Note: Descriptions are shown in the official language in which they were submitted.
~322357
WEB WINDING MACHINE AND METHOD
Thls application is a division of Canadian Serial No.
506,523, filed April 11, 1986.
BACKGROUND OF THE INVENTIONo
This invention relates to a method of web winding and
machine therefor and, in particular, to a surface winder.
In web winding there are two basic methods for winding
a web on a series of cores. These are center winding and surface
winding. In center winding, a core is mounted on a mandrel
which rotates at high speed at the beginning of a winding cycle
and slows down as the diameter of the log being wound builds up.
In surface winding the core and web being wound thereon
are driven by contact with belts, rotating rolls, or the liXe,
which operate at or near web speed.
Illustrative of belt surface winding is U. S. Patent
No. 3,148,843. More recently, the art has gone to rotating
cradle rolls as illustrated by U. S. Patent 4,327,877.
SUMMARY OF THE INVENTION:
The invention provides a surface winding machine in
which the core is inserted into the nip between two co-acting
belt systems which are slightly divergent. The belts in the
two co-acting systems travel in opposite directions at constant
but different velocities, and the resultant velocity differential
between the belts causes a steady advancement of the core and
log being wound during the winding cycle from core insertion
to wound log discharge~
While core inserting systems are known for surface
winders, the invention provides a unique core transfer/feeder
system based on hypocycloidal motion. This motion yields a
precise and repeatable core insertion which can be advantageously
employed in prior art machines as well as the dual belt surface
winder described herein.
~32~3~7
~ roadly the invention contemplates a method of trans-
porting cores from a source to a nip-deEining winding station
in a continuous winding machine for web logs which comprises
sequentially removing cores from the source in synchronism with
the winding of the web into successive logs, and moving the
cores through a generally hypocycloidal path to rapidly introduce
the cores into the nip.
The invention also includes a surface winder which
comprises a frame, a means on the frame for delivering a web
to a winding station for winding on a core, and a core transport
rneans on the frame for delivering a core to the winding station,
with the core transport means including means on the frame for
rnoving the core through a generally hypocycloidal path.
In another embodiment, the invention provides a method
of winding a web on a series of cores with the web having longi-
tudinally spaced transversely extending lines Or perforations
comprising the steps of advancing the web along a path, pinching
the web at a first point in the path while the web is advancing,
and using a core to pinch the web against a stationary plate
at a second point upstream of the first point and while a line
of perforationsis positioned between the points.
That embodiment also includes a surface winder for winding
a web on a series of cores comprising a frame defining a web
path having an entering end and a discharge end, a first winding
roll on one side of the path adjacent the path entering end,
a second winding roll on the opposite side of the path spaced
downstream from the entering end, a rider roll on the one path
side downstream of the first winding roll, and a stationary plate
on the frame on the opposite side of the path and operative with
th~ first winding roll to pinch the web between a core and the
stationary plate whereby the rotation of the winding rolls creates
a web tension -to sever the web.
-- 2
31~
In a further embodiment the invention contemplates a
method of winding a web sequentially upon a series of cores
wherein the web has equally longitudinally spaced lines of
transverse perforations and which is advanced along a path having
an upstream web pinching point and a spaced downstream pinching
point with the pinching points being arranged to over-tension the
web and cause severance thereof along a line of perforations
located between the points. This method is characterized by
defining the upstream pinching point by a new core to be wound and
a stationary plate, maintaining the web continually under tension
between the core and the downstream pinching point and inserting a
new core between the stationary plate and a winding roll to cause
severance to occur when the web i.s pinched against the stationary
plate.
This embodiment includes the apparatus consis-ting of a
surface winder for winding a perforated web on a series of cores
and comprises a frame, a roll rotatably mounted on the frame in
the path of web travel when the web is being wound on a core to
provide a log, a stationary plate on the frame adjacent to but
spaced from the roll to accommodate a core therebetween and
provide a first pinch-point for the web, and a means on the frame
downstream in the path of web travel from the first pinch point
for engaging the surface of the log to provide a second pinch
point cooperative with the first pinch point provided by the
stationary plate, core and roll to tension the web between the
pinch points and cause web severance along a line of perforations
between the pinch points.
The invention also includes a novel method and apparatus
for severing a perforated web being wound which facilitates
continuous, high-speed operation. The web, while being advanced
along a path, is pinched at a first point. At the time of
- 2a -
~223a7
proposed severance a core is used to pinch the web against a
stationary plate at a second point upstream of the first point and
while a line of perforations ls positioned between the two points.
Because the web is advancing at the first point and stationary at
the second point, the web is under increasing tension which causes
it to snap at the line of perforations.
DESCRIPTION OF THE DRAWINGS:
.
