US20070084958A1 - Center rewinder with two turrets and a bedroll with two transfer positions for transferring a web to each of the turrets - Google Patents

Center rewinder with two turrets and a bedroll with two transfer positions for transferring a web to each of the turrets Download PDF

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Publication number
US20070084958A1
US20070084958A1 US11/253,228 US25322805A US2007084958A1 US 20070084958 A1 US20070084958 A1 US 20070084958A1 US 25322805 A US25322805 A US 25322805A US 2007084958 A1 US2007084958 A1 US 2007084958A1
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United States
Prior art keywords
web
roll
turret
transferring
bedroll
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US11/253,228
Inventor
Thomas Daul
David Kacynski
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Paper Converting Machine Co
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Paper Converting Machine Co
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Publication date
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Priority to US11/253,228 priority Critical patent/US20070084958A1/en
Assigned to PAPER CONVERTING MACHINE COMPANY reassignment PAPER CONVERTING MACHINE COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DAUL, THOMAS J., KACYNSKI, DAVID A.
Publication of US20070084958A1 publication Critical patent/US20070084958A1/en
Abandoned legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H19/00Changing the web roll
    • B65H19/22Changing the web roll in winding mechanisms or in connection with winding operations
    • B65H19/2207Changing the web roll in winding mechanisms or in connection with winding operations the web roll being driven by a winding mechanism of the centre or core drive type
    • B65H19/2223Turret-type with more than two roll supports
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H19/00Changing the web roll
    • B65H19/22Changing the web roll in winding mechanisms or in connection with winding operations
    • B65H19/26Cutting-off the web running to the wound web roll
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H19/00Changing the web roll
    • B65H19/22Changing the web roll in winding mechanisms or in connection with winding operations
    • B65H19/28Attaching the leading end of the web to the replacement web-roll core or spindle
    • B65H19/283Attaching the leading end of the web to the replacement web-roll core or spindle by applying adhesive to the core
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2301/00Handling processes for sheets or webs
    • B65H2301/40Type of handling process
    • B65H2301/41Winding, unwinding
    • B65H2301/414Winding
    • B65H2301/41419Starting winding process
    • B65H2301/41422Starting winding process involving mechanical means
    • B65H2301/414222Starting winding process involving mechanical means fixed to frame, tucking leading edge to core, e.g. by brush
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2408/00Specific machines
    • B65H2408/20Specific machines for handling web(s)
    • B65H2408/23Winding machines
    • B65H2408/231Turret winders
    • B65H2408/2312Turret winders with bedroll, i.e. very big roll used as winding roller
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2408/00Specific machines
    • B65H2408/20Specific machines for handling web(s)
    • B65H2408/23Winding machines
    • B65H2408/231Turret winders
    • B65H2408/2315Turret winders specified by number of arms
    • B65H2408/23157Turret winders specified by number of arms with more than three arms
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65HHANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2513/00Dynamic entities; Timing aspects
    • B65H2513/10Speed

Definitions

  • This invention relates to a center rewinder having two or more turrets and a bedroll with two or more transfer positions for transferring a web to a web-winding member such as a mandrel at each of the transfer positions.
  • Rewinders are used to convert large parent rolls of paper into retail sized rolls of bathroom tissue and paper towels. Two types of rewinders are commonly used—center rewinders and surface rewinders. Center rewinders are described, for example, in U.S. Reissue Pat. No. 28,353 and wind the web on a core which is rotated by a mandrel. Surface rewinders are described, for example, in U.S. Pat. Nos. 4,723,724 and 5,104,055 and wind the web on a core which is rotated by a three roll cradle. The terms “rewinders” and “winders” are sometimes used interchangeably.
  • the critical operation in both center rewinders and surface rewinders is the sequence of steps referred to as cutoff and transfer.
  • the web must be severed to end the winding of one roll, the leading edge of the severed web must be transferred to a new core, and the new core must be rotated to begin winding a new roll. These steps must be accomplished repeatedly and reliably while the web is moving at high speed. It is also desirable that each roll have exact sheet count and that the web is wound uniformly and substantially without wrinkles.
  • bedroll refers to the main winding roll of a rewinder, either a center rewinder or a surface rewinder.
  • a bedroll is commonly used in conjunction with a chopper roll to sever the web after a predetermined length has been wound into a log and to transfer the leading edge of the severed web to a new core in a continuous winding process.
  • a latch mechanism is commonly used to retain the severing and transferring mechanism in an inoperative position until the proper length of web has been wound onto the log.
  • a cam follower is controlled by an electric solenoid or pneumatic cylinder to unlatch the latch mechanism to release the severing and transferring mechanism.
  • the severing and transferring mechanism is then controlled by one or more cams to perform the cutoff and transfer operations on the web.
  • the latch is thereafter reset by the cam to retain the severing and transferring mechanism in the inoperative position.
  • the severing and transfer mechanism includes transfer pins 56 , cutoff blades 58 and 59 , and transfer pads 55 , all of which are movably mounted in the bedroll.
  • the transfer pads When the severing and transfer mechanism is unlatched, the pins 56 hold the web against the rotating bedroll while the web is severed by a chopper roll 49 and the blades 58 and 59 (see FIGS. 20 and 21 ).
  • the transfer pads thereafter urge the leading end of the severed web against a new core 53 ( FIGS. 22 and 23 ).
  • a solenoid is actuated to unlatch the latch mechanism.
  • Magnetic rewinders sold by Paper Converting Machine Company of Green Bay, Wisconsin under the name “Magnum” include similar movable pins in a bedroll for holding the severed web against the bedroll and a similar latch mechanism for retaining the pins in an inoperative position until the web is to be severed.
  • a cutoff knife is movably mounted in a chopper roll and is retained in an inoperative position by a latch mechanism which is similar to the latch mechanism which is used on the bedroll of a center rewinder.
  • U.S. Pat. No. 6,179,241 describes a latch mechanism which is controlled by a camshaft which is mounted axially in the bedroll and by a servo motor which rotates the camshaft.
  • the servo motor normally rotates the camshaft in the same direction and at the same speed as the bedroll.
  • the speed of the servo motor is either increased or decreased to rotate the camshaft relative to the bedroll.
  • the rotation of the camshaft allows push rods in the bedroll to move radially inwardly to release the severing and transferring mechanism.
  • Cam followers for the severing and transferring mechanism engage a stationary cam and control the movement of the mechanism. After the web is severed and transferred, the camshaft is rotated to force the push rods radially outwardly to relatch the severing and transferring mechanism.
  • U.S. Pat. No. 6,513,750 describes a bedroll which includes a lockout cam, a pin cam, and a pad cam for operating the pins and pads instead of the cams, latch mechanism, and solenoid of U.S. Reissue Pat. No. 28, 353.
  • FIGS. 26 and 27 of the '750 patent illustrate a rewinder which omits the lockout cam, pin cam, and pad cam and uses rotatable hubs to rotate the pin shaft and pad shaft.
  • FIGS. 28 and 29 of the '750 patent illustrate another rewinder in which the lockout is omitted but which includes a pin cam and a pad cam.
