Machine and method for winding webs

Abstract

A winding machine can wind webs into a plurality of rolls at spaced positions. The machine has a winding roll assembly including a winding roll support and driver. A rider support supports a plurality of rider rollers at and between the spaced winding positions, without projecting between the rider rollers. Some of the rider rollers can contact the rolls. Each of the rider rollers includes a rim wheel encircling the rider support and a pusher reciprocatably mounted on the rider support within the rim wheel. Each of the pushers is commonly coupled within the rider support to enable the pushers to be driven toward an extended position in response to a common force. An extrinsic force can push the pusher into a retracted position to switch into a holding state limiting the ability of the pusher to move to the extended position.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to machines and methods for winding webs into a plurality of rolls and, in particular, to rollers for engaging the surface of the rolls during winding.

[0003] 2. Description of Related Art

[0004] Sheet material made of paper, plastic or other materials is manufactured in a web that is wound into a relatively large roll. In many instances, this roll is too large for use in other manufacturing processes. For that reason, the web is often unwound and rewound into smaller rolls. In some cases, the web is slit into a plurality of webs that are then simultaneously wound into a number of axially shorter rolls.

[0005] When rolls are wound at high-speed air entrained on the moving web may be trapped between layers so that the roll is not wound tightly. This effect can be reduced by pressing a roller (variously referred to as a rider roller, contact roller, or touch roller) against the web at its point of arrival at the growing roll. Conventionally, rider rollers having a width that matches the width of the individual rolls are supported on either end by arms that are pivotally attached to a support beam. Hydraulic cylinders press the arms and the rider rollers against the growing rolls. The support beam is typically retracted as the diameter of the roll grows.

[0006] In U.S. Pat. No. 5,785,271 a cylinder 19 swings bracket 15 to press roller 14 against winding 13. The beam 16 supporting bracket 15 can be vertically adjusted by cylinder 17. See also U.S. Pat. No. 5,806,783.

[0007] In U.S. Pat. No. 3,834,642 pressure unit 23 rotates lever 11 to press roller 19 against winding 33. In U.S. Pat. No. 5,273,222 a contact roller 8 can be adjusted with two degrees of freedom as shown in FIG. 4. See also U.S. Pat. No. 5,813,623.

[0008] In FIGS. 1-5 of U.S. Pat. No. 5,320,299 a plurality of wheels 30 are pressed against the winding 24 by a plurality of arms 32. Counterbalancing pistons 52 and 56 adjust arms 32 and wheels 30.

[0009] In U.S. Pat. No. 6,182,919 a plurality of rollers 3 are carried in either a pair of plates 5 or a pair of plates 5′. Pneumatic cylinder-pistons 7 can each press one of the rollers 3 against the winding roll 2. The rollers 3 can operate in unison depending on whether guides 24 are linked by sliding the bolts 23.

[0010] In U.S. Pat. No. 6,209,818 a pair of weighting rollers 2 and 2′ are mounted on a common bracket 30 that is attached to a beam 1. Hydraulic pressure is applied to chamber 5 to move internal piston 12, while pneumatic pressure is applied to chamber 6 to move opposing internal piston 13.

[0011] In U.S. Pat. No. 3,648,342 a plurality of rollers 2 and 3 can be pressed outwardly by bellows 7.

[0012] In U.S. Pat. No. 3,389,450 a shaft 28 is fitted with a number of internal pistons that can shift shoes 36 and 38 to straighten the spools 18.

[0013] In U.S. Pat. No. 5,161,747 the pressing rollers 6 are mounted eccentrically on shaft 7 as shown in FIG. 2 and are used against the web. See also DE 39 41 384.

[0014] In U.S. Pat. No. 3,91 5,404 an eccentrically mounted contact roller 9 is spring biased to bear against the winding surface 39.

[0015] In U.S. Pat. No. 3,670,980 spring and air pressure applied to the distal and of arm 4 controls the pressure applied by contact roller 1.

[0016] In U.S. Pat. No. 4,669,646 spreading appliances employ a plurality of rollers 10 mounted on a deflectable support member 8. Member 8 can be adjusted by a plurality of bellows 12 and springs 13.

SUMMARY OF THE INVENTION

[0017] In accordance with the illustrative embodiments demonstrating features and advantages of the present invention, there is provided a winding machine for winding webs into a plurality of rolls. The machine has a winding roll assembly including a winding roll support and driver. Also included are a rider support and a plurality of rider rollers mounted on the rider support for contacting the rolls. Each of the rider rollers includes a rim wheel encircling the rider support and a pusher reciprocatably mounted on the rider support within the rim wheel. The pusher can move between an extended position and a retracted position. Each of the pushers is commonly coupled within the rider support to enable the pushers to be driven toward the extended position in response to a common force. The pusher is operable in response to extrinsic force pushing the pusher into the retracted position to switch into a holding state limiting the ability of the pusher to move to the extended position.

[0018] In accordance with another aspect of the invention a winding machine can wind webs into a plurality of rolls. The machine has a winding roll assembly that includes a winding roll support and driver means. Also included is a rider support means including a hollow shaft with a pressurized, central longitudinal passageway and a plurality of transverse bores intersecting the central longitudinal passageway. The winding machine also includes a carriage means for supporting the rider support means. A carriage drive means is coupled to the carriage means for moving the rider support means. Also included is a sensor means for measuring the diameter of at least one of the plurality of rolls. A control means is coupled to the sensor means and the carriage drive means for bringing the rider support means toward the plurality of rolls in response to the sensor means. The winding machine also includes a plurality of rider roller means mounted on the rider support means for contacting the rolls. The rider support means supports the plurality of rider roller means without projecting between the plurality of rider roller means. Each of the rider roller means includes (a) a rim wheel encircling the rider support means; and (b) a pusher means reciprocatably mounted in a different corresponding one of the transverse bores on the rider support means within the rim wheel to move between an extended position and a retracted position. The pusher means has an axially varying, cross-sectional area for producing from pressure in the hollow shaft a net axial force on the pusher means tending to drive the pusher means through the transverse bore toward the extended position. The pusher means is operable in response to extrinsic force pushing the pusher means into the retracted position to switch into a holding state limiting the ability of the pusher means to move to the extended position. The pusher means has a yielding means encircling the pusher means. The transverse bore has an annular groove positioned and sized to receive the yielding means upon the pusher means moving into the retracted position.