The invention will be explained in conjunction with an
illustrative embodiment shown in the accompanying drawings, in
which --
FIG. 1 is a fragmentary top perspective view of theinventive machine from the product discharge end;
FIG. 2 is a sectional view ta]cen along line 2-2 of FIG. l;
FIG. 3 is an enlarged fragmentary view of FIG. 2;
FIG. 3A is a fragmentary view constituting a modification
of FIG. 3;
FIGS. 4-8 are schematic views illustrating the se~uence of
web transfer;
FIG. 9 is a sectional view of one end of a core feeding
device viewed essentially along the line 9-9 of FIG. 2;
FIG. 10 lllustrates a portion of the core feeding assembly
viewed along line 10-10 of FIG. 9;
FIG. 11 is a schematic side elevational view of a modified
form of surface winder;
FIGS. 12-15 are enlarged fragmentary views of the central
portion of FIG. 11 and illustrate the sequence of web cutoff and
transfer;
FIG. 16 is a fragmentary top plan view taken along the
line 16-16 of FIG. 11,
FIG. 17 is a schematic view of the drive system for the
winder of FIG. 11;
-- 3
~3223~7
FIG. 18 is a schematic side elevational view of
a modified form of machine embodying a different surface
winder but utilizing the hypocycloidal core ~eeder;
FIG. 18A is a fraymentaxy view of the central
portion of FIG. 18 showing a further modification; and
FIG. 19 is a schematic side elevational view of
yet another modification embodying a different core feeder
with the dual belt winder.
DETAILED DESCRIPTION:
. . .
Operation in General
Referring to FIG. 1, a rewinder or web winding
machine 11 processes a web W in the direction of arrow 12
After processing it through a perforator 13 which puts
transverse lines of perforation 1~ across the web, the web
15 is transferred through a series of rolls and finally is
transferred to a pre-glued core at the nip position 15 --
see also the core C at the lower.left in FIG. 3.
It is subsequently wound between an upper belt
system 16 which contacts the top of a web-wound core
(ultimately the log 17) which moves along a path in the
direction of arrow 18 -- see the right hand portion of FIGS.
2 and 3 -- and a lower belt system 19 which moves in the
direction of arrow 20 at a different speed which is less
than the speed of upper screen belt system 16. The belts
are advantageously driven through the rolls which define
nip 15.
A series of cores 21 (see the left hand portion
of FIG. 2) is fed through a chute 22 to posi~ion 23 from
which the cores are transferred by two assemblies which
travel in a three-cusp hypocycloidal motion, as shown by
the dotted lines 26, 27 and 28, to the nip position 15.
~322~7
Referring to FIG. 2, the core transfer device with the just-
mentioned hypocycloidal motion picks up a core at position
23 and transfers it to position 24 where it comes lnto
contact with a roll 29 having glue on its surface. The
roll 29 is arranged to apply an interrupted line of adhesive
to the core.
The first assembly with hypocycloidal motion
then moves the core from position 24 to position 25 where
it is transferred to, and is then under control of, a second
assembly with hypocycloidal motion. The second assembly
grips the core between glue segments and moves the core from
position 25 to the nip position 15. The nip 15 is approximately
equal to the outside diameter of the core and represents
the minimum distance between upper belt system 16 and lower
belt system 19.
Prlor to this instant, the perforated web is
carried forward around a series of rolls until it contacts
the line of adhesive on the core and is thus transferred
to the core. The now-rotating core and web being wound move
from position 15 in the direction of arrow 18 until the
log is completely wound, as at position 17 -- see FIG. 1.
Conventional equipment can be used for transferring the wound
logs to subsequent operations, such as cutting into individual
consumer size rolls, wrapping and cartoning.
Upper and Lower ~elts Generally
The perspective view of FIG. 1 also shows that
the upper screen belt system 16 and associated rolls are
generally cantilever mounted on one side frame 30. Thus,
the upper belt system is not movable, but the screen can be
removed and replaced from one side. Likewise, the lower
~322~
belt system 19 (having a plurality of belts and associated
parts) is generally cantilever mounted on a subframe (not
shown ) which is vertically movable on sllde shafts 31, 32
(see the lower right hand portion of FIG. 2). Blocks 33
mount shafts 31 and 32 securely to slde frame 30. Thus,
the lower belt system can be adjusted up or down relative
to the fixed upper belt system, and the gap therebetween
can be varied to compensate for differences in core diameter.
The front or operating side of the machine has
a side frame 30', illustrated only fragmentarily and at the
lower left in FIG. 1. This frame is cast with openi.ngs
to remove the two belt systems. It also provides a means
for mounting upper and lower brackets 34 and 35 -- see
the central right portion of FIG. 2. The brac~ets 34 and
35 serve as the means for supporting the cantilevered sides
of the two belt systems 16 and 19.
Still referring to FIG. 2, it will be seen that
the upper belt front support includes a first jack screw
36 extending downwardly from bracket 34. This engages the
upper end of a transverse beam 37 which is the main support
member for the upper belt system 16.
Extending downwardly from beam 37 is a second
jack screw 38 which is threadably received in beam 39 --
the one that carries the lower belt system 19. Extending
downwardly from beam 39 is a third jack screw 40 which, at
its lower end, is threadably received in rotary jack 41
mounted on bracket 35.
The upper beam 37 is rigidly mounted on the rear
frame 30 and the ~ower beam is slidably mounted relative
to the rear frame 30 on the aforementioned slide shafts 31,
32. Thus, by removing the three jack screws 36, 38 and 40,
- ' -:
~ ~ 2 ~
the front end of each of the beams 37, 39 is unsupported and
the upper and lower belts may be removed and replaced.
Upper Belt System Details
The upper beam 37 is equipped with a palr of
longitudinally-extending wings -- longitudinal in the
se~se of the direction of web travel in the machine.
