} · nips ${left+1}–${right+1}`,interpolated:true,anchors:[left,right],extrapolated:!!(loadings[left].extrapolated||loadings[right].extrapolated)}; }); } function singleSidedEstimates(state,profile,settings) { const base=state.gaps.map((g,i)=>predictLoading(profile.nips[i],g,state.measuredGsm?.[i])); const loading=interpolateLoadings(base,state.gaps,profile.interpolation??"gap"); const densityAt=i=>profile.densities?.[i]??settings.density; return loading.map((load,i)=>{ const outputDensity=densityAt(i); const outgoingUm=load.ok&&Number.isFinite(outputDensity)&&outputDensity>=2.2&&outputDensity<=2.6?load.value/outputDensity:NaN; const common={loading:load,outgoingUm,outputDensity}; if(i===0)return {...common,incomingUm:NaN,contact:NaN,min:NaN,max:NaN,reason:"Powder feed: use a manual contact length"}; const upstream=loading[i-1],density=densityAt(i-1),foil=i===4?settings.foilUm:0; if(!upstream.ok)return {...common,incomingUm:NaN,contact:NaN,min:NaN,max:NaN,reason:`Need loading after nip ${i}`}; if(!Number.isFinite(density)||density<2.2||density>2.6||!Number.isFinite(foil)||foil<0)return {...common,incomingUm:NaN,contact:NaN,min:NaN,max:NaN,reason:"Check upstream density and foil thickness"}; // Upstream film density follows that film into the next nip. const incomingUm=upstream.value/density+foil; const contact=geometricContact(settings.diameterMm,incomingUm,state.gaps[i]); const low=geometricContact(settings.diameterMm,upstream.value/2.6+foil,state.gaps[i]); const high=geometricContact(settings.diameterMm,upstream.value/2.2+foil,state.gaps[i]); return {...common,incomingUm,inputDensity:density,contact:contact.length,min:low.length,max:high.length,reason:contact.reason,upstream,rangePartial:!low.ok||!high.ok}; }); } function blankProfile(name="Material 1") { return {name,interpolation:"gap",densities:Array(5).fill(2.4),nips:Array.from({length:5},()=>({method:"points",points:[{gap:null,gsm:null},{gap:null,gsm:null}],slope:null,intercept:null,min:null,max:null}))}; } function operationModel(mode,state,settings,count=2) { const rows=stages(mode,count); let estimates; if(mode==='single') { estimates=singleSidedEstimates(state,{...blankProfile(),densities:state.densities,interpolation:state.interpolation},settings); estimates[0].reason='Powder entry: compaction model needed'; } else { const size=mode==='two'?count:5; const gaps=mode==='two'?state.passes.slice(0,count).map(p=>p.gap):state.gaps; const base=Array.from({length:size},(_,i)=>{ const value=state.measuredGsm[i]; return Number.isFinite(value)&&value>0?{ok:true,value,source:'Measured'}:{ok:false,value:NaN,source:value===null||value===undefined?'Uncalibrated':'Invalid measured loading'}; }); const loads=mode==='two'?interpolateLoadings(base,gaps,state.interpolation):base; if(mode==='double'&&!loads[2].ok&&loads[2].source==='Uncalibrated'&&loads[1].ok&&loads[3].ok)loads[2]={ok:true,value:loads[1].value+loads[3].value,source:'Two film loadings combined'}; estimates=loads.map((loading,i)=>{ const density=state.densities[i]; const outgoingUm=loading.ok&&Number.isFinite(density)&&density>0?loading.value/density:NaN; let incomingUm=NaN,reason='Need upstream film loading and density'; if(mode==='two') { const value=i===0?state.incomingGsm:loads[i-1].value; const rho=i===0?state.incomingDensity:state.densities[i-1]; if(Number.isFinite(value)&&value>0&&Number.isFinite(rho)&&rho>0)incomingUm=value/rho; } else if(i===0||i===4)reason='Powder entry: compaction model needed'; else if(i===2) { if(loads[1].ok&&loads[3].ok&&state.densities[1]>0&&state.densities[3]>0&&Number.isFinite(settings.foilUm)&&settings.foilUm>=0)incomingUm=loads[1].value/state.densities[1]+loads[3].value/state.densities[3]+settings.foilUm; else reason='Need both incoming films and foil thickness'; } else { const