Flying paster core winding method and apparatus

Abstract

A method and an apparatus for winding or rewinding a running web onto the center core shafts of rolls. While the running web is being wound, at a selected speed, onto a first roll which is, disposed in an operating position, a center core shaft of a new, second roll is disposed in a splicing position so that the center core shafts are side by side and adjacent to each other. A fixed drive assembly and a movable drive assembly control the speeds of the first and second rolls, respectively. The first roll has had a determined amount of web wound thereon, the running web is spliced onto the center core shaft of the second roll and thereafter is wound onto the second roll. Thereafter, the second roll is disconnected from the fixed drive assembly and is removed from the operating position. The second roll, with the running web now being wound thereon, is then moved, with the movable drive assembly, from the splicing position to the operation position. Once there, the fixed drive assembly is connected with the second roll, and the movable drive assembly is disconnected from the second roll and moved back adjacent to the splicing position, ready to be connected with the center core shaft of another roll.

Description

BACKGROUND OF THE INVENTION

The present invention relates to methods and apparatus for winding or rewinding a running web of material into rolls. More particularly, the present invention relates to methods and apparatus for winding a web of material that is running from a web handling operation and that is to be wound sequentially about the center core shaft of one roll and then about the center core shaft of another roll without stopping the running web.

Various apparatus for winding or rewinding running webs into rolls are known. Basically such apparatus falls into two general classes; surface winders, and core winders. Surface winders generally have a drum that has a uniform diameter, and the roll of web material being wound is forced against the outer surface of the drum. This allows the use of smaller horsepower (for example, 4 horsepower), cost effective motors. In contrast and due to the build-up ratio, a comparable core winder might require a 40 horsepower motor. The difference in motor sizes results in a significant difference in the costs for the winders. Largely because of this cost difference, surface winders have been generally preferred by cost conscious purchasers.

Surface winders have, however, had long recognized disadvantages. For instance, they cannot be used with web materials whose surfaces cannot or should not be touched during the winding operation. Additionally, satisfactory tapered tension control is more difficult, and thus more expensive, to achieve in surface winders as compared to core winders. Those working in the art have long sought a winder, without the disadvantages of surface winders, that would be more cost competitive with surface winders.

Conventional core winders have other disadvantages, besides cost, vis-a-vis surface winders. Typical turret-type core winders tend to be large and require space to accommodate the swinging of their roll bearing arms through the approximately 180.degree. arcs. Additionally, turret type core winders require another motor to affect the movement of their roll bearing arms, as well as mechanisms to attempt to assure the proper level and angular alignment of the rolls after such movement, particular where high quality rolls are being wound. This adds to the cost of the core winders. Again, those working in the art have also sought a core winder that would be cost competitive with surface winders and that would not have these aforementioned disadvantages.

SUMMARY OF THE INVENTION

In principal aspect, the present invention is directed to an improved flying paster core winding method and apparatus for winding or rewinding a running web of material sequentially onto center core shafts of a plurality of rolls. The present invention overcomes the aforementioned disadvantages associated with the prior core winders while being quite cost competitive with conventional surface winders. The present invention may be embodied in a flying paster core winder that does not employ a turret concept, and accordingly, does not need the space required by conventional turret-type core winders for similar sized rolls. Flying paster core winders of the present invention are thus less expensive to manufacture, vis-a-vis conventional turret-type core winders, because they do not include the turret and associated structures.

Instead of having to be pivoted through a major arc, the rolls in the flying paster core winders of the present invention are only moved approximately 30 inches, along a straight, horizontal path, between a splicing position and an operating or web winding position. Then, after a determined amount of web has been wound onto a roll, the roll is again moved a similar distance, again along a substantially straight path, to a position where the roll may be easily off-loaded from the core winder.

Further and instead of using a large horsepower motor, like conventional core winders, the improved flying paster core winders of the present invention utilize two, relatively smaller horsepower motors (for example and with reference to the exemplary motors noted above, two 7 horsepower motors). The savings in motor costs enables the flying paster core winders of the present invention to compete, on a cost basis, favorably with conventional surface winders without having the aforementioned disadvantages of such surface winders.

