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# RollCalc Quick Reference
## 1. Before You Start
RollCalc is an engineering support tool for roll geometry, roll weight, and transport capacity assessment. It helps experienced technical users prepare and interpret calculations, but it does not replace production, handling, or shipping approval.
Before using a result operationally, check that the selected article, article data, manually entered values, and transport assumptions match the actual case. The calculated result is only meaningful if the input data is technically plausible.
Use this Quick Reference for the most common workflows. For background, detailed interpretation, and troubleshooting, use the full `User Manual`.
## 2. Which Function Should I Use?
| Task | Function / Calculation Mode |
| --- | --- |
| Calculate the diameter of a planned roll | `Direct Calculation` → `Roll Diameter` |
| Estimate product length from a measured roll | `Direct Calculation` → `Product Length` |
| Determine maximum permitted product length | `Direct Calculation` → `Target Diameter` |
| Estimate a new roll from a reference roll | `Extrapolation` |
| Assess transport capacity | `Load Optimizer` |
| Understand why a transport result is limited | `Capacity Summary` and `Capacity Analysis` |
| Visually check the geometric arrangement | `Front View – Cross-Section` |
## 3. Article Selection and Input Data
Use `Article Number (optional)` when an article is available in the article data. The current application can prefill available article values such as `Product Thickness`, tolerance data, `Area Weight`, and `Core Diameter` when these values are present in the data source.
Prefilled values are starting values, not approvals. The values currently visible in the input fields are decisive for the calculation. You can manually change the populated values before calculating.
Planned article-data extension: future article data may also provide a typical `Roll Width` for automatic prefilling. Do not assume `Roll Width` is currently populated by article selection unless it is visibly filled in the UI.
Check before calculation:
- `Product Category` and `Production Site` match the intended context.
- `Article Number (optional)` refers to the correct article.
- `Product Thickness` is plausible for the product.
- `Area Weight` is current and product-specific.
- `Core Diameter` matches the actual core.
- `Roll Width` is entered when `Calculated Weight` or `Load Optimizer` will be used.
## 4. Direct Calculation – Roll Diameter
Use `Direct Calculation` with `Calculation Mode` `Roll Diameter` when a planned `Product Length` is known and the expected outer roll size must be assessed.
### Required inputs
- `Core Diameter (d)`
- `Product Thickness (t)`
- `Product Length (L)`
### Optional weight inputs
- `Roll Width`
- `Area Weight`
### Main results
- `Roll Diameter (D)`
- tolerance range when tolerance is entered
- `Calculated Weight`, when `Roll Width`, `Area Weight`, and `Product Length` are available
- `Forklift Check`, where applicable
### Check before use
- Units: mm for diameters and thickness, m for length and width, g/m² for `Area Weight`, kg for weight.
- `Product Thickness` is plausible and belongs to the article.
- `Core Diameter` matches the actual core type.
- `Product Length` is realistic for the planned roll.
- `Calculated Weight` is plausible before using the result in `Forklift Check` or `Load Optimizer`.
## 5. Direct Calculation – Product Length
Use `Direct Calculation` with `Calculation Mode` `Product Length` when a roll has a measured `Roll Diameter` and the product length on the roll must be estimated.
### Required inputs
- `Core Diameter (d)`
- `Roll Diameter (D)`
- `Product Thickness (t)`
### Main result
- `Product Length (L)`
### Typical use
- measured roll
- stock check
- quality check
- comparison with a planned or nominal length
### Important caution
The accuracy depends directly on the measured `Roll Diameter` and the assumed `Product Thickness`. If either value is inaccurate or does not match the actual product, the calculated `Product Length` will be inaccurate as well.
## 6. Direct Calculation – Target Diameter
Use `Direct Calculation` with `Calculation Mode` `Target Diameter` to determine the maximum allowed `Product Length` for one roll under entered diameter and weight limits. This is a limit workflow for a single roll. It is not a transport optimization and does not answer how many rolls fit into a container or vehicle.