  • the rewinder includes a single rotatable turret.
  • a plurality of mandrels are rotatably mounted on the turret, and the turret indexes to move the mandrels successively to a web-transferring position adjacent the bedroll.
  • the bedroll has a single transfer position at a particular rotational position of the bedroll at which the web is transferred to a mandrel or to a core which is mounted on the mandrel.
  • the operating mechanism for the pins and the pads is designed to move the pins and pads so that transfer occurs at that single transfer position.
  • U.S. Pat. No. 5,497,959 describes a coreless winder with two transfer positions.
  • the bedroll uses vacuum and air pressure for maintaining control over the web during cutoff and transfer.
  • U.S. Pat. No. 5,226,611 describes a surface winder with two transfer positions.
  • the rewinder includes a vacuum transfer roll 28 and two additional vacuum rolls 40 and 42 to advance the web to two surface winding stations.
  • U.S. Pat. No. 3,157,371 describes a winder with two turrets. This type of winder is typically used to wind a slit web. Part of the web is wound on one turret while the other part of the web is wound on the other turret. This patent does not describe using two turrets and two separate transfer positions for transferring a web from a bedroll to the turrets.
  • One embodiment of the invention provides a bedroll with two or more transfer positions for transferring a web to mandrels or cores.
  • the mandrels or cores may or may not be mounted on turrets.
  • Another embodiment of the invention uses the bedroll with two or more turrets for transferring and winding a web on multiple turrets.
  • a rewinder with multiple turrets and multiple transfer positions is capable of operating at a substantially increased cycle rate.
  • a center rewinder having a single turret and a single transfer position is generally limited to producing about 35 logs per minute.
  • a rewinder in accordance with the invention having two turrets and two transfer positions can produce about 70 logs per minute.
  • FIG. 1 illustrates a prior art center rewinder which includes a single turret and a bedroll having a single transfer position
  • FIG. 2 illustrates a rewinder in accordance with the invention which includes two turrets and a bedroll with two transfer positions, the web being wound on the right turret;
  • FIG. 3 is a view similar to FIG. 2 showing the bedroll in the cutoff position and a log on the right turret completing its wind;
  • FIG. 4 illustrates continued rotation of the bedroll and indexing of the left turret to move a mandrel to the transfer position and to move a completed log toward a tailseal apparatus
  • FIG. 5 illustrates the bedroll at one of its transfer positions and the log on the left turret indexed to a glue applicator for applying tailseal adhesive to the log;
  • FIG. 6 illustrates the rewinder after transfer to a mandrel on the left turret
  • FIG. 7 illustrates the left turret in a winding position in which the web is being wound on a mandrel on the left turret
  • FIG. 8 illustrates a chopper roll and a bedroll which is equipped with pins for retaining a web on the bedroll and pads for transferring the web to a core;
  • FIG. 9 is a view similar to FIG. 8 showing the chopper roll and bedroll in the web cutoff position
  • FIG. 10 is a view similar to FIG. 8 showing the bedroll in one of its transfer positions
  • FIG. 11 is a view similar to FIG. 10 showing the bedroll in a second transfer position
  • FIG. 12 illustrates a mechanism for operating the pins and pads of the bedroll of FIG. 8 ;
  • FIG. 13 is an enlarged fragmentary view of the mechanism of FIG. 12 ;
  • FIG. 14 is a timing chart for one of the turrets
  • FIG. 15 is a timing chart for the other turret
  • FIG. 16 is a timing chart which combines the timing charts for the two turrets
  • FIG. 17 is a timing chart for the roll stripper conveyor for one of the turrets
  • FIG. 18 is a timing chart for the roll stripper conveyor for the other turret.
  • FIG. 19 is a timing chart which combines the timing charts for the two roll strippers.
  • FIG. 1 illustrates a prior art center rewinder 20 of the type which is described in U.S. Pat. No. 6,513,750.
  • the rewinder 20 includes a frame 21 and a bedroll 22 which is rotatably mounted on the frame.
  • a turret assembly 23 is rotatably mounted on the frame adjacent the bedroll.
  • the turret assembly includes a plurality of rotating mandrels 24 on which paperboard cores are mounted.
  • An adhesive-applying apparatus 25 applies transfer adhesive to a new core before each winding cycle.
  • a web W is advanced by draw rolls 26 through a perforator 27 to the bedroll 22 .
  • the perforator forms longitudinally spaced transverse lines of perforation in the web.
  • the surface speed of the bedroll matches the speed of the web, and the bedroll delivers the web to a log L which is wound on the mandrel at about the 1:00 o'clock position of the turret.
  • the web will be severed by a chopper roll 28 and a new winding cycle will begin.
  • the bedroll 22 is equipped with a pin and pad assembly 30 which is described in detail in U.S. Pat. No. 6,513,750. A similar pin and pad assembly is described in U.S. Reissue Pat. No. 28,353.
  • such a pin and pad assembly includes a plurality of transfer pins for holding the web against the rotating bedroll while the web is severed by the chopper roll.
  • the transfer pads thereafter strip the web from the pins and urge the leading end of the severed web against a new core to begin a new winding cycle.
  • the pins and pads are mounted on a pin shaft and a pad shaft, respectively, which are independently rotatable by the operating mechanism of the pin and pad assembly as described in U.S. Pat. No. 6,513,750 and U.S. Reissue Pat. No. 28,353.
  • the inventive rewinder 30 includes a frame 31 , a bedroll 32 which is rotatably mounted on the frame, and a pair of turrets 33 and 34 which are rotatably mounted on the frame.
  • the turrets may be conventional and each turret includes a plurality of mandrels 35 .
  • FIG. 2 illustrates three mandrels on each turret, but more or less may be used.
  • Each mandrel is direct coupled to a conventional drive motor.
  • a paperboard core may be mounted on each mandrel before the web is wound on the mandrel, or the web can be wound directly on a coreless mandrel. If the web is wound on cores, a line of transfer adhesive maybe applied to each core as the core is loaded onto a mandrel. The position of the line of adhesive or glue is maintained by a motor encoder.
  • a web W is advanced by conventional infeed draw rolls (not shown) through a perforator (not shown) and over outfeed draw rolls 37 and the bedroll 32 .
  • the web is fed from the bedroll alternatively to the right and the left turrets 33 and 34 .
  • the web is being wound on a mandrel of the right turret 33 to form a log L 1 .
  • the web is severed by a chopper roll 38 .
  • a previously wound log L 2 is mounted on another mandrel of the right turret.
  • Previously wound logs L 3 and L 4 are mounted on mandrels of the left turret 34 .
  • a rider roll 40 is mounted on a swingable arm 41 and is in contact with the winding log L 1 .
  • the rider roll alternates between the two turrets, depending on which turret is winding product.
  • the position of the arm 41 and thus the rider roll 40 is controlled by a servo motor which is operated by the programmable logic control (PLC) of the rewinder.
  • PLC programmable logic control
  • the diameter of the wound log is controlled by the rider roll position and the metered winding speed of the web, both of which are controlled by the PLC. Control of product diameter by rider roll position reduces sensitivity to the tensile strength of the perforations and increases product range and production efficiency.
