U.S. patent number 3,822,838 [Application Number 05/236,122] was granted by the patent office on 1974-07-09 for web handling apparatus.
This patent grant is currently assigned to Butler Automatic Inc.. Invention is credited to Rudy R. Arendt, Richard A. Butler, Jr., Jack T. Hansen, August R. Rump.
United States Patent |
3,822,838 |
Butler, Jr. , et
al. |
July 9, 1974 |
**Please see images for:
( Certificate of Correction ) ** |
WEB HANDLING APPARATUS
Abstract
Web handling apparatus pulls web from a supported roll at a
selected speed. A brake is provided for controlling the roll speed
and a sensor senses changes in the tension of the web caused by
changes in the pulling force of the web. The brake is controlled in
accordance with the output of the tension sensor so that the web is
maintained substantially under constant tension. Also, the
apparatus responds to the instantaneous size of the roll by
modulating the braking means so that the drag force imparted by the
brake to the web is substantially independent of roll size.
Inventors: |
Butler, Jr.; Richard A.
(Chestnut Hill, MA), Hansen; Jack T. (Needham, MA), Rump;
August R. (Chicago, IL), Arendt; Rudy R. (South Wales,
NY) |
Assignee: |
Butler Automatic Inc. (Canton,
MA)
|
Family
ID: |
22888214 |
Appl.
No.: |
05/236,122 |
Filed: |
March 20, 1972 |
Current U.S.
Class: |
242/417.2;
242/417.3; 242/421.1; 242/421.2; 242/421.7; 242/552 |
Current CPC
Class: |
B65H
19/14 (20130101); B65H 23/063 (20130101) |
Current International
Class: |
B65H
19/14 (20060101); B65H 19/10 (20060101); B65H
23/06 (20060101); B65h 025/28 () |
Field of
Search: |
;242/75.43-75.45,57,58.1,58.4,187 ;318/6,7 ;156/504 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Christian; Leonard D.
Attorney, Agent or Firm: Cesari and McKenna
Claims
We claim:
1. Web handling apparatus comprising
A. means for supporting a roll of running web,
B. means for pulling web from the roll at a selected speed,
C. means for braking the roll,
D. means for sensing changes in the tension of the web as it runs
caused by changes in the pulling force on the web,
E. means for controlling the braking means in accordance with the
output of the tension change sensing means so as to tend to
maintain substantially constant web tension,
F. means responsive to the instantaneous size of the roll, and
G. means for modulating the control of the braking means so that
the drag force imparted by the brake to the web is substantially
independent of roll size.
2. Web handling apparatus as defined in claim 1 wherein the size
responsive means comprise
A. means for measuring the angular velocity of the roll of running
web,
B. means for measuring the angular velocity of a fixed diameter
roll engaged by the running web,
C. means for processing the two roll velocities to obtain a ratio
which reflects the size of the roll of running web.
3. Web handling apparatus as defined in claim 2 wherein
A. the roll velocity measuring means comprise tachometers driven by
the rolls, and
B. the processing means comprise a divider which divides the output
of the tachometer associated with the fixed diameter roll by the
output of the tachometer associated with the roll of running
web.
4. Web handling apparatus as defined in claim 1 wherein the means
for sensing changes in web tension comprise
A. a deflectible member,
1. having a selected spring constant, and
2. engaged by the running web so that the web moves the member in
one direction when its tension increases and moves the member in
another direction when its tension decreases, and
B. means for sensing the position of the member to develop an
output to control the braking means.
5. Web handling apparatus as defined in claim 1 wherein
A. the deflectible member is a dancer in a web accumulator situated
downstream from the roll of running web, and
B. the position sensing means is a potentiometer associated with
the dancer which changes its resistance value as the dancer moves
in response to changes in web tension.
6. Web handling apparatus as defined in claim 5 and further
including
A. means for measuring the instantaneous velocity of the
dancer,
B. means for applying the velocity measurement as a damping factor
in the brake controlling means so as to increase the braking force
on the roll of running web as dancer velocity increases.
7. Web handling apparatus as defined in claim 6 and further
including
A. means for actuating the braking means so as to decelerate the
roll of running web to a selected minimum speed at a programmed
rate, and
B. means for detecting when the web speed is below a predetermined
value.
