Web tension equalizing roll and tracking apparatus

Abstract

An equalizing roll and web tracking apparatus to be used in manufacturing for providing equal tension across a web during winding operations such as used in polymer film applications, corrugators, paper machines, printing presses, cloth winders, and metal winding operations.The equalizing roll utilizes a common axis shaft mounted horizontally on two bearings or clamped rigid supports allowing for rotation. Mounted in the center of the axis shaft is a bearing assembly having convex and concave portions disposed within a sleeve. The bearing assembly is centrally mounted inside a hollow cylinder or roll machined to be in balance with respect to the centrally disposed bearing assembly. The mating of the concave and convex portions of the bearing permits a selected degree of lateral rotation in a range of from about 1 degree to about 10 degrees. As the web runs over the roll, any imbalance of lateral tension will cause the roll to pivot at it's center permitting the roll to move upward on the side of least tension until the web tension is equalized across the entire roll.The equalizing roll tracking apparatus utilizes an adjustable control arm assembly having a pair of adjustable pivot arms with steering arms linked to sensor arms. The distal ends of the sensor arms are in contact with the outer edges of a web, sheet, or belt of material supported by at least one idler roll and utilizing at least one equalizing roll. The steering arms float on the outer diameter of the equalizing roll. The sensor arms are pivotally linked to the steering arms so that the misalignment of the belt, sheet or web moves the sensor arms slightly causing the steering arms to pivot and exert pressure on the equalizing roll thereby counteracting and aligning the direction of the web, belt, or sheet of material supported thereby.

Description

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates to surface winding and unwinding of cloth, paper, metal, or plastic webs and the like from web rolls. The present invention utilizes an equalizing roll to be used in manufacturing for providing equal tension across a web, belt, or sheet of material during winding and conveying operations such as used in polymer film processing applications, corrugators, paper machines, printing presses, cloth winders, and metal winding operations.

2. Background Information

The present invention comprises an equalizing roll which may be used as a stand alone unit or in a tracking apparatus for stabilizing the run of a material web which is being rolled off of or onto a drum or through a series of rollers. The present invention is designed to provide a method of optimally stabilizing, controlling the tension, controlling the slack, and the direction of a web, belt, or sheet of material while the web is traveling between rolls.

One application is in the drying section of a high speed paper machine where the paper web to be dried meanders over drying cylinders. The present equalizing roll is also useable in connection with a "transfer foil", i.e., a device for transferring the paper web from the press section to the drying section such as described in U.S. Pat. No. 4,551,203. The present invention may also be utilized for stabilizing and controlling the tension of a paper web of paper coaters. It is contemplated that the present invention can also be used in the fabric industry; plastics film, sheet, and tape industry; and in the metal film and foil industry. The invention may be used in small diameter, narrow width applications measurable in centimeters of inches or industrial operations wherein the rolls may extend thirty, fifty feet in length or longer depending on the application.

The equalizing roll of the present invention in the paper industry solves the problem of wrinkles and slack being formed in the paper or plastic film web during processing by an apparatus such as is described in U.S. Pat. No. 4,441,263. The present invention provides a means to control the pressure conditions in the area where the paper web runs together with a backing belt on a receiving drying cylinder and across the entire width of the paper web extending across the entire length of the drying cylinder or other such conveyor assembly. As is generally known, air flow transverse to the drying section causes the edges of the paper web to flutter and/or the formation of wrinkles in the paper web as shown in FIG. 1. This occasionally causes the paper web to break or a plastic web to be stretched and permanently distorted. A stable, smooth run of the paper web requires that the forces resulting from the longitudinal tension of the paper web being equal. The longitudinal tension on the paper web caused by the drying cylinder in combination with a backing belt creates a region in the paper web where the curvature is irregular as viewed across the width of the paper web. In the center, the paper web bows out more heavily than on the edges resulting in stretching and deformation of the web.

Another application for the present invention is in the cloth industry to avoid wrinkling cloth being unwound from rolls on surface winders and unwinders, batchers, cradle let-offs and the like. As set forth in U.S. Pat. No. 5,431,358, hereby incorporated by reference, in the area where the support rolls engage the cloth roll, the cloth roll is indented presenting a shorter cloth roll radius at that point than the radius in the unengaged areas of the roll resulting in the formation of a bulge or bagging down in advance of the support roll. Sometimes, the bulge or loose pucker resulting from such bagging down advances entirely about the wound roll causing wrinkling, marking and uneven tension.

