This invention relates to a center rewinder having two or more turrets and a bedroll with two or more transfer positions for transferring a web to a web-winding member such as a mandrel at each of the transfer positions.
Rewinders are used to convert large parent rolls of paper into retail sized rolls of bathroom tissue and paper towels. Two types of rewinders are commonly used—center rewinders and surface rewinders. Center rewinders are described, for example, in U.S. Reissue Pat. No. 28,353 and wind the web on a core which is rotated by a mandrel. Surface rewinders are described, for example, in U.S. Pat. Nos. 4,723,724 and 5,104,055 and wind the web on a core which is rotated by a three roll cradle. The terms “rewinders” and “winders” are sometimes used interchangeably.
The critical operation in both center rewinders and surface rewinders is the sequence of steps referred to as cutoff and transfer. The web must be severed to end the winding of one roll, the leading edge of the severed web must be transferred to a new core, and the new core must be rotated to begin winding a new roll. These steps must be accomplished repeatedly and reliably while the web is moving at high speed. It is also desirable that each roll have exact sheet count and that the web is wound uniformly and substantially without wrinkles.
The term “bedroll” refers to the main winding roll of a rewinder, either a center rewinder or a surface rewinder.
As described in U.S. Reissue Pat. No. 28,353, a bedroll is commonly used in conjunction with a chopper roll to sever the web after a predetermined length has been wound into a log and to transfer the leading edge of the severed web to a new core in a continuous winding process. In center rewinders a latch mechanism is commonly used to retain the severing and transferring mechanism in an inoperative position until the proper length of web has been wound onto the log. A cam follower is controlled by an electric solenoid or pneumatic cylinder to unlatch the latch mechanism to release the severing and transferring mechanism. The severing and transferring mechanism is then controlled by one or more cams to perform the cutoff and transfer operations on the web. The latch is thereafter reset by the cam to retain the severing and transferring mechanism in the inoperative position.
A conventional latch mechanism and a severing and transferring mechanism for center rewinders is described in detail in U.S. Reissue Pat. No. 28,353. The severing and transfer mechanism includes transfer pins 56, cutoff blades 58 and 59, and transfer pads 55, all of which are movably mounted in the bedroll. When the severing and transfer mechanism is unlatched, the pins 56 hold the web against the rotating bedroll while the web is severed by a chopper roll 49 and the blades 58 and 59 (see
Surface rewinders sold by Paper Converting Machine Company of Green Bay, Wisconsin under the name “Magnum” include similar movable pins in a bedroll for holding the severed web against the bedroll and a similar latch mechanism for retaining the pins in an inoperative position until the web is to be severed. A cutoff knife is movably mounted in a chopper roll and is retained in an inoperative position by a latch mechanism which is similar to the latch mechanism which is used on the bedroll of a center rewinder.
U.S. Pat. No. 6,179,241 describes a latch mechanism which is controlled by a camshaft which is mounted axially in the bedroll and by a servo motor which rotates the camshaft. The servo motor normally rotates the camshaft in the same direction and at the same speed as the bedroll. When the web is to be severed, the speed of the servo motor is either increased or decreased to rotate the camshaft relative to the bedroll. The rotation of the camshaft allows push rods in the bedroll to move radially inwardly to release the severing and transferring mechanism. Cam followers for the severing and transferring mechanism engage a stationary cam and control the movement of the mechanism. After the web is severed and transferred, the camshaft is rotated to force the push rods radially outwardly to relatch the severing and transferring mechanism.
U.S. Pat. No. 6,513,750 describes a bedroll which includes a lockout cam, a pin cam, and a pad cam for operating the pins and pads instead of the cams, latch mechanism, and solenoid of U.S. Reissue Pat. No. 28, 353.
In all of the foregoing patents which describe a center rewinder, the rewinder includes a single rotatable turret. A plurality of mandrels are rotatably mounted on the turret, and the turret indexes to move the mandrels successively to a web-transferring position adjacent the bedroll. The bedroll has a single transfer position at a particular rotational position of the bedroll at which the web is transferred to a mandrel or to a core which is mounted on the mandrel. The operating mechanism for the pins and the pads is designed to move the pins and pads so that transfer occurs at that single transfer position.
U.S. Pat. No. 5,497,959 describes a coreless winder with two transfer positions. The bedroll uses vacuum and air pressure for maintaining control over the web during cutoff and transfer.
