TURN-UP PAPERBAND GUIDE WITH VARIABLE TENSION CONTROL

FIELD OF THE DISCLOSURE

The present disclosure relates to methods and apparatus form improved turn-up processes on a paper manufacturing machine. More specifically, the present disclosure presents methods and apparatus for controlling an amount of tension experienced by a paperband during a turn-up procedure on a paper making machine.

BACKGROUND OF THE DISCLOSURE

The modern industrial paper machine includes a continuous manufacturing process that forms a sheet of paper and winds the newly formed sheet of paper on a steel spindle or spool sometimes coated with a rubber or fibrous sheath and drum spinning with significant force as the paper roll reaches a desired maximum diameter. In order to transfer the collection of the newly formed sheet of paper from a first spool with full roll of paper to an empty spool that will continue to wind the paper requires a turn-up process. The turn-up process severs the moving paper and transfers it to the empty spool. Typically, a transfer turn-up tape is extended across a width of the newly formed paper roll and used to sever the paper.

Deployment of turn-up tape, also called paperband, has constraints on how fast the paperband may be deployed without jamming. Consequently, known turn-up processes have inherent risks that diminish efficiency using the paper making machine. Nevertheless, paperband-based turn-up systems for the paper industry have made significant contributions to improving plant efficiency (salable tonnage), which in turn moderately reduces the plant's environmental impact. It may also be argued that the greatest and most important contribution to the industry by automated turn-up systems is dramatically improved safety for reel section paper machine operators.

The technology of paper making is continually improving and advancing and in general, these advancements increase the level of complexity for performing turn-up operations. As a non-limiting example, production is performed on increasingly wider and faster paper machines. Recent efforts to integrate the most advanced paperband-based turn-up systems with these modern paper machines have had mixed results. Thus, the industry is developing a need for even greater sophistication in turn-up systems. It would, therefore, be desired to have a more sophisticated, reliable and efficient method for supplying turn-up paperband during a turn-up process.

SUMMARY OF THE DISCLOSURE

The present invention provides for improved function, performance and overcoming of shortcomings of advanced paperband-based turn-up systems. Methods and apparatus enable adjustment of an amount of tension experienced by a paperband that is being deployed during a turn-up procedure on a paperband machine.

In one aspect, an apparatus for deploying a paperband for a paper machine turn-up operation includes a cross track, and the cross track includes at least a first internal slot for the paperband to move upon and an attaching feature to affix at least a first apron to a surface proximate to the first internal slot. The first apron may lie across a surface above the location for the paperband, and the first apron may interact with and contact the paperband when the paperband is pulled out of the cross track during a paper machine turn-up operation. An apron tensioning device may provide an additional force against at least an edge of the surface of the first apron. A curve track may hold the paperband at an angle to an axis of the cross track. A paperband feeding device may advance the paperband during at least an initial portion of a turn-up operation.

The apparatus may also include an attaching feature with an apron holding slot along the length of the cross track. The first apron may include a portion of its body that fits within the apron holding slot.

In some embodiments, the tensioning device includes a second apron The second apron may be affixed to the cross track and the second apron may contact at least a portion of the first apron. Still further, in some embodiments, additional tension additional is applied to the paperband when the paperband exits the cross track and the paperband contacts at least a portion of a surface of the first apron.

In some embodiments, the apron tensioning device may include a bladder. In such embodiments, the bladder may be held over at least a first surface of the first apron and the bladder may be held in place by a bracket affixed to the cross track. The bladder may contact at least a portion of the first apron, and apply additional tension to the paperband when the paperband exits the cross track contacts a surface of the first apron.

In some embodiments, the bladder may be molded to the first apron. The attaching feature may include an apron holding slot along the length of the cross track. A first apron may include a portion of its body that fits within the apron holding slot. The bladder may contact at least a portion of the first apron and apply additional tension to the paperband as the paperband exits the cross track.

In some embodiments, the apparatus may also include a bar with a length approximately equal to a width of a spool of the paper making machine. The bar may be positioned between the cross track and the spool. The paperband may contact the bar as the paperband is drawn through a nip.

The apparatus may also include further includes a pair of bars with a length approximately equal to a width of a spool. The pair of bars may be positioned between the cross track and the spool such that the paperband passes between the pair of bars as the paperband is drawn into a nip.

The apparatus may also include where the cross track further includes a gas system to pressurize at least a portion of the cross track that supports the paperband. Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.

In some embodiments, the present invention includes methods of deploying a paperband during a paper machine turn-up operation. The method may include the step of loading a paperband into an apparatus and deploying the paperband during the turn-up operation. The paperband may be deployed via a cross track.

The method may also include holding a bladder over at least a first surface of the first apron and where the bladder is held in place by a bracket affixed to the cross track and contacting at least a portion of the first apron with the bladder to apply additional tension to the paperband when the paperband exits the cross track and when the paperband contacts at least a portion of a surface of the first apron.

The method may also include connecting the bladder to a gas control system and controlling an inflation status of the bladder.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a paper processing system with an Empty Web Spool set up and positioned for paper web transfer.

FIGS. 1A-1E illustrate aspects of paperband location for attachment during turn-up of a paperband according to some embodiments the present invention.

FIGS. 2A-2B illustrate aspects of paperband attachment and evolution during turn-up of a paperband along with sensitivities according to some embodiments the present invention.

FIGS. 3A-3D illustrate aspects of tracks for turn-up tape dispensers according to some embodiments the present invention.

FIG. 4A-4B illustrates aspects of paperband attachment and evolution during turn-up of a paperband along with sensitivities according to some embodiments the present invention.

FIGS. 5A-5D illustrate aspects of curve tracks for turn-up tape dispensers according to some embodiments the present invention.

FIGS. 6A-6F illustrate aspects of bars for turn-up tape dispensers according to some embodiments of the present invention.

FIG. 7 illustrates aspects of bars and tracks for turn-up tape dispensers according to some embodiments of the present invention.

