CROSS-REFERENCE TO RELATED APPLICATIONS The present application claims priority to U.S. Non-Provisional application Ser. No. 18/189,904 entitled Dual Position Automatic Winder and filed on Mar. 24, 2023, the content of which is hereby incorporated by reference herein in its entirety.
TECHNOLOGICAL FIELD The present application is generally directed to converting and printing machinery. Particularly, the present application relates to devices and systems for transferring webs of material to new cores for winding into rolls of material. More particularly, the present application relates to devices and systems for automatically transferring a running web to a new core without slowing or stopping the running web and with the running web consistently being wound the same way (e.g., with the same side consistently being wound either in our out).
BACKGROUND The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventor, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
Converting and printing machinery may include unwinds and winders. Unwinds are used to feed web to a converting process. Once the process is completed the product is typically wound into rolls at a winder. For continuous operation, it is often difficult to transfer the winding web from the roll being completed (e.g., a full roll) to a new core. Further complicating matters, and in some cases, it may be desired that the same side of the web is always facing in or, alternatively, always facing out on the completed roll. In some cases, this can affect further downstream processing of the web, which may require the web to be facing a particular direction.
Introducing a new core at the winder can be performed in several ways. In its most basic form, the running machine is stopped, the web is cut, the completed roll of wound web is removed from the machine, a new core is placed into the machine, the leading edge of the web that is still in the machine is attached to the new core and the machine is restarted. This method results in large production time losses. To address this, sometimes, multiple winder positions can be used avoiding the need to remove the completed roll or load a new core while winding is stopped, which helps reduce the stoppage time of the winder. Additionally, a device such as an accumulator may be located between the process and the winder and may be used to store the processed web while the winder is stopped for roll change, which allows stoppage of the winder without stoppage of the overall process. Nonetheless, all of these processes involve an operator performing the task of cutting the web and transferring the leading edge to the new core, which can be dangerous and labor intensive. Moreover, devices such as accumulators can take up significant floor space, they are expensive, they introduce multiple rollers into contact with the web increasing the risk of damaging it, they can result in issues in handling the web, and they do not lend themselves well to high-speed operations, where the amount of storage required can become impractical.
There are also systems available that allow for the automatic cutting and transferring of the web to a new core without the need for slowing or stopping the web. That is, the winding process as well as the production process may both continue when switching to a new winding roll. Surface winders can do this. However, surface winders involve a driven roller that is in contact with winding roll for the purpose of driving the winding roll. These systems can put significant stress on the web material as the winding roll of web is driven through the outer wraps which may preclude it from being used for certain products. Turret winders can also cut the web and transfer to a new core without stopping the process. Unlike surface winders, turret winders drive the winding roll directly, but they involve multiple winding spindles on a turret assembly that rotates. The rotation of the turret allows the winder to place a new core against the web upstream of the winding roll. However, turret winders require significant space, they are very costly, and they have many moving parts that require maintenance.
The present applicant, New Era, offers an additional proprietary method for automatic winding of rolls that includes two fixed winding positions and a cutoff assembly between them. The web passes between the two winders and alternates between being accumulated on one of the two winders. This design is a more cost-effective solution than either the surface winder or turret winder, has fewer moving parts and requires less space. However, the web passing between the winders results in opposite facing of the webs on the completed rolls.
German Patent DE 44 30 111 describes a device that winds alternatively onto central winding shafts (4) at two winding points (3′, 3″) alongside each other with parallel axes. The winding points are driven in the same direction. The device comprises a rolling head (6) with clearance (8) through which the material runs out of the head. There is a guide roller (10,11) at each winding point, above the roller and close to its circumference. It guides the material when it is separated crosswise in the head at the winding point for roller change.
SUMMARY The following presents a simplified summary of one or more embodiments of the present disclosure in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments and is intended to neither identify key or critical elements of all embodiments, nor delineate the scope of any or all embodiments.
In one or more examples, a winder for winding process webs on roll cores may include a first winding position configured for rotatably securing a first roll core and rotating the first roll core in a first rotational direction. The winder may also include a second winding position configured for rotatably securing a second roll core parallel to the first roll core and rotating the second roll core in the first rotational direction. The winder may also include a roll positioning assembly configured to move a portion of the web upstream of the second winding position from a first side of the first winding position to a second side of the first winding position.
In one or more examples, a method of winding webs on rolls may include accumulating a web onto a roll core at a lower winding position, moving a portion of the web upstream of the roll core from a first side of an upper winding position to an opposite side of the upper winding position using a roll positioning assembly. The method may also include installing a new roll core in the upper winding position and transferring the incoming web to the new roll core.
While multiple embodiments are disclosed, still other embodiments of the present disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the various embodiments of the present disclosure are capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as forming the various embodiments of the present disclosure, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying Figures, in which:
FIG. 1 is a side view of a winder, according to one or more examples.
FIG. 2 is a front view of a winding position thereof, according to one or more examples.