These wings 42, 43 (see the central right hand portion of
FIG. 2) support the various rolls that carry the upper belt.
Since the upper screen is of a width corresponding
to web W, it is desirably guided. For this purpose, idler
roll 44 is arranged with one journal mounted in a commercially
available "cocking" device and which skews the roll as a
function of a screen edge guide sensor (not shown). In
this fashion, the full width screen is guided around the
multi-roll assembly. Upper roll 45 is supported on each
end by bearing blocks 46 which, through jacks 47, are movable in
either direction at the urging of pneumatic pillows 48. To
insure parallel movement of the roll 45 relative to idler
roll 49, pinions 50 are mounted on a common ross shaft. The
other roll associated with the upper screen belt assembly
is a vacuum transfer roll 51 operating in conjunction with
vacuum chamber 52, both of which are supported from the main
upper beam 37 through the wing 42.
Lower Belt System Details
~s mentioned previously, the support for the lower ;~
belt system is the transverse beam 39. This is adjustable
vertically by means of rotary jacks 41 (front and rear).
The beam 39 likewise carries a pair of longitudinally
extending wings 53, 54 which carry the various supporting
rollsO Through the operation of the jack screws 38, 40
the height of the beam 39 can be varied, thereby adjusting
the distance between the upper and lower belt syste~l. The
- 7 -
~13~23~l
rotary jacks are employed for aligning the ends of the
beam 39. The lower belt is advantageously driven through
the lower roll 51' of the nip 15.
To compensate for different finished roll dlameters,
the roll 55 (indirectly carried by the wing 54) can be
adjusted vertically. This is achieved by further rotary
jacks 56 mounted on the wings 43. Here it will be appreciated
that, for the sake of clarity of presentation, only
the front wing has been shown, but in accordance with
established machine practice, similar supporting means
are provided on the rear side.
Referring now to the upper left portion of FIG.
2, the major components in the web path first include a
web draw roll section generally designated 57. Provided
as part of this section is a spreader roll 58 and two co-
acting draw rolls 59, 60 which have an adjustable nip and
can be variable speed controlled. The perforating component `
13 includes a perforating head having anvils mounted therein
and a perforating roll 61 which has perforating blades,
20 generally as seen in U. S. Patent No. 2,870j840.
The cutoff and transfer section includes four rolls
consisting of a roll 62, a pivotable cutoff roll 63 having
blades 64 mounted therein, an anvil-bedroll 65 and the trans-
fer roll 51. Details of the cutoff and transfer section are
shown in FIG. 3, the details of the transfer sequence are
shown in FIGS. 4-8.
Gutoff and Transfer
FIG. 3 is an enlarged view of the cutoff and
transfer roll assembly shown in FIG. 2. Web W wraps roll
6~ which is driven at web speed and roll 62 may be in
contact with anvil roll 65 if desired. When the web passes
roll 62 and is entrained on the surface of roll 65, it
bridges slot 66. The cutoff roll 63 mounted to pivot
- 8 -
:L~22~37
abou~ shaft 67 is arranged with the blade 64 extendingradially outward of its periphery. When slot 66 is ro-tated to
about the two o'clock posltion as shown in FIG. 3, roll
assembly 63 is pivoted downward so blade 64 will pun~ture
the web and produce a free leading edge. Vacuum from an
external source (not shown) is applied to concentric slot
68 of an external vacuum manifold. By use of inserts 69
and 70, which are adjustable, that portion of the concentric
slot 68 extending clockwise from line 71 to line 72 is
vacuumized. Details of the external vacuum manifold are
well known and are generally described in co-owned U.S. Patents
3,490,762 and 3,572,681.
While roll 65 rotates from position 71 at about
ten o'clock until it reaches line 72 at about five o'clock,
vacuum manifold slot 6~ communicates with the trafisverse
vacuumized passage 73. Through a series of radial ports
74 aligned transversely across the face of roll 65 and
directly behind slot 66, vacuum is provided to control the
leading edge of the severed web segment. This leading
edge is held on the periphery of roll 65 by vacuum until it
reaches line 72 at the five o'clock position and from there
until about the seven olclock position at line 75, lt will
be entrained on the surface of the roll 65 by the upper
screen belt 16.
Vacuum chamber 52 which includes transEer roll
51, has an upper lip 76 which extends to about the four
o'clock position relative to roll 65 and serves to limit the
extent of vacuum chamber 52 at that location, as shown. This
permits the vacuum in chamber 52 to act upon the web W
before it leaves roll 65 ensuring reliable transfer of web
W onto the upper screen belt 16.
~32~3~7
Transfer roll Sl is essentlally a hollow roll
with a series of holes or apertures 77 in the surface
thereof. Advantageously, commercially available materials
such as expanded metal grating or other apertured
metallic plates, can be used for the porous surface of roll
51. It is noted that a strip 78 installed parallel to the
axis of the roll does not permlt vacuum to be effective in
arcuate portion 79 on the surface of roll 51.
