Information
-
Patent Grant
-
6425547
-
Patent Number
6,425,547
-
Date Filed
Tuesday, August 31, 199925 years ago
-
Date Issued
Tuesday, July 30, 200222 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
-
CPC
-
US Classifications
Field of Search
US
- 242 527
- 242 5301
- 242 531
- 242 5334
- 242 5336
- 242 542
- 242 5423
-
International Classifications
-
Abstract
A system for producing coreless fabric rolls includes a feed station (12) operable to supply a leading edge of a fabric web (24) from a parent roll (18). The system includes a first tucking station (132) operable to position the leading edge of the fabric web (24) adjacent one of a plurality of spindles (48, 50, 52) coupled to a turret (46). The system also includes a winding station (38) comprising a winding roller (36). The winding station (38) is operable to receive the leading edge in a nip defined by the spindle (48, 50, 52) and the winding roller (36) and wind the fabric web (24) into a fabric roll about the spindle (48, 50, 52). The system also includes a cutting station (40) operable to separate the fabric roll from a remaining portion of the fabric web (24). The system also includes a second tucking station (42) operable to receive the spindle (48, 50, 52) from the winding station (36) and wind a trailing edge of the fabric roll about the fabric roll.
Description
TECHNICAL FIELD OF THE INVENTION
The present invention relates generally to the field of fabric or paper converting processes and machinery, and more particularly, to a system and method for producing coreless fabric rolls.
BACKGROUND OF THE INVENTION
Fabric rewind systems are generally used to unwind paper or fabric from a large parent roll and conduct the fabric through a finishing or converting operation. For example, the converting operation may include rewinding the fabric into a roll of a specific size which is generally smaller than the size of the parent roll. For example, the system may be used to produce products such as rolls of sanitary or tissue paper.
An example of a fabric rewind system may include a plurality of mandrels coupled to a rotatable turret. The mandrels rotate in a circular path a fixed distance from an axis of the turret. As the turret rotates, cores are placed on each mandrel, adhesive or glue is applied to the cores, and then the fabric is brought into contact with the cores. The cores are then driven in rotation by rotating the mandrels to wind the fabric about the cores.
An example of a coreless fabric rewind system may include a pair of winding rollers and an actuator to adjust the position of one winding roller relative to the other winding roller. The winding rollers are brought into contact with each other to sever fabric disposed between the winding rollers. As the winding rollers rotate in the same direction, the severed end of fabric curls on itself to begin the formation of a fabric roll. The actuator controls the position of one of the winding rollers to allow for an increase in diameter of the fabric roll during formation.
Prior systems suffer several disadvantages. For example, systems including rotating turrets may require actuators to adjust the position of either winding rollers or the turret prior to, during, and/or after the winding process to avoid interference between the fabric rolls, winding rollers, or other system components during rotation of the turret. Additionally, turret systems do not generally accommodate surface winding of the roll.
Coreless winding systems generally initiate winding by compressing the severed end of the fabric to roll the severed end back on itself to begin the fabric roll. Thus, this process compresses and flattens the fabric, thereby creating a hard center portion of the fabric roll.
SUMMARY OF THE INVENTION
Accordingly, a need has arisen for a system and method for producing coreless fabric rolls that increases the efficiency and reduces the amount of movement of system components. The present invention provides a system and method for producing coreless fabric rolls that address the short comings of prior systems and methods.
According to one embodiment of the present invention, a system for producing coreless fabric rolls include a winding station operable to wind a fabric web into a fabric roll about one of a plurality of spindles coupled to a turret. The system also includes a cutting station operable to separate the fabric roll from the remaining portion of the fabric web to form a leading edge of a fabric web and a trailing edge of a fabric reroll. The system includes a tucking station operable to receive the spindle from the winding station and wind the trailing edge about the fabric roll. The system further includes a stripping station operable to receive the spindle from the tucking station and remove the fabric roll from the spindle.
