Note: Descriptions are shown in the official language in which they were submitted.
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FIELD OF INVENTION
The present invention relates to a control valve to con-
tinually monitor and control a guide roll position and to effec-
tively cause this guide roll to be moved in the necessary direc-
tion to maintain an endless web traveling in a straight run
around a series of rolls.
SUMMARY AND OBJECTS OF INVENTION
The present invention presents a spool type pneumatic
controller valve which operates within a 35 to 75 psi input range
and feeds this output pressure directly to a ~uide mechanism to
accomplish necessary control and corrections. The present
control valve is unique in that it is not a pilot device but
handles full flow directly to diaphragms or a cylinder end
without the benefit of additional linkage, mechanisms or pneuma-
tic boosters.
The controller valve of the present invention is
designed to control a guide roll very precisely and this is
accomplished through the particular design of the porting
within the valve. The "dead zone" or area of ~no correction" at
the palm's neutral position is approximately one-eighth inch.
This porting design and arrangement was designed and developed to
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give ~ast and acc-lrate response even at the low range o~ lnlet
pressure operation o~ 30-35 psi, and to maintain any correction
to the guide roll position until an additional correction is
called for as a result of a change in the position of the web or
material being guided and controlled. This unique design feature
of the valve controller eliminates the "hunting" characteristic
usùally associated with a guide valve of this type. This design
reature within the controller valve is possible because of the
relatively small movement oE the spool within the valve body com-
pared to web movement. ~he present spool design and the large
ratio of palm movement to spool movement makes the valve sen-
sitive and responsive to small changes in web position.
It is, therefore, an object of the present invention to
provide a spool valve for a fluidic guiding system of the type
that controls the running angle of material passing over a guide
roll that overcomes many of the disadvantages and drawbacks of
conventional control systems.
A further object of the present invention is to provide
a control valve for a fluidic guiding system of the character
referred to above which is simple in construction, includes rela-
tively few moving parts, is reliable, and which requires little
or no maintenance.
It is also an object of the present invention to provide
a spool type control valve for a web guide roll guiding system
that accurately and precisely responds to the movement of the web
or other material passing over the guide roll.
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Another object of the ?resent invention resides in the
provision of a spool t~pe control valve ~oc such a guiding system
which includes a pivot arm directly operating the sliding spool
which is responsive to lateral movement of material passing over
the guide roll for actuating the spool accordingly so as to vary
and control the running angle of the material passing over the
same guide roll.
A further object of the present invention resides in the
provision of a spool type control valve for a guiding system that
is relatively inexpensive, but which is rugged in construction.
It is also an object of the present invention to
provide a spool type control valve for controlling a web guiding
system of the character referred to above which re~uires no
adjustments and whose operation is not subject to temperature
changes.
Still a further object of the present invention resides
in the provision of a spool type control valve for a web guiding
system of the character referred to above which is applicable and
can be used with all web guiding applications.
A further object of the present invention resides in the
provision of a spool type control valve for a web guiding system
that requires no air supply treatment due to the relatively large
orifices utilized.
Another object of the present invention resides in the
provision of a web guiding system control valve which includes a
universal mounting that enables the same to be mounted either
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r.i~ht h~ncled or Le-ft harlded and whic~l can be converlientLy
located remotely ~`rom the guiding .system.
Another ob.jec-t ol! the present invention resides in
-the provision of a web g~liding system spool -t-ype control
valve th..lt can be u.secl on single dia-ph:r~gm spring re-tllrn -type
guiding sys-tems by simply plugging one outle-t prot.
S-ti:Ll a f~lrther object Oe the present inven-tion
resides :in the provi.sion of a web guiding system control
valve that includes a following arm and palm tha-t is biased
to continuously monitor the edge of the material passing over
a guide roll, wherein the pressure e~erted against the guide
arm, in order -to follow the -~eb in a contact relationship, is
of a relatively low pressure.
It is also an object of the present invention to
provide a spool type control valve of the charac-ter referred
to above wherein the biasing action eluded to is achieved
through the accomplishment of a differential pressure across
the ends of the valve's spool.
Another object of the present invention resides in
the provision of a spool type control valve for a web guiding
system that is completely enclosed so as to prevent
contamination.
Finally it is an object of the present inven-tion to
provide a web guiding sys-tem con.trol valve that is very
compact.