When the leading edge of the cut web, carried on
the upper screen belt 16 by vacuum from chamber 52, ap-
proaches roll 51 at about 12 o'clock, it is matched
with the leading edge of strip 78 so that a portion of
the cut web, approximately equal in length to strip 78
is not held onto screen belt 16 as it wraps around roll
51. This leading web portlon, from leading edge to the
trailing edge of strip 78 folds back onto the following
portion of the web which is secuxely held against screen
belt 16 as it wraps around roll 51 by the vacuum in chamber
52. This fold back occurs during the movement of strip
78 from 12 o'clock on roll 51 to 6 o'clock where the nip
15 is formed so that fold back is present at the instant
of transfer to a new core at nip 15. The length of the
fold back is determined by the length of strip 78. Fold
back is not necessary for single ply webs but is advantageous
25 with webs of two or more plies.
At the instant the leading edge of folded portion
reaches the six o'clock position, a core C is inserted as
shown in phantom and is instantly trapped in the nip between
upper belt 16 and lower belt 19 as shown in position 15.
As soon as the core contacts both upper and lower belts,
it begins to rotate in a clockwise direction and almost
instantaneously, the velocity of its surface equals
web speed. ~f both belts were traveling at the same
-- 10 --
~ 3223~7
velocity, but in opposite directions as shown, the core
would remain stationary directly below the six o'clock
position of transfer roll 51. However, the velocity of lower
belt 19 is less than upper screen belt 16, and this difference
in belt velocities results in movement of the core and the
roll being wound successively from nip position 15 this
movement of the progressively wound log being in the direction
of arrow 18.
FIGS. 4~8 show the transfer of reverse folded
web as it approaches nip line 15'. There it contacts core
C with glue stripes 80, is glued (see FIGS. 5 and 6) as
it begins to rotate downwardly and as it rotates past
bottom belt contact point 19 (FIG. 7). In FIG. 8, the
leading edge of the web is secured to the core by
glue stripe 80 by completing one wrap and is thereafter
trapped by oncoming web segment until the winding process
is completed, analogous to co-owned U. S. Patent Re. 2~,353.
It will be recognized that the multiple apertures
77 result in a very porous surface of transfer roll 51 ~;
which, at the same time, allow high flow rates through that
portion of the porous surface that is enclosed within the
extended lip portions of vacuum chamber 52, (see FIG. 3).
While other arrangements are possible, hollow construction
with a porous surface of roll 51 is preferred, since the
arrangement shown makes possible the use of continuous
vacuum as opposed to very costly and complicated vacuum
systems that require cycling vacuum pressures. This is
particularly advantageous in achieving high speeds and also
in overcoming the normal difficulty in obtaining uniform
vacuum across a roll, especially when wider machines are
involved.
-- 11 --
, , ,
3 ~ 7
Core Transport and Feeding
The core feeding section generally designated
81 includes two rotating assemblies 82 and 83 -- see FIG.
2. Each develops a three-cusp hypocycloidal motion
which is advantageous ln transferring the core from the pickup
position 23 -- see FIG. 2 -- to the gluing position 24,
a transfer posltion 25 and a nip insertion position 15.
Details of this particular mechanlsm are seen in FIGS. 9
and 10. Each of the assemblies 82 and 83 are similar
in construction and motion, but are dimensioned differently
for this particular arrangement. For example, a rotating
vacuum roll 84 (see left bottom corner of FIG. 2) --
rotates about shaft 85 in an orbit 86 shown in phantom.
Upper transfer assembly 83 has a simllar rotating vacu-lm
15 roll 87 rotating about axis 88 in an orbit 89 -- also
shown in phantom.
Essentially, the lower transfer assembly 82
picks up cores at position 23 and moving through a
hypocycloidal path, moves the core to position 24 where
an interrupted axially-extending glue line is applied by
glue roll 29, and subsequently moves the core to position
25. The core is held on the transfer assembly by
vacuum. With the hypocycloidal motion, it is noted that
a glue line printed on the outside of the core at position
24 shows at transfer position 25 as a glue line in position
90 -- see FIG. 2. At position 25, vacuum on the lower assembly
is shut off and the vacuumized roll 87 on the upper transfer
assembly takes over control of the core and moves it to
the nip position.
The hypocycloidal motion of the core is achieved
in the illustrated embodiment by orbiting a vacuum roll
- 12 -
~32233~
84 about the axis of shaft 85 ~see FIG. 2) -- while at
the same time rotating the roll 84 relative to arm 91 --
see FIG. 10. The arm 91 is rotatably mounted on shaft
85. In FIG. 9, certain parts are stationary and include
the shaft 85 keyed to side frame 30, and an attached pulley
92 also keyed as at 93 to shaft 85. A vacuum valve 94,
having a concentric vacuum manifold 95, is attached to
the stationary frame 30 via bolts 96. Thus, it too remains
stationary.
The moving parts include pulley 97 rotatably
mounted on shaft 85, being driven by belt 98 from an
external source and synchronized with cutoff and transfer.
The arm 91 is secured to pulley 97 and carries vacuum con-
necting pipe 98 and sleeve 99 to rotate about shaft 85.
The end of arm or bracket 91 supports bearing
100, roll journal 101, pulley 102 attached thereto and
vacuum roll 84. While these parts also orbit, they rotate
relative to arm 91 due to action of belt 103 which is
entrained around fixed pulley 92 and pulley 102. The ~-
diameter of pulley 92 is three times that of pulley 102
which thus produces the three cusp hypocycloidal motion.
