1. Field of the Invention
The present invention relates to a web tensioning assembly configured to exert a tension on a web in a process direction and to balance the tension across a width of the web extending substantially in a direction perpendicular to the process direction. The present invention also pertains to a web processing apparatus comprising such a web tensioning assembly.
2. Description of Background Art
Web tensioning assemblies that exert a tension on a web in a process direction are known in the background art. An example of such assembly is a suspended roller assembly. Such assembly comprises a roller rotatably mounted on an axis that is mounted on two linkages, which are mounted freely rotatable in a frame. If the web is fed in a curve around such a roller, the position and weight of the roller exerts a tension on the web in the feed direction. Such arrangement call; however, not account for differences in path length across the width of the web, resulting in a variation in tension across the web.
It is an object of the present invention to provide a web tensioning assembly for applying tension in a process direction that takes into account differences in path length across the width of the web. To this end a web tensioning assembly according to an embodiment of present invention for tensionably guiding a web in a web processing apparatus, comprises an elongated torsion-resilient element extending in an axial direction having at least two opposing axial end portions; a suspension that suspends said elongated torsion-resilient element, the suspension comprising a first and second suspension linkage, each linkage being non-rotatably connected to the opposing axial end portions of the elongated torsion-resilient element at a first portion of the first and second suspension linkages, respectively, the first and second suspension linkages being rotatably mountable to a frame at a second portion of the first and second suspension linkages, the second portion being located remotely with respect to said first portion, such that the first and second suspension linkages are independently rotatable about an axis extending substantially parallel to said axial direction; and a web guide at least partially surrounding the elongated torsion-resilient element for guiding the web over said elongated torsion-resilient element, wherein the web tensioning assembly is configured to exert a tension on the web in a process direction and to balance the tension across a width of the web extending substantially in a direction perpendicular to the process direction.
The web tensioning assembly for tensionably guiding a web in a web processing apparatus according to the present invention, takes into account applying a tension in a transport or processing direction while the web is transported along the web transport path. The web tensioning assembly comprises an elongated torsion-resilient element, which extends in an axial direction. The elongated torsion-resilient element is resilient to a torsional loading of the element. If a torsional load is applied on the elongated torsion-resilient element, e.g. an axial torsional load, the elongated torsion-resilient element may deform to a certain extent while resisting against said deformation.
The elongated torsion-resilient element is suspended on the axial end portions of the elongated torsion-resilient element on a suspension. The suspension comprising a first and a second suspension linkage, which are both non-rotatably connected to the opposing end portions of the elongated torsion-resilient element at a first portion of the first and second suspension linkages.
The first and second suspension linkages are rotatably mountable to a frame at a second portion of the suspension linkages. The second portion of the first and second suspension linkages are located remotely with respect to the first portion, thereby constituting a mechanical arm between the end portions of the elongated torsion-resilient element and the points of rotation at the second portion on which the suspension linkages are rotatably mountable to the frame.
The first and second suspension linkages are independently rotatable at the second portions of the first and second suspension linkages about an axis extending substantially parallel to the axial direction of the elongated torsion-resilient element.
The web tensioning assembly farther comprises a web guide that guides the web over the elongated torsion-resilient element. This web guide surrounds the elongated torsion-resilient element at least partially.
The web tensioning assembly is arranged such that the web tensioning assembly is configured to exert a tension on the web in the process direction and balances the tension across the width of the web. The width of the web is the width of the web in the direction extending substantially perpendicular to the process direction.