According to another embodiment of the present invention, a method for producing coreless fabric rolls include winding a fabric web about one of the plurality of the spindles to form a fabric roll at a first station. The spindles are coupled to a turret. The method includes transferring a spindle from the first station to a second station and separating the roll from the fabric roll. Separating the fabric roll from the fabric web forms a leading edge of the fabric web and a trailing edge of the fabric roll. The method also includes winding the trailing edge about the fabric roll at the second station and transferring the spindle from the second station to a third station. The method further includes removing the fabric roll from the spindle at the third station.
The technical advantages of the present invention include providing a system and method for producing wound articles with increased efficiency over prior systems and methods. For example, according to one aspect of the present invention, a rotating turret transfers a plurality of spindles through different stations to produce a fabric roll. Thus, the present invention provides an increased cycle rate for producing fabric rolls.
Another technical advantage of the present invention includes reduced movement of system components, thereby increasing efficiency and decreasing the amount of time required to form fabric rolls. For example, according to one aspect of the present invention, a rotating turret transfers a plurality of spindles through different stations along a generally hypocycloidal path, thereby substantially eliminating interference between the fabric rolls and other system components. Additionally, the present invention substantially eliminates a requirement to translate various system components toward or away from the fabric roll during formation of the fabric roll or to transfer the spindles between different stations.
Other technical advantages of the present invention will be readily apparent to one skilled in the art from the following figures, descriptions and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in connection with the accompanying drawings, in which:
FIG. 1
is a diagram illustrating a system for producing coreless fabric rolls in accordance with an embodiment of the present invention;
FIG. 2
is a diagram illustrating a control system for the system for producing coreless fabric rolls in accordance with the an embodiment of the present invention;
FIG. 3
is a diagram illustrating a differential of an accumulator for the system in accordance with an embodiment of the present invention;
FIGS. 4A-4D
are diagrams illustrating a turret of the system in accordance with the embodiment of the present invention; and
FIGS. 5A-5H
are diagrams illustrating the production of coreless fabric rolls in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention and the advantages thereof are best understood by referring to the following descriptions and drawings, wherein like numerals are used for like and corresponding parts of the drawings.
FIG. 1
is a diagram illustrating a system
10
for producing coreless fabric rolls in accordance with an embodiment of the present invention. System
10
includes a feed station
12
, and accumulator
14
and a rewind station
16
. Feed station
12
comprises a parent roll of fabric
18
rotatably mounted to an unwind support (not explicitly shown). Parent roll
18
may comprise paper, woven material, non-woven material or other suitable materials for producing coreless fabric rolls. For example, parent roll
18
may include woven or non-woven cotton or rayon/polyester fabric which may be used for producing rolled bandages. Parent roll
18
may also comprise one or more roll units
20
of fabric.
Feed station
12
also comprises unwind rollers
22
for feeding a fabric web
24
downstream from parent roll
18
. Unwind rollers
22
rotate in the direction indicated by arrows
26
to control the feed rate of fabric web
24
downstream from parent roll
18
. Thus, in operation, fabric web
24
is unwound from parent roll
18
by rotating parent roll
18
in a direction indicated by arrow
28
. As used throughout this description “downstream” relates to the direction of fabric travel though system
10
, whereas the term “upstream” refers to a direction opposite that of fabric travel.
Fabric web
24
is fed downstream to feed rollers
30
and accumulator
14
. Accumulator
14
comprises festoon rollers
32
that move toward or away from each other to discharge or accumulate, respectively, a reserve portion of fabric
24
. Festoon rollers
32
may be driven by a chain or timing belt
33
to control an amount of the reserve portion of fabric web
24
accumulated or discharged; however, other suitable devices or methods may be used to control the movement and speed of festoon rollers
32
.
In operation, unwind rollers
22
and feed rollers
30
feed fabric web
24
from parent roll
18
to accumulator
14
at a substantially constant rate of speed, thereby maintaining a substantially constant amount of tension in fabric web
24
. Unwind rollers
22
and feed rollers
30
may be electrically and/or mechanically coupled such that unwind rollers
22
and feed rollers
30
operate at substantially the same speed. During winding of fabric rolls at rewind station
16
, accumulator
14
accumulates the reserve portion of fabric web
24
to accommodate a reduced feed rate of fabric web
24
to rewind station
16
. In response to an increase in the feed rate of fabric web
24
to rewind station
16
, accumulator
14
discharges the reserve portion of fabric web
24
. Thus, accumulator
14
accumulates the reserve portion of fabric web
24
when the feed rate to rewind station
16
is less than the feed rate of feed station
12
and discharges the reserve portion of fabric web
24
when the feed rate to rewind station
16
is greater than the feed rate of feed station
12
.
