FIELD OF THE INVENTION
The present invention relates generally to winders for winding film on cores and more particularly to a winding apparatus having a support arm for mitigating deflection of a spindle, upon which the cores are mounted, in response to a force applied by multiple lay on rolls.
BACKGROUND OF THE INVENTION
Turret winders wind webs of paper, paperboard and non-paper products, such as film and polyethylene, onto cores and into rolls which have uniform tension and density across the width of the web. A benefit of this type of winder is its ability to wind pressure sensitive materials under low winding pressures and to wind low tensile strength products under low tension. Each winder is custom engineered to meet the needs of the particular product to be produced and to be able to operate both continuously and intermittently. To be able to operate in a continuous mode, turret winders utilize various types of roll changers.
Products, properties, speeds and widths vary from winder to winder and from plant to plant. The proper procedure of threading and attaching each particular product to the winder, therefore, varies as well from winder to winder.
In addition, many turret winders wind rolls of paper or film using a pressure roll, sometimes called rider roll, pack roll, lay-on roll, or bump roll. Typically, the lay-on roll is a straight beam (e.g., cylindrical shaft, spindle or tube) which applies pressure to the film as it is being wound onto one or more cores into one or more winding rolls positioned on a core shaft of the turret winder. When multiple cores are positioned on the core shaft for winding, the web or film can have some variation in thickness, whereby the lay-on roller may not touch the edges of each winding roll. In the case of a long core shaft and when in line slitting, where, for example, six rolls of 20″-wide-film are being produced, it becomes quite difficult for the lay-on roller to contact all 12 edges of the six winding rolls of film due to the variations in thickness of the web or deflection of the core shaft.
SUMMARY
According to aspects illustrated herein there is provided a winding apparatus 10 which includes first and second frame members. A shaft is rotatably mounted to the first and second frame members. One or more arms extend radially outward from the shaft, each of which have a coupling and a connector positioned thereon. The connectors secure the arms to the shaft for rotation therewith. One or more support arms extend radially outward from the shaft and are positioned between the arms. Each of the support arms have a support arm coupling and a support arm connector positioned thereon. A spindle is rotatably supported by the couplings. The spindle is rotatably mounted in the support arm coupling which cooperates with the support arm to mitigate deflection of the first spindle in response to forces applied thereto.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side schematic view of a turret winder of the present invention;
FIG. 2 is schematic view of a portion of the turret winder of FIG. 1 with a loading system shown therewith;
FIG. 3A is a top view of the turret winder of FIG. 2 shown with the loading system in side view and taken along line 3-3 of FIG. 2;
FIG. 3B is a top view of the turret winder of FIG. 2 shown with the loading system in side view and taken along the line 3-3 of FIG. 2 wherein a third frame member is included;
FIG. 4A is a side view of a support arm and a clamp, showing the clamp in a closed position;
FIG. 4B is a side view of the support arm and clamp of FIG. 4A wherein the clamp is in an open position;
FIG. 5 is an enlarged view of the support arm and the clamp of FIG. 3A;
FIG. 6 is a schematic of the support arm and a first turret arm wherein the support arm is positioned to allow cores to be placed on a spindle;
FIG. 7A is a schematic of the support arm wherein the support arm has a first portion and a second portion which are pivotally attached to a body portion, wherein the first portion and the second portion are in an engaged position;
7B is a schematic of the support arm of FIG. 7A wherein the first portion and the second portion are in a disengaged position;
FIG. 8A is a schematic of the support arm and clamp of FIG. 6 wherein the clamp is attached to the support arm via a pin and clevis joint;
FIG. 8B is a schematic of the support arm and clamp of FIG, 8A wherein the clamp is detached from the support arm;
FIG. 9A is a schematic of the support arm and clamp of FIG. 6 wherein the clamp is attached to the support arm via a pair of elongate bodies pivotally mounted thereon, wherein the clamp is shown in a closed position;
FIG. 9B is a schematic of the support arm and clamp of FIG. 9A wherein the clamp is shown in an open position;
FIG. 10A is a side view of the turret winder of FIG. 1, wherein a plurality of turret arms is shown, wherein each turret arm is spaced 120 degrees apart from each adjacent turret arm;
FIG. 10B is a side view of the turret winder of FIG. 1, wherein a plurality of turret arms is shown, wherein each turret arm is spaced 90 degrees apart from each adjacent turret arm;
FIG. 11 is a top view of the turret winder of FIG. 2 shown with the loading system in side view and taken along line 3-3 of FIG. 2 wherein a spindle includes two portions thereof;
FIG. 12 is a top view of the turret winder of FIG. 2 shown with the loading system in side view and taken along line 3-3 of FIG. 2 wherein the spindle includes two portions thereof, each portion being removable from the turret winder;
FIG. 13 is a photograph of a web rolled on a core with improper pressure applied to the edge during winding; and
FIG. 14 is a photograph of webs rolled on cores with proper pressure applied to the edge during winding.