By arranging the web tensioning assembly, e.g. such that the web guide rests on the web on a position where the web transport path is curved, the arrangement of the web tensioning assembly creates a force by means of the weight of the web tensioning assembly, which is, via the mechanical arm of the suspension linkages, transferred onto the web via the web guide, thereby exerting a tension on the web in process direction. If, during operation, a difference in path length occurs across the width of the web, the web tends to curve due to path length differences of the web. By the curving of the web across the width of the web, the web may exert a non-uniform mechanical pressure on the web guide. By exerting a non-uniform mechanical pressure on the web guide, the web guide may be rotated to some extent about an axis of rotation extending parallel to the process direction. The web guide passes this rotation on to the elongated torsion-resilient element, following the rotation of the web guide. Because the elongated torsion-resilient element is non-rotatably connected to the suspension linkages, which are independently rotatable, the rotation of the web guide is transferred into a torsional deformation of the elongated torsion-resilient element. This elongated torsion-resilient element deforms to a certain extent while resisting against said deformation. This resisting against the deformation urges the web guide back to the equilibrium position thereby urging the web into its normal orientation, correcting for path length differences across the width of the web.
It is further known to correct for path length differences across a web, by using a separate gimbal assembly. Such a gimbal assembly forces a web back into its normal transport path by introducing a rotational degree of freedom in the web transport path, which is resiliently urged towards a desired equilibrium situation.
It is a disadvantage of such a gimbal assembly, that such a gimbal assembly introduces an additional degree of freedom in at least a portion of the web transport path, thereby introducing a position of uncertainty. Such a position of uncertainty in the web transport path degrades the accuracy of the web transport and introduces complexity in driving the transport means of the web transport path by means of servomotors.
Using the gimbal assembly in sequential addition to a web tensioning assembly increases the required cumulative space of these assemblies, in particular because the separate application of a gimbal assembly in sequential addition to a web tensioning assembly needs a stretch of web between both assemblies to be able to introduce the necessary degree of freedom of the web at the gimbal assembly.
The functional merging of the web tensioning function in the process direction and the balancing of the tension across the width of the web increases the quality of the web transport in the web transport path. While the application of the separate functions requires a stretch of web in between the two functions, in the present invention, both functions are merged into one location. This reduces the required space to house both functions, and reduces the stretch of the web inbetween the web tensioning in the process direction and the balancing of the tension across the width of the web. A large tension across the width of the web may result in damaging the web and even tearing of the web, thereby rendering the web possibly unusable.
In an embodiment of the web tensioning assembly according to the present invention, the web guide comprises a roller. Preferably, the roller surrounds the elongated torsion-resilient element at least partially, such that the web guide guides the web via the roller over the elongated torsion-resilient element. A roller is advantageous because this implementation for the web guide enables a simple and efficient guidance of the web, while deformations of the web due to tensional differences across the width of the web are easily passed towards the elongated torsion-resilient element.
In a further embodiment, the web tensioning assembly further comprises a bearing for moveably mounting the roller on the elongated torsion-resilient element. A bearing such as, e.g. a ball bearing, dry-running, hydrodynamic or hydrostatic bearing, enables a smooth rotation of the web guide, in particular the roller over the elongated torsion-resilient element. Thereby the web guide minimizes the influence on the motion of the transport of the web, while the web tensioning assembly applies its tension in the process direction.
In another embodiment, the roller of the web tensioning assembly is freely rotatable about an axis of rotation extending substantially parallel to the axial direction of the elongated torsion-resilient element. By enabling the roller to rotate freely about an axis of rotation extending substantially parallel to the axial direction of the elongated torsion-resilient element, the roller's rotation influences the movement of the web transport minimally, while the deformation of the web due to tensional differences across the width of the web are easily transferred into a resilient deformation of the elongated torsion-resilient element.
In another embodiment, the roller of the web tensioning assembly is rotatable over a limited portion of an axial revolution. The interfacing between the web and the web guide may be rolling or sliding, or any combination of these interfacing types. By allowing a partial rotation of the roller, the web tensioning assembly is prevented to apply a too large frictional shear tension on the web.
In another embodiment, the roller of the web tensioning assembly is rotatably fixed in an axial direction with respect to the suspension, thereby creating a sliding interface between the web guide and the web. The web slides along the contacting surface of the web while the web is being transported in the process direction. In case of sliding, interfacing between the web and the web guide, the contacting surface of the web guide, which contacts the web during the transport of the web in the process direction, is preferably smooth and applies a low frictional force in the process direction.