FIGS. 8A-8C illustrate additional aspects of bars and tracks for turn-up tape dispensers according to some embodiments of the present invention.

FIGS. 9, 9A-9K illustrate aspects of tensioning devices and associated track designs.

FIGS. 10A-10D illustrate aspects of adjustable tensioning devices and associated track designs.

FIGS. 11A-11B illustrate alternative examples of tensioning devices and associated track designs.

DETAILED DESCRIPTION

The present invention provides methods, devices, features and apparatus for an improved paper machine turn-up apparatus and turn-up process, and in particular improvements that enable setting a paperband tension during a turn-up process. Specific examples and embodiments of the improvements are defined herein to provide enablement of the inventions claimed, however, alternatives and modifications of the provided examples that are consistent with the claimed innovations are within the scope of the present disclosure.

Referring to FIG. 1, apparatus included in a Paper Making Machine 100 involved in a Paper Turn-Up Process are illustrated. An Empty Web Spool 101 is positioned to receive the Paper Web 103 as it is moved by the Empty Web Spool 101 in the direction as shown by the arrows. The Parent Web Spool 102 is approaching its capacity to take up the Paper Web 103.

In an exemplary procedure an operator of a Paper Making Machine 100 with an associated turn-up tape dispensing apparatus (as described herein with reference to FIGS. 1A-8B) may begin with initiation of a load cycle by closing a load switch. The Paper Making Machine 100 may be producing paper and spooling it onto a Parent Web Spool 102 which may be nearing a full state.

A feed of the Paperband 105 into a transverse track may be initiated to start a turn-up process. In many examples, the feeding of the Paperband 105 may be integrated with other control systems on the other portions of the Paper Making Machine 100. Thus, initiation may occur automatically or may occur in response to an operator's action such as the pressing of a button. Initiation may cause a feed press (not illustrated in FIG. 1) to pinch the Paperband 105.

A feed actuator (not illustrated in FIG. 1) may cycle to advance the Paperband 105 towards an Empty Web Spool 101 to which it will attach. The feed actuator may have a programmed amount of stroke to move the turn-up tape, which may depend on aspects of the Paper Making Machine 100 such as, for example, the paper making machine's width and speed.

Sensor 112 may be used to detect an end of stroke of a piston deploying a Paperband 105 and a turn-up process may occur, after which the turn-up system may reset the Sensor 112 to prepare for a next turn-up operation.

In some embodiments of the present invention, a turn-up procedure failure may be caused by one or more adverse conditions, such as, for example, a load position may be closer than optimal to one or more of: an Empty Web Spool 101, a Parent Web Spool 102, and a Nip 104 between an Empty Web Spool 101 and a Parent Web Spool 102. The load position may be closer, for example if the mechanism is adjusted more closely than optimal, if a paper band extends further than optimal, or a condition that allows for a sequence of mechanical events to occur with less than optimal timing.

For example, if a load position is closer than an optimal load position during a turn-up procedure, a paperband may enter a Nip 104 between the Empty Web Spool 101 and Parent Web Spool 102 before the actuator completes its cycle. When this happens, the feed nip may release. A brake may be applied after the Nip 104 between the Empty Web Spool 101 and Parent Web Spool 102 begins to pull paperband from the track. A resulting ‘brake delay’ may be desirable for the paperband to wrap farther around the spool before applying tension to initiate the turn-up.

In some embodiments, a Feed Actuator Sensor 112 may be positioned beyond the end of an ideal stroke. In such examples, the Feed Actuator Sensor 112 may not see the piston at the end of an ideal stroke. In the event that the feed actuator fails to see the piston at the end of the ideal stroke, a control circuit of the turn-up tape distribution system may not appropriately change a state of the turn-up tape distribution system, resulting in the feed press remaining engaged. In these examples, the brake may not engage, and an entire length of paperband may be pulled through the nip without performing the turn-up.

Alternatively, in some examples, the Feed Actuator Sensor 112 may be positioned before the end of stroke. In such examples, in a typical configuration, the feed press and brake valves may cycle simultaneously and instantaneously as the piston passes the Sensor 112. This action may occur so quickly that neither the press nor brake change state. In some cases, the feed actuator may complete its stroke, and again the brake may not be applied. In such cases, the aberrant result that ensues may be that the entire length of paperband may be pulled through the nip without performing the turn-up.

In some exemplary embodiments, an Empty Web Spool 101 may have been formed, or may wear in such a way that it exhibits crowning, where the thickness at its center is higher than at its edges. An Empty Web Spool 101 in use may be designed for other systems to have such a crown. In these non-limiting examples, edges of a paper web being processed may become loose and/or flutter which may complicate a turn-up procedure. In some extreme cases, crowning of an Empty Web Spool 101 surface is excessive, such that there may not be enough nip pressure to compress the center of the crown and edges of the Empty Web Spool 101 may not make sufficient contact with the reel drum to pull the paper web and keep its edges taught.

Furthermore, in such examples, even if the Empty Web Spool 101 contacts a Parent Web Spool 102 all the way across, a smaller diameter of ends of an Empty Web Spool 101 relative to the Empty Web Spool 101 center may contribute to slack at an edge portion of the web where the spool circumference and surface feet per minute, are lower than at the center. In such examples where the web edges are so effected, a result may be that the loose edges of the sheet may cause the sheet to pull out from under the paperband.

In some further examples of crowned spools, and particularly for examples including a high amount of crowning, a result may be lowered pressure in a nip area that a paper tape may be applied to. For example, if a nip 104 is significantly open due to crowing an adhesive of a paperband when the paperband may not firmly adhere to the Empty Web Spool 101. In such examples, the paperband 105 may not follow the Empty Web Spool 101 in wrapping and instead just proceed through the nip 104. The paperband 105 may then just follow and be pulled through the Nip 104 without wrapping around the spool. In some procedures, where spools are found to have excessive crowning, the spool may be prepared with a wrapping of paper around the spool, such as in a non-limiting sense 2-3 inches of paper, before the spool is used. The result may be less effect of the crowning. In other examples, a procedural step may be to measure spools for crowning and then to reject them. In some examples, a strategy to improve turn-up operations may be adjustments of the angle of curve relative to trim of the turn-up tape distribution system 109.