[0019] In accordance with still another aspect of the invention a winding machine can wind webs into a plurality of rolls. The machine has a winding roll assembly that includes a winding roll support and driver. Also included is a rider support, and a plurality of rider rollers mounted on the rider support for contacting the rolls. The rider support supports the plurality of rider rollers without projecting between the rider rollers. Each of the rider rollers includes: (a) a rim wheel encircling the rider support; and (b) a pusher reciprocatably mounted on the rider support within the rim wheel to move between an extended position and a retracted position.

[0020] In accordance with yet another aspect of the invention, a method is provided that employs a plurality of rider rollers for winding webs into a plurality of rolls. The method includes the step of directing webs to a plurality of spaced winding positions across a winding region. Another step is positioning a plurality of rider rollers at and between the spaced winding positions while supporting the rider rollers at either end of the winding region without employing supporting structure projecting between rider rollers in the winding region. The method also includes the step of winding the webs at the spaced winding positions into a plurality of rolls while pressing associated ones the rider rollers at the spaced winding positions in a common direction against the rolls to limit air entrapment. Unassociated ones of the rider rollers between the associated ones of the rider rollers are unused.

[0021] In accordance with still yet another aspect of the invention, a winding machine can wind webs into a plurality of rolls with a winding roll assembly including a winding roll support and driver. The winding machine also has a rider support and a plurality of rider rollers mounted on the rider support for contacting the rolls. Each of the rider rollers includes: (a) an inner ring encircling the rider support; (b) a rim wheel encircling the inner ring; and (c) a pusher reciprocatably mounted on the rider support within said rim wheel. The pusher can move between an extended position and a retracted position. The inner ring and the pusher are pivotally connected to allow the ring to translate and rotate relative to the rider support.

[0022] By employing methods and machines of the foregoing type, improvements are achieved in the winding of webs into rolls. In a preferred embodiment pressure actuated pistons can be mounted in transverse bores in a central support shaft. A central passageway in the preferred support shaft can be pressurized to extend the pistons and drive individual rim wheels located around the support shaft against the growing rolls.

[0023] In a preferred embodiment the rim wheels are arranged as a plurality of contiguous rider rollers extending across the width of the winding machine. If the contiguous rider rolls are appropriately narrow, the same arrangement can be used to accommodate the winding of rolls of various widths. The rider rollers located between rolls then simply extend without effect.

[0024] It is highly preferred to bring the rider rollers close to each other to avoid gaps that may allow entry of entrained air that can cause annular bulges or stripes around the wound packages.

[0025] In one preferred embodiment the rim wheels of individual rider rollers can be pushed back to a stable, retracted position where that retracted rider roller will no longer engage any of the growing rolls. This feature can effectively eliminate a rider roller that might otherwise use only a small percentage of its width to engage the edge of a growing roll. In embodiments where each rider roller exerts about the same force, a partially engaged rider roller concentrates all its force in a very narrow area to produce unacceptably high pressure that will squeeze and deform the edge of the growing roll. Even if a rider roller does not initially engage the growing roll, the roll may grow at an angle and eventually rub against the initially unused rider roller. For this reason, rider rollers that are close to the edge of a web will be pushed back to the stable, retracted position to avoid the possibility of future interference.

[0026] In one preferred embodiment a piston is arranged to be normally driven in an extended direction by hydraulic or pneumatic pressure, but is capable of becoming immune to such driving pressure when pushed back into a stable, retracted state. In this embodiment a reduced-diameter portion of the piston can be driven back into a pressure-isolating cavity so that the other portions that remain exposed to such driving pressure have a relatively uniform diameter and no net tendency to move in response to such driving pressure. Other embodiments are disclosed that do not employ a piston.

[0027] The above stable, retracted state can be established or enhanced by a device that physically holds the active pusher element in a retracted position. For example, a garter spring around a piston can snap into a groove in the cylinder containing the piston. Alternatively, a spring-loaded ball detent can perform a similar function.

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The above brief description as well as other objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of presently preferred but nonetheless illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings, wherein:

[0029] FIG. 1 is an axial sectional view of a plurality of rider rollers mounted on a rider support;

[0030] FIG. 2 is a detailed view of a portion of the apparatus of FIG. 1;

[0031] FIG. 3 is a schematic, elevational view of the apparatus of FIG. 1 operating in a winding machine and engaging a plurality of rolls;

[0032] FIG. 4A is a schematic end view of the winding machine of FIG. 3 with a web arriving at the point where the rider rollers engage the growing roll;

[0033] FIG. 4B is a schematic end view of the winding machine of FIG. 3 with a web engaging the rider rollers before winding onto a roll;

[0034] FIG. 5 is a perspective view of the portion of the winding machine supporting the apparatus of FIG. 1, with a section broken away for illustrative purposes;

[0035] FIG. 6 is a schematic elevational view of supporting apparatus that is an alternate to that of FIG. 5;

[0036] FIG. 7 is a schematic elevational view of supporting apparatus that is an alternate to that of FIGS. 5 and 6;

[0037] FIG. 8 is a schematic elevational view of supporting apparatus that is an alternate to that of FIGS. 5-7 and designed for surface drive;

[0038] FIG. 9 is a cross-sectional view of an apparatus that is an alternate to that of FIG. 2;

[0039] FIG. 10 is a cross-sectional view of an apparatus that is an alternate to that of FIG. 9;

[0040] FIG. 11 is a cross-sectional view of an apparatus that is an alternate to that of FIG. 10;

[0041] FIG. 12 is a cross-sectional view of an apparatus that is an alternate to that of FIG. 11;

[0042] FIG. 13 is a detailed view of the outer portion of the apparatus of FIG. 12;

[0043] FIG. 14 is a detailed cross-sectional view of the inner portion of the apparatus of FIG. 12; and

[0044] FIG. 15 is a cross-sectional view of an apparatus that is an alternate to that of FIG. 12 and designed for surface drive.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0045] Referring to FIGS. 1 and 2 a hollow shaft 10 has a central longitudinal passageway 12 that is closed at opposite ends of the shaft. The passageway 12 can be pressurized by connecting a source of pneumatic pressure to the fitting opening 14, which communicates with passageway 12. Also communicating with passageway 12 are a plurality of radially aligned, cylindrical, transverse bores 20 having a back portion 20A and a forward portion 20B. Forward portion 20B has a greater diameter than back portion 20A.