U.S. Pat. Nos. 1,738,170, 3,433,429 and 4,026,487 illustrate efforts to solve the problem through compressible support roll coverings wherein an effort is made to match the compressibility of the support roll to the compressibility of the wound web roll. An inflatable support roll and other efforts to solve the problem include uniform or continuously spaced fluting on the support rolls. Such fluting may be skewed or spiralled in respect to the longitudinal axis. A roll having spaced segments is illustrated in U.S. Pat. No. 1,093,913, whereas U.S. Pat. No. 3,239,163 illustrates uniformly spaced compressible fluting having upper surface areas conforming to the curvature of the flexible roll. Attempts to match or otherwise utilize the relative compressibility of the support rolls in relation to the compressibility of the wound rolls have met with limited success. Fluted rolls having uniform circumferential spacing result in vibration or chattering and sometimes mark the wound rolls with the pattern of the fluted segments due to the limited areas of support.

The present invention provides an equalizing roll means to equalize the tension of the web as the web runs over the rolls distributing the lateral forces so that any imbalance of lateral tension will cause the roll to pivot at it's center permitting the roll to move upward on the side of least tension until the web tension is equalized across the entire roll.

SUMMARY OF THE INVENTION

The equalizing roller of the present invention is a universal mount idler roll that works off of a center pivot point and is able to swivel a selected amount preferably in a range of from about 0 to about 15 degrees. The equalizing roll is placed before or after, and in alignment with a plurality of idler rollers having a web roll or belt of material in order to maintain a constant tension of the web or sheet of material unrolling from a web roll to prevent stretching or wrinkling of the material and facilitating off rolling of the material in a straight line so that the sheet or ribbon does not want to veer to one side. Moreover, the tracking apparatus may be used in conventional conveyor assemblies to provide directional stability to a belt, sheet, or web of material being conveyed over at least one equalizing roll.

A common axis shaft is mounted horizontally on two shaft bearings or clamped rigid to support means allowing for rotation. Mounted in the center of the axis shaft is a center self aligning bearing assembly having an inner convex ball and an outer concave socket portion disposed within a housing sleeve. The single center bearing assembly is mounted inside a hollow cylinder or roll machined to be in balance with respect to the centrally disposed bearing assembly. The mating of the concave and convex portions of the bearing permits a selected degree of lateral rotation and allows the roll to rotate independent of the shaft. As the web runs over the roll, any imbalance of lateral tension will cause the roll to pivot at it's center permitting the roll to move upward on the side of least tension until the web tension is equalized across the entire roll.

The preferred embodiment of the present invention provides an equalizing roll for controlling web tension including a longitudinal shaft having distal ends rotatably supported by a pair of shaft bearings, a self aligning center bearing assembly having an inner ball portion fixedly connected to the weighted center of the shaft and an outer socket portion fixedly connected to the weighted center of a cylindrical roll coaxially mounted around the shaft, wherein the deflection of the roll with respect to the shaft is in the range of from about one degree to about ten degrees, and most preferably about six degrees. A compressible bearing of selected rigidity may be utilized between the roll and shaft at one or more selected positions to limit or control oscillations of the roll with respect to the shaft.

Accordingly, it is an important object of the present invention to provide a means for winding and unwinding paper, film, plastic, cloth or metal webs and avoid the problem of wrinkling, stretching, and marking of the web.

It is another object of the present invention to provide an equalizing roll to control the tension of a web to prevent the web from veering to one side.

It is another object of the present invention to provide an equalizing roll to control oscillation by use of a central pivoting means.

It is yet another object of the present invention to use a single bearing as a central pivoting means.

It is another object of the present invention to utilize the equalizer roll in tools such as with belt sanders or other equipment utilizing alignable belts.

Furthermore, the tracking assembly apparatus of the present invention comprises an equalizing roll, and an adjustable control arm assembly comprising at least one pair of pivoting arm assemblies. Each pivoting arm assembly includes a sensing arm linked to a steering arm by a means for pivoting. The sensing arm is in cooperative engagement with a web of material. The steering arm is in cooperative engagement with the equalizing roll. Whereby misalignment of the web of material moves the sensing arm pivotly linked to the steering arm exerting pressure on the equalizing roll correcting the alignment of the web of material.