Accordingly, the primary object of the present invention is to provide an improved flying paster core winding method and apparatus for winding or rewinding a running web where the running web is initially being wound onto the center core shaft of a first roll; where after the first roll has had a determined amount of web wound thereon, the running web is spliced onto and thereafter wound about the center core shaft of a second roll; and where the running web is run at a preselected speed while the running web is being wound about or into the first roll, while the running web is being spliced and while the running web is being wound about or into the second roll.

Another object of the present invention is to provide an improved method and apparatus, as described above, where the first roll is driven, by a fixed drive assembly, while the first roll is disposed in an operating position so that the running web runs at the preselected speed; where the central core shaft of the second roll is disposed in a splicing position which is adjacent to the first roll in its operating position; where the running web is run so that it passes adjacent to the center core shaft of the second roll before it is wound onto the first roll; where the center core shaft of the second roll is driven, while in its splicing position, by a movable drive assembly so that the rotational speed of the center core shaft of the second roll matches the preselected speed of the running web; where an adjacent portion of the running web is pressed into surface to surface contact with the outer peripheral surface of the center core shaft of the second roll such that that portion will adhere to the outer peripheral surface of the center core shaft of the second roll; where the second web is then cut, downstream of the adjacent portion of the running web, so that the running web will then begin to wind about the center core shaft of the second roll; and where the first roll is disconnected from the fixed drive assembly and moved from the operating position; and where the second roll and the movable drive assembly is then moved, along a substantially straight path, from the splicing position to the operating position.

Still another object of the present invention is to provide an improved method and apparatus, as described, where the first and second rolls, in their operating and splicing position, respectively, are adjacent to each other and are disposed side by side; and where the second roll is generally moved horizontally from the splicing position to the operating position.

A further object of the present invention is to provide an improved method and apparatus, as described, where the fixed drive assembly is connected with the center core shaft of the second roll after the second roll has been moved from the splicing position to the operating position; and where the first roll is moved from the operating position, and after being moved, may be easily lifted out of the core winder apparatus of the present invention by means incorporated in the apparatus.

A still further object of the present invention is to provide an improved method and apparatus, as described, where the movable drive assembly is disconnected from the center core shaft of the second roll after the fixed drive assembly has been connected with the center core shaft of the second roll; and where the movable drive assembly is then moved back to a position where it may be connected with another roll's center core shaft that is thereafter disposed at the splicing position.

These and other objects, advantages and benefits of the present invention will become apparent from the following description of the preferred embodiment of the invention as illustrated in the drawings next described.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing a flying paster unwinder, such as disclosed in co-pending application Ser. No. 08/136,609, on the left, and a flying paster core winder of the present invention on the right;

FIG. 2 is a perspective, operator side, side view of the flying paster core winder apparatus of the present invention with its two side housings shown in phantom lines;

FIG. 3 is an operator side, side view of the flying paster core winder of the present invention;

FIG. 4 is an operator side, side view of the running web splice assembly of the present invention illustrating the assembly in its normal web running, its splice reparation and its splicing positions;

FIG. 5 is an operator side, side view of the flying paster core winder of the present invention illustrating the movement of a roll as it moves from the operating position;

FIG. 6 is a drive or gear side view of the flying paster core winder of the present invention corresponding to the FIG. 5 view;

FIG. 7 is a partial top plan view illustrating the means for connecting the center core shafts to the moving and fixed drive assemblies;

FIG. 8 is an operator side, front view of the fixed drive assembly for driving the center core shaft of a roll;

FIG. 9 is a drive or gear side, front view of the moving drive assembly for driving the center core shaft of a roll;

FIG. 10 is a partial, drive or gear side, front view of the moving core retainer assembly;

FIG. 11 is an end view of the assembly shown in FIG. 10;

FIG. 12 is a partial, drive or gear side, front view of the fixed core retainer assembly showing the fixed core retainer plate securing the operator side end of the center core shaft while contacting the core moving retainer plate;

FIG. 13 is a partial side view of the fixed core retainer assembly;

FIG. 14 is a partial end view of the operator side of the core winder of the flying paster of the present invention illustrating the fixed drive assembly; and

FIG. 15 is a partial end view of the drive or gear side of the flying paster core winder of the present invention illustrating the movable drive assembly.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, a preferred embodiment of the flying paster core winder of the present invention is generally shown at 22. As noted, the primary function of the core winder 22 is to wind or rewind a running web 24, which may comprise a variety of different materials, into rolls. Prior to coming to the core winder 22, the web 24 will usually have passed through web handling operation, such as, for example, a printing press. (In FIG. 1, such a web handling operation is represented by a roller 26.)

