Patent Application
20240391721
The disclosure is directed to a roll handling assembly and a method for handling a roll used on a machine in a converting line. In particular, the disclosure is directed to a roll handling assembly that allows the transfer of rolls used on an embossing and/or lamination machine, for instance, embossing rolls, anvil rolls, rubber rolls, adhesive rolls (applicator rolls and gravure/anilox rolls), and/or marrying rolls, between the machine and a storage assembly. More in particular, the disclosure is directed to a roll handling assembly that includes a storage assembly positioned vertically above the machine of the converting line that uses the roll, and a transfer assembly that is configured to move a desired roll between the storage assembly and the machine.
The storage assembly 18 further includes at least one roll mover 22 for each rack 20. The roll mover 22 is adapted and configured to move horizontally in the machine direction between a stored position and an extended position. The roll mover 22 may comprise an actuator 24 to move the roll mover horizontally between the stored and extended positions. The actuator 24 may be, for instance, a screw jack actuator provided by Joyce model WJ1000U4S-29-STDX-STDX-X, or a similar type of actuator known in the art capable of moving the roll between the storage position and the extended position. Preferably, two roll movers 22 are provided for each rack 20; one for each axial end of the roll stored in the rack. Preferably, the roll mover 22 is similar to the roll extractor 26 used in the machine 14 so as to simplify the construction and number of parts, and to allow the same surfaces of the roll 12 to be engaged by the roll mover 22 during storage and by the roll extractor 26 during machine operation. To that end, the roll mover 22 may have an end effector 28 adapted and configured to engage an axial end of the roll to be stored in the storage structure. The end effector 28 may have any configuration necessary to engage the roll and hold the roll in place while the actuator 24 moves the roll mover 22 between the storage position and the extended position. The end effector 28 may also engage surfaces on the axial ends of the roll used to rotate and drive the roll during normal operations of the machine. The end effector may also engage the operating surface of the roll. The end effector can be advantageously shaped in order to move the roll with repeatability to the desired positions for transfer to and from the rack.
The roll handling assembly 10 further includes a transfer assembly 36 that is adapted and configured to move the roll between the storage assembly and the machine. The transfer assembly 36 includes first and second vertical supports 38,40 on laterally opposite sides of the converting line 16. The first and second vertical supports 38,40 are adjacent to and extend above the machine 14 that uses the roll. The first and second vertical supports 38,40 are preferably independent of the structure of the machine 14 so as to allow the first and second vertical supports to be installed over and around the machine, for instance, in a retrofitting application. The first and second vertical supports may be connected with the support structure of the storage assembly or may be independent therefrom.
The transfer assembly 36 further includes a lifter 42 operatively connected to and supported by the first and second vertical supports. The lifter 42 is adapted and configured to move vertically relative to the first and second vertical supports 38,40 between the storage assembly 18 and the machine 14. The lifter 42 may comprise a pair of journal cradles 44 that are positioned vertically by a pair of ball or acme lead screws 46 driven with a servo motor 48. The lifter 42 may comprise a first cradle associated with the first vertical support 38, and a second cradle associated with the second vertical support 40. The ball or acme lead screw 46 for effecting vertical movement of the lifter may be driven by a servo motor 48 mounted on the top vertical end of the respective vertical support 38,40. The lifter 42 may be configured to engage axial ends of the roll. For instance, each cradle 44 of the lifter 42 may be configured as necessary to engage an axial end of the roll. The cradle may comprise a hook shape so that vertical movement of the lifter may enable the cradle to engage and disengage from the axial end of the roll. The lifter 42 is configured for movement in a vertical axis or plane relative to the first and second vertical supports 38,40. The path of motion of the lifter 42 intersects that of the roll mover 22 so as to allow transfer of the roll 12 between the lifter 42 and the roll mover 22, when the roll mover moves horizontally from the storage position to the extended position. In one aspect, the cradle 44 associated with each vertical support 38,40 may have a hook shape and may be positioned laterally outboard of the roll mover 22 in the extend position (see, e.g.
The method of handling the roll 12 used in the machine 14 in the converting line 16 will next be described. To install a new roll 12 in a vacant location in the machine 14, the lifter 42 may be moved on the first and second vertical supports 38,40 vertically so as to position the lifter adjacent to the rack 20 of the storage assembly 18. The rack 20 may store a selected roll 12 to be used in the machine 14. The lifter 42 may have a home position within the storage assembly 18 or a home position in an intermediate location between the storage assembly and the machine 14. So, depending on the home position, the lifter 42 may move vertically upward or downward to be adjacent the selected roll and rack 20. In one aspect, the lifter 42 may first be positioned below the rack 20 to allow clearance for the roll 12 and roll mover 22 as they move to the extended position. Thus, once the roll mover 22 moves to the extended position, the lifter may move vertically upward to engage the roll and move the roll off the roll mover. The roll mover 22 of the rack 20 may move horizontally from the storage position to the extended position. Then the roll may be transferred from the roll mover 22 to the lifter 42. Once the roll has been transferred to the lifter, the roll mover 22 may be moved from the extended position to the storage position. The lifter may then move from the storage assembly 18 to the machine 14, and the roll 12 may be transferred from the lifter to the machine.