Fabric web
24
is fed downstream from accumulator
14
through draw rollers
34
to rewind rollers
36
of rewind station
16
. Draw rollers
34
and rewind rollers
36
may be electrically and/or mechanically coupled such that draw rollers
34
and rewind rollers
36
operate at substantially the same speed, thereby maintaining a substantially constant tension of fabric web
24
. Additionally, feed rollers
30
and draw rollers
34
operate to isolate accumulator
14
to maintain a substantially constant tension of fabric web
24
.
Rewind station
16
comprises a winding station
38
, a cutting station
40
, a tucking station
42
, and a stripping station
44
. Rewind station
16
also includes a turret
46
comprising spindles
48
,
50
and
52
. In operation, turret
46
transfers spindles
48
,
50
, and
52
in a three-cusp hypocycloidal path between stations
38
,
42
, and
44
. Briefly, fabric web
24
is wound about spindles
48
,
50
, and
52
at winding station
38
using winding rollers
36
as each spindle
48
,
50
, and
52
is transferred through winding station
38
. Cutting station
40
severs the wound fabric rolls from fabric web
24
and tucking station
40
winds any remaining fabric after severing about the wound fabric rolls. The wound fabric rolls are removed from spindles
48
,
50
, and
52
at stripping station
44
.
FIG. 2
is a diagram illustrating a control system
54
of system
10
in accordance with an embodiment of the present invention. Control system
54
comprises a controller
56
and servo motors
58
,
60
,
62
, and
64
. Controller
56
comprises a computer, workstation, mini-computer, mainframe or other computing device. Controller
56
controls the operation of motors
58
,
60
,
62
, and
64
. For example, motor
58
may be slaved to motor
60
, and controller
56
may control the operation of motor
60
such that fabric web
24
is fed at a substantially constant rate of speed from parent roll
18
to accumulator
14
.
Additionally, for example, motor
64
may be slaved to motor
62
, and controller
56
may control the operation of motor
62
to control the feed rate of fabric web
24
from accumulator
14
to rewind station
16
. Thus, motors
62
and
64
may be controlled to deliver a predetermined length of fabric web
24
to rewind station
16
for producing fabric rolls.
As illustrated in
FIG. 2
, accumulator
14
comprises a differential
66
to control operation of festoon rollers
32
to accumulate or discharge a reserve portion of fabric web
24
. For example, differential
66
may be mechanically coupled to feed rollers
30
and draw rollers
34
to control timing belt
33
. However, a servo motor or other suitable type of method or device may be used to control timing belt
33
.
FIG. 3
is a diagram illustrating differential
66
of system
10
in accordance with an embodiment of the present invention. Differential
66
comprises an input gear
68
, an input gear
70
, a spider pinion gear
72
and a spider
74
. Differential
66
receives input from feed rollers
30
through input gear
68
in the direction indicated by arrow
76
. Differential
66
also receives input from draw rollers
34
through input gear
70
in the direction indicated by arrow
78
. In operation, feed rollers
30
are operated at a substantially constant speed to provide a substantially constant feed rate of fabric web
24
to accumulator
14
. Input from draw rollers
34
is cyclic as fabric rolls are produced at rewind station
16
. Thus, differential
66
operates to regulate the position of festoon rollers
32
based on input speeds from feed rollers
32
and draw rollers
34
.
In operation, if the input from feed rollers
30
is greater than the input from draw rollers
34
, an output shaft
80
of spider
74
delivers output to timing belt
33
in the direction indicated by arrow
82
. If the input from feed rollers
30
is less than the input from draw rollers
32
, the output from shaft
80
of spider
74
is in a direction opposite that indicated by arrow
82
. If the input from feed rollers
30
equals the input from draw rollers
32
, festoon rollers
32
will remain in a substantially static condition. Thus, accumulator
14
accumulates or discharges a reserve portion of fabric web
24
using differential
66
based on the speeds of feed rollers
30
and draw rollers
34
.