  • both product diameter and firmness are measured, e.g., by a laser PE and a load cell. This information is fed back in a closed loop to controls upstream of the bedroll to optimize runability.
  • the bedroll 32 includes pins 44 and pads 45 of the type which are described in U.S. Pat. No. 6,513,750. Just before the web is severed by the chopper roll 38 , the pins 44 are moved outwardly to pierce the web and to hold the web against the surface of the bedroll after the web is severed. As will be described hereinafter, the pads 45 are extended to strip the web off of the pins and to press the leading end of the severed web against a new core to begin a new winding cycle.
  • Exact sheet count in a wound log can be obtained either by matching the sheet count to the circumference of the bedroll or by slipping the bedroll relative to the web prior to cutoff and transfer. Slipping the bedroll relative to the web to adjust sheet count is well known in the art and is described for example, in U.S. Pat. No. 4,687,153.
  • the speed of the bedroll is matched to web speed and remains matched until just after transfer to eliminate sensitivity to web tensile strength and web stretch.
  • Activation of the pins is controlled by a servo motor, which enables variable pin displacement based on the position of the winding turret, thereby permitting increased cycle rates of 60 to 70 logs per minute.
  • FIG. 2 the web is being wound on the right turret 33 to form log L 1 , and the rider roll 40 is in contact with the winding product. Both the right and left turrets are stationary. The pins 44 and pads 45 are retracted inside of the outer surface of the bedroll 32 .
  • FIG. 3 illustrates the web being severed by the chopper roll 38 .
  • the pins 44 are extended out of the bedroll beyond the outer surface of the bedroll to engage the web.
  • a blade 48 ( FIG. 4 ) on the chopper roll 38 extends through the web and engages with blades on the pins to cut the web on one of the perforation lines of the web.
  • the right turret 33 remains stationary, but the left turret 34 is in the process of indexing clockwise.
  • the log L 3 ( FIG. 2 ) has been stripped from its mandrel on the left turret by a conventional log-stripping device.
  • FIG. 4 illustrates the bedroll and left turret just before transfer.
  • the pins 44 are in the process of being retracted into the bedroll 32 , but the pins still engage the web and carry the web for transfer to the core on mandrel 35 a of the left turret 34 .
  • the left turret is indexing clockwise to rotate the mandrel 35 a to the transfer position illustrated by the radial line T.
  • the trailing end of the severed web continues to be wound on the log L 1 .
  • the completed log L 4 on the left turret 34 is being indexed to a tailseal apparatus 50 .
  • the tailseal apparatus includes an air nozzle 51 which provides an air blast to blow the tail 52 of the log L 4 past the tailseal apparatus.
  • FIG. 5 illustrates one of the transfer positions of the bedroll 32 .
  • the left turret 34 has indexed the mandrel 35 a to the transfer position of the left turret indicated by the radial line T.
  • the pins 44 are retracted into the bedroll 32 , and the pads 45 strip the web from the pins and press the web onto the glued core carried by the mandrel 35 a , thereby transferring the web to the glued core.
  • the transfer glue on the core adhesively transfers the web to the core.
  • the trailing end of the severed web continues to be wound on the log L 1 on the right turret.
  • the left turret is indexing clockwise at peak velocity.
  • a glue applicator roll 53 of the tailseal apparatus 50 rotates with a speed which is matched to the indexing speed of the left turret and prints a line of adhesive on the wound log L 4 .
  • FIG. 6 the leading end of the severed web has been transferred to the core on the mandrel 35 a , and a new log L 5 begins to wind.
  • the pins 44 and pads 45 are retracted into the bedroll 32 .
  • the left turret 34 continues to index clockwise, and the rider roll 40 begins to move from the right turret to the left turret.
  • the glue applicator 53 in the tailseal apparatus returns to a dwell position.
  • the clockwise indexing of the left turret moves the log LA and its tail 52 toward a presser roll 56 .
  • both the left and right turrets are stationary.
  • the web W is being wound on the log L 5 on the left turret.
  • the log L 4 has been moved past the presser roll 56 so that its tail 52 is secured by the line of tailseal glue which was applied by the tailseal apparatus 50 .
  • the rider roll 40 engages the winding log L 5 on the left turret.
  • the portion of the winding cycle which is illustrated in FIG. 7 corresponds generally to the portion of the winding cycle which is illustrated in FIG. 2 , except that the winding log L 5 in FIG. 7 is on the left turret rather than on the right turret.
  • the right turret will be indexed counterclockwise from its FIG. 7 position to move the wound log L 1 past a tailseal apparatus 58 for the right turret which will apply a line of tailseal glue to the log L 1 in the manner previously described with respect to the tailseal apparatus 50 .
  • the tail of the wound log L 1 will be pressed against the log by a presser roll 59 .
  • the right turret 33 When the log L 5 approaches the end of its winding cycle, the right turret 33 will be indexed counterclockwise to move the mandrel 35 b thereof into the transfer position of the right turret which is indicated by the radial line T in FIG. 7 .
  • the pins 44 will be extended to hold the web while the web is severed by the chopper roll 38 , and the pins 44 will carry the web to the second transfer position of the bedroll, which is aligned with the radial line T of the right turret in FIG. 7 .
  • the pins will be retracted, and the pads 45 will be extended to strip the web from the pins and to transfer the web to the glued core on the mandrel 35 b .
  • the new log will then be wound on the right turret, and the winding cycle will be repeated.
  • the transfer pins 44 are mounted on a pin shaft 65
  • the transfer pads 45 are mounted on a pad shaft 66 .
  • the transfer pins 44 are clamped to the pin shaft 65 by clamps 67 .
  • the pads 45 are clamped to the pad shaft 66 by clamps 68 .
  • a pair of spaced-apart cutoff blades 69 is mounted on each of the transfer pins 44 .
  • FIG. 9 illustrates the bedroll 32 in the cutoff position.
  • the pin shaft 65 has been rotated counter clockwise so that the pins 44 extend beyond the outer surface of the bedroll 32 and impale the web (not shown in FIG. 9 for clarity of illustration) which wraps a portion of the outer surface of the bedroll.
  • One of the blades 48 on the chopper roll 38 enters the space between the cutoff blades 69 on the pins 44 to sever the web. After the web is severed, the leading end portion of the severed web is held on the rotating bedroll by the pins 44 .
  • the transfer pads 45 remain retracted in the bedroll 32 .
  • FIG. 10 illustrates the bedroll 32 in its transfer position for the left turret 34 .
  • the pin shaft 65 has been rotated clockwise to retract the pins 44
  • the pad shaft 66 has been rotated clockwise to move the pads 45 beyond the outer surface of the bedroll so that the pads strip the web (not shown in FIG. 10 for clarity of illustration) from the pins 44 and presses the web against the core on the mandrel 35 a of the left turret 34 .
  • the web is retained on the core by the transfer glue which was previously applied to the core.
  • FIG. 11 illustrates the bedroll 32 in its transfer position for the right turret 33 .
  • the pin shaft 65 and pad shaft 66 are rotated to retract the pins 44 and extend the pads 45 to strip the web (not shown) from the pins and to press the web against the core on the mandrel 35 b of the right turret.