In a farther embodiment, the web tensioning assembly comprises a drag linkage extending between the frame and an eccentric location at an axial end portion of the roller, such that an axial rotation of the roller is prevented. By mounting an element, such as a drag linkage, between the frame on which the web tensioning assembly is mounted and a location of the roller, which lays at a distance with respect to the axis of axial rotation of the roller, the axial rotation of the roller is thereby prevented. It is found that locating the drag linkage at an end portion of the roller, e.g. the sides of the roller, near the outer surface of the roller, the drag linkage is most efficient, as this applies the largest mechanical arm to prevent a rotation of the roller.
In a further embodiment, the drag linkage is selectably engaged and disengaged with the roller, thereby selectably enabling a sliding or a rotating interfacing between the web guide and the web, respectively. The selection may, e.g. be implemented as a clamping of the drag linkage to the roller. When the drag linkage is clamped to the roller, the roller is prevented from rotating over the elongated torsion-resilient element, and when the drag linkage is unclamped from the roller, the roller is freely rotatable with respect to the elongated torsion-resilient element.
In another embodiment, the suspension is in operation urged towards a predetermined angular equilibrium position with respect to the frame. By applying an urging force from the frame on the suspension, the suspension will be urged towards an angular equilibrium position with respect to the frame. This is, e.g. advantageous in cases where the web tensioning assembly does not apply its tensioning of the web in process direction at a location along the web transport path where the web guide rests its full weight via the mechanical arm of the suspension on the web. The urging of the suspension, in general enables an operator to choose the tension that is applied on the web in the process direction and enables the web tensioning assembly to maintain a predetermined equilibrium position, different from the fully resting position, i.e. the situation in which the suspension is freely rotatable with respect to the frame and no urging force is applied from the frame to the suspension. The urging force from the frame to the suspension is preferably applied on both suspension linkages, but may also be applied to only one of the suspension linkage.
In a further embodiment, the suspension is spring loaded towards the predetermined angular equilibrium position. A spring enables the configuration of the equilibrium position to be carried out with a simple construction. Depending on the actual arrangement of the spring with respect to the suspension, the web guide is supported by the spring or alternatively an additional pressure is applied on the web via the web guide, e.g. may be implemented by directing the spring force in the direction of the gravitational movement of the web guide.
In another embodiment of the web tensioning assembly according to the present invention, the elongated torsion-resilient element is a torsion bar. The torsion bar is an element, which resiliently deforms under a torsional load. The relation between the deformation of the torsion bar and the torsional load may be chosen to fulfil the desired behavior of the elongated torsion-resilient element. Torsion bars may be designed to perform a deformation in linear proportional relation with the applied torsional load, or may be chosen to have a non-linear relation with the applied torsional load. A linear relation will be appreciated in particular when the deformation, and the proportional resisting counter force or the elongated torsion-resilient element, should increase in a linear fashion when the torsional load on the elongated torsion-resilient element increases. A non-linear relation will be in particular appreciated when, e.g. the resisting counter force should only come into play when the deformation of the elongated torsion-resilient element passes a certain threshold. The elongated torsion-resilient element may consist of a single torsion bar, or may comprise a plurality of interconnected torsion-resilient sub-elements.
In a further embodiment, the torsion bar is formed such that it comprises a substantially star shaped axial cross-section. A star shaped axial cross-section of a torsion bar is in particular advantageous in configurations where the torsional load is applied in an axial direction. Such a torsion bar may be formed as a single integral part, or be constructed, e.g. by joining two or more elongated strips of metal, plastics or the like.
In another further embodiment, the torsion bar is formed such that it comprises a substantially cylindrical axial cross-section. A cylindrical formed axial cross-section of a torsion bar is in particular advantageous in configurations where the torsional load is applied in an axial and/or in process direction. Cylindrical torsion bars have in general a very simple construction and may be relatively cheap.