U.S. Pat. No. 5,226,611 describes a surface winder with two transfer positions. The rewinder includes a vacuum transfer roll 28 and two additional vacuum rolls 40 and 42 to advance the web to two surface winding stations.
U.S. Pat. No. 3,157,371 describes a winder with two turrets. This type of winder is typically used to wind a slit web. Part of the web is wound on one turret while the other part of the web is wound on the other turret. This patent does not describe using two turrets and two separate transfer positions for transferring a web from a bedroll to the turrets.
One embodiment of the invention provides a bedroll with two or more transfer positions for transferring a web to mandrels or cores. The mandrels or cores may or may not be mounted on turrets. Another embodiment of the invention uses the bedroll with two or more turrets for transferring and winding a web on multiple turrets. A rewinder with multiple turrets and multiple transfer positions is capable of operating at a substantially increased cycle rate. For example, a center rewinder having a single turret and a single transfer position is generally limited to producing about 35 logs per minute. However, a rewinder in accordance with the invention having two turrets and two transfer positions can produce about 70 logs per minute.
The invention will be explained in conjunction with illustrative embodiments shown in the accompanying drawing, in which
A web W is advanced by draw rolls 26 through a perforator 27 to the bedroll 22. The perforator forms longitudinally spaced transverse lines of perforation in the web.
The surface speed of the bedroll matches the speed of the web, and the bedroll delivers the web to a log L which is wound on the mandrel at about the 1:00 o'clock position of the turret. When the proper length of web has been wound on the log, the web will be severed by a chopper roll 28 and a new winding cycle will begin.
The bedroll 22 is equipped with a pin and pad assembly 30 which is described in detail in U.S. Pat. No. 6,513,750. A similar pin and pad assembly is described in U.S. Reissue Pat. No. 28,353.
As is well known in the art, such a pin and pad assembly includes a plurality of transfer pins for holding the web against the rotating bedroll while the web is severed by the chopper roll. The transfer pads thereafter strip the web from the pins and urge the leading end of the severed web against a new core to begin a new winding cycle. The pins and pads are mounted on a pin shaft and a pad shaft, respectively, which are independently rotatable by the operating mechanism of the pin and pad assembly as described in U.S. Pat. No. 6,513,750 and U.S. Reissue Pat. No. 28,353.
Referring now to
A web W is advanced by conventional infeed draw rolls (not shown) through a perforator (not shown) and over outfeed draw rolls 37 and the bedroll 32. As will be described hereinafter, the web is fed from the bedroll alternatively to the right and the left turrets 33 and 34. In
A previously wound log L2 is mounted on another mandrel of the right turret. Previously wound logs L3 and L4 are mounted on mandrels of the left turret 34.
A rider roll 40 is mounted on a swingable arm 41 and is in contact with the winding log L1. The rider roll alternates between the two turrets, depending on which turret is winding product. The position of the arm 41 and thus the rider roll 40 is controlled by a servo motor which is operated by the programmable logic control (PLC) of the rewinder. The diameter of the wound log is controlled by the rider roll position and the metered winding speed of the web, both of which are controlled by the PLC. Control of product diameter by rider roll position reduces sensitivity to the tensile strength of the perforations and increases product range and production efficiency.
At the completion of the wind, both product diameter and firmness are measured, e.g., by a laser PE and a load cell. This information is fed back in a closed loop to controls upstream of the bedroll to optimize runability.
The bedroll 32 includes pins 44 and pads 45 of the type which are described in U.S. Pat. No. 6,513,750. Just before the web is severed by the chopper roll 38, the pins 44 are moved outwardly to pierce the web and to hold the web against the surface of the bedroll after the web is severed. As will be described hereinafter, the pads 45 are extended to strip the web off of the pins and to press the leading end of the severed web against a new core to begin a new winding cycle.
Exact sheet count in a wound log can be obtained either by matching the sheet count to the circumference of the bedroll or by slipping the bedroll relative to the web prior to cutoff and transfer. Slipping the bedroll relative to the web to adjust sheet count is well known in the art and is described for example, in U.S. Pat. No. 4,687,153.
When the bedroll pins are extended to engage the web, the speed of the bedroll is matched to web speed and remains matched until just after transfer to eliminate sensitivity to web tensile strength and web stretch. Activation of the pins is controlled by a servo motor, which enables variable pin displacement based on the position of the winding turret, thereby permitting increased cycle rates of 60 to 70 logs per minute.