The rotation of pulley 102 causes vacuum roll
84 to rotate and with lt vacuum pucks or nozzles 104 and
core C -- about an axis provided by journal 101. This
combined motion results in the center of the core tracing
a hypocycloidal cuxve -- see phantom lines FIGS. 1 and 2
similar to that provided in co-owned U.S. Patent 3,994,486.
Referring to FIG. 9, stationary vacuum valve
94 bears against finished surface 105 of the rotating arm
91. The circular vacuum manifold 95 contains inserts 106,
107, which are spaced apart and define a vacuum zone V.
This zone is vacuumized through an external connect:ion 108
leading to a vacuum source (not shown).
- 13 -
- - 13223;~
Vacuum applied through plpe 108 communlcates
with the circular manifold 95 and when the opening 109
of pipe 98 communicates with vacuum zone V, vacuum is
transmitted through vacuum pocket 110 of sleeve 99 to
the central hollow chamber 111 of roll 84 through a
series of ports 112 which communicate wlth pocket 110.
In this manner, vacuum can be applled to the axlally-spaced
vacuum pucks over a selected portion V of the orbit in any
predetermined or programmed manner and as vacuum force is
needed to pick up, hold and release the cores.
Operation of Core Transport
-
To achieve the hypocycloidal motlon of the core,
it is orbited about the axls of the fixed shaft 85 or
88 while being revolved about the axis of the core transport
roll 84 or 87. In the illustratlon given, there are
three revolutions per orbit but any other lnteger num~er
can be used, dependlng upon the geometry of the system.
It wlll also be appreclated that gears or other transmission
coupllngs may be employed in place of the flrst pulley means
20 97, 98 for rotating the arm 91 to orbit the core transport
roll 84 or 88 and the core C ~- and ln place of the second
pulley means 92, 102, 103 for rotating the core transport
roll 84 or 88 to cause the core C to revolve around the
core transport roll 84 or 88. The core C ls offset from
25 the axls or the core transport roll 84 or 87 by the use of ;
generally radially extending puck means 104.
The cores are sequentially engaged and released,
in the illustration given, by vacuum. However, depending
upon the system geometry, other engaging/disengaging means
may be employed such as pins or grlppers on the core
engaglng member 84 or 87. Vacuum is preferred because it
minlmizes the use of movlng parts.
~ 14 -
3 ar~
For example, the only movement in the vacuum
system illustrated is that of the vacuum pipe 98
past the vacuum manifold 95 (see FIG. 9) and the rotation
of the ports 112 past the sleeve 99. Limiting the effect of
the vacuum -- and thereby the ability of the puck means
104 to maintain the cores in engaged relation -- is readily
achieved by blocking off parts of the manifold 95 by the
inserts 106. The location of the inserts thus programs the
clamping and unclamping of the cores by the core trans-
port roll means 84, 87.
Also in the illustration given, I make the orbit89 substantially larger -than the orbit 86. This permits
the use of longer puck means 10~ and thereby develops a lonyer,
narrower cusp to facilitate insertion of the core into the
15 nip 15. It also means that the puck means 104 are equally
quickly retracted from the vicini.ty of the nip so as not
to interfere with the winding of the roll being wound.
Reference is now made to FIG. 3A which shows a
modified form of the belt surface winder and focusing on
the parts thereof originally described with respect to
FIG. 3. The essential difference between the showing in
FIG. 3A from that of FIG. 3 is in the core insertion nip
which in FIG. 3A is designated 15a. Reference to FIG. 3A
shows that the lower roll 51'a has been displaced down
stream from the location in FIG. 3 and the core insertion
nip 15a is now developed by the upper roll 51a and a
stationary pla-te ~7a. The purpose of providing the
stationary plate 217a is to get the core C away from
the core inserting mechanism more rapidly. The core
inserting mechanism is depicted only schematically by
the fragmentary cusp designated 28a which is the path
followed by the center line of the core when the same is
- 15 -
~3223 .~7
supported by the vacuum puck means 104. This results
in a simplification of the core inserting means 81 because
there does not have to be quite as a rapid a withdrawal
of the vacuum puck means 104.
Also in thls connection it will be noted that
there are two nips provided, in effect. There is the core
insertion nip 15a and then downstream a short distance
therefrom a second nip, the belt system nip 223. The
nip 223 is that developed between the cooperative action of
the upper and lower belt systems. In the embodiment
of FIGS. 1-10, the single nip 15 accommodated both the
function of core insertion and the initiation of the
double belt system winding. In this modification, the
first nip 15a still accommodates the core insertion
function but the second nip 223 is the one that accommodates the
initiation of double belt system winding.
- MODIFICATIO~ OF FIGS. 11-17 -
A simple yet advantageously effective modification
of the surface winder of the type just described is
illustrated in FIGS. 11-17. It is simple because it
eliminates the following:
(1) the mechanism which cuts off the web
before transfer which consists of two
driven rolls and a complex cam
mechanism for moving one of the rolls
for cutoff;
- 16 -
(2) the vacuum pump and system which carrles
the cutoff web to the point of transfer
to the new core;
(3) the upper vacuum screen and guiding
system; and
(4) one of the two hypocycloial core handling
mechanisms.