For illustration and not in any limiting sense, transfer from the lifter 42 to the machine 14 will be described with reference to the machine described in U.S. Pat. No. 10,730,274 as follows: (i) the adhesive unit/sub-frame is moved to the disengaged position to create a space between the mainframe and the adhesive unit/subframe; (ii) the extractor 26 moves to the exchange position in the space between the spaced away mainframe and adhesive unit/subframe; (iii) the lifter 42 lowers the roll 12 on to the extractor 26 and continues downward motion to disengage the lifter from the roll and leave the roll on the extractor; (iv) the extractor 26 moves to the normal operating position; (v) the lifter 42 moves vertically upward to leave the space between the mainframe and the adhesive unit/subframe; (vi) the adhesive unit/sub-frame is moved to the engaged position with the mainframe; and (vii) the machine 14 is returned to production.
For illustration and not in any limiting sense, transfer from the machine to the lifter will be described with reference to the machine described in U.S. Pat. No. 10,730,274 as follows: (i) the machine stops; (ii) the adhesive unit/sub-frame is moved to the disengaged position away from the mainframe; (iii) the lifter 42 moves vertically downward in the space between the mainframe and the adhesive unit/subframe to a position below the extractor 26 so as to provide clearance for the roll and extractor as they move to the exchange position; (iv) the extractor 26 moves the roll 12 from the normal operating position to the exchange position; (v) the lifter 42 moves vertically upward, engages the roll and separates the roll from the extractor 26; and (vi) the lifter continues to move vertically upward to the storage assembly 18.
Once in the storage assembly 18, the lifter 42 moves adjacent to the selected rack 20 which is to receive the preceding roll. In one aspect, the lifter 42 moves to a position above the roll mover 22 to provide clearance for the roll mover as it moves to the extended position. The roll mover 22 moves horizontally from the storage position to the extended position. The lifter 42 transfers the preceding roll from the lifter to the roll mover 22. In one aspect, once the roll mover 22 is in the extended position, the lifter may move from its upward staging location downward to place the roll on the extended roll mover. The lifter may continue downward motion to disengage the lifter from the roll. With the lifter 42 disengaged from the roll, the roll mover may move from the extended position to the storage position.
In a preferred embodiment, there is one more rack in the storage assembly 18 than the number of rolls to be stored in the storage assembly. In the example shown in
In an alternate embodiment, the racks in the storage assembly are staggered vertically and/or horizontally. In this embodiment, roll movers with horizontal strokes of different lengths may be provided as needed to reach the roll lifter.
In an alternate embodiment, the lifter may be provided with roll movers. In this embodiment, the LEM may still be provided with roll movers, but the storage assembly may not be provided with roll movers. The roll movers provided on the lifter may be spaced axially from the roll movers in the LEM to allow rolls to be exchanged between the LEM and the lifter as described above. The horizontal movement of the rolls into the storage assembly would be provided by the lifter. This embodiment may provide a more complex and higher cost roll lifter, but may be a lower cost overall since fewer total roll movers are needed. In this embodiment, the rolls in the storage assembly may be arranged vertically or staggered vertically and horizontally as desired.
In an alternate embodiment, the roll lifter may be omitted, and the function of moving rolls between the machine and the storage location(s) may be performed using an overhead crane. In this embodiment, the same crane that is used to remove rolls from the converting line for use outside the converting line may be used to exchange rolls within the converting line. Roll exchange within the converting line requiring only vertical movement makes using even a manually operated crane feasible and safe.
The roll handling assembly provides benefits in that it is compact and requires no additional floor space. Accordingly, it is retrofittable to existing converting lines, and all of the original converting line equipment may remain in its original location with no significant alteration. The storage assembly is scalable. As few as one roll storage location and up to five or more storage locations may be provided, the limits being the height and the weight capacity of the support structure and storage assembly. The storage assembly above the machine provides the advantage of less risk of contamination from fiber and adhesive when compared to conventional systems that store the rolls in or below the machine. The storage assembly may be provided with air blasts to periodically remove any fiber or dust that has settled on the rolls. With the storage assembly above the machine, rolls are more easily accessed, for instance, for removal from the converting line to be installed in another converting line. For instance, a facility general purpose crane may be used to access a roll in the storage assembly by actuating the roll mover of a specific rack to move to the extended position. Such operations may occur without interrupting normal machine operations. The roll movers may be identical to the roll extractors used in the machine to provide simpler construction. Further, each roll in the embosser may be changed including the upper embossing roll and the lower embossing roll.
As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.
This application claims priority benefit of U.S. provisional application Ser. No. 63/468,563, filed May 24, 2023, the disclosure of which is incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 63468563 | May 2023 | US |