Generally the web 24 will have been unwound from rolls by an unwinding apparatus, such as generally shown at 28 in FIG. 1, before it passes through the web handling operation. This apparatus 28 may be the flying paster unwind apparatus disclosed in co-pending U.S. patent application (hereinafter the "Application") Ser. No. 08/136,609, filed Oct. 15, 1993. The disclosure of this Application is incorporated herein by reference thereto.

As best illustrated in FIGS. 1-2, the core winder 22 includes an operator side housing 32 and a drive or gear side housing 34. Each of these housings 32 and 34 is a generally rectangular structure, that has a generally open interior, that is constructed from heavy steel sheets, and that supports and houses various components of the core winder 22.

The housings 32 and 34 have spaced apart, facing side walls 33 and 35 that are generally parallel to each other. These walls are spaced apart a predetermined distance that is greater than the width of the running web 24. Rolls of the web 24, which are being wound on the core winder 22, are adapted to be positioned between these facing side walls 33 and 35 while the running web is running and rolls of the web are being wound. The running web 24 enters the core winder 22, or more particularly, the space between the housings 32 and 34, at one end 36 of that space (that is, the end facing the flying paster unwinding apparatus 28 as shown in FIG. 1) and completed, wound rolls exit from the core winder 22 from a roll exit end 38.

Referring now to FIGS. 2 and 3, the web 24 enters the web entry end 36 and passes around a first turning roller 42 which directs the web generally downwardly. The web 24 next passes about a second turning roller 44 that again directs the web generally upwardly. The ends of the rollers 42 and 44 are mounted for rotation on the housings 32 and 34.

The running web 24 then passes about a conventional, single roller pivoting dancer assembly 46, or more specifically, about the roller 48 of that assembly. Exiting from the dancer assembly 46, the running web 24 next passes around or about a web splice assembly 52. After passing around the assembly 52, the web 24 is wound on a steel center core shaft. (In practice, a center core shaft will have a fiberboard, tubular core placed over them by the core winder operator before the shaft is put into the winder 22. Additionally, double sided adhesive tape will be applied by the operator to the exterior surface of the fiberboard core to facilitate splicing the web 24 onto the fiberboard core or onto the center core shaft.) In FIG. 3, the web 24 is shown as being wound into a roll 54 that has a center core shaft 56 and that, as shown, is disposed in the operating position in the core winder 22. Referring again to FIG. 3, the operator side end of the center core shaft 56 is connected with a fixed drive assembly 58 that rotates the shaft 56, and thus the roll 54, so as to pull the web 24 and wind it about the shaft 56.

A conventional lay-on roller assembly 62 includes a roller 64. This roller is adapted to lay across and presses against the web 24, in a conventional manner, as it is wound about the roll 54.

A core carrier assembly 66 is adapted to receive and carry the ends of a second center core shaft 68. The assembly 66 includes parts positioned adjacent to both of the facing side walls 33 and 35 of the housings 32 and 34 and is adapted to receive the ends of the center core shaft 68 that has been introduced into the core winder 22 through the web entry end 36. Once the ends of the center core shaft 68 are received by the core carrier assembly 66, the core carrier assembly, and the shaft 68, move forward slightly (that is, toward the end 38) so that the shaft 68 is positioned in the splice position. (The phantom line illustrations in FIG. 3 of the shaft 68 at 68', 68" and 68"' illustrate the shaft as it is introduced into the winder 22, and moved to the splicing position--where the shaft 68 is shown in solid lines in FIG. 3.) When the shaft 68 is in the splice position, the drive side end of the center core shaft 68 is connected with a movable drive assembly 74.

