System and method for producing coreless fabric rolls

Information

  • Patent Grant
  • 6425547
  • Patent Number
    6,425,547
  • Date Filed
    Tuesday, August 31, 1999
    25 years ago
  • Date Issued
    Tuesday, July 30, 2002
    22 years ago
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.
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