It is another object of the present invention to utilize the equalizing roll in combination with an adjustable control arm assembly in cooperative engagement with an equalizer roll and the web of material to sense misalignment of the belt or web of material conveyed thereon and correct the alignment or tracking of the material by proportional adjustment of the equalizing roll.

BRIEF DESCRIPTION OF THE DRAWINGS

A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the several views and wherein:

FIG. 1 is a top perspective view showing wrinkles formed in a web supported by a plurality of rollers;

FIG. 2 is front view of the equalizing roll of the present invention showing the roll supported coaxially equal distance around a shaft supported by stationary bearings;

FIG. 3 is a partial cut-away view showing a central bearing assembly supporting the roll coaxially around the shaft wherein the roll is spaced equal distance from the surface of the shaft providing limited longitudinal movement of the roll around the shaft, and showing the shaft supported by a stationary end bearing;

FIG. 4 is a front view showing the equalizing roll of FIG. 2, wherein application of tension to roll has caused the left end of the roll to raise upward nearer the bottom of the shaft and the right end of the roll to lower downward toward the top of the shaft;

FIG. 5 is a partial cut-away view showing a central bearing assembly supporting the roll coaxially around the shaft wherein the distal ends of the roll are spaced an unequal distance from the surface of the shaft providing limited longitudinal movement of the roll around the shaft, and showing the shaft supported by a stationary end bearing;

FIG. 6 shows a perspective view of the present invention showing a plain spherical roller bearing capable of pivoting upward, downward, back and forth such as is used for the center bearing assembly;

FIG. 7 is a cut-away view of the plain spherical roller bearing of FIG. 6, showing the degree of movement of the ball within the socket;

FIG. 8 is a radial cross section showing a bearing subassembly in a the mounting socket such as is used in the center bearing assembly of the present invention showing the ball, socket, and cap;

FIG. 9 is a top view showing the rigid bushing of the compressible bushing assembly which is mounted coaxially to around the shaft;

FIG. 10 is a top view showing a flexible outer bushing member mounted coaxially onto the rigid bushing of FIG. 9;

FIG. 11 is a side view showing the compressible bushing assembly of FIG. 10 mounted onto the shaft of the present invention showing unidirectional slots within the flexible outer bushing member;

FIG. 12 is a side view of the equalizing roll of the present invention showing the compressible bushing mounted onto the shaft and the compressible bushing assembly being inserted into the roll;

FIG. 13 is a side view of the bushing of FIG. 12, showing compression of the outer flexible bushing on one side;

FIG. 14 is front view of the equalizing roll of FIG. 2, showing the roll supported by a shaft supported by a stationary bearing and rigid support member, and showing compressible bearing assemblies inserted within the roll coaxially around the shaft;

FIG. 15 is a partial cut-away view showing a central bearing assembly supporting the roll coaxially around the shaft as shown in FIG. 3, wherein the roll is spaced equal distance from the surface of the shaft providing limited longitudinal movement of the roll around the shaft, and showing the shaft supported by a stationary end bearing, and showing compressible bearing assemblies inserted within the roll coaxially around the shaft;

FIG. 16 is a front view showing the equalizing roll of FIG. 14, wherein application of tension to roll has caused the left end of the roll to raise upward nearer the bottom of the shaft and the right end of the roll to lower downward toward the top of the shaft and showing compression of the outer flexible bushing of the compressible bearing assemblies inserted within the roll coaxially around the shaft;

FIG. 17 is a partial cut-away view showing a central bearing assembly supporting the roll coaxially around the shaft wherein the distal ends of the roll are spaced an unequal distance from the surface of the shaft providing limited longitudinal movement of the roll around the shaft showing the shaft supported by a stationary end bearing, and showing compression of the outer flexible bushing of the compressible bearing assemblies inserted within the roll coaxially around the shaft;

FIG. 18 is a side view showing another embodiment of a compressible bushing assembly;

FIG. 19 is a perspective view of another embodiment of the present invention showing the roll supported by a center pivoting bearing assembly utilizing a pair of bearings spaced apart from a pivot member and being positioned coaxially around the shaft;