FIG. 3 is a side view of a tension control device of the winder of FIG. 1, according to one or more examples.
FIG. 4 is a side view of a transfer assembly of the winder of FIG. 1, according to one or more examples.
FIG. 5 is a side view of a roll positioning system, of the winder of FIG. 1, according to one or more examples.
FIG. 6 is a side view of the winder of FIG. 1 accumulating web material at a lower winding position, according to one or more examples.
FIG. 7 is a side view of the winder of FIG. 1 where a roll positioning system has moved a portion of the web material and is positioning a new roll core at the upper winding position on a same side of the web as the lower winding position, according to one or more examples.
FIG. 8 is a side view of the winder of FIG. 1 where an upper transfer assembly has engaged the web to position a bump roller in close proximity to the new roll core, according to one or more examples.
FIG. 9 is a side view of the winder of FIG. 1 where the transfer assembly has advanced the bump roll further to press the web against the new roll core and cut it, according to one or more examples.
FIG. 10 is a side view of the winder of FIG. 1, with the upper transfer assembly retracted, the roll positioning assembly retracted, the full roll at the lower winding position removed, and a new core installed at the lower winding position, according to one or more examples.
FIG. 11 is a side view of the winder of FIG. 1, with a lower transfer assembly extended to push the web in close proximity to the new roll core at the lower winding position, according to one or more examples.
FIG. 12 is a side view of the winder of FIG. 1 where the transfer assembly has advanced the bump roll further to press the web against the new roll core and cut it, according to one or more examples.
FIG. 13 is a side view of the winder of FIG. 1 with the lower transfer assembly retracted and the full roll at the upper winding position removed, according to one or more examples.
FIG. 14A is a diagram depicting several method steps for a method of winding web material, according to one or more examples.
FIG. 14B is a diagram depicting several additional methods steps for the method of winding web material, according to one or more examples.
DETAILED DESCRIPTION The present application, in one or more examples, includes a winding system involving multiple stationary winding positions that allow for switching, on-the-fly, between winding at one position and winding at another position. While the winding positions are stationary, the winding system still provides for maintaining the direction of winding when switching from one position to another. In particular, a roll positioning mechanism functions to adjust the position of the web upstream of the winding roll and, in some cases, places a new core at a winding position after and/or in conjunction with adjusting the position of the upstream web. The system is simple, efficient, and less costly than turret systems by having stationary winding positions, while also providing for powered winding positions that avoid the need for surface winders. As such, the present winding system provides desired versatility without being complicated and expensive and while be conscious of available space.
FIG. 1 shows a winder 100 designed to allow for the continuous winding of a web of material 102 that is coming to the winder from a previous process such as coating, laminating, printing, embossing, or other converting process. The incoming web material can be one of many items such as paper, films, foils, or fabrics. The incoming web is typically of a flattened shape with a thickness sufficient for being fed through the winder. The winder is configured to wind the web material onto cores and to alternate between winding at one position until the core is full and then winding at another position. Moreover, the winder is configured to do so without stopping or slowing the winding process and without changing which face of the web is facing in/out on the wound roll. In one or more examples, the winder 100 may include a main frame assembly 101, one or more idler rolls 103, a tension control device 104, an upper winding position 105, a lower winding position 106, an upper transfer assembly 107, a lower transfer assembly 108, and a roll positioning assembly 109.
With continued reference to FIG. 1, the main frame assembly 101 may be configured to provide support to the several components of the winder 100. For example, the main frame assembly may include a pair of frames, walls, panels, or other side structures that are spaced apart from one another to accommodate a width of web between them. That is, the side structures may be spaced from one another to accommodate several web widths and, as such, may be spaced based on a maximum anticipated web width the winder will be used to wind. The side structures may have a base configured for securing to a floor or a moveable base may be provided. The side structure may be designed to carry the weight of the web when it is wound onto rolls and, as such, may be designed to carry the weight of multiple rolls in addition to the several components of the system spanning between the side structures.
With continued reference to FIG. 1, several idler rolls 103 are shown. The idler rolls 103 may be configured to route the incoming web of material 102 through the winder in a manner that accommodates other stationary and/or moving components within the winder, maintain clearance from these other components, and allow the web to run smoothly about the idler rolls. That is, the idler rolls 103 may define the contour or profile of the web 102 as it passes through much of the winder 100. The idler rolls 103 may be rotating rolls extending from a side structure on one side of the winder 100 to a side structure on another side of the winder 100. The idler rolls 103 may be generally fixed in position relative to the side structures and other aspects of the winder except that they may be free to rotate about a central axis aligned with a center of the idler roll 103. The idler rolls 103 may include a cylindrically shaped body that may be fabricated from a material such as steel or aluminum and may include bearings that allow the body to rotate about the central axis. The idler rolls 103 may rotate generally freely such that their surface speed matches the speed of the web of material 102. As may be appreciated, the quantity and location of the idler rolls 103 will be determined by the configuration of the winder 100. In the present example, there are two idler rollers 103 near the top of the winder 100, one slightly below and offset laterally from the other forming a step down of the web 102 as it enters the winder 100 and heads to a tension control device 104. Another idler roll 103 may be arranged to receive the web 102 exiting the tension control device 104 and providing a position about which the web 102 turns downward and enters a winding region of the winder 102. Still two further idler rolls 103 may be arranged to guide the web along an arc or segmented arc leading to a lower winding position 106. While a particular idler roll arrangement has been shown, still additional or fewer idler rolls 103 may be provided and/or different positions of the idler rolls 103 may be provided.
