U.S. patent number 3,680,804 [Application Number 05/002,137] was granted by the patent office on 1972-08-01 for foil separator and rewind machine.
This patent grant is currently assigned to Midland-Ross Corporation. Invention is credited to Charles Aaron, Gerrit De Gelleke, Robert E. Mount.
United States Patent |
3,680,804 |
Aaron , et al. |
August 1, 1972 |
**Please see images for:
( Certificate of Correction ) ** |
FOIL SEPARATOR AND REWIND MACHINE
Abstract
This invention relates to a machine for continuously separating
and rewinding webs of foil material wherein the supply roll, dancer
roll, separator roll, rewind rolls, ironing rolls, rewind roll
shaft's driving coupling and rewind roll core mounting means are
all constructed and arranged to permit high speed and high quality
operation.
Inventors: |
Aaron; Charles (West Caldwell,
NJ), Mount; Robert E. (Pine Brook, NJ), De Gelleke;
Gerrit (Parsippany, NJ) |
Assignee: |
Midland-Ross Corporation
(Cleveland, OH)
|
Family
ID: |
21699379 |
Appl.
No.: |
05/002,137 |
Filed: |
January 12, 1970 |
Current U.S.
Class: |
242/530; 242/540;
242/547; 242/599.3 |
Current CPC
Class: |
B65H
19/2207 (20130101); B65H 2301/41486 (20130101); B65H
2301/4148 (20130101) |
Current International
Class: |
B65H
19/22 (20060101); B65h 017/02 () |
Field of
Search: |
;242/56,56.2,56.4,58.1,65,67.1,67.2,67.3,67.4,67.5,68.1,68.4,75.43,75.53 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Schroeder; Werner H.
Claims
What is claimed and desired to be secured by Letters Patent is:
1. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
adapted to support at their outer ends a rewind shaft on which
shaft a web of foil material is to be wound into a rewind roll, the
inner ends of each pair of rewind arms being fixedly mounted on a
rewind arm supporting pivot shaft, a fluid piston and cylinder
assembly engaging at least one of said rewind arms to pivot said
rewind roll during buildup, a pair of ironing roll arms adapted to
support at their outer ends an ironing roll in engagement with said
rewind roll, means mounting said ironing roll arms for pivotal
movement, a servo valve actuatable by said means mounting said
ironing roll arms for actuating said rewind arms to index said
rewind roll outwardly in a direction away from said ironing roll
for accommodating buildup of foil on said rewind roll, said means
mounting said ironing roll arms for pivotal movement comprising an
ironing roll pivot shaft, each of the ironing roll arms having an
outer collar pivotally movable about said pivot shaft, an inner
collar fixedly attached to said pivot shaft under each of said
outer collars, each of said inner collars having an upstanding
projection, each of said ironing roll arms having a pin engageable
with its respective upstanding projection when said rewind roll has
urged said ironing roll a preselected arcuate distance due to
buildup of material on said rewind roll.
2. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
adapted to support at their outer ends a rewind shaft on which
shaft a web of foil material is to be wound into a rewind roll, the
inner ends of each pair of rewind arms being fixedly mounted on a
rewind arm supporting pivot shaft, a fluid piston and cylinder
assembly engaging at least one of said rewind arms to pivot said
rewind roll during buildup, a pair of ironing roll arms adapted to
support at their outer ends an ironing roll in engagement with said
rewind roll, means mounting said ironing roll arms for pivotal
movement, a servo valve actuatable by said means mounting said
ironing roll arms for actuating said rewind arms to index said
rewind roll outwardly in a direction away from said ironing roll
for accommodating buildup of foil on said rewind roll, said means
mounting said ironing roll arms for pivotal movement comprising an
ironing roll pivot shaft pivotally movable responsive to movement
of said ironing roll arms, said servo valve being mounted adjacent
one end of said pivot shaft, a collar fixedly mounted on said pivot
shaft adjacent said servo valve for engaging said servo valve
responsive to rotation of said pivot shaft, said piston and fluid
cylinder assembly for said rewind arms being actuatable by said
servo valve.
3. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
adapted to support at their outer ends a rewind shaft on which
shaft a web of foil material is to be wound into a rewind roll, the
inner ends of each pair of rewind arms being fixedly mounted on a
rewind arm supporting pivot shaft, at least one of said rewind arms
having an extension, a fluid piston and cylinder assembly engaging
said extension to pivot said rewind roll during buildup, a pair of
ironing roll arms adapted to support at their outer ends an ironing
roll in engagement with said rewind roll, an ironing roll pivot
shaft, each of the ironing roll arms having an outer collar
pivotally movable about said pivot shaft, an inner collar fixedly
attached to said pivot shaft under each of said outer collars, each
of said inner collars having an upstanding projection, each of said
ironing roll arms having a pin engageable with its respective
upstanding projection when said rewind roll has urged said ironing
roll a preselected distance to buildup the material on said rewind
roll, a rotary spool servo valve mounted adjacent one end of said
pivot shaft, a collar fixedly mounted on said pivot shaft adjacent
said servo valve for engaging said servo valve responsive to
rotation of said pivot shaft, said fluid piston and cylinder
assembly for said rewind arms being actuatable by said servo valve
to index said rewind roll outwardly in a direction away from said
ironing roll for accommodating buildup of foil on said rewind
roll.
4. A foil separator and rewind machine comprising a front section
and a rear section, said rear section being upwardly and rearwardly
disposed with respect to said front section, each section having a
pair of rewind arms pivotally supported at their inner ends, each
pair of rewind arms being adapted to support rewind shaft at their
outer ends on which shaft a web of foil material is to be wound
into a rewind roll, each pair of rewind arms extending upwardly and
forwardly, means for driving said rewind shafts, a separating roll
mounted between and closely adjacent said rewind rolls, ironing
rolls being mounted substantially between said separating roll and
said rewind rolls respectively, said rewind rolls being rotatable
in both directions respectively for winding the foil with the
desired side thereof facing outwardly, a fluid piston cylinder
assembly engaging at least one of said rewind arms to pivot said
rewind roll during buildup, for each of said sections a pair of
ironing roll arms adapted to support at their outer ends one of
said ironing rolls in engagement with said rewind roll, means
mounting said ironing roll arms for pivotal movement, a servo valve
actuatable by said means mounting said ironing roll arms for
actuating said rewind arms to index said rewind roll outwardly in a
direction away from said ironing roll for accommodating buildup of
foil on said rewind roll.
5. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
pivotally supported at their inner ends, each pair of rewind arms
being adapted to support a rewind shaft at their outer ends on
which shaft a web of foil material is to be wound into a rewind
roll, ironing means adapted to engage the peripheries of said
rewind rolls, means for arcuately moving said rewind arms in
response to the buildup of said rewind rolls respectively, a
coupling, motive means for driving said coupling, said rewind shaft
being driven by said coupling, said coupling comprising a first
member mounted on the end of said rewind shaft, a pair of
diametrically opposed cam rollers carried by said first member
adjacent the periphery thereof, a second coupling member fixedly
attached to the end of said motive means, a pair of diametrically
opposed cam rollers carried by said second member adjacent the
periphery thereof, an intermediate member mounted on said second
member, said intermediate member being free for radial movement,
said intermediate member having a diametrical slot for receiving
the cam rollers carried by said first member, and said intermediate
member having recesses for receiving the cam rollers carried by
said second member.
6. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
pivotally supported at their inner ends, each pair of rewind arms
being adapted to support a rewind shaft at their outer ends on
which shaft a web of foil material is to be wound into a rewind
roll, ironing means adapted to engage the peripheries of said
rewind rolls, means for arcuately moving said rewind arms in
response to the buildup of said rewind rolls respectively, a
coupling, motive means for driving said coupling, said rewind shaft
being driven by said coupling, said coupling comprising a first
member mounted on the end of said rewind shaft, a pair of
diametrically opposed cam rollers carried by said first member
adjacent the periphery thereof, a second coupling member fixedly
attached to the end of said motive means by a shoulder screw, a
pair of diametrically opposed cam rollers carried by said second
member adjacent the periphery thereof, an intermediate member
mounted on said second member, said intermediate member being free
for radial movement, said intermediate member having a diametrical
slot for receiving the cam rollers carried by said first member,
the ends of said slot adjacent the periphery thereof being of
reduced width to provide a close fit with said cam rollers, said
intermediate member having recesses for receiving the cam rollers
carried by said second member, said motive means comprising a drive
shaft mounted on said second member, a pulley mounted on said drive
shaft, a second shaft having an electric motor connected to one end
thereof and a second pulley connected to the other end thereof, a
drive belt having teeth on its driving surface being connected
between said two pulleys.