FIGS. 4A-4D
are diagrams illustrating turret
46
of rewind station
16
in accordance with an embodiment of the present invention. Turret
46
comprises a fixed sun gear
84
, a planet carrier
86
, and planet gears
88
rotatably coupled to sun gear
84
. In operation, planet carrier
86
is rotated about the axis of shaft
90
of planet carrier
86
. As planet carrier
86
rotates, teeth (not explicitly shown) of planet gears
88
engage teeth (not explicitly shown) of sun gear
84
, thereby causing rotation of planet gears
88
. Planet gears
88
are coupled to spindles
48
,
50
, and
52
such that spindles
48
,
50
, and
52
travel in a generally three-cusp hypocycloidal motion.
Referring to
FIGS. 4B and 4C
, spindles
48
,
50
, and
52
are coupled to planet gears
88
by spindle carriers
92
. Spindle carriers
92
each comprise a yoke
94
, a support
96
, and springs
98
disposed between yoke
94
and support
96
. Yoke
94
comprises an outwardly extending pin
100
. Support
96
comprises an opening
102
for receiving one of spindles
48
,
50
, and
52
. In operation, yoke
94
cooperates with support
96
such that springs
98
bias a clamping surface
104
of yoke
94
towards a clamping surface
106
of opening
102
of support
96
to secure spindles
48
,
50
, and
52
within opening
102
. Thus, spindle carriers
92
secure spindles
48
,
50
, and
52
in a predetermined position relative to a center axis of planet gears
88
.
Referring to
FIG. 4D
, as spindles
48
,
50
, and
52
are positioned at winding station
38
, a downwardly directed force is applied to pin
100
to resist the bias force of springs
98
and direct yoke
94
downwardly relative to support
96
, thereby releasing spindles
48
,
50
, and
52
for movement within opening
102
. For example, the force may be applied to pin
100
from a pneumatically operated cylinder (not explicitly shown) controlled by controller
56
; however, other suitable devices or methods may be used to apply a downwardly directed force to pin
100
. As yoke
94
moves downwardly relative to support
96
, spindles
48
,
50
, and
52
also move downwardly within opening
102
so that spindles
48
,
50
, and
52
are positioned in a nip defined by adjacent winding rollers
36
. As fabric web
24
is surface wound about spindles
48
,
50
, and
52
, spindles
48
,
50
, and
52
are operable to move upwardly within opening
102
to accommodate an increasing diameter of fabric roll formed about spindles
48
,
50
, and
52
. After the fabric roll is formed to a desired size, pin
100
may be released, thereby causing yoke
94
to be biased upwardly from springs
98
to secure spindles
48
,
50
, and
52
. Thus, spindle carriers
92
releasably engage spindles
48
,
50
, and
52
to locate spindles
48
,
50
, and
52
in a position for surface winding of spindles
48
,
50
, and
52
, and to accommodate an increasing diameter of the fabric rolls during formation of the fabric rolls.
In the embodiment illustrated in
FIGS. 4B-4D
, spindle carriers
92
comprise pin
100
for directing yoke
94
downwardly relative to support
96
to releasably engage spindles
48
,
50
, and
52
. However, other suitable methods or devices may be used to releasably engage spindles
48
,
50
, and
52
to provide positional control of spindles
48
,
50
, and
52
relative to winding rollers
36
.
FIGS. 5A-5H
are diagrams illustrating rewind station
16
in accordance with an embodiment of the present invention. Referring to
FIG. 5A
, rewind station
16
comprises winding station
38
, cutting station
40
, tucking station
42
, and stripping station
44
. As described above, turret
46
rotates about a central axis to transfer spindles
48
,
50
, and
52
between winding station
38
, tucking station
42
, and stripping station
44
along generally three-cusp hypocycloidal paths
108
,
110
, and
112
.
