Note: Descriptions are shown in the official language in which they were submitted.
CA 02678912 2009-09-17
SYSTEM AND METHOD FOR THE CONTINUOUS MANUFACTURE OF
LONG-LENGTH PRODUCTS OR THE LIKE
FIELD OF THE INVENTION
[0001] This application relates to apparatus and processes for the wrapping or
winding
of long-length continuous products, such as hose, cable, wire, rope and
composite pipe.
The methods and apparatus allow for the continuous wrapping or winding of such
products without stopping or slowing the production line for re-loading spools
or bobbins
of winding/wrapping material. The application also relates to an automatic
loading
system for loading and unloading the spools or bobbins or winding/wrapping
material.
BACKGROUND OF THE INVENTION
[0002] The manufacture of long-length continuous products such as hose, cable,
wire,
rope and composite pipe typically involves wrapping a reinforcement layer
around an
inner core or liner pipe. By way of example, hose or composite pipe typically
contains a
reinforcement layer of individual fibers, filaments, wires, or tape. In the
case where the
reinforcement layer is in the form of individual fibers, the individual fibers
are typically
wrapped around the inner liner pipe using a spiral winding machine, the spiral
winding
machine including a multiple of bobbins or spools containing wound up fibers
that are
continually unwound and wrapped in a helical orientation around the inner core
or liner
pipe of the product as the product passes through the spiral winding machine.
The inner
core or liner acts as a support for the fibers as they are applied.
[0003] In the case where the fibers are in the form of a pre-fabricated tape,
a wrapping
machine is used, which acts in a similar fashion to the spiral winding machine
and wraps
one or more tapes in a helical orientation around the inner liner. By way of
further
example, wire or cable is made in a similar way where wires, fibers or tapes
are
dispensed from a multiple of bobbins or spools and wrapped around an inner
core which
supports the wires, fibers or tapes as they are applied.
[0004] Typically the reinforcement layer of a long-length product consists of
two layers
of material wrapped or wound in opposite directions, namely clockwise and
counter
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clockwise, around the inner core or liner pipe to enhance the strength of the
product
from internal pressure and to otherwise improve the overall strength of the
product under
various design loads and stresses.
[0005] One limitation of tape wrapping and spiral winding machines is that the
machine
rotation must be stopped to change the bobbin or spool when the end of the
reinforcement material on the bobbin or spool is reached. Typically, the
machine rotation
must come to a complete stop before it is possible to remove the empty bobbins
or
spools and replace them with full bobbins or spools of reinforcement fiber or
tape. During
this wrapper or winder reloading sequence, production of the continuous
product must
stop. Where the inner core or liner pipe is simultaneously being manufactured,
this
process must also be stopped or diverted until the winder/wrapper is slowed,
stopped,
re-loaded and re-started. A halt in production reduces production capacity and
stopping
and starting of the production process can also lead to imperfections in the
product.
[0006] Another limitation of winding/wrapping machines is that upon restarting
the
winder/wrapper rotation after a bobbin or spool has been changed, the machine
must
accelerate from a standstill to the correct rotation/wrapping speed to provide
the desired
angle of wrapping around the inner liner pipe or core. Thus, unless the line
speed of the
inner liner is increased gradually to match the increasing rotation speed of
the
winder/wrapper, the wrap angle will be incorrect until such time as the
winder/wrapper
has achieved its correct rotation speed to match the liner traverse speed. As
above, a
product with an incorrect wrap angle may have reduced performance
capabilities.
Moreover, such imperfections may be located within middle sections of the
product that
would have to be cut-out and hence shorten the length of the product and
otherwise end
up as production waste.