Upper and lower winding positions 105/106 are also shown in FIG. 1. The winding positions may include roll cores 113 from time to time depending on the status of the winding process. That is, the winding positions may receive empty roll cores 113 when preparing a winding position to receive web material and may hold and/or rotate the roll core at the winding position to collect the web material. Once full, the roll core 113 with the web material may be removed and replaced with another empty roll core 113. An example of an upper winding system at the upper wind position 105 is shown in FIG. 2. A same or similar lower winding system may be provided at the lower wind position 106.
As shown in FIG. 2, the upper winding position 105 may include components arranged on opposing portions of the main frame 101 and a particular winder roll core 113 may be placed between and selectively held by the components on each side structure of the main frame 101. The winder roll core 113 may generally be empty when placed, may remain in position at the upper winding position 105 unless/until it is filled with web material 102, and then it may be removed and replaced with another empty winder roll core 113. As such, the upper winding position 105 and its several components may be configured to selectively engage, hold, rotate, and selectively release the winder roll cores 113.
Starting with the non-drive side of the winder 102, a non-drive side chucking cylinder 110 may be mounted on the side structure of the main frame 101. The chucking cylinder 110 may be configured to extend and retract a non-drive side winder support spindle 111. A non-drive side core chuck 112 may be mounted on an end of the spindle 111 such that when the spindle 111 is extended/retracted, the core chuck 112 is also extended/retracted. The spindle 111 may include a bearing to allow the core chuck 112 to rotate about its center axis. The bearing may be between the spindle and the chuck or between the spindle and the frame. The extension/retraction of the spindle 111 by the chucking cylinder 110 may provide for engaging/disengaging the end of a roll core 113 with the core chuck 112. As such, when a roll core 113 is brought into position and in alignment with the core chuck 112, the chucking cylinder 110 may extend the spindle 111 to drive the core chuck 112 into supporting engagement of the end of the roll core 113. When the roll core 113 is full and/or is to be removed from the winding position, the full roll may be supported by a cart, fork lift, or other roll management equipment and the chucking cylinder 110 may retract the spindle 111 to disengage the core chuck 112 from the end of the roll core 113 leaving the roll core 113, and the material it is carrying, free to be moved laterally relative to the axis of the winding position 105 extending between the side structures.
Similarly, on the drive side of the winding position 105, a drive side chucking cylinder 114 may be mounted to the side structure of the main frame 101 and may be configured to extend and retract the drive side winder support spindle 115 and a corresponding drive side core chuck 116. Bearings may be included between the main frame 101 and the drive side spindle 115 to allow the drive spindle 115 and the core chuck 116 to rotate about its center axis. Like the non-drive side, the extension and retraction of the spindle 115 by the chucking cylinder 114 provides for engaging and disengaging the end of the roll core 113 with the core chuck 116 to allow the core roll 113 to be moved laterally into position, engaged, rotated when receiving material, and then released when the roll is full to allow for lateral removal of the full roll from the winding position.
The drive side core chuck 116 may include a locking mechanism for resisting slip between the core chuck 116 and the winder roll core 113 such that drive motion of the chuck 116 functions to drive rotation of the roll core 113. In one example, the core chuck 116 may expand pneumatically or mechanically. For example, teeth, gears, cleats, points, or other engaging elements may be arranged to actuate radially to engage an inner surface of the roll core 113. In other cases, the chuck may include longitudinally extending splines (or grooves) that may mate with grooves (or splines) on an inside surface of the roll core 113. Still other mechanisms to rotationally engage the roll core 113 with the core chuck 116 may be provided.
The drive side of the winding position may also include a winder position motor 118 that is coupled to the spindle 115 with a drive transmission 117. The winder position motor 118 may rotate the spindle 115 about its center axis, which rotates the drive side core chuck 116 and, thus, roll core 113 when the drive side core chuck 116 is locked therein.
It is to be appreciated that there are other designs available that allow the winder roll core 113 to be supported, including by a shaft inside it that is supported by the non-drive side winder support spindle 111 at one end and the drive side winder support spindle 115 at the other end. In some cases this may involve loading the roll cores longitudinally from the side of the winder or may involve having the shafts present in the roll cores when they are laterally carried into position to winding position. Still other support mechanisms for the roll core at the winding positions may be provided.