FIG. 20 is a partial cut-away view of FIG. 19 showing the roll supported by a center pivoting bearing assembly utilizing a pair of bearings spaced apart from a pivot member and being positioned coaxially around the shaft;

FIG. 21 is a side view of FIG. 20;

FIG. 22 is a longitudinal sectional view of FIG. 20;

FIG. 23 is a perspective view of an equalizing roll tracking assembly apparatus showing the adjustment arm assembly having the steering arms in contact floating on the equalizing roll;

FIG. 24 is a perspective cutaway view showing the equalizing roll tracking assembly of FIG. 23 conveying a web or belt of material;

FIG. 25 is a top view of the equalizing roll tracking assembly of FIG. 23;

FIG. 26 is a rear view showing the equalizing roll and adjustable control arm assembly having the steering arm float on the surface of the equalizing roll;

FIG. 27 is a side view of the equalizing roll tracking assembly of FIG. 23.

FIG. 28 is a perspective view of an equalizing roll tracking assembly wherein the equalizing roll provides an end pulley idler utilizing the adjustable control arm assembly to correct misalignment of a belt of web of material being conveyed thereon shown in phantom lines; and

FIG. 29 is a top plan view of the sensing arm.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The equalizing roll and tracking assembly of the present invention is manufactured from readily available materials and simple in design. The preferred embodiment is comprised of metal, more particularly stainless steel, steel, or brass; however, it is contemplated that plastic or other polymer composite materials, such as graphite fiber, nylon, or even fiberglass, could be molded and used in combination with or substituted for the steel components of the present invention.

Equalizing Roll

With reference to FIGS. 1-8, the equalizing roll 10 of the present invention utilizes an axle or longitudinal shaft 12 of a selected cross-sectional area having the distal ends 14 supported by stationary shaft bearings assemblies 16, rigid support means 17 fixedly mounted as shown in FIG. 14, or a combination thereof. The shaft 12 is disposed through a pivotable center bearing assembly 18 comprising a spherical plain bearing such as shown in FIG. 8, a hog-ring bearing, a ball bearing, or a needle roller bearing in such a manner as to be positioned and balanced in the weighted center of the shaft 12. The center bearing 18 must provide for rotation as well as pivoting side to side oscillation and may be self aligning such as are commercially available from distributors. Spherical plain bearings are further described in U.S. Pat. No. 5,265,965, hereby incorporated by reference, which are designed for applications where both misaligning and oscillatory motions are present. These self aligning bearings such as best shown in FIGS. 6-8 typically comprise a bearing assembly 18 having a inner convex portion having a spherical outer diameter referred to as the ball 20 fixedly connected to the shaft 12. The ball 20 is rotatably and swivelly mounted within an opening or socket 22 formed in a housing or cap 23 to form a ball and socket bearing. The socket 22 comprises an outer concave inner surface or raceway 24 that is integral and remains stationary with respect to the housing. The socket 22 inner raceway 24 and the outer spherical diameter of the ball 20 must have a very closely tolerance fit to assure consistent bearing performance and long life. U.S. Pat. No. 5,265,965 discloses several other ball and socket bearings in the references cited which may be usable in the present invention.

As shown in FIGS. 3, 5, 15, and 17, a sleeve may be formed of metal such as steel or other material, such as a high durometer polymer such as teflon or graphite fiber, to form a housing or sleeve 26 immovably attached to the exterior surface of the socket 22. In the preferred embodiment a spacer 28 is inserted into one end of the sleeve adjacent the cap 23 of the center bearing 18 for positioning the center bearing assembly 18 at the balancing point defining the weighted center of the equalizing roll 10. The exterior surface of the cap 23 is held immobile in the housing sleeve 26 which is fixedly connected with the inner surface of a coaxial cylindrical roll 30 allowing the cylindrical roll 30 to rotate about the axis of the shaft 12 and for the distal ends 32 of the cylindrical rolls to be deflected according to the force applied by the tension of the web. FIG. 4 shows an end view of the equalizing roll 10 assembly.