[0007] Specifically in the production of composite pipe, the inner liner pipe
is typically
extruded from a thermoplastic such as polyethylene. If the pipe-manufacturing
process is
a one-step process where the inner liner pipe is extruded simultaneously and
in-line with
the reinforcement layer winding/wrapping operation, then the inner liner pipe
extrusion
process must be stopped during the winder/wrapper reloading process, or the
inner liner
pipe produced during the reloading period becomes waste. If the pipe-
manufacturing
process is a two-step process where the inner liner pipe is extruded before
and
independently of the wrapper/winder process, then the finished pipe production
must be
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halted during the reloading of the winder/wrapper. As is well-known, any halt
in
production process reduces production capacity and may lead to inferior or
weakened
product at the point of the stoppage.
[0008] Accordingly, there has been a need for a production system and method
that
overcomes the above shortcomings of known manufacturing processes in the
production
of continuous products such as hose, cable, wire and composite pipe. In
particular, there
has been a need for a production system and method which enables the
essentially
continuous production of continuous products in which fiber spools or bobbins
can be
exchanged without stopping or slowing the production line.
[0009] A review of the prior art reveals numerous reinforced composite pipe
products
and methods of manufacture, as described in U.S. Pat. No. 7,254,933; U.S. Pat.
No.
6,804,942; U.S. Pat. No. 6,889,716; U.S. Pat. No. 7,093,620; U.S. 6,807,988;
and U.S.
Pat. No. 4,347,090. However, the prior art is generally silent with respect to
the
shortcomings of the manufacturing process of continuous products as described
previously.
SUMMARY OF THE INVENTION
[0010] In accordance with the invention, there is provided a system and method
for the
continuous production of long length products such as fiber or wire reinforced
products.
[0011 ] More specifically, there is provided a system for continuously
manufacturing a
reinforced product, the reinforced product including an inner layer and a
reinforcement
layer, the system comprising:
a carriage operable along a rail system between an upstream end and a
downstream end;
a winding system supported by the carriage for winding a reinforcement layer
around the inner layer, the winding system including at least one spool
containing
a reinforcement material for winding around the inner layer;
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a drive system for operative movement of the carriage with respect to the rail
system and for controlling the speed of winding of the winding system;
wherein the drive system enables:
a controlled winding speed of the reinforcement layer when a spool does not
require replacement;
a controlled reduction in winding speed synchronized with downstream
movement of the carriage when a spool requires replacement;
a stopped winding speed synchronized with downstream movement of the
carriage wherein the winding system is stationary with respect to the inner
pipe to enable replacement of the spool with a new spool;
a controlled increase in winding speed synchronized with upstream
movement of the carriage after the new spool has been configured to the
winding system; and
a controlled reduction in winding speed to the speed of the reinforcement
layer when a spool does not require replacement synchronized with a
reduction in speed of the carriage as the carriage approaches the upstream
end.
[0012] In one embodiment of the invention, the carriage and winding system
support two
spools and wherein the winding system winds the reinforcement material in
opposite
directions around the inner layer from the two spools.
[0013] Preferably, the reinforcement material is a tape made from natural or
synthetic
fiber. In another embodiment, the reinforcement material is a wire that can
serve
structural purposes as well as carry an electrical current or digital signal.
[0014] In one embodiment, the inner layer is a solid core. In another
embodiment, the
inner layer is a hollow pipe.
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[0015] In other embodiments, the system includes an upstream support system
for
supporting the inner layer at the upstream end of the rail system wherein the
upstream
support system is operable between a contracted position and an expanded
position
depending on the position of the carriage on the rail system and/or the
upstream support
system includes a plurality of supports having a lower end for operable
engagement with
the rail system and an upper end having at least one roller for operable
engagement with
the inner layer.
[0016] In another embodiment, each support of the upstream support system is
operably connected to one another by a flexible connection system.
[0017] In a further embodiment, the system includes a downstream support
system for
supporting the inner layer and fiber layer at the downstream end of the rail
system
wherein the downstream support system is operable between a contracted
position and
an expanded position depending on the position of the carriage on the rail
system and/or
the downstream support system includes a plurality of supports having a lower
end for
operable engagement with the rail system and an upper end having at least one
roller for
operable engagement with the inner layer and fiber layer.
[0018] In one embodiment, each support of the downstream support system is
operably
connected to one another by a flexible connection system.