8. Web handling apparatus as defined in claim 7 wherein the web
speed detecting means comprise
A. a tachometer associated with a roll engaged by the running web,
and
B. means for detecting when the output of the tachometer falls
below a predetermined value.
9. Web handling apparatus as defined in claim 7 wherein the
actuating means comprise a ramp generator.
10. Web handling apparatus as defined in claim 6 wherein
A. the dancer velocity measuring means comprise means for
differentiating a signal reflecting the potentiometer resistance
value, and
B. the applying means include a summing network that sums the
output of the differentiator with the output provided by the
potentiometer.
11. Web handling apparatus as defined in claim 8 and further
including
A. means for supporting a roll of ready web, and
B. means for accelerating the ready roll supporting means after the
web speed falls below said predetermined value.
12. Web handling apparatus comprising
A. means for supporting a roll of running web,
B. means for supporting a roll of ready web,
C. means for pulling web selectively from said roll at a selected
speed,
D. means for braking the rolls,
E. a deflectible member contacting the running web and around which
the running web moves,
F. means for sensing the position of the deflectible member, said
sensing means emitting a signal when the member deviates from a
selected position,
G. means for differentiating the signal from the position sensing
means,
H. means for summing the outputs of the position sensing means and
the differentiating means, and
I. means for controlling the braking means in accordance with the
output of the summing means so as to tend to maintain substantially
constant tension in the running web.
13. Web handling apparatus as defined in claim 12 and further
including means for modulating the output of the summing means in
accordance with the size of the roll of running web so that the
braking force applied to the running roll varies inversely with the
size of the running roll.
14. Web handling apparatus as defined in claim 13 wherein the
modulating means comprise
A. means responsive to the diameter of the running web roll and
emitting an output signal in response thereto, and
B. means for multiplying the output of the responsive means by the
output of the summing means prior to the application of the latter
to the brake control means.
15. Web handling apparatus as defined in claim 14 wherein the
running web roll diameter detecting means comprise
A. means for measuring the angular velocity of the running web
roll,
B. means for measuring the angular velocity of a fixed diameter
roll in contact with the running web,
C. means for dividing the output of the first angular velocity
measuring means by the output of the second angular velocity
measuring means, and
D. means for multiplying the quotient of said division by the
output of the summing means prior to application of the latter to
the brake control means.
16. Web handling apparatus as defined in claim 13 further
including
A. means for measuring the speed of the running web and delivering
an output signal in response thereto, and
B. means responsive to the output of the modulating means for
controlling the brake control means so as to brake the running web
roll to a selected minimum speed when the running web roll diameter
reaches a pre-determined minimum size.
17. Web handling apparatus as defined in claim 16 comprising
A. means for accelerating the roll of ready web after the running
web roll reaches said selected minimum speed, and
B. means for disabling the accelerating means after the ready web
roll reaches a pre-determined higher speed.
18. Web handling apparatus as defined in claim 17 wherein the
disabling means include
A. a first detector means responsive to the output of the
differentiating means for emitting an output when the velocity of
the deflectible member in one direction from the selected position
is less than a minimum value,
B. second detector means responsive to the output of the
differentiating means for emitting an output when the velocity of
the deflectible member in the opposite direction from the selected
position is less than said minimum value, and
C. means for disabling the accelerating means up on the
simultaneous occurrence of outputs from the two detector means.
19. Web handling apparatus as defined in claim 18 further including
means responsive to the output of the differentiating means for
causing the brake control means to brake the running web roll to a
stop when the velocity of the deflectable member exceeds a selected
maximum value.
Description
BACKGROUND OF THE INVENTION
This invention relates to web handling apparatus. It relates more
particularly to a system for controlling web tension in such
apparatus.
The apparatus with which we are concerned here is used to provide
web uninterruptedly to machines which consume the web at high
speed, a printing press, for example. The apparatus is designed to
automatically splice the leading end of a roll of ready web to the
trailing end of a depleted roll of running web and to deliver the
web continuously in a controlled fashion to the web-consuming
machine. In order to accomplish this, the apparatus includes an
accumulator situated between the splicer and the web-consuming
machine. When the running web is stopped to splice its trailing end
to the ready web, there is enough material in the accumulator to
supply the needs of the web-consuming machine until the ready web
roll is accelerated to running speed after the splice is made.