After a predetermined amount of web 24 has been wound onto the roll 54, the movable drive assembly 74 causes the shaft 68, in the splice position, to rotate so that the surface speed of the shaft matches that of the running web 24. The web splice assembly 52 is disposed, when ready for a splice, so that a portion of the running web passes closely adjacent to the shaft 68 as the web runs into the roll 54. The assembly 52 is then actuated so as to splice a portion of the running web 24 onto the center core shaft 68. As noted and to facilitate the splice, the outer or exterior surface of the fiberboard core, which has been placed over the shaft 68, has had double-sided sticky adhesive tape applied to it so that the portion of the running web will adhere to that core at the time of splicing. Thereafter the web 24 is cut immediately downstream of the spliced portion so that the web 24 no longer winds onto the roll 54, but rather begins to wind about the shaft 68.

After a splice has been made and the web cut, the fixed drive assembly 58 permits the rotation of the web roll 54 to stop. The operator side end of the center core shaft 56 is then disconnected from the fixed drive assembly 58. A core dump chain assembly 76 is used to transport the center core shaft 56, and thus the roll 54, from the operating position toward the roll exit end 38. When the roll 54 reaches the end 38, the ends of the center core shaft 56 are received in the crooked or hooked ends 78 of a pair of roll unload arms 82 and 84. These hooked ends 78 are adapted to catch and hold the ends of the center core shaft 56, as best shown in FIGS. 5 and 6. When the arms 82 and 84 are disposed in their upper positions, the roll 54 will be suspended above the floor. A roll unload assembly 86, which includes the arms 82 and 84, may then be actuated by the core winder operator to lower the arms 82 and 84 to their lower position so that the roll 54 may be easily removed from the winder 22 and stored.

After the roll 54 has been moved from the operating position and is supported by the roll unload arms 82 and 84 (or has been removed from the core winder 22 completely), the center core shaft 68, with the running web 24 being wound thereon, is moved, along a predetermined path, from the splicing position (as shown in FIGS. 5 and 6) to the operating position by the core carrier assembly 66. The path of movement is straight, horizontal and relatively short, for example, may be about thirty inches. As noted, the movable drive assembly 74 moves with the assembly 66 and the shaft 68, and continues to rotate the shaft 68 during this movement and after the shaft 68 reaches the operating position.

After the center core shaft 68 and the movable drive assembly 74 have been moved to the operating position, the fixed drive assembly 58 is connected with the operator side end of the center core shaft 68 and also begins to drive the shaft 68. Thereafter, the movable drive assembly 74 is disconnected from the drive side end of the center core shaft 68. The carrier assembly 66 is again actuated and moves the movable drive assembly 74 back along the path to a position adjacent to the splicing position so that when another center core shaft is placed into the core winder 22, the drive side end of that center core shaft may be connected with the assembly 74.

The fixed drive assembly 58 continues, thereafter, to drive the center core shaft 68, and the roll of web material that is being wound thereon, until again a predetermined amount of web has been wound onto the roll. While this winding occurs, and as noted, still another center core shaft may be introduced into the core winder 22 so as to be positioned for another splice and to permit the above described winding operation to be repeated.

Turning now to the various assemblies and components of the flying paster core winder 22, these assemblies and components are structurally and functionally similar to the corresponding assemblies and components described in the Application except as noted. In this regard, the single roller pivoting dancer assembly 46 is similar to the dancer assembly 102 in the Application. The ends of the roller 48 are supported for rotation between the distal ends of a pair of spaced apart arms 88 and 89. The other ends of the arms 88 and 89 are connected to a cross rod 92 so that the arms may pivot about the longitudinal axis of that cross rod. The ends of the rod 92 are supported by the housings 32 and 34. The one ends of two conventional double-acting fluid cylinders 94 and 95 are connected with the arms 88 and 89, between the ends of the arms, so that actuation of the cylinders will pivot the arms about the longitudinal axis of the rod 92. The other ends of the cylinders 94 and 95 are connected with the housings 32 and 34, respectively.