[0019] In another embodiment, the system includes a spool replacement system
operably connected to the rail system for removing a spool from the winding
system and
replacing the spool with another spool. The spool replacement system may
include a
second carriage operable between a dormant position and a replacement position
on the
rail track wherein in the replacement position, the spool replacement system
is adjacent
the winding system and in the dormant position the spool replacement system is
linearly
separated from the winding system. The spool replacement system may include at
least
two spool support arms rotatably supported on the spool replacement carriage
and
wherein the spool support arms are rotatable about the longitudinal axis of
the inner
layer for alignment with one or more spools on the winding system.
[0020] In another embodiment, each spool support arm is rotatably operable to
a
position adjacent a spool on the spool replacement system and each spool
support arm
includes means for transferring an empty spool on the winding system to a
spool support
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arm on the spool replacement system. In one embodiment, a spool support arm
includes
means for transferring a spool from the winding system to the spool
replacement
system.
[0021] In another embodiment, the spool replacement system includes four spool
support arms and the winding system includes two spools and wherein during
replacement, two of four spool replacement arms are loaded with replacement
spools
and two of four spool replacement arms are unloaded.
[0022] In one embodiment, the spool replacement system is operably connected
to the
carriage.
[0023] In another embodiment, the spool replacement system includes at least
one
swing arm.
[0024] In yet a further embodiment, the reinforced product includes an
exterior layer and
the system further comprises a second extruder downstream of the rail track
for
extruding the exterior layer over the inner layer and reinforcement layer.
[0025] In a preferred embodiment, the drive system is computer controlled.
[0026] In another embodiment, the system will include a cutting device
adjacent the
winding system for cutting the reinforcement material located between the
spool and the
inner layer when the spool requires replacement and/or an attachment device
adjacent
the winding system for attaching the reinforcement material from a spool to
the
previously cut reinforcement layer wound around the inner layer after the
spool has been
replaced.
[0027] In another embodiment, the first and second edge of a reinforcement
tape are
each lined with a colored thread and the system includes an optical
recognition system
for sensing the placement of the colored thread during the winding of the
fiber around
the inner layer and transmitting the placement information to the drive
system, whereby
the drive system adjusts the winding speed and/or the carriage speed to line
up the first
and second edges of the reinforcement tape.
[0028] In another aspect of the invention, a method for replacing a spool
containing a
reinforcement material during continuous manufacture of reinforced product is
provided,
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the reinforced product including an inner layer and a reinforced layer, the
method
comprising the steps of:
a) passing the inner layer to a wrapping system operable along a rail system
between an upstream end and a downstream end of the rail system;
b) winding a reinforcement layer around the inner layer at a controlled
winding
speed from a spool containing the reinforcement layer; and
when the spool requires replacement:
c) synchronizing a reduction in the controlled winding speed with downstream
movement of the wrapping system;
d) synchronizing a stop in winding speed with downstream movement of the
wrapping system wherein the wrapping system becomes stationary with respect
to the inner layer;
e) replacing a spool with a new spool while downstream movement of the
wrapping
system is stationary with respect to the inner layer;
f) synchronizing an increase in winding speed with upstream movement of the
carriage after the new spool has been configured to the wrapping system; and
g) synchronizing a reduction in winding speed to the controlled speed defined
in b)
as the wrapping system approaches the upstream end.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention is described with reference to the accompanying figures
in which:
FIG I is a side view of a continuous pipe assembly system in accordance with a
first embodiment of the invention;
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FIG 2A is an end view of an upstream support system of a continuous pipe
assembly system in accordance with a first embodiment of the invention;
FIG 2B is a side view of an upstream support system of a continuous pipe
assembly system in accordance with a first embodiment of the invention;
FIG 3 is an end view of a wrapping system of a continuous pipe assembly
system in accordance with a first embodiment of the invention;
FIG 3A is a top view of a wrapping system in accordance with a first
embodiment
of the invention;
FIG 4 is a side view of a wrapping system and an automatic loading system in
accordance with a second embodiment of the invention; and
FIG 5A is an end view of an automatic loading system in accordance with a
second embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Overview
[0030] With reference to the figures, an apparatus 10 and process for the
production of
long-length products such as composite pipe that allows for the continuous
wrapping of
such products with a reinforcement layer such as a tape is described.
