CONTINUOUS WINDER AND METHOD OF WINDING SLIT ROLLS OF LARGE DIAMETER ON SMALL DIAMETER CORES

BOBINOIR CONTINU ET PROCEDE DE BOBINAGE DE ROULEAUX DE REFENTE DE GRAND DIAMETRE SUR DES MANDRINS DE FAIBLE DIAMETRE

English Abstract

A drum type continuous winder
for winding slit sections of a web onto
individual cores on a core shaft (20)
includes a pair of primary support arms
(24, 25) having radial slots (28) that
receives the core shaft from a fixed cam
plate (29) permitting the core shaft to
move with the cores into engagement
with a moving web on a main winding
drum (22) for web cutting and transfer
to fresh cores. A driven nip roll (30)
supported on arms (24, 25) engages the
cores on the core shaft during web
transfer so that the core shaft is sandwiched
between the nip roll (30) and the
primary drum (22) providing web
transfer onto the cores free of critical speed
limitations. Secondary ai-ms (50, 51)
which receive the core shaft support a
secondary winding drum (52) in guide
tracks (55) for radial movement into
engagement with the rolls being wound.

French Abstract

L'invention concerne un bobinoir continu du type tambour permettant de procéder au bobinage des parties de refente d'une feuille continue sur plusieurs mandrins d'une tige de bobinage (20), ce bobinoir comprenant deux bras support primaires (24, 25) sur lesquels sont ménagées des fentes radiales (28) destinées à recevoir ladite tige de bobinage depuis un disque à cames fixe (29), ce qui permet à cette tige de bobinage et au mandrins d'entrer en contact avec une feuille continue qui se déplace sur un tambour de bobinoir principal (22). La feuille continue est ainsi coupée et transférée vers de nouveaux mandrins. De plus, un cylindre exprimeur entrainé (30), reposant sur lesdits bras (24, 25), est conçu pour entrer en contact avec les mandrins de la tige de bobinage pendant le transfert de la feuille continue, de sorte que cette tige de bobinage est prise en sandwich entre le cylindre exprimeur (30) et le tambour primaire (22), le transfert de cette feuille continue vers les mandrins s'effectuant donc sans ralentissement particulier. Enfin, des bras secondaires (50, 51) sont destinés à recevoir la tige de bobinage et à soutenir un second tambour de bobinoir (52) dans des glissières de guidage (55), de manière à imprimer un mouvement radial et à provoquer un contact avec les rouleaux en cours de bobinage.

Claims

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-CLAIMS-


1. A method of continuously winding split webs onto individual cores carried
on a
common elongated shaft into a corresponding plurality of large diameter rolls
including
transfer of the split webs, substantially at line speed, from fully wound
rolls onto such
cores, comprising the steps of:
(a) placing the core shaft with cores thereon into surface contact with such
split
webs supported on a winding drum and bringing said core shaft and cores
thereon
up to line speed;
(b) applying a driven nip roll to said cores substantially at line speed while

simultaneously constricting the ends of said core shaft against movement
lateral to
a radius line from the axis of rotation of said drum through said core shaft;
(c) while said core shaft is so restrained, severing the split webs at
positions
downstream of the region of contact of said cores with said webs by said drum
and simultaneously transferring said webs onto corresponding cores on said
core
shaft;
(d) continuing to wind said webs onto said cores while said core shaft is so
constrained laterally and constrained by said driven nip roll against core
shaft
deflections that would otherwise cause critical speed limitations,
in which the winder has a movable secondary support drum that is movable into
contact with rolls building on the cores and in spaced relation to the winding
drum,
further including the step of bringing the secondary drum into contact with
such rolls
when the rolls have attained a predetermined diameter while maintaining
contact of said
driven nip roll with said building rolls.

2. The method according to claim 1, in which said core shaft and the cores
thereon
are brought substantially to web line speed by the driven nip roll prior to
contact of the
cores with the split webs on the winding drum.

3. The method according to claim 1, in which said restraining step includes
securing
the core shaft at its ends against lateral movement by capturing the ends of
the core shaft
in an elongated slot that extends in a direction generally radially of the
drum and provides



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a pathway for the core shaft with loaded cores thereon to be moved into
contact with split
rolls on said drum.

4. The method according to claim 1, in which the step of restraining said core
shaft
against lateral movement is terminated following engagement of the secondary
drum with
the building rolls.

5. The method according to claim 1, in which the nip roll is maintained in
contact
with the building rolls at least until the secondary drum has come into
contact with the
building rolls.

6. The method according to claim 5, in which the pressure of the nip roll on
the
building rolls is increased with increasing diameters of the rolls.

7. A method according to claim 1, including the step of spraying an adhesive
on the
inside surface of the webs leading to the fully wound rolls immediately prior
to said
cutting step for simultaneously gluing the tail segments of the cut webs onto
the
respective wound rolls and providing an adhesive surface by which the
individual webs
are attached to the respective cores on the core shaft.

8. The method according to claim 1, in which the secondary support drum is
mounted on secondary support arms that operate independently of the primary
drum and
nip roll in which the secondary support arms include a core shaft support for
receiving the
core shaft with partially wound rolls thereon and in which the secondary drum
is movable
on the secondary arms into contact with the partially wound rolls when the
core shaft is so
supported on the support arms with the partially wound rolls supported
simultaneously
between the primary and secondary drums comprising the further step of counter-

balancing the weight of said rolls by said secondary drum.

9. The method according to claim 8, in which said further step includes a
measurement of the angle of the secondary arms and modifying the counter-
balancing
force of the secondary drum to prevent excessive bending of the core shaft.




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10. The method according to claim 1, further including the step of applying a
braking
force to the wound rolls through said secondary drum to stop rotation thereof
following
said transferring step.


11. A method as recited in claim 1, wherein the step of restraining said core
shaft
against lateral movement is maintained while winding said webs on said cores
with said
cores being held in secondary arms, said secondary arms holding said building
rolls in
contact with said secondary drum.


12. A method as recited in claim 1, wherein an axis of said core shaft is
located in a
plane which passes through an axis of said winding drum and which defines an
angle of
about -20° with respect to a vertical plane which passes through said
axis of said winding
drum when said severing the split webs occurs, and said core shaft is moved
during said
continuing to wind said webs onto said cores to a position where said axis of
said core
shaft is in a plane which passes through said axis of said winding drum and
defines which
an angle of about +30° with respect to said vertical plane.


13. A method of continuously winding split webs onto individual cores carried
on a
common elongated shaft into a corresponding plurality of large diameter rolls
including
transfer of the split webs, substantially at line speed, from fully wound
rolls onto such
cores, comprising the steps of:
(a) placing the core shaft with cores thereon into surface contact with such
split
webs supported on a winding drum and bringing said core shaft and cores
thereon
up to line speed;
(b) applying a driven nip roll to said cores substantially at line speed while

simultaneously constricting the ends of said core shaft against movement
lateral to
a radius line from the axis of rotation of said drum through said core shaft;
(c) while said core shaft is so restrained, severing the split webs at
positions
downstream of the region of contact of said cores with said webs by said drum
and simultaneously transferring said webs onto corresponding cores on said
core
shaft;




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(d) continuing to wind said webs onto said cores while said core shaft is so
constrained laterally and constrained by said driven nip roll against core
shaft
deflections that would otherwise cause critical speed limitations,
in which the nip roll is driven at a speed mode prior to the cutting step and
is
switched to a speed limited adjustable torque mode following the transfer of
the webs
onto the cores of the core shaft.


14. A drum type winder for continuously winding a split web into large
diameter rolls
on individual cores carried on a core shaft, comprising a frame, a main
winding drum on
said frame, a pair of arms mounted on said frame for rotation about an axis in
common
with the axis of said main winding drum, an elongated core shaft for
supporting a
plurality of cores thereon, a nip roll carried on said arms and engagable with
cores on
such core shaft, said arms being provided with generally radially extending
slots through
which the ends of said core shaft extend when a core is received in said
slots, each said
slot defining walls that resist lateral movements of the core shaft ends while
permitting
rotation of said core shaft on said arms and movement of said core shaft
radially of said
drum along said slots, said slots being open at their respective outer radial
ends to receive
said core shaft therein and having a radial length that permits said core
shaft to move
radially inwardly to place the cores thereon in engagement with a web carried
on the
surface of said drum while said cores are simultaneously engaged by said nip
roll, thereby
maintaining said core shaft in a generally straight line position for transfer
of webs onto
cores on said shaft.