upstream=i===1?0:4; if(loads[upstream].ok&&state.densities[upstream]>0)incomingUm=loads[upstream].value/state.densities[upstream]; } const geometric=geometricContact(settings.diameterMm,incomingUm,gaps[i]); return {loading,outgoingUm,incomingUm,contact:geometric.length,reason:Number.isFinite(incomingUm)?geometric.reason:reason}; }); } const results=rows.map(row=>{ const i=row.index,e=estimates[i],p=state.passes[i]; const calc=mode==='two'?nipCalculation(p.left,p.right,p.gap,e.contact):nipCalculation(state.speeds[i],state.speeds[i+1],state.gaps[i],e.contact); return {...row,...calc,contact:e.contact,reason:e.reason}; }); return {estimates,results}; } function calibrationStore() { const store={profiles:[blankProfile("Imported dashboard")],active:0,settings:{...notebookInitialState.settings}}; try {const saved=JSON.parse(localStorage.getItem("rolling-notebook-machine-v1")||"null");if(saved)store.settings={...store.settings,...saved};}catch{} store.save=()=>{try{localStorage.setItem("rolling-notebook-machine-v1",JSON.stringify(store.settings));}catch{}}; return store; } const css = `.rolling-app{padding:14px;background:#f4f6f5;width:calc(100vw - 110px);max-width:1800px;position:relative;left:50%;transform:translateX(-50%);} .rolling-app{--ink:#243b35;--muted:#697b74;--line:#d9e1dc;--green:#176d58;--blue:#4e69ad;color:var(--ink);font:13px/1.4 system-ui,sans-serif;max-width:1800px;margin:auto} .rolling-app *{box-sizing:border-box}.rolling-app :is(h1,h2,h3,h4,p){max-width:none;color:inherit}.rolling-app h1{font-size:26px;letter-spacing:-.7px;line-height:1.2;margin:0 0 4px}.rolling-app h2{font-size:16px;margin:0 0 12px}.rolling-app h3{font-size:13px;margin:15px 0 9px}.rolling-app h4{font-size:11px;letter-spacing:.15px;margin:14px 0 7px}.rolling-app p{margin:6px 0 10px}.rolling-app .subtitle{color:var(--muted);font-size:12px;margin:0}.rolling-app .micro,.rolling-app .caption{font-size:10px;color:var(--muted);line-height:1.45}.rolling-app .caption{margin:4px 0}.rolling-app .dashboard-header{display:flex;justify-content:space-between;align-items:center;gap:20px;background:white;border:1px solid var(--line);border-radius:10px;padding:16px 20px;margin-bottom:14px}.rolling-app .header-controls{display:flex;gap:12px;align-items:end}.rolling-app label{font-size:11px;font-weight:600;display:block}.rolling-app :is(input,select,button){font:inherit;color:var(--ink);border:1px solid #bdccc3;border-radius:5px;background:white;padding:5px 7px;max-width:100%}.rolling-app input{font-variant-numeric:tabular-nums;min-width:0;width:100%}.rolling-app input:invalid{border-color:#b27660;background:#fff7f2}.rolling-app input::placeholder{font-size:10px;color:#85968f}.rolling-app select{width:100%;min-width:0}.rolling-app .header-controls select{margin-top:4px;min-width:180px}.rolling-app .header-controls label:last-child:not(:first-child) select{min-width:60px}.rolling-app button{font-size:10px;cursor:pointer}.rolling-app :is(input,select,button):focus-visible{outline:3px solid #6caf9470;outline-offset:1px}.rolling-app .workspace{display:grid;grid-template-columns:minmax(370px,420px) minmax(0,1fr);gap:14px;align-items:start}.rolling-app .input-sidebar{background:#fff;border:1px solid var(--line);border-radius:10px;padding:12px;position:sticky;top:10px;max-height:calc(100vh - 22px);overflow:auto}.rolling-app .section-head{display:flex;align-items:center;justify-content:space-between;gap:10px;margin-bottom:10px}.rolling-app .section-head h2{margin:0}.rolling-app .section-head select{width:auto;min-width:90px;font-size:11px}.rolling-app .scenario-columns{display:grid;grid-template-columns:1fr 1fr;gap:10px}.rolling-app .scenario{min-width:0;border:1px solid var(--line);border-top:3px solid var(--green);border-radius:6px;padding:8px;background:#fafcfb}.rolling-app .scenario.b{border-top-color:var(--blue)}.rolling-app .scenario>h3{font-size:15px;margin:0 0 10px;padding-bottom:8px;border-bottom:1px solid var(--line)}.rolling-app .compact-field{display:grid;grid-template-columns:minmax(0,1fr) 68px;align-items:center;gap:6px;margin-bottom:5px;font-size:11px}.rolling-app .compact-field input{font-size:12px;padding:4px 6px;height:28px}.rolling-app .shared-constants{border:1px solid var(--line);border-radius:6px;padding:10px;margin-top:10px;background:#f7f9f8}.rolling-app .shared-constants h3{margin:0 0 10px}.rolling-app .shared-constants .compact-field{grid-template-columns:1fr 130px}.rolling-app .input-table{width:100%!important;display:table!important;table-layout:fixed;border-collapse:collapse;margin:0;font-size:10px}.rolling-app .input-table th:first-child{width:20px}.rolling-app .input-table :is(td,th){padding:4px 2px;border-bottom:1px solid #e3eae5;text-align:center;white-space:normal}.rolling-app .input-table input[type=number]{width:100%;height:29px;padding:4px 2px;text-align:center;font-size:11px;-moz-appearance:textfield}.rolling-app .input-table input[type=number]::-webkit-inner-spin-button{appearance:none}.rolling-app .density-control span{display:block;font-size:10px;color:var(--green);font-weight:700}.rolling-app .density-control 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.legend{display:flex;gap:15px;font-size:10px;color:var(--muted);margin-bottom:8px}.rolling-app .legend span:before{content:'';width:13px;height:7px;background:var(--green);display:inline-block;margin-right:5px}.rolling-app .legend .right:before{background:var(--blue)}.rolling-app .model-notice{font-size:10px;color:#736449;background:#faf7ed;border:1px solid #e8dfc7;border-radius:7px;padding:9px 12px;margin:0 0 12px}.rolling-app .loading-comparison{display:grid;grid-template-columns:1fr 1fr;gap:12px}.rolling-app .loading-card{min-width:0;background:#fafcfb;border:1px solid var(--line);border-radius:7px;padding:10px}.rolling-app .loading-card h3{margin:0 0 6px}.rolling-app .loading-profile-chart{display:block;width:100%;max-height:190px}.rolling-app .loading-profile-chart text{font:11px system-ui;fill:#697b74}.rolling-app .scroll{overflow-x:auto}.rolling-app details summary{font-weight:650;cursor:pointer}.rolling-app .documentation{font-size:11px}.rolling-app .documentation p{margin-top:12px} @media(max-width:1100px){.rolling-app .workspace{grid-template-columns:350px minmax(0,1fr)}.rolling-app .input-sidebar{padding:9px}.rolling-app .scenario-columns{gap:7px}.rolling-app .scenario{padding:6px}.rolling-app .pair strong{font-size:17px}.rolling-app .metrics{gap:5px}.rolling-app .metric{padding:8px}.rolling-app .charts{grid-template-columns:1fr}.rolling-app .chart{max-height:200px}.rolling-app .loading-comparison{grid-template-columns:1fr}} @media(max-width:850px){#observablehq-main{padding:10px}.rolling-app .workspace{grid-template-columns:1fr}.rolling-app .input-sidebar{position:static;max-height:none}.rolling-app .dashboard-header{align-items:start;flex-direction:column;padding:14px}.rolling-app .header-controls{width:100%}.rolling-app .header-controls>label{flex:1}.rolling-app .header-controls select{min-width:0}.rolling-app .compact-field{grid-template-columns:1fr 90px}.rolling-app .charts{grid-template-columns:repeat(3,minmax(0,1fr))}.rolling-app .loading-comparison{grid-template-columns:1fr 1fr}.rolling-app .pair strong{font-size:20px}} @media(max-width:500px){.rolling-app .metrics{grid-template-columns:1fr}.rolling-app .charts,.rolling-app .loading-comparison{grid-template-columns:1fr}.rolling-app .scenario-columns{gap:7px}.rolling-app .compact-field{grid-template-columns:1fr 65px}} `; const fmt = (n, digits = 4) => Number.isFinite(n) ? n.toLocaleString("en-GB", {maximumSignificantDigits:digits}) : "—"; const metricDefs = [["shearRate","Nominal shear rate","s⁻¹"],["residenceTime","Residence time","s"],["shearStrain","Shear strain","–"]]; function numberInput(value, label, min = 0, step = "any") { const input = document.createElement("input"); input.type = "number"; input.value = Number.isFinite(value) ? value : ""; input.min = min; input.step = step; input.required = true; input.setAttribute("aria-label",label); return input; } function element(tag, text, className) { const e = document.createElement(tag); if (text !