Turning now to FIG. 3, the tension control device 104 is shown. The tension control device 104 may be configured to maintain a suitable force, referred to as web tension, in the web 102 during processing to help avoid wrinkles, bags, or other deformations in the web 102. This device can take one of several forms including force transducer rolls or, as shown in this case, dancers. The dancer includes several main components including a dancer roll 120 which may be similar in design to the previously described idler rolls 103 and is used to contour the web of material 102 through the dancer. That is, the dancer roll 120 may span across the width of the winder 100 from one pivoting arm 121 to another pivoting arm 121. The dancer arms 121 support the dancer roll 120 at each end from a dancer pivot shaft assembly 122. The dancer pivot shaft assembly 122 may be mounted in bearings on the main frame assembly 101, allowing the arms 121 to swing. The dancer may also include a dancer loading cylinder 123 attached to the dancer pivot shaft assembly 122 and a dancer position feedback device 124 which can be one of several items including a rotational position pot or an encoder. The air pressure or other fluid pressure to the dancer loading cylinder 123 may be controlled to a particular value, resulting in a particular force being applied to the web of material 102 as it travels about the dancer roll 120. The dancer position feedback device 124 may be used to sense the dancer position and automatically adjust the speed of the previously described winding position motor 118. These two systems may work together to maintain the dancer in the proper position as the diameter of the roll of winding material changes, as the upper/lower transfer assemblies 107/108 engage the web, and/or as the roll positioning assembly 109 moves. This may help to assure that the continuous feed of web material 102 to the winder 100 is not interrupted and/or that the web remains under a reasonably steady amount of tension throughout these changing conditions. In other cases, the tension control device 104 can be used to allow for the tension profile to be automatically adjusted as the roll of web material 102 builds in size. By way of example, for particular products, it may be desirable to continuously reduce the web tension as the roll of web material 102 continues to increase in size so as not to damage the inner layers of product.
Turning now to FIG. 4, one example of a transfer assembly 108 is shown. The assembly 108 may be configured to extend to move an upstream portion of the web in close proximity to a new roll core 113 prior to adhering and cutting of the web. The assembly may also be configured to cause the web to engage, and thus adhere to, the new roll core and to cut the web at a suitable time. The assembly 108 may be further configured to retract clear of the running web once the web is winding on the new roll core 113. Like several other aspects of the winder 100, the assembly 108 may include moving components secured to the main frame 101 at each side of the winder which may be connected by a bump roll 131. That is, the moving components that function to move the bump roll 131 (and the knife assembly for that matter) may be arranged at or near the main frame side structures while the bump roll 131 and knife assembly or other cutting assembly extend across the width of the winder 102 and interface with the web 102.
As shown, the assembly 108 may include a main carriage 125 that is mounted on a main carriage rail system 126 and operable by a main carriage positioning assembly 127. One set of these components may be provided at each side structure on each side of the winder 100. The main carriage positioning assembly 127 may be configured to translate the main carriage 125 along the main carriage rail system. More particularly, the main carriage positioning assembly 127 may function to move the main carriage 125 into position prior to a transfer being made and away from the winding roll once the transfer is completed. For example, FIG. 10 shows the main carriage 125 in a retracted position, FIG. 11 shows the main carriage 125 in an advanced or extended position, and FIG. 13 shows the main carriage 125 retracted again. The main carriage position assembly 127 may include hydraulic or pneumatic cylinders, motor driven screws, or other translational actuators to move the main carriage 125 along the main carriage rail system 126.
The main carriage 125 may include an additional carriage and rail system. That is within or on the moving main carriage 125, a bump roll/cutter carriage 128 may be provided. The bump roll/cutter carriage 128 may move along a bump roll/cutter rail 129 by way of a bump roll/cutter position assembly 130. Like the main position assembly 127, the bump roll/cutter position assembly may include hydraulic or pneumatic cylinders, motor driven screws, or other translational actuators to move the bump roll/cutter carriage 128 along the bump roll/cutter rail 129. The bump roll/cutter carriage 128 may carry the bump roll 131 into position to cause the web to contact the roll core 113 during transfer operations. That is, the bump roll/cutter carriage/rail 128/129 may offer a finer or more precise level of motion for the bump roll 131 than the main carriage and rail 125/126.
The bump roll 131 may extend between bump roll/cutter carriages 128 on either side of the winder 100. Like the idler rolls 103, the bump roll 131 may include a cylindrically shaped body typically fabricated from a material such as steel or aluminum. However, the bump roll 131 may also include a rubber covering. The bump roll 131 may be mounted with bearings that allow the body to rotate about its central axis. The bump roll 131 is designed to press on a side of the running web of material 102 opposite the roll core 113 to cause the web to engage the surface of the roll core 113. The design of the system is such that the bump roll 131, or other similarly designed rolls, can also be used such that the roll stays in contact with the surface of the winding roll of material as it continues to grow in diameter as the web of material 102 continues to wind. Alternatively or additionally, the design of the system is such that the bump roll 131, or other similarly designed rolls, can be used such that the roll stays in close proximity to the surface of the winding roll of material as it continues to grow in diameter as the web of material 102 continues to wind. Depending on the winding requirements, bump roll 131 may be interconnected with an assembly such as a motor, allowing for the motor or similar device to rotate the bump roll 131 about its central axis.