A conventional machine of this type is disclosed in U.S. Pat. No.
3,305,189 and the present invention will be described in terms of a
machine of that type.
Basically, the apparatus includes supports for a pair of web rolls,
one of which is running and one of which is at the ready. The
running web is conducted into an accumulator and the web material
leaving the accumulator travels into the web-consuming machine. The
accumulator is comprised of a set of fixed rolls and a movable
dancer carrying a second set of rolls. The web is looped between
the fixed rolls and the dancer rolls, forming a series of bights.
The amount of material in the accumulator is controlled by moving
the dancer toward or away from the set of fixed rolls. In other
words, as the dancer moves further away from the set of fixed rolls
(i.e., upward), the amount of material in the accumulator
increases, and vice-versa. In operation, the dancer is biased away
from the fixed rolls under constant pressure and is caused to move
by changes in the tension in the web.
Usually, web is pulled from the running roll by a pulling roll in
the web-consuming machine at a constant rate whose value depends
upon the requirements of the web-consuming machine. The running
supply roll is braked in a controlled fashion to maintain the
proper web tension. In the apparatus illustrated in the above
patent, the amount of braking force applied to the running web
roll, i.e., the amount of tension imparted to the web, is
determined by the position of the dancer in the accumulator which,
as pointed out above, reflects web tension.
As the dancer moves toward the set of fixed rolls (i.e., downward)
indicating an increase in the web tension, the web braking force is
reduced so that web runs into the accumulator at a faster rate,
thereby tending to move the dancer up away from the set of fixed
rolls. Conversely, if the dancer moves upward, indicating a web
tension decrease, the braking force on the running roll is
increased to slow down the rate at which web enters the
accumulator. This tends to move the dancer downward toward the set
of fixed rolls. Thus, during normal operation of the apparatus, the
dancer seeks a zero position in an attempt to maintain
substantially constant tension in the web. This position is
selected so that there is enough web in the accumulator to satisfy
the needs of the web-consuming machine when the running roll is
stopped for splicing.
These prior system work well at relatively low web speeds. However,
at higher speeds, on the order of 1,500 feet per minute, certain
problems develop. More particularly, in an attempt to maintain
constant web tension at these high speeds, the dancer tends to hunt
about its zero point, causing unwanted web tension changes. This is
due in large part to the inertia of the dancer and the delay
between the time when the dancer issues a command signal to the
brake and the time when the brake responds. Also, the running web
supply roll is constantly decreasing in diameter so that its moment
of inertia is constantly changing. Accordingly, when the brakes are
applied, the web tension is affected differently, depending upon
the amount of material remaining on the roll. In practice, this
effect causes a gradual increase in web tension, with the result
that the dancer moves down and reduces the amount of available
material in the accumulator. Also, in the prior machines, there is
a relatively long time delay between the various events which take
place during the splicing cycle, and after splicing there is
inadequate control over the refilling of the accumulator. These and
other problems make the prior apparatus unsatisfactory for
operation at high speeds, particularly when handling the finer
webs.
SUMMARY OF THE INVENTION
Accordingly, this invention aims to provide a web tension control
system which operates reliably at high web speeds.
Another object of the invention is to provide a web tension control
system which maintains close control over web tension immediately
before and after a splice.
A further object of the invention is to provide a web tension
control system which alleviates the dancer hunting problem.
Yet another object of the invention is to provide a web tension
control system which assures that a splice is made only when the
running web is at a standstill.
A further object of the invention is to provide a web tension
control system which is relatively easy and inexpensive to make and
maintain.
Still another object of the invention is to provide a web tension
control system which responds quickly to an emergency situation
such as a web break.
Yet another object of the invention is to provide a web tension
control system which enables the operator to maintain close control
over the position of the dancer in the accumulator during all
phases of operation of the web supply apparatus, including
emergency stops.