DETAILED DESCRIPTION OF THE INVENTION
In reference to FIGS. 1-3B, a winding apparatus, for example a turret winder, is generally designated by the numeral 10. The turret winder 10 has a base portion 12 having a first frame member 12A and a second frame member 12B. A shaft 16 extends between and is rotatably supported by the first frame member 12A and a second frame member 12B. As illustrated in FIGS. 1-3B, the shaft 16 is supported, proximate ends thereof, by suitable bearings 20A and 20B, for example journal bearings or roller bearings. The shaft 16 is also supported between the ends, for example proximate a mid-section of the shaft, by another bearing 20C, for example a journal bearing or a roller bearing. As shown in FIGS. 3A and 3B, a support arm 40 is secured (i.e., fixed) to the shaft 16 proximate a bearing 20C via a connector 41 (e.g., a weld, press fit or staking). In one embodiment, as shown in FIGS. 3A and 3B, the support arm 40 is approximately centrally positioned between the turret arms 14. However, the present invention is not limited in this regard, as the support arm 40 may be slightly offset from the center defined by the turret arms 14 or may comprise two or more support arms 40, the mean position of which is approximately centrally located between the turret arms or slightly offset therewithin, without departure from the broader aspects of the present invention.
The approximately central positioning of the support arm 40 in relation to the turret arms 14 minimizes deflection of the spindle 28A and 28B in response to forces applied thereto by the lay on rolls 50A and 50B as described further herein. The minimized deflection produces a substantially uniform distribution of pressure along the cores 30A, 30B, 30C and 30D, as described herein. The substantially uniform distribution of pressure results in enhanced contact between the lay-on rollers 50A and 50B and each winding roll edge 52 of the film wound around the cores 30A, 30B, 30C and 30D. The enhanced contact results in a better quality of roll, as shown in FIG. 14.
As shown in FIG. 3A, a driver D which is fixedly coupled to the shaft 16 causes the shaft 16 to rotate relative to the first frame member 12A and the second frame member 12B to sequence the spindles into and out of an operating position. The first frame member 12A has a first frame member bearing 20A positioned thereon. The second frame member 12B has a second frame member bearing 20B positioned thereon. The first frame member bearing 20A and the second frame member bearing 20B allow rotation of the shaft 16 relative to the first frame member 12A and the second frame member 12B. Although two frame members 12A and 12B are shown in FIG. 3A, the present invention is not limited in this regard, as any suitable number of frame members may be used, for example a third frame member 12C may be used, as shown in FIG. 3B.
Referring to FIGS. 3A and 3B, the first frame member 12A is spaced apart from the second frame member 12B. A first turret arm 14A is fixedly secured to the shaft 16 at a point defined by the longitudinal center of the turret arm 14A. A second turret arm 14B is fixedly secured to the shaft 16 at a point defined by the longitudinal center of the turret arm 14A. The turret arm 14A has a first portion 14A′ and a second portion 14A″. The turret arm 14B has a first portion 14B′ and a second portion 14B″. The first turret arm 14A and the second turret arm 14B extend radially outward from their rotatably mounted position (i.e., the longitudinal center) around the shaft 16. Although two turret arms are shown in FIGS. 3A and 3B, the present invention is not limited in this regard, as any suitable number of turret arms may be used, such as three turret arms or four turret arms. Although the first portion of the turret arm 14A′ and the second portion of the turret arm 14A″ are shown as being spaced apart by an angle of 180 degrees, the present invention is not limited in this regard, as the turret arms and portions thereof may be spaced apart at any suitable angle, for example 90 degrees or 120 degrees.
A spindle 28A is rotatably mounted between the first portion 14A″ of the turret arm 14A and the first portion 14B″ of the turret arm 14B and driven by a suitable drive mechanism D1. A spindle 28B is rotatably mounted between the second portion 14A′ of the turret arm 14A and the second portion 14B′ of the turret arm 14B and driven by a suitable drive mechanism D2. Two bores B1 and B2 are positioned at axially opposite locations along the turret arm 14B. Two bores B3 and B4 are positioned at axially opposite locations along the turret arm 14A. A bearing 44C is positioned inside of the bore B1. A bearing 44B is positioned inside of the bore B4. The spindle 28A is rotatably mounted to the first portion 14A″ of the turret arm 14A and to the first portion 14B″ of the turret arm 14B via the bearing 44C and the bearing 44B, respectively. A bearing 44D is positioned inside of the bore B2. A bearing 44A is positioned inside of the bore B3. The spindle 28B is rotatably mounted to the second portion 14A′ of the turret arm 14A and to the second portion 14B′ of the turret arm 14B via the bearing 44C and the bearing 44B, respectively. Although two turret arms are shown in FIGS. 3A and 3B, the present invention is not limited in this regard, as any suitable number of turret arms may be used, for example three turret arms or four turret arms.