Reference is now made to FIG. 11 whlch shows
the modified rewinder at the moment when the log being
wound is finlshed and a new core has been inserted into the
transfer nip.
The web W enters the machine at the left after
being unwound from a parent roll (or parent rolls) and
processed by embossing, laminating, printing, etc. It
wxaps draw rolls 201 nd 202 which feed the web
to the perforator roll 203. Draw roll 202 is normally
.~.
located at 9 o'clock relative to the perforator roll 203
but in this case is is moved to abou-t 7 o'clock to provide
access to the perforator roll surface (7 o'clock to 10 o'
clock) for changing perforator blades. The perforator roll
203 contains flexible perforating blades which perforate
the web by acting against anvils in the stationary
perforator bar 204. Blades and anvils are now shown in
order to simplify the sketch.
The web then wraps idling guide roll 205 and
driven roll 206, and continues onto the log being wound
207, passing through the core insertion nip 20~3 -- see
FIG. 12 which shows the web path just after roll 206 in
- 17 -
1~3223~7
larger scale. The log being wound 207 is held firmly
between upper belts 209 and lower belts 210 which cause
both rotation/winding of the log being wound and also
hori ontal movement of the log being wcund from
transfer to completion during the wlnding cycle. The
surface speed of roll 206 and the speed of upper belts
209 are the same and very close (+0~ to +56) to web
speed which is set by draw rolls 201 and 202 and perforator
roll 203.
The speed of the lower belts~210 ls less than the
speed of the upper belts 209 by an amount which causes
the log being wound to reach position 207 (approaximately)
at the completlon of winding. This speed difference is about
3~6 to 106 of web speed, and it is adjusted, by the
operator, to match the length of web in the finished
log (see FIG. 17 which is a Drive Schematic). In FIG.
17, the following symbols are employed:
"CW" refers to clockwise rotation
"CCW" refers to counterclockwise rotation
"B" refers to belt drive
"TB" refers to timing belt drive
"CH" refers to chain drive
"G" refers to gear drive
"~S" refers to variable speed drive
"M" refers to motor
:~.
- 18 -
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The upper and lower belts 209 and 210 are actually
several narrow belts (5-6 inches wide) which are close to-
gether (1-2 inch gap between belts~ and cover the entire
web width. The gaps between the upper belts are centered
opposite lower belts and vice versa so the entire width
is covered by at least one belt during winding.
Rolls 211 and 212 establish the working line of
upper belts 209. Roll 212 is the drive roll. Roll 211
is adjustable toward roll 206 to adjust the core insertion
nip 208, to match core diameter (1/2 inch to 2 inches range).
Roll 212 is in a fixed position which is not adjustable. Rolls
213 are several rolls, one for each belt or upper belts 209, ~;
and they are aix or spring loaded ayainst their bel-ts to
act as belt tighteners and hold all belts at equal operating
tension.
Rolls 214 and 215 establish the working line of
lower belts 210. Roll 214 is the drive roll, and it is
also adjustable vertically to match core diameter. Roll
215 is adjustable vertically to match finished log diameter
(2 inches to 6 inches is usual range). Rolls 216 are
several rolls, one for each belt of lower belts 210 and they
are air or spring loaded against their belts to act as belt
tighteners and hold all belts at equal operating tension.
A stationary plate 217 spans the distance from
roll 206 to the belts on roll 214. The core, with the
initial wraps of web after transfer, rolls along stationary
plate 217, driven by upper belts 209. The stationary plate
is adjustable vertically to match core diameter.
FIG. 11 shows the 3-cusp hypocycloidal core handling
mechanisrn 218 which is preferred because it uses only continuous,
steady, rotary motions -- no cams, cranks, or linkages. With
the 12 inch diameter mechanism shown in FIG. 11, the maximum
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acceleration of the core is only 2.5 G's at 60 logs per
minute (LPM) which is quite gentle, reasonable, and acceptable.
The acceleration is only 5.5 G's at 90 LPM which is also
acceptable and reasonable.
Core handling mechanism 218 makes one revolution
(cycle) per finished log produced, moving through paths
226, 227 and 228 defining cusps 226a, 227a and 228a. As
seen ln FIGS. 12 and 13, during that revolution (cycle) the
mechanism 218 holds and carries the core by means of vacuum
puck means. In this embodiment, a continuous stripe of
adhesive is laid down and opposite to the side engaged by
the vacuum puck means so that a continuous puck can be
emplo~ed. The mechanism performs 3 tasks during each revolution
(cycle).
(1) It picks up a new core from -the one-at-a-
time core escapement wheels 219. The vacuum
in the core carrying arms is turned on
shortly before the pick-up action.
(2) It presses the core against glue roll
220, which turns ~owly in a pan of transfer
glue so its surface is always covered with a
film of fresh glue. Glue roll 220 turns
constantly at fixed speed lndependent of
machine speed (see FIG. 17). This action
puts a line of transfer glue on the core at
the correct location for transfer (see FIGS.
` 12, 13 and 14).
(3) It inserts the glued core into the core
insertion nip 208 between rolls 206 and 211
at the correct moment in the winding cycle,
synchronized with the periorator and
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pinch-plate mechanism 221 to break and
transfer the web onto the new core with exact,
constant, sheet count per log. The vacuum
is turned off at the moment the core enters
the transfer nip 208.