As illustrated in
FIG. 5A
, fabric web
24
is wound about spindle
48
using rewind rollers
36
of winding station
38
to form a fabric roll
114
. For example, fabric roll
114
may be surface wound about spindle
48
by rotating rewind rollers
36
in the direction indicated by arrows
115
. As described above, spindle carrier
92
disengages spindle
48
at winding station
38
to position spindle
48
in a nip defined by adjacent winding rollers
36
. Additionally, spindle carrier
92
disengages spindle
48
to allow rotation of spindle
48
caused by the rotation of winding rollers
36
. The speed and duration of winding may be controlled using control system
54
to form fabric roll
114
to a desired size. After fabric roll
114
has been wound to the desired size, rotation of winding rollers
36
and draw rollers
34
is dwelled to prevent feeding additional fabric web
24
to winding station
38
. Additionally, spindle carrier
92
engages spindle
48
in preparation for indexing of turret
46
.
FIG. 5B
illustrates an indexing of turret
46
to transfer spindles
48
,
50
, and
52
between stations
38
,
42
, and
44
. For example, spindle
48
and fabric roll
114
are transferred from winding station
38
to tucking station
42
along hypocycloidal path
108
. Additionally, spindle
50
is transferred from tucking station
42
to stripping station
44
along path
110
, and spindle
52
is transferred from stripping station
44
to winding station
38
along path
112
. Transferring spindles
48
,
50
, and
52
between stations
38
,
42
, and
44
along generally hypocycloidal paths
108
,
110
, and
112
prevents interference between components of rewind station
16
and alleviates additional movement of components of rewind station
16
to avoid interference.
As illustrated in
FIG. 5C
, turret
46
has completed indexing and has positioned spindle
48
and fabric roll
114
at tucking station
42
and spindle
50
at stripping station
44
. Additionally, as described above, spindle carrier
92
disengages spindle
52
at winding station
38
, thereby allowing spindle
52
to be disposed within a nip defined by adjacent winding rollers
36
. As turret
46
indexes, fabric web
24
is positioned between spindle
52
and rewind rollers
36
such that fabric web
24
becomes secured between rewind rollers
36
and spindle
52
as spindle
52
reaches winding station
38
.
Cutting station
40
comprises shear blades
116
and
118
to separate fabric roll
114
from a remaining portion of fabric web
24
. As illustrated in
FIG. 5C
, as spindle
52
reaches winding station
38
, spindle
52
causes a tension in a portion of fabric web
24
extending from winding station
38
to fabric roll
114
so that shear blades
116
and
118
may separate fabric web
24
from fabric roll
114
. For example, shear blade
118
may be moved in a direction indicated by arrow
120
to cooperate with shear blades
116
to separate fabric web
24
from fabric roll
114
. Controller
56
may be used to control actuation of shear blades
116
and
118
to separate fabric web
24
from fabric roll
114
.
Referring to
FIG. 5D
, shear blade
118
engages shear blade
116
to separate fabric web
24
from fabric roll
114
, thereby forming a leading edge
122
of fabric web
24
and a trailing edge
124
of fabric roll
114
. Tucking station
42
comprises a tucking roller
126
to wind trailing edge
124
about spindle
48
and fabric roll
114
. For example, tucking roller
126
may be operated in a direction indicated by arrow
128
, thereby causing fabric roll
114
to rotate in a direction indicated by arrow
130
to wind trailing edge
124
about fabric roll
114
. Controller
56
may be used to operate tucking roller
126
after separation of fabric roll
114
from fabric web
24
. Rewind station
16
also comprises a tucking station
132
to position leading edge
122
of fabric web
24
into a position to form another fabric roll about spindle
52
.
Referring to
FIG. 5E
, shear blade
118
is retracted and tucking roller
126
continues rotation to wind trailing edge
124
about fabric roll
114
. Tucking station
132
comprises an arm
133
to engage leading edge
122
of fabric web
24
and position leading edge
122
about spindle
52
at winding station
38
in preparation for forming another fabric roll. However, tucking station
132
may also comprise other suitable methods or devices for positioning leading edge
122
of fabric web
24
adjacent spindle
52
, including, but not limited to, an air jet.
Referring to
FIG. 5F
, rewind rollers
36
are activated in the direction indicated by arrows
115
to wind fabric web
24
about spindle
52
to form a fabric roll
134
. As described above, spindle carrier
92
disengages spindle
52
at winding station
38
to allow movement of spindle
52
to accommodate formation of fabric roll
134
. As illustrated in
FIG. 5F
, spindle
52
moves upwardly away from the nip of winding rollers
36
to accommodate an increase in diameter of fabric roll
134
.