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:In keep:ing wi-th the fore~o-ing there is prov-ide~l in
accordance with the presen-t invention a spoo:l type controller
assesnbly -tor con-tro:L:Iing and direct:ing ail rrom an air source
to either side of a dual diaphragm pne~Ima~ic gIlid:ing system
that is operatively corInected -to a guide roll ~'or moving and
adjusting the guide ro:ll so as to appropriately guide
material such as wire OI' felt web over -the guide roll, said
spool type controller comprising:
A. a valve having a body, a spool movably moun-ted
therein, an air inlet port, a pair of outlet ports, an
exhaust port means formed therein wi-th each outle-t port being
adapted to be communicatively connected to a respective
diaphragm of said pneumat:ic guiding system;
B. biasing means operatively associated with said
spool for biasing -the same toward a selected position within
said valve;
C. spool actuating means for engaging an edge of
said material passing over said guide roll and moving said
spool back and forth within said valve in response to the
lateral shifting of said material as the same passes over
said guide roll wherein the movemen-t of said spool, as a
result of the lateral movement o~ said material, results in
-the guiding system adjusting the position of said guide roll
so as to adjust the running angle of the material passing
over said guide roll;
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~ . wherein said spool act~l~ting rneans includes pivot
arm means clirectlv cou-p:Led to said spool for moving saicl
spool ~ack and forth within said valve as said pivot arm
means is moved back and forth, said p:ivot arm means .inclllding
5 an inner end movably molln-ted -to said spool and extending
thererom and fur-ther ;nclucl-ing a remo-te end having a
follower secured thereto for engaging the edge of saicl
ma-terial passing over said guide roll, such that said pivo-t
arm means actuates and moves said spool bac,k and f'orth within
said valve in response -to the lateral shifting of -the
material passing over said guide roll;
E. said spool and pivot arm adapted to assume a
first neutral position and wherein from said neutral position
said pivot arm may pivo-t -to second and third extreme
positions on each side of said neutra:L position; and
F. wherein said valve and spool inc,lude means for
opening said outlet ports and exposing the same to air
pressure while closing said exhallst port means in response to
said spool and pivot arm assuming said neutral posi-tion,
thereby preven-ting the valve from experiencing "hunting".
BR _F DESCRIPTION OF DRAWINGS
The invention is illus-trated by way of example in the
accompanying drawing wherein:
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Fio,llre l is a sicle view ill~lstr~tion of an end.less
web p,lss:irlg arollnd a series o~ ro:Lle~s incl~lclin~ a ~ui.de
~ol.ler.
Fi~gllres 2a, 2b and 2c are -top pl.an views of three
separ~-te web ~rrangements similar -to tha-t shown in Figure 1
wherein in each o-f -the th:ree cases the g~ide roller is shown
in a partic-llar position to illustrate the natural direction
that the web tends to follow as a resu:Lt of -the par-ticular
positioning of one end of the guicle roller.
Figure 3 is a schematic illustration of the guide
roll, control valve, and associated plumbing for directing
air to and -through the control valve and into the guide roll
control system.
Figure 4 is a sectional view illustrating the spool
type controller of the present invention with the spool being
shown in a neutral posi-tion.
Figure 5 is a fragmentary enlarged sectional view
showino a selected por-tion of the valve and its spool with
the spool being in the neutral position.
Figure 5A is a sectional view of the valYe shown in
Figure 4 particularly ilLustrating the side by-pass air
channe:L formed in the body of the valve that enables air to
be channeled to both sides of the spool.
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Figure 6 is a schematic illustration o the control
valve o the present invention illustrating the flow of air
therethrough when the palm of the control valve as shown in
Figure 4 assumes the leftmost extreme position (position No. 2).
Figure 7 is a schematic illustration of the control
valve of the present invention illustrating the flow of air
therethrough when the palm of the control valve as shown in
Figure 4 assumes the neutral position (position No. 1).
Figure 8 is a schematic illustration of the control
valve of the present invention illustrating the flow of air
therethrough when the palm of the control valve as shown in
Figure 4 assumes the rightmost extreme position (position No. 3).
Figure 9 is a graph illustration showing pressure
measurements for various palm movements o~ the control valve of
the present invention.
DESCRIPTION OF INVENTION
With further reference to the drawings, reference is
made to Figures 1, 2a, 2b and 2c in order to illustrate the
manner of maintaining proper running alignment of an endless web.
In Figure 1 an endless web 10 is shown passing around a series of
carrier rolls 12. A guide roll, indicated by the numeral 16, is
provided and as seen in Figure 1 web 10 travels thereover. In
addition a palm or guide arm 18 that contacts the edge of web 10
is illustrated in Figure 1. Palm or follower 18, as will be
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~nderstood from subseq~ent portions of this disclosure, is uti-
li~ed in conjunctio~ ~ith a control system that is responsive to
lateral or side-to-side movement of the web 10 for appropriately
correcting and controlling the running ali~nment of the web 10.
In Figure 2a, the position of guide roll 16 results in
the web 10 moving in the direction of the arrow shown therein.