In addition to the bump roll 131, the cutter assembly 132 may also be mounted to the bump roll/cutter carriage 128. In one or more examples, as shown, the cutter assembly 132 may include a razor mounted on a traversing cylinder (e.g., a moving knife blade). However, the cutter assembly 132 can take one or more forms including, plunge style knives that penetrate the web to cut it and traversing rotary cutters, for example. Still other cutter types may be provided. The cutter assembly can also be configured to allow for cutting without any tail at the core, a feature that can be highly desirable in certain applications. Such a cutter may be termed a tail-free cutter and it may be a cutter that allows for the very leading edge of the web to be secured to the core.
It is to be appreciated that while the bump roll 131 and cutter assembly 132 have been shown to be mounted in the same carriage and on the same transfer assembly, other designs are possible where they are mounted in separate carriages on separate transfer assemblies. Moreover, while the system in FIG. 1 shows an upper transfer assembly 107 as well as a lower transfer assembly 108, a single transfer assembly may be provided that pivots, for example, to service both winder positions. Moreover, while the upper transfer assembly 107 has not been described in detail, it may include the same or similar components as the lower assembly 108 that was described. In some examples, the reach of the assembly 107/108 may play a role in how robust the components of the assembly are, which is why the upper assembly 107 appears smaller and less robust than the lower assembly 108. Nonetheless, the assemblies 107/108 may have the same or similar components with same or similar functionalities (e.g., main carriage/rail/positioning assembly and bump roll/cutter carriage, rail, and positioning assembly).
Turning now to the roll positioning assembly 109, FIG. 5 shows a side view thereof. The roll positioning assembly 109 is configured to move a portion of the running web material to an opposite side of a winding position axis and deliver a new roll core 113 to that respective winding position. For example, as shown by comparing FIG. 6 to FIG. 7, the running web may be below and to the right of the upper winding position 105 in FIG. 6 and the roll positioning assembly 109 may move the web to be above and to the left of the upper winding position 105 in FIG. 7. The roll positioning assembly 109 may include a pair of roll positioning support arms 134 that are interconnected to the main frame assembly 101 by a pivot shaft 135 or other pivot connection. The pivot shaft 135 or other pivoting connection may be operably connected with a device such as a motor or cylinders that allow it to rotate the pivot shaft so that support arm may swing upward as shown by comparing FIG. 6 to FIG. 7. In one or more examples, the support arms 134 may be mounted to the side structures outboard of the connections of the idlers and other assemblies to the side structures. That is, as shown by comparing FIG. 6 to FIG. 7, for example, the arms may swing upward to move the web and to position a new roll core. By mounting the arms 134 outboard of these other structures, they may avoid interfering with, for example, the idler rolls 103 and the bump roll of the lower transfer assembly 108. At or near the bottom of the support arms 134, a guide roller or pin 138 may extend inward through a radiused slot 140 (see FIG. 1) in the side structures and a forward extending ledge or shelf arm 142 may be provided for supporting a positioning roll that extends across the winder 100. The positioning roll 133 may be similar to the idler rolls 103 or other rolls described herein by being a cylindrically shaped body fabricated from a material such as steel or aluminum, and including bearings that allow the body to rotate about its central axis so that when it is in contact with the web of material 102 its surface speed and direction matches the speed and direction of the web of material 102. In addition, a core holder 136 may be mounted on the forward extending ledge or shelf arms 142. The core holder 136 may be designed to support a winder roll core 113 that is being carried, for example, to a winder position (e.g., upper winder position 105). The assembly may be designed so that when the positioning roll 133 is located to contour the web of material 102 about the upper winding position 105, the winder roll core 113 located in the core holder 136 is in position for engagement by the chucks 112/116 of the upper winding position 105. That is, when the non-drive side chucking cylinder 110 extends the non-drive side winder support spindle 111, the non-drive side core chuck 112 enters one end of the winder roll core 113 and when the drive side chucking cylinder 114 extends the drive side winder support spindle 115, the drive side core chuck 116 enters the other end of the winder roll core 113. While the roll positioning assembly 109 is shown as a pivoting assembly in this design it can also be a system that moves by other means including translating through the use of a driven screw system, for example. Still other actuation mechanisms can be used.
As mentioned, the roll positioning assembly 109 may include a core holder 136 used to position a new winder roll core 113 between the chucks of the upper winding position 105. The figures show one of the possible ways that the new winder roll core 113 for the winding position about which the running web of material 102 is moved can be loaded and supported once the running web of material 102 is moved into position. There are other methods available such as having the roll positioning assembly 109 move the new winder roll core 113 with a shaft inside it, so that the upper winding position 105 can support the new winder roll core 113 by the shaft, or having the new winder roll core 113, either with or without a shaft inside it, being loaded from the side of the winder (e.g., through an opening in a side structure, across the width of the winder to the opposing side structure) once the running web of material 102 is moved into position by the roll positioning assembly 109.
