U.S. patent application number 14/129767 was filed with the patent office on 2014-05-15 for automatic splicing system and method.
This patent application is currently assigned to ESSEL PROPACK LTD.. The applicant listed for this patent is Parag Chaturvedi, Pradeep Ramteke. Invention is credited to Parag Chaturvedi, Pradeep Ramteke.
Application Number | 20140131504 14/129767 |
Document ID | / |
Family ID | 46604392 |
Filed Date | 2014-05-15 |
United States Patent
Application |
20140131504 |
Kind Code |
A1 |
Ramteke; Pradeep ; et
al. |
May 15, 2014 |
AUTOMATIC SPLICING SYSTEM AND METHOD
Abstract
A system for automatic web splicing, comprises of an unwinding
section, a splicing section, an accumulator, and a controller to
facilitate clamping, cutting and splicing of the webs to provide
continuous web supply to a utilizing machine, the system comprises
also at least two receiving platforms, a space defining a splicing
area between the delivering platform and the receiving platform,
one platform for receiving a running web and other platform for a
new web and at least one dispenser so as to splice trailing edge of
a running web and a leading edge of a new web with an adhesive
tape. The system joins the two webs in completely auto mode and
keeps the utilizing machine running continuously without
stoppage.
Inventors: |
Ramteke; Pradeep; (Kamala
City, IN) ; Chaturvedi; Parag; (Kamala City,
IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ramteke; Pradeep
Chaturvedi; Parag |
Kamala City
Kamala City |
|
IN
IN |
|
|
Assignee: |
ESSEL PROPACK LTD.
Mumbai
IN
|
Family ID: |
46604392 |
Appl. No.: |
14/129767 |
Filed: |
February 2, 2012 |
PCT Filed: |
February 2, 2012 |
PCT NO: |
PCT/IN2012/000079 |
371 Date: |
December 27, 2013 |
Current U.S.
Class: |
242/556.1 |
Current CPC
Class: |
B65H 19/102 20130101;
B65H 2301/46064 20130101; B65H 2301/46222 20130101; B65H 2301/4607
20130101; B65H 19/18 20130101; B65H 19/1852 20130101 |
Class at
Publication: |
242/556.1 |
International
Class: |
B65H 19/18 20060101
B65H019/18 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 1, 2011 |
IN |
571/MUM/2011 |
Claims
1. A system for automatic web splicing adapted on a running path of
a web between an unwinding section and a utilizing machine for
providing continuous flow of web to the utilizing machine, said
system comprising: at least two receiving platforms, one platform
for receiving a running web and other platform for a new web; a
delivering platform for delivering running web; a space defining a
splicing area between the delivering platform and the receiving
platform; an adjusting means for moving, adjusting, and maintaining
the delivering platform and one of the receiving platforms in-line
with each other; a clamping means for each platform for clamping
the webs during splicing; a shearing blade for cutting a trailing
edge of a finished running web held between the delivering platform
and the receiving platform by clamping means; at-least one
dispenser arranged to travel in cross machine direction within the
said space so as to splice trailing edge of a running web and a
leading edge of a new web with an adhesive tape; and a controller
to facilitate clamping, cutting and splicing of the webs.
2. A system for automatic web splicing as claimed in claim 1,
wherein the receiving platforms is adapted on the adjusting means
for moving and bringing one of the receiving platform in-line with
the delivering platform.
3. A system for automatic web splicing as claimed in claim 1,
wherein the delivering platform is adapted on the adjusting means
for moving and bringing in-line the delivering platform with one of
the receiving platform.
4. A system for automatic web splicing as claimed in claim 1
wherein the controller includes a sensor for each web adapted on
the running path of web in the unwinding section to sense and
activate the controller as the web is finished.
5. A system for automatic web splicing as claimed in claim 1,
wherein the dispenser comprises a one-sided adhesive tape, a rubber
roller to apply pressure over the adhesive applied web edges, and a
vacuum pad to hold front end of the adhesive tape having adhesive
side facing towards the web.