  • FIGS. 12 and 13 illustrate one specific embodiment of a mechanism for operating the pins 44 and pads 45 of the bedroll in more than one transfer position.
  • the structure of FIGS. 12 and 13 is also illustrated and described in U.S. Pat. No. 6,513,750, to which reference can be had for a detailed description. However, the bedroll of the '750 patent has only one transfer position.
  • the pin shaft 65 and pad shaft 66 are rotatably mounted in the bedroll 32 , and are driven by timing belts 72 and 73 .
  • the timing belt 73 is driven by hub 74 which is rotatably mounted on the journal 75 of the bedroll.
  • the timing belt 72 is driven by a hub 76 which is rotatably mounted on the hub 74 .
  • the hubs 74 and 76 are driven through timing belts 77 and 78 by differentials 79 and 80 and electric servo motors 81 and 82 .
  • the servos 81 and 82 are controlled by the PLC of the rewinder.
  • a pulley 83 on the bedroll journal 75 is connected to pulleys on the differentials 79 and 80 by belt 84 .
  • the bedroll is driven by a servo motor which is controlled by the PLC of the rewinder.
  • the hubs 74 and 76 are rotated at bedroll speed during most of the winding cycle by the differentials 79 and 80 .
  • the appropriate servo 81 or 82 provides additional rotational speed to rotate the pin shaft or pad shaft relative to the bedroll.
  • the differentials are mechanical motion “combiners”, and the output from each differential is the sum of a constant rpm input from the bedroll journal plus the trim rpm input from the servo 81 or 82 .
  • the pin and pad shafts need to rotate relative to the bedroll in order to execute cutoff and transfer and also need to rotate relative to each other.
  • the extension of the pins varies depending upon the position of the mandrel relative to the bedroll.
  • the extension of the pads is constant when the pads are extended.
  • Timing Chart Turret Bedroll Position Ref.: Notes: Right Turret 0 deg (0 rev) Bedroll phasing hub & bedroll at matched speed. Pin timing hub is at start of move. Web winding on right turret. 180 deg (1 ⁇ 2 rev) Pin timing drive is phased to fully extend pins. Cutoff has occurred. Pad timing hub is phasing with pads moving outward.
  • 270 deg (3 ⁇ 4 rev) Pads are retracting into bedroll. Transfer has occurred. Pins are fully retracted into bedroll. 360 deg (1 rev) Pads are fully retracted into bedroll. (reset for next cutoff & transfer) Left Turret 0 deg (0 rev) Bedroll phasing hub & bedroll at matched speed. Pin timing hub is at start of move. Web winding on left turret. 180 deg (1 ⁇ 2 rev) Pin timing drive is phased to fully extend pins. Cutoff has occurred. 270 deg (3 ⁇ 4 rev) Pads are extending out from the bedroll. Pins are fully extended from the bedroll. 360 deg (1 rev) Pads are retracting into bedroll. Transfer has occurred. Pins are fully retracted into bedroll. 450 deg (11 ⁇ 4 rev) Pads are fully retracted into bedroll. (reset for next cutoff & transfer)
  • Each turret indexes or rotates during about 25% of the winding cycle and dwells or is stationary for about 75% of the winding cycle.
  • a rewinder using more than one turret for transfer and winding makes possible cycle rates of up to 70 logs per minute or more. That is double the cycle rate of current rewinders using a single turret.
  • pin shaft and pad shaft could be operated by cams or separate timing belt drives.
  • FIG. 14 is a timing chart for one of the turrets 33 or 34 , for example, the right turret 33 .
  • the chart shows the position, velocity, and acceleration of the turret.
  • the x axis is machine degrees and represents two winding cycles of the rewinder or 720°.
  • the y axis is turret index position in degrees.
  • the right turret dwells during the first 300° of the machine cycle and then moves 120° during the next 120° of the machine cycle. The right turret then dwells for the remaining 300° of two winding cycles.
  • the vertical line just prior to movement of the turret at 300° represents the return to start since the chart shows the turret rotating only 120° rather than showing three separate turret moves of 120° for a total movement of 360°.
  • FIG. 15 is a similar timing chart for the left turret 34 . Again, the turret moves 120° during two winding cycles of the machine.
  • FIG. 16 is a timing chart for both of the turrets.
  • FIG. 17 is a timing chart for a conventional roll stripper conveyor which strips the wound log from one of the mandrels of the right turret when the turret is stationary.
  • FIG. 18 is a similar timing chart for the roll stripper conveyor for the left turret.
  • FIG. 19 is a timing chart for both of the roll stripper conveyors.
  • the timing charts for the core loading axis for each turret would be similar.
  • Two conventional core loaders are driven synchronously with the roll strip conveyors. Core loading onto an empty mandrel of a turret takes place at the same time as roll stripping on that turret and while the turret dwells.
  • web-winding member can refer to a mandrel, a core, or an equivalent device which rotates to wind the web.
  • web-transferring member can refer to either or both of the transfer pins and transfer pads or equivalent devices for transferring the web from the bedroll to the rotating core or mandrel

Abstract

A rewinder includes a bedroll and first and second turrets. Each turret includes a plurality of rotatable mandrels. The bedroll includes a web-transferring mechanism for transferring a web on the bedroll to a mandrel at first and second rotational positions of the bedroll. The first turret is rotatable to successively move each of its mandrels to a first web-transferring position adjacent the first rotational position of the bedroll. The second turret is rotatable to successively move each of its mandrels to a second web-transferring position adjacent the second rotational position of the bedroll. After a web is transferred to a mandrel, the mandrel rotates to wind the web into a log. As the web is being wound on a mandrel of one of the turrets, a completed log on the other turret is removed.

Description

    BACKGROUND
  • This invention relates to a center rewinder having two or more turrets and a bedroll with two or more transfer positions for transferring a web to a web-winding member such as a mandrel at each of the transfer positions.
  • Rewinders are used to convert large parent rolls of paper into retail sized rolls of bathroom tissue and paper towels. Two types of rewinders are commonly used—center rewinders and surface rewinders. Center rewinders are described, for example, in U.S. Reissue Pat. No. 28,353 and wind the web on a core which is rotated by a mandrel. Surface rewinders are described, for example, in U.S. Pat. Nos. 4,723,724 and 5,104,055 and wind the web on a core which is rotated by a three roll cradle. The terms “rewinders” and “winders” are sometimes used interchangeably.
  • The critical operation in both center rewinders and surface rewinders is the sequence of steps referred to as cutoff and transfer. The web must be severed to end the winding of one roll, the leading edge of the severed web must be transferred to a new core, and the new core must be rotated to begin winding a new roll. These steps must be accomplished repeatedly and reliably while the web is moving at high speed. It is also desirable that each roll have exact sheet count and that the web is wound uniformly and substantially without wrinkles.
  • The term “bedroll” refers to the main winding roll of a rewinder, either a center rewinder or a surface rewinder.