While a particular example of a winder 100 has been described, still other approaches may be provided. For example, the configuration shown in FIG. 1 features the upper winding position 105 and the lower winding position 106 arranged vertically, with the upper winding position 105 being located over the lower winding position 106. Alternatively, these can be configured horizontally, next to each other, or at an angle. In addition, the configuration shown in FIG. 1 features the incoming web being wound on the winding positions with the bottom side in. Alternatively, the system can be configured with the top side of the web being wound in. In either case, the upper/lower winding position can accommodate consistent facing winding.
Still, with respect to the transfer assemblies 107/108, FIG. 1 shows two separate transfer assemblies 107/108, an upper transfer assembly 107 that is associated with the upper winding position 105 and a lower transfer assembly 108 that is associated with the lower winding position 106. Alternate designs are possible where one transfer assembly is used for both the upper winding position 105 and the lower winding position 106. For example, a pivoting transfer assembly may allow for it to address both winding positions. Still further, other designs are possible that have the bump roll assembly separate from the cutter assembly (e.g., not part of a same transfer assembly). Still further, while the present winder discusses moving new cores into place by the roll positioning assembly 109 and then supporting the roll core by machine mounted chucks that engage the ends of the core, other approaches may be used. For example, the roll positioning assembly may move the core with a shaft inside it, so that the winder can support the core by the shaft, or having the core, either with or without a shaft inside it, being loaded from the side of the winder once the web is moved into position by the positioning roll assembly.
In operation and use the winder 100 may allow for the continuous winding of a running web of material 102 that is coming to the winder from a previous process. The method 200 of operation may include several steps as detailed in FIGS. 14A and 14B. FIGS. 6 through 13 show various equipment positions relating to the method 200. The method 200 may provide for a full repeatable sequence allowing for transferring between winding the web at the upper position 105 and the lower position 106 and again at the upper position 105 and so on. The duration of the full sequence may vary based on many factors including the incoming speed of the web of material 102, the thickness of the web of material 102, and the size of the rolls of material that will be wound on the winder 100. The sequence shown in the figures is based on the described design. As previously indicated, there are several parts of the equipment that may have varying designs. These design variations may have an impact on the steps in the sequence. Also, while not described in detail, the method 200 may include receiving the web from a process, passing the web through a tension control device 104, passing the web over one or more idler rolls 103 and passing the web 102 on to a winding region of the winder 100. That is, these steps involved in getting the web 102 to the winding region of the winder 100 and controlling the tension of the web during winding may be continuous and ongoing during the below described method 200 and may function responsively to the steps performed in the method 200. For example, the tension control device may be continuously monitoring the tension in the web 102 based on operations being performed and may continuously adjust the position of the dancer roll 120 to accommodate the tension or lack thereof.
With reference to FIGS. 14A and 14B, the method 200 may include accumulating 202 the web onto a roll core at a lower winding position. The method 200 may also include moving 204 a portion of the web upstream of the roll core from a first side of the upper winding position to an opposite side of the upper winding position using a roll positioning assembly. The method 200 may also include carrying 206 a new roll core to the upper winding position during the moving. The method 200 may also include engaging 208 the new roll core with the chucks of the upper winding position. The method 200 may also include engaging 210 the web with a bump roll from an upper transfer assembly by actuating a main carriage thereof. The method 200 may also include moving 212 the web to a position of close proximity to the new roll core at the upper winding position with the main carriage. The method 200 may also include pressing 214 on the web with the bump roll to cause the web to engage the new roll core using a bump roll/cutter carriage and actuating a cutting device. The method may include retracting 216 the upper transfer assembly using the main carriage and retracting 218 the roll positioning assembly. The method may also include accumulating 220 the web onto the new roll core at the upper winding position. The method may also include removing 222 the completed roll from the lower winding position and installing 222 a new roll core at the lower winding position. The method may also include moving 224 a portion of the web upstream of the upper winding position to a position of close proximity to the new roll core at the lower winding position with the main carriage of the lower transfer assembly. The method may also include pressing 226 on the web with the bump roll to cause the web to engage the new roll core using a bump roll/cutter carriage of the lower transfer assembly and actuating a cutting device thereof. The method may also include retracting 228 the bump roll and cutoff knife by retracting the main carriage of the lower transfer assembly. The method may be repeated by, again, accumulating 202 the web onto a roll core at a lower winding position.
Each of these method steps may be explained in more detail with reference to FIGS. 6-13. For example, with respect to operations that are ongoing throughout the method, FIG. 6 shows the web of material 102 entering the winder 100 from the previous process steps, passing through the web tension control device 104, around a series of idler rolls 103, and directing it to the winding region of the winder via a series of idler rolls 103. With respect to step 202, the web is being wound on the lower winding position 106 in a counterclockwise direction (bottom side in). The incoming web of material 102 continues to wind on the lower winder position 106, with its winder position motor 118 having its speed controlled by the web tension control device 104, resulting in the formation of a roll of web material 137. During this time, a new winder roll core 113, complete with double sided tape or adhesive on its surface, is loaded into the core holder 136 located on the positioning roll assembly 109. The new winder roll core 113 can either be loaded into the core holder 136 manually by the operator or automatically.
