Note: Descriptions are shown in the official language in which they were submitted.
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COMPACT MACHINE FOR UNWINDING MULTIPLE STRANDS OF MATERIAL
FIELD OF THE INVENTION
The present disclosure relates to a machine for unwinding strands of material
from wound
packages. In particular, the present disclosure relates to a compact machine
for continuously
unwinding multiple strands of material from wound packages.
BACKGROUND OF THE INVENTION
Take off equipment is used to unwind strands of material that have been pre-
wound onto
cores. The pre-wound cores are called packages. Take off equipment unwinds a
strand and then
feeds the unwound strand to downstream equipment. Take off equipment can
unwind packages
in sequence while continuously feeding the downstream equipment. Each package
has a single
continuous strand of material with a leading end and a trailing end. In a take
off process, the
trailing end of a first package can be joined to the leading end of second
package.
As take off equipment finishes unwinding the first (active) package, it pulls
off the
trailing end, which pulls off the leading end of the second (standby) package,
which begins the
unwinding of the second package. The standby package becomes the new active
package. The
finished first package can be replaced with a new standby package. This
process of connecting
ends and replacing packages can be repeated indefinitely. Thus, in a take off
process, there is no
need to stop the downstream equipment to replace packages.
In this process, for each strand being unwound, the take off equipment
typically has two
package unwind stations, for the active and standby packages. The two stations
are typically
adjacent to each other, with each station angled toward a shared downstream
infeed location.
Together, the two package unwind stations and the downstream infeed location
form a take off
apparatus, which can unwind one strand of material.
When the downstream equipment requires multiple strands of material, multiple
take off
apparatuses are used. However, in many machines, the take off apparatuses are
arranged in a
manner that leaves large open areas, which result in inefficiently used space,
and thus, an
unnecessarily large footprint for the unwinding machine.
SUMMARY OF THE INVENTION
The present disclosure relates to machines for unwinding strands of material
from wound
packages. As discussed in more detail below, machines for continuously
unwinding multiple
strands of material from wound packages according to the present disclosure
may be arranged to
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be relatively more compact machines, wherein open areas are more efficiently
used space,
leading to a smaller and more compact footprint for the machines.
In one form, a machine comprises: a first apparatus having first package
unwind stations,
a first downstream infeed location, and a first centerline, wherein the first
apparatus is configured
to unwind a first strand from a first package in one of the first unwind
stations to the first
downstream infeed location, and the first strand follows a first overall
direction; and a second
apparatus having second package unwind stations, a second downstream infeed
location, and a
second centerline, wherein the second apparatus is configured to unwind a
second strand from a
second package in one of the second unwind stations to the second downstream
infeed location,
and the second strand follows a second overall direction; and a downstream
apparatus, which is
downstream from the first apparatus and the second apparatus, and which uses
the first strand and
the second strand in a machine process; wherein the first centerline and the
second centerline are
substantially parallel, and the first overall direction is opposite from the
second overall direction.
In another form, a machine comprises: a first apparatus having first package
unwind
stations, a first downstream infeed location, and a first centerline that is
centered on and
perpendicular to the first downstream infeed location, wherein the first
apparatus is configured to
unwind a first strand from a first package loaded into one of the first unwind
stations to the first
downstream infeed location, and the first strand follows a first overall
direction; and a second
apparatus having second package unwind stations, a second downstream infeed
location, and a
second centerline that is centered on and perpendicular to the second
downstream infeed location,
wherein the second apparatus is configured to unwind a second strand from a
second package
loaded into one of the second unwind stations to the second downstream infeed
location, and the
second strand follows a second overall direction; and a third apparatus having
third package
unwind stations, a third downstream infeed location, and a third centerline
that is centered on and
perpendicular to the third downstream infeed location, wherein the third
apparatus is configured
to unwind a third strand from a third package loaded into one of the third
unwind stations to the
third downstream infeed location, and the third strand follows a third overall
direction; and a
downstream apparatus, which is downstream from the first apparatus, the second
apparatus, and
the third apparatus, and which uses the first strand, the second strand, and
the third strand in a
machine process; wherein the first centerline, the second centerline, and the
third centerline are
arranged in a substantially radial array, and the first overall direction, the
second overall
direction, and the third overall direction are directed inward toward a center
of the array.