Track Curve Adjustments

Referring now to FIG. 1A, an example of a Track Curve 107 may be observed. The general components of the Paper Making Machine 100 in a plan view perspective may include an Empty Web Spool 101, a Parent Web Spool 102, and a Paper Web 103. The Turn-up Tape Distribution System 109 may include a Paperband 105 which may include adhesive applied to its end. A Transverse Track 106 (sometimes referred to a cross machine track) of the Turn-up Tape Distribution system 109 may also include a portion of Track Curve 107. In numerous examples, the shape and position of a Track Curve 107 may be such that a paperband is positioned parallel to the trim, or perpendicular to the axis of the drum for example. Furthermore, in such examples, an end of the Track Curve 107 may be located such that it may inject the Paperband 105 outside an Edge 121 of the Paper Web 103.

Referring now to FIG. 1B, an elevation view illustrates paper making machine elements and the Turn-up Tape Distribution System 109 elements, an ideal orientation of the Paperband 105 as it enters the nip of the Parent Web Spool 102 and Empty Web Spool 101 may be as close to parallel as practical compared to the orientation of the Paper Web 103. In some examples, such an alignment may cause the paperband to exit the curve at the tip first, and the point at which the paperband exits the track progresses down the curve and across the cross-machine track to the exit point and brake.

Referring now to the inset of FIG. 1C, a close up view of a paperband in its initial phases of a turn-up operation is presented. As shown, the Parent Web Spool 102 and Empty Web Spool 101 are close together to form a Nip 110. In the Nip 110, the Paperband 105 may be attached to the Parent Web Spool 102 with Adhesive 111. As illustrated the Paperband 105 may lie outside the Edge 121 of the Paper Web 103,

A set of ideal conditions for a paper machine turn-up process may be at least partially dependent upon physical attributes of a paper web being processed. For example, during a turn-up procedure involving a thicker paper web, or a paper web that includes stronger fibers, it may be desirable to turn a tip of a track curve in toward the paper web to inject the paperband into the nip on top of the paper.

Referring now to FIG. 1D an illustration of examples for thick paper is provided. Since the example is different from the previous types of examples, the elements have different reference numbers, however, it is likely that some the elements may be similar or the same as elements referred to in the examples of FIGS. 1A-1C.

Again, in reference to FIG. 1D, a Spool 113 and a Drum 115 may be brought together to form a Nip 120 into which a Paperband 105 may be injected. A thicker Paper Web 116 may be being formed on the paper machine, and a different curve setting may be used to feed the Paperband 105 onto the Spool 113.

In the illustration of FIG. 1D, the Angle of Injection 114 at which the Paperband 105 may be pointing with reference to the Edge 122 of the thicker paper web is illustrated. In addition, it may be apparent that the Paperband 105 may be positioned under the thicker Paper Web 116 not to the side as in other examples. The inset of FIG. 1E illustrates this with a Spool 113 and a Drum 115 forming a Nip 123. The thicker Paper Web 116 may have the Paperband 105 and Adhesive 117 lying between the thicker Paper Web 116 and the surface of the Spool 113. In some examples, if the Angle of Injection 114 of the paperband is too severe, the paperband may pull taught and pops out of the belly of the curve. In these examples, the lower point of exit may then advance along the cross-machine track and at some point, the band may pull out of the tip of the curve.

Flutter of Paperband on Turn-Up

In studies of various conditions of paperband based turn-up operations, video recording of a turn-up process on a fast paper machine show various aspects, which include, for example, under certain conditions the paperband flutters as the paperband is moved, and in some examples this fluttering may cause the paperband to twist as the paperband enters the nip. Under conditions where the paperband is fluttering, a twist may be caused in the paperband as it enters the nip. In some examples, flutter may result in compressing folded or twisted paperband in the nip and weakening it sufficiently that the paperband breaks, which may cause the turn-up is missed.

In such examples a solution includes a Track Curve 107 that has a larger radius, and the tip position that is parallel to the trim, although it is still pointed in a position to cause the paperband to land on the web. The effect of such realignment may be to smooth the paperband's exit from the Transverse Track 106, encouraging the paperband to pull out of the tip of the Track Curve 107 first and discouraging it from popping out of a belly of the Track Curve 107.

Referring to FIG. 2A, an example with flutter is illustrated. As in previous examples for thick paper webs, the Paperband 210 may be inserted at a High Angle 203 to the Edge 204 of the paper web where the Drum 201 and the Spool 202 are as illustrated. With such a high angle of the curve, the Paperband 210 may immediately pull out of the Curve 205 and then introduce Flutter 206 as may be observed as the paperband proceeds down the track from Point 207 to a Next Point 208. In reference to FIG. 2B, an alternative is illustrated. The Drum 201 and Spool 202 are the same as illustrated. The Paperband 210 may be inserted with a Curve 211 of higher radius and may be placed more parallel to the trim of the system. The result may be that as the paperband is pulled during the turn-up it more smoothly leaves the curve and the track as it proceeds from Position 212 through Position 213 and to Position 214 without the introduction of flutter.

Grooves and Band Tension

During the use of paper producing machine, wear may be introduced into various components. In an example, grooves may form by various processes in the reel drum with use. In some examples, these grooves may tend to spiral out to the edges of the reel drum from the center, and these grooves may have the effect of impeding the progress of the paperband across the paper until it passes the center of the machine, at which point the grooves tend to favor the progress to the near side.

Under the scenario where grooves impede the progress of the paperband across the width of the paper web, it may be important that tension is developed in the paperband. For example, if no tension were developed in the paperband, it may be pulled from the end of the curve without advancing at all. By introducing conditions which apply tension to the paperband the result may be to cause the paperband to seek the shortest path between where it has entered the nip and whatever is applying the resistance, whether it be the track or brake of the paperband dispensing device. In many examples, the insertion point is located outboard of the point of resistance, and in these examples, the shortest line may lie at an angle to the drum-spool nip. This angle may cause the tearing of the paper to advance across the web while also encouraging the paperband to move across the width of the spool and drum as the paperband is consumed in the nip.