  • As described in U.S. Reissue Pat. No. 28,353, a bedroll is commonly used in conjunction with a chopper roll to sever the web after a predetermined length has been wound into a log and to transfer the leading edge of the severed web to a new core in a continuous winding process. In center rewinders a latch mechanism is commonly used to retain the severing and transferring mechanism in an inoperative position until the proper length of web has been wound onto the log. A cam follower is controlled by an electric solenoid or pneumatic cylinder to unlatch the latch mechanism to release the severing and transferring mechanism. The severing and transferring mechanism is then controlled by one or more cams to perform the cutoff and transfer operations on the web. The latch is thereafter reset by the cam to retain the severing and transferring mechanism in the inoperative position.
  • A conventional latch mechanism and a severing and transferring mechanism for center rewinders is described in detail in U.S. Reissue Pat. No. 28,353. The severing and transfer mechanism includes transfer pins 56, cutoff blades 58 and 59, and transfer pads 55, all of which are movably mounted in the bedroll. When the severing and transfer mechanism is unlatched, the pins 56 hold the web against the rotating bedroll while the web is severed by a chopper roll 49 and the blades 58 and 59 (see FIGS. 20 and 21). The transfer pads thereafter urge the leading end of the severed web against a new core 53 (FIGS. 22 and 23). A solenoid is actuated to unlatch the latch mechanism.
  • Surface rewinders sold by Paper Converting Machine Company of Green Bay, Wisconsin under the name “Magnum” include similar movable pins in a bedroll for holding the severed web against the bedroll and a similar latch mechanism for retaining the pins in an inoperative position until the web is to be severed. A cutoff knife is movably mounted in a chopper roll and is retained in an inoperative position by a latch mechanism which is similar to the latch mechanism which is used on the bedroll of a center rewinder.
  • U.S. Pat. No. 6,179,241 describes a latch mechanism which is controlled by a camshaft which is mounted axially in the bedroll and by a servo motor which rotates the camshaft. The servo motor normally rotates the camshaft in the same direction and at the same speed as the bedroll. When the web is to be severed, the speed of the servo motor is either increased or decreased to rotate the camshaft relative to the bedroll. The rotation of the camshaft allows push rods in the bedroll to move radially inwardly to release the severing and transferring mechanism. Cam followers for the severing and transferring mechanism engage a stationary cam and control the movement of the mechanism. After the web is severed and transferred, the camshaft is rotated to force the push rods radially outwardly to relatch the severing and transferring mechanism.
  • U.S. Pat. No. 6,513,750 describes a bedroll which includes a lockout cam, a pin cam, and a pad cam for operating the pins and pads instead of the cams, latch mechanism, and solenoid of U.S. Reissue Pat. No. 28, 353. FIGS. 26 and 27 of the '750 patent illustrate a rewinder which omits the lockout cam, pin cam, and pad cam and uses rotatable hubs to rotate the pin shaft and pad shaft. FIGS. 28 and 29 of the '750 patent illustrate another rewinder in which the lockout is omitted but which includes a pin cam and a pad cam.
  • In all of the foregoing patents which describe a center rewinder, the rewinder includes a single rotatable turret. A plurality of mandrels are rotatably mounted on the turret, and the turret indexes to move the mandrels successively to a web-transferring position adjacent the bedroll. The bedroll has a single transfer position at a particular rotational position of the bedroll at which the web is transferred to a mandrel or to a core which is mounted on the mandrel. The operating mechanism for the pins and the pads is designed to move the pins and pads so that transfer occurs at that single transfer position.
  • U.S. Pat. No. 5,497,959 describes a coreless winder with two transfer positions. The bedroll uses vacuum and air pressure for maintaining control over the web during cutoff and transfer.
  • U.S. Pat. No. 5,226,611 describes a surface winder with two transfer positions. The rewinder includes a vacuum transfer roll 28 and two additional vacuum rolls 40 and 42 to advance the web to two surface winding stations.
  • U.S. Pat. No. 3,157,371 describes a winder with two turrets. This type of winder is typically used to wind a slit web. Part of the web is wound on one turret while the other part of the web is wound on the other turret. This patent does not describe using two turrets and two separate transfer positions for transferring a web from a bedroll to the turrets.
  • SUMMARY OF THE INVENTION
  • One embodiment of the invention provides a bedroll with two or more transfer positions for transferring a web to mandrels or cores. The mandrels or cores may or may not be mounted on turrets. Another embodiment of the invention uses the bedroll with two or more turrets for transferring and winding a web on multiple turrets. A rewinder with multiple turrets and multiple transfer positions is capable of operating at a substantially increased cycle rate. For example, a center rewinder having a single turret and a single transfer position is generally limited to producing about 35 logs per minute. However, a rewinder in accordance with the invention having two turrets and two transfer positions can produce about 70 logs per minute.
  • DESCRIPTION OF THE DRAWING
  • The invention will be explained in conjunction with illustrative embodiments shown in the accompanying drawing, in which
  • FIG. 1 illustrates a prior art center rewinder which includes a single turret and a bedroll having a single transfer position;
  • FIG. 2 illustrates a rewinder in accordance with the invention which includes two turrets and a bedroll with two transfer positions, the web being wound on the right turret;
  • FIG. 3 is a view similar to FIG. 2 showing the bedroll in the cutoff position and a log on the right turret completing its wind;
  • FIG. 4 illustrates continued rotation of the bedroll and indexing of the left turret to move a mandrel to the transfer position and to move a completed log toward a tailseal apparatus;
  • FIG. 5 illustrates the bedroll at one of its transfer positions and the log on the left turret indexed to a glue applicator for applying tailseal adhesive to the log;
  • FIG. 6 illustrates the rewinder after transfer to a mandrel on the left turret;
  • FIG. 7 illustrates the left turret in a winding position in which the web is being wound on a mandrel on the left turret;
  • FIG. 8 illustrates a chopper roll and a bedroll which is equipped with pins for retaining a web on the bedroll and pads for transferring the web to a core;
  • FIG. 9 is a view similar to FIG. 8 showing the chopper roll and bedroll in the web cutoff position;
  • FIG. 10 is a view similar to FIG. 8 showing the bedroll in one of its transfer positions;
  • FIG. 11 is a view similar to FIG. 10 showing the bedroll in a second transfer position;
  • FIG. 12 illustrates a mechanism for operating the pins and pads of the bedroll of FIG. 8; and
  • FIG. 13 is an enlarged fragmentary view of the mechanism of FIG. 12;
  • FIG. 14 is a timing chart for one of the turrets;
  • FIG. 15 is a timing chart for the other turret;
  • FIG. 16 is a timing chart which combines the timing charts for the two turrets;
  • FIG. 17 is a timing chart for the roll stripper conveyor for one of the turrets;
  • FIG. 18 is a timing chart for the roll stripper conveyor for the other turret; and
  • FIG. 19 is a timing chart which combines the timing charts for the two roll strippers.
  • DESCRIPTION OF SPECIFIC EMBODIMENTS
  • FIG. 1 illustrates a prior art center rewinder 20 of the type which is described in U.S. Pat. No. 6,513,750. The rewinder 20 includes a frame 21 and a bedroll 22 which is rotatably mounted on the frame. A turret assembly 23 is rotatably mounted on the frame adjacent the bedroll. As is well known in the art, the turret assembly includes a plurality of rotating mandrels 24 on which paperboard cores are mounted. An adhesive-applying apparatus 25 applies transfer adhesive to a new core before each winding cycle.