By moving one end of guide roll 16 to the position shown in
Figure 2b causes web 10 to move generally in the direction of
the arrow shown therein, By moving guide roll 16 to the position
shown in Figure 2c results in the web lQ moving in the direction
of the arrow as shown therein.
Therefore, in the case of an endless web 10, it is
desirable to continuously sense the position of the edge of the
~eb 10 with a palm or follower 18 (as illustrated in Figure 1)
and in response ~o that position to adjust the end of guide roll
16 so as to appropriately control and correct the alignment of
the web 10.
Now turning to Figure 3, an actuator or guide system for
moving guide roll 16 back and forth is shown therein and indi-
cated generally by the numeral 20. Actuator 20 is of a conven-
tional design and includes a saddle bearing holder 22 that is
designed to receive an end bearing assembly of guide roll 160
~isposed on each side of saddle bearing holder 22 is a pair of
diaphragms 24 and 26. It is appreciated that by inflating and
deflating ~he respective diaphragms 24 and 26, that saddle bearing
holder 22 and accordingly guide roll 16, can be moved back and
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forth. I~ is this back-and-forth control mo~Jement that results
in the continuo~s control o~ the alignment of web 10.
The present invention particularly relates to a control
valve, 1ndicated generally by the numeral 15, for controlling
actuator 20 and the respecti~e diaphragms 24 and 26 thereof.
Details of the control valve will be specifically dealt with sub-
sequently herein. Peior to viewing details of sontroller valve
15, a general discussion of the air flow to the control valve and
on to the actuator 20 will be dealt with.
In this regard, reference is made to Figure 3. Therein
an air supply indicated by the numeral 28 is provided. Air from
air supply 28 is directed through an inlet line 13 to a par-
ticular inlet port of the control valve 15. Air passing through
line 13 wlll pass through an on-off valve 30, filter 32 and a
pressure regulator 34.
Control valve 15 is mounted adjacent the traveling web
10 by a support structure 210 ~5 will be discussed in more
detail subsequently herein, control valve 15 includes a palm or
follower 18 that continuously monitors the edge of web 10 and
responds to the lateral movement thereof so as to continuously
vary the output flow from control valve 15. Note in Figure 3
that control valve 15 further includes two additional ports, that
again will be discussed in more detail subsequently hereinO
These two ports are operatively connected to diaphragms 24 and 26
via lines 17 and 19.
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Turning to Figure 4, there is shown therein a spool type
valve controller, indicated generall~ by the numeral 15. Control
valve 15 comprises a housing structure 36 which includes a
sliding spool 37. Secured to each end of the spool by hardware
43 and 44 are rolling diaphragms 38 and 39. These diaphragms are
also secured between housing 36 and respective end covers 36a and
36b thereby forming separate chambers 41 and 42 at each end of
spool 37.
Valve 15 includes an inlet port 40 formed in end cover
36a that directs inlet pressure to both chambers 41 and 42
through a by-pass port 36c formed in housing 36 and end caps 36a
and 36b~ This by-pass port 36c is shown particularly in Figure
5A.
By specifically designing a suitable difference in an
effective area b,etween diaphragms 38 and 39, the spool is biased
to assure that palm 18 and connecting rod 45 will follow the web
10 being guided.
Pressure supply to the valve proper is accomplished
through a port 37a formed through the center of spool 37. Flow
gains entrance to port 37a through an opening located in
retaining screw 43. Port 37a terminates short of the palm
actuating mechanism area but extends sufficiently to feed
pressure ports 37b and 37c.
Continuing to refer to Figure 4, a rod 45 extends from
pivot arm 47 which is pivotably mounted to valve body 36 through
a pivot pin 46. This imparts thrust to spool 37 in either a
~10~
le~t or right direction, the particular direction beirlg deter-
mined by the movement of pal~ 18. A ball cap 48 is designed to
receive pivot arm 47. Ball cap 48 includes a circular section
and is fitted in a mating circular bore in spool 37. This allows
the rotary motion of pivot arm 47 to convert to slidinq motion
between ball cap 48 and spool 37. Expressed in another way, as
rod 45 is swung back and forth, pivot arm 47 can rotate or
oscillate in ball cap 48 and ball cap ~8 can move transversely or
back and forth within the spool 37 and within the confines of the
valve housing 36. This design essentially permits the rod 45 and
extending palm 54 to effectively move spool 37 back and forth.
A bellows 49 is provided to protect the interior of the
valve from exterior contaminants and as shown in Figure 4 extends
from the valve body 36 to cover the pivot arm 47 extending
from the valve.~
Provided in valve housing 36 are two outlet ports 50 and
51. In addition there is an exhaust port 52. A vent 53 is pro-
vided to prevent the build up of back pressure against diaphragm
38 by any pressure leakage past spool 37.