Referring to
FIG. 5G
, turret
46
indexes and transfers spindle
48
and fabric roll
114
from tucking station
42
to stripping station
44
along hypocycloidal path
110
, spindle
52
and fabric roll
134
from winding station
38
to tucking station
42
along hypocycloidal path
108
, and spindle
50
from stripping station
44
to winding station
38
along hypocycloidal path
112
. As illustrated in
FIG. 5G
, shear blades
116
and
118
have been releasably engaged to separate fabric web
24
from fabric roll
134
, thereby forming leading edge
122
of fabric web
24
and trailing edge
124
of fabric roll
134
. Trailing edge
124
may then be wound about spindle
52
and fabric roll
134
using tucking roller
126
.
Referring to
FIG. 5H
, stripping station
44
comprises one or more paddles
136
to remove fabric rolls formed on spindles
48
,
50
, and
52
. Paddles
136
each comprise fingers
138
that extend across and straddle spindles
48
,
50
, and
52
adjacent fabric rolls formed on spindles
48
,
50
, and
52
. In operation, paddles
136
are translated along spindles
48
,
50
, and
52
to slide and remove the fabric rolls from spindles
48
,
50
, and
52
.
Paddles
136
may be coupled to a belt
140
for repeated positioning and translating of paddles
136
in stripping station
44
. For example, referring to
FIG. 1
, belt
140
may be driven in a direction indicated by arrow
142
to remove fabric rolls from spindles
48
,
50
, and
52
. Belt
140
may be driven at a speed and with various quantities of paddles
136
to correspond with indexing of turret
46
. However, other suitable methods or devices may be used for repeated stripping of fabric rolls from spindles
48
,
50
, and
52
. Fabric rolls may then be transferred to a conveyor
144
or other suitable transfer device or method to transport the fabric rolls to additional processing stations.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made therein without departing from the spirit and scope of the present invention as defined by the appended claims.
Claims
- 1. A method for producing coreless fabric rolls comprising:winding a fabric web onto one of a plurality of spindles to form a coreless fabric roll at a first station, the spindles coupled to a turret; transferring the spindle, after winding the fabric web onto the spindle, from the first station to a second station along a generally hypocycloidal path; separating the coreless fabric roll from the fabric web; forming a leading edge of the fabric web and a trailing edge of the coreless fabric roll; winding the trailing edge about the coreless fabric roll at the second station; transferring the spindle from the second station to a third station along a generally hypocycloidal path; and removing the coreless fabric roll from the spindle at the third station.
- 2. The method of claim 1, further comprising:securing the spindle in a first position relative to the turret; and releasing the spindle at the first station to provide movement of the spindle from the first position to a second position during forming of the coreless fabric roll.
- 3. The method of claim 1, wherein the removing step comprises disposing a paddle adjacent an end of the coreless fabric roll and translating the paddle along the spindle.
- 4. The method of claim, 1, further comprising tucking the leading edge of the fabric web adjacent another spindle disposed at the first station.
- 5. The method of claim 1, wherein the separating step comprises activating a shear blade disposed between the first and second stations to sever the fabric web from the coreless fabric roll.
- 6. The method of claim 1, further comprising:providing the fabric web from a feed station at a substantially constant feed rate; and accumulating a reserve portion of the fabric web while the spindle is transferred from the first station to the second station.
- 7. A system for producing coreless fabric rolls comprising:a hypocycloidal turret having a plurality of spindles; a winding station operable to wind a fabric web onto one of the spindles to form a coreless fabric roll; a cutting station operable to separate the coreless fabric roll from the fabric web to form a leading edge of the fabric web and a trailing edge of the coreless fabric roll; a tucking station operable to wind the trailing edge about the coreless fabric roll; a stripping station operable to remove the coreless fabric roll from the spindle; and a control system operable to transfer each of the spindles to the winding, tucking, and stripping stations along a generally hypocycloidal path.