An alternative method of insertion of the center bearing assembly 18 into the roll 30 and fixedly connected to the shaft 12 is to cut the cylindrical roll 30 into two sections for insertion of the center bearing assembly 18 and then using precision welding to weld the roll back together. Upon assembly the distal ends 32 of the cylindrical roll 30 may require drilling to remove weight, or welding to add weight to obtain a perfectly balanced roll 30 wherein the inner surface of the roll 30 is equal distant from the shaft 12.

During operation the equalizing roll 10 is loaded by outer force action along a tangent such as shown in FIGS. 4 and 5. The ball 20 may be deflected off center by as much as ten degrees depending upon the application and length and diameter of the coaxial roll 30; however, the preferred embodiment provides for about six degrees of movement for controlling the tension of the web in paper processing applications. As the web runs over the roll 30, any imbalance of lateral tension will cause the roll 30 to pivot at its center permitting the roll 30 to move upward on the side of least tension until the web tension is equalized across the entire roll 30.

A compressible bushing assembly 34 as illustrated in FIGS. 10 and 11, consists of a generally rigid inner bushing 36 as shown in FIG. 9 which rotates coaxially around the shaft 12 together with a flexible outer bushing member 38 fixedly connected using by a friction fit with the interior surface of the roll 30. The compressible bushing 34 is inserted into selected positions within the roll 30 coaxially mounted on the shaft 12 at or near the distal ends of the roll. The compressible bushing assemblies 34 are not necessary for all applications, but are useful when a large amount of unequal tension is produced from a particular process operation. The compressible bearing 34 provides a means for allowing the roll 30 to move and oscillate, but to still bias the roll urging it to return to the center position to align the web and control the tension thereof. The inner bushings 36 are usually fabricated from teflon, carbon graphite, nylon, metal, or other tough self lubricating plastic material; however, it is contemplated that a lubricatable bushing can be used. The composition of the material selected for the inner bushing 36 is dependent upon the heat generated by the process or retained within the web material being conveyed. As shown in FIGS. 11-12 and 19 the flexible outer bushing member 38 is generally comprised of a flexible material such as an elastomer or other polymer such as PVC, polyethylene, or urethane, and including rubber and/or silicon compounds. The selection of the composition of the flexible outer bushing member 38 is determined by the heat exposure of the compound which is often as high as 400.degree. F. and durability. The degree of hardness desired to provide the desired cushioning is selected depending upon the web strength and the amount of "play" which is acceptable due to the oscillation of the roll 30 around the shaft 12. The preferred embodiment utilizes flexible outer bushing 38 materials having Durometer hardness in a range of about 45 to 60, and more preferably about 50. The design of the slots within the flexible bushing member 38 and or the design of the thickness, radius, and/or curvature of the irregularities or projections on the outer surface of the flexible bushing member 38 provide another means to select and control the cushioning effect of the compressible bushing assembly 34.

FIGS. 14 and 15 shows the equalizing roll 10 supported by the shaft 12 which is supported by stationary bearings 17 and showing compressible bearing assemblies 34 inserted within the roll coaxially around the shaft. More particularly, the center bearing assembly 18 supporting the roll 30 coaxially around the shaft 12 shows the roll 30 is spaced equal distance from the surface of the shaft 12 providing limited longitudinal movement of the roll 30 around the shaft 12. The shaft 12 is supported by a pair of stationary end bearings 17. The compressible bearing assemblies 34 inserted within the roll 30 coaxially around the shaft 12 are shown in the compressed state in FIGS. 16 and 17, wherein application of tension to roll 30 has caused the left end of the roll 30 to raise upward nearer the bottom of the shaft 12 and the right end of the roll 30 to lower downward toward the top of the shaft 12 and showing compression of the outer flexible bushing 38 of the compressible bearing assemblies 34 inserted within the roll 30 coaxially around the shaft 12. As shown best in FIG. 17, a center bearing assembly 18 supporting the roll 30 coaxially around the shaft 12 has the distal ends of the roll 30 spaced an unequal distance from the surface of the shaft 12 providing limited longitudinal movement of the roll 30 around the shaft 12. The shaft 12 is shown supported by a pair of stationary end bearings 16, and the tension of the roll causes the compression of the outer flexible bushing 38 of the compressible bearing assemblies 34 inserted within the roll 30 coaxially around the shaft 12.