The structure and function of the web splice assembly 52 is generally like the Application's splice assembly 48, except as shown in FIG. 4, the assembly 52 is not moved up to a generally horizontal position when the web 24 is normally running onto a roll in the operating position. A fluid cylinder 98, which corresponds to the Application cylinder 88, moves the assembly 52 between an upper, normal web running position 102, a splice preparation position 104 and a splice position 106, all of which positions are shown in FIG. 4. In all positions, the web 24 passes about a roller 108 supported by the assembly 52. In the latter two positions 104 and 106, the web also passes about a roller 112 that is also supported by the assembly 52. After the assembly 52 is moved to its splice position, a portion of the running web 24 is pressed, as noted above, against the outer surface of a fiberboard core (which the core winder operator has placed over the center core shaft 63 prior to putting the shaft in the winder 22) and thus against the double-sided adhesive tape wrapped about this fiberboard core. The web 24 is then cut, downstream from that portion, as is described in the Application.

The fixed drive assembly 58 and the movable drive assembly 74 are structurally and functionally similar to the Application's assemblies 44 and 42, respectively, except that the assemblies 58 and 74 include regenerative drive motors 113 and 114. These regenerative drive motors 113 and 114 may either be a D.C. drive system or an A.C. vector system. They need only be relatively small horsepower motors (for example, seven horsepower) because of the unique structure and method of operation of the core winder 22. As best illustrated in FIGS. 8 and 9, polychain "KEVLAR" brand belts 115 are utilized to interconnect the output shafts of the motors 113 and 114 with the longitudinally movable spindles 116 and 118, respectively, via drive pulleys 120. The distal ends 122 and 124 of the spindles 116 and 118, respectively, are adapted to be connected with and be disconnected from the operators side and the drive side ends, respectively, of the center core shaft 56 and 68 as described in the Application.

Referring to FIGS. 2, 3, 5 and 6, the lay-on assembly 62 includes a pair of arms 126 whose distal ends journal the ends of the conventional lay-on roller 64. This roller 64 is adapted to lay-on the most recently laid layer or turn of the web 24 being wound into a roll, whether the roll being wound is in the splice position or in the operating position. The other ends of the arms 126 are connected with a cross rod 128 whose ends are supported by the housings 32 and 34. The operator's side end of that rod 128 includes a sprocket 132, and this sprocket cooperates with a chain 134. The chain 134 extends around a second sprocket 136 that is also mounted for rotation on the housing 32. The opposite ends of the chain 134 are connected with the opposite ends of a conventional double-acting fluid cylinder 138 that is also mounted on the housing 32. Actuation of the cylinder 138 causes the roller 64 to pivot about the longitudinal axis of the cross rod 128.

Also referring to FIGS. 2, 3, 5 and 6, the ends of the center core shaft 66 move along a pair of parallel move rails 150 that are attached to the housings 32 and 34. These rails 150 are horizontally disposed between the splice and operating positions and are inclined downwardly from the operating position to the roll exit end 38. Between the end 36 and a point slightly or just upstream from the splice position, the rails 150 are disposed in a horizontal plane spaced slightly above the horizontal plane of the rails 150 disposed between the splice and operating positions.

The core carrier assembly 66 is generally similar, in structure and function, to the Application assembly 104. In assembly 66, two carrier keepers 142 carry the ends of the shaft 68 from the splicing position to the operating position. The carrier keepers 142 are structurally and functionally identical except that the carrier keeper 142 on the drive side moves with the movable drive assembly 74.

As best shown in FIGS. 10-11, the carrier keeper 142 on the operator's side is mounted on a carrier member 144 that, in turn, is supported on and is movable along a horizontally disposed carrier rail 146 attached to the housing 32. A plurality of mounting rollers 152 are attached to the plate 144 and ride on the rail 146. A plurality of guide rollers 154 guide the plate 144 as it moves along the rails 146. The ends of a drive chain 156 are connected with the opposite ends of the plate 144. The chain 156 passes about a plurality of sprockets 157 and is driven by a relative small conventional electric motor 158.

A similar drive chain 156 is connected with the assembly 74, which includes the carrier keeper 142 and member 144 that carries the drive side end of the shaft 68. (The assembly 74 moves along a carrier rail 150 by means of a plurality of mounting and guide rollers.) The motor 158 drives both chains 156 by means of a cross-rod 162 (as best seen in FIG. 2) that extends between the housings 32 and 34 and that synchronizes the movement of the chains. Movements of the drive chains 156 moves both carrier keepers 142, and on the drive side, also moves the movable drive assembly 74.