15. The drum type winder according to claim 14, further comprising cams on
said
frame one each adjacent each of said arms, each of said cams defining a
surface
positioned generally radially outwardly of said arm slot open ends for
supporting said
core shaft prior to said core shaft entering said slot open ends.


16. The drum type winder according to claim 14, further comprising a pair of
secondary arms rotatably mounted on said frame, a secondary support drum
mounted
between said secondary arms, generally radially extending guide ways on said
secondary
arms supporting said secondary support drum for movement along positions
radially of
said secondary arms, said secondary support drum being movable by said
secondary arms




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into engagement with building rolls on said core shaft at a position in spaced
relation to
the engagement position of said main winding drum with said building rolls
thereby
cradling said building rolls between said drums.


17. The drum type winder according to claim 16, further comprising cylinders
on said
secondary arms providing a lifting force to said secondary support drum by
which at least
a substantial portion of the weight of said building rolls on said core shaft
may be
supported on said secondary support drum to maintain said core shaft in a
generally
straight line condition.


18. The drum type winder according to claim 16, in which said secondary arms
are
formed with core shaft-receiving notches on the ends thereof into which said
core shaft
ends may be received after said building rolls have built up to the point
where the core
shaft has reached said open ends of said slots in said primary arms, said core
shaft and the
rolls thereon being movable by said secondary arms about said secondary
support drum to
a loading position remote from said primary arms.


19. The drum type winder according to claim 18, further comprising motor drive

means for said secondary drum for dynamically braking the rotation of said
rolls thereon
for unloading built up rolls from said winder.


20. A winder for winding a web onto a core shaft, comprising:
a winding drum, said winding drum being driven and being rotatable about a
winding drum axis;
a pressure roll, said pressure roll being driven, said pressure roll being
movable
among a plurality of pressure roll positions, said pressure roll being
rotatable about a
respective pressure roll axis in each of said pressure roll positions, each of
said respective
pressure roll axes being substantially parallel to each other and to said
winding drum axis,
a support roll, said support roll being driven, said support roll being
movable
among a plurality of support roll positions, said support roll being rotatable
about a
respective support roll axis in each of said support roll positions, each of
said respective
support roll axes being substantially parallel to each other, to each of said
respective
pressure roll axes and to said winding drum axis,




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a first support structure for supporting a first core shaft, said first core
shaft having
at least one first core mounted thereon, at a first location where said first
core is not in
contact with said winding drum or said support roll, and at a first core shaft
orientation
where an axis of said first core shaft is substantially parallel to each of
said respective
support roll axes, each of said respective pressure roll axes and said winding
drum axis,
one of said pressure roll positions being a position where said pressure roll
is in
contact with said first core in said first location, whereby said pressure
roll causes said
first core shaft to rotate about said axis of said first core shaft and
controls a rate of
rotational acceleration of said first core shaft about said axis of said first
core shaft,
a guide structure for guiding said first core shaft from said first location
to a
second location where said first core abuts a first surface of a moving web, a
second
surface of the moving web being in contact with said winding drum,
a second support structure for supporting said first core shaft at a third
location,
said third location being a position where a wound web wound on said first
core abuts
said winding drum and abuts said support roll such that said support roll and
said winding
drum together support said wound web, said third location being spaced from
said first
location such that a second core shaft, said second core shaft having at least
one second
core mounted thereon, can be positioned in said first location while said web
is
continuing to be wound on said wound web on said first core shaft in said
third location.

21. A winder as recited in claim 20, wherein said web is a split web.


22. A winder as recited in claim 21, wherein said first core shaft has a
plurality of first
cores mounted thereon and aligned along said axis of said first core shaft.


23. A winder as recited in claim 20, further comprising at least two primary
support
arms, said primary support arms each having slots, said guide structure
comprising said
slots.


24. A winder as recited in claim 23, wherein said slots are substantially
radially
aligned with a radius of said winding drum.




-25-

25. A winder as recited in claim 23, wherein said primary support arms are
rotatable
about said winding drum axis.


26. A winder as recited in claim 23, wherein said pressure roll is mounted on
at least
two pressure roll support arms which are rotatably mounted on said primary
support arms.

27. A winder as recited in claim 25, further comprising at least one cam
plate, said
first support structure comprising a core shaft supporting surface of said cam
plate, said
core shaft supporting surface of said cam plate being substantially
perpendicular to axes
of said slots, whereby upon rotation of said primary support arms, said first
core shaft is
moved off of said core shaft supporting surface of said cam plate and then
along said
slots, thereby moving said first core shaft from said first location to said
second location.

28. A winder as recited in claim 20, further comprising a web transfer and cut-
off
shoe which extends transversely adjacent an outer surface of said winding
drum, said web
transfer and cut-off shoe being rotatable about said winding drum axis, said
web transfer
and cut-off shoe comprising a knife which is extendible above said shoe into a
path of
said web.


29. A winder as recited in claim 20, further comprising at least two secondary
support
arms, said second support structure comprising elements mounted on said
secondary
support arms.


30. A winder as recited in claim 29, further comprising at least two support
roll
mounting elements mounted on respective secondary support arms, said support
roll
mounting elements supporting said support roll and being movable relative to
said
secondary support arms, whereby said support roll can be moved relative to
said first core
shaft and can apply a desired pressure on said wound web wound on said first
core.


31. A winder as recited in claim 30, further comprising a frame, at least two
primary
support arms, and at least one cam plate,
said secondary support arms being rotatable relative to said frame along a
secondary support arm axis, said secondary support arm axis being
substantially parallel




-26-

to each of said respective support roll axes, each of said respective pressure
roll axes and
said winding drum axis,
said primary support arms each having slots,
said guide structure comprising said slots,
said winding drum being mounted on said frame,
said primary support arms being mounted on said frame and being rotatable
about
said winding drum axis,
said pressure roll being mounted on at least two pressure roll support arms
which
are rotatably mounted on said primary arms,
said first support structure comprising a core shaft supporting surface of
said cam
plate,
said surface of said cam plate being substantially perpendicular to axes of
said
slots, whereby upon rotation of said primary support arms, said first core
shaft is moved
off of said surface of said cam plate and then along said slots, thereby
moving said first
core shaft from said first location to said second location.


32. A winder as recited in claim 31, further comprising:
a first angle encoder for measuring an angle of said pressure roll support
arms
relative to said primary support arms, for detecting the location of said
pressure roll
relative to said primary support arms;
a second angle encoder for measuring an angle of said secondary support arms
relative to said frame;

a web transfer and cut-off shoe which extends transversely adjacent an outer
surface of said winding drum, said web transfer and cut-off shoe being
rotatable about
said winding drum axis, said web transfer and cut-off shoe comprising a knife
which is
extendible above said shoe into a path of said web;

said secondary support arms each comprising a notch for receiving an end of
said
first core shaft;

notch closing slides mounted on respective secondary support arms, said notch
closing slides being movable between a notch slide open position, in which
said first core
shaft can be removed from said notches, and a notch slide closed position, in
which said
first core shaft is locked in said notches;




-27-

at least one proximity switch mounted on at least one of said secondary
support
arms, said proximity switch being positioned such that it is actuated only if
said first core
shaft is lifted upwardly within at least one of said notches; and
a spray bar and a plurality of spray nozzles mounted on said spray bar, said
spray
bar being positioned such that said web passes adjacent to said spray bar and
then passes
adjacent to said web transfer and cut-off shoe.


