This invention relates to a method and apparatus for supporting product during cutting, and more particularly, to supporting product for cutting by a saw which transversely severs material such as a log of convolutely wound bathroom tissue or kitchen toweling in single or multiple lanes, rolls of wipes material, and the like.
In the production of rolls of bathroom tissue, kitchen toweling, or wipes, a jumbo sized parent roll of web material is unwound and rewound into an elongated log which has the diameter of the final product. The log is cut into individual rolls of bathroom tissue, kitchen toweling, or wipes by a saw. When the individual rolls are produced, two end trim pieces are also produced since the lengths of the log are variable due to variations in width of jumbo size parent rolls and the rewinding process. The ends of the logs need to be cut off straight and perpendicular to the axis of the log. The ends are present when the log length is longer than an even multiple of the number of rolls cut therefrom. Typical end trim cuts are approximately 1.0 to 3.0 inches in length and are waste in the production.
Log saws are described, for example, in U.S. Pat. No. 6,123,002, U.S. Pat. No. Re. 30,598, U.S. Pat. No. 5,799,555, and U.S. Pat. No. 8,037,794
In most present log saw assemblies, the elongated log is advanced longitudinally or axially toward the path of the blade, which passes generally transversely through the log. The log is supported upstream of the blade, and the cut rolls plus the roll which is being cut are supported downstream of the blade.
The problems with current log saws vary depending upon the saw. In some designs the conveyor for the log intermittently advances the log through the saw, and the log is stopped during cutting. U.S. Pat. No. 5,647,259 illustrates a log support for an intermittent motion log saw. The log support is rigid and provides a narrow opening parallel to the path of the blade. This narrow opening allows the support to provide additional support of the log during cutting. Saws that intermittently advance the log cut the log at a lower rate due to cutting the log while it is stopped.
In other designs of log saws, e.g., as is shown in U.S. Pat. No. 5,799,555, the log is moving longitudinally or axially during cutting, and the blade also moves longitudinally or axially with the log during the cutting process as the blade moves generally transversely through the log. Again, the log support, which is generally called a clamp, is rigid, but the opening between the upstream and downstream support assemblies forms a āVā to provide clearance for the path of the axial movement of the blade. See particularly
In U.S. Pat. No. 5,799,555 the blade is mounted for rotation on an axis which is parallel to the axis of movement of the log and moves generally transversely through the log to cut the log while also moving axially in a path which is parallel to the axial movement of the log. The wider V-shaped opening of the product and requires a wider end trim cut to be taken to provide adequate support of the product versus the prior indexing saws. If the trim width is too narrow and there is not enough support for the end of the log, the first cut will not be straight or perpendicular to the axis of the log.
U.S. Pat. Nos. Re. 30,598 and 6,123,002, which are co-owned by applicants' assignee, also describe a continuous motion saw in which the log moves axially while it is being cut. However, in U.S. Pat. Nos. Re. 30,598 and 6,123,002 a pair of blades are mounted for orbiting movement on an orbiting axis which is skewed relative to the axial movement of the log. As each blade passes through the log, the blade has both transverse and axial components of motion relative to the log. The axial component of motion of the blade matches the axial movement of the log.
U.S. Pat. No. 8,037,794 describes another continuous motion saw which is similar to the saw of U.S. Pat. No. 5,799,555 but which includes two pairs of axially spaced blades which are mounted for orbiting movement.
Continuous motion saws cut logs into rolls at a higher rate, but provide reduced log support because of the need to provide clearance for the axial movement of the blade. This reduced support can result in lower quality end rolls when end trim pieces are shorter and can also affect the quality of the cut rolls intermediate the ends of the log.
As shown in U.S. Pat. No. 6,332,527 and Int. Pub. No. WO 01/62454 A1, saws that cut the end trim pieces may also remove the end trim pieces adjacent to the cutting area.
In still other designs, as shown in U.S. Pat. No. 3,213,731, the saw is adapted to cut the log which has been previously cut to the exact length of an integral number of the individual rolls. To cut the log to the exact length, a separate module from the saw is used. The separate module, as is shown in U.S. 2006/0107805 A1 and EP 1 539 440 B1, is capable of cutting shorter or longer end trim pieces as previously described for intermittent or continuous motion saws. The module creates the need for additional floor space for the equipment, two additional saw blades for sharpening and maintenance, and two end trim piece removal locations.
The invention solves the problem of requiring a wide end trim length of a log in a saw that cuts longitudinally moving elongated product into individual rolls, improves both the end cut and center cut quality, and reduces waste by narrowing the required parent roll width or by allowing an additional product to be cut from the elongated log. End trim cuts can be reduced to a smaller length, such as 0.5 inch on many products, with better or equal quality to cut products.
The inventive method and apparatus for supporting product during cutting provides axially movable upstream and downstream supports for the log close to the path of the blade, in particular while cutting the end trim pieces, using a continuous motion saw. The method and apparatus are suitable for use with all of the foregoing continuous motion saws, particularly those described in U.S. Pat. Nos. 5,799,555, Re. 30,598, 6,123,002, and 8,037,794. The method and apparatus allows the saw to cut shorter end trim pieces at a higher speed while providing good support for the cut rolls adjacent to the end trim pieces. The invention also optionally allows the axially movable product supports to be:
1. at a greater distance from the path of the blade when cutting longer end trim pieces;
2. close to the path of the blade when not cutting the end trim pieces;
3. at a greater distance from the path of the blade when not cutting the end trim pieces; and/or
4. closer to the blade around the product.