System Overview
[0031 ] The system is described in the context of manufacturing flexible
reinforced piping
(a composite pipe) having an inner plastic pipe layer, a tape reinforced layer
and an
outer plastic pipe layer. As shown in FIG 1, the apparatus includes a first
extruder 12,
upstream support system 14, support carriage 16, wrapping system 18,
downstream
support system 22 and second extruder 24. Each of the upstream support system
14,
support carriage 16, and downstream support system 22 are supported by rail
system
26. In operation, the system enables the continuous manufacture of composite
pipe.
First Extruder
[0032] An inner liner pipe of polyethylene or similar material is continuously
extruded
from the first extruder 12 as known to those skilled in the art. The first
extruder includes
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a hopper 12a and integral die head and cooling system (not shown).
Polyethylene or
similar polymeric materials are introduced to the hopper 12a and subsequently
melted,
extruded through the die head and cooled so as to form an inner liner pipe 30
having a
desired diameter and wall thickness. The first extruder can operate
essentially in a
continuous manner as raw material can be continually introduced into the
extruder.
Upstream Support System 14
[0033] As shown in FIG 2A and 2B, the upstream support system 14 receives and
supports the inner liner pipe 30 as it is extruded from the first extruder.
The upstream
support system generally includes a plurality of support frames including a
vertical
support 14a and horizontal support 14b. The support frames each move
independently
along the rail system 26 through support frame rollers 14c. In addition, the
upstream
support system includes a series of upper rollers including support rollers
14d and side
rollers 14e for supporting the inner liner pipe above the rail system. As
shown in FIG 2B,
each of the support frames are connected to one another by a chain 14f with
the
furthermost downstream support frame connected to the support carriage 16.
Each
support frame can independently slide along the rail system but also move with
adjacent
support frames when the chain is taut or adjacent support frames are abutting
against
one another. The operation of the upstream support system will be explained in
greater
detail below.
Rail system
[0034] The rail system 26 is laid out at ground level along the production
line
downstream of the first extruder and upstream of the second extruder 24,
running
parallel to the inner liner pipe.
Support Carriage
[0035] As shown in FIG 2B and 3A, the support carriage 16 is engaged with the
rail
system 26 through carriage rollers 16a and can move upstream or downstream
along
the rail system. Typically, the movement of the support carriage along the
rail system is
controlled by a motor 32 with a sprocket and gear system (not shown) or
similar linear
motion system as known to those skilled in the art. The downstream end of the
support
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carriage may include rails for an automatic loading system (ALS) 50 to engage
with and
move along, as will be explained in greater detail below.
Wrapping System
[0036] As shown in FIG 3 and 3A, the wrapping system 18 is located on the
support
carriage 16 and moves with the support carriage as the carriage travels along
the rail
system. The wrapping system includes winding heads 28, 29 that each include a
winding
arm 28a, 29a and a shaft 28b, 29b that hold a spool 40 wound with tape 40a,
40b.
During production, the tape 40a, 40b is wrapped helically around the inner
liner pipe as
is known to those skilled in the art. The first winding head 28 wraps the tape
in one
direction and the second winding head 29 wraps the tape in the opposite
direction (i.e.
clockwise and counterclockwise). The first and second winding heads can
operate at
variable winding/rotation speeds to ensure proper alignment and tension of the
wrapping
tape 40a, 40b.
Reinforcement Layer
[0037] The reinforcement layer can be in the form of a tape or individual
filaments of
natural or synthetic fiber. Depending on the product being manufactured, the
reinforcement layer can also be a wire. As well as serving structural
purposes, the wire
can carry an electrical current or a digital signal.