In
The completed log L4 on the left turret 34 is being indexed to a tailseal apparatus 50. The tailseal apparatus includes an air nozzle 51 which provides an air blast to blow the tail 52 of the log L4 past the tailseal apparatus.
The left turret is indexing clockwise at peak velocity. A glue applicator roll 53 of the tailseal apparatus 50 rotates with a speed which is matched to the indexing speed of the left turret and prints a line of adhesive on the wound log L4.
In
In FIGS. 7 both the left and right turrets are stationary. The web W is being wound on the log L5 on the left turret. The log L4 has been moved past the presser roll 56 so that its tail 52 is secured by the line of tailseal glue which was applied by the tailseal apparatus 50. The rider roll 40 engages the winding log L5 on the left turret.
The portion of the winding cycle which is illustrated in
When the log L5 approaches the end of its winding cycle, the right turret 33 will be indexed counterclockwise to move the mandrel 35b thereof into the transfer position of the right turret which is indicated by the radial line T in
Referring to
The pin shaft 65 and pad shaft 66 are rotatably mounted in the bedroll 32, and are driven by timing belts 72 and 73. The timing belt 73 is driven by hub 74 which is rotatably mounted on the journal 75 of the bedroll. The timing belt 72 is driven by a hub 76 which is rotatably mounted on the hub 74. The hubs 74 and 76 are driven through timing belts 77 and 78 by differentials 79 and 80 and electric servo motors 81 and 82. The servos 81 and 82 are controlled by the PLC of the rewinder.
A pulley 83 on the bedroll journal 75 is connected to pulleys on the differentials 79 and 80 by belt 84. The bedroll is driven by a servo motor which is controlled by the PLC of the rewinder.
The hubs 74 and 76 are rotated at bedroll speed during most of the winding cycle by the differentials 79 and 80. When rotation of the pin shaft 65 or pad shaft 66 is required, the appropriate servo 81 or 82 provides additional rotational speed to rotate the pin shaft or pad shaft relative to the bedroll. As described in U.S. Pat. No. 6,513,750, the differentials are mechanical motion “combiners”, and the output from each differential is the sum of a constant rpm input from the bedroll journal plus the trim rpm input from the servo 81 or 82.
The pin and pad shafts need to rotate relative to the bedroll in order to execute cutoff and transfer and also need to rotate relative to each other. The extension of the pins varies depending upon the position of the mandrel relative to the bedroll. The extension of the pads is constant when the pads are extended.
With the rewinder illustrated in the drawings, which includes two turrets, cutoff and transfer requires between one and two bedroll revolutions. The perforator roll is the master axis, with the distance between perforation and cutoff remaining constant. The movement of either the right or left turret, along with the movement of the pin and pad shafts, is referenced off of the master.
The following timing chart reflects the bedroll positions for two turrets. It will be apparent to those skilled in the art that the timing chart could be expanded to provide additional transfer positions if more than two turrets are used and could also be modified if means other than turrets are used to move the mandrels into the transfer positions.
Each turret indexes or rotates during about 25% of the winding cycle and dwells or is stationary for about 75% of the winding cycle.
A rewinder using more than one turret for transfer and winding makes possible cycle rates of up to 70 logs per minute or more. That is double the cycle rate of current rewinders using a single turret.
Other mechanisms for actuating the pins and pads could also be used. For example, the pin shaft and pad shaft could be operated by cams or separate timing belt drives.
The right turret dwells during the first 300° of the machine cycle and then moves 120° during the next 120° of the machine cycle. The right turret then dwells for the remaining 300° of two winding cycles.
The vertical line just prior to movement of the turret at 300° represents the return to start since the chart shows the turret rotating only 120° rather than showing three separate turret moves of 120° for a total movement of 360°.
The timing charts for the core loading axis for each turret would be similar. Two conventional core loaders are driven synchronously with the roll strip conveyors. Core loading onto an empty mandrel of a turret takes place at the same time as roll stripping on that turret and while the turret dwells.
As used herein, the term “web-winding member” can refer to a mandrel, a core, or an equivalent device which rotates to wind the web. The term “web-transferring member” can refer to either or both of the transfer pins and transfer pads or equivalent devices for transferring the web from the bedroll to the rotating core or mandrel
While in the foregoing specification a detailed description of specific embodiments was set forth for the purpose of illustration, it will be understood that many of the details herein given may be varied considerably by those skilled in the art without departing from the spirit and scope of the invention.