Other objects will in part be obvious and will in part appear
hereinafter. The invention accordingly comprises the features of
construction, combination of elements and arrangement of parts
which are exemplified in the construction hereinafter set forth,
and the scope of the invention will be indicated in the claims.
We will describe the present system in conjunction with a web
supply apparatus of the type disclosed in the aforesaid patent. The
apparatus includes arbors for supporting a roll of running web and
a roll of ready web. Both rolls, or more particularly the arbors
therefor, are equipped with brakes to vary the speed at which the
rolls turn when web is being pulled from them. The running web is
fed through an accumulator to the web-consuming machine, i.e., a
printing press. In the accumulator, the web is looped between
movable dancer rolls and stationary rolls, with the amount of
material in the accumulator being determined by the position of the
dancer.
During normal operation of the apparatus, the web-consuming machine
pulls web out of the accumulator with a force sufficient to
maintain the web at a selected, substantially constant velocity,
depending upon the requirements of the web-consuming machine. The
position of the dancer is continuously measured by a pontentiometer
whose resistance is employed as a basis for modulating the braking
force applied to the roll of running web to maintain a selected
tension in the web. The system also determines dancer velocity at
each instant and this measurement is used to further modulate the
braking force applied to the supply roll to minimize instabilities
and the tendency of the dancer to hunt about its selected zero
position point.
Still further, the size of the roll of running web is measured
continuously. This is not done by measuring the size of the roll
directly by a follower arm. Rather, it is done by obtaining the
ratio of the angular velocities of a fixed guide roll ahead of the
accumululator and the running roll and employing that measurement
to vary the gain of the system to reduce the braking force applied
to the running roll as the roll size diminishes. This gives
improved braking control for web rolls of all diameters and over a
full range of web speeds from thread speed up to full speed
emergency stops. This variable gain feature also tends to maintain
the dancer at its selected zero position point so that there is no
tendency for the dancer to move down, decreasing the web supply in
the accumulator as the roll size diminishes.
When the size of the running roll reaches a selected minimum size,
the system automatically activates the splice cycle to decelerate
the running web, make the actual splice at a time when the web is
stopped and acclerate the ready web to running speed. This is
accomplished with a minimum delay between these steps so that a
good splice is made in a short time. Consequently, the system
conserves a maximum amount of web storage during the splice
cycle.
The aforesaid controls over web tension and web and dancer
movements are achieved substantially entirely by electronic means.
Therefore, the system responds very quickly to changing conditions.
Moreover, the electronic components which make up the present
tension control system are more reliable and require less
maintenance than the pneumatic and mechanical elements found in the
prior apparatus.
BREIF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the
invention, reference should be had to the following detailed
description taken in connection with the accompanying drawings, in
which:
FIG. 1 is a diagrammatic view of web supply apparatus incorporating
the present invention; and
FIG. 2 is a block diagram partly in schematic form showing the
tension control system in the FIG. 1 apparatus in greater
detail.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIG. 1 of the drawings, a roll 10 of running web is
supported for rotation on a suitable shaft or arbors 12. The web W
from roll 10 is conducted through a splicing station 14 and under a
guide roll 16 to an accumulator shown generally at 18. The web
leaving the accumulator is conducted under a guide roll 22 and
thence to the web-consuming machine, ilustratively a printing press
24. During normal operation, a pull roll in press 24 pulls web W
with a force which is sufficient to give the web a fixed velocity
V.sub.p into the press.
The apparatus also includes a roll 26 of ready web also rotatively
supported on a suitable shaft or arbors 28. The leading end of roll
26 is set in the splicing station to await the depletion of the
running roll 10. Whereupon it is spliced to the trailing end of the
running web as described in the aforesaid patent so that web
proceeds uninterruptedly through the accumulator 18 into the press
24. The activation of the splice cycle will be described later.
A conventional tachometer 32 is geared to an arbor 12. The
tachometer develops an output signal which is proportional to the
velocity of arbors 12 and, hence, roll 10. This signal is coupled
to a control console 34 and processed in the manner to be described
later. A similar tachometer 36 is geared to an arbor 28 to apply a
signal to the console 34 which is proportional to the velocity of
roll 26.