[0046] The shaft 10 acts as a rider support (or rider support means) for supporting a plurality of rider rollers 16 (also referred to as rider rollers means). Five rider rollers 16 (rollers 16A-16D) are shown evenly distributed in FIG. 1, although it will be appreciated that many more rollers are mounted on shaft 10 and that these other rollers were broken away for illustrative purposes. The rollers 16 are essentially contiguous, although a close inspection will show a small spacing between rollers 16 that is less than five percent, and preferably less than two percent, of the predetermined width of each of the rider rollers 16. It is desirable to keep the spacing between adjacent rider rollers 16 as small as practically possible without causing rubbing between adjacent rollers. A pair of end caps 21 encircle and lock onto shaft 10 to cover the rider rollers 16 primarily for cosmetic purposes.

[0047] Each of the rider rollers 16 has a pair of pushers 18 (also referred to as pusher means) mounted in transverse bores 20. Pushers 18 are shown herein as pistons having axially varying cross-sectional areas. Pushers 18 are axially symmetric; that is, figures of revolution having for the most part cylindrical surfaces. First section 18A of pusher 18 has a relatively small outside diameter. An annular groove 18B about the middle of section 18A is encircled by a sealing U-cup 22, which is shown in section in FIG. 2, but is absent from FIG. 1.

[0048] At the opposite end of pusher 18 is a larger second section comprising a larger intermediate section 18E and a larger still cylindrical section 18G. The intermediate section 18E is located between sections 18A and 18G. An annular groove 18F near the inside end of section 18G contains a sealing U-cup 24, which is shown in section in FIG. 2, but is absent from FIG. 1.

[0049] An annular groove 18H near the outside end of section 18G contains a holding mechanism 26, which is shown in section in FIG. 2, but is absent from FIG. 1. Holding mechanism 26 is in this embodiment a garter spring, although other yielding members or yielding means can be used in other embodiments. Holding mechanism 26 is designed to snap into recess 28 in forward portion 20B. Recess 28 is an annular groove bordered by the funneling mouth 30, which is designed to ease the entry of garter spring 26 into recess 28.

[0050] An annular groove 18C located between first section 18A and the second section (sections 18E and 18G) contains an O-ring 32 (shown in section in FIG. 2 but absent from FIG. 1). O-ring 32 is shown in FIG. 2 located in forward portion 20B of transverse bore 20. As described further hereinafter, O-ring 32 will act as a switching seal that can retract into the seat 34 at the inner end of back portion 20A to isolate the pusher's first section 18A from the central longitudinal passageway 12.

[0051] The tapered tip 18J of pusher 18 fits into the hole 40 of cylindrical collar 42. The distal end of section 18G of pusher 18 fits into the hole 44 of collar 42. The positions of pushers 18 are fixed inside collar 42 by two split snap rings 48, which fit in grooves (not shown) in the perimeter of collar 42. Rings 48 also embrace the inside corners of bearing 50 and hold the bearing in position along the axis of collar 42.

[0052] Bearing 50 encircles collar 42 and rotatably supports the inside of a rim wheel, shown herein in the form of a cylindrical collar 52 overlaid with a contact material 54, which may be neoprene, a soft metal, or other materials designed to engage a web arriving at a growing roll (described hereinafter). The position of bearing 50 along the axis of collar 52 is fixed by a pair of snap rings 56, which fit into internal grooves in collar 52 and embrace the outer corners of the bearing 50. Another pair of snap rings 58 fitting in grooves on the inside of collar 52 on either side of rings 56 provide a surface that is useful when pulling the rim wheel off bearing 50 and collar 42.

[0053] Referring to FIG. 2, pushers 18 are locked into collar 42 and so both move in unison relative to the axis of the transverse bores 20 of shaft 10. Pushers 18 are shown in a fully extended position in FIG. 2. Motion to this fully extended position can be accomplished by pneumatic pressure applied to passageway 12. This pressure produces a common force on all of the pushers 18 along the passageway 12. U-cups 22 and 24 limit the region over which pressure in passageway 12 has influence. Basically, this pressure will bear against section 18G and the portion of section 18A between seals 22 and 24. Since section 18G is the larger of the two sections, pneumatic pressure in passageway 12 will tend to push section 18E outwardly; that is, in the common direction 19. The extension of pushers 18 is limited by rings 48, which are shown abutting the distal end of section 18G of pushers 18.

[0054] The pushers 18 can be driven in a direction opposite to common direction 19 by extrinsic forces on rim wheel 52/54, either applied manually or as a result of reactive forces from growing rolls pressing on the rim wheels as described hereinafter. If pushed back sufficiently, pushers 18 will be fully retracted so that O-rings 32 will be driven into seat 34. This will isolate section 18A from the effect of pressure in passageway 12. Consequently, only section 18G will be exposed to this pneumatic pressure. Thus, there will be very little net force along the axis of pushers 18 that might tend to drive pushers 18 in the common direction 19.

[0055] When pushers 18 retract in this fashion, garter spring 26 will slide over the tapered surfaces of mouth 30 and snap into recesses 28. This produces additional force to detain pushers 18 in the fully retracted position.

[0056] Referring to FIG. 5, previously mentioned shaft 10 is shown supporting rider rollers 16. The opposite ends of shaft 10 are supported on a carriage (also referred to as a carriage means). In this embodiment, the carriage includes a pair of supporting arms, one of them shown herein as pivotally supported arm 60 and its supporting structure. The distal end of arm 60 supports shaft 10, while the proximal end is attached through bracket 62 to plate 64, which is welded to shaft 66. Shaft 10 is locked onto arm 61 by bolting the block 61 on the distal end of arm 60 over the end of shaft 10.