6. A system for automatic web splicing as claimed any one of the
preceding claims, wherein the system preferably comprises two
dispensers, arranged above and below running web within the space
to apply adhesive tape from top and bottom simultaneously.
7. A system for automatic web splicing as claimed in claim 6,
wherein at-least one of the dispensers includes a cutter for
cutting the adhesive tape after splicing the webs.
8. A system for automatic web splicing as claimed in claim 7,
wherein the cutter is preferably adapted in a top dispenser to cut
the adhesive tape after splicing.
9. A system for automatic web splicing as claimed in claim 1,
wherein the system comprises a holding means for holding corners of
the leading edge of a new web and the trailing edge of a finished
web and front edge of the adhesive tape together while splicing the
webs.
10. A system for automatic web splicing as claimed in claim 1,
wherein the adjusting means moves the platform preferably in a
vertical direction.
11. A system for automatic web splicing as claimed in claim 1
further comprises an accumulator to accumulate the spliced web
enough to supply web continuously to the utilizing machine during
splicing operation.
12. A system for automatic web splicing as claimed in claim 1,
wherein the unwinding section comprises a spindle corresponding to
each receiving platform for mounting a web core of running web and
a web core of new web, a running path for each web.
13. A method for automatic web splicing comprising the steps of:
sensing that running web core is finished; clamping the finished
web using clamping means; cutting the finished web; aligning and
adjusting leading edge of a new web in-line with a trailing edge of
the finished web; applying an adhesive tape over the aligned webs
and pressing the applied adhesive tape simultaneously; and cutting
the adhesive tape thereby effecting the splicing of the web.
14. A method for automatic web splicing as claimed in claim 13,
wherein the step of applying adhesive tape includes a step of
holding the corners of the leading edge of a new web and the
trailing edge of a finished web and front edge of the adhesive
tape.
15. A method for automatic web splicing as claimed in claim 13,
wherein the adhesive tape is preferably applied on top and bottom
of the webs simultaneously.
16. A method for automatic web splicing as claimed in claim 13,
wherein speed of splicing is dependent on speed of an utilizing
machine.
Description
FIELD OF THE INVENTION
[0001] The present invention generally relates to a splicing system
for providing continuous web supply and a method thereof.
BACKGROUND OF THE INVENTION
[0002] Continuous flow of web is required in paper and plastic
laminate manufacturing process and preferably for printing.
Accordingly, leading edge of a new roll of web is spliced with the
trailing edge of an old web.
[0003] Traditionally, splicing of webs is achieved by
manually/automatically joining the trailing edge of the old web
with leading edge of a new web from webs being unwound from rolls
carried on cores. The splicing is done by applying adhesive over
trailing end or leading end and joining by overlapping the web or
by using an adhesive tape to join the two ends with overlap or butt
splicing.
[0004] To carry out such splicing manually, either subsequent
machine is stopped or requires slowing down of the subsequent
machine and use of an accumulator considering the time required to
splice the webs. Moreover, in web-printing, precision plays
important role in splicing as incorrect splicing may lead to
improper printing registration resulting in rejections.
Furthermore, the overlapping splicing method has a serious
disadvantage since the thickness of the web increases at the
overlapped portion, the variation in thickness effects coating or
printing results when the web is fed through a coating or printing
machine.
[0005] U.S. Pat. No. 6,016,989 granted in the year 2000 discloses a
`Paper Web Autosplicer` to produce a double-sided web splice for
paper webs. However, in this patent the leading and trailing edges
are required to be settled downwardly under their own weight onto
the adhesive face of the tape and hence splicing accuracy depends
upon the weight of the web.
[0006] Therefore, there is a need for an automatic splicing system
and method to resolve above issues.