Several elements of the turn-up system and process may contribute to the generation of tension in the paperband between its exit from the track and the spool-drum nip. For example, the role of tension may include providing the force to pull the paperband longitudinally through the track. The tension may also provide the force to peel the paperband out of the curve, which may be called curve pull-out. The tension may also provide the force to peel out the paperband out of the track which may be called track pull-out. The tension may also provide the force to pull the paperband through the brake.

In some examples, a force required to pull Paperband 210 through the track may be affected by the length of the track, the severity of the curve. Further the force to pull the band through the track may be affected by the presence, or absence of moisture in the track coupled with how long the paperband is left in the track. Moreover, the force to pull the band through the track may be affected by the accumulation of debris in the track. The thickness and width of the Paperband 210 may also contribute. The force required to peel the paperband out of the track may also be affected by the stiffness of the paperband, the angle at which the band is leaving the track, and the speed of the paper machine.

Standard track may be provided with an apron that protects the paperband and the track from debris and moisture. It also provides for a degree of control over the paper band's exit from the track. Referring to FIG. 3A, a cross section view of a Track 303 with an Apron 301 is illustrated. As can be seen, as the paper band leaves the track it interacts with the apron which provides a frictional force to the Paperband Exiting 304 the track.

An alternative design of the track may be observed in FIG. 3B. A Second Apron 306 which may be held down by a Clamp 307 may be added up the First Apron 305. The force required to pull the band from the track can be increased by installing this second apron over the first.

Referring now to FIG. 3C, an addition of a Track Tensioning Device 310 is illustrated which may applies adjustable pressure to the track apron. A Pressurized Bladder 308 may be held in a position above an Apron 309. When the forces of the system begin to withdraw the paperband and lift the Apron 309 it may compress the Pressurized Bladder 308 which will increase the force that the apron applies to the withdrawing paperband. In some examples, the pressurized bladder may be connected to a controllable gas control system so that dynamic changes of the pressure in the bladder may be affected. In a non-limiting example, the pressure may be increased if a different processing condition motivates a changed pressure or if operational performance on prior turn-up operations indicates a desired change in the pressure on the apron.

Referring now to FIG. 3D, a version of a pressurized bladder apron device is illustrated. In some examples, the pressurized bladder apron device may be a Single Unit 312 incorporating a surface like an apron into a body that contains an envelope for contained gas. The Single Unit 312 may also include features that allow it to attach into the Track 311 without the need of additional clamping features or the like. Such a design may be considered self-fixing. In some examples, the self-fixing bladder with integral apron and drip edge may include a fixed pressurization in the bladder. As with other examples, the pressure within the body of the bladder may also include examples which may be regulated by a gas control system so that adjustments may be made to the pressure in the bladder

Increasing the tension may tend to increase the angle at which Paperband Exiting 304 a Track 303, and, therefore, may contribute to a more controlled advance of the Paperband Exiting 304 across the paper machine. A greater angle may shorten the free length of the paperband between the track and the nip, reducing flutter and twisting.

Referring now to FIGS. 4A and 4B, comparison to results from low and high tension are illustrated. For example, in FIG. 4A a low tension condition is illustrated. The Spool 402 and the Drum 404 may form a Nip 403 into which the paperband may be injected at a high angle. With little tension developed on the paperband, the forces generated as the paperband proceeds into the nip may rapidly draw a Large Free Length 405 of the paperband at a Low Angle 406 until the exited paperband rapidly reaches the brake. Although such conditions may result in smaller amounts of paperband being used, the Large Free Length 405 may cause the types of flutter conditions to be enhanced.

Referring now to FIG. 4B, a higher tension example is illustrated. A Spool 402 and a Drum 404 may form a Nip 403 into which a paperband may be injected with conditions to form high tension. The result may be that the Angle 412 that the paperband makes as it wraps may be large resulting in smaller spacing between Wraps 407. In such an example, the free length of the Paper band 409 may be relatively short and therefore have less propensity to exhibit flutter and the like and its associated failure modes of the turn-up.

These various track component additions which effect control parameters of the exit of the paperband in the track as it is pulled through the nip may help ensure that the paperband is not pulled out at the near edge of the trim. In some examples, the maintenance of the paperband in the track while it proceeds across the width of the paper machine guides the tail portions of the paperband to encourage interleaving of the paperband with accumulating layers of paper on the spool. In some examples, the control of the paperband during turn-up may prevent the tail from whipping wildly around the spool shaft.

In many examples, there may be a force applied by the brake during the turn-up that is important to realize the turn-up. For example, the tension developed as the brake holds the paperband may be important in overcoming the tear resistance of the web. Increasing brake pressure may also hastens the advancing pullout of the paperband across the machine.

In some examples, positioning of the brake along the track near the exit point shortens the length of paperband required by the turn-up. In especially fast paper machines, the friction of the paperband in the track itself, combined with the rate at which the band is consumed by the nip, especially with respect to the designs described herein may be enough to initiate and sustain the turn-up.

Improvements Providing Greater Control of Tension in Paperband Through the Turn-Up Process

In many examples, it may be important to control tension effects in a turn-up paper band and a rate at which tension upon the paperband can change. Accordingly, the present invention provides for some embodiments in which tension is gradually applied and maintained as consistently as possible throughout a turn-up process.

In some examples, a manner to do this includes balancing a multiple variables involved in the turn-up process. In general, the present invention provides for apparatus and methods that control variables involved in the turn-up process. A first variable to be controlled includes a force required to pull the paperband longitudinally through the track which may be reduced by enlarging the band path. In some examples, In some examples, it may also be increased marginally by installing a lead-in track with a hump in it. The magnitude of the hump may be increased until the resulting drag overcomes the dispenser's ability to push the paperband.