In another embodiment, the suspension is functionally connected to an angular position encoder, such that the angular position of the suspension with respect to the frame is measurable. By monitoring the angular position of the suspension linkages, the behavior of the web guide can be monitored. If the behavior occurs to be extraordinary, this may point out that something should be adapted in the processing of the web. Alternatively, this may be used to detect an absence of a web under the web guide, in particular in configurations where the web guide rests on the web, an absence of such a web is easily detectable using an angular position sensor measuring the position of the suspension linkages. Such a sensor may be implemented on one of the suspension linkages or on a plurality thereof.
In another aspect, the present invention pertains to a web processing apparatus, comprising a web feed station for feeding a web, a web processing station for processing the web and a web tensioning assembly according to the present invention.
In a further embodiment of this aspect of the invention, the web processing apparatus comprises a printing station for applying marking material to the web. It is important in such stations to provide the web in a defined fashion and therefore the web should be delivered under a certain tension in process direction, while the differences in path length and tension across the width of the web should be balanced to perform a printing operation on defined positions of the web.
In a further embodiment of this aspect of the invention, the web processing apparatus comprises a recording station for recording an image from the web. It is important in such stations to provide the web in a defined fashion and therefore the web should be delivered under a certain tension in process direction, while the differences in path length and tension across the width of the web should be balanced to perform a recording operation on defined positions of the web.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
The present invention will now be described with reference to the accompanying drawings, wherein the same reference numerals have been used to identify the same or similar elements throughout the several views.
The printing device 10 further includes an interface assembly 20. The interface assembly 20 is configured for connecting a roll-to-roll web processing device to the printing device 10 such that the printing device 10 is enabled to print on a media that is supplied from a roll instead of a medium that is positioned on the printing surface 14, although it is noted that in an embodiment the medium that is supplied from a roll may be moveably supported by, guided over and positioned on the printing surface 14. In such an embodiment, the medium may be transported from a supply roll arranged at a first side of the printing surface 14 to a media receiving roll arranged at a second side of the printing surface 14. Hereinafter, an embodiment, which is illustrated in the drawings, is elucidated, in which embodiment a media supply roll and a media receiving roll are arranged at one side of the printing surface 14.
For printing, the medium supplied from a roll arranged in the roll-to-roll web processing device 22 is guided through the roll-to-roll web processing device 22 such that the media is moveably supported by and positioned on a media printing surface 30, possibly provided with a device that holds the medium substantially flat on the media printing surface 30. Such holding device may include, but is not limited to, a suction device. For guiding, one or more medium guiding rolls may be provided. For example, a first guiding roll 32A and a second guiding roll 32B may be provided. The second guiding roll 32B, in combination with mechanisms 40A and 40B form a web tensioning assembly according to the present invention.
One or both media rolls may be driven by a motor 36, for example through the media roll supporting device 28 supporting the media roll. In
Flanges 59A and 59B are rotatably mounted over the torsion bar 55, as well as roller carrier flanges 58A and 58B. The flanges 58A, 58B, 59A and 59B are mounted on the torsion bar 55 by means of a dry-running plastic bearing bushing 52. Flange 59A and roller carrier flange 58A are non-rotatably connected to each other by means of bolts, just as the opposing pair of flanges.
Suspension linkage 49A is connected to an angular position sensor 56, which measures the angular orientation of the suspension linkage 49A. The signal of the sensor 56 is fed to a signal processing unit (not shown).
The rotation of the coupled flanges 59B and 59A is prevented by drag linkage 51, which is connected to the frame 45B and a portion of the flange 59B remote from the axis of rotation.
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In the situation of
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In practice, it shall be clear that both the effects of
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 60/960,952, filed on Oct. 22, 2007, the entirety of which is expressly incorporated herein by reference.
Number | Date | Country | |
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60960952 | Oct 2007 | US |