33. A winder for winding a web onto a core shaft, comprising:
a winding drum, said winding drum being driven and being rotatable about a
winding drum axis;
a pressure roll, said pressure roll being driven, said pressure roll being
movable
among a plurality of pressure roll positions, said pressure roll being
rotatable about a
respective pressure roll axis in each of said pressure roll positions, each of
said respective
pressure roll axes being substantially parallel to each other and to said
winding drum axis,
a support roll, said support roll being driven, said support roll being
movable
among a plurality of support roll positions, said support roll being rotatable
about a
respective support roll axis in each of said support roll positions, each of
said respective
support roll axes being substantially parallel to each other, to each of said
respective
pressure roll axes and to said winding drum axis,
a first core shaft positioned at a first location, said first core shaft
having at least
one first core mounted thereon,
a first support structure supporting said first core shaft at said first
location, said
first core shaft being not in contact with said winding drum or said support
roll, an axis of
said first core shaft being substantially parallel to each of said respective
support roll
axes, each of said respective pressure roll axes and said winding drum axis,
said pressure roll being in contact with said first core, thereby causing said
first
core shaft to rotate about said axis of said first core shaft and controlling
a rate of
rotational acceleration of said first core shaft about said axis of said first
core shaft,
a second core shaft positioned at a third location, said second core shaft
having at
least one second core mounted thereon,
a moving web being wound on said second core to form a wound web,




-28-

a guide structure for guiding said first core shaft from said first location
to a
second location where said first core shaft abuts a first surface of said
moving web, a
second surface of said moving web being in contact with said winding drum,
a second support structure supporting said second core shaft at said third
location,
where said wound web being wound on said second core abuts said winding drum
and
said support roll such that said support roll and said winding drum together
support said
wound web.


34. A winder as recited in claim 33, wherein said web is a split web.


35. A winder as recited in claim 34, wherein said first core shaft has a
plurality of first
cores mounted thereon and aligned along said axis of said first core shaft.


36. A winder as recited in claim 33, further comprising at least two primary
support
arms, said primary support arms each having slots, said guide structure
comprising said
slots.


37. A winder as recited in claim 36, wherein said slots are substantially
radially
aligned with a radius of said winding drum.


38. A winder as recited in claim 36, wherein said primary arms are rotatable
about
said winding drum axis.


39. A winder as recited in claim 36, wherein said pressure roll is mounted on
at least
two pressure roll support arms which are rotatably mounted on said primary
arms.


40. A winder as recited in claim 38, further comprising at least one cam
plate, said
first support structure comprising a core shaft supporting surface of said cam
plate, said
core shaft supporting surface of said cam plate being substantially
perpendicular to axes
of said slots, whereby upon rotation of said primary support arms, said first
core shaft is
moved off of said core shaft supporting surface of said cam plate and along
said slots,
thereby moving said first core shaft from said first location to said second
location.




-29-

41. A winder as recited in claim 33, further comprising a web transfer and cut-
off
shoe which extends transversely adjacent an outer surface of said winding
drum, said web
transfer and cut-off shoe being rotatable about said winding drum axis, said
web transfer
and cut-off shoe comprising a knife which is extendible above said shoe into a
path of
said web.


42. A winder as recited in claim 33, further comprising at least two secondary
support
arms, said second support structure comprising elements mounted on said
secondary
support arms.


43. A winder as recited in claim 42, further comprising at least two support
roll
mounting elements mounted on respective secondary support arms, said support
roll
mounting elements supporting said support roll and being movable relative to
said
secondary support arms, whereby said support roll can be moved relative to
said second
core shaft and can apply a desired pressure on said wound web wound on said
second
core.


44. A winder as recited in claim 43, further comprising a frame, at least two
primary
support arms, and at least one cam plate,
said secondary support arms being rotatable relative to said frame along a
secondary support arm axis, said secondary support arm axis being
substantially parallel
to each of said respective support roll axes, each of said respective pressure
roll axes and
said winding drum axis,
said primary support arms each having slots,
said guide structure comprising said slots,
said winding drum being mounted on said frame,
said primary support arms being mounted on said frame and being rotatable
about
said winding drum axis,
said pressure roll being mounted on at least two pressure roll support arms
which
are rotatably mounted on said primary arms,
said first support structure comprising a core shaft supporting surface of
said cam
plate,




-30-

said surface of said cam plate being substantially perpendicular to axes of
said
slots, whereby upon rotation of said primary support arms, said first core
shaft is moved
off of said surface of said cam plate and along said slots, thereby moving
said first core
shaft from said first location to said second location.


45. A winder as recited in claim 44, further comprising:
a first angle encoder for measuring an angle of said pressure roll support
arms
relative to said primary support arms, for detecting the location of said
pressure roll
relative to said primary support arms;
a second angle encoder for measuring an angle of said secondary support arms
relative to said frame;
a web transfer and cut-off shoe which extends transversely adjacent an outer
surface of said winding drum, said web transfer and cut-off shoe being
rotatable about
said winding drum axis, said web transfer and cut-off shoe comprising a knife
which is
extendible above said shoe into a path of said web;
said secondary support arms each comprising a notch for holding an end of said

second core shaft;
notch closing slides mounted on respective secondary support arms, said notch
closing slides being movable between a notch slide open position, in which
said second
core shaft can be removed from said notches, and a notch slide closed
position, in which
said second core shaft is locked in said notches;
at least one proximity switch mounted on at least one of said secondary
support
arms, said proximity switch being positioned such that it is actuated only if
said second
core shaft is lifted upwardly within at least one of said notches; and
a spray bar and a plurality of spray nozzles mounted on said spray bar, said
spray
bar being positioned such that said web passes adjacent to said spray bar and
then passes
adjacent to said web transfer and cut-off shoe.


46. A method of winding a web onto a core shaft, comprising:
positioning a first core shaft on a first support structure at a first
location, said first
core shaft having at least one first core mounted thereon;



-31-


bringing a pressure roll into contact with said first core shaft, said
pressure roll
having a pressure roll axis which is substantially parallel to a pressure roll
axis of said
first core shaft;
driving said pressure roll about said pressure roll axis, thereby causing said
first
core shaft to rotate about said first core shaft axis due to said contact
between said
pressure roll and said first core shaft;
moving said first core shaft from said first location to a guide structure and

through said guide structure to a second location, in which said first core
abuts a first
surface of a moving web, a second surface of said moving web being in contact
with a
winding drum, an axis of said first core shaft in said second location being
substantially
parallel to an axis of said winding drum;
cutting said moving web to produce a first tail end of said web and a first
leading
end of said web;
contacting said first leading end of said web with said first core;
initiating winding of said web onto said first core;
continuing winding of said web on said first core to produce a growing wound
web wound on said first core, said growing wound web being supported by said
winding
drum and being pressured by said pressure roll;
continuing winding of said web on said first core while bringing into contact
with
said growing wound web a support roll, said support roll having a support roll
axis which
is parallel to an axis of said first core, whereby said growing wound web is
supported by
said winding drum and said support roll;
continuing winding of said web on said first core while said growing wound web

is being supported by said winding drum and said support roll, and said first
core shaft is
being held in place by a second support structure;
continuing winding of said web on said first core while positioning a second
core
shaft on said first support structure at said first location, said second core
shaft having at
least one second core mounted thereon;
continuing winding of said web on said first core while bringing said pressure
roll
into contact with said second core, said pressure roll axis being
substantially parallel to an
axis of said second core shaft;



-32-


continuing winding of said web on said first core while driving said pressure
roll
about said pressure roll axis, thereby causing said second core shaft to
rotate about said
second core shaft axis due to said contact between said pressure roll and said
second core;
continuing winding of said web on said first core while moving said second
core
shaft from said first location to a guide structure and through said guide
structure to said
second location, in which said second core abuts said first surface of said
moving web,
said second surface of said moving web being in contact with said winding
drum, an axis
of said second core shaft in said second location being substantially parallel
to an axis of
said winding drum;
cutting said moving web to produce a second tail end of said web and a second
leading end of said web;
contacting said second leading end of said web with said second core;
initiating winding of said web onto said second core; and
moving said first core shaft, said first core and said wound web wound on said

first core to a removal position.

47. A method as recited in claim 46, wherein said web is a split web.

48. A method as recited in claim 47, wherein said first core shaft has a
plurality of
cores aligned along said axis of said first core shaft.

49. A method as recited in claim 46, wherein said guide structure comprises
slots
formed in at least two primary support arms, said slots being substantially
radially aligned
with a radius of said winding drum, said primary arms being rotatable about
said winding
drum axis, said pressure roll being mounted on at least two pressure roll
support arms
which are rotatably mounted on said primary arms.

50. A method as recited in claim 49, wherein said moving said first core shaft
from
said first location to a guide structure and through said guide structure to a
second
location is carried out by rotating said primary support arms, thereby causing
said first
core shaft to move off of a core shaft supporting surface and into said slots,
said first core
shaft being moved through said slots by gravity, thereby moving said first
core shaft from
said first location to said second location.



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51. A method as recited in claim 49, wherein during said winding of said web
on said
first core to produce a growing wound web wound on said first core, said
growing wound
web being supported by said winding drum and being pressured by said pressure
roll, said
first core shaft moves within said slots.