  • A web W is advanced by draw rolls 26 through a perforator 27 to the bedroll 22. The perforator forms longitudinally spaced transverse lines of perforation in the web.
  • The surface speed of the bedroll matches the speed of the web, and the bedroll delivers the web to a log L which is wound on the mandrel at about the 1:00 o'clock position of the turret. When the proper length of web has been wound on the log, the web will be severed by a chopper roll 28 and a new winding cycle will begin.
  • The bedroll 22 is equipped with a pin and pad assembly 30 which is described in detail in U.S. Pat. No. 6,513,750. A similar pin and pad assembly is described in U.S. Reissue Pat. No. 28,353.
  • As is well known in the art, such a pin and pad assembly includes a plurality of transfer pins for holding the web against the rotating bedroll while the web is severed by the chopper roll. The transfer pads thereafter strip the web from the pins and urge the leading end of the severed web against a new core to begin a new winding cycle. The pins and pads are mounted on a pin shaft and a pad shaft, respectively, which are independently rotatable by the operating mechanism of the pin and pad assembly as described in U.S. Pat. No. 6,513,750 and U.S. Reissue Pat. No. 28,353.
  • Referring now to FIGS. 2-7, the inventive rewinder 30 includes a frame 31, a bedroll 32 which is rotatably mounted on the frame, and a pair of turrets 33 and 34 which are rotatably mounted on the frame. The turrets may be conventional and each turret includes a plurality of mandrels 35. FIG. 2 illustrates three mandrels on each turret, but more or less may be used. Each mandrel is direct coupled to a conventional drive motor. A paperboard core may be mounted on each mandrel before the web is wound on the mandrel, or the web can be wound directly on a coreless mandrel. If the web is wound on cores, a line of transfer adhesive maybe applied to each core as the core is loaded onto a mandrel. The position of the line of adhesive or glue is maintained by a motor encoder.
  • A web W is advanced by conventional infeed draw rolls (not shown) through a perforator (not shown) and over outfeed draw rolls 37 and the bedroll 32. As will be described hereinafter, the web is fed from the bedroll alternatively to the right and the left turrets 33 and 34. In FIG. 2 the web is being wound on a mandrel of the right turret 33 to form a log L1. When the proper length of web has been wound on the log L1, the web is severed by a chopper roll 38.
  • A previously wound log L2 is mounted on another mandrel of the right turret. Previously wound logs L3 and L4 are mounted on mandrels of the left turret 34.
  • A rider roll 40 is mounted on a swingable arm 41 and is in contact with the winding log L1. The rider roll alternates between the two turrets, depending on which turret is winding product. The position of the arm 41 and thus the rider roll 40 is controlled by a servo motor which is operated by the programmable logic control (PLC) of the rewinder. The diameter of the wound log is controlled by the rider roll position and the metered winding speed of the web, both of which are controlled by the PLC. Control of product diameter by rider roll position reduces sensitivity to the tensile strength of the perforations and increases product range and production efficiency.
  • At the completion of the wind, both product diameter and firmness are measured, e.g., by a laser PE and a load cell. This information is fed back in a closed loop to controls upstream of the bedroll to optimize runability.
  • The bedroll 32 includes pins 44 and pads 45 of the type which are described in U.S. Pat. No. 6,513,750. Just before the web is severed by the chopper roll 38, the pins 44 are moved outwardly to pierce the web and to hold the web against the surface of the bedroll after the web is severed. As will be described hereinafter, the pads 45 are extended to strip the web off of the pins and to press the leading end of the severed web against a new core to begin a new winding cycle.
  • Exact sheet count in a wound log can be obtained either by matching the sheet count to the circumference of the bedroll or by slipping the bedroll relative to the web prior to cutoff and transfer. Slipping the bedroll relative to the web to adjust sheet count is well known in the art and is described for example, in U.S. Pat. No. 4,687,153.
  • When the bedroll pins are extended to engage the web, the speed of the bedroll is matched to web speed and remains matched until just after transfer to eliminate sensitivity to web tensile strength and web stretch. Activation of the pins is controlled by a servo motor, which enables variable pin displacement based on the position of the winding turret, thereby permitting increased cycle rates of 60 to 70 logs per minute.
  • In FIG. 2 the web is being wound on the right turret 33 to form log L1, and the rider roll 40 is in contact with the winding product. Both the right and left turrets are stationary. The pins 44 and pads 45 are retracted inside of the outer surface of the bedroll 32.
  • FIG. 3 illustrates the web being severed by the chopper roll 38. The pins 44 are extended out of the bedroll beyond the outer surface of the bedroll to engage the web. A blade 48 (FIG. 4) on the chopper roll 38 extends through the web and engages with blades on the pins to cut the web on one of the perforation lines of the web. The right turret 33 remains stationary, but the left turret 34 is in the process of indexing clockwise. The log L3 (FIG. 2) has been stripped from its mandrel on the left turret by a conventional log-stripping device.
  • FIG. 4 illustrates the bedroll and left turret just before transfer. The pins 44 are in the process of being retracted into the bedroll 32, but the pins still engage the web and carry the web for transfer to the core on mandrel 35 a of the left turret 34. The left turret is indexing clockwise to rotate the mandrel 35 a to the transfer position illustrated by the radial line T. The trailing end of the severed web continues to be wound on the log L1.
  • The completed log L4 on the left turret 34 is being indexed to a tailseal apparatus 50. The tailseal apparatus includes an air nozzle 51 which provides an air blast to blow the tail 52 of the log L4 past the tailseal apparatus.
  • FIG. 5 illustrates one of the transfer positions of the bedroll 32. The left turret 34 has indexed the mandrel 35 a to the transfer position of the left turret indicated by the radial line T. The pins 44 are retracted into the bedroll 32, and the pads 45 strip the web from the pins and press the web onto the glued core carried by the mandrel 35 a, thereby transferring the web to the glued core. The transfer glue on the core adhesively transfers the web to the core. The trailing end of the severed web continues to be wound on the log L1 on the right turret.
  • The left turret is indexing clockwise at peak velocity. A glue applicator roll 53 of the tailseal apparatus 50 rotates with a speed which is matched to the indexing speed of the left turret and prints a line of adhesive on the wound log L4.
  • In FIG. 6 the leading end of the severed web has been transferred to the core on the mandrel 35 a, and a new log L5 begins to wind. The pins 44 and pads 45 are retracted into the bedroll 32. The left turret 34 continues to index clockwise, and the rider roll 40 begins to move from the right turret to the left turret. The glue applicator 53 in the tailseal apparatus returns to a dwell position. The clockwise indexing of the left turret moves the log LA and its tail 52 toward a presser roll 56.
  • In FIGS. 7 both the left and right turrets are stationary. The web W is being wound on the log L5 on the left turret. The log L4 has been moved past the presser roll 56 so that its tail 52 is secured by the line of tailseal glue which was applied by the tailseal apparatus 50. The rider roll 40 engages the winding log L5 on the left turret.