SUMMARY OF THE INVENTION
[0007] Accordingly, the present invention provides in a first
aspect a system for automatic web splicing adapted on a running
path of a web between an unwinding section and a utilizing machine
for providing continuous flow of web to the utilizing machine. The
said system comprises at least two receiving platforms, one
platform for receiving a running web and other platform for a new
web, a delivering platform for delivering running web, a space
defining a splicing area between the delivering platform and the
receiving platform, an adjusting means for moving, adjusting, and
maintaining the delivering platform and one of the receiving
platforms in-line with each other, a clamping means for each
platform for clamping the webs during splicing, a shearing blade
for cutting a trailing edge of a finished running web held between
the delivering platform and the receiving platform by clamping
means, at-least one dispenser arranged to travel in cross machine
direction within the said space so as to splice trailing edge of a
running web and a leading edge of a new web and a controller to
facilitate clamping, cutting and splicing of the webs.
[0008] According to one embodiment of the system of the present
invention, either receiving platform or delivery platform is
mounted on the adjusting means. Advantageously, the receiving
platforms are adapted on the adjusting means for moving and
bringing one of the receiving platform in-line with the delivering
platform. Alternatively, the delivery platform can be adapted on
the adjusting means for moving to bring in-line with one of the
receiving platform.
[0009] According to the present invention, the controller includes
a sensor for each web adapted on the running path of web in the
unwinding section to sense and activate the controller as the web
is finished.
[0010] According to another embodiment of the system of the present
invention, the system comprises two dispensers, arranged above and
below running web within the space to apply adhesive tape from top
and bottom simultaneously. The dispenser comprises a one-sided
adhesive tape, a rubber roller to apply pressure over the adhesive
applied web edges, and a vacuum pad to hold frond end of the
adhesive tape having adhesive side facing towards the web.
[0011] According to one another embodiment of the system of the
present invention, at-least one of the dispensers includes a cutter
for cutting the adhesive tapes after splicing. Advantageously, the
cutter is adapted in a top dispenser to cut the adhesive tape after
splicing.
[0012] According to further embodiment of the system of the present
invention, the system comprises a holding means for holding corners
of the leading edge of a new web and the trailing edge of a
finished web and front edge of the adhesive tape together while
splicing the webs.
[0013] According to further another embodiment of the system of the
present invention, the system optionally comprises an accumulator
to accumulate the spliced web enough to supply web continuously to
the utilizing machine during splicing operation.
[0014] In a second aspect, the present invention provides a method
for automatic web splicing comprising the steps of sensing that
running web core is finished, clamping the finished web using
clamping means, cutting the finished web; aligning and adjusting
leading edge of a new web in-line with a trailing edge of the
finished web, applying an adhesive tape over the aligned webs and
pressing the applied adhesive tape simultaneously, and cutting the
adhesive tape thereby effecting the splicing of the web.
[0015] In preferred embodiment of the method of the present
invention, the step of applying adhesive tape includes a step of
holding the corners of the leading edge of a new web and the
trailing edge of a finished web and front edge of the adhesive
tape.
[0016] According to the present invention, the method preferably
applies adhesive tape on top and bottom of the webs
simultaneously.
[0017] According to the present invention the splicing speed of the
system is dependent on speed of an utilizing machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Reference will be made to embodiments of the invention,
examples of which may be illustrated in the accompanying figures.
These figures are intended to be illustrative, not limiting.
Although the invention is generally described in the context of
these embodiments, it should be understood that it is not intended
to limit the scope of the invention to these particular
embodiments.