52. A method as recited in claim 46, wherein said second support structure
comprises
at least one support element mounted on each of at least two secondary support
arms,
at least one support roll mounting element mounted on each of said secondary
support arms,
said support roll mounting elements supporting said support roll and being
movable relative to said secondary support arms, whereby said support roll can
be moved
relative to said first core and can apply a desired pressure to said growing
wound web,
said secondary support arms being rotatable relative to a frame along a
secondary
support arm axis,
said secondary support arm axis being substantially parallel to said winding
drum
axis,
said winding drum being mounted on said frame,
said primary support arms being mounted on said frame and being rotatable
about
said winding drum axis,
said pressure roll being mounted on at least two pressure roll support arms
which
are rotatably mounted on said primary arms.

53. A method as recited in claim 46, further comprising closing at least two
notch
closing slides after said initiating winding of said web onto said first core,
said notch closing slides being mounted on respective secondary support arms,
said secondary support arms each supporting at least one support element,
said support elements comprising said second support structure,
said secondary support arms each comprising a notch,
said first core shaft being positioned within notches when said notch closing
slides
are closed, thereby locking said first core shaft in said notches.



-34-


54. A method as recited in claim 53, wherein said first core shaft is locked
in said
notches when said first core shaft, said first core and said wound web wound
on said first
core are moved to a removal position.

55. A method as recited in claim 46, further comprising spraying an adhesive
onto
said web prior to and during said cutting said moving web.

56. A method as recited in claim 55, further comprising spraying an adhesive
onto
said web after said cutting said moving web.

57. A method as recited in claim 46, wherein said first core shaft is rotating
at a
rotational speed which substantially matches a speed of said moving web before
moving
said first core shaft from said first position to second position.

58. A method as recited in claim 46, wherein after said cutting said moving
web, said
pressure roll is switched from a speed mode, where a rate of rotation of said
pressure roll
substantially matches a speed of said moving web, to a speed limited
adjustable torque
mode.

59. A method as recited in claim 46, wherein during said continuing winding of
said
web on said first core while said growing wound web is being supported by said
winding
drum and said support roll, and said first core shaft is being held in place
by a second
support structure, said pressure roll is retracted out of contact from said
growing wound
web.

60. A method as recited in claim 46, wherein during said continuing winding of
said
web on said first core while said growing wound web is being supported by said
winding
drum and said support roll, and said first core shaft is being held in place
by a second
support structure, said support roll is switched from a speed mode, where a
rate of
rotation of said pressure roll substantially matches a speed of said moving
web, to a speed
limited adjustable torque mode.



-35-


61. A method as recited in claim 46, wherein during said continuing winding of
said
web on said first core while said growing wound web is being supported by said
winding
drum and said support roll, and said first core shaft is being held in place
by a second
support structure, said support roll is switched from a balanced mode, where
said support
roll merely supports the weight of the first core shaft, the first core and
the growing
wound web, to a programmed support pressure mode, where said support roll
applies
supports said weight and also applies pressure to said growing wound web
according to a
pressure program.

62. A method as recited in claim 46, wherein before said cutting said moving
web,
said pressure roll is moved into contact with said first core after said first
core shaft has
been moved to said second location, said pressure roll rotating at a rate of
rotation which
substantially corresponds to a rate of speed of said moving web.

63. A method as recited in claim 46, wherein a rate of rotation of said first
core shaft
about said first core shaft axis is increased when said first core shaft
reaches said second
location and comes into contact with said first surface of said moving web.

64. A method as recited in claim 46, wherein when said first core shaft is in
said
second location, said first core shaft is sandwiched between said pressure
roll and said
winding drum, whereby critical speed problems are avoided.

65. A method as recited in claim 46, wherein said first core shaft axis is
located in a
plane which passes through said axis of said winding drum and which defines an
angle of
about -20° with respect to a vertical plane which passes through said
axis of said winding
drum when said cutting said moving web occurs, and said core shaft is moved
during said
continuing winding of said web on said first core to a position where said
first core shaft
axis is in a plane which passes through said axis of said winding drum and
which defines
an angle of about +30° with respect to said vertical plane.

66. A winder for winding a web onto a core shaft, comprising:
a winding drum, said winding drum being driven and being rotatable about a
winding drum axis;




-36-

at least a first secondary support arm, said first secondary support arm being
rotatable about a secondary support arm axis, said secondary support arm axis
being
substantially parallel to said winding drum axis;
at least a first core shaft support structure for supporting a core shaft
rotatably
with respect to a core shaft axis which is substantially parallel to said
winding drum axis,
said first core shaft support structure being on said first secondary support
arm; and
a support roll mounted on said secondary support arm, said support roll being
rotatable about a support roll axis, said support roll axis being
substantially parallel to
said winding drum axis.


67. A winder as recited in claim 66, further comprising at least a second
secondary
support arm, said second secondary support arm being rotatable about said
secondary
support arm axis;
said support roll being mounted on said first and second secondary support
arms;
said second secondary support arm having a second core shaft support
structure,
said first core shaft support structure and said second core shaft support
structure being
adapted to cooperate to support a core shaft.


68. A winder as recited in claim 66, further comprising a core shaft, a core
and a
moving web, said core shaft being at least partially supported by said first
core shaft
support structure, said core being mounted on said core shaft, and at least a
portion of said
moving web being wound on said core to form a wound web.


69. A winder as recited in claim 66, wherein said support roll is movable
relative to
said first secondary support arm with said support roll axis remaining
substantially
parallel to said winding drum axis.


70. A method of winding a web onto a core shaft, comprising:
winding a moving web onto a wound web which is wound around a core shaft
while said core shaft is rotating about a core shaft axis, said moving web
passing between
and in contact with said wound web and a winding drum, said moving web also
passing
between and in contact with said wound web and a support roll, said winding
drum
rotating about a winding drum axis which is substantially parallel to said
core shaft axis,




-37-

said support roll rotating about a support roll axis which is substantially
parallel to said
core shaft axis, said core shaft and said support roll each being at least
partially supported
by a first secondary support arm;
cutting said moving web; and
pivoting said first secondary support arm about a first secondary support arm
axis,
said first secondary support arm axis being substantially parallel to said
core shaft axis.

71. A method as recited in claim 70, further comprising moving said support
roll
relative to said first secondary support arm from a first position where said
support roll is
not in contact with said moving web to a second position where said support
roll is in
contact with said moving web, said support roll axis being substantially
parallel to said
core shaft axis while said support roll is in said first position and while
said support roll is
in said second position.


72. A method as recited in claim 70, further comprising causing said support
roll to
apply pressure to said wound web in order to brake said core shaft and wound
web to
reduce a rate of rotation of said core shaft about said core shaft axis.

Description

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WO 00/55079 -1- PCT/US00/06327
CONTINUOUS WINDER AND METHOD OF WINDING SLIT ROLLS OF
LARGE DIAMETER ON SMALL DIANJETER CORES

Backaround of the Invention

This invention relates to a windinL, method. and to a continuous drum
type surface winder. adapted particularly for winding slit web material onto
individual core segments carried on a common core shaft. and more particularlv
to a
method and winder adapted to wind a slit web into individual rolls of
substantial

diameter. such as 60 inches or izreater. on wide and relativelv small diameter
core
shafts.
In the winding of large diameter shippable high quality rolls of web
material, including films. non-woven materials, paper. paperboard material and
composites onto cores, the slitting and windina operation is preferably
positioned in-

line with the web forming and converting process. Such a continuous winding
arrangement reduces production costs and scrap, and permits quick
identification of
process control problems. Continuous winding requires that the handoff of
completed rolls. the transfer of the individual slit webs at high speed onto
corresponding core segments, and the initiation of the -,vinding process on
the new

core segments all be handled smoothly and at line speed.
The continuous winding of large diameter slit rolls on wide machines
has presented significant problems. A particular problem arises from the fact
that a
long, small diameter core shaft bends under its own weight, and exhibits
critical
speed limitations during speed up and prior to web transfer. Such critical
speed
limitations are primarily the result of core shaft deflection resulting in
harmonic and
dvnamic imbalances. Such critical speed conditions produce vibrations that
interfere
with the web transfer, and can result in an improper or defective start, and a
start in
which the rolls lack sufficient hardness. Also. shaft deflection can cause
roll quality
problems when winding slit rolls to a large diameter. The above identified
problems

are particularlv acute when the core shafts are quite small. such as. for
example,
shafts for supporting three inch inside diameter cores across a wide width
that may
exceed 200 inches. and for winding to roll diameters that mav exceed 60
inches.