BRIEF DESCRIPTION OF THE DRAWINGS
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Figure 1A illustrates a front view of a prior art take off apparatus.
Figure 1B illustrates a top view of Figure 1A.
Figure 1C illustrates a front view of a portion of a prior art machine with a
number of take
off apparatuses, arranged in horizontal rows and vertical columns.
Figure 1D illustrates a top view of Figure 1C.
Figure 2 illustrates a side view of a portion of a machine with a number of
take off
apparatuses, arranged in staggered vertical columns.
Figure 3 illustrates a side view of a portion of a machine with a number of
take off
apparatuses, arranged in staggered horizontal rows.
Figure 4A illustrates a side view of a portion of a machine with a number of
take off
apparatuses, arranged in a horizontal row, with adjacent apparatuses having
differing overall
directions.
Figure 4B illustrates a top view of Figure 4A.
Figure 5 illustrates a side view of a portion of a machine with a number of
take off
apparatuses, arranged with apparatuses in adjacent columns having differing
overall directions,
and with staggered vertical columns.
Figure 6 illustrates a side view of a portion of a machine with a number of
take off
apparatuses, arranged in horizontal rows, with adjacent apparatuses in the
same row having
differing overall directions, and with staggered horizontal rows.
Figure 7 illustrates a side view of a portion of a machine with a number of
take off
apparatuses, arranged in alternating directions, offset horizontally and
vertically from each other.
Figure 8 illustrates a side view of a portion of a machine with a number of
take off
apparatuses, arranged in a radial array.
DETAILED DESCRIPTION OF THE INVENTION
As mentioned above, current take off apparatuses may be arranged in a manner
that
leaves large open areas, resulting in inefficiently used space, and thus, an
unnecessarily large
footprint for the unwinding machine. Such inefficient use of space is
discussed in more detail
below with respect the prior art arrangements are illustrated in Figures 1A-
1D.
For example, Figure 1A illustrates a front view of one prior art take off
apparatus 101
with a first package unwind station 111 holding a first package 112 and a
second package unwind
station 114 holding a second package 115. The first package 112 can unwind a
strand, where the
outline 113 of the unwinding strand has a substantially conical overall shape,
as it travels from
the package 112 to a downstream infeed location 117. The second package 115
can also unwind
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a strand, where the outline 116 of the unwinding strand also has a
substantially overall conical
shape, as it travels from the package 115 to the downstream infeed location
117. Figure 1B
illustrates a top view of Figure 1A. The apparatus 101 has a centerline 118
disposed halfway
between the first package unwind station 111 and the second package unwind
station 114, and
centered on the downstream infeed location 117. The apparatus 101 also has an
overall direction
119, which is oriented in the downstream direction for the unwinding strand
and aligned with the
centerline 118. Each take off apparatus described herein has the same overall
configuration, with
like-numbered elements configured in the same way.
Figure 1C illustrates a front view of a portion of a prior art machine 100
with six take off
apparatuses, arranged in horizontal rows and vertical columns. All of the take
off apparatuses in
Figure 1C are configured to provide unwound strands to a common downstream
apparatus, which
uses the strands in a machine process. A first take off apparatus 101, a
second take off apparatus
102, and a third take off apparatus 103 form a horizontally arrayed top row. A
fourth take off
apparatus 104, a fifth take off apparatus 105, and a sixth take off apparatus
106 form a
horizontally arrayed bottom row. The first take off apparatus 101 and the
fourth take off
apparatus 104 form a first vertical column. The second take off apparatus 102
and the fifth take
off apparatus 105 form a second vertical column. The third take off apparatus
103 and the sixth
take off apparatus 106 form a third vertical column. For all of the
apparatuses 101-106, their
centerlines are parallel, and their overall directions are oriented in the
same direction (toward the
viewer).