  • The portion of the winding cycle which is illustrated in FIG. 7 corresponds generally to the portion of the winding cycle which is illustrated in FIG. 2, except that the winding log L5 in FIG. 7 is on the left turret rather than on the right turret. It will be understood by those skilled in the art that the right turret will be indexed counterclockwise from its FIG. 7 position to move the wound log L1 past a tailseal apparatus 58 for the right turret which will apply a line of tailseal glue to the log L1 in the manner previously described with respect to the tailseal apparatus 50. As the right turret continues to index counterclockwise, the tail of the wound log L1 will be pressed against the log by a presser roll 59.
  • When the log L5 approaches the end of its winding cycle, the right turret 33 will be indexed counterclockwise to move the mandrel 35 b thereof into the transfer position of the right turret which is indicated by the radial line T in FIG. 7. The pins 44 will be extended to hold the web while the web is severed by the chopper roll 38, and the pins 44 will carry the web to the second transfer position of the bedroll, which is aligned with the radial line T of the right turret in FIG. 7. The pins will be retracted, and the pads 45 will be extended to strip the web from the pins and to transfer the web to the glued core on the mandrel 35 b. The new log will then be wound on the right turret, and the winding cycle will be repeated.
  • Referring to FIG. 8, the transfer pins 44 are mounted on a pin shaft 65, and the transfer pads 45 are mounted on a pad shaft 66. The transfer pins 44 are clamped to the pin shaft 65 by clamps 67. The pads 45 are clamped to the pad shaft 66 by clamps 68. A pair of spaced-apart cutoff blades 69 is mounted on each of the transfer pins 44.
  • FIG. 9 illustrates the bedroll 32 in the cutoff position. The pin shaft 65 has been rotated counter clockwise so that the pins 44 extend beyond the outer surface of the bedroll 32 and impale the web (not shown in FIG. 9 for clarity of illustration) which wraps a portion of the outer surface of the bedroll. One of the blades 48 on the chopper roll 38 enters the space between the cutoff blades 69 on the pins 44 to sever the web. After the web is severed, the leading end portion of the severed web is held on the rotating bedroll by the pins 44. The transfer pads 45 remain retracted in the bedroll 32.
  • FIG. 10 illustrates the bedroll 32 in its transfer position for the left turret 34. The pin shaft 65 has been rotated clockwise to retract the pins 44, and the pad shaft 66 has been rotated clockwise to move the pads 45 beyond the outer surface of the bedroll so that the pads strip the web (not shown in FIG. 10 for clarity of illustration) from the pins 44 and presses the web against the core on the mandrel 35 a of the left turret 34. The web is retained on the core by the transfer glue which was previously applied to the core.
  • FIG. 11 illustrates the bedroll 32 in its transfer position for the right turret 33. Again, the pin shaft 65 and pad shaft 66 are rotated to retract the pins 44 and extend the pads 45 to strip the web (not shown) from the pins and to press the web against the core on the mandrel 35 b of the right turret.
  • FIGS. 12 and 13 illustrate one specific embodiment of a mechanism for operating the pins 44 and pads 45 of the bedroll in more than one transfer position. The structure of FIGS. 12 and 13 is also illustrated and described in U.S. Pat. No. 6,513,750, to which reference can be had for a detailed description. However, the bedroll of the '750 patent has only one transfer position.
  • The pin shaft 65 and pad shaft 66 are rotatably mounted in the bedroll 32, and are driven by timing belts 72 and 73. The timing belt 73 is driven by hub 74 which is rotatably mounted on the journal 75 of the bedroll. The timing belt 72 is driven by a hub 76 which is rotatably mounted on the hub 74. The hubs 74 and 76 are driven through timing belts 77 and 78 by differentials 79 and 80 and electric servo motors 81 and 82. The servos 81 and 82 are controlled by the PLC of the rewinder.
  • A pulley 83 on the bedroll journal 75 is connected to pulleys on the differentials 79 and 80 by belt 84. The bedroll is driven by a servo motor which is controlled by the PLC of the rewinder.
  • The hubs 74 and 76 are rotated at bedroll speed during most of the winding cycle by the differentials 79 and 80. When rotation of the pin shaft 65 or pad shaft 66 is required, the appropriate servo 81 or 82 provides additional rotational speed to rotate the pin shaft or pad shaft relative to the bedroll. As described in U.S. Pat. No. 6,513,750, the differentials are mechanical motion “combiners”, and the output from each differential is the sum of a constant rpm input from the bedroll journal plus the trim rpm input from the servo 81 or 82.
  • The pin and pad shafts need to rotate relative to the bedroll in order to execute cutoff and transfer and also need to rotate relative to each other. The extension of the pins varies depending upon the position of the mandrel relative to the bedroll. The extension of the pads is constant when the pads are extended.
  • With the rewinder illustrated in the drawings, which includes two turrets, cutoff and transfer requires between one and two bedroll revolutions. The perforator roll is the master axis, with the distance between perforation and cutoff remaining constant. The movement of either the right or left turret, along with the movement of the pin and pad shafts, is referenced off of the master.
  • The following timing chart reflects the bedroll positions for two turrets. It will be apparent to those skilled in the art that the timing chart could be expanded to provide additional transfer positions if more than two turrets are used and could also be modified if means other than turrets are used to move the mandrels into the transfer positions.
    Timing Chart
    Turret: Bedroll Position Ref.: Notes:
    Right Turret  0 deg (0 rev) Bedroll phasing hub & bedroll at matched
    speed. Pin timing hub is at start of move.
    Web winding on right turret.
    180 deg (½ rev) Pin timing drive is phased to fully extend
    pins. Cutoff has occurred. Pad timing hub is
    phasing with pads moving outward.
    270 deg (¾ rev) Pads are retracting into bedroll. Transfer has
    occurred. Pins are fully retracted into bedroll.
    360 deg (1 rev) Pads are fully retracted into bedroll.
    (reset for next cutoff & transfer)
    Left Turret  0 deg (0 rev) Bedroll phasing hub & bedroll at matched
    speed. Pin timing hub is at start of move.
    Web winding on left turret.
    180 deg (½ rev) Pin timing drive is phased to fully extend
    pins. Cutoff has occurred.
    270 deg (¾ rev) Pads are extending out from the bedroll. Pins
    are fully extended from the bedroll.
    360 deg (1 rev) Pads are retracting into bedroll. Transfer has
    occurred. Pins are fully retracted into
    bedroll.
    450 deg (1¼ rev) Pads are fully retracted into bedroll. (reset for next
    cutoff & transfer)
  • Each turret indexes or rotates during about 25% of the winding cycle and dwells or is stationary for about 75% of the winding cycle.
  • A rewinder using more than one turret for transfer and winding makes possible cycle rates of up to 70 logs per minute or more. That is double the cycle rate of current rewinders using a single turret.
  • Other mechanisms for actuating the pins and pads could also be used. For example, the pin shaft and pad shaft could be operated by cams or separate timing belt drives.