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WO 00/55079 -2- PCT/US00/06327
A need exists for a continuous .vinder and method of operating a
winder in which larae diameter slit rolls are wound at wide machine widths in
a
continuous operation, in which core shaft deflection and critical speed
conditions are

controlled, and in which the building roll set is controlled for density
throughout the
~ winding process.

Summarv of the Invention

This invention provides a continuous surface type drum winder and
method for winding slit webs onto individual core segments of -Wide web
materials at
high speeds into large diameter rolls on small diameter cores. In particular a
winder
and winding method provides the transfer of split webs of line speed onto
cores
supported on a long and slender core shaft, as previously described.
A first or primary driven drum is provided with a driven primary nip
roll that is rotatablv mounted on support arms. These arms are pivotally
mounted on
primary arms that rotate about or in common with the axis of the drum. The
primary

arms are further provided with a slot, recess or other means by which the ends
of a
core shaft are supported or guided in the initial stages of winding, such that
the core
shaft is sandwiched between the driven primary nip roll and the driven primary
drum
thereby eliminating core shaft resonances and deflections that cause critical
speed

limitations and wrinkling at the web transfer and startup.
The buildup of the roll segments. i.e., the individual rolls. on the core
shaft is begun while the core shaft is supported on the primary arms. The
geometry
of the arms, the primary or main drum, and the nip roll is such that the core
shaft is
supported during the web transfer, and during the initial roll building, in
the manner
that assures that the core shaft and cores are straight or parallel with the
surface of
the primary drum. and a good start is obtained by way of proper loading by the
primary nip roll.
Also. during the roll building phase. the primary arms are programed
to move from a roll change position to a roll transfer position, in which the
core shaft
and the rolls thereon are transferred to a pair of support arms referred to
herein as
secondary support arms. The secondary support arms are associated Aith a
support
drum that is movable on the secondary arms and in relation to the secondarv
arms so


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WO 00/55079 -3- PCT/US00/06327
as to come into a supporting engagement with the building rolls While the
rolls
continue at all times to be engaged with the main ,vindinu drum. In addition.
the
primary nip roll also continues in engagement with the winding rolls, so that
the
windinQ of the rolls continues as if on a two drum xvinder in which both drums
are

~ driven, either in a speed or torque mode as desired, and nipped by a driven
rider roll.
The primary nip roll is released after the winding rolls' -vveivht supplies
sufficient nip
loading with the support drum.
The changing roll diameter is known at all times through a reading of
angle transducers incorporated into the pivot arm for the primarv nip roll and
by the
position of the secondan, support drum on the secondary arms. The loading of
the
primary nip roll and the loading of the secondary support drum may be
controlled by
roll diameter as well as roll weight to provide roll density and deflection
control.
The slow movement of the winding roll set. when carried by the

primary arms to the position of hand off to the secondary or support arms,
results in
very little change in web length and therefore very little change in web
tension, and
allows the winding of the full roll set diameter while the roll set is
maintained in part
on the main drum to help minimize winding roll deflection.
The winding set, at the beginning of the wind following web transfer,
is sandwiched between the main drum and the driven primary nip roll, and the
core
shaft is retained in slots defined in the primary arms. The secondary arms,
after the

completed roll set is unloaded, return to a start position that permits the
primary
arms, through a total rotation of about 60 , to deliver the partially wound
core set to
the secondary arms, while maintaining contact by the driven nip roll. The
winding
roll builds until initiating contact with the counter-balanced secondary
support drum
2-5 that is being driven at line speed. This condition of three roll or three
point
engagement is maintained throughout a major portion of the building of the
rolls of
the roll slot while the secondary arms and support drum cooperate with the
primary
drum to carry the weight of the building rolls and maintain the core shaft in
a

straight-line condition.
Upon the roll set achieving sufficient size that a rider roll is no longer
required, the primary arms and their associated nip roll are fully retracted
to permit
the placement therein of a new core shaft with cores. the ends of which shaft
are


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WO 00/55079 -4- PCT/US00/06327
retained in a slot in the primarv arms and supported on a fixed cam surface. A
transfer shoe-type web cutting svstem is pivotally mounted on an axis common
with
axis of the main drum. and rotationally moves under the on-running web, and
comes
to rest at a point upstream of the nip and between the new cores on the core
shaft and
the building roll. The primary nip roll lowers onto the new core shaft. The
nip roll
drive goes into the speed mode to speed-up the new cores and core shaft. The
primary arms then rotate approximately 5` so the core shaft moves off the canz
surface and into the arm slots where the cores come to line speed by running
engagement with the web on the drum at a position just prior (upstream) of the
point

where the web is lifted off of the drum by the transfer shoe.
An adhesive spray applicator is mounted between the priman= arms
and has individual spray heads operational to spray the -Vveb surfaces with
adhesive
upstream of the core shaft. The primary arms then rotate another approximate 5

which triggers the adhesive spray. At the same time a precision ground cut off
knife

comes out of the shoe into the split webs and impales the webs. The web
tension and
the momentum of the building rolls pull the webs through the knife thereby
causing a
clean straight line cut, with the adhesive causing transfer of the individual
Nvebs onto
the new cores. At the same time, adhesive on the cut tails causes the tails to
be

attached to the surfaces of the respective completed rolls.
Then, the secondary arms index the fully wound set of rolls awav
from the primary drum and into a braking position where braking torque is
regeneratively applied by the secondary drum to stop roll rotation. The wound
roll
set is then moved to an unloading position. At the same time, the shoe type
web
cutting system is pivoted by its arms to a lowered rest position, and the new
core set.

with the webs attached. continues to be wound. retained in the primary arms,
and
loaded against the primary drum by the driven primary arm nip roll. In this
sandwiched position, the core shaft is maintained substantially free of
deflection,
providing a hard winding start of the individual split web sections on the
respective
cores. with the hardness being controlled by torque and pressure supplied by
the
primary nip roll. Natural deflection of the core shaft is eliminated or
controlled that
otherwise could cause wrinkling of the web at the start and which could cause
critical
speed problems.


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The apparatus and method of this invention provide certain features
and advantages believed to be unique to winders of this kind. These include
elimination of or control of critical speed problems and related core shaft
deflection
problems common to continuous winding of wide and/or large slit rolls.

The sandwiching of the new cored shaft between a main driven
winding drum and a driven nip roll at and following roll change eliminates the
critical speed and natural deflection that causes va7inkling at the ,vinding
start.
The transfer shoe system with a pop-up knife ensures a straight clean
transfer regardless of web speed.
The driven primary arm nip roll assures a good hard start and proper
hardness profiling through a programmed nip and programmed torque control as a
function of the winding roll's diameter through a position sensor on the
driven
primary nip roll's pivot.
A slow and controlled movement of the winding roll set from about
-20 from a vertical center line through the main drum to about +30 winding
position provides excellent roll support and causes very little web length
change and
therefore very little web tension change, and allows winding to the full roll
set
diameter while supported on the main or primary drum to help minimize
deflection
of the core shaft and the winding rolls.
The driven support drum supports the winding roll set in the winding
position to also help minimize the winding roll's deflection.
The driven support drum assures that the building rolls have proper
density profile through the programming of the nip pressure and the torque
control of
the drive. This system approximates the well known two drum winding system
used
extensively in the industry for stop/start slitting and rewinding operation.

The driven support drum is also used to support and stop the wound
set after transfer by providing regenerative braking.
The primary support arms with the nip roll provide safety and ensure
that the winding roll set is contained inside and within the working surfaces
of the
two winding drums and prevent lateral movement of the winding roll set until
the set
is handed off to the secondary arms.
Shaft sensing devices are incorporated in the secondarv support arm to


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WO 00/55079 -6- PCT/US00/06327
prevent excessive loading of the core shaft from excessive loading of the
support
drum.
The secondarv arms are used for safety to insure the winding roll set
in contained inside the two winding drums. They are also used to prevent
lateral
~ movement of the winding roll set and to eject the finished roll set.