With respect to step 204, reference is made to FIG. 7. The web of material 102 continues to be wound on the lower winding position 106. The winder position motor 118 may have its speed controlled by the web tension control device 104 while forming a roll of web material 137. Meanwhile, the roll positioning assembly 109 may translate at the appropriate time to move the running web of material 102 about the upper winding position 105. The appropriate time may be determined automatically by the control system based on the diameter or length of web material on the roll 137, for example, or an operator may initiate the roll positioning assembly 109. With respect to step 206, the assembly 109 may carry a new roll core 113 in the core holder 136 and may stop moving the web when the new winder roll core 113, held by the core holder 136, is arrange between the chucks 112/116 of the upper winding position 115. With respect to step 208, the non-drive side chucking cylinder 110 of the upper winding position 105 may extend the non-drive side winder support spindle 111 which causes the non-drive side core chuck 112 to enter one end of the new winder roll core 113. The drive side chucking cylinder 114 of the upper winding position 105 may extend the drive side winder support spindle 115 which causes the drive side core chuck 116 to enter the other end of the new winder roll core 113. The drive side core chuck 116 may also be expanded to engage the inner surface of the roll core 113.
Turning now to FIG. 8 and with respect to step 210, the web of material 102 may continue to be wound on the lower winding position 106, with its winder position motor 118 having its speed controlled by the web tension control device 104 and continuing to form a roll of web material 137. Meanwhile, the main carriage assembly 125 of the upper transfer assembly 107 may translate into close proximity to the new winder roll core 113. With respect to step 212, this may bring the running web of material 102 in close proximity with the new winder roll core 113. At the appropriate time, either initiated automatically by the control system when the roll at the lower winding position is full or as initiated by the operator, the new winder roll core 113 in the upper winding position may be rotated up to speed by the winder position motor 118 so that the surface speed and direction of the new winding roll core 113 matches that of the running web of material 102.
With respect to step 214 and as shown in FIG. 9, the incoming web of material 102 may continue to be wound on the lower winder position 106, with its winder position motor 118 having its speed controlled by the web tension control device 104. At the appropriate time, either initiated automatically by the control system when the roll 137 in the lower winding position 106 is approaching being full or as initiated by the operator, the bump roll/cutter carriage 128 of the upper transfer assembly 107 is translated forward by the bump roll/cutter positioning assembly 130. This may cause the bump roll 131 to force the web into contact with the new winder roll core 113 that is being held at the upper winding position and includes double sided tape or adhesive on its surface and is running with a surface speed and direction that matches that of the running web of material 102. The cutter assembly 132 located in the bump roll/cutter carriage 128 of the upper transfer assembly 107 translates the blade mounted on it, severing the incoming web of material 102 between the new winder roll core 113 and the roll of web material 137 being wound on the lower winder position 106. As a result, the incoming web of material 102 begins to wind on the new winder roll core 113 that is being held at the upper winding position 105 in a counterclockwise direction (bottom side in, as was the case on the lower winding spindle 106). The web tension control device 104 is automatically switched to controlling the winder position motor 118 associated with the upper winding position 105.
With respect to method step 220, as shown in FIG. 10, the web of material 102 is accumulated on the upper winding position 105, with its winder position motor 118 having its speed controlled by the web tension control device 104, continuing to form a roll of web material 137. With respect to method steps 216 and 218, the positioning roll assembly 109 translates to its original position and the blade in the cutter assembly 132, the bump roll/cutter carriage 128, and the main carriage assembly 125 all associated with the upper transfer assembly 107 return to their original positions. With respect to method step 222, the completed roll of web may be removed from the lower winding position 106 by supporting the roll and disengaging the chucks from each end. That is, the system may remove the expansion of the drive side core chuck 116. The system may also retract the non-drive side chucking cylinder 110 of the lower winding position 106 which retracts the non-drive side winder support spindle 111 which causes the non-drive side core chuck 112 to retract from the completed roll's core. Likewise, the system may retract the drive side chucking cylinder 114 of the lower winding position 106 retracting the drive side winder support spindle 115 which causes the drive side core chuck 116 to retract from the completed roll's core. With the chucks disengaged, the completed roll of material may be removed. There are many manual and automatic methods available for supporting and removing the completed roll including hoists and carts. Once the completed roll is removed, a new winder roll core 113, complete with double sided tape or adhesive on its surface, is loaded into the lower winding position 106. The new winder roll core 113 may be placed between the non-drive side core chuck 112 and the drive side core chuck 116 of the lower winding position 106. Each respective chucking cylinder 110/114 may extends the respective spindle 111/115 which causes respective core chuck 112/116 to enter respective ends of the new winder roll core 113. The drive side core chuck 116 may also be expanded. There are many manual and automatic methods that can be used to place the new winder roll core 113 between the non-drive side core chuck 112 and the drive side core chuck 116 of the lower winding position 106.