A third tachometer 38 is geared to the guide roll 16 and generates
an output signal to console 34 which is proportional to the
velocity of roll 16. Control console 34 processes the signals from
tachometer 38 and from either tachometer 32 or tachometer 36 to
develop a control signal which represents the instantaneous size of
the roll of running web, i.e., either roll 10 or roll 26.
The accumulator 18 comprises a set of fixed rolls 42 and a set of
dancer rolls 44 in a movable dancer 46 situated directly above
rolls 42. The rolls 42 and 44 are staggered so that the web W can
be looped around the rolls festoon fashion so that an appreciable
amount of web can be stored in the accumulator. The amount of web
stored in this manner depends upon the distance between the dancer
46 and the fixed rolls 42. As the spacing increases, more web is
stored in the accumulator and vice versa.
The dancer 46 carrying the rolls 44 is supported by suitable means
such as a cable 52 which extends up vertically and is passed around
a pulley 54 positioned above the fixed rolls 42. The cable extends
around a second pulley 56 and is attached to a rod 58 of a piston
which includes a cylinder 62. The full stroke of the piston causes
the dancer 46 to move from its lowermost position adjacent the
fixed rolls 42 to an upper position wherein the accumulator stores
a maximum amount of web W. In practice, differential pulleys or
other means may be employed so that the stroke of the piston can be
considerably less than the stroke of dancer 46. A solenoid valve 63
feeds air to or bleeds air from the upper chamber within cylinder
62 (i.e., above the piston). Normally, a constant pressure is
applied to the piston which is sufficient to support the dancer 46
above rolls 42.
A potentiometer 66 is geared to pulley 54 so that a full stroke of
the dancer 46 varies the resistance of the potentiometer over its
complete range. Thus, the instantaneous position of the dancer 46
is reflected by a selected resistance value in potentiometer 46
which is applied to and processed by console 34 as will be
described later.
During normal operation, the dancer 46 seeks a zero position
Y.sub.O and stores enough web in the accumulator to supply the
press 24 when the web input to the accumulator stops during the
splicing cycle. At this time, press 24 pulls the web W with a force
sufficient to maintain the constant running speed V.sub.P. This
force necessary to remove the web at constant velocity is the sum
of the inertia force caused by rolls 42 and 44 and the drag force
at the running roll, i.e., roll 10. Since the inertia force is
substantially constant, if constant web tension is to be
maintained, then the drag force at the running roll must be varied
as the pulling force by the press varies. This is accomplished at
roll 10 by a pneumatically operated disc brake 72 connected by an
air line 74 to console 34. A similar brake 76 controls the speed of
the ready web roll 26, the fluid for this brake being applied from
the console through a fluid line 78.
Thus, during normal operation, changes in web tension are reflected
by a movement of the dancer 46 up or down from its zero position
Y.sub.O. The instantaneous dancer position is in turn reflected by
a given resistance in the potentiometer 66. This causes the console
34 to vary the pressure applied to the brake 72 controlling the
running web to increase or decrease the drag force on the running
web as necessary to return the dancer to its zero position
Y.sub.O.
As will be seen later also, the console processes the resistance
value of potentiometer 66 to develop a signal which represents the
velocity of the dancer 46. This signal is also used to modulate the
drag force applied by brake 72 to obtain even closer control over
web tension and the movements of dancer 46. Still more control over
web tension and dancer movements is obtained by varying the gain of
the closed servoloop in the console in accordance with the size of
roll of running web by processing the signals from tachometers 32
and 38. As a result, the system minimizes the hunting movements of
the dancer over the full range of web speeds. Also, just the proper
amount of braking force is applied to the running web roll for the
existent operating conditions.
When the size of the running roll 10 reaches a predetermined
minimum diameter, this is detected by console 34 which thereupon
initiates the splicing cycle. The console applies a constantly
increasing pressure to the break 72 on the running roll so that the
roll decelerates at a predetermined rate. By varying the gain of
the system in accordance with roll size, as the roll diminishes in
size, the dancer can be made to move up, making more storage
available at time of splice. Also, as the roll diminishes in size,
less storage is required for emergency stops. Accordingly, this
system can be programmed so that just enough reserve storage is
available in the accumulator to handle an emergency stop
proportional to roll diameter.