== undefined) e.textContent = text; if (className) e.className = className; return e; } function processDiagram(mode, pass, directions, id) { const two = mode === "two", double = mode === "double"; const centers = two ? [392.5,562.5] : [115,260,405,550,695,840]; const r = two ? 82 : 64, y = 155; let svg = ``; } function chart(rowsA,rowsB,key,label,unit) { const box = element("div"); box.append(element("h3",`${label} (${unit})`)); const max = Math.max(0,...rowsA.concat(rowsB).map(r=>r[key]).filter(Number.isFinite)); const scale = max > 0 ? max * 1.15 : 1; const w = Math.max(320,rowsA.length * 62 + 64), h = 220, left=53, top=15, base=180, step=(w-left-12)/rowsA.length; let svg = ``); return box; } function loadingChart(estimates,gaps,method) { const div=element("div"); const data=estimates.map((e,i)=>({...e.loading,i,x:method==="stage"?i+1:gaps[i]})).filter(d=>d.ok&&Number.isFinite(d.x)&&d.x>0); if(!data.length){div.append(element("p","Enter loadings to display the connected loading profile.","route"));return div;} const xMin=Math.min(...data.map(d=>d.x)),xMax=Math.max(...data.map(d=>d.x)),yMin=Math.min(...data.map(d=>d.value)),yMax=Math.max(...data.map(d=>d.value)); const x=v=>48+(v-xMin)/(xMax-xMin||1)*350,y=v=>165-(v-yMin)/(yMax-yMin||1)*125; let svg=``; div.innerHTML=svg;div.append(element("p","Solid points: entered measurements. Hollow points / dashed segments: interpolation between known nips. No points beyond the anchors are inferred.","caption"));return div; } let instance=0; function createDashboard() { const root=element('div',undefined,'rolling-app'); const style=element('style',css);root.append(style); const id=`rolling-${++instance}`,store=calibrationStore(); const cache=structuredClone(notebookInitialState.scenarios); try{const saved=JSON.parse(localStorage.getItem('rolling-notebook-scenarios-v1')||'null');for(const m of Object.keys(modes))for(const w of ['a','b'])if(saved?.[m]?.[w]&&Array.isArray(saved[m][w].speeds)&&Array.isArray(saved[m][w].passes))cache[m][w]={...cache[m][w],...saved[m][w]};}catch{} for(const m of Object.keys(modes))for(const w of ['a','b']) { const s=cache[m][w],n=m==='two'?12:5; s.measuredGsm=Array.from({length:n},(_,i)=>s.measuredGsm?.[i]??null); s.densities=Array.from({length:n},(_,i)=>s.densities?.[i]??store.profiles[store.active].densities[i%5]); s.interpolation||=store.profiles[store.active].interpolation; s.incomingDensity??=2.4; } let {mode,count,selected}=notebookInitialState.layout;let directions=[...notebookInitialState.layout.directions]; try{const ui=JSON.parse(localStorage.getItem('rolling-notebook-layout-v1')||'null');if(ui&&modes[ui.mode]){mode=ui.mode;count=Math.min(12,Math.max(1,ui.count||2));selected=ui.selected||0;if(Array.isArray(ui.directions)&&ui.directions.length===12)directions=ui.directions;}}catch{} let output,diagram,notice,loadPlots; const persist=()=>{try{localStorage.setItem('rolling-notebook-scenarios-v1',JSON.stringify(cache));localStorage.setItem('rolling-notebook-layout-v1',JSON.stringify({mode,count,selected,directions}));}catch{}}; function num(value,label,change,{min=0,max,step='any',optional=false}={}) { const input=numberInput(value,label,min,step);input.required=!optional;if(max!