As shown in FIGS. 19-22, an alternate embodiment of the present invention comprises a self-aligning pivoting bearing sleeve assembly 39 utilizes a pair of pivotal spherical bearing assemblies 18 spaced apart from one another at a selected short distance whereby a convex sleeve member 40 has an inner surface fixedly attached coaxially around the shaft 12 in between the bearing assemblies 18. The convex sleeve member 40 cooperately and rotatably engages a concave sleeve member 42 having an exterior surface fixedly attached to the inner surface of the roll 30, (or sleeve within the roll) providing a limited pivotal movement of the convex sleeve member 40 with the concave sleeve member 42. As shown in FIG. 22, compressible bushing assemblies 34 may also be utilized with the pivoting bearing sleeve assembly 39.

Tracking Assembly Apparatus

With reference to FIGS. 23-29, the tracking assembly 100 utilizes at least one equalizing roll 10 therein employing the aligning capabilities of the equalizing roll 10 in a unit together with an adjustable control arm assembly 102.

FIG. 23 shows a preferred embodiment of the tracking assembly 100 comprising an equalizing roll 10 mounted between a pair of idler rolls 104 spaced apart in alignment with one another. Of course, the spacing and alignment in the horizontal axis need not be equal depending upon the application.

The adjustable control arm assembly 102 of the tracking assembly 100 includes a sensor arm 106 which is adjustable. The sensor arm 106 may be a one piece member or it may define a telescoping first outer arm 108 slidably engaging a second inner arm 110. The sensor arm 106 may be formed having a particular shape on the distal end 112 in order to contact the side edge 114 of the web, sheet, or belt of material 116, shown best in FIG. 24, such as a "fork" shape. The preferred embodiment includes a sliding head 118. As shown in the illustrations, the sensor arm 106 is formed having a square cross-sectional; however, it is contemplated that the sensor arm 106 could be cylindrically shaped so that the head 118 could be rotated at an angle to optimize contact with the web or belt material 116. The sliding head 118 could also be used to contact the edge 114 of the material 116; however, the preferred embodiment utilizes a bar member 120 defining a spindle 122 having a rotating wheel 124 rotatably attached thereto. The bar member 120 may be utilized by itself and comprise a durable, low friction material such as TEFLON.TM., graphite or other hard polymer, or even metal. The wheel 124 of the preferred embodiment includes a groove 126 therein to assist in stabilizing and guiding the wheel 124 with respect to the edge 114 of the web material 116 being conveyed. The inner end of the sensor arm 106 defines a "washer" or collar 130 having a hole therethrough for cooperative engagement and rotational "pivoting" movement with respect to a pin or bolt 134 secured to the means for mounting the equalizing roll 10. The preferred embodiment includes a flat plate 136 having a curved slot 138 therein for adjusting the angle of the sensor arm 106 with respect to the equalizer roll 10 and steering arm 140. Also, see FIG. 29. A pin or screw 142 extends upward through the curved slot 138 and is secured by a nut 144 in order to adjust the angle between the sensor arm 106 and steering arm 140.

The adjustable control arm assembly 102 of the tracking assembly 100 includes a steering arm 140 which is generally fixed, but may also be designed to be adjustable. The plate 136 is attached to the proximate end 146 of the steering arm 140 by a collar 149 which is rotatably supported by the bolt 134. As shown in FIGS. 23-28, the steering arm 140 is positioned above the sensor arm 106; however, the positions could be reversed. Also the plate 136 could be secured to the steering arm 140 so long as the pin and groove adjustment arrangement could be utilized. It should be noted that the operation of the control arm assembly is not dependent upon the angle of adjustment provided by the plate 136; however, the angle between the steering arm 140 and sensor arm 106 would have to be determined for particular applications and adjusted for different width belts or webs of material 116. A means for contact such as a contact block, roller, or other member 148 is connected to the distal end 150 of the steering arm 140. The contact block need not be of any particular shape; however, the surface should be smooth, tough, and durable because pressure will be exerted on the exterior surface of the equalizer roll 10 through the contact block 148 floating thereon in response to the movements of the steering arm 140 and sensor arm 106. A roller mechanism may be used as the contact block 148; however, a block of polymeric material such as graphite, nylon, or TEFLON.TM. may be utilized therefor. Preferably, the contact block 148 is adjustable in order to set the sensitivity of the "steering" action. As shown in the preferred embodiment the length of the sensor arm 106 is approximately three times the length of the steering arm providing about a 3:1 leverage ratio. In practice forces of least than one foot pound are sufficient to maintain alignment of the material; however, the force needed will vary with the type and weight of material. Of course, at least some correctional forces originate at the equalizer roll 10 and are transmitted through the steering arm 140 to the sensor arm 106 to the web of material 116 as well.