### Relevant inputs
- `Core Diameter (d)`
- `Product Thickness (t)`
- `Roll Width`
- `Area Weight`
- `Max. Roll Diameter`
- `Max. Roll Weight`
- `Minimum Product Length`
### Main results
- `Maximum Allowed Product Length`
- `Resulting Roll Diameter`
- `Resulting weight`
- `Minimum length`
- `Difference`
- `Limiting factor`
- diameter and weight utilization line
### Interpretation
| Result situation | Meaning |
| --- | --- |
| `Limiting factor: Diameter` | `Max. Roll Diameter` is reached before the weight limit. |
| `Limiting factor: Weight` | `Max. Roll Weight` is reached before the diameter limit. |
| `Limiting factor: Diameter + Weight` | Both limits are reached at the same practical length. |
| warning below `Minimum length` | The requested `Minimum Product Length` cannot be achieved under the entered limits. |
The result describes the maximum allowed single-roll layout under the entered limits. It is not automatically the best roll design.
## 7. Roll Weight and Forklift Check
`Roll Weight` depends on `Product Length`, `Roll Width`, and `Area Weight`. Similar `Roll Diameter` values can therefore produce very different roll weights if width, length, or material weight differ.
`Calculated Weight` is used as the practical roll weight for downstream assessment. It is relevant for handling, `Forklift Check`, `Max. Roll Weight` checks, and the `Load Optimizer`.
`Forklift Check` is a technical warning or handling indication. It may show messages such as `Forklift Check OK`, `Heavy Roll – Special Equipment Required`, or `Weight Limit Exceeded`. It is not an operational approval, prohibition, or safety release.
Check first if `Forklift Check` appears unexpected:
- `Calculated Weight`
- `Core Diameter`
- `Product Category`
- `Roll Width`
- `Area Weight`
- article data used for the calculation
## 8. Extrapolation
Use `Extrapolation` when a `Known Reference Roll` exists and a comparable roll with a changed length must be estimated.
### Use only when
- a known reference roll exists,
- the same article is used,
- `Core Diameter` is unchanged,
- material structure and `Product Thickness` are comparable,
- mainly `Product Length` changes.
### Required inputs
- `Core Diameter (d)`
- `Known Roll Diameter (D₀)`
- `Known Roll Length (L₀)`
- `New Roll Length (L₁)`
### Main result
- `Extrapolated Roll Diameter (D₁)`
- optional min/max range when `Tolerance (optional)` is entered
### Do not use when
- the article changes,
- `Product Thickness` changes,
- `Core Diameter` changes,
- reference data is uncertain,
- a full technical roll layout is required.
The quality of the result depends on the quality and comparability of the reference roll.
## 9. Load Optimizer
Use `Load Optimizer – Transport Capacity Calculator` after the roll has already been defined. The `Load Optimizer` evaluates an existing roll in a selected transport space. It does not redesign the roll and does not automatically select the best transport mode.
### Required roll data
- `Roll Diameter`
- `Roll Width`
- `Roll Weight`
These values are taken from the completed `Direct Calculation` workflow. Roll data must be plausible before the transport calculation is meaningful.
### Required transport data
- `Preset Transport Type:`
- or `Custom` with `Length (m)`, `Width (m)`, `Height (m)`, and `Max. Load (kg)`
- `Loading Clearances`
- `Side Wall Clearance (one side)`
- `Ceiling Clearance (top only)`
`Loading Clearances` reduce the effective loading space. They can change the number of rolls that fit geometrically and may change the `Governing Constraint`.
## 10. Reading the Transport Results
Read transport results in this order:
1. Read `Capacity Summary`.
2. Check `Total Rolls`.
3. Identify the `Governing Constraint`.
4. Review `Remaining Capacity`.
5. Check `Front View – Cross-Section`.
6. Use `Capacity Analysis` to understand the technical limit.
### Capacity Summary
`Capacity Summary` shows the actual transport result. It is divided into:
- `Governing Constraint`
- `Transport Result`
- `Remaining Capacity`
`Transport Result` includes `Total Rolls`, `Weight Utilization`, `Volume Utilization`, and the transported product area. Use these values together; a single utilization value does not explain the transport limit by itself.
Use this area first because it shows the result that can actually be reached under the entered assumptions.