Formed on spool 37 is a raised annular exhaust control
shoulder 35 that is flanked on each side by raised annular
control collars 31 and 33. Exhaust shoulder 35 includes a
transverse channel or cross over 37d which allows air entering
the valve through either ports 50 or 51 to cross over and be
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exhausted through exhaus~ port 52. It is appreciated that the
shifting of spool 37 in either direction will allow exhaust port
52 to be opened to one of the ports 50 or 51.
As seen in Figures 4 and 5, in a neutral position,
outlet ports 50 and 51 are aligned with respective raised annular
collars 31 and 33 so that the port5 50 and 51 assume a generally
closed position. However, the annular collars 31 and 33 are each
slightly notched so as to continuously supply a pressure to each
of the diaphragms 24 and 26 of the actuator or guiding system 20
This compensates for any pressure loss due to "blow by" when the
valve is in a neutral position. Note in Figure 5 that the
notched area of annular collar 31 is specifically shown and
re~erred to by 31a.
In Figure 4 valve 15 is shown in the neutral posi-
tion. In the neutral position, inlet air enters port 40 and
spool ports 37a, 37b and 37c. This maintains inlet air pressure
on outlet ports 50 and 51. Exhaust port 52 is closed.
In Figure 4 construction line 60 represents palm posi-
tion No. 2 which moves a maximum of twenty degrees from the
neutral position. In this position port 50 is fully open to
inlet pressure via ports 37a and 37b. Port 51 is opened to
exhaust port 52 via cross over 37d.
Also in Figure 4, construction line 62 represents a
third palm position. In this third position, the palm 54 moves
a maximum of twenty degrees to the right of the neutral position,
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as shown in Figure 4. In this third palrn position, port 51 is
fully open to inlet pressure via ports 37a and 37c. Port 50 is
opened to exhaust port 52 via cross over 37d.
Palm position No. 2 and palm position No. 3 occur at the
full extremes of the palrn's movementO When palm 54 moves
slightly toward construction line 60, outlet port 50 becomes
increasingly exposed to inlet pressure and outlet port 51 becomes
increasingly exposed to exhaust port 520 For minor corrections
to the web 10 position, the flow rates are low and the
corresponding speed of correction is slow. This design elimina-
tes over-reaction and consequent "hunting" of the guide.
Essentially the flow to the respective diaphragms 24 and 26 (or
to a cylinder end) is proportional to the displacement of palm
18 relative to the neutral position.
The opposite conditions prevail when palm 18 moves
slightly towards the No. 3 position tCOnStrUCtiOn line 62). That
ls, outlet port 51 becomes increasingly exposed to inlet pressure
while outlet port 50 becomes increasingly exposed to exhaust port
52. Again the flows are proportional to spool displacement.
In Figures 6, 7 and 8, the flow of fluid or air through
valve 15 is illustrated in each of the three positions just
described. In Figure 6, palm position No. 2 (construction line
60) is illustrated. In Figure 7~ the neutral position is
illustrated. Figure 8 illustrates the third position or the
position occupied by the palm when the same assumes that position
represented by construction line 62 in Figure 4.
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It should be reiterated that valve 15 and spool 37
are particularly designed such that the effective areas on the
opposite side of the spool are not equal. Because of this there
exists a differential pressure across the ends of the spool 37
and in the present case, this results in the spool tending to be
displaced toward the left (see Figure 4). Therefore, it is
appreciated that palm 18 follows the edge of the web or material
lO passing over guide roll 16. As the palm 18 follows the edge of
web lO, the rod or swing arm 45 is operative to control actuator
or guiding system 20. As the palm 18 oscillates between the two
extreme positions indicated in Figure 4, it is appreciated that
the respective diaphragms 24 and 26 are altern~tely inflated and
exhausted and this results in the end of guide roll 16 being
moved laterally back and forth so as to adjust the running angle
of the material or web ]0 passing over the various carrier rolls
12.
Figure 9 displays a graph Oe actual diaphragm pressures
plotted from the ~ero or neutral position of the actuator or
guide roll carrier. These pressures are given for each 0.25~ of
palm movement, and illustrate the gradual and relatively straight
line increase in pressure on the high pressure side and the
corresponding decrease in pressure on the exhaust or low pressure
side.
The gradual increase in force on the ~igh pressure side
results in a very uniform speed of movement, and provides precise
control of the guide roll through the entire range of movement.
Reversal of high pressure and low pressure sides would
result in a mirror image of the graph.
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The present invention may, of course, be carried out in
other specific ways than those herein set forth without departing
from the spirit and essential characteristics of the invention.
The present embodiments are, therefore, to be considered in all
respects as illustrative and not restrictive, and all changes
comi.ny within the meaning and equivalency range of the appended
Claims are intended to be embraced therein.
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