The spindles 28A and 28B are configured to receive a plurality of cores thereon, for example four cores 30A, 30B, 30C and 30D are shown. The cores 30A, 30B, 30C and 30D are removably secured to the spindle 28A and 28B via a clamping means (e.g., a clamp, not shown) positioned along the spindle 28A and 28B at axially opposite ends of the cores 30A, 30B, 30C and 30D and proximate thereto. Each of the spindles 28A or 28B is configured to receive multiple cores, e.g., four cores 30A, 30B, 30C and 30D. While the turret 10 is shown with two turret arms 14A and 14B and two spindles 28A and 28B, the present invention is not limited in this regard as the turret arms may be modified to receive only one spindle, three spindles, four spindles or more. While the spindles 28A and 28B are shown having four cores 30A, 30B, 30C and 30D positioned thereon, the present invention is not limited in this regard as any number of cores may be positioned on the spindles 28A and 28B.
In one embodiment, as shown in FIGS. 11 and 12, the spindle 28A includes a first portion 28A′ and a second portion 28A″. The first portion 28A′ and the second portion 28A″ are centrally supported by the support arm 40. The first portion 28A′ is driven by a first suitable driver D2′ and the second portion 28A″ is driven by a second suitable driver D2″.
As used herein, the term spindle configuration refers to a spindle 28 having a first portion 28A′ and a second portion 28A″ mounted thereon, a first suitable driver D2′ which drives the first portion 28A′ and a second suitable driver D2″ which drives the second portion 28A″. Although in FIGS. 11 and 12, only one spindle configuration is shown, the present invention is not limited in this regard, as any suitable number of spindle configurations may be used, such as two spindle configurations, three spindle configurations or four spindle configurations.
In one embodiment, as shown in FIG. 11, the first portion 28A′ and the second portion 28A″ are pivotally mounted to the turret arms 14A and 14B, respectively. The first portion 28A′ pivots about a first point X on the turret arm 14A. When the first portion 28A′ is in a disengaged position, as shown in FIG. 11, the cores 30A and 30B may be mounted to and removed from the second portion 28A″ of the spindle 28A. The second portion 28A″ pivots about a second point Y on the turret arm 14B. When the second portion 28A′ is in a disengaged position, as shown in FIG. 11, the cores 30C and 30D may be mounted to and removed from the second portion 28A″ of the spindle 28A. In one embodiment, the first portion 28A′ and the second portion 28A″ are configured to releasably engage one another at an approximately central location. In one embodiment, the first portion 28A′ and the second portion 28A″ engage one another in a bore within the support arm 40, although the present invention is not limited in this regard, as the first portion 28A′ and the second portion 28A″ may engage one another in the absence of the support arm 40.
In an alternative embodiment, as shown in FIG. 12, the first portion 28A′ is removably mounted to the turret arm 14A and the support arm 40. The second portion 28A″ is removably mounted to the turret arm 14B and the support arm 40.
The support arm 40 is rotatable with the shaft 16 and opposing ends thereof are selectively and releasably secured to one of the spindles 28A and 28B. For example, the first portion of the support arm 40B and a second portion of the support arm 40C are releasably secured to a portion of each of the spindles 28A and 28B by a clamp 42. The purpose of the support arm 40 is to eliminate or reduce the deflection of the spindles 28A and 28B where a long spindle of a small diameter is used to wind a product substrate or film. The first portion of the support arm 40B reduces deflection of the spindle 28A due to weight (e.g., weight of the film and/or spindles) and reduces or eliminates a critical rotational speed allowing substrate (e.g., film 60) processing at elevated speeds not possible by a shaft of similar length but not have a support arm but supporting similar weight or turning at similar speeds. The second portion of the support arm 40C reduces deflection of the spindle 28B due to weight (e.g., weight of the film and/or spindles) and reduces or eliminates a critical rotational speed allowing substrate (e.g., film 60) processing at elevated speeds not possible by a shaft of similar length but not have a support arm but supporting similar weight or turning at similar speeds.