Referring again to FIGS. 10 and 11, the end adjacent to the roll entry end 32 of each carrier keeper 142 is pivotally mounted, by a pivot pin 164, to the plate 144. A generally horizontally disposed coil spring 166 is connected between the plate 144, at its left end (as seen in FIG. 10) and the keeper 142, on its right hand end. The spring 166 exerts a counter-clockwise bias on the carrier keeper 142 about the pin 164. A limit pin 168, mounted on the plate 144, limits the counter-clockwise pivoting of the carrier keeper 142 so that the carrier keeper is normally horizontally disposed. The upper surface of the carrier keeper 142 includes an upwardly facing notch 172 and has a trailing or upstream shoulder 174 as shown in FIG. 10. The notch 172 is adapted to "capture" the adjacent shaft end and prevent it from moving, relative to the keeper, along the move rail 150.

As noted above, when preparing for a splice, the core winder operator places a fiberboard core about the center core shaft, such as the shaft 68, and lays the ends of the shaft 68 on the move rail 150 adjacent to the end 36. He or she then slides or rolls the shaft along the move rail 150 until the ends of the shaft drop down into the notches 172 in the carrier keepers 142. The carrier keepers 142, and the shaft 68, are then moved forward (that is, toward the end 38) until the shaft 684, is in the splice position, as illustrated in the solid line position of the shaft 68 in FIGS. 5 and 6.

After a splice has been made, the motor 158 is actuated, and the carrier keepers 142, and thus the shaft 68 (as well as the movable drive assembly 74), are moved from the splice position to the operating position. When the shaft 68 reaches the operating position, core retaining plates 175, one for each end of the shafts 68, are actuated to retain the ends of the shaft 68 by "capturing" the shaft ends in retaining notches 176 formed in the lower edges of the plates 175.

As best shown in FIG. 12, the retaining plate 175 on the operator side (the retaining plate 175 on the drive side being identical in structure and function except as noted) is pivotally mounted, by a pin 178, on a fixed plate 177, which is, in turn, attached to the housing 32. The plate 175 may pivot about the pin 178 between an upper position where notch 176 does not "capture" the shaft end, and a lower, shaft retaining position where the notch 176 "captures" or overlies the end of the shaft 68 and holds it against movement along the move rail 150. A double-acting fluid cylinder 180 is connected with the plate 175 and moves the plate 175 between these two positions. (The cylinder 180' on the drive side is connected with the retaining plate 175 on that side by means of a member 181, also shown in FIG. 12; whereas, on the operator's side, the cylinder 180 is directly connected with the plate 175.)

Each of the retaining plates 175 includes a pin 182 that is adjacent to the upstream edge of the notch 176 and that is adapted to contact the shoulder 174 of its associated carrier keeper 142 when the plate 175 is moved to its lower retaining position. Such contact causes the carrier keepers 142 to pivot or move downwardly, about their pins 164 and against the bias of the springs 166, so that their notches no longer "capture" the shaft 66. This movement permits the carrier keepers 142--along with the movable drive assembly 74--to be moved back to the splice position by the assembly 66.

The core dump chain assembly 76 includes a pair of endless chains 184, one mounted for rotation on the housing 32 and the other mounted for rotation on the housing 34. Each of the chains 184 passes about a plurality of sprockets 186 that are mounted on their respective housings and that define a generally, triangularly shaped path of movement for the chain. The upper portion of this triangular path generally parallels the inclined portion of the move rail 150 and extends from the operating position to the end 38. A plurality of core dump tabs 188 are carried, at spaced intervals, by the chains 184, and are adapted to cooperate with the shaft (such as the shaft 56) as the shaft 56, and the roll 54, move down the inclined move rail 150 from the operating position. A small conventional electric motor 192 is used to drive the chains 184. A cross rod 194 extends between the housings 32 and 34 and synchronizes the movement of the chains 184.

A pair of dump assist wheels 196, best shown in FIGS. 7, 12 and 13, are utilized to initiate movement of the shaft 56 along the inclined move rail 150. Each of the wheels 196 is mounted on one end of a core dump assist pivot arm 198, with one of the arms 198 being mounted on the housing 32 and the other being mounted on the housing 34. More specifically, the arms 198 are mounted, between their ends, by pins 202 so that they may pivot about the axes of those pins. Each of the other ends of the arms 198 is connected to one end of core dump assist coil springs 204 such that the springs 204 bias the wheels 196 downwardly and in a counter-clockwise direction around the mounting pins 202, as shown in FIG. 12. The other ends of the springs 204 are attached to their respective housings 32 and 34.