A position sensing device is incorporated into a secondary arm pivot
to counter balance the arm assembly thru support arm cylinders to prevent
excessive
loading of the core shaft bv the support arms that would cause shaft
deflection.

It is accordinglv an important object of the invention to provide a
continuous two drum surface type winder and method, in which a core shaft is
supported throughout the entire winding process, from web transfer, startup,
and
completion, in such a manner as to eliminate bending and deflection, and
reducing
critical speed problems.
A further object of the invention is the provision of a two drum type
winder in which a lay on roll is operable to provide three point xvinding
control
throughout a major portion of the winding of a split web onto individual core
segments, on a core shaft.
A still further object of the invention is the provision of a winder, as
outlined above, in which a secondary winding drum is controlled, on secondary
arms.
in such a manner as to support the weight of the building rolls on the core
shaft so
that the core shaft mav remain relatively straight throughout the winding
process.
Other objects and advantages of the invention will be apparent from
foregoing and following descriptions, and the accompanying drawings claims.

Brief Description of Drawing

Fig. 1 is a partially broken away prospective view of a continuous
winder according to this invention;
Fig. 2 is a partially broken away end view of the winder of Fig. I
looking at the machine from the off running side, with some of the parts moved
in
relation to their position in Fig. 1 for the purpose of illustration;
Fig. 3 is a side view of the winder of Fig. 2; and
Figs. 4 - 9 respectively are sequential views showing the operation


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WO 00/55079 -7- PCT/US00/06327
and method of the ,vinder, in which:
Figure 4 shows the new core shaft in position. the knife shoe is
indexed to the roll change position. and the priman, nip roll is moved to the
core
speed-up position:
FiR. 5 illustrates the primarv arms moved to a -25 ~~ position permitting
the core to drop against the drum and causing the speed-up core to contact the
web
on the primary drum, ready to move to a roll change position in ,hich the
priman
arms rotate to a-20' position. causing adhesive to spray on the web and a
spring
loaded knife to fire making a transfer onto the new core:
Fig. 6 shows the wound roll being transferred to a braking position on
the secondary arms and then stopped by the associated support drum while the
knife
shoe indexes to a parked position;
Fig. 7 shows the primary arms after being slowly indexed to a+30
position. the latch assembly on the secondary arm retracts permitting the
wound roll
to be lifted by a lift table to a shaft puller and recording position, as
shown,
permitting the support arms to index counterclockwise of Fig. 4 to a transfer
position
(Fig. 8), stopping at such position by a proximity switch sensing the core
shaft;
Fig. 8 shows the support arms returned to the transfer position. ready
to receive the core shaft from the primary arms. in which the rolls continue
to build
under balanced conditions and at a given diameter the primary nip roll will
release
and the support drum on the support arms will increase pressure for desired
hardness
while the primary arms indexed back to a shaft loading position is shown in
Fig. 9:
and,
Fig. 9 illustrates the primary arms in the -30 ~: core shaft loading

position resting on the cam surface as the building rolls are supported
between the
drum and the driven support roll.

Description of Preferred Embodiment
Referring to the drawings, which represent a preferred embodiment of
the invention, a continuous winder particularlv designed and constructed for
windino
on small cores a slit web into individual rolls of large diameter, is
illustrated
generally at 10 in the figures. Winder 10 includes apparatus supported on a
frame 12


CA 02367976 2007-11-22

-8-
including a first side frame 13 and a spaced second side frame 14. A
rectangular
tubular cross member 15 extends between the frames 13 and 14 adjacent the on
running side of the winder. The process direction is indicated by the arrow 17
in Fig.
1.

The winder may wind on core shafts as small as 3 inches in diameter or
smaller and at widths that may exceed 200 inches or more. The diameter of the
individual roll segments wound on the core shaft 20 may exceed 60 inches.

Winder 10 is intended to be used in a process line which could have an
upstream slitter and which could have a spreader roll similar to the spreader
roll 16
positioned at the inlet end of the winder 10 as shown in Figs. I and 3. This
apparatus
may include the usual process tension isolation and control rolls that lead
the split
webs to the winder for winding on cores (not shown) supported on a core shaft
20. A
typical core shaft 20 as used with this invention is shown in elevation in
Fig. 2. Also,
core shaft withdrawing and loading mechanisms may be employed, as well known
in
the art.

A first or primary winding drum 22 is rotatable mounted between the side
frames 13 and 14, and driven by a floor mounted electric drive, not shown. A
pair of
primary arms 24, 25 are pivotally mounted on the side frames about a pivot
axis
concentric with the rotational axis of the drum 22 and are positioned at each
respective transverse end of the drum.

The primary arms are each formed with generally radially extending core
shaft receiving recesses or slots 28 that receive the ends of the core shaft
20 during the
initial winding steps. Using vertical the radial line through the center of
the slot 28 as
the neutral position, the arms 24 and 25 are rotatable by cylinders 36 about
the axis of
the main winding drum 22 from a position of about -30 as shown in Fig. 4 to a
position of about +30 as shown in Fig 8.

A fixed cam plate 29 is provided on each of the side frame members 13 and
14. Each cam plate 29 has a forward facing sloping surface 31 that is inclined
at an
angle substantially parallel to the slot 28 in about the -25 position of the
arms and is
provided further with an upper horizontal core shaft supporting cam surface
32, at
least a portion of which is exposed when the primary arms 22 are rotated to
approximately -30 position.


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IRM 1'2 MAR 2001
-9-

The primary arms 24 and 25 in turn support a driven primary arm nip
roll 30. The nip rol130 is supported on nip roll support arms 33 that are
pivoted at 35
on the primary arms 24. The pivot 35 incorporates a shaft angle encoder so
that the
diameter of a building roll on the drum 22 may be determined. The primary nip
roll
is covered with silicone rubber or is plasma release coated. The positions of
the arms
33 and the supported primary nip ro1130 are controlled by actuators or
cylinders 36,
one on each side of the winder. The cylinders 36 can move the nip ro1130 from
an
elevated position, as shown in Figs. 2 and 3, to a fully lowered position in
engagement with cores on the core shaft 20 as shown for example in Figs 1 and
6.
The roll 30 is driven by a drive motor 37 and belt 38.

Also, as best shown in Fig. 3 and 5, a web transfer and cut-off shoe 40
extends transversely adjacent the outer surface of the drum 22 between the
frames 13
and 14 and rotates about the axis in common with the axis of the drum 22. The
shoe
40 is movable on its support arms 41 between a lowered or retracted position,
as
shown in Fig. 3 to a rotated operative position, as shown in Figs. 1, 4 and 5,
and
carries with it a web cut off knife 42 which may be extended above the shoe
and into
the path of the webs passing over the drum 22 for severing the webs.

The shoe 40 provides an upper curved surface that is designed to be
operated with the web running over the surface. The arms 41 supporting the
shoes
are connected by a common shaft to a drive motor 39, Fig. 1 by which the shoe
40
may be positioned between its lowered inoperative position, as shown in
outline form
~..~ in Fig. 3 to its elevated operative position, including the cut off knife
as shown in
Figs. 4 and 5.

A spray bar in the form of a cross member 45 supports a plurality of
adjustably positionable adhesives spray nozzles 46. The spray nozzles are
connected
to a source of adhesive and may be aligned so that primarily only the web
segments
are sprayed by adhesive for transfer to a new core.

A pair of support arms 50, 51, referred to herein as secondary arms,
are pivotally mounted at the off running ends of the side frames 13 and 14. An
encoder 50A is incorporated into the pivot support to read out the angular
position of
the support arms.

The secondary arms 50 and 51 have a number of functions. First, they
1~~~M &I


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provide a means by which the core shaft 20 is supported during a major portion
of
the winding. The arms 50. 51 also provide the support for a driven support
drum.
referred to herein as a secondarv ,vinding drum 52. The drum 52 is mounted on
secondarv support plates 53 and 54 that are vertically movable on pairs of
guide

tracks 55 supported on the inner facing surfaces of the respective rotatable
arms 50
and 5 1. The secondary plates 53 and 54 in effect form a movable carriage
coupled by
a cross frame member 71 and ride on parallel tracks 55 (Fig. 3) by "vhich the
secondan, drum 52 may be moved vertically between a lo-'vered position for
example. in Figs. I and 2. to intermediate and to elevated positions as shown
respectively in Figs. 8 and 9. The movement and position of the support drum
52 is
controlled by a pair of cvlinders 58 and 59 extending between the arms 50 and
51
and joining at a clevis 60 with the secondary roll support plates 53 and 54.
The
secondarv support plates 53 and 54 move in unison by means of a rack and
pinion
mechanism. 56 and 56A. and an interconnecting rotan, shaft 61 coupling the
rotational movement of pinion gears 56A together with racks 56 associated with
each
of the plates 53 and 54, thereby assuring uniform movement of the drum 52 by
the
motivating cylinders 58, 59.