As soon as the speed of the running web W reaches zero or a
selected minimum speed, as measured by the tachometer 38, console
34 emits a control signal to the splicing station 14 to bring the
leading edge of the ready web from roll 26 against the trailing
edge of the running web W, the ready web having previously been
laid into the splicing station 14 and provided with double-faced
adhesive as described in the aforesaid patent. The two webs now
being spliced together, the control console 34 actuates a knife
which cuts the running web immediately behind the splice.
Thereupon, the console emits a signal to a conventional eddy
current drive 82 associated with the arbors 28 supporting the roll
26 of ready web. Drive 82 accelerates the ready roll for a
predetermined time sufficient to bring the ready web substantially
up to the web running speed V.sub.P. A similar drive 84 is
associated with arbors 12 for accelerating those arbors when they
are supporting a roll of ready web.
During the aforesaid splice cycle, the amount of web W entering the
accumulator 18 is much less than the amount of material being
pulled from the accumulator by press 24. Accordingly, the supply of
web stored in the accumulator is reduced, causing the dancer 46 to
move down toward the fixed rolls 42. Upon completion of the
splicing cycle, console 34 controls the speed of the web entering
the accumulator and the movements of the dancer to control the rate
at which the accumulator refills with web. In other words, if the
supply of web is substantially depleted, the dancer is returned to
its zero position Y.sub.O at a faster rate than if there is only a
small web deficiency in the accumulator. Since a closed loop
servocontrol system is employed, there is much closer control over
the movements of dancer 46, particularly during the splice service
cycle when the accumulator is being refilled.
As will be described presently, the system also provides means for
detecting excessive movements of the dancer 46 which signal some
emergency condition such as a web break. In response to these
emergency conditions, this system stops the web in a controlled
fashion in a minimum of time. All of these factors make the present
system preferable to the prior pneumatic tension control systems
exemplified in the aforesaid patent.
Referring now to FIG. 2 which shows in greater detail the
components in console 34, the present system measures running roll
size indirectly by tachometers which measure the angular velocities
of the running roll and the fixed speed guide roll 16. This can be
done because the following relationship holds:
r.sub.1 = r.sub.2 (.omega..sub.2 /.omega..sub.1) (1)
Where:
r.sub.1 = radius of roll 10
r.sub.2 = radius of roll 16
.omega..sub.1 = angular velocity of roll 10
.omega..sub.2 = angular velocity of roll 16
More particularly, the output voltage of tachometer 32 (or
tachometer 36) is applied to an amplifier 92 which filters the
signal to eliminate tachometer noise and provides gain so that the
output from the amplifier 92 reflects the RPM of the running roll.
A similar circuit 94 conditions the output of tachometer 38. The
signals from circuits 92 and 94 are applied to an analog divider 96
which divides the latter by the former to develop an output voltage
which reflects the instantaneous size of the running roll, e.g.,
roll 10.
The output of the analog divider 96 is applied to an amplitude
comparator 98 which compares this voltage with the voltage from an
adjustable splice radius threshold control 102. The voltage output
of control 102 represents the running roll size at which it is
desired to commence the splice cycle. When the voltage applied to
comparator 98 by the divider drops to this value, indicating that
the roll of running web is almost depleted, the output of
comparator 98 actuates a current driver 104 which energizes a relay
106 to commence the deceleration of the running web in preparation
for the splice as described above.
The output of circuit 94 indicative of the speed of the guide roll
16 and, hence, the speed of the web entering the accumulator 18, is
applied to a second amplitude comparator 108 where it is compared
with the voltage from a velocity threshold control 110. When the
speed of roll 16 falls to zero or a selected minimum value at which
a satisfactory splice can be formed, comparator 108 develops an
output which activates the driver 112 controlling a relay 114. The
relay, in turn, initiates the events in the splicing operation
described in the aforesaid patent. Thus, the splice is accomplished
the instant that the running web stops after commencement of the
splicing cycle. The relay 114 also engages the eddy current drive
82 which immediately accelerates the ready web 26 following the
splice. Thus, there is minimal delay between the various steps in
the splicing cycle.