As noted above, once a predetermined amount of web has been wound onto a center core shaft (such as the shaft 56) positioned in the operating position, the web 24 is spliced onto a new center core shaft disposed in the splice position. After a splice has been accomplished, rotation of the roll in the operating position (such as the roll 54) is stopped. The retainer plates 175 are then returned, by actuation of the cylinders 180 and 180', back to their upper positions, as shown in phantom lines in FIG. 12. The wheels 196, which are in contact with the upstream side of the center core shaft 56, urge the shaft, under the bias of the spring 204, to move along the inclined move rail 150 toward the end 38. Movement of the shaft 56, and thus the roll 54, along this portion of the move rail 150 (the shaft in this position is shown at 56' in FIGS. 5 and 6) is controlled by the chains 184 and their core dump tabs 188.

As stated above, the roll unload assembly 86 includes a pair of roll unload arms 82 and 84. The hooked ends 78 of these arms projects beyond the end of 38 of the core winder 22. The other ends of the arms 82 and 84 are pivotally mounted on the housings 32 and 34, respectively, between the side facing walls of these housings and are adapted to be moved between a upper position and a lower position. When the arms 82 and 84 are in their upper position, they are adapted to receive the ends of the core center shaft 56 as those ends move down the incline portion of the move rail 150. After the endless chains 184 pass about the sprockets 186, which are adjacent to the end 38, the center core shaft 56, and roll 54, will be supported entirely by the arms 82 and 84 and will continue to roll or slide along the arms until the shaft is "caught" by the hooked ends 78 (as shown by 56" in FIGS. 5 and 6). When the arms 82 and 84 are moved to their lower position, the roll 54 (shown by 54" in FIGS. 5 and 6) may be easily removed from the arms and transported to storage.

Double acting fluid cylinders 206 and 208 cause the arms 82 and 84, respectively, to move between their upper and lower positions. Chains 212 and 214 connect the ends of the cylinders 206 and 208, respectively, with members 216 and 218 that are attached to the arms 82 and 84, respectively. The chains 212 and 214 pass around sprockets 222 and 224 mounted on the ends of a cross rod 226. The cross rod 226 is supported by the housings 32 and 34. Actuation of the cylinders 206 and 208 thus results the arms 82 and 84 being raised and lowered between their upper and lower positions.

The control circuitry for the functioning of the core winder 22 includes a Motorola micro-controller chip, identified by the Motorola No. 68HC 11 D 3 and manufactured by the Motorola Corporation of Schaumburg, Ill. This chip is used with a printed circuit board having conventional components. The following copyrighted ladder-logic program is used by the control circuitry to control the operation of the winder 22 as described as follows: ##SPC1##

The preferred embodiment of the present invention has now been described. This preferred embodiment constitutes the best mode contemplated by the inventors for carrying out their invention. Because the invention may be copied without copying the precise details of the preferred embodiment, the following claims particularly point out and distinctly claim the subject matter which the inventors regard as their invention and wish to protect:

Claims

1. An improved method of winding a running web of material, where the running web is initially being wound onto and about the center core shaft of a first roll; where after the first roll has had a determined amount of web would thereon, the running web is to be spliced and thereafter is to be wound, after splicing, onto and about a center core shaft of a second roll; and where the running web is running at a preselected speed while the running web is being wound about the first roll, while the running web is being spliced, and while the running web is being wound about the second roll, the improved method comprising the steps of:

driving the first roll, through a fixed drive assembly, while the first roll is disposed in an operating position so that the running web runs at the preselected speed;

disposing the central core shaft of the second roll in a splicing position, which is adjacent to the operating position of the first roll;

running the running web so that it passes adjacent to the center core shaft of the second roll before it is wound onto the first roll;

driving the center core shaft of the second roll, while the center core shaft of the second roll is in its splicing position, through a movable drive assembly so that the surface speed of the center core shaft of the second roll matches the predetermined speed of the running web;

pressing an adjacent portion of the running web into surface to surface contact with the outer peripheral surface of the center core shaft of the second roll such that the portion will adhere to the outer peripheral surface of the center core shaft of the second roll;

cutting the running web downstream of the adjacent portion of the running web so that the running web will then begin to wind about the center core shaft of the second roll;

disconnecting the first roll from the fixed drive assembly;

moving the first roll from the operating position; and

moving the second roll, and the movable drive assembly, along a substantial straight path, from the splicing position to the operating position.