[0038] When the reinforcement layer is in the form of individual filaments or
wire, the
filaments or wire are wound around the inner layer by similar means as a tape
is
wrapped around the inner layer, as previously described.
Downstream Support System
[0039] The downstream support system 22 receives and supports the pipe after
it has
been wrapped by the wrapping system and has passed through the ALS 50. The
downstream support system is generally identical to the upstream support
system as
shown in FIG 2A and 2B and includes the same plurality of support frames that
are
connected to one another by a chain with the furthermost upstream support
frame
connected to the support carriage 16. The operation of the support system will
be
explained in greater detail below.
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Second Extruder
[0040] The second extruder 24 is similar to the first extruder 12 and includes
a hopper
24a and integral die head and cooling system (not shown). The second extruder
receives the wrapped pipe from the downstream support system and extrudes
melted
polyethylene or similar polymeric materials through the die head where it is
cooled to
form an outer jacket around the wrapped pipe having a desired diameter and
wall
thickness.
Operation of the Upstream Support System
[0041] As noted above, the upstream support system moves along the rail system
in
order to provide continuous support of the inner liner pipe regardless of the
position of
the support carriage on the rail system. When the support carriage 16 is at
the most
upstream position on the rail system (as explained below), the upstream
support frames
are located directly adjacent to one another with the chains linking the
support frames
being slack. As the support carriage moves downstream and the chain linking
the
support carriage to the first adjacent support frame is taut, the first
support frame moves
downstream along with the support carriage. When the chain linking the first
support
frame and the second support frame adjacent to the first support frame is
taut, the
second support frame moves downstream. This process continues until the
support
carriage is located at the end of the rail system and all the support frames
are spaced
along the entire rail system with taut chains. The support frame at the
beginning of the
rail system is secured to the rail system (or equivalent) and remains
stationary at all
times.
[0042] When the support carriage reverses directions and moves upstream
towards the
start of the rail system (explained below), the support carriage contacts the
first support
frame adjacent to the carriage and pushes the first support frame upstream
until it
comes in contact with the second adjacent support frame, which is then pushed
upstream with the first support frame and the support carriage. This process
continues
whereby the support carriage pushes the plurality of support frames to the
beginning of
the rail system as the carriage moves upstream.
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Operation of the Downstream Support System
[0043] The downstream support system operates similarly to the upstream
support
system to support the wrapped pipe as it exits the wrapping system 18 prior to
its entry
into the second pipe extruder 24. The last support frame located at the end of
the rail
system is stationary and the other support frames move with the support
carriage as
described above, only in the opposite direction as the downstream support
system is
located on the opposite side of the support carriage from the upstream support
system.
Operation of the Wrapping System during the Spool Changing Process
[0044] During typical production line operation, the support carriage 16
remains
stationary adjacent the upstream end of the rail system. As the inner liner
pipe is
extruded and moves down the production line (at a generally fixed speed), the
winding
heads 28, 29 (having tape on one or more spools) located on the support
carriage 18
wrap the tape around the inner liner pipe also at a generally fixed speed.
[0045] In accordance with the invention, when a spool is near depletion of
tape, the
spool changing process begins.
[0046] The first step in the spool changing process is to initiate downstream
movement
of the support carriage at increasing speed until it reaches the same speed as
the
extrusion speed of the inner liner pipe. Synchronously, the winding heads
decrease
speed until they completely stop rotating at the same time the support
carriage speed
equals the extrusion speed. Upon reaching the same speed as the inner liner
pipe, the
support carriage continues to move with the inner liner pipe at the same speed
(i.e the
carriage and inner liner pipe are stationary with respect to one another). At
this time, the
support carriage is moving downstream at the same speed as the inner liner
pipe, the
winding head is no longer rotating, and no tape is being wrapped around the
pipe. The
synchronization of the support carriage speed and winding head speed during
the
transition from full wrapping speed to a stop in wrapping allows the tape to
be continually
wrapped around the pipe with proper tension and alignment as the winding heads
slow
to a stop.