These actions of pick-up, gluing, and inserting are sequential
and the sequence is repeated every product winding cycle.
FIG. 11 shows mechanism 218 in all three operating positlons
in order to show these positions on a single sketch.
The mechanism 221 is the pinch-plate mechanism.
Its function and purpose is to pinch the web W firmly against
the upper belts 209 at the moment of web-break (see FIG.
14). The mechanism is arranged and located so that the
distance between point A, where the pinch-plates pinch the
web against the upper belts, and polnt B where the core
pinches the web firmly against statlonary plate 217, is
less than twice the distance between two lines
of perforation. lt is timed to core insertion and per-
foration so that the specific line of perforation P to be
broken lies intermediate, i.e., about mid-way between points
A and B in FIG. 14. The surface speed of the pinch-plates
ls the same as the speed of the upper belts 203. At point
A, the web is moving between the pinch-plates and upper belts
at full web speed. At point B, the web is stationary/
stopped between the core and the line of perforation
P between A and B breaks. This yields:
(1) Exact sheet count in each finished log.
(2) Clean web-break at a line of perforation.
(3) A short bit of web (about 1/2 the
distance between A and B) folded back
around the core; a relatively neat and
attractive transfer quality.
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(4) Reverse-fold foldback around the core
which traps both plies of 2-ply webs.
F~G. 16 is a view looking vertically downward from above the
centerline of the shaft 222 of the pinch-plate mechanism. On
the shaft 222 there are several radial arms (one for each
belt of upper belts 209) each of which carries a curved
pinch-plate which is as long axially as its matching belt
is wide. The stationary plate 217, contains an H-shaped
hole for each radial arm. These holes allow the pinch--
plates to pass through the stationary plate yet the holesare small (narrow) enough not to disturb the web winding around
the core as it rolls over the holes. The pinch plates pass
through the legs of the H while the radial arms pass through
the cross bar of the H shaped opening.
Pinch-plate mechanism 221 rotates continuously
during the entire winding cycle so it pinches the ~eb
against upper belts 209 several/many times yet it does not
disturb the web flow/winding or break any perforations except
at the precise moment of web-break and transfer; once per
log. Thls situation/condition exists because:
(1) Roll 206 is located so that the web path
lies on the lower surface of upper belts 209
(see FIG. 12~, viz., the upper surface of
roll 206 is aligned with the surface of the
lower run of belts 209.
(2) The surface speed of the pinch-plates is
the same as the speed of the upper
belts 209.
The circumference of the circular path of the surface of
the pinch-plates is e~ual to an integer number of sheets
times the distance between the perforation lines which define
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~ 3223~7
those sheets.
FIGS. 11-16 show a pinch-plate mechanism with a
circumference of 45 inches (10 sheets x 4-1/2 inches per
sheet). This meàns that the number of sheets in a finished
log must be some integer multiple of 10 (100, 130, 210,
etc.). Other pinch-plate mechanism sizes are entirely
feasible, but they must meet several design criteria:
(1) Circumference of the circular path of
the surface of the pinch-plates equals
an integer number of sheets times the
length per sheet.
(2) Distance between A and B in FIG. 14 less than
two times sheet length. In the U.S. this is
less than 9 inches on toilet tissue which is
the most demanding application. Less demanding
is the European product which has a typical
sheet length of 140 mm. (approximately 5-1/2").
(3) Surface speed of the pinch-plates equals
speed of upper belts 209 and web speed.
(4) Perforator and pinch-plate mechanism
are synchronized so perforator creates
N lines of perEoration per revolution of
the pinch-plate mechanism where N is the
integer number of sheets in the circumference
of the circular path of the surface of the
pinch-plates.
(5) Radius of pinch-plate mechanism (Erom
center line of shaft to outer surf~ce of pinch-
plates) must be large enough to accommodate
and include:
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(a) Core diameter
(b) Shaft radius
(c) Stationary plate thickness
For example, within these design criteria a circumference of
22-1/2 inches (5 sheets x 4-1/2 inches per sheet) is feasible.
This permits the number of sheets in a finished log to be
some integer multiple of 5 (95, 135, 215, etc.). This will
be very advantageous for many applic~tions where multiples
of 5 sheets in the finished product is desired.
FIGS. 12-15 show what happens in a very brief
instant from just before the core is inserted into core
insertion nip 208, until the glue line on the core picks
up the web and winding begins.
The time from FIG. 13 to FIG. 15 in a rewinder
running 3000 FPM ls only about 5 milli-seconds.
(1) The core with its glue line approaches
the core insertion nip 208 which is adjusted
to be less than the core diameter in order
to pinch the core firmly in the nip.
(2) The core is firmly pinched in core insertion
nip 208 and it is moved at web speed through
the nip b~ the surfaces of roll 206 and upper
belts 209 wrapping roll 211 which are both
moving at web speed and in the same direction.
(3) The core rolls onto stationary plate 217
pinching the web firmly against the stationary
plate at point B and stopping the web motion.
The perforation P between A and B breaks.
(4) The core continues rolling on stationary plate
217 un~il the glue line lies between the ~ `;
core and the severed web (about 6 o'clock
on the core in FIG. 15). The glue picXs up
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13223~
the web to start winding. Radial acceleration
of web and glue at pick-up/transfer is one-
fourth that of prior art winding machines.