As used here in, the term upstream refers to progression in the direction annotated by the arrow R2, and the term downstream refers to progression in the direction opposite that annotated by the arrow R2. An idler roller 66 is positioned downstream the lay-on rollers 50A and 50B. The idler roller 66 keeps the substrate 60 in tension, thereby eliminating irregularities in the substrate (e.g., wrinkles).
As shown in FIG. 5, a bearing 41A (e.g., a journal bearing, roller bearing or needle roller bearing) is positioned on a recessed portion of the spindles 28A and 28B at a location (e.g., an approximately central location) on the spindles 28A and 28B, between the ends S1, S2, S3 and S4 of thereof. The bearing 41A is recessed from an exterior surface of the spindles 28A and 28B by a distance R, so that the cores 30A, 30B, 30C and 30D can be slid onto and removed from the spindles 28A and 28B. The clamp 42 which is positioned on the ends of the support arm 40 is secured around the bearing 44 so that the spindles 28A and 28B are rotatably supported by the clamp 42 which is retracted for installation of the cores 30A, 30B, 30C and 30D on the spindles 28A and 28B.
As shown in FIG. 5, the bearing 41A is positioned within a recess 68 having a depth R. The bearing has an outer race 41A and a plurality of lay-on rollers 67 rotatably positioned around a narrowed portion 69 of the spindle 28A. In one embodiment, the bearing is a split bearing (i.e., the outer ring of the bearing is split into two or more sections) to allow assembly in the recess 68. Although the bearing is shown as a needle roller bearing in FIG. 5, any suitable type of bearing, such as a ball bearing or a journal bearing, may be used without departure from the broader aspects of the present invention.
Referring to FIGS. 4A and 4B, the clamp 42 clampingly engages the spindle 28A, thereby fixing the spindle 28A in place relative the support arm 40. The clamp 42 allows for the spindle 28A to be manipulated so that the cores 30A, 30B, 30C and 30D are positioned therealong. When the clamp 42 is in an open position, as shown in FIG. 4B, the spindle 28A is released from the clamp 42 and the support arm 40. When the clamp 42 is in a closed position, as shown in FIG. 4A, the clamp 42 rotatably secures the spindle to the support arm 40.
In one embodiment, as shown in FIG. 6, the support arm 40 is pivotally mounted to the shaft 16. In this embodiment, the support arm 40 is free to rotate away from the winding apparatus via a bearing 41′ for installation and removal of the cores 30A, 30B, 30C and 30D from the spindles 28A and 28B. In another embodiment, as illustrated in FIGS. 7A and 7B, the support arm includes a body portion 40A, a first portion 40B and a second portion 40C. The first portion 40B and the second portion 40C are pivotally mounted to the body portion 40A. FIG. 7A shows the first portion 40B and the second portion 40C engaged with the body portion 40A. FIG. 7B shows the first portion 40B and the second portion 40C disengaged from the body portion 40A to allow the first portion 40B and the second portion 40C to swing.
In another embodiment, as shown in FIGS. 8A and 8B, the support arm 40 includes a pin P which removably attaches a detachable portion 40′ and the clamp 42 to the support arm 40 via a clevis joint. FIG. 8A shows the pin P in an engaged position and thus the detachable portion 40′ in an attached position. FIG. 8B shows the pin P removed from the support arm 40 and thus the detachable portion 40′ in a detached position for installation and removal of the cores 30A, 30B, 30C and 30D. In yet another embodiment, as shown in FIGS. 9A and 9B, the support arm 40 includes a first elongate body 40D and a second elongate body 40E pivotally mounted thereon and fixedly coupled to adjacent ends of the clamp 42 proximate the support arm 40. FIG. 9A shows the clamp in a closed position. FIG. 9B shows the clamp in an open position to allow for installation and removal of the cores 30A, 30B, 30C and 30D.
As shown in FIGS. 3A and 3B, an outwardly facing edge E6 of the core 30A is spaced apart from an outwardly facing edge El of the lay-on roll 50A by a distance W5. An outwardly facing edge E3 of the core 30B is spaced apart from an inwardly facing edge E2 of the lay-on roll 50A by the distance W5. An outwardly facing edge E12 of the core 30C is spaced apart from an inwardly facing edge E5 of the lay-on roll 50B by the distance W5. An outwardly facing edge E9 of the core 30D is spaced apart from an outwardly facing edge E8 of the lay-on roll 50B by the distance W5. The lay-on roll 50A is spaced apart from the lay-on roll 50B by a distance W4. These distances are important, as they allow for optimum distribution of the force F along the roll of substrate 60 and the edges 52 thereof.