[0057] The majority of shaft 66 at broken away in this diagram, but it will be appreciated that an arm similar to arm 60 is mounted on shaft 66 to support the other end of shaft 10. Shaft 66 is pivotally mounted in the machine frame (not shown) and is rotated by the carriage drive (or carriage drive means), shown herein as an electrical actuator 68 that is pivotally attached to lever 70 for rotating shaft 66.

[0058] In the alternate embodiment of FIG. 6, previously mentioned rider rollers 16 and shaft 10 are again supported by arms 60, bracket 62 and plate 64. Instead of having a support shaft running across the machine (for example, shaft 66 of FIG. 5), here plate 64 is attached to a spaced pair of wheels 72 rotatably mounted in the machine frame (not shown) at opposite ends of shaft 10. The two wheel 72 are kept in synchronism by gears 74 that are connected by endless chains 76 to underlying follower gears 78. In order to rotate synchronously, gears 78 are connected at opposite ends of the machine frame by common shaft 80. Accordingly, the two arms 60 will maintain the same angle of elevation.

[0059] Referring to FIG. 7, previously mentioned shaft 10 is supported at either end by a carriage having a pair of support blocks 82A and 82B that are in turn supported by endless chains 84A and 84B. Chains 84A and 84B circulate over a pair of upper gears 86 and lower gears 88. Gears 88 are coaxially attached to a pair of intermeshed gears 90 that synchronize gears 88 and therefore chains 84A and 84B. It will be appreciated that structure complementary to that illustrated in FIG. 7 will exist at the opposite end of shaft 10. In some embodiments a common shaft may extend across the machine to interconnect one or more of the gears 88 to synchronize the carriages at the opposite ends of shaft 10.

[0060] To facilitate an understanding of the principles associated with the foregoing apparatus, the operation of the apparatus of FIGS. 1-3, 4A, and 5 will be briefly described. The winding roll assembly shown in FIGS. 3 and 4A has a winding roll support and driver, shown herein as a common support mandrel 92 extending across the winding region of the illustrated winding machine. In this embodiment mandrel 92 is driven by a drive motor (not shown) so that mandrel 92 acts as a winding roll support and driver (or winding roll support and driver means). Mandrel 92 is initially fitted with a plurality of cores 94. These cores 94 can be installed by lifting mandrel 92 from the machine to allow access to the mandrel. Significantly, cores of varying width can be placed on the mandrel for different runs or for individual runs that accommodate a mix of cores of differing widths.

[0061] Thereafter webs W (FIG. 4A) from a slitter or other source can be routed to the winding positions at the cores 94 and taped in place in the usual fashion. The rider rollers 16 can be pressed against the web W on cores 94 by lowering arms 60 (FIG. 5). Rider rollers 16 can be driven against the web W by applying pneumatic pressure (or in some embodiments, hydraulic pressure) through port 14 (FIG. 1) into passageway 12. In the manner described previously, this common force will tend to drive pushers 18 in the common direction 19 as illustrated in FIG. 2.

[0062] As shown in FIG. 3 the rider rollers 16 in intervals 96 are located alongside the cores 94 and the growing rolls R, and are referred to as associated ones of the rider rolls 16. The intervening rider rollers 16 in intervals 98 are referred to as unassociated ones of the rider rollers 16. The associated ones of the rider rollers in intervals 96 are shown pressed toward an extended position 19 against the outside of a growing roll R in response to the common force produced by pressure inside hollow shaft 10.

[0063] Most of the rider rollers 16 in intervals 98 are shown as fully extended rider rollers 16B (FIGS. 1 and 3) extending in the common direction 19. Selected ones 16D (FIGS. 1 and 3) of the rider rollers 16 are placed in a retracted position by extrinsic force pushing them into a retracted holding state. The setting back to the retracted position can be performed by manually pushing rider rollers 16D back to the holding states as shown. The foregoing assumes that the pressure inside hollow shaft 10 can be manually overcome.

[0064] As previously mentioned, O-rings 32 (FIG. 2) will land in seats 34, isolating first section 18A of pushers 18. At the same time, garter springs 26 will snap into recess 28. Consequently, pushers 18 will remain retracted in a holding state and essentially immune to pressure in passageway 12.

[0065] Most of the retracted rider rollers 16D are spaced axially from the growing rolls R. The spacing is beneficial in that a roll R may grow with a slight cant and may eventually reach a neighboring rider roller 1.6 that was never before aligned with a growing roll R. This delinquent alignment would cause the side of the roller 16 to rub against the side of the growing roll R. The effect of such delinquent alignment of a rider roller 16 is avoided if that roller is retracted to a holding state as shown for the rider rollers 16D, in which case roller 16D never touches roll R.

[0066] Even if a rider roller 16 is in position to initially engage the growing roll R, such engagement may be undesirable if only a small portion of the rider rollers 16 will engage the roll R. One of the retracted rider rollers has such an orientation and is identified with a prime, that is, rider roller 16D′. Rider roller 16D′ is referred to as a selected one of the retracted rider rollers. Roller 16D′ was selected because it partially overhangs the associated roll R to such a small extent. It is desirable to retract such a rider roller if the percentage of the width of the roller looming over the roll R is less than 10% axially. If such a narrow portion of a rider roller were allowed to press on a growing roll R, it would apply the same force as the other rolls but to a highly concentrated region that would produce unacceptably high pressures tending to squeeze and deform the growing roll R.

[0067] The winding mandrel 92 (FIG. 4A) can grip the cores 94 with conventional devices that are operated pneumatically or otherwise. Accordingly, mandrel 92 is a drive shaft that can act as a winding roll support and driver that is part of a winding roll assembly. In some embodiments the cores 94 may be locked to mandrel 92, or may be allowed to slip somewhat. In any event, mandrel 92 will rotate the rolls R while the associated ones of the rider rollers 16 press against the webs W as they reach the rolls R. The pressure applied by rollers 16 tends to press the web W directly onto the rolls R and eliminate or reduce the introduction of air entrained under the web W, so that the rolls R can be wound tightly.