In another example, the force required to peel the paperband out of the track may be reduced by widening the throat of the track and-or removing the apron. Alternatively, the force may be increased by adding aprons or installing track tensioning devices that may hold the apron down.

In some examples, controls of the force to pull the paperband through and around the exit point may be affected by the radius the paperband must negotiate. In some examples, the smaller the radius, the greater the force—all other factors remaining the same. In other examples, large radii may add surface area, which may eventually become a factor.

In still further examples, a force required to pull the paperband through the brake may be adjusted by air pressure. However, in practice low pressure adjustments may be impractical due to unreliable performance at low pressures, such as below approximately 20 P.S.I.

Experimentation and analysis performed with various examples as have been described herein demonstrates that in some embodiments of the present invention, operation of turn-up tracks in high speed machines does not require use of the brake function. According to the present invention, under high speed operations of a paper machine, a force to pull a paperband through the dispenser mechanism and through the track may be enough to initiate and propagate the turn-up. Consequently, it may be possible to remove brake drag from the sum of forces by not actuating the brake. This also reduces one change in the developed tension through the duration of the turn-up event, potentially eliminating one cause of paperband breakage.

In studies, applying brake pressure increases the rate of the paperband pull-out which may result in decreasing the angle, and lengthening the uncontrolled span from track to nip, and potentially increasing flutter and twisting. In contrast then, in some examples reducing the brake pressure may decreases the advance of the pullout, increase the angle, and shorten the uncontrolled span of paperband as illustrated previously.

In some examples, increasing the stiffness of a track apron may further slow an advance of the pullout, increase the angle and shorten the uncontrolled span. However, in some examples increasing the angle, such as to approaching 90 degrees may slow the advance of the pullout across the paper machine and may increase the paper band's tendency to follow the drum grooves. The shallower the angle, which may be adjusted by increasing brake pressure and having a soft apron, the more the condition may hasten the advance of the pullout, which may allow the paperband to overcome the grooves by approaching the nip at a high angle to the circumferential grooves. Again, these conditions may increase the propensity for the paperband to flutter.

Curve Aprons

Additional improvement may be obtained by controlling tension of the paperband during turn-up processing. In some examples, improvement may be obtained by reducing changes in tension throughout the turn-up event. For example, in some examples, improvement may be obtained by continuing the apron along the lower portion of the curve track which could reduce or eliminate the transition in tension from curve pull-out where aprons are typically absent, to track pull-out where aprons are traditionally used. In some examples, a clip that secures the apron to the curve may be used.

Referring now to FIG. 5A, Clips 502 may be used to hold an Apron 501 to a curve track. In an example, the clips may be used 3 to 4 inches to have as smooth an effect as possible. Although the clips and the geometry of the curve accommodate only one apron, there may be a second track apron extended along the curve.

Referring to FIG. 5B, a curve track is illustrated with multiple aprons such as a First Track Apron 508 which may extend to a Point 505 and a Second Track Apron 507 which may extend to a Point 506.

Referring to FIGS. 5C and 5D, the examples may also have an improved transition aspect by cutting the ends of aprons at an angle. In FIG. 5C the example of a single apron may have an Angle 509 at the end. And, in FIG. 5D, both aprons may have angles cut out as shown in the angle of the First Apron 510 and the angle of the Second Apron 511.

Smoothing the Effect of the Brake

In many examples, the standard brake mechanism for a Turn-up Tape Distribution System 109 may include an air cylinder with a shoe pressing the paperband against an anvil, which may present a constant effect. For example, in cases where the other aspects of the turn-up system present significantly different degrees of resistance, the constant resistance of the brake may result in a stress when the break becomes activated that could overcome the tensile strength of the paperband, which could result in turn-up failures as have been described. An alternative may be to replace the piston based brake system with an idle wheel and a nip roll. Increasing pressure on the nip roll may increase resistance against pulling the band through the nip. Increasing the mass of the wheel may also increase its resistance to acceleration. The combined effect may smooth the jerkiness in tension as the turn-up process advances through its stages.

The Use of Bars to Minimize the Effect of Flutter

The length of free paperband between the cross-machine track and the drum-spool nip has been discussed, especially in relation to how this distance allows the paperband to twist. A solution to this may be a pair of bars aligned in parallel or near parallel positions. In some examples, the parallel bars may be positioned approximately two-thirds of the distance between the cross-machine track and the drum-spool nip, and lying parallel to the nip.

Referring to FIG. 6A a parallel bar example is illustrated. A Spool 601 and Drum 602 may be positioned to form a nip into which paperband is injected. The Paper Web 603 may be advanced along a Lead In Roller 604. The Paperband 606 may be deployed between the parallel bars which may be called Tension Bars or Bars 605. The Bars 605 may be positioned relative to one another to prevent twisting of the band by requiring the paperband to run over the first and under the second, or vice versa. As discussed, preventing the band from twisting may reduce the risk of crushing and breaking the paperband in the nip.

In some examples, the distance between, and therefore the resistance presented by, the bars may be adjusted in sequential zones that flow seamlessly from one to the next.

Referring now to FIG. 6B an illustration of bars with Adjusted Sequential Zones 607, 608 and 609 which have different distances providing for nearly infinite adjustability to compensate for, augment, or supplant the tension imparted by the system's curve and cross-machine tracks, and the presumably abrupt changes in tension caused by aprons, accessories, exit points and brake mechanism.

The function of these bars may be enhanced by the opportunity to install them close to the drum-spool nip, between the frames of the paper machine, whereas the turn-up system dispenser and cross-machine beam must be mounted in a clear path across the entire width of the paper machine. Referring to FIG. 6C, an illustration is made to show the ability to position the bars close to the drum spool nip. A Spool 601, a Drum 602 and an Advancing Paper Web 611 is illustrated with a Lead In Roller 612 for example. The system may include a Track 614 with aprons as have been described. A paperband with Flutter 613 may pass through the Bars 605 which may be at a Distance 610 close to the Spool 601, Drum 602 nip much closer than other elements of the system.