The web behind the core (to the left of glue
contact with web) continues to feed creating
a slack web (zero tension) which lasts during
the first wrap around the core.
(5) The core, with the initial wraps of web,
rolls rapidly to the nip 223 between the
two slightly divergent, co-acting belt
systems 209 and 210. More particularly, this
nip 223 is provided with roll 214 and upper belts
209. This is where the horizontal motion of
log being wound slows substantially and
"double-belt" winding begins and continues
until the log is completed as at 207.
At 3,000 FPM, the time from FIG. 13 until the core reaches
12 o'clock relative to roll 214 (nip 223) is only about 63
milli-seconds (about 38 inches of paper). There are several
unique features in this transfer and cut-off/web-brea~
concept.
(1) Web fold-back at the core is "reverse" fold
which traps both plies of 2 ply webs and makes
high speed (3,000 FPM) feasible with 2-ply webs.
(2) When the glue line on the core reaches
6'clock where the core presses the glue
against the web creating transfer of the severed
web to the core, the radial acceleration which
the glue must overcome for successful transfer
is very low compared with prior art winders.
- 25 -
~2~31c~7
(3) The core irons the glue line against
the web 3 times before the first wrap
around the core is completed.
By contrast:
(a) On a prior art center-wind rewinder,
the transfer pads iron the web against
the glue only once.
(b) On a rewinder, according to the '877
patent, the core irons the glue against the web
only twice.
(4) The glue line on the core covers the entire
web width for best possible transfer action.
By contrast, on prior art rewinders, the trans-
fer glue is applied to the core as narrow rings
which cover much less than l/2 the web width.
(5) During the initial rotation of the core
after web break-off until the glue line
reaches 12 o'clock, the winder does not take
away all the web being perforated. This
creates a brief period of low web tension
(virtually zero), which means that the
transfer glue does not have to overcome
any web tension and the first wrap around
the core will be somewhat loose and wrinkled.
This is a minor disadvantage compared to the
result produced by the embodiment of FIGS.
l-10 but is completely justified in terms of
the significant reduction in machine
complexity. Thereafter the united web and
core advance to the nip 223 defined by an
;' .
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~3~3~7
intermediate point in the run of the upper
belts 209 and the upstream end of the lower
belts 210.
(6) The whole process is independent of core
diameter.
The modification of FIG. 11 also permits the opportunity
to include a unique feature which has never been used
before. A dancer roll can now be positioned between the
perforator and winding to control winding tension directly
Also, there are some variations of this new "double-
beltl' surface rewinder concept which may be useful in some
applications:
(1) Eliminate the pinch-plate mechanism 22L The machine
still makes logs reliably, but the logs contain quality
defects which may be unacceptable.
(a) Sheets per log will vary 5 sheets
(approximately).
(b) Break-off may be on two or more different
lines of perforation, leaving a ragged, uneven,
tail on the log.
(c) Tail folded back around the core may be
as long as 5 sheets.
(d) With 2-ply webs, the two plies may break
at different lines of perforation.
(2) Eliminate the pinch-plate mechanism 221 and by
means of a double flexing blade perforator whlch makes
a very weak line of perforation, instead of the
normal perfora~ion, once per winding cycle. Then time
core insertion in the transfer nip to occur shortly
(2 to 3 inches) after the very weak perforation passes
that nip.
- 27 -
(3) For non-perEorated products, eliminate the
pinch-plate mechanism 221 and make a line of
perforation once per winding cycle. Then time
core insertion in the transfer nlp to occur
shortly (2 to 3 inches) after the perforation
passes that nip.
Features and Advantages of FIG. 11 Embodiment
(1) ALL motions and actions are continuous,
steady, and rotary. There are no cams, cranks,
indexers, or similar devices.
(2) Performance up to 60 LPM and above 3000 FPM.
Other modificatlons include the use of the hypo-
cycloidal core feeder 218 in combination with a prior art
surface winder 301 of the '877 patent type as seen in FIG.
18.
In -the embodiment of FIG. 18 relative to the winder
301, windlng is achieved by coaction of a three roll cluster
including rolls 311, 314 and a rider roll 3.~. Cutoff is
achieved through cooperation of the roll 311 and the stationary
plate 317 much as in the operation previously described
with reference to FIG. 14 where the core holds ths web
against the st~tionary plate a-t B and the product being
wound creates a second holding point as at A.
The same operation is possible by a modified version
as seen in FIG. 18A. There, the winding cradle rolls are
the same as in FIG. 18 but a larger stationary plate 417
is provided -- thereby eliminating the lower nip forming
roll 206. Also possible is the use of a conventional core
feeder 501 in conjunction with the inventive surface winder
having belts 209, 310 as seen in FIG. 19. The feeder 501
- 28 -
~ ~23 a7
has an articulated arm 502 which moves from a core pick-
up station to an adhesive pick-up station to a nip station
while under the control of a pivot arm 503.
While in the foregoing specification a detailed
description of an embodiment of the invention has been
set down for the purpose of illustration, many variations
in the details hereingiven may be made by those skilled
in the art without departing from the spirit and scope of
the invention.
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