[0047] As the carriage and wrapping system continue to move downstream, the
tape
from the near empty spools on each winding head 28, 29 are cut between the
spools
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and the pipe, allowing the empty spools to be removed and replaced with full
spools.
The ends of the tape from the full spools are attached (e.g. by gluing or
stitching) to the
cut ends of the tape wrapped around the pipe by means of a suitable attachment
system
(such as sewing device) well-known to those versed in the art. Thereby, the
tape on the
full spool is a continuation of the tape from the previous spool. The process
for changing
the spools can be done manually or with the automatic loading system (ALS), as
described below.
[0048] After the spools are changed, the winding heads 28, 29 then make the
transition
from the fully stopped rotation speed at a location towards the downstream end
of the
rail system to the normal wrapping speed with the winding heads and carriage
returned
to the upstream end of the rail system. During this process, it is important
that the
system ensures no section or portions of pipe are improperly wrapped.
[0049] Initially, in this step, as noted, the carriage is stopped relative to
the inner liner
pipe but continues to move towards the downstream end of the rail system with
the inner
liner pipe. At this point, the carriage reverses direction to travel upstream
on the rail
system in the opposite direction to the inner liner pipe movement.
Synchronously, with
the initial upstream acceleration of the carriage and subsequent uniform
upstream speed
of the carriage, the winding heads wrap tape around the pipe at an appropriate
speed
that matches the relative movement of the carriage to the inner liner pipe.
That is, the
wrapping speed will steadily increase as the carriage begins its upstream
motion on the
rail system, wrap at a uniform speed as the carriage is moving at a uniform
rate up the
track and slow to the original wrapping speed as the carriage slows down upon
reaching
the upstream end of the rail system. The winding heads then continue the
normal
wrapping process until the spool requires changing again and the process is
repeated.
Automatic Loading System (ALS)
[0050] In a further embodiment, the process for removing the empty spools of
tape and
replacing them with full spools is done by the automatic loading system (ALS)
50. As
shown in FIG 4, in one embodiment, the ALS is located downstream on a second
support carriage 52, adjacent to the wrapping system 18 and first support
carriage 16.
The second support carriage 52 is slidingly engaged with wheels or rollers to
the rail
system 26 such that the second support carriage 52 and ALS can move axially
toward or
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away from the wrapping system 18. In the other embodiment, the ALS may be
located
on the first support carriage 16 together with the wrapping system such that
the ALS can
move axially on the first support carriage away from or toward the wrapping
system by
means of rails located on the downstream end of the first support carriage
(not shown).
[0051] As best shown in FIG 5A, the ALS includes a support frame 54 attached
to the
second support carriage 52, a support body 56 and a rotating member 58 with a
hole in
the centre of the member to allow for the inner liner pipe 30 to pass through
the ALS.
Four arms 60 extend outward from the rotating member at 90 degrees to one
another.
Each arm includes an inner arm 60a and an outer arm 60b. The inner arm 60a
extends
directly outward and the outer arm 60b angles inward toward the pipe by means
of a
rotating cam 60c. A shaft 62 projects perpendicular to the outer arm and can
engage
with a full or empty spool of wrapping tape 40. The four arms rotate with the
rotating
member 58 clockwise or counterclockwise around the pipe. A loading/unloading
system
is located on each arm that can pull spools onto the shaft of the arm or push
spools off
of the shaft of the arm (not shown).
[0052] The ALS is used to unload the empty spools from the wrapping system and
re-
load full spools onto the wrapping system. In the ready position prior to
spool-changing,
the wrapping system 18 has stopped rotating with the two shafts holding the
empty or
nearly empty spools positioned horizontally on either side of the pipe. There
are no
spools on the two horizontal arms on the ALS, and the two vertical arms on the
ALS are
located above and below the pipe, each holding a full spool of wrapping tape.