As the V-shaped opening of prior art clamps which allows clearance for the blade to enter and exit while axially moving forward is no longer required in the invention, the product support can be designed to provide full support around the product. The end of the product support near the blade can be parallel to the saw blade, providing the best possible support around the entire log.
Further, the upstream and downstream product supports can be at an equal distance from the path of the blade or at different distances from the path of the blade.
In a multiple lane saw, the product supports for each lane or each set of lanes can be close to or at a greater distance from the path of the blade, and the upstream and downstream product supports for each lane or set of lanes can be at an equal or non-equal distance from the path of the blade.
In the preferred embodiment of the invention, each lane of a multiple lane saw includes an upstream product support and a downstream product support which are slidably mounted for reciprocal movement along the path in which the log is advanced, i.e., parallel to the axial or longitudinal movement of the log. The path of the blade extends through a gap between the upstream and downstream product supports, and the product supports move axially in a downstream direction during cutting to accommodate the movement of the blade in the axial direction. The movement of each product support for each lane or each set of lanes is preferably independently controlled so that the spacing between the product supports of each lane or each set of lanes and the spacing of each product support from the blade may be controlled as desired.
The invention will be explained in conjunction with an illustrative embodiment shown in the accompanying drawings, in which:
Similar prior art clamps or product supports for log saws are described in U.S. Pat. Nos. 5,357,833, 5,647,259, and 6,532,851.
The product support assembly 30 includes a stationary frame 35 which includes a flat stationary plate 36. The four product supports 31-34 are slidably mounted on the frame for reciprocating forward and backward movement along the longitudinal or axial direction in which the four lanes of products flow. Each of the movable product supports 31-34 includes an upstream support 38 and a downstream support 39 which are spaced apart to provide a gap 40 through which the cutting blade of the log saw passes to cut the products which are supported by the product supports.
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A pair of upstream entry rods 50 (see also
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The pair of upstream product supports 38 which are illustrated in
As can be seen in
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Each of the motors 78, 94 can be independently controlled by a processor or programmable logic controller (PLC) 95 or a similar device so that the position of each of the upstream and downstream product supports and the gap between the product supports can be controlled as desired throughout the cutting process. If desired, the motors can be controlled by the same processor which controls the cutting blade so that the longitudinal movement of the product supports can be coordinated with the longitudinal movement of the cutting blade. The manner of controlling such devices is well known to those skilled in the art and need not be explained herein.
The dimension of the gap 40 between the upstream and downstream product supports is also controlled by the motors 78, 94. The dimension of the gap can be varied so that the gap is relatively narrow when cutting an end trim piece and relatively wide when cutting rolls.
As is well known in the art, logs are moved through a log saw by pushers which are mounted on a conveyor. The product supports can move at a rate that is equal to or slower than the product during the cutting process. If the product supports are stationary or move slower than the pushers, the log remains against the pusher and is controlled by the pusher. If the product supports move faster than the product, the product could be pulled downstream away from the pusher. This could be avoided, however, by modifying the conventional hold down shoes of log saws. Hold down shoes are stationary members which are located upstream of the conventional clamps or product supports to apply more pressure on the log to help hold the log against the pusher. If these hold down shoes apply more friction on the log than the movable product supports which are described herein, then the log will remain against the pusher even if the movable product supports move at a greater speed than the pusher.
The gap between the movable product supports can remain constant during the cut or can vary as long as the velocity of the supports is not faster than the product. The upstream and downstream supports do not have to move at the same velocity. The downstream support must be spaced sufficiently from the path of the blade so that the blade does not contact the downstream support. The movement of one or both of the supports can be reversed prior to completion of the cut so long as the supports do not contact the blade.
In the embodiment which is illustrated and described, the upstream product supports for two lanes are driven by one drive, and the downstream product supports for those two lanes are driven by one drive. However, it will be understood that the upstream and downstream product supports for each lane can be driven by a separate drive. Alternatively, the upstream product supports for more than two lanes can be driven by a separate drive and the downstream product supports for more than two lanes can be driven by a separate derive. Moving two lanes at a time is currently preferred because it requires fewer parts than moving each lane individually and moves less mass than would be involved in moving more than two lanes.
In
In
When the product supports for two lanes are connected for common longitudinal movement, the longitudinal movement of the product supports is not reversed until after the blade exits the gap between the product supports for the second lane. In a four lane log saw, when the cutting blade enters the gap between the product supports for the third lane and exits the gap for the second lane, the servo motors for the first two lanes can be operated to reverse the movement of the product supports of the first and second lanes to return those product supports to their original positions to receive the next pass of the cutting blade. Beginning the reverse movement early allows more time for the reverse movement, thereby reducing acceleration stresses. The reverse movement of the product supports causes the product supports to move over the product in the direction which is opposite to the direction of product movement.
In
In
In the preferred embodiment which is illustrated in
Each of the upstream and downstream product supports could also be mounted on a pivot mechanism for pivoting movement about a transverse axis. If the pivot arm is long, the product supports would move in the longitudinal direction with little vertical movement.
Further, the log and the frame which supports the product supports could also be pivotally mounted with respect to the cutting blade.
While in the foregoing specification a detailed description of specific embodiments of the invention has been set forth, it will be understood that many of the details herein given may be varied considerably by those skilled in the art without departing from the spirit and scope of the invention.