==undefined)input.max=max; input.addEventListener('input',()=>{change(input.value===''?null:input.valueAsNumber);refresh();});return input; } function choice(value,label,options,change) { const input=element('select');input.setAttribute('aria-label',label); for(const [v,t]of options){const o=element('option',t);o.value=v;input.append(o);}input.value=value; input.addEventListener('change',()=>change(input.value));return input; } function rowInput(parent,label,input) {const row=element('label',undefined,'compact-field');row.append(element('span',label),input);parent.append(row);} function densityControl(state,i,name) { const cell=element('div',undefined,'density-control'),value=element('span',state.densities[i].toFixed(2)); const slider=element('input');slider.type='range';slider.min='2.2';slider.max='2.6';slider.step='0.01';slider.value=state.densities[i];slider.setAttribute('aria-label',`${name} film density after ${mode==='two'?'pass':'nip'} ${i+1} (g/cm³)`); slider.addEventListener('input',()=>{state.densities[i]=slider.valueAsNumber;value.textContent=slider.valueAsNumber.toFixed(2);refresh();});cell.append(value,slider);return cell; } function scenario(which) { const state=cache[mode][which],name=`Scenario ${which.toUpperCase()}`,panel=element('section',undefined,`scenario ${which}`); panel.append(element('h3',name)); if(mode!=='two') { panel.append(element('h4','Surface speeds · m/min')); state.speeds.forEach((v,i)=>rowInput(panel,`Roller ${i+1}`,num(v,`${name} roller ${i+1} speed (m/min)`,n=>state.speeds[i]=n))); } else { panel.append(element('h4','Incoming film · first pass')); rowInput(panel,'Loading · gsm',num(state.incomingGsm,`${name} first-pass incoming film loading (gsm)`,n=>state.incomingGsm=n,{min:0.001,optional:true})); rowInput(panel,'Density · g/cm³',num(state.incomingDensity,`${name} first-pass incoming film density (g/cm³)`,n=>state.incomingDensity=n,{min:2.2,max:2.6,step:0.01})); } panel.append(element('h4',mode==='two'?'Pass conditions':'Nips · film-only loading')); const table=element('table',undefined,'input-table');table.innerHTML=`${mode==='two'?'Pass':'Nip'}µmgsmg/cm³`; const tb=element('tbody'); const stageRows=stages(mode,count).sort((a,b)=>a.index-b.index); for(const stage of stageRows) { const i=stage.index,tr=element('tr');tr.append(element('td',i+1)); const gap=element('td');gap.append(num(mode==='two'?state.passes[i].gap:state.gaps[i],`${name} ${stage.name} gap (µm)`,n=>{if(mode==='two')state.passes[i].gap=n;else state.gaps[i]=n;},{min:0.001})); const gsm=element('td'),input=num(state.measuredGsm[i],`${name} ${stage.name} measured loading (gsm)`,n=>state.measuredGsm[i]=n,{min:0.001,optional:true});input.placeholder='Auto';gsm.append(input); const rho=element('td');rho.append(densityControl(state,i,name));tr.append(gap,gsm,rho);tb.append(tr); if(mode==='two') { const extra=element('tr'),td=element('td');td.colSpan=4;const pair=element('div',undefined,'pass-speeds'); for(const [key,label]of [['left','Left'],['right','Right']])rowInput(pair,label,num(state.passes[i][key],`${name} ${stage.name} ${key} roller speed (m/min)`,n=>state.passes[i][key]=n));td.append(pair);extra.append(td);tb.append(extra); } } table.append(tb);panel.append(table); if(mode!=='double') { panel.append(element('h4','Connect missing loadings')); panel.append(choice(state.interpolation,`${name} missing loading interpolation`,[['gap','By set gap'],['stage',mode==='two'?'By pass position':'By nip position'],['none','No interpolation']],v=>{state.interpolation=v;refresh();})); } const note=element('p','Blank gsm values are estimated only between known points. Density is for the film leaving each step.','micro'); if(mode==='double')note.textContent='Enter each branch’s film loading. Nip 3 combines both incoming films; the branches are not interpolated across each other.'; panel.append(note);return panel; } function refresh() { const