[0068] As the rolls R grow, the carriage supporting rider rollers 16 needs to retract. The growing of the rolls R is sensed by a sensor means 100 that may be an optical, infrared, ultrasonic, or other sensor that is arranged to sense or measure the diameter of one of the rolls R, which is considered one of the operating parameters of the winding machine. The signal from sensor means 100 is applied to a control means 102 that may be a microcontroller, or other type of controller. Control means 102 generates a control signal to control the carriage 104. A specific example of controllable carriage is given in FIG. 5, where actuator 68 is controlled to swing lever 70 and rotate shaft 66 thus changing the angle of elevation of arm 60, in order to reposition shaft 10 and rider rollers 16.

[0069] While the foregoing arrangement use a closed feedback loop based on a measured diameter, carriage 104 can also be positioned without the use of diameter sensors. For example, the revolutions of shaft 10 can be counted and multiplied by a predetermined value of web material thickness to calculate the roll diameter. More sophisticated calculations can use the footage wound to determine roll thickness. The carriage 104 can be positioned base upon this calculated diameter.

[0070] Carriage 104 provides the gross positioning of rider rollers 16, while the previously mentioned pushers 18 (FIG. 2) provide the fine, higher speed positioning. Furthermore, the various rider rollers 16 can move relative to one another to accommodate nonuniformities or perturbations in the surface of a growing roll R. The rider rollers 16 can move between the fully extended position (rider roller 16B of FIG. 1) to the retracted position of roller 16C, which is just short of entering into the retracted holding state as shown for roller 16D. An intermediate positioning is shown with rider roller 16A.

[0071] The foregoing routing of the web W directly to the nip point between a rider roller and 16 and a growing roll R is commonly referred to as a “C wrap.” An “S wrap” is shown in FIG. 4B, where the webs W arrive first at the rider rollers 16 and travel approximately halfway around the rider rollers to reverse direction before being laid on the growing rolls R. As before, the carriage 104 supporting rider rollers 16 is controlled by controller 102, based on the signals from sensor 100.

[0072] In the foregoing the growing rolls R are both supported and driven by mandrel 92, which is commonly referred to as a “center drive.” In situations where the center drive is inadequate for turning relatively large rolls, supplemental drive is applied to the surface of the roll to achieve what is often called “center-surface drive.” In FIG. 8 previously described rider rollers 16 are supported on an alternate carriage means, shown herein as a carriage 106 employing a lever pivoted on journal 108. The pivoting of lever 106 can be controlled by a controller similar to the controller 102 shown in FIG. 4A.

[0073] In FIG. 8 rider rollers 16 are driven by a winding roll driver in the form of a driver roller 110 in order to achieve a surface drive. Webs W arrive first at the rider rollers 16 and are turned by the rollers before being wound onto rolls R. Rider rollers 16 are arranged so that their internal pushers drive the rollers in the common direction 19, in the manner previously described. Common direction 19 is oriented to drive the rollers 16 in a direction between the rolls R and driving roller 110. It will be appreciated that driving roller 110 may be a single roller that extends across the winding region of the winding machine.

[0074] Referring to FIG. 9, a rim wheel 112 is rotatably supported through bearing 114 to a collar 116 that encircles a rider support 118. Support 118 comprises a shaft with a central longitudinal passageway 120 running the length of a winding region; typically the width of the working section of the winding machine. Elements 112, 114, and 116 are relatively narrow to act as part of a rider roller.

[0075] In this embodiment a plurality of pushers 122 are mounted in transverse bores 124 in rider support 118. A U-cup seal 126 is mounted in an annular groove in pusher 122. A switching seal 128 in the form of an O-ring is also mounted in a groove in pusher 122. Seal 128 is normally compromised by being straddled by passageway 120 so that pressure in that passageway tends to urge pusher 122 in the common direction 19. If pusher 122 is retracted sufficiently in a direction opposite to the common direction 19, seal 128 is no longer compromised by the passageway 120. Consequently, pressure from passageway 120 no longer tends to drive pusher 122, which then enters into a holding state.

[0076] The stability of this holding state is enhanced by a yielding member (or yielding means) in the form of a pair of detent balls 130 driven inwardly by compression springs 132. When pusher 122 reaches the fully retracted position, balls 130 will snap into a recess in the form of annular groove 134. To prevent perturbation of the axis of rotation of elements 112 and 114, collar 116 has a pair of pins 136 that slidably engage a pair of bores 138 in rider support 118.

[0077] Referring to FIG. 10, a rim wheel 140 is rotatably supported through bearing 142 to a collar 144 that encircles a rider support 146. Support 146 comprises a shaft with a longitudinal slot 148 running the length of a winding region; typically the width of the working section of the winding machine. Elements 140, 142, and 144 are relatively narrow to act as part of a rider roller. A pusher block 152 having about the same width (in the axial direction) as collar 144 is slidably mounted in slot 148. An inflatable bladder 150 is mounted in slot 148 underneath pusher 152 so that elements 150 and 152 together act as a pusher.

[0078] A guide means is shown herein as a guide rod 154 connected to the inside surface of collar 144 and slidably mounted in a bore in rider support 146. Rod 154 prevents perturbation of the axis of rotation of elements 140 and 142.

[0079] Pressure inside bladder 150 presses block 152 outwardly in the common direction 19 to operate in a manner similar to that previously described. This arrangement provides a stable holding state using a garter spring 153 in a fashion similar to that shown in FIG. 2 for garter spring 26. Spring 153 can snap into annular groove 155, entering this cavity through a funnel-shaped mouth facing spring 153. Accordingly, the rim wheel 140 can be retracted and stay retracted in spite of modest pressure in bladder 150. In other embodiments, a locking means employing structure similar to that described elsewhere herein can be provided to keep rim wheel 140 retracted.