- 8. The system of claim 7, wherein the turret further Comprises a spindle carrier coupled to each of the spindles to secure each of the spindles in a first position, and wherein the control system is further operable to disengage the spindle carrier from the spindle to provide for movement of the spindle from the first position to a second position in response to forming the coreless fabric roll.
- 9. The system of claim 7, further comprising:a feed station operable to provide the fabric web at a substantially constant feed rate; and an accumulator operable to accumulate a reserve portion of the fabric web as the spindles are transferred between each of the winding, tucking, and stripping stations.
- 10. The system of claim 9, wherein the accumulator is further operable to discharge the reserve portion of the web during forming of the coreless fabric roll.
- 11. The system of claim 7, wherein the stripping station comprises a paddle having a plurality of fingers, the fingers operable to extend over the spindle, and wherein the control system is further operable to translate the paddle along the spindle to remove the coreless fabric roll from the spindle.
- 12. The system of claim 7, wherein the cutting station comprises a shear blade, and wherein the control system is further operable to activate the shear blade to separate the coreless fabric roll from the fabric web while the spindle is disposed at the tucking station.
- 13. A method for producing fabric rolls, comprising:providing a fabric web at a substantially constant feed rate; moving a first spindle of a turret to a first station; accumulating a reserve portion of the fabric web during movement of the first spindle to the first station; discharging the reserve portion to the first station to form a fabric roll about the first spindle; transferring the first spindle from the first station to a second station along a generally hypocycloidal path; accumulating a next reserve portion of the fabric web during transfer of the first spindle from the first station to the second station; moving a second spindle of the turret to the first station; separating the fabric roll from the fabric web; winding a remaining portion of the fabric web about the fabric roll at the second station; discharging the next reserve portion to the first station to form another fabric roll about the second spindle; transferring the first spindle from the second station to a third station along a generally hypocycloidal path; and removing the fabric roll from the first spindle at the third station.
- 14. The method of claim 13, wherein accumulating the reserve portion comprises:receiving the fabric web from a feed station at a plurality of festoon rollers; and moving the festoon rollers away from each other to accumulate the reserve portion.
- 15. The method of claim 14, wherein discharging the fabric web comprises moving the festoon rollers toward each other to discharge the reserve portion.
- 16. The method of claims 13, wherein moving the first spindle comprises moving the first spindle to the first station following a substantially hypocycloidal path.
- 17. The method of claim 13, further comprising:receiving the reserve portion of the fabric web at a plurality of rollers of the first station; disposing a portion of the fabric web adjacent the first spindle; and rotating the plurality of rollers to form the fabric roll about the first spindle.
- 18. A method for producing fabric rolls, comprising:disposing a spindle of a turret adjacent a plurality of winding rollers in a winding station; providing a fabric web from a feed station to an accumulator at a first feed rate; providing the fabric web from the accumulator to the winding station at a second feed rate; rotating the plurality of winding rollers to wind the fabric web about the spindle at the winding station to form a fabric roll; transferring the spindle from the winding station to a tucking station following a substantially hypocycloidal path; reducing the second feed rate to less than the first feed rate during transfer of the spindle from the winding station to the tucking station; and accumulating a reserve portion of the fabric web at the accumulator when the second feed rate is less than the first feed rate.
- 19. The method of claim 18, further comprising discharging the reserve portion when the second feed rate is greater then the first feed rate.
- 20. The method of claim 18, wherein accumulating comprises:receiving the fabric web at a plurality of festoon rollers of the accumulator; and moving the festoon rollers away from each other to accumulate the reserve portion.
- 21. The method of claim 20, further comprising discharging the reserve portion from the accumulator by moving the festoon rollers towards each other when the second feed rate is greater than the first feed rate.
- 22. The method of claim 18, wherein winding comprises:releasing the spindle to a first position adjacent a plurality of rollers in the winding station; rotating the rollers to wind the fabric web about the spindle, the spindle moving from the first position to a second position in response to an increasing thickness of the fabric roll; and securing the spindle at the second location for transfer from the winding station.