Due to the arrangement of the apparatuses 101-106 and the need for spacing
between the
package unwind stations, the machine 100 has a number of vertically oriented
open spaces
between the different parts of the apparatuses. Open spaces 161, 162, and 163
exist between the
centers of apparatuses in the same column. Open spaces 171 and 172 exist
between the outer
extents of the apparatuses, at the intersection of the rows and the columns.
These open areas
represent inefficiently used space, and thus, an unnecessarily large footprint
for the machine 100.
Figure 1D illustrates a top view of Figure 1C. Due to the arrangement of the
apparatuses 101-
106 and the need for spacing between the packages, the machine 100 has a
number of
horizontally oriented open spaces between the apparatuses. Open spaces 181 and
182 exist
between the sides of adjacent apparatuses in the same row. These open areas
also represent
inefficiently used space, and an unnecessarily large footprint for the machine
100.
As discussed in more detail below, machines for continuously unwinding
multiple strands
of material from wound packages according to the present disclosure may be
arranged to be
relatively more compact machines, wherein open areas are more efficiently used
space, leading
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to a smaller and more compact footprint for the machines. For example, Figure
2 illustrates a
side view of a portion of a machine 200 with six take off apparatuses,
arranged in staggered
vertical columns. All of the take off apparatuses in Figure 2 are configured
to provide unwound
strands to a common downstream apparatus, which uses the strands in a machine
process. A first
5 take off apparatus 201 and a fourth take off apparatus 204 form a first
vertical column. A second
take off apparatus 202 and a fifth take off apparatus 205 form a second
vertical column. A third
take off apparatus 203 and a sixth take off apparatus 206 form a third
vertical column. In the
machine 200, adjacent vertical columns are staggered with respect to each
other (i.e. disposed at
different elevations), such that an apparatus in one column does not form a
horizontal row with
the neighboring apparatus in the adjacent column.
In Figure 2, the columns are vertically offset such that the centerlines of
the apparatuses
in each column are vertically disposed halfway between the centerlines of the
apparatuses in an
adjacent column, however in various embodiments, this staggered spacing can be
varied to
various distances. For all of the apparatuses 201-206, their centerlines are
completely horizontal
and thus completely parallel. However, in various embodiments, one or more of
their centerlines
may only be substantially horizontal and one or more of their centerlines may
only be
substantially parallel with the other centerlines. For all of the apparatuses
201-206, their overall
directions are oriented in the same direction (toward the viewer).
Due to the arrangement of the apparatuses 201-206, the sizes of open spaces
(such as 171
and 172 in Figure 1C) between the outer extents of the apparatuses are
reduced. These open
areas are more efficiently used space, leading to a smaller and more compact
footprint for the
machine 200. The embodiment of Figure 2 can also be varied with different
numbers on
apparatuses, arranged as described above.
In another example, Figure 3 illustrates a side view of a portion of a machine
300 with six
take off apparatuses, arranged in staggered horizontal rows. All of the take
off apparatuses in
Figure 3 are configured to provide unwound strands to a common downstream
apparatus, which
uses the strands in a machine process. A first take off apparatus 301, a
second take off apparatus
302, and a third take off apparatus 303 form a horizontally arrayed top row
(all at one elevation).
A fourth take off apparatus 304, a fifth take off apparatus 305, and a sixth
take off apparatus 306
form a horizontally arrayed bottom row (all at another elevation). In the
machine 300, adjacent
horizontal rows are horizontally offset with respect to each other, such that
an apparatus in one
row does not form a vertical column with the neighboring apparatus in the
adjacent row.