[0080] Referring to FIG. 11, a rim wheel 154 is rotatably supported through bearing 156 to a collar 158 that encircles a rider support 160. Support 160 comprises a shaft with a longitudinal slot 162 running the length of a winding region; typically the width of the working section of the winding machine. Elements 154, 156, and 158 are relatively narrow to act as part of a rider roller. An inflatable bladder 164 is mounted in slot 162 to act as a pusher. If longitudinal slot 162 is considered located at the 6 o'clock position, the shaft has at the 3 o'clock and the 9 o'clock positions flat surfaces that match the interior flat surfaces of collar 158. The central opening inside collar 158 is sufficiently large to allow it to reciprocate in direction 19 with respect to the rider support 160. These flats prevent perturbation of the axis of rotation of elements 154 and 156.

[0081] Pressure inside bladder 164 presses collar 158 outwardly in the common direction 19 to operate in a manner similar to that previously described. Again, this arrangement provides a stable holding state where the rim wheel 154 is retracted and stays retracted in spite of modest pressure in bladder 164. Specifically, collar 158 has a spring loaded ball detent 157 similar to detent 130/132 in FIG. 9. Detent 157 engages a cavity 159 in rider support 160 when collar 158 is in a retracted position. In other embodiments, a locking means employing structure similar to that described elsewhere herein can be provided to keep rim wheel 154 retracted.

[0082] Referring to FIGS. 12-14, collar 166 can support a bearing and rim wheel in a manner similar to that previously disclosed. Collar 166 has an ear 167 projecting inwardly at the 3 o'clock position in these views. Ear 167 is pierced by a hole 168.

[0083] The illustrated rider support is a shaft 170 with a longitudinal slot 172 running the length of a winding region; typically the width of the working section of the winding machine. An inflatable bladder 174 is mounted in slot 172 to act as a pusher.

[0084] A plug 176 is mounted in a hole in rider support 168 at the 3 o'clock position in these views. Plug 176 is pierced by a hole 178. As shown in FIG. 12 pin 180 is mounted through the holes in ear 167 and plug 176 to allow collar 166 to swing in the common direction 19. Again, this arrangement does not provide a stable holding state where the collar 166 is retracted and stays retracted in spite of pressure in bladder 174. In other embodiments, a locking means employing structure similar to that described elsewhere herein can be provided to keep collar 166 retracted.

[0085] Referring to FIG. 15, a rim wheel 182 is rotatably supported through bearing 184 to an inner ring 186 that encircles a rider support 188. Support 188 comprises a shaft with a longitudinal passageway 190 running the length of the shaft, which typically extends the width of the working section of the winding machine. Elements 182, 184, and 186 are relatively narrow to act as part of a rider roller.

[0086] A pusher 192 is mounted in a transverse bore 194 that intersects passageway 190. Pusher 192 may be one of a pair of pushers in some embodiments. Pusher 192 has an O-ring 196 (shown in section) mounted in an annular groove in pusher 192 so that pressure in passageway 190 can drive pusher 192 outwardly in the common direction 19.

[0087] The distal end of pusher 192 extends into a hole 197 in ring 186 and is attached there by pivot pin 198 to allow the inner ring 186 to swing about pivot pin 198 as indicated by arrows 200. Accordingly, ring 186 has two degrees of freedom, namely, translation 19 and rotation 200. These two degrees of freedom 19 and 200 are useful for a center-surface drive (for example, the center-surface drive of FIG. 8).

[0088] In the embodiment of FIG. 15 the rider roller's rim wheel 182 is pressed against a growing roll R and winding roll driver 202 by being pushed by pusher 192 in the common direction 19. Collar 186 can rotate about pin 198 to accommodate modest changes in the spacing of roll driver 202 and roll R. For example, inner ring 186 can rotate counterclockwise to move toward roll driver 202 and away from roll R. This motion can be especially helpful as roll R grows if supplemented by a backward translation of pusher 192 (the reverse of direction 19). As before, rider support 188 can be mounted on a carriage to move relative to roll R as the roll grows.

[0089] It is appreciated that various modifications may be implemented with respect to the above described, preferred embodiment. While all rider rollers are shown herein supported by a single support shaft, other embodiments could have multiple support shafts, each servicing one of multiple winding regions. In such an arrangement the supports for each winding region would not extend between the rider rollers of that region, but all the used and unused (associated and unassociated) rollers in that winding region would be compactly supported side by side without interference.

[0090] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.

Claims

1. A winding machine for winding webs into a plurality of rolls, comprising: a winding roll assembly including a winding roll support and driver; a rider support; and a plurality of rider rollers mounted on said rider support for contacting said rolls, each of said rider rollers including: (a) a rim wheel encircling said rider support; and (b) a pusher reciprocatably mounted on said rider support within said rim wheel to move between an extended position and a retracted position, each of said pushers being commonly coupled within said rider support to enable said pushers to be driven toward said extended position in response to a common force, said pusher being operable in response to extrinsic force pushing said pusher into said retracted position to switch into a holding state limiting the ability of said pusher to move to said extended position.

2. A winding machine according to claim 1 wherein said rider support supports said plurality of rider rollers without projecting between the rider rollers.

3. A winding machine according to claim 1 wherein said rider support supports said plurality of rider rollers without projecting past said rim wheel between any of the rider rollers.

4. A winding machine according to claim 1 wherein said plurality of rider rollers are contiguous.

5. A winding machine according to claim 1 wherein said plurality of rider rollers each have a predetermined width, the spacing between adjacent ones of said rider rollers being less than 5% of said predetermined width.

6. A winding machine according to claim 1 wherein said plurality of rider rollers reside alongside and between each of the plurality of rolls.

7. A winding machine according to claim 6 wherein said plurality of rider rollers are distributed evenly along said rider support.

8. A winding machine according to claim 6 wherein said plurality of rider rollers are each smaller in width than any of the plurality of rolls.

9. A winding machine according to claim 1 wherein said rider support comprises a hollow shaft with a central longitudinal passageway.

10. A winding machine according to claim 9 wherein said hollow shaft has a plurality of transverse bores intersecting said central longitudinal passageway, the pushers of said rider rollers being separately mounted in individual ones of said transverse bores.

11. A winding machine according to claim 10 wherein said hollow shaft is pressurized to urge said pushers through said transverse bores in order to push said rim wheels.