Proceeding to Furthermore, the bars may be shaped and positioned to pass above and below the curve track to facilitate the transition of the band path from the track to that defined by the bars. The bars may also be adjusted to present an irresistible stop to the paper band's advance across the paper machine, acting as a second exit point.

In some examples such as in FIG. 6D the Leading Bar 625 and the Second Bar 626 may be positioned such that the Leading Bar 625 is above Second Bar 626.

In other embodiments, such as in FIG. 6E, the Leading Bar 625 and the Second Bar 627 may be positioned such that the Leading Bar 625 and the Second Bar 627 are relatively even along the path of the paperband.

In some embodiments, such as in FIG. 6F, the Leading Bar 625 may be below the Second Bar 628. In some examples, the bars may be mounted immediately adjacent to the cross-machine track.

Referring to FIG. 7, the Track 701 and Apron 702 may control the release of Paperband 703. In the near proximity the Bars 704 and 705 may be located to control the paperband and to serve the purpose of smoothing transitions in tension in cases where the track lies close enough to the drum-spool nip that its position and other factors mitigate twisting of the paperband.

In some examples, only a single bar may be placed relatively close and parallel to the spool-drum nip. The curve may be positioned above the bar and the exiting paperband may then run over this bar as illustrated in FIG. 8A. Referring to FIG. 8A, a Spool 801 and Drum 802 are positioned to create a spool/drum nip. In some examples, a Cross Track 803 may have an End Curve 804 which together are used to inject a Paperband 805 into the nip. A Paper Web 808 may be driven by the paper making machine and be run into the spool and drum nip position. In some examples, a Lead In Roller 806 may interact with the Paper Web 808. In some examples, as illustrated in FIG. 8A the system may include a Single Bar 807 which may interact with the Paperband 805 to help eliminate flutter as well as improve aspects such as tension on the paperband during the turn-up processing.

Positioning the bar high enough in the reel section may prevent the paperband from contacting a grooved drum, eliminating the influence of the grooves which may first retard, and then accelerate the advance of the paperband across the web. The bar may also serve as a control point to reduce flutter in the paperband entering the nip.

Referring now to FIG. 8B, a Spool 801 and Drum 802 are positioned to create an appropriate spool/drum nip. A Single Bar 807 may be positioned at a Distance 811 close to the spool/drum nip. A Cross Track 803 may release the Paperband 810 into the spool/drum nip. The Paperband 810 may run along and interact with the Single Bar 807. In some examples, as illustrated the Paperband 810 may experience flutter between the Cross Track 803 and the nip, which may be diminished by interaction with the Single Bar 807 before it gets close to the nip. In some examples, the Paper Web 808 may run along a Lead In Roller 806 as illustrated.

Referring to FIG. 8C, the elements are illustrated in a plan view including the Spool 801, Drum 802, Cross Track 803, End Curve 804, and the Paperband 810. As illustrated, the Paperband 810 may interact with the Single Bar 807 as it proceeds through the turn-up. In some examples, the interaction of the Paperband 810 with the Single Bar 807 may introduce tension into the system. Depending on the placement of the Single Bar 807, in some examples, the tension created may be large enough to dominate other sources of tension in the system which may lead to a more stable total amount of tension as the turn-up process proceeds. As discussed herein, the cross track may have a Break 815 or roller device included to create a controllable amount of tension on the paperband end.

The various examples in this disclosure refer to a track described a cross track, which may also be referred to a cross machine track, or a track to distribute the paperband tape. A cross machine track may be formed of semi-rigid or rigid material, such as for example a metallic body. In some embodiments, a metallic cross track body may be formed of extruded aluminum. In other embodiments, a cross track body may be formed as a composite of extruded aluminum and a plastic, such as in a non-limiting example polyurethane, UHMW polyurethane or other high strength plastics. It may be important that surfaces that a paperband would slide upon may have a controlled friction aspect which may be either smooth or alternatively roughened. Since the environment of the paper making machines may have high levels of particulates, particles, fibers, humidity and other environmental constituents that can affect consistency of operation the various examples of cross tracks may include gaseous purging flows which may pressurize portions of the track. As outlined in previous sections, the tracks may include aprons to cover the top of the track. They may be involved in keeping an atmospheric pressurization within a paperband area of the cross track. In some examples, a formed cross track body may include slots, clamps with attachment features or the like to hold the one or more aprons onto the cross track. In some examples, pressurized air (or other atmospheric gas, such as an inert gas, such as Nitrogen) may provide a cushion that the paper bands may ride upon for smooth operation. These various aspects of the cross track may be included in the various examples.

Referring to FIG. 9, a First Removable Tensioner as Pop-in Tensioner 902 and a Second Removable Tensioner as Second Pop-in Tensioner 903 are illustrated in a Dual Level Track 901 which may also be referred to herein as a track or a cross track. As illustrated, the track is illustrated as a Dual Level Track 901, however the present invention may also be implemented a single level track (not illustrated) or a multi-level track with more than two tracks (not illustrated).

According to the present invention, a Removable Tensioner(s) 902-903, such as a pop-in flexible seal type tensioner illustrated, may be positioned in a pathway of a Paperband 906 deployed during a turn-up procedure. One or more physical parameters of the removable tensioner(s) 902-903 may cause an amount of resistance to a Paperband 906 as the paperband is deployed from the Dual Level Track 901 during a turn-up procedure.

In some examples, a Removable Tensioner(s) 902-903 may include a Securing Portion 900A and a Paperband Engagement Portion 900B. In FIG. 9 the Securing Portion 900A is illustrated as a first tubular length, and the Paperband Engagement Portion 900B is illustrated as a second tubular portion. The Securing Portion 900A and the Paperband Engagement Portion 900B may be held in position relative to each other with a Connection Medium 900C.