In Figure 3, the rows are horizontally staggered such that the centerlines of
the
apparatuses in each row are disposed about a quarter of the way between the
centerlines of the
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apparatuses in an adjacent row, however in various embodiments, this staggered
spacing can be
varied to various distances. For all of the apparatuses 301-306, their
centerlines are completely
horizontal and thus completely parallel. However, in various embodiments, one
or more, or even
all of their centerlines may only be substantially horizontal and one or more,
or even all of their
centerlines may only be substantially parallel with the other centerlines. In
other embodiments,
one or more or even all of their centerlines may be nonparallel with one or
more, or even all of
the other centerlines. For all of the apparatuses 301-306, their overall
directions are oriented in
the same direction (toward the viewer).
Due to the arrangement of the apparatuses 301-306, the sizes of open spaces
(such as 161,
162, and 163 in Figure 1C) between the centers of the apparatuses are reduced.
These open areas
are more efficiently used space, leading to a smaller and more compact
footprint for the machine
300. The embodiment of Figure 3 can also be varied with different numbers on
apparatuses,
arranged as described above.
Figure 4A illustrates a side view of a portion of a machine 400 with four take
off
apparatuses, arranged in a horizontal row, with adjacent apparatuses having
differing overall
directions. All of the take off apparatuses in Figure 4A are configured to
provide unwound
strands to a common downstream apparatus, which uses the strands in a machine
process. A first
take off apparatus 401, a second take off apparatus 402, a third take off
apparatus 403, and a
fourth take off apparatus 404 form a horizontally row (all at one elevation).
Due to the differing
overall directions, the first take off apparatus 401 and the third take off
apparatus 403 are facing
toward the viewer, while the second take off apparatus 402 and the fourth take
off apparatus 404
are facing away from the viewer.
Figure 4B illustrates a top view of Figure 4A. In the embodiment of Figure 4B,
the
footprints of the apparatuses (that is, the outer extents of the apparatuses,
when viewed from the
top) do not overlap each other. For all of the apparatuses 401-404, their
centerlines are
completely horizontal and thus completely parallel. However, in various
embodiments, one or
more, or even all of their centerlines may only be substantially horizontal
and one or more, or
even all of their centerlines may only be substantially parallel with the
other centerlines. In other
embodiments, one or more or even all of their centerlines may be nonparallel
with one or more,
or even all of the other centerlines.
Adjacent apparatuses 401 and 402 have opposite overall directions. Also,
adjacent
apparatuses 402 and 403 have opposite overall directions. Further, adjacent
apparatuses 403 and
404 have opposite overall directions.
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For adjacent apparatuses, portions of the substantially conical overall shapes
of their
strand outlines are parallel with each other. A portion of the strand outline
416 is parallel with a
portion of the strand outline 423, separated by distance 481. A portion of the
strand outline 426
is parallel with a portion of the strand outline 433, separated by distance
482. A portion of the
strand outline 436 is parallel with a portion of the strand outline 443,
separated by distance 483.
In any of the embodiments described herein, the distance between adjacent
unwinding
strands (such as the distances 481, 482, and 483 in the embodiment of Figure
4B) can be set to
various dimensions to reduce the possibility of interference between adjacent
unwinding strands.
In any of the embodiments described herein, the distance can be set to a
particular dimension
such as: less than or equal to 50 cm, less than or equal to 45 cm, less than
or equal to 40 cm, less
than or equal to 35 cm, less than or equal to 30 cm, less than or equal to 25
cm, less than or equal
to 20 cm, less than or equal to 15 cm, or less than or equal to 10 cm, or any
integer value between
any of these, or any range made from any of these values. In any of the
embodiments described
herein, the distance can be set to a dimension that is based on a maximum
diameter size for
packages to be unwound by the apparatuses. In any of the embodiments described
herein, the
machine can additionally or alternatively include a guard, shield, or
separating panel, set in
between adjacent apparatuses, to prevent interference between adjacent
unwinding strands.