The rotational movement of the secondarv arms, themselves, is
controlled by cylinders 63 and 64. one each. pivotally anchored at one of the
side
frames 13. 14. with an actuator rod extending to a clevis 66 attached to one
of the
arms 50. 51 respectively. The secondary arms are movable between extreme
positions by the cylinders 63, 64, these extreme positions being shown
respectively
in Figs. 7 and 8.

A motor 70 and gear reducer 72 drives the driven support drum 52
through a timing belt drive 74 best shown in Figs. 2 and 3. The motor 70 is
capable
of regenerative braking, for the purpose of stopping the rotation of a
completed roll
set as to be further described below. The motor 70 and reducer 72 are mounted
to the
cross frame member 71 for vertical movement as part of the secondary frame
structure with the secondary support roll 52.
The upper and upstream facing edges of the secondary arms 50 and 51
are provided with rearwardlv facing notches 80 that are proportioned to
receive an
end of the core shaft 20. Cvlinders 82 operate notch closing slides 84 mounted
on


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the arms 50 and 5 1 b- which the core shaft may be locked in position in the
receiving
notches 80 or by which the core shaft may be removed from the notches.
The operation of the continuous winder 10 is best understood by
reference to the sequential drawings 4 - 9. Referring first to Ficy. 4. a
fully xvound roll
~ set 100 is attached to a slit in-feeding web 102 and is being supported on
the

secondary arms between the main drum 22 and the support drum 52. and
substantially the Nveight of the roll set 100 is counter balanced bv hydraulic
pressure
in the cylinders 63. 64 so that the core shaft 20 remains straight and in a
substantially
neutral position. The ends 20A of the core shaft 20 are captured in the notch
80 by
the closure plates 84.
A freshly cored core shaft 20 is resting on the fixed upper cam surface
32 of the cam plate 29 while the nip roll 30. that has previously retracted to
permit
the core shaft placement, is now lowered into engagement with the core shaft
and
resting on the core shaft, ready to speed-up the new cores. The knife transfer
shoe 40

has been rotated from a lowered rest position to an upper operative position
under the
on-running web 102 and in fact lifts the on-running web over its upper surface
and
then downward to the nip 105 formed between the main drum and the roll set
100.

Referring to Fig. 5, upon initiation of a roll change sequence, the
priman, arms are rotated +5 from the -30 ` position sho -n in Fig. 4 to a -
25

position shown in Fig. 5. In this position, the slot 28 clears the forward cam
surface
31, and the core shaft 20 with the cores thereon drops do n to the bottom of
the slot
28 where the cores come into contact with the upper surfaces of the individual
sections of the on running web 102. At this position, the nip roll and the
core shaft
are now turning substantially at web speed.
The movement of the primary arms from the -25 to the -20 position.
Fig. 5. actuates the web cutting and transfer process. An adhesive is sprayed
onto the
exposed upper surface of the on running web 102, through the spaced nozzles 46
and. at the same time. the knife 42 is fired out of the shoe 40 and into the
path of the
overriding web. The inertia of movement of the split web causes the web
sections to
be severed on the knife and the individual web strips become adhered to the
respective cores on the core shaft 20 to begin the winding process. The
adhesive


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WO 00/55079 -12- PCT/US00/06327
remaining on the upper surface of the webs. now ,veb tails, serves to giue or
fix the
-eb tails to the outer circumference of the rolls of the roll set 100.
After a successful cut and transfer. the completed roll set 100 may be
moved to the position shown in Fig. 6 by the cylinders 63. 64. and rotation of
the roll
set stopped by regenerative braking through the motor 70 and the support drum
52.

In this position, the weight of the roll set is carried by the hydraulic
cylinders 58. 59.
It is important to recognize at this point, that at the very beginning of
the wind on the new core set, the core shaft is supported along its length on
the outer
surface of the primarv drum 22. with the core shaft ends captured within the
arm slot

28 of the primar_y arms, and the nip is. at the same time. loaded by the
driven priman-
nip roll 30. When the priman, nip roll 30 is lowered. it is driven at a speed
mode to
match or nearly match the speed of the new cores to line speed. The new core
shaft
is now sandwiched between the rolls 30 and 22 and held in the slot 28. and is
held in
a straight axial position therebv eliminating critical speed problems. The
roll 30

prevents radial movement and the slots 28 prevent lateral movement of the core
shaft. After web cut off, the primary nip roll 30 switches from web speed to a
speed
limited adjustable torque (SLAT) mode, and winding continues. A nip relief
system
is activated, by controlling the pressure in the cylinders 36, to provide nip
loading
between the cores and the drum 22 as a function of roll diameter. with roll
diameter
being measured by a shaft angle encoder at the pivot point 35 of the nip roll
arms 33.
Further. after successful transfer, and following the movement of the
secondary anns toward the vertical position shown in Fig. 6, the knife cut off
and
web transfer shoe assembly 40 may be rotated clockwise on its support arms to
a rest
position at the approximate 180-185 position bv motor/gear box 23 & 23A.
The new roll set 100A continues to build between the nip roll 30 and
the primarv drum 22 while the core shaft moves, as necessary, radially of the
slot 28
with the building diameter of the roll set. This condition is shown in Fig.7.
During
this time. the secondary arms 50. 51 after the roll set 100 has been
regenerative
braked to a stop by the support drum 52. may be moved to a full clockwise
unload
position as shown in Fig. 7 and the core retainer notches 80 opened by the
retraction
of the plates 84. The elevator table lifts the wound rolls to a clearance
position for


CA 02367976 2007-11-22

-13-
the secondary arm 50, 51 to pivot to the primary/secondary transfer position
as
diagrammatically illustrated at 110 in the position shown in Fig. 7. The core
shaft
may be pulled and recored, and a recored shaft may be returned for readiness
to be
placed in the primary arms 24 in the slot 28 and on the cams 29, according to
core

handling apparatus well known in the art.

Also, following regenerative braking by the support dnun 52, where a
percentage of support drum pressure may be added to the support drum to
prevent
slippage during braking, and preceding the off loading of the completed roll
set 100,
the carriage sub-assembly for the secondary support drum 52 is fully lowered
to its
lowered position, by relative movement of the plates 50, 51 on the tracks 55
of the
secondary arms. This fully lowered position is illustrated in Fig. 7.

During the continued winding of the roll set 100A, the primary arms
24, 25 continue to rotate and slowly move the winding set to the +30 from the
vertical position as defined. After the primary arms are in the 30 position,

substantially as shown in Figs. 7 and 8, and the winding roll I OOA reaches a
specific
diameter of say 18", the secondary or support arms are moved slowly back
toward
the primary drum 22 and are stopped by a proximity switch 120 on the ends of
the
arms, at the notch 80. During this time the secondary support drum 52 is
brought
into raised position in a speed mode. The proximity switch 120 indicates that
the
core shaft 20 is now in the notch, and the position substantially is shown in
Fig. 8.
At that time, the latch plate 84 is activated by the cylinders 80 to lock and
secure the
core shaft in the notch 80 of the secondary arms. The winding now progresses,
as
shown in Fig. 8, in which the building roll set is wound into the secondary
drum
while engagement by the nip roll 30 is maintained. The up position of the
support
drum, at 52, reduces the lift pressure in cylinders 59 to a counter balancing
pressure
applied by the cylinders 59 to the effect that the loading on the roll I OOA
is zero or
negligible so the primary nip roll 30 loading is dominant.