The steering arm 140 is positioned and sized so that the distal end 150 rests near or on the edge of the equalizer bar 10 to maximize the force thereon. The sensor arm 106 may be adjusted in length depending on the speed of the web, flexibility of the material 116, length of the web, distance of conveyance, etc. to determine the pressure to exert in order to maintain alignment of the material 116.

More than one equalizer roll 10 may be used in each tracking assembly 100. In addition, a plurality of tracking assemblies may be used in a conveyor system to maintain alignment of the material 16 conveyed thereby.

FIGS. 23-24 shows the tracking assembly 100 used in combination before a tail idler "tail pulley" because that is where the web of material usually tends to track off and out of alignment. As shown, in the tracking assembly 100, the web or belt of material is conveyed over and under at least one equalizer roll 10 and a plurality of conventional idler rollers 104 to decrease slack and maintain optimal control over the material 116.

As shown in FIGS. 23 and 24, the tracking assembly 100 consists of two permanently mounted idler rolls 104 straddling one equalizing roll 100, wherein all three rolls, 100, 104, and 104, share common mounting rails 152. Each rail 152 includes a mounting point pivot 154 for attachment of an adjustable control arm 102. The distal ends 112 of the sensor arms 106 are set to ride on the outer edges 114 of the material 116 to be tracked. When the web of material 116 moves to the left of right of center it contacts the sensor arm 106. The sensor arm 106 on the side contacted is pushed outward in relation to the web of material 116, causing the steering arm 140 to contact the equalizing roll 10. As the sensor arm 106 is moved outwardly, the steering arm 140 forces the equalizing roll 10 to pivot into an out of parallel condition. The "steering" of the equalizing roll 10 effectively counters the misalignment forces of the belt of material 116 causing it to track back into center alignment.

As shown in FIG. 28, the tracking assembly 100 is utilized as an end roller. Note that the adjustable control arms 102 are positioned to respond to the top of the web of material. The adjustable arms 102 are mounted according to the direction of the material 116.

The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modifications will become obvious to those skilled in the art based upon more recent disclosures and may be made without departing from the spirit of the invention and scope of the appended claims.

Claims

1. A web tracking assembly, comprising:

at least one pivoting conveyor roll pivotally and rotatably supported at its center providing axial movement therearound; and

an adjustable control arm assembly comprising a pair of pivoting arm assemblies, each one including a sensor arm linked to a steering arm by means for pivoting, said sensor arm cooperatively engaging a web of material supported by said at least one pivoting conveyor roll having a length at least as wide as said web of material, and said steering arm cooperatively engaging said pivoting conveyor roll near its distal ends, whereby misalignment of said web of material moves said sensor arm exerting pressure on said steering arm pivotally linked to said sensor arm, said steering arm thereby exerting pressure on said pivoting conveyor roll pivoting said roll supporting said web of material on its axis thereby dissipating the force and correcting the alignment of said web of material.

2. The web tracking assembly of claim 1, wherein the means for sensing and guiding is an adjustable control arm assembly.

3. The web roll tracking assembly of claim 1, wherein said at least one pivoting conveyor roll is mounted between a pair of idler rolls spaced apart in alignment with one another.

4. The web roll tracking assembly of claim 2, wherein said adjustable control arm assembly comprises an adjustable sensor arm.

5. The web roll tracking assembly of claim 4, wherein said adjustable sensor arm comprises a telescoping first outer arm slidably engaging a second inner arm.

6. The web roll tracking assembly of claim 4, wherein said adjustable sensor arm includes means for cooperatively engaging a side edge of a web, sheet, or belt of material.

7. The web roll tracking assembly of claim 4, wherein said adjustable sensor arm includes a sliding head.

8. The web roll tracking assembly of claim 7, wherein said sliding head rotating at an angle optimizing contact with the web or belt of material.