As shown in FIG. 11, as the web of material 102 continues to be wound on the upper winding position 105, with its winder position motor 118 having its speed controlled by the web tension control device 104, continuing to form a roll of web material 137. Meanwhile, and with respect to method step 224, the main carriage assembly 125 of the lower transfer assembly 108 may translate into close proximity to the new winder roll core 113 which has previously been inserted into the lower winding position 106, bringing the running web of material 102 in close proximity with the new winder roll core 113. At the appropriate time, either initiated automatically by the control system when the roll 137 of web in the upper winding position 105 is approaching being full or as initiated by the operator, the new winder roll core 113 in the lower winding position 106 is rotated up to speed by the respective winder position motor 118 so that the surface speed and direction of the new winding roll core 113 matches that of the running web of material 102.
As shown in FIG. 12, the incoming web of material 102 continues to wind on the upper winder position 105, with its winder position motor 118 having its speed controlled by the web tension control device 104. With respect to step 226, at the appropriate time, either initiated automatically by the control system when the roll of web in the upper winding position 105 is full or as initiated by the operator, the bump roll/cutter carriage 128 of the lower transfer assembly 108 is translated forward by the bump roll/cutter positioning assembly 130, causing the bump roll 131 to press the web into contact with the new winder roll core 113 in the lower winding position. The new roll core 113 may be complete with double sided tape or adhesive on its surface and is running with a surface speed and direction that matches that of the running web of material 102. The cutter assembly 132 located in the bump roll/cutter carriage 128 of the lower transfer assembly 108 translates the blade mounted on it, severing the incoming web of material 102 between the new winder roll core 113 and the roll of material 137 being wound on the upper winder position 105. As a result, the incoming web of material 102 begins to wind on the new winder roll core 113 that is being held by chucks 112/116 of the lower winding position 106, in a counterclockwise direction (bottom side in, as was the case on the upper winding spindle 105). The web tension control device 104 is automatically switched to controlling the winder position motor 118 associated with the lower winding position 106.
As shown in FIG. 13, the web of material 102 continues to wind on the lower winding position 106, with its winder position motor 118 having its speed controlled by the web tension control device 104, continuing to form a roll of web material 137. With respect to method step 228, the blade in the cutter assembly 132, the bump roll/cutter carriage 128, and the main carriage assembly 125 all associated with the lower transfer assembly 108 return to their original positions. The completed roll of web is removed from the upper winding position 105 by supporting the roll, removing the expansion of the drive side core chuck 116 and retracting the respective chucking cylinders 110/114, the respective spindles 111/115, and the respective chucks 112/116, and removing the completed roll of material. There are many manual and automatic methods available for supporting and removing the completed roll including hoists and carts. At this point, the method may be repeated starting with method step 202.
The present winder may be advantageous for a variety of reasons. In particular, the winder may allow for the continuous winding of rolls of material without the need to stop or slow the running web and the running web of material may consistently be wound on the rolls with the same side in (or out). In one or more examples, the present winder provides for this by moving the running web with a roll positioning assembly before loading the new roll core into its winding position. This new design addresses the issue of needing to stop the running web at the winder to make a transfer like some of the previously described systems do. It addresses the issue of winding rolls of material in opposite directions on each of the two winding positions. It also addresses the issue of driving rolls of material via contact with the web like the surface winder does. Additionally, it has fewer moving parts, is less expensive and takes up less space than the turret winder system.
As used herein, the terms “substantially” or “generally” refer to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” or “generally” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking, the nearness of completion will be so as to have generally the same overall result as if absolute and total completion were obtained. The use of “substantially” or “generally” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, an element, combination, embodiment, or composition that is “substantially free of” or “generally free of” an element may still actually contain such element as long as there is generally no significant effect thereof.
To aid the Patent Office and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants wish to note that they do not intend any of the appended claims or claim elements to invoke 35 U.S.C. § 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.
Additionally, as used herein, the phrase “at least one of [X] and [Y],” where X and Y are different components that may be included in an embodiment of the present disclosure, means that the embodiment could include component X without component Y, the embodiment could include the component Y without component X, or the embodiment could include both components X and Y. Similarly, when used with respect to three or more components, such as “at least one of [X], [Y], and [Z],” the phrase means that the embodiment could include any one of the three or more components, any combination or sub-combination of any of the components, or all of the components.
In the foregoing description various embodiments of the present disclosure have been presented for the purpose of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The various embodiments were chosen and described to provide the best illustration of the principals of the disclosure and their practical application, and to enable one of ordinary skill in the art to utilize the various embodiments with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the present disclosure as determined by the appended claims when interpreted in accordance with the breadth they are fairly, legally, and equitably entitled.