Each Tubular Length 900A-900B may have a Cavity 905 or other compressible medium that allows for portions of the Removable Tensioner(s) 902-903 to deform. Deformation may allow for a Securing Portion 900A to be compressed and pressed into a Retaining Pocket 904 of the Dual Level Track 901; and compress and allow the Paperband 906 to pass by with a frictional force pressing against the Paperband 906.

An amount of frictional force between the Removable Tensioner(s) 902-903 and the Paperband 906 may determine a tension of the Paperband 906 as the Paperband 906 is deployed during a turn-up procedure. An amount of frictional force may also be based upon a shape of the Removable Tensioner(s) 902-903, a material of the Removable Tensioner(s) 902-903, and a position of the Removable Tensioner(s) 902-903 relative to the Paperband 906; a modulus of the Removable Tensioner(s) 902-903; or other variable of an interaction between the Removable Tensioner(s) 902-903 and the Paperband 906.

A Removable Tensioner as Pop-in Tensioner 902 may protrude into the center region of the Dual Level Track 901 and thereby interact with a Paperband 906 in a first position as it is withdrawn from the track. The surface of the pop-in Tensioner 902 places the paperband in tension based on the friction between surface contact between the Paperband 906 and the Removable Tensioner(s) 902-903. As the Pop-in Tensioner 902 and the paperband develop the tension, the body of Removable Tensioner(s) 902-903 may deform in compliance from the force of the Paperband 906 against the Removable Tensioner(s) 902-903. An available amount of compliance may limit a level of tension that may develop based upon friction between the Paperband 906 and the Removable Tensioner(s) 902-903.

Referring now to FIG. 9A, a cross track with a single removable tensioner is illustrated with a Paperband 907 in the second position.

Referring now to FIG. 9B, the alternative tensioning device is illustrated where the paperband is located in a second location as illustrated by the Paperband 907 in the second position. In some examples, the paperband may release from the second position and have a similar interaction with the surface of the Pop-in Tensioner 902.

Referring to FIG. 9C, a paper manufacturing systems comprising a Tensioning Device 913 is illustrated. In a similar fashion to previous discussions a paper manufacturing system may include a Spool 908 and a Drum 910 which may form a Nip 909. The paper manufacturing system may include an Alternative Type of Tensioning Device 913 on a turn-up track. As the turn-up process occurs the paperband may form Wraps 911. The free length of the Paperband 912 may be affected by numerous processing variables including the tension on the paperband. In some examples, the tension imparted to the paperband may vary along a dimension 914 essentially along a surface of the Spool 908. For example, referring to FIG. 9D, the tension may vary along the dimension 915 along the surface of Spool 915 in a peaked manner as illustrated. There may be numerous manners to cause the tension to vary in a peaked fashion such as by varying the material property of the tensioner, or by varying the thickness of the tensioner and the like. Other profiles of tension may be programmed into the tensioning device, for example, referring to FIG. 9E, a Linearly Increasing Tension 916 may be programmed. In other examples, a Complex Increasing Tension 917 may be created in the tensioner device as illustrated in FIG. 9F.

Referring to FIGS. 9G-9K, examples of manners of altering tension in different types of pop-in tensioners 918-922 are illustrated. Referring to FIG. 9G, a pop-in tensioner 918 may include a Round Surface 923.

Referring to FIG. 9H, the shape of a feature may be varied such as with a Peaked Pop In Tensioner 919 which may have a Peaked Surface 924. The different shapes on the tensioner may vary the tension in ways that can be measured and predicted. In some examples, the shape may be varied along the direction of the track to program a varied tension profile. In some examples, the shape of the tensioner surface may be varied along the length of the tensioner to provide ability to program a tension profile along the length of the tensioner.

Referring to FIG. 9I, a Pop In Tensioner 920 may include multiple disparate materials 925-926 may form the pop-in tensioner 920. The disparate materials 925-926 may include materials of different tensioning characteristics. For example, different materials may have different elasticity modulus or stiffness may be used to form the portion of the tensioner which sits in the middle of the track. In other examples, an entire pop in tensioner may be formed of a material with a stronger stiffness, and when the paperband interacts with the tensioner it then may form more tension before the tensioner bends. In still further examples, the tensioner may be formed with different material formulations employed along the length of the tensioner. The different material formulation along the length may allow the programing of tension profiles as has been discussed.

Referring now to FIG. 9J, some exemplary pop-in tensioners 921 may include a variation in a Surface Texture 927. In some examples, the Surface Texture 927 on an arcuate surface may be varied to adjust an effective tension that the Pop-in Tensioner 921 imparts in some examples. In some examples, the Surface Texture 927 may be varied along a length of the tensioner to provide ability to program a tension profile along the length of the Pop-in Tensioner 921.

Referring now to FIG. 9K, some Pop-in Tensioners 922 may include a Different Size Surface 928 imparted to the tensioner element. In some examples, the size on the round surface may be varied to adjust the effective tension that the tensioner imparts. The size may vary along a length of the Pop-in Tensioner 922 to provide a tension profile along a length of the Pop-in Tensioner 922.

In the discussion of FIGS. 9G-9K, individual manners of effecting the tension imparted by the tension element have been discussed as discrete effects. In some examples a combination of any up to all of the effects may be utilized to control and program the tension applied by a tensioner during a turn-up process.

Referring now to FIG. 10A, an alternative example of a tensioning device is illustrated with a Track 1001 having two tension bands. In some examples, an Adjustable Track Top Holder 1002 may be configured to allow for adjustment of the overlap between a Top Tension Band 1003 and a Bottom Tension Band 1004. The portion of the bottom tension band that sticks into the space at the middle of the track and does not have a portion of the Top Tension Band 1003 in contact with it is the easier portion that can comply as a paperband is pulled during a turn-up process. Accordingly, the position of the Adjustable Track Top Holder 1002 may be adjusted.