To unload
the empty spools from the wrapping system, the ALS moves horizontally toward
the
wrapping system by means as described above such that the two empty horizontal
shafts of the ALS are in line with the two shafts on the wrapper holding the
empty
spools. Synchronously, both pulling devices on the horizontal ALS arms engage
with the
corresponding empty spools on the wrapper shafts and pull the empty spools
onto the
ALS shaft.
[0053] To load the full spools from the ALS onto the wrapping system, the ALS
moves
horizontally away from the wrapping system to allow the rotating mechanism to
rotate 90
degrees such that the two full spools are positioned horizontally. The ALS
moves
towards the wrapping system, aligning the two horizontal shafts with full
spools on the
ALS with the two empty shafts on the wrapping system. Synchronously, both
pushing
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devices on the horizontal ALS arms engage with the two full spools on the ALS
arms
and push the spools onto the two wrapping system shafts. The ALS moves away
from
the wrapping system such that the wrapping system can begin to operate again.
[0054] As the ALS is located downstream from the wrapping system and out of
the
rotation path of the winding head during the operation of the wrapping system,
the
rotating mechanism and arms of the ALS can rotate at any time during normal
operation
of the wrapping system to facilitate the loading and unloading of full or
empty spools
from the ALS by manual or automatic means.
[0055] In a further embodiment, the spool changing process is controlled
automatically
by a computer system. Sensory devices detect a spool is nearing depletion on
the
winding system and transmit the information to the computer system which
initiates the
start of the spool changing process.
[0056] In yet a further embodiment, the computer system controls the unloading
of
empty spools on the ALS and the reloading of full spools on the ALS between
spool
changing processes.
End Attachment System
[0057] Prior to the exchange of spools and subsequent to the exchange of
spools, the
ends of the first tape and second tape must be prepared for attachment and
subsequently attached to one another. In a preferred embodiment, as the first
spool
approaches depletion and the spool exchange process has been initiated wherein
the
winding heads have come to a stop, the first tape is cut on a cutting surface
and secured
on the cutting surface until the second spool has been loaded and the end of
the second
tape brought together with the end of the first tape. Ideally, the two ends
are stitched,
glued or taped together on the cutting surface to ensure an appropriate
continuous
connection between the tape ends of the first and second spools.
Optical Recognition of Tape Edges
[0058] In a further embodiment, a colored thread is sewn onto the edges of the
tape
during the manufacturing of the tape, allowing for digital camera and optical
recognition
software to line up the edges of the tape during the wrapping process to order
to
facilitate superior consistency during manufacture. That is, the optical
recognition system
CA 02678912 2009-09-17
will recognize a gap between the wound tape or an overlap of the tape, detect
this as an
abnormality and transmit the information to a computer to control the winding
speed
and/or the velocity of the carriage to allow for the correct alignment of the
tape edges.
General Example
[0059] In a typical pipe production line, the line speed may be 6.5 m/min
based on the
pipe extrusion rate with a winding head rotation speed of 41 rpm, resulting in
a total
travel length of 13.0 m needed for a spool changing process. As shown in Table
1,
typical line parameters are shown assuming a slow-down and start-up time of 30
seconds each and a spool unloading/reloading time of 1 minute.
Table I - Typical wrapper rotation speeds, line speeds, and corresponding
travel
lengths for flexible composite pipe production
Wrapper Rotation Speed (rpm) 41 33 23 16 9
Line Speed (m/min) 6.5 6.5 6.0 5.0 3.5
Travel Length for Slow-down (m) 3.3 3.3 3.0 2.5 1.8
Travel Length for Loading (m) 6.5 6.5 6.0 5.0 3.5
Travel Length for Start-up (m) 3.3 3.3 3.0 2.5 1.8
Total Travel Length Required (m) 13.0 13.0 12.0 10.0 7.0
[0060] Although the present invention has been described and illustrated with
respect to
preferred embodiments and preferred uses thereof, it is not to be so limited
since
modifications and changes can be made therein which are within the full,
intended scope
of the invention as understood by those skilled in the art.
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