In a particular alternate embodiment of Figure 4B, adjacent apparatuses can be
moved
closer with respect to each other, such that the footprints of the apparatuses
(that is, the outer
extents of the apparatuses, when viewed from the top) do partially overlap
each other. For
example, the first take off apparatus 401 and the second take off apparatus
402 can be moved,
with respect to each other (inward sideways, or in the overall direction(s),
or in a combination of
these directions), such that strand outlines 416 and 423 at least partially
overlap. This overlap
condition can exist, without interference, in certain process conditions. For
example, if the
package in the left package unwind station of apparatus 401 is the active
package, and the
package in the left package unwind station of apparatus 402 is the active
package, then the strand
outline 423 will not interfere with strand outline 416, because the right hand
package of
apparatus 401 is not active; so the strand outline 416 will not create
interference. In this way, the
footprints of adjacent apparatuses can partially overlap each other so long as
the package cores
and the frames of closest package unwind stations do not fall within the
footprint of the adjacent
apparatus. This overlapping relationship can also be repeated for other
adjacent apparatuses in
the machine 400.
Due to the arrangement of the apparatuses 401-404, the sizes of open spaces
(such as 181
and 182 in Figure 1D) between the sides of the apparatuses are reduced. These
open areas are
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more efficiently used space, leading to a smaller and more compact footprint
for the machine
400. The embodiment of Figure 4A can also be varied with different numbers on
apparatuses in
a row, and any number of rows, with the apparatuses in each row arranged as
described above.
Figure 5 illustrates a side view of a portion of a machine 500 with six take
off apparatuses
(501-506), arranged with apparatuses in adjacent columns having differing
overall directions, and
with staggered vertical columns. The machine 500 is configured in the same way
as the machine
400 of Figures 4A and 4B, except that adjacent vertical columns are staggered
with respect to
each other, as described in connection with the embodiment of Figure 2.
Due to the arrangement of the apparatuses 501-506, the sizes of open spaces
between the
apparatuses are reduced. These open areas are more efficiently used space,
leading to a smaller
and more compact footprint for the machine 500. The embodiment of Figure 5 can
also be varied
with different numbers on apparatuses, arranged as described above.
Figure 6 illustrates a side view of a portion of a machine with six take off
apparatuses
(601-606), arranged in horizontal rows, with adjacent apparatuses in the same
row having
differing overall directions, and with staggered horizontal rows. The machine
600 is configured
in the same way as the machine 400 of Figures 4A and 4B, except that adjacent
horizontal rows
are staggered with respect to each other, as described in connection with the
embodiment of
Figure 3.
Due to the arrangement of the apparatuses 601-606, the sizes of open spaces
between the
apparatuses are reduced. These open areas are more efficiently used space,
leading to a smaller
and more compact footprint for the machine 600. The embodiment of Figure 6 can
also be varied
with different numbers on apparatuses, arranged as described above.
Figure 7 illustrates a side view of a portion of a machine 700 with four take
off
apparatuses, arranged in alternating directions, offset horizontally and
vertically from each other.
In the embodiment of Figure 7, a first take off apparatus 701 and a second
take off apparatus
form one horizontal row, and have overall directions that are commonly aligned
in one direction
(toward the viewer), while a third take off apparatus 703 and a fourth take
off apparatus 704 form
another horizontal row (vertically offset from the one row) and have overall
directions that are
commonly aligned in another direction (away from the viewer).
Due to the arrangement of the apparatuses 701-704, the sizes of open spaces
between the
apparatuses are reduced. These open areas are more efficiently used space,
leading to a smaller
and more compact footprint for the machine 700. The embodiment of Figure 7 can
also be varied
with different numbers on apparatuses, arranged as described above.
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Figure 8 illustrates a side view of a portion of a machine with four take off
apparatuses,
arranged in a radial array. The take off apparatuses 801, 802, 803, and 804
are arranged in a
circular array, such that all of their overall directions are directed inward
toward the center of the
array.
All of the take off apparatuses in Figure 8 are configured to provide unwound
strands to a
common downstream apparatus, which uses the strands in a machine process. A
first take off
apparatus 801, a second take off apparatus 802, a third take off apparatus
803, and a fourth take
off apparatus 804 form a horizontally oriented circle (all at one elevation).