### Governing Constraint
| Governing Constraint | Meaning |
| --- | --- |
| `Geometry` | No additional roll fits into the actual arrangement. Payload or volume may remain unused. |
| `Weight` | The permitted payload is reached before geometric capacity is exhausted. |
| `Volume` | The calculated transport volume is reached before another constraint becomes decisive. |
`Governing Constraint` is not a recommendation. It is the technical constraint that determines the final `Total Rolls`.
### Remaining Capacity
`Remaining Capacity` shows reserves after the actual loading result:
- `Remaining Payload`
- `Unused Payload`
- `Unused Volume`
Remaining values do not automatically mean that another roll fits. They must be read together with `Governing Constraint` and `Front View – Cross-Section`.
### Capacity Analysis
`Capacity Analysis` is a constraint analysis, not a list of alternative loading solutions. Its rows show theoretical capacity limits for:
- `Weight`
- `Volume`
- `Geometry`
The smallest applicable limit determines the actual `Total Rolls`. The governing row is marked with `→ Governing Constraint`.
The table columns are:
- `Constraint`
- `Max Rolls`
- `Total Weight`
- `Transported Area [m²]`
- `Payload Util. %` — indicates the percentage of the permitted payload that is used.
### Front View – Cross-Section
`Front View – Cross-Section` visualizes the actual geometric loading configuration. Use it to check whether the geometric arrangement is plausible, especially when `Geometry` is the `Governing Constraint`.
### Important interpretation rules
- `Remaining Payload` does not automatically mean that another roll fits.
- `Unused Volume` does not automatically mean that another roll fits.
- `Capacity Analysis` does not show alternative loading solutions.
- `Weight`, `Volume`, and `Geometry` are theoretical capacity limits.
- The smallest applicable limit determines the actual `Total Rolls`.
## 11. Final Plausibility Check
Before using a result for production, handling, or transport planning, check:
- [ ] Correct article selected
- [ ] `Product Thickness` checked
- [ ] `Area Weight` checked
- [ ] `Core Diameter` checked
- [ ] `Roll Width` checked
- [ ] `Product Length` or `Roll Diameter` checked
- [ ] `Roll Weight` plausible
- [ ] `Calculated Weight` plausible
- [ ] Transport dimensions correct
- [ ] `Max. Load (kg)` correct
- [ ] `Loading Clearances` realistic
- [ ] `Governing Constraint` understandable
- [ ] `Remaining Payload` and `Volume Utilization` plausible
- [ ] `Front View – Cross-Section` plausible
- [ ] Result compared with experience or a reference case
## 12. Common Problems
| Observation | Check first |
| --- | --- |
| `Roll Diameter` is unexpectedly high or low | `Product Thickness`, `Product Length`, `Core Diameter`, units |
| `Product Length` is much larger or smaller than expected | measured `Roll Diameter`, `Product Thickness`, `Core Diameter` |
| `Roll Weight` appears incorrect | `Product Length`, `Roll Width`, `Area Weight` |
| Similar `Roll Diameter` values have very different weights | `Roll Width`, `Area Weight`, `Product Length` |
| `Forklift Check` appears unexpected | `Calculated Weight`, `Core Diameter`, `Product Category`, article data |
| `Extrapolation` result appears implausible | `Known Roll Diameter (D₀)`, `Known Roll Length (L₀)`, `New Roll Length (L₁)`, comparability of both rolls |
| Fewer rolls fit than expected | roll data, `Loading Clearances`, transport dimensions, `Governing Constraint` |
| `Remaining Payload` is available but no additional roll fits | `Geometry`, `Front View – Cross-Section` |
| `Capacity Analysis` appears contradictory | governing row, `Capacity Summary`, `Remaining Capacity`, `Front View – Cross-Section` |
| Similar calculations produce different results | article data, roll geometry, transport data, `Loading Clearances` |
Recalculate completely after changes to article data, roll geometry, or transport parameters. Old results should not be interpreted after changing values such as `Product Thickness`, `Area Weight`, `Core Diameter`, `Roll Width`, `Max. Load (kg)`, or `Loading Clearances`.
## 13. Key Rule
> The calculated result is only as reliable as the entered article data, roll data, and transport assumptions. Always perform a technical plausibility check before operational use.