As shown in FIGS. 1-3B, two lay-on rolls 50A and 50B (e.g., idler rolls) are rotatably mounted on a single shaft 55. The lay-on rollers 50A and 50B ride on the winding product 60 for the purpose of reducing in-wound air between subsequent wraps of substrate or film 60. The shaft 55 is urged towards the cores 30A, 30B, 30C and 30D in the direction indicated by the arrow R2 by an actuator 65 so that the lay-on roll 50A rollingly contacts the film 60 being wound on the cores 30A and 30B; and so that the lay-on roll 50B rollingly contacts the film 60 being wound on the cores 30A and 30B. As best shown in FIGS. 3A and 3B, the lay-on rolls 50A and 50B have a width W1 which is greater than the width W3, so that the lay-on roll 50A extends over and contacts each of the edges 52 of the film 60 being rolled on the cores 30A and 30B; and so that the lay-on roll 50B extends over and contacts each of the edges 52 of the film 60 being rolled on the cores 30C and 30D. While two lay-on rolls 50A and 50B are shown and described as being positioned on the shaft 55, the present invention is not limited in this regard as more than two lay-on rolls, for example three, four, five, six or more lay on rolls may be positioned on the shaft 55. In one embodiment, as shown in FIGS. 11 and 12, the lay-on roll 50A is driven by a suitable driver D4′ and the lay-on roll 50B is driven by the driver D4″. The drivers D4′ and D4″ apply a force F to the lay-on rolls 50A and 50B, respectively. The force F urges the lay-on rolls 50A and 50B into contact with the roll of substrate 60. In one embodiment, the force F acts along a straight path. In one embodiment, the force F includes a force resulting from torque. In one embodiment, the force F is a resultant force of a first force acting along a straight path and a second force resulting from torque.
As shown in FIGS. 3A and 3B, the shaft 55 is supported by four linkage arms 51 that are pivotally coupled to a frame 64 at one end and pivotally connected to the shaft 55 at an opposing end thereof, for example, by a suitable bearing. A loading system 62 includes a pneumatic or motor actuator 65, which is coupled to a portion of linkage arms 51 to urge the shaft 55, and thereby the lay-on rollers 50A and 50B, towards the cores 30A, 30B, 30C and 30D in the direction indicated by the arrow R2 (FIGS. 1-3B) to impart a force on each of the edges 52 of the film 60 being wound on the cores 30A, 30B, 30C and 30D, as shown in FIG. 5.
In the embodiment shown in FIG. 3A, the lay-on rolls 50A and 50B contact each edge 52 of the cores 30A, 30B, 30C and 30D, respectively. One lay-on roll for four edges 52 produces a better edge quality than one lay-on roll for eight edges as the film is not completely flat over the full width. This is of significant importance in the manufacturing of stretch film.
As shown in the photograph of FIG. 13, poor quality edges 52 where were produced using only one lay-on roll for multiple cores and no support arm, such that the edges were not in contact with the lay-on roll as the film was or is thinner and the roll wound smaller in diameter. As shown in the photograph of FIG. 14, high quality edges 52 are generated where contact with a lay-on roll was made throughout the entire winding cycle from core to full roll.
By the use of multiple lay-on rolls 50A and 50B as applied to one of the single winding spindles 28A or 28B or single and center supported winding core shaft (mounted in a turret of 2 or more winding spindles, or singular) the operating window of having the lay-on rollers 50A and 50B contacting each winding roll edge 52 is greatly enhanced, whereby a better quality roll (e.g., see FIG. 13) of product is produced (e.g., CD edge quality as is sometimes used to describe the desired winding quality of roll edge).
By using only one spindle 28A for multiple cores (or 28B for multiple cores) and multiple lay-on rollers 50A and 50B, the cost of the equipment is greatly reduced where by the alternative solution is typically by use of multiple winding systems.
As shown in FIGS. 3A and 3B, the spindles 28A and 28B are also supported at opposing ends thereof by suitable bearings 44A, 44B, 44C and 44D (e.g., roller bearings or journal bearings). Each of the cores 30A, 30B, 30C and 30D has a width W2. As shown in FIGS. 3A and 3B, an inwardly facing edge E5 of the core 30A is spaced apart from an inwardly facing edge E4 of the core 30B by a distance G3. The cores 30A and 30B and the distance G3 occupy a total distance W3. An inwardly facing edge E11 of the core 30c is spaced apart from an inwardly facing edge E10 of the core 30D by a distance G3. The cores 30C and 30D and the distance G3 occupy a total distance W3.
While the present disclosure has been described with reference to various exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
Patent Application
20140263805