12. A winding machine according to claim 11 wherein said pusher has an axially varying, cross-sectional area for producing from pressure in said hollow shaft a net axial force on said pusher tending to drive said pusher through said transverse bore toward said extended position.

13. A winding machine according to claim 12 wherein said pusher has a first and a second section, said second section having an effectively larger cross-sectional area than said first section, said pusher having between said first and said second section a switching seal, said switching seal being normally located in said central longitudinal passageway, motion of said pusher toward said retracted position ultimately bringing said switching seal out of said central longitudinal passageway to seal said switching seal in said transverse bore and isolate said first section from said central longitudinal passageway, so that the net axial force on said pusher is repressed.

14. A winding machine according to claim 1 wherein each of said rider rollers has a holding mechanism for holding said pusher upon arrival of the pusher in the retracted position in order to undermine the ability of said pusher to move toward said extended position.

15. A winding machine according to claim 14 wherein said pusher has a peripherally mounted yielding member, said transverse bore having a recess positioned and sized to receive said yielding member upon said pusher moving into said retracted position.

16. A winding machine according to claim 14 wherein said pusher has a yielding member encircling said pusher, said transverse bore having an annular groove positioned and sized to receive said yielding member upon said pusher moving into said retracted position.

17. A winding machine according to claim 14 wherein said rider support has at each of said transverse bores an inwardly biased yielding member, said pusher having a recess positioned and sized to receive said yielding member upon said pusher moving into said retracted position.

18. A winding machine according to claim 1 comprising: a carriage supporting said rider support; and a carriage drive coupled to said carriage for moving said rider support relative to said plurality of rolls.

19. A winding machine according to claim 18 comprising: a sensor responsive to the quantity of the web wound onto the winding roll assembly of said winding machine; and a controller coupled to said sensor and said carriage drive for bringing the rider support in proximity to said plurality of rolls in response to said sensor.

20. A winding machine according to claim 18 comprising: a sensor responsive to an operating parameter of said winding machine; and a controller coupled to said sensor and said carriage drive for bringing the rider support in proximity to said plurality of rolls in response to said sensor.

21. A winding machine according to claim 18 wherein said carriage comprises a pair of pivotally supported arms with distal ends supporting opposite ends of said rider support.

22. A winding machine according to claim 20 wherein said controller is operable to bring said rider rollers to bear on said plurality of rolls in order to avoid entrapment of air entrained on the webs.

23. A winding machine according to claim 22 wherein the web arrives at said rider rollers and said rolls substantially simultaneously.

24. A winding machine according to claim 22 wherein the web arrives at said rider rollers and substantially reverses direction before arriving at said rolls.

25. A winding machine according to claim 22 wherein the winding roll assembly comprises a drive shaft supporting said plurality of rolls.

26. A winding machine according to claim 25 wherein said winding roll assembly comprises: a driving roller spaced from said plurality of rolls, motion of said rider rollers toward said extended position bringing said rider rollers into contact with said driving roller and said plurality of rolls, said driving roller engaging and driving said rider rollers in order to drive said rolls.

27. A winding machine according to claim 22 wherein each of said rider rollers has a width corresponding to an associated one of the plurality of rolls.

28. A winding machine according to claim 27 comprising: a driving roller spaced from and extending across said plurality of rolls, motion of said rider rollers toward said extended position bringing said rider rollers into contact with said driving roller and said plurality of rolls, said driving roller engaging and driving said rider rollers.

29. A winding machine according to claim 1 wherein each of said rider rollers comprises: an inner ring encircling said rider support, said rim wheel encircling said inner ring, said inner ring and said pusher being pivotally connected to allow said inner ring to translate and rotate relative to said rider support.

30. A winding machine for winding webs into a plurality of rolls, comprising: a winding roll assembly including a winding roll support and driver means; a rider support means including a hollow shaft with a pressurized, central longitudinal passageway and a plurality of transverse bores intersecting said central longitudinal passageway; a carriage means for supporting said rider support means; a carriage drive means coupled to said carriage means for moving said rider support means; a sensor means for measuring a parameter corresponding to the amount of the web wound at least one of said plurality of rolls; a control means coupled to said sensor means and said carriage drive means for bringing the rider support means toward said plurality of rolls in response to said sensor means; and a plurality of rider roller means mounted on said rider support means for contacting said rolls, said rider support means supporting said plurality of rider roller means without projecting between the plurality of rider roller means, each of said rider roller means including: (a) a rim wheel encircling said rider support means; and (b) a pusher means reciprocatably mounted in a different corresponding one of said transverse bores on said rider support means within said rim wheel to move between an extended position and a retracted position, said pusher means having an axially varying, cross-sectional area for producing from pressure in said hollow shaft a net axial force on said pusher means tending to drive said pusher means through said transverse bore toward said extended position, said pusher means being operable in response to extrinsic force pushing said pusher means into said retracted position to switch into a holding state limiting the ability of said pusher means to move to said extended position, said pusher means having a yielding means encircling said pusher means, said transverse bore having an annular groove positioned and sized to receive said yielding means upon said pusher means moving into said retracted position.

31. A winding machine for winding webs into a plurality of rolls, comprising: a winding roll assembly including a winding roll support and driver; a rider support; and a plurality of rider rollers mounted on said rider support for contacting said rolls, said rider support supporting said plurality of rider rollers without projecting between the rider rollers, each of said rider rollers including: (a) a rim wheel encircling said rider support; and (b) a pusher reciprocatably mounted on said rider support within said rim wheel to move between an extended position and a retracted position.

32. A winding machine according to claim 31 wherein each of said pushers are commonly coupled within said rider support to enable said pushers to be driven toward said extended position in response to a common force.

33. A winding machine according to claim 31 wherein said rider support supports said plurality of rider rollers without projecting past said rim wheel between any of the rider rollers.

34. A winding machine according to claim 31 wherein said plurality of rider rollers are contiguous.

35. A winding machine according to claim 31 wherein said plurality of rider rollers each have a predetermined width, the spacing between adjacent ones of said rider rollers being less than 5% of said predetermined width.

36. A winding machine according to claim 31 wherein said plurality of rider rollers reside alongside and between each of the plurality of rolls.