2. The improved running web winding method of claim 1 in which the first and second rolls, in their operating and splicing positions, respectively, are adjacent to each other and are disposed side by side.

3. The improved running web winding method of claim 2 in which the second roll is moved generally horizontally from the splicing position to the operating position.

4. The improved running web winding method of claim 1 which includes the steps of connecting the fixed drive assembly with the second roll after the second roll has been moved from the splicing position to the operating position.

5. The improved running web winding method of claim 4 which includes the steps of disconnecting the movable drive assembly from the second roll after the fixed drive assembly has been connected with the second roll and after the second roll has been moved; and moving the movable drive assembly back to a position where it may be connected with another roll's center core shaft that is thereafter disposed in the splicing position.

6. The improved running web winding method of claim 5 which includes them step of moving the movable drive assembly along a substantially horizontal path.

7. The improved running web winding method of claim 6 which includes the step of moving the second roll and movable drive assembly in a direction substantially parallel with the direction of the path of travel of the moving web.

8. The improved running web winding method of claim 7 in which the first and second rolls, in their operating and splicing positions, respectively, are adjacent to each other and are disposed side by side.

9. An improved flying paster core winding apparatus for winding a running web of material, where the running web is initially being wound onto the center core shaft of a first roll; where after the first roll has had a determined amount of web wound thereon, the running web is to be spliced and thereafter is to be wound about the center core shaft of a second roll; and where the running web is run at a preselected speed while the running web is being wound about the first roll, while the running web is being spliced and while the running web is being wound about the second roll, the improved apparatus including:

means for disposing the first roll in an operating position;

a fixed drive assembly for driving the center core shaft of the first roll, when disposed in its operating position, so that the running web runs onto and about the first roll at the preselected speed;

means for disposing the central core shaft of the second roll in a splicing position, which is adjacent to the operating position of the first roll;

an assembly for causing the running web to run so that a portion of it passes adjacent to the center core shaft of the second roll before it is wound onto and about the first roll;

a movable drive assembly for driving the center core shaft of the second roll, while the center core shaft of the second roll is in its splicing position, so that the surface speed of the center core shaft of the second roll matches the preselected speed of the running web;

an assembly for pressing an adjacent portion of the running web into surface to surface contact with the outer peripheral surface of the center core shaft of the second roll such that the portion will adhere to the outer peripheral surface of the center core shaft of the second roll when it is pressed against the center core shaft;

an assembly for cutting the running web, downstream of the adjacent portion of the running web, so that the running web will then begin to wind about the center core shaft of the second roll;

means for disconnecting the center core shaft of the first roll from the fixed drive assembly means;

means for moving the first roll from its operating position; and

an assembly for moving the second roll, and the movable drive means, along a substantially straight line path, from the splicing position to the operating position.

10. The improved core winding apparatus of claim 9 which includes a device for connecting the fixed drive assembly with the center core shaft of the second roll after the second roll has been moved from the splicing position to the operating position.

11. The improved core winding apparatus of claim 10 which includes means for disconnecting the movable drive assembly from the center core shaft of the second roll after the fixed drive assembly has been connected with the center core shaft of the second roll; and which also includes an assembly for moving the movable drive assembly back to a position where it may be connected with another roll's center core shaft that is then disposed in the splicing position.

12. The improved core winding apparatus of claim 11 wherein the assembly for moving the movable drive assembly moves the movable drive assembly along a substantially horizontal path that is substantially parallel the direction of the path of travel of the moving web.

13. The improved core winding apparatus of claim 12 which includes an assembly for lifting the first roll from the apparatus after the first roll has been moved from the operating position.

14. The improved core winding apparatus of claim 9 which includes an assembly for lifting the first roll from the apparatus after the first roll has been moved from the operating position.