- 23. A system for producing a fabric roll, comprising:a feed station operable to provide a fabric web at a substantially constant feed rate; a turret operable to intermittently move each of a plurality of spindles into a winding station, a tucking station, and a stripping station through a substantially hypocycloidal path; the winding station operable to wind the fabric web about one of the spindles; and an accumulator operable to accumulate a reserve portion of the web during movement of the spindles relative to the winding station, the accumulator is further operable to discharge the reserve portion of the fabric web to the winding station after another of the spindles is positioned at the winding station.
- 24. The system of claim 23, wherein the accumulator comprises a plurality of festoon rollers, the festoon rollers operable to receive the fabric web from the feed station and move away from each other to accumulate the reserve portion.
- 25. The system of claim 24, wherein the festoon rollers are further operable to move towards each other to discharge the reserve portion to the winding station.
- 26. The system of claim 23, wherein the winding station comprises a plurality of rollers operable to wind the fabric web about one of the spindles, and wherein the turret comprises a spindle carrier operable to disengage one of the spindles to dispose one of the spindles into a first position adjacent the rollers, the spindle carrier operable to reengage the one spindle in a second position after forming the fabric roll, the one spindle moving from the first position to the second position in response to an increasing diameter of the fabric roll.
- 27. A system for producing a fabric roll, comprising:a turret having a plurality of spindles, the turret operable to intermittently move each of the plurality of spindles into a winding station, a tucking station, and a stripping station through a substantially hypocycloidal path; a feed station operable to provide a fabric web at a first feed rate; the winding station operable to receive the fabric web at a second feed rate and wind the fabric web about the spindles; and an accumulator operable to receive the fabric web from the feed station and transfer the fabric web to the winding station, the accumulator further operable to accumulate a reserve portion of the fabric web when the second feed rate is less than the first feed rate.
- 28. The system of claim 27, wherein the accumulator is further operable to discharge the reserve portion to the winding station when the second feed rate is greater than the first feed rate.
- 29. The system of claim 27, wherein the accumulator comprises a plurality of festoon rollers operable to move away from each other to accumulate the reserve portion.
- 30. The system of claim 29, wherein the festoon rollers are further operable to move toward each other to discharge the reserve portion to the winding station.
- 31. The system of claim 27, wherein the turret further comprises a spindle carrier coupled to each of the spindles, each spindle carrier operable to provide for movement of the spindle during formation of the fabric roll in response to an increasing size of the fabric roll.
- 32. The system of claim 27, wherein the winding station comprises a plurality of rollers operable to rotate relative to one of the spindles to wind the fabric web about the one spindle.
- 33. The system of claim 32, further comprising an arm operable to position a portion of the fabric web in a nip defined by one of the spindles and one of the plurality of rollers in preparation for rotation of the rollers.
- 34. A method for producing coreless fabric rolls comprising:providing a fabric web to a winding station having a winding roller; rotating a turret having a plurality of spindles to dispose one of the spindles at the winding station; positioning a portion of the fabric web proximate a nip defined by the spindle and the winding roller; rotating the winding roller to wind the fabric web onto the spindle at the winding station to form a coreless fabric roll; separating the coreless fabric roll from the fabric web; and removing the coreless fabric roll from the spindle.
- 35. The method of claim 34, wherein providing the fabric web comprises providing the fabric web at a substantially constant feed rate, and further comprising accumulating a reserve portion of the fabric web during rotation of the turret.
- 36. The method of claim 35, further comprising discharging the reserve portion to the winding station after positioning one of the plurality of spindles at the winding station.
- 37. The method of claim 34, wherein removing the fabric roll comprises disposing a paddle adjacent the fabric roll and translating the paddle along the one spindle.
- 38. The method of claim 34, further comprising:disengaging the one spindle to position the one spindle in a first position adjacent the roller; and reengaging the one spindle at a second location after formation of the fabric roll, the one spindle moving from the first location to the second location in response to an increasing size of the fabric roll.
- 39. The method of claim 34, wherein rotating the roller comprises rotating the roller to form a plurality of coreless fabric rolls on the one spindle, and wherein removing comprises removing each of the plurality of fabric rolls from the one spindle.
US Referenced Citations (27)
Foreign Referenced Citations (1)
Number |
Date |
Country |
9640578 |
Dec 1996 |
WO |