The output of the analog divider 96 which reflects the
instantaneous size of the roll of running web is also used to vary
the gain of the control system so that the braking force applied to
the roll of running web is varied in accordance with the amount of
material on the roll. More particularly, the output of the divider
96 is applied to a multiplier 122 whose other input is a voltage
tension command T.sub.c developed as will be described presently by
measuring the instantaneous position of dancer 46 (FIG. 1). This is
because the tension force on web W due to the application of brake
72 varies linearly with the drag force caused by the brake.
However, the drag force does not vary linearly with the pressure
applied by the transducer 126 to the brake. Rather, the drag force
varies in accordance with the pressure divided by the radius of the
running roll 10. In the present system, a linear variation between
the commanded tension T.sub.c and resultant paper tension T is
achieved by multiplying the commanded tension T.sub.c by the radius
r.sub.1 of roll 10 in multiplier 122. The output of multiplier 122
then controls a current driver 124 which drives the pressure
transducer 126 operating the brake 72.
When the roll on the lower set of arbors 28 is the running roll,
the output of multiplier 122 is applied to a similar current driver
128 which drives a transducer 130 associated with brake 76. Thus,
the pressure applied to the brake controlling the running web roll
always reflects the size of the roll. For a given tension command,
this pressure becomes less as the roll becomes smaller because less
drag force is necessary to maintain the same amount of tension in
the web.
Still referring to FIG. 2, to develop the tension command T.sub.c,
the resistance value of potentiometer 66 is used to measure the
position of dancer 47. More particularly, the voltage developed
across the potentiometer is applied to an amplifier 150 having a
variable offset control 152 which sets the dancer zero position
Y.sub.O. The output of the amplifier 150 is a positive or negative
voltage reflecting the deviation of the dancer from its zero
position Y.sub.O. This voltage is applied by way of a switchable
attenuator 154 to a resistor 156 which forms one leg of a summing
network shown generally at 158. Attenuator 154 is switched to
increase the gain of the circuit to brake the running roll to a
halt during an emergency stop situation by a FAST STOP signal
applied to its terminal 155 as will be described later.
The voltage across the potentiometer 66 is also applied to a
differentiator 162 whose output represents the rate at which the
dancer 47 is moving at any given time. This signal is amplified by
an amplifier 164 and applied by way of a second switchable
attenuator 166 to the summing circuit 158 through the summing
resistor 168.
The net voltage at network 158 represents the tension command
T.sub.c. This voltage is applied via a normally closed switch 172
and an amplifier 174 to the multiplier 122 as noted above.
During normal operation of the apparatus, switch 172 is closed and
the gain of the servoloop is such that as the dancer moves away
from its zero position Y.sub.O in response to a change in web
tension, a tension command T.sub.c is issued which, when multiplied
by the radis r.sub.1 of the running roll, applies just the right
braking force to restore the proper tension condition in the web
and return the dancer to its zero position. The desired tension
T.sub.O can be set by way of an operator-controlled variable
resistor 176 in the summing network 158 which is connected to a
suitable positive voltage source.
The inclusion of dancer velocity feedback in the servoloop which
develops the tension command T.sub.c introduces a damper into the
system so that proper selection of position and velocity gains in
the servoloop results in a well-behaved system. For example, in a
typical apparatus, a 10 pound change in web tension results in a
dancer 46 displacement of only one inch. The preferred system is
designed with unity gain so that there is minimal overshoot of the
dancer 46 when it changes position.
When, for one reason or another, it is desired to brake the running
web to a stop very quickly, a FAST STOP signal is applied to
terminal 155. This changes the gain of the system so that the
system responds as though there were a rapid decrease in web
tension by greatly increasing the tension command voltage applied
to multiplier 122. This, in turn, results in rapid increase in the
brake pressure applied to brake 72 controlling the running web. It
is important to note at this point that the braking force applied
to the running roll during an emergency stop is still modulated by
the size of the running roll. Therefore, more braking force is
applied for a large roll than for a smaller roll. Consequently, a
roll of any size is brought to a stop in a controlled fashion in a
minimum amount of time.
When the running roll is almost depleted, a COMMENCE SPLICE signal
from relay 106 opens switch 172 disconnecting the summing network
158 from the amplifier 174. The signal also closes a switch 184
which applies the output of a ramp generator 186 to the amplifier.