  • FIG. 14 is a timing chart for one of the turrets 33 or 34, for example, the right turret 33. The chart shows the position, velocity, and acceleration of the turret. The x axis is machine degrees and represents two winding cycles of the rewinder or 720°. The y axis is turret index position in degrees.
  • The right turret dwells during the first 300° of the machine cycle and then moves 120° during the next 120° of the machine cycle. The right turret then dwells for the remaining 300° of two winding cycles.
  • The vertical line just prior to movement of the turret at 300° represents the return to start since the chart shows the turret rotating only 120° rather than showing three separate turret moves of 120° for a total movement of 360°.
  • FIG. 15 is a similar timing chart for the left turret 34. Again, the turret moves 120° during two winding cycles of the machine.
  • FIG. 16 is a timing chart for both of the turrets.
  • FIG. 17 is a timing chart for a conventional roll stripper conveyor which strips the wound log from one of the mandrels of the right turret when the turret is stationary.
  • FIG. 18 is a similar timing chart for the roll stripper conveyor for the left turret.
  • FIG. 19 is a timing chart for both of the roll stripper conveyors.
  • The timing charts for the core loading axis for each turret would be similar. Two conventional core loaders are driven synchronously with the roll strip conveyors. Core loading onto an empty mandrel of a turret takes place at the same time as roll stripping on that turret and while the turret dwells.
  • As used herein, the term “web-winding member” can refer to a mandrel, a core, or an equivalent device which rotates to wind the web. The term “web-transferring member” can refer to either or both of the transfer pins and transfer pads or equivalent devices for transferring the web from the bedroll to the rotating core or mandrel
  • While in the foregoing specification a detailed description of specific embodiments was set forth for the purpose of illustration, it will be understood that many of the details herein given may be varied considerably by those skilled in the art without departing from the spirit and scope of the invention.

Claims (13)

1. An apparatus for transferring a web at two different transfer positions comprising:
a frame,
a roll rotatably mounted on the frame for rotation about a longitudinal axis, the roll having an outer surface for contacting a web,
first and second web-winding members rotatably mounted on the frame for winding a web,
a web-transferring member movably mounted on the roll and being movable between a first position and a second position in which the web-transferring member transfers a web to one of the web-winding members, and
means for moving the web-transferring member to said second position at a first rotational position of the roll for transferring a web to the first web-winding member and for moving the web-transferring member to said second position at a second rotational position of the roll for transferring a web to the second web-winding member.
2. The apparatus of claim 1 in which said web-transferring member includes pins for piercing a web.
3. The apparatus of claim 1 in which the web-transferring member includes pads for pushing a web away from the outer surface of the roll.
4. The apparatus of claim 1 in which the roll includes a journal rotatably mounted on the frame, said means for moving the web-transferring member including a hub rotatably mounted on the journal and drive means connecting said hub to said web-transferring member for moving the web-transferring member between the first and second positions, and means for varying the rotational speed of the hub with respect to the rotational speed of the roll.
5. The apparatus of claim 1 in which the web-transferring member includes pins movable between a first position in which the pins do not engage a web on the outer surface of the roll and a second position in which the pins pierce a web on the outer surface of the roll and pads movable between a first position in which the pads do not engage a web on the outer surface of the roll and a second position in which the pads engage a web on the outer surface of the roll, the roll including a journal rotatably mounted on the frame, first and second hubs rotatably mounted on the journal, first drive means connecting the first hub to said pins for moving the pins between the first and second positions, second drive means connecting the second hub to said pads for moving the pads between the first and second positions, means for varying the rotational speed of the first hub with respect to the rotational speed of the roll, and means for varying the rotational speed of the second hub with respect to the rotational speed of the roll.
6. The apparatus of claim 1 including first and second turrets rotatably mounted on the frame for rotation about a longitudinal axis, said first web-winding member being rotatably mounted on the first turret and said second web-winding member being rotatably mounted on the second turret, said first turret being rotatable to move said first web-winding member to a first web-transferring position adjacent said first rotational position of said roll whereby a web may be transferred from the roll to the first web-winding member, said second turret being rotatable to move said second web-winding member to a second web-transferring position adjacent said second rotational position of said roll whereby a web maybe transferred from the roll to the second web-winding member.
7. An apparatus for transferring a web at two different transfer positions comprising:
a frame,
a roll rotatably mounted on the frame for rotation about a longitudinal axis, the roll having an outer surface for contacting the web,
a first turret rotatably mounted on the frame for rotation about a longitudinal axis,
a plurality of web-winding members rotatably mounted on the first turret, rotation of the first turret bringing each of the web-winding members of the first turret into a first transfer position which is adjacent the roll at a first rotational position of the roll,
a second turret rotatably mounted on the frame for rotation about a longitudinal axis,
a plurality of web-winding members rotatably mounted on the second turret, rotation of the second turret bringing each of the web-winding members of the second turret into a second transfer position which is adjacent the roll at a second rotational position of the roll,
whereby a web on the roll can be transferred to a web-winding member on the first turret at the first rotational position of the roll and can be transferred to a web-winding member on the second turret at the second rotational position of the roll.
8. The apparatus of claim 7 including means for transferring a web to a web-winding member on the first turret at the first rotational position of the roll and for transferring a web to a web-winding member on the second turret at the second rotational position of the roll.
9. The apparatus of claim 8 in which said transfer means includes a pusher movably mounted on the roll.
10. The apparatus of claim 9 in which said transfer means includes means on a web-winding member on the first turret for holding a web and means on a web-winding member on the second turret for holding a web.
11. The apparatus of claim 10 in which each of said means for holding a web includes adhesive on the web-winding member.
12. The apparatus of claim 8 in which said transferring means includes adhesive on a web-winding member on the first turret and adhesive on a web-winding member on the second turret.
13. The apparatus of claim 7 including a blade mounted on the frame adjacent said roll for severing a web on the roll, pins movably mounted on the roll for movement between a retracted position below the surface of the roll and an extended position above the surface of the roll for retaining a web on the roll, and means for moving the pins from the extended position to the retracted position as the roll moves toward the first rotational position and for moving the pins from the extended position to the retracted position as the roll moves toward the second rotational position.
US11/253,228 2005-10-18 2005-10-18 Center rewinder with two turrets and a bedroll with two transfer positions for transferring a web to each of the turrets Abandoned US20070084958A1 (en)

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US20140290865A1 (en) * 2010-02-26 2014-10-02 The Procter & Gamble Company Winding Method
US20150122934A1 (en) * 2011-07-05 2015-05-07 Windmöller & Hölscher Kg Winder and a turret unit
US10033064B2 (en) 2014-06-24 2018-07-24 Duracell U.S. Operations, Inc. Method and apparatus for forming a wound structure
US20210253392A1 (en) * 2018-06-20 2021-08-19 Ims Technologies S.P.A. Machine and method for providing rolls of material for use in sheet form, particularly aluminum for food uses, of the coreless type

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US20210253392A1 (en) * 2018-06-20 2021-08-19 Ims Technologies S.P.A. Machine and method for providing rolls of material for use in sheet form, particularly aluminum for food uses, of the coreless type

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Effective date: 20051010

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