In a preferred embodiment, in which 60 inch diameter rolls 100 are
formed, the initial engagement of the secondary arms as described above and as
illustrated in Fig. 8 may take place at about a minimum 18 inch diameter and
winding then continues by continuing to drive the secondary drum 52 in the
speed


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WO 00/55079 -14- PCTIUSOO/06327
mode with the nip roll 30 engaged. This may continue to a predetermined
interim
position. for example. 24 to 30 inches in diameter. At such a time. the nip
roll 30 is
retracted. as sho,,vn in Fi~~. 9. while winding continues and the support drum
52 is
changed from speed control to the SLAT mode and the support drum changes from

balanced to a programed support pressure as applied by the cvlinders 58, 59.
After the primary arm nip roll 30 has been fully elevated and the drive
stopped. the priman- arms mav be rotated back to a load position shown in
Fig.9, at
-30 .
The nip of the programed support pressure bv the secondan, drum 52
is adjusted to control roll hardness. Another proximity switch 130 on the
support
arms 50. 51 senses if the drum 52 is supplying excessive support pressure and
liftino.:
of the winding set. This can be a proximity switch also located in the notch
80.
When this proximity switch senses the core shaft. indicating the movement of
the
core shaft upwardly in the notch. the support drum pressure may be slowly
decreased

until the core shaft and rolls lower from the proximity switch. The winding
continues until the maximum selected diameter is achieved as illustrated in
Fig. 9,
ready for a roll change.
The width of the slot 28 formed generallv radially in the arms 24 and
is such that it forms a close fit with one of the support surfaces adjacent
the ends
20 of the core shaft 20. The core shaft 20 is shown in elevation at the top of
Fig. 2

where it may be seen that each end of the core shaft is provided with a pair
of support
surfaces 20a and 20b at each end. The slots 28 form a close fit with the core
shaft
surface 20a and prevents lateral movement of the core shaft. The alignment of
the
slot in the arms approximates the arc of movement of the lay on roll 30 at the
start-up

25 position, as shown in Fig. 7. Therefore. at this critical time, the ends of
the core shaft
20 are restrained by the walls of the slot 28 against lateral movement.
The building diameter of the roll segments as defined bv the
individual cores is accomplished bv movement of the core shaft radiallv
outwardly
,vithin the slot 28, against the force of the lay on roll 30.
It will also be noticed that the primarv arms 24. 25, receive the core
shaft at the inner of the two pairs of support surfaces 20a and the hand-off
to the


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~~ 12 MAR 2001
-15-

secondary arms, in the slots 80, is accomplished by receiving the core shaft
in the
slots 80 at the outer support surfaces 20b.
The hand-off of the building rolls 100A from the primary to the secondary
arms, accomplished in views 7 and 8, occurs at a time when the building rolls
have
achieved a sufficient diameter so that the core shaft may be released from the
slot 28.
This is a function of the design of the machine but typically may be a
diameter of 18
inches or greater. The secondary arms 50, 51, following the off- loading of
the first
roll set 100, are moved into a receiving position as shown in Figs. 7 & 8 and
the
transfer is smoothly made by engaging the core shaft at the adjacent support
surface
20b stopping secondary arms 50, 51 rotations by sensor 120, and closing the
slots 80
with the cylinders 82 and slot retainers 84, that move in non-interfering and
adjacent
relation to the primary arms with counter balance pressure programming as a
function of secondary arms 51, 52 position by sensor 50A provided to cylinders
63,
64.
Seguence of Operations
1. While winding set is between driven main winding drum 22 and
driven support drum 52 and with driven primary arm nip roll 30 retracted, a
new
freshly cored shaft 20 is automatically loaded onto cams 32 around slot 28 in
primary
arms in the -30 from vertical centerline position.
2. Upon initiation of roll change sequence, the knife shoe 40 is indexed
around drum, under web and stops in cut position on the other side of core.

3. The driven primary arm nip ro1130 lowers to cored shaft and goes into
speed mode to speed up the new cores close to line speed. See Figure 4.
4. Spray adhesive applicator nozzles 46 are in close proximity to the
respective web 102.

5. Primary arms 25, 25 move 5 to -25 position from vertical centerline
and core shaft 201owers off cams 32 and onto web 102 and drum 22,
straightening
the natural deflection.
6. As primary arms moves to -20 position, adhesive sprays onto web
and pastes down the tails on the slit wound rolls 100. See Figure 5.

AWWft s>EEt'


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WO 00/55079 -16- PCT/US00/06327
7. The priman, arms stop in the -20 position NNhich causes the
precision ground cutoff knife 42 to come out of the shoe 40 and impales the
webs.
The %veb tension and ,vindina roll's momentum pulls the -ebs throuLh the
knife
causina a clean straight line transfer to the new cores =ith a slight
foldback.

8. The driven primarv arm nip roll 30 switches from speed mode
to a speed limited adjustable torque (SLAT) mode.

9. The nip relief system is activated and provides nip loading as a
function of roll diameter from an anale encoder at the pivot point of the arms
33
sensing the nip roll's position.
10. The support arms 50. 51 index the wound set 100 of slit rolls
away from the drum 22 to the braking position. See Figure 6.

1 1. The knife shoe 40 rotates around the drum. the knife retracts
and shoe stops under the drum.

12. The driven support drum 52 remains nipped on the roll set and
regenerates to stop the wound set. A percentage of support drum pressure is
added to
support drum to prevent slippage.

13. After the support drum 52 reaches zero speed. the support
arms 50, 51 move to the unload position. See Figure 7. In this position, the
weight
of the wound rolls, and the retraction of the drum 52. causes the wound rolls
to sac,.

The extend of sag is limited by the upper edges of the roll sets coming into
contact
with each other thereby limiting the extent of sag. When the roll set is
supported by
the elevating table, the core shaft resumes its straight line position.

14. The table 110 raises until it supports the wound set and
automatically stops.

15. The support arm latches 84 retract.

16. The wound set of rolls is lifted to the core shaft retraction
position.
17. The primar}, arms 24. 25 slowlv move the winding set to the
-30 froni vertical position.
18. After the priman, arms are in the +30' position and after the
winding set reaches a min. diameter of sav 18". the support arms 50. 51 rotate
back


CA 02367976 2001-09-13
WO 00/55079 PCT/USOO/06327
~ ii 2 MAR 1001

toward the drum 22 and are stopped when a proximity switch 140 on the arm 50
senses it is close to the new winding shaft. See Figure 8. Switch 140 is shown
in
Figure 4.

19. The support arm latch 84 extends and closes an interlock which
allows the support arm retraction under counterbalance pressure.
20. The support drum 52 raises as the support arms pivot toward the drum
22 in the speed mode under raise pressure and switches to balance pressure at,
say,
24" diameter and the winding set winds into the balanced support drum.
21. As the rolls wind, a position sensor 50A on support arm's pivot is
used to program the counterbalance pressure of the support arm by the
cylinders 58,
59 to prevent excessive bending of the core shaft during the winding
operation.
22. When the winding set reaches a 24" to 30" diameter, the driven
primary arm nip rol130 raises and the support drum 52 changes from balance to
programmed support pressure and the drive changes from speed to SLAT mode.
23. After the primary arm nip roll 30 has fully raised and the drive
stopped, the primary arms 24, 25 rotate back to the load position. See Figure
9.
24. The nip of the programmed support pressure is adjusted to control roll
hardness. The proximity switch 130 on the support arm senses if the support
drum is
supplying excessive support pressure and lifting the winding set. If this
switch
senses the core shaft, the support drum pressure is slowly decreased until the
rolls
~ and core shaft lower away from the switch.

25. After step 15, a shaft puller automatically engages with the core shaft
and bleeds out the inflation pressure.
26. The shaft 20 is then retracted from the wound set 100 by an automatic
shaft puller.

27. The table 1101owers the rolls to the roll platform (not shown) and
tilts to eject the rolls on the platform.

28. New cut cores are either manually or automatically loaded onto the
table.

29. After the table senses that new cores have been loaded, the

`1~ a-~~


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WO 00/55079 PCT/USOO/06327
I !oZ 17)442v0
-18-

table raises to the shaft insertion position.
30. The shafts are automatically inserted and automatically inflated.
31. An overhead hoist then picks up the shaft and when the primary arms
have rotated back to the load position, the shaft is automatically loaded back
onto the
cam 32 around the slot 28 in the primary arms.
32. The winder is now ready for the next automatic roll change after the
programmed footage or diameter on the winding roll is reached.
While the method herein described, and the form of apparatus for carrying
this method into effect, constitute preferred embodiments of this invention,
it is to be
understood that the invention is not limited to this precise method and form
of
apparatus, and that changes may be made in either without departing from the
scope
of the invention, which is defined in the appended claims.
What is claimed is:

ti ~~~~ =~~~

Representative Drawing