models={a:operationModel(mode,cache[mode].a,store.settings,count),b:operationModel(mode,cache[mode].b,store.settings,count)}; persist(); diagram.innerHTML=processDiagram(mode,mode==='two'?Math.min(selected,count-1):selected,directions,id); output.replaceChildren(); const rows=models.a.results;if(!rows.some(r=>r.index===selected))selected=rows[0].index; const head=element('div',undefined,'section-head');head.append(element('h2','Key outputs · comparison')); head.append(choice(selected,'Inspect nip or pass',rows.map(r=>[r.index,r.name]),v=>{selected=+v;refresh();}));output.append(head); const metrics=element('div',undefined,'metrics'); for(const[key,title,unit]of metricDefs) { const card=element('div',undefined,'metric');card.append(element('h3',`${title} · ${unit}`));const pair=element('div',undefined,'pair'); for(const w of ['a','b']){const cell=element('div'),r=models[w].results.find(r=>r.index===selected);cell.append(element('small',`Scenario ${w.toUpperCase()}`),element('strong',fmt(r[key])));pair.append(cell);}card.append(pair);metrics.append(card); }output.append(metrics); const invalid=Object.values(models).flatMap(m=>m.results).filter(r=>!Number.isFinite(r.contact)); notice.textContent=invalid.length?'— means the contact model has insufficient inputs or predicts no compression. Powder-entry contact needs a separate compaction model; nominal shear rate is still shown.':'Contact length is calculated from incoming film thickness, roller diameter and nip gap. Foil is included at lamination.'; const table=element('table',undefined,'result-table');table.innerHTML=`${mode==='two'?'Pass':'Nip'}Shear A
s⁻¹Shear B
s⁻¹Time A
sTime B
sStrain AStrain B`; const tb=element('tbody');rows.forEach((a,i)=>{const tr=element('tr');if(a.index===selected)tr.className='selected-row';const label=element('td',a.name);label.title=a.role;tr.append(label);for(const key of ['shearRate','residenceTime','shearStrain'])for(const r of [a,models.b.results[i]]){const td=element('td',fmt(r[key]));td.title=r.reason||'Calculated';tr.append(td);}tb.append(tr);});table.append(tb);const wrap=element('div',undefined,'scroll');wrap.append(table);output.append(element('h3','Nip-by-nip comparison'),wrap); const plots=element('div',undefined,'charts');for(const def of metricDefs)plots.append(chart(models.a.results,models.b.results,...def)); const legend=element('div',undefined,'legend');legend.innerHTML='Scenario AScenario B';output.append(element('h3','Comparison visualisations'),legend,plots); const loading=element('div',undefined,'loading-comparison'); for(const w of ['a','b']) { const section=element('section',undefined,'loading-card');section.append(element('h3',`Scenario ${w.toUpperCase()} · film loading`)); const state=cache[mode][w],gaps=mode==='two'?state.passes.slice(0,count).map(p=>p.gap):state.gaps; section.append(loadingChart(models[w].estimates,gaps,state.interpolation));loading.append(section); }loadPlots.replaceChildren(loading); const detailTable=element('table',undefined,'result-table');detailTable.innerHTML='StepGSM AGSM BFilm A
µmFilm B
µmContact A
mmContact B
mm'; const detailBody=element('tbody');for(const row of rows){const tr=element('tr');tr.append(element('td',row.name));for(const key of ['loading','outgoingUm','contact'])for(const w of ['a','b']){const e=models[w].estimates[row.index],td=element('td',fmt(key==='loading'?e.loading.value:e[key]));td.title=key==='loading'?e.loading.source:e.reason||'Calculated from selected film density';tr.append(td);}detailBody.append(tr);}detailTable.append(detailBody);const detailWrap=element('div',undefined,'scroll');detailWrap.append(detailTable);loadPlots.append(element('h3','Calculated film thickness & contact length'),detailWrap); } function render() { root.replaceChildren(style); const header=element('header',undefined,'dashboard-header'),title=element('div');title.append(element('h1','Rolling Process