37. A winding machine according to claim 36 wherein said plurality of rider rollers are distributed evenly along said rider support.

38. A winding machine according to claim 36 wherein said plurality of rider rollers are each smaller in width than any of the plurality of rolls.

39. A winding machine according to claim 31 wherein said rider support comprises a hollow shaft with a central longitudinal passageway.

40. A winding machine according to claim 39 wherein said hollow shaft has a plurality of transverse bores intersecting said central longitudinal passageway, the pushers of said rider rollers being separately mounted in individual ones of said transverse bores, said hollow shaft being pressurized to urge said pushers through said transverse bores in order to push said rim wheels.

41. A winding machine according to claim 31 wherein the winding roll assembly comprises a drive shaft supporting said plurality of rolls.

42. A winding machine according to claim 41 comprising: a driving roller spaced from said plurality of rolls, motion of said rider rollers toward said extended position bringing said rider rollers into contact with said driving roller and said plurality of rolls, said driving roller engaging and driving said rider rollers.

43. A winding machine according to claim 31 wherein each of said rider rollers has a width corresponding to an associated one of the plurality of rolls.

44. A winding machine according to claim 43 comprising: a driving roller spaced from and extending across said plurality of rolls, motion of said rider rollers toward said extended position bringing said rider rollers into contact with said driving roller and said plurality of rolls, said driving roller engaging and driving said rider rollers.

45. A winding machine according to claim 31 wherein each of said rider rollers comprises: an inner ring encircling said rider support, said rim wheel encircling said inner ring, said inner ring and said pusher being pivotally connected to allow said inner ring to translate and rotate relative to said rider support.

46. A winding machine for winding webs into a plurality of rolls, comprising: a winding roll assembly including a winding roll support and driver; a rider support; and a plurality of rider rollers mounted on said rider support for contacting said rolls, each of said rider rollers including: (a) an inner ring encircling said rider support; (b) a rim wheel encircling said inner ring; and (c) a pusher reciprocatably mounted on said rider support within said rim wheel to move between an extended position and a retracted position, said inner ring and said pusher being pivotally connected to allow said inner ring to translate and rotate relative to said rider support.

47. A winding machine according to claim 46 wherein the winding roll assembly comprises: a drive shaft supporting said plurality of rolls; and a driving roller spaced from said plurality of rolls, motion of said rider rollers toward said extended position bringing said rider rollers into contact with said driving roller and said plurality of rolls, said driving roller engaging and driving said rider rollers.

48. A method employing a plurality of rider rollers for winding webs into a plurality of rolls, comprising the steps of: directing webs to a plurality of spaced winding positions across a winding region; positioning a plurality of rider rollers at and between the spaced winding positions while supporting said rider rollers at either end of said winding region without employing supporting structure projecting between rider rollers in the winding region; and winding the webs at said spaced winding positions into a plurality of rolls while pressing associated ones said rider rollers at said spaced winding positions in a common direction against said rolls to limit air entrapment, unassociated ones of said rider rollers between said associated ones of said rider rollers being unused.

49. A method according to claim 48 wherein said rider rollers are driven in the common direction in response to a common force that is commonly coupled to said rider rollers.

50. A method according to claim 48 wherein said associated ones of said rider rollers are driven toward said plurality of rolls in response to a common force that is commonly coupled to said associated ones of said rider rollers.

51. A method according to claim 48 comprising the step of: extrinsically pushing at least a selected one of the rider rollers into a retracted position and contemporaneously switching the selected one into a holding state limiting the ability of the selected one to move in the common direction.

52. A method according to claim 51 wherein the selected one of the rider rollers is (a) adjacent to an edge of an adjacent one of the webs, and (b) next to one of the rider rollers that initially touches the adjacent one of the webs.

53. A method according to claim 52 wherein the selected one of the rider rollers is spaced to the outside of the adjacent one of the webs in a position to avoid initial contact with said adjacent one.

54. A method according to claim 52 wherein the selected one of the rider rollers and said adjacent one of the webs have a partially overhanging relationship.

55. A method according to claim 54 wherein the portion of the selected one of the rider rollers looming against said adjacent one of the webs is less than 10% axially.

56. A method according to claim 48 most of the unassociated ones of said rider rollers are deployed in the common direction farther than the associated ones of the rider rollers.

57. A method according to claim 48 comprising the step of: extrinsically pushing some of the unassociated ones of the rider rollers into a retracted position and contemporaneously switching the retracted ones of the rider rollers into a holding state limiting the ability of the retracted ones to move in the common direction, the unassociated ones of the rider rollers that are not among the retracted ones are deployed in the common direction farther than the associated ones of the rider rollers.

58. A method according to claim 48 wherein said plurality of rider rollers are positioned contiguously.

59. A method according to claim 48 wherein said plurality of rider rollers each have a predetermined width, the method includes keeping the spacing between adjacent ones of said rider rollers less than 5% of said predetermined width.

60. A method according to claim 48 wherein said plurality of rider rollers are distributed evenly.

61. A method according to claim 48 wherein said plurality of rider rollers are each smaller in width than any of the plurality of rolls.

62. A method according to claim 48 comprising the step of: simultaneously moving said rider rollers as a group relative to said plurality of rolls.

63. A method according to claim 62 comprising the step of: measuring an operating parameter associated with a relation between the plurality of rolls and the rider rollers, the step of simultaneously moving said rider rollers as a group being performed by bringing the group in proximity to said plurality of rolls in accordance with said operating parameter.

64. A method according to claim 63 wherein the step of simultaneously moving said rider rollers as a group is performed to bring said rider rollers to bear on said plurality of rolls in order to avoid entrapment of air entrained on the webs.

65. A method according to claim 64 wherein the web arrives at said rider rollers and said rolls substantially simultaneously.

66. A method according to claim 64 wherein the web arrives at said rider rollers and substantially reverses direction before arriving at said rolls.

67. A method according to claim 48 employing a driving roller spaced from said plurality of rolls, motion of said rider rollers in said common direction bringing said rider rollers into contact with said driving roller and said plurality of rolls, the method including the step of: engaging and driving said rider rollers with said driving roller.