[0019] The above and other objects, features and advantages of the
present invention will be more clearly understood from the
following detailed description taken in conjunction with the
accompanying drawing, in which:
[0020] FIG. 1 shows an automatic splicing system according to the
present invention;
[0021] FIG. 2 shows a block diagram of automatic splicing system
according to the present invention;
[0022] FIG. 3 shows a splicing section of the automatic splicing
system according to the present invention;
[0023] FIG. 4 shows a top dispenser as per a preferred embodiment
of the present invention;
[0024] FIG. 5A-5D shows side views of splicing section of the
automatic splicing system of the present invention, where:
[0025] FIG. 5A shows a position of the dispenser before moving in
cross machine direction;
[0026] FIGS. 5B and 5C shows movements of dispenser after moving in
cross-machine direction;
[0027] FIG. 5D shows a position of dispenser moving in opposite
cross-machine direction after tape pasting.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Hereinafter, the preferred embodiments of the present
invention will be described in detail with reference to the
accompanying drawings. Reference now should be made to the
drawings, in which the same reference numerals are used throughout
the different drawings to designate the same or similar
components.
[0029] The present invention provides a system for automatic web
splicing for providing continuous flow of web to a utilizing
machine. The system joins the two webs in completely auto mode and
keeps the utilizing machine running continuously without
stoppage.
[0030] FIG. 1 and FIG. 2 show an automatic web splicing system
according to a preferred embodiment of the present invention.
[0031] The automatic splicing system (100) comprises an unwinding
section (110), a splicing section (120), an accumulator (130) and a
controller (140) to facilitate clamping, cutting and splicing of
the webs to provide continuous web supply to a utilizing
machine.
[0032] As shown in FIG. 1, the unwinding section (110) comprises
two spindles (112a, 112b) for mounting web cores (114a, 114b) and
two running paths (a, b) guiding the webs (115a, 115b) to splicing
section. Sensors (116a, 116b) are mounted on the running path of
each web (115a, 115b). For sake of explanation, webs adapted to the
web cores (114a, 114b) may be referred as running web (115a) and
new web (115b). Further, as shown in FIG. 1, the system comprises
of an accumulator (130). The accumulator (130) is adapted generally
below the splicing section (120) to accumulate the web (115) enough
to supply the web continuously to a utilizing machine to avoid the
stoppage of machine.
[0033] FIG. 3 and FIG. 5 show the splicing section as per a
preferred embodiment of the present invention.
[0034] Referring at this point to FIG. 3 which shows the splicing
section (120) comprising of a delivering platform (124) and
at-least two receiving platforms (122a, 122b)--a first receiving
platform (122a) for a running web (115a) and a second receiving
platform (122b) for a new web (115b), and a shearing blade (127)
for cutting a trailing edge of a finished running web (115a) held
between the receiving and delivering platform by clamping means
(125 a, 125b, 125). The clamping means (125a, 125b, 125) clamp the
webs while splicing the webs.
[0035] Further, the delivering platform (124) and receiving
platforms (122a, 122b) are adjusted and maintained in-line with
each-other via an adjusting means. The adjusting means moves the
platform preferably in a vertical direction. According to the
present invention, the receiving platforms (122a, 122b) or the
delivering platform (124) may be adapted to the adjusting means. As
shown in the FIG. 3, and as per the preferred embodiment of the
invention, the delivering platform (124) is fixed and the receiving
platforms (122a, 122b) are movable by adapting it to the adjusting
means for moving and bringing one of the receiving platforms (122a,
122b) in-line with the delivering platform (124) for splicing. As
shown, a space (x) defines a splicing area between the receiving
platform (122a, 122b) and the delivering platform (124) depending
on width of an adhesive tape. According to the invention, the
adhesive tape is dispensed from at-least one dispenser. According
to the present invention, the splicing system comprises two
dispensers arranged above and below the space defined between the
delivering and receiving platforms.
[0036] FIG. 4 shows the top dispenser (128a) of the present
invention. The dispenser (128a) comprises one side adhesive tape
roll (10a), a rubber roller (20a) to apply pressure and a vacuum
pad (22) to hold adhesive of the adhesive tape facing towards the
web. As shown in FIG. 4, a cutter (129) is also adapted in the top
dispenser to cut the adhesive tape (10a). Alternatively, a cutter
can be adapted in the bottom dispenser.