The voltage ramp from generator 186 causes the transducer 126 to
apply a gradually increasing pressure on brake 72 controlling the
running web so that the roll stops at a predetermined rate.
When the running web reaches zero speed (or a selected minimal
speed), the relay 114 initiates the splicing sequence and then
activates the eddy current drive associated with the ready web roll
26 which supplements the acceleration given the ready roll by the
pulling force of the web. The eddy current drive is turned off when
the ready web reaches some selected percentage of running web speed
V.sub.P, usually on the order of 70-90 percent as will be described
presently.
As the ready roll 26 is being accelerated, the dancer 46 continues
to move down for a time because there is still a net loss of web
from the accumulator 18. Then it moves upward as the accumulator
refills. Since there is a danger that the dancer might bottom or
move up too far, the attenuator 166 in the dancer velocity feedback
branch is changed to increase gain and thus increase velocity
damping. This limits the acceleration of the dancer during its
downward movement and also as it moves upwards during the splice
service cycle. This high gain condition is initiated at the
beginning of the roll acceleration by a signal from relay 114
applied to attenuator 166 by way of a HOLD circuit 191. Circuit 191
switches the attenuator 166 back to normal after 30-60 seconds. By
this time, the dancer is close to its zero position Y.sub.O.
Alternatively, the attenuator 166 can be turned on for a selected
time interval after cessation of the COMMENCE SPLICE signal.
The point at which the ready web has reached the desired speed is
sensed by detecting when the dancer 46 is at rest or has a certain
minimum velocity. More particularly, the output of amplifier 164
which represents dancer velocity is applied to a pair of dancer
velocity detectors 192 and 194. Detector 192 generates an output
signal when the dancer is moving upwards at a rate less than a
predetermined magnitude, while detector 194 generates a similar
output when the downward velocity of the dancer is less than a
predetermined magnitude. An output from both detectors
simultaneously thus signifies that the dancer is at rest or is
moving at a velocity which is within a certain acceptance band
signifying that the ready web is at the desired percentage of
running speed V.sub.p. This coincidence is detected by an AND
circuit 196 whose output opens a switch 198 which deenergizes a
relay 202 controlling the drive 82 associated with the ready web
roll 26.
The signal from amplifier 164 representing dancer velocity is also
used to detect when an emergency condition exists such as a break
in the web W. When the web breaks, there is a drastic decrease in
web tension which causes the dancer 46 to move up rapidly away from
fixed rolls 42. In the present system, the output of amplifier 164
is applied to an amplitude comparator 204 which also receives an
output voltage from a velocity threshold control 206. When the
voltage from circuit 164 exceeds the threshold velocity, comparator
204 actuates a driver 208 which closes a relay 210. The closing of
the relay 210 can be arranged to brake the running roll to a stop
or to control the air pressure applied to cylinder 62 biasing the
dancer 46 to slow down the dancer before it reaches its upper and
lower limit stops.
The variable gain feature of the present system allows one to
control the amount of reserve storage remaining in the accumulator
18 for emergency stops in accordance with roll size. In other
words, the amount of necessary reserve storage becomes less as the
roll diameter decreases. Therefore, the output of the divider 96
can be applied to vary the zero position control 152 so that the
zero position Y.sub.O of the dancer is lowered as the running roll
becomes smaller. The accumulator can also operate much fuller
during normal operation because dancer hunting is minimized.
Finally, it is important to note that the present system is
substantially entirely electronic and therefore it requires a
minimum amount of maintenance as compared with prior pneumatic
tension control systems. Furthermore, there is less inertia and
inherent delays in the present system so that much closer control
can be maintained over web and dancer movements. Furthermore, the
electrical components consisting in large part of standard
operational amplifiers and other stock components, are relatively
inexpensive to make.
It will thus be seen that the objects set forth above, among those
made apparent from the preceding description, are efficiently
attained and, since certain changes may be made in the above
construction without departing from the scope of the invention, it
is intended that all matter contained in the above description or
shown in the accompanying drawings shall be interpreted as
illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended
to cover all of the generic and specific features of the invention
herein described.
* * * * *