Dashboard'),element('p','Compare roller settings, film loading and calculated shear exposure.','subtitle')); const controls=element('div',undefined,'header-controls'),label=element('label','Rolling operation');label.append(choice(mode,'Rolling operation',Object.entries(modes).map(([v,m])=>[v,m.name]),v=>{mode=v;selected=v==='two'?0:2;render();}));controls.append(label); if(mode==='two') { const label=element('label','Passes');label.append(choice(count,'Number of passes',Array.from({length:12},(_,i)=>[i+1,i+1]),v=>{count=+v;selected=Math.min(selected,count-1);render();}));controls.append(label); }header.append(title,controls);root.append(header); const workspace=element('div',undefined,'workspace'),aside=element('aside',undefined,'input-sidebar'),inputHead=element('div',undefined,'section-head');inputHead.append(element('h2','Inputs')); const reset=element('button','Reset operation');reset.addEventListener('click',()=>{cache[mode]={a:defaults(mode),b:defaults(mode,true)};for(const w of ['a','b']){const s=cache[mode][w];s.measuredGsm=Array(mode==='two'?12:5).fill(null);s.densities=Array(mode==='two'?12:5).fill(2.4);s.interpolation='stage';s.incomingDensity=2.4;}render();});inputHead.append(reset);aside.append(inputHead); const columns=element('div',undefined,'scenario-columns');columns.append(scenario('a'),scenario('b'));aside.append(columns); const shared=element('section',undefined,'shared-constants');shared.append(element('h3','Machine constants · shared')); for(const[key,label,min]of [['diameterMm','Roller diameter · mm',0.001],['foilUm','Foil thickness · µm',0]])rowInput(shared,label,num(store.settings[key],label,n=>{store.settings[key]=n;store.save();},{min})); if(mode==='two') { const detail=element('details');detail.append(element('summary','Pass transfer directions')); for(let i=0;i{directions[i]=v;refresh();}));shared.append(detail); } shared.append(element('p','Density is assumed within 2.2–2.6 g/cm³. Your inputs save in this browser.','micro'));aside.append(shared); const main=element('main',undefined,'dashboard-main'),process=element('section',undefined,'panel process-panel');process.append(element('h2',modes[mode].name));diagram=element('div',undefined,'diagram-wrap');process.append(diagram,element('p',modes[mode].description,'micro'));main.append(process); output=element('section',undefined,'panel comparison-panel');main.append(output);notice=element('p',undefined,'model-notice');main.append(notice); const loadingPanel=element('section',undefined,'panel');loadingPanel.append(element('h2','Film loading & calculated contact'));loadPlots=element('div');loadingPanel.append(loadPlots);main.append(loadingPanel); const help=element('details',undefined,'panel documentation');help.innerHTML='

Equations & model assumptions

Film thickness (µm) = film-only loading (gsm) / film density (g/cm³). Contact length = √[R Δh − Δh²/4], with radius R and thickness reduction Δh in mm. Contact length refers to the compression zone, not the wrap around the roller.

Nominal shear rate = |U₂ − U₁| / gap; residence time = calculated contact length / mean surface speed; shear strain = shear rate × residence time. Speeds convert from m/min to m/s.

Density after a nip determines the film thickness entering the next nip. Foil thickness is added at lamination. Set gap is used as an operating-gap approximation. Roll opening, springback and powder slip are not modelled. Contact length at powder entry is unavailable; no manual or default contact lengths are used.

Interpolated loadings are assumptions between measured anchors for the current run. A missing estimate is shown as —. In double-sided operation, nip 3 uses both incoming films plus foil. For 2R, supply incoming film loading and density to estimate contact in the first pass.

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