[0037] FIGS. 5A to 5D show side views of operation of an automatic
splicing system as per a preferred embodiment of the present
invention showing dispensers (128a, 128b) adapted on a rod-less
cylinder unit to allow the dispensers to move in a cross-machine
direction for splicing. FIGS. 5A to 5D also shows holding means
(127) for holding corners of the leading edge of a new web and the
trailing edge of a finished web and front edge of the adhesive tape
together while splicing the webs. As shown, each dispenser (128a,
128b) comprises one side adhesive tape roll (10a, 10b), a rubber
roller (20a, 20b) to apply pressure, and a vacuum pad (22) to hold
front end of the adhesive tape (10a, 10b) facing towards the web. A
cutter (129) is adapted in one of the dispenser to cut the adhesive
tape (10a, 10b) to cut the adhesive tape after splicing.
[0038] FIG. 1 and FIG. 5A-5D illustrates operability method of the
automatic splicing system, wherein, a web core (114a) mounted on
spindle (112a) is running through a first receiving platform
(122a), delivering platform (124) and accumulator (130), while web
core (114b) mounted on another spindle (112b) is readily mounted on
the second receiving platform (122b). During this period, the
splicing section (120) is inactive as showing in FIG. 5A and allows
the running web (115 a) to pass to a utilizing machine.
[0039] As the running web (115a) on web core (114a) finishes, the
sensor (116a) mounted on the running path of the unwinding section
for said web (115a) senses that the web (115a) on the core (114a)
is finished and accordingly passes the information to the
controller (140) which activates the clamps (125a) on receiving
platform (122a) and the clamp (125) on delivering platform (124) to
clamp the running web as well as activates the accumulator (130).
As soon as the web (115a) is clamped between the two clamps, the
shearing blade (126) activates and cross cuts the clamped web.
After cutting, an adjusting means moves the receiving platforms
(122a, 122b) so as to adjust the receiving platform (122b) in-line
with the delivering platform (124) thereby bringing leading edge of
the new web (115b) in-line with the cut edge i.e. trailing edge of
the finished web. The dispensers (128a, 128b) then moves in cross
machine direction on the rod-less cylinder unit as shown in FIGS.
5B and 5C, and comes in contact with the holding means (127) which
hold the free edges of the adhesive tapes (10a,10b) having adhesive
face over the edges of the leading and trailing web from
longitudinal side of the webs and then dispensers (128a, 128b)
moves in the opposite direction as shown in FIG. 5D applying the
adhesive tape (10a, 10b) and pressing the adhesive tape
simultaneously by rubber rollers (20a, 20b) applied over the web
edges thereby butt splicing the web edges from both sides i.e. top
and bottom side. On splicing, the cutter (129) adapted in the upper
dispenser (128a) cuts the adhesive tape and splicing is completed
thereby forming a continuous web. After completion of the splicing,
clamps over the running web frees the web and the machine starts
drawing of web from the new web core. Similarly, when a running
roll is processed and finished, the sensor passes a signal to the
controller and the controller changeovers to a new web by clamping,
cutting and splicing the running web with next web and keeps the
machine running.
[0040] According to the present invention the splicing speed of the
system depends upon speed of the utilizing machine. In this aspect,
the splicing system does not require its own drive. For example,
for a laminate printing machine operating at tension 5 kg and
having a printing speed of 80 meters/min, splicing system of the
present invention requires total cycle time of about 4 to 6 seconds
depending on width of web for splicing.
[0041] Advantageously, the present invention provides auto splicing
along with increase in machine up time, reduction in scarp,
reduction in man-hours, improved quality of joint, elimination of
paper shifting, as well as elimination of breakage of papers by
providing a quality of joint on both side of the web along with
improved strength. Further, the splicing system of the present
invention is a compact machine which can be easily adapted to on an
in-use continuous plastic or paper web processing machine without
major modifications.
* * * * *