9. The web roll tracking assembly of claim 1, wherein said means for cooperative engagement with the side edge of the web, sheet, or belt is a spindle supporting a rotating member.

10. The web roll tracking assembly of claim 9, wherein said rotating member includes a groove around the periphery thereof.

11. The web roll tracking assembly of claim 9, wherein the rotating member is connected to said spindle by a member comprising a durable, low friction material selected from the group consisting of a polytetrafluoroethylene, a graphite, and a self lubricating polymer.

12. The web roll tracking assembly of claim 1, wherein said adjustable control arm assembly includes a steering arm.

13. The web roll tracking assembly of claim 4, wherein said sensor arm of said adjustable control arm assembly wherein includes an inner end defining a collar having a hole therethrough cooperatively engaging means for mounting the conveyor roll and a member having a curved slot therein for adjusting the angle of said sensor arm with respect to said pivoting roll and steering arm.

14. The web roll tracking assembly of claim 13, including means for adjusting the angle between the sensor arm and steering arm.

15. The web tracking assembly of claim 1, wherein said pivoting roll comprises:

a longitudinal fixed shaft having distal ends supported by a pair of support members;

a cylindrical sleeve having an inner surface defining an internal diameter greater than the external diameter of said fixed shaft, said cylindrical sleeve being spaced apart from said fixed shaft, said cylindrical sleeve supporting a web of material being conveyed over an external surface of said cylindrical sleeve between a first distal end and a second distal end;

a pivotal rotatable center bearing assembly having a single inner convex ball portion having a bore therethrough fixedly connected to said fixed shaft extending therethrough and an outer concave socket portion having an external surface fixedly connected to said inner surface of said cylindrical sleeve being positioned and balanced at a weighted center of said cylindrical sleeve being coaxially mounted around and spaced apart from said fixed shaft said cylindrical sleeve extending outwardly past said pivotal rotatable center bearing assembly;

said cylindrical sleeve being deflectable by unequal tension of said web of material passing thereover and said fixed shaft limiting the deflection of said cylindrical sleeve and allowing for deflection and swiveling in an arc about said pivotal rotatable bearing assembly.

16. The web tracking assembly of claim 15, wherein balancing of said cylindrical sleeve at the center thereof corrects deflections caused by the unequal tension in the conveyance of the web of material thereover.

17. The web tracking assembly of claim 15, wherein said pivoting conveyor roll includes at least one compressible bushing member comprising an rotating inner bushing and a soft flexible fixed outer bushing member disposed coaxially around said shaft and in cooperative communication with said inner surface of said cylindrical sleeve for absorbing shock due to deflections created by variations of the tension of the web of material passing thereover.

18. The web tracking assembly of claim 1, wherein said pivoting conveyor roll comprises:

a longitudinal fixed shaft having distal ends supported by a pair of support members;

a cylindrical sleeve having an inner surface defining an internal diameter greater than the external diameter of said fixed shaft, said cylindrical sleeve being spaced apart from said fixed shaft, said cylindrical sleeve supporting a web of material being conveyed over an external surface of said cylindrical sleeve between a first distal end and a second distal end;

a self aligning pivotal rotatable center bearing assembly having a single inner convex ball portion having a bore therethrough fixedly connected to said fixed shaft extending therethrough and an outer concave socket portion having an external surface fixedly connected to said inner surface of said cylindrical sleeve being positioned and balanced at a weighted center of said cylindrical sleeve being coaxially mounted around and spaced apart from said fixed shaft said cylindrical sleeve extending outwardly past said pivotal rotatable center bearing assembly;

said cylindrical sleeve being deflectable by unequal tension of said web of material passing thereover and allowing for deflection and swiveling in an arc about said pivotal rotatable bearing assembly.

19. The web tracking assembly of claim 18, whereby balancing said cylindrical sleeve at the center thereof corrects deflections caused by the unequal tension in the conveyance of the web of material thereover.

20. The web tracking assembly of claim 18, including at least one compressible bushing member disposed coaxially around said shaft and in cooperative communication with said inner surface of said cylindrical sleeve for absorbing shock due to deflections created by variations of the tension of the web of material passing thereover.