In an example, an Adjustment Screw 1005 may be used to move the Top Tension Band 1003 forward and backward as the Adjustment Screw 1005 is advanced or retracted. In some examples, the combination of two tension bands may be located on two sides of the Track 1001. In FIG. 10A this may be observed by the Second Top Tension Band 1008, the Second Bottom Tension Band 1007, and a Second Adjustable Track Top Holder 1006. Thus, the tension applied to a paperband as it is released from the track may be adjusted on the track with adjustment screws located on either or both sides of the Track 1001.

Referring now to FIG. 10B, a perspective view is provided for the alternative example of a tensioning device illustrated in FIG. 10B. As is illustrated, there may be multiple adjustment screws that are located down the length of the track such as Adjustment Screw 1005 and Second Adjustment Screw 1009. Different tension profiles may, therefore, be created by adjustments on the tensioning screws. As has been described with respect to the pop-in tensioner examples, there may also be manners of adjusting the tension provided by the bottom tension band and its interaction with the paperband by varying the texture of the surface of the bottom tension band, the thickness of the bottom tension band, the materials that the bottom tension band comprises, and the shape of the edges of the bottom tension band which may interact with the paperband. In each of these types of tensioning modification the examples may include those where variations along the length of the tension band along the track in the particular property occur. Furthermore, in some examples two or more of these types of variations in the properties of the bottom tension band or the top tension band may be utilized to create the base level of tension of the device as well as variations in that level of tension along the length of the track.

Referring now to FIG. 10C, an illustration of the change in overlap between the Top Tension Band 1003 and the Bottom Tension Band 1004 as the Adjustment Screw 1005 is tightened. The result of the tightening may be that there is a Decreased Spacing 1010 between the edge of the Top Tension Band 1003 and the edge of the Bottom Tension Band 1004. In some examples a decrease in the spacing of these edges may result in a stiffening of the bottom tension band as it imparts tension on a paperband as it is pulled along the tensioner. Likewise, the opposite result where a reduced stiffening and a resulting decrease in the amount of tension imparted to the paperband when the spacing between the edge of the Top Tension Band 1003 and the edge of the Bottom Tension Band 1004 is increased based on loosening of the Adjustment Screw 1005. In some examples, the settings of the Adjustment Screw 1005, and others, may be performed manually. In other examples, the adjustment screws may be advanced electronically and therefore a more automatic adjustment of the screw tension may be provided. In some examples, the adjustment screw or a similar entity may be comprised of materials that may expand or contract in response to heating of the screw body. In other examples, materials may expand, or contract based on electrical settings such as may be the case with piezo electric materials. In still other examples, motor devices may apply torque to the screw to advance or withdraw the screw based on electrical signals being applied to the screw with attached motors. The expansion or contraction may adjust the spacing between the tension bands as has been discussed for manual adjustments.

Referring now to FIG. 10D, in some examples, the Track 1001 may only have a first side with an Adjustable Track Top Holder 1002 including a combination of a Top Tension Band 1003 and a Bottom Tension Band 1004. The second side may include no features or may include an Apron 1011. In some examples, the Apron 1011 may be held in place by a Holding Screw 1012 or be seated in a cavity which may hold the Apron 1011. As has been described, the various versions of tracks may be formed by various manners such as extrusion of a shape, molding of a shape, machining of a shape and the like.

Referring now to FIG. 11A, the shape that a dual level track is formed in may be varied to create different effects with a tensioner. As illustrated in FIG. 11A, the top portion of the track that holds a Pop-in Tensioner 902 may be angled at a Different Tilt Angle of Tensioner Holders 1101 than just horizontally along the body. Such a track may be called a track with angled Tensioner Holders 1102. The remaining components such as the Pop-in Tensioner 902, a Second Pop-in Tensioner 903 a Retaining Pocket 904 a Cavity 905 and a Paperband 906 in a first position may be included in a Track with Angled Tensioner Holders 1102. Such deployment of the tensioning members at tilted angles to the slot that the paperband sits in may affect numerous aspects of the dynamics of interaction between a paperband as it is pulled out of the track. For example, a larger amount of the surface of the tensioner element may interact with the paperband when it is tilted as illustrated. In general, this may be expected to increase frictional forces and increase the tension.

Proceeding now to FIG. 11B, an example of an embodiment of a track with multiple adjustable tension bands may also be angled at a Different Tilt Angle of Tensioner Holders 1101. Such a track may be called a Track with Angled Tension Holders 1103. The same components such as an Adjustable Track Top Holder 1002, a Top Tension Band 1003, a Bottom Tension Band 1004, an Adjustment Screw 1005, a Second Adjustable Track Top Holder 1006, a Second Top Tension Band 1008 and a Second Bottom Tension Band 1007 may be included with a Track with Angled Tension Holders 1103.

Various examples have been used herein to describe a cross track, also called a cross machine track, or track to distribute the paperband tape. There may be numerous designs that may be consistent with the various examples herein. In one type of example, a cross machine track may include a body formed of a metallic base. Such metallic cross track bodies may be formed of extruded aluminum. In some examples, the cross track body may be formed as a composite of extruded aluminum and plastic such as in a non-limiting example polyurethane, UHMW polyurethane or other high strength plastics. A surface that a paperband slides upon may have a controlled friction aspect which may be either smooth or alternatively roughened.

An environment of a paper making machine may have high levels of particulates, particles, fibers, humidity, and other environmental constituents that can affect consistency of operation the various examples of cross tracks may include gaseous purging flows which may pressurize portions of the track. As outlined in previous sections, the tracks may include aprons to cover the top of the track. They may be involved in keeping the pressurization within the paperband area of the cross track. In some examples, the formed cross track body may include slots, clamps with attachment features or the like to hold the one or more aprons onto the cross track. In some examples, the pressurized air may provide a cushion that the paperbands may ride upon for smooth operation. These various aspects of the cross track may be included in the various examples.

While the invention has been described in conjunction with specific embodiments, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this description is intended to embrace all such alternatives, modifications and variations as fall within its spirit and scope.

TURN-UP PAPERBAND GUIDE WITH VARIABLE TENSION CONTROL

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