In the embodiment of Figure 8, the footprints of the apparatuses (that is, the
outer extents
of the apparatuses, when viewed from the top) do not overlap each other. For
all of the
apparatuses 801-804, their centerlines are completely horizontal.
However, in various
embodiments, one or more, or even all of their centerlines may only be
substantially horizontal.
For all of the apparatuses 801-804, their centerlines intersect at a common
point, and thus are
completely radial. However, in various embodiments, one or more, or even all
of their
centerlines may only be substantially radial.
In Figure 8, for adjacent apparatuses, portions of the substantially conical
overall shapes
of their strand outlines are substantially or completely parallel with each
other. However, in
various embodiments, for adjacent apparatuses, portions of the substantially
conical overall
shapes of their strand outlines may be nonparallel with each other. A portion
of the strand
outline 816 is parallel with a portion of the strand outline 823, separated by
distance 881. A
portion of the strand outline 826 is parallel with a portion of the strand
outline 833, separated by
distance 882. A portion of the strand outline 836 is parallel with a portion
of the strand outline
843, separated by distance 883. A portion of the strand outline 846 is
parallel with a portion of
the strand outline 813, separated by distance 884.
In any of the embodiments described herein, the distance between adjacent
unwinding
strands (such as the distances 881, 882, and 883 in the embodiment of Figure
8) can be set to
various dimensions to reduce the possibility of interference between adjacent
unwinding strands.
In any of the embodiments described herein, the distance can be set to a
particular dimension
such as: less than or equal to 50 cm, less than or equal to 45 cm, less than
or equal to 40 cm, less
than or equal to 35 cm, less than or equal to 30 cm, less than or equal to 25
cm, less than or equal
to 20 cm, less than or equal to 15 cm, or less than or equal to 10 cm, or any
integer value between
any of these, or any range made from any of these values. In any of the
embodiments described
herein, the distance can be set to a dimension that is based on a maximum
diameter size for
packages to be unwound by the apparatuses. In any of the embodiments described
herein, the
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machine can additionally or alternatively include a guard, shield, or
separating panel, set in
between adjacent apparatuses, to prevent interference between adjacent
unwinding strands.
Due to the arrangement of the apparatuses 801-804, the sizes of open spaces
(such as 181
and 182 in Figure 1D) between the sides of the apparatuses are reduced. These
open areas are
5 more efficiently used space, leading to a smaller and more compact
footprint for the machine
800.
The embodiment of Figure 8 can also be varied in a number of ways. Different
numbers
of apparatuses can be used in the radial array. The radial array may or may
not form a complete
circle. A machine can include any number of radial arrays stacked vertically
on top of each
10 other, with the apparatuses in each radial array arranged as described
above. When the machine
includes two or more radial arrays stacked vertically on top of each other,
adjacent apparatuses
may be vertically and/or radially aligned or may be vertically or radially
offset from each other,
as described in connection with the embodiments of Figures 2 and 3.
The dimensions and values disclosed herein are not to be understood as being
strictly
limited to the exact numerical values recited. Instead, unless otherwise
specified, each such
dimension is intended to mean both the recited value and a functionally
equivalent range
surrounding that value. For example, a dimension disclosed as "40 mm" is
intended to mean
"about 40 mm."
Every document cited herein, including any cross referenced or related patent
or
application, is hereby incorporated herein by reference in its entirety unless
expressly excluded
or otherwise limited. The citation of any document is not an admission that it
is prior art with
respect to any invention disclosed or claimed herein or that it alone, or in
any combination with
any other reference or references, teaches, suggests or discloses any such
invention. Further, to
the extent that any meaning or definition of a term in this document conflicts
with any meaning
or definition of the same term in a document incorporated by reference, the
meaning or definition
assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated
and
described, it would be obvious to those skilled in the art that various other
changes and
modifications can be made without departing from the spirit and scope of the
invention. It is
therefore intended to cover in the appended claims all such changes and
modifications that are
within the scope of this invention.