7. A foil separator and rewind machine comprising a front section
and a rear section, said rear section being upwardly and rearwardly
disposed with respect to said front section, each section having a
pair of rewind arms pivotally supported at their inner ends, each
pair of rewind arms being adapted to support a rewind shaft at
their outer ends on which shaft a web of foil material is to be
wound into a rewind roll, each pair of rewind arms extending
upwardly and forwardly, ironing rolls adapted to engage the
peripheries of said rewind rolls respectively, means for arcuately
moving said rewind arms in response to the buildup of said rewind
rolls respectively, a separating roll mounted between and closely
adjacent said rewind rolls, said ironing rolls being mounted
substantially between said separating roll and said rewind rolls
respectively, and said rewind rolls being rotatable in both
directions respectively for winding the foil with the desired side
thereof facing outwardly, a coupling, motive means for driving said
coupling, said rewind shaft being driven by said coupling, said
coupling comprising a first member mounted on the end of said
rewind shaft, a pair of diametrically opposed cam rollers carried
by said first member adjacent the periphery thereof, a second
coupling member fixedly attached to the end of said motive means, a
pair of diametrically opposed cam rollers carried by said second
member adjacent the periphery thereof, an intermediate member
mounted on said second member, said intermediate member being free
for radial movement, said intermediate member having a diametrical
slot for receiving the cam rollers carried by said first member,
and said intermediate member having recesses for receiving the cam
rollers carried by said second member.
8. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
adapted to support at their outer ends a rewind shaft on which
shaft a web of foil material is to be wound into a rewind roll, the
inner ends of each pair of rewind arms being fixedly mounted on a
rewind arm supporting pivot shaft, a fluid piston and cylinder
assembly engaging at least one of said rewind arms to pivot said
rewind roll during buildup, a pair of ironing roll arms adapted to
support at their outer ends an ironing roll in engagement with said
rewind roll, means mounting said ironing roll arms for pivotal
movement, a servo valve actuatable by said means mounting said
ironing roll arms for actuating said rewind arms to index said
rewind roll outwardly in a direction away from said ironing roll
for accommodating buildup of foil on said rewind roll, a coupling,
motive means for driving said rewind shaft being driven by said
coupling, said coupling comprising a first member mounted on the
end of said rewind shaft, a pair of diametrically opposed cam
rollers carried by said first member adjacent the periphery
thereof, a second coupling member fixedly attached to the end of
said motive means, a pair of diametrically opposed cam rollers
carried by said second member adjacent the periphery thereof, an
intermediate member mounted on said second member, said
intermediate member being free for radial movement, said
intermediate member having a diametrical slot for receiving the cam
rollers carried by said first member, and said intermediate member
having recesses for receiving the cam rollers carried by said
second member.
9. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
pivotally supported at their inner ends, each pair of rewind arms
being adapted to support a rewind shaft at their outer ends on
which shaft a web of foil material is to wound into a rewind roll,
ironing means adapted to engage the peripheries of said rewind
rolls, means for arcuately moving said rewind arms in response to
the buildup of said rewind rolls respectively, a core interposed
between said rewind shaft and said rewind roll, said rewind shaft
having a plurality of spaced longitudinally extending slots, a
driving collar having a corresponding plurality of spaced
wedge-shaped lugs mounted at each end of said core, said lugs
fitting in said slots and acting as a wedge between said core and
said rewind shaft, and means for locking said driving collars
against said core on each end of said shaft.
10. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
pivotally supported at their inner ends, each pair of rewind arms
being adapted to support a rewind shaft at their outer ends on
which shaft a web of foil material is to be wound into a rewind
roll, ironing means adapted to engage the peripheries of said
rewind rolls, means for arcuately moving said rewind arms in
response to the buildup of said rewind rolls respectively, a core
interposed between said rewind shaft and said rewind roll, said
rewind shaft having three spaced longitudinally extending slots, a
driving collar having three spaced wedge-shaped lugs mounted at
each end of said core, said lugs fitting in said slots and acting
as a wedge between said core and said rewind shaft, a
longitudinally extending lug carried by said driving collar
adjacent one of said wedge-shaped lugs, said core having a
longitudinally extending slot for receiving said longitudinally
extending lug, and means for locking said driving collars against
said core on each end of said shaft.
11. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
pivotally supported at their inner ends, each pair of rewind arms
being adapted to support a rewind shaft at their outer ends on
which shaft a web of foil material is to be wound into a rewind
roll, ironing rolls adapted to engage the peripheries of said
rewind rolls, means for arcuately moving said rewind rolls in
response to the buildup of said rewind rolls respectively, a
separating roll mounted between and closely adjacent said rewind
rolls, said ironing rolls being mounted substantially between said
separating roll and said rewind rolls respectively, and said rewind
rolls being rotatable in both directions respectively for winding
the foil with the desired side thereof facing outwardly, a core
interposed between said rewind shaft and said rewind roll, said
rewind shaft having a plurality of spaced longitudinally extending
slots, a driving collar having a corresponding plurality of spaced
wedge-shaped lugs mounted at each end of said core, said lugs
fitting in said slots and acting as a wedge between said core and
said rewind shaft, and means for locking said driving collars
against said core on each end of said shaft.
12. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
adapted to support at their outer ends a rewind shaft on which
shaft a web of foil material is to be wound into a rewind roll, the
inner ends of each pair of rewind arms being fixedly mounted on a
rewind arm supporting pivot shaft, a fluid piston cylinder assembly
engaging at least one of said rewind arms to pivot said rewind roll
during buildup, a pair of ironing roll arms adapted to support at
their outer ends an ironing roll in engagement with said rewind
roll, means mounting said ironing roll arms for pivotal movement, a
servo valve actuatable by said means mounting said ironing roll
arms for actuating said rewind arms to index said rewind roll
outwardly in a direction away from said ironing roll for
accommodating buildup of foil on said rewind roll, a core
interposed between said rewind shaft and said rewind roll, said
rewind shaft having a plurality of spaced longitudinally extending
slots, a driving collar having a corresponding plurality of spaced
wedge-shaped lugs mounted at each end of said core, said lugs
fitting in said slots and acting as a wedge between said core and
said rewind shaft, and set screws for mounting said driving collars
against the ends of said core on each end of said shaft.
13. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
pivotally supported at their inner ends, each pair of rewind arms
being adapted to support a rewind shaft at their outer ends on
which shaft a web of foil material is to be wound into a rewind
roll, ironing means adapted to engage the peripheries of said
rewind rolls, a coupling, motive means for driving said coupling,
said coupling comprising a first member mounted on the end of said
rewind shaft, a pair of diametrically opposed cam rollers carried
by said first member adjacent the periphery thereof, a second
coupling member fixedly attached to the end of said motive means, a
pair of diametrically opposed cam rollers carried by said second
member adjacent the periphery thereof, an intermediate member
mounted on said second member, said intermediate member being free
for radial movement, said intermediate member having a diametrical
slot for receiving the cam rollers carried by said first member,
and said intermediate member having recesses for receiving the cam
rollers carried by said second member, a core interposed between
said rewind shaft and said rewind roll, said rewind shaft having a
plurality of spaced longitudinally extending slots, a driving
collar having a corresponding plurality of spaced wedge-shaped lugs
mounted at each end of said core, said lugs fitting in said slots
and acting as a wedge between said core and said rewind shaft, and
means for locking said driving collars against said core on each
end of said shaft.
14. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
pivotally supported at their inner ends, each pair of rewind arms
being adapted to support a rewind shaft at their outer ends on
which shaft a web of foil material is to be wound into a rewind
roll, ironing means adapted to engage the peripheries of said
rewind rolls, means for arcuately moving said rewind arms in
response to the buildup of said rewind rolls respectively, a
coupling, motive means for driving said coupling, said rewind shaft
being driven by said coupling, said coupling comprising a first
member mounted on the end of said rewind shaft, a pair of
diametrically opposed cam rollers carried by said first member
adjacent the periphery thereof, a second coupling member fixedly
attached to the end of said motive means by a shoulder screw, a
pair of diametrically opposed cam rollers carried by said second
member adjacent the periphery thereof, an intermediate member
mounted on said second member, said intermediate member being free
for radial movement, said intermediate member having a diametrical
slot for receiving the cam rollers carried by said first member,
the ends of said slot adjacent the periphery thereof being of
reduced width to provide a close fit with said cam rollers, said
intermediate member having recesses for receiving the cam rollers
carried by said second member, said motive means comprising a drive
shaft mounted on said second member, a pulley mounted on said drive
shaft, a second shaft having an electric motor connected to one end
thereof and a second pulley connected to the other end thereof, a
drive belt having teeth on its driving surface being connected
between said two pulleys, a core interposed between said rewind
shaft and said rewind roll, said rewind shaft having three spaced
longitudinally extending slots, a driving collar having three
spaced wedge-shaped lugs mounted at each end of said core, said
lugs fitting in said slots and acting as a wedge between said core
and said rewind shaft, a longitudinally extending lug carried by
said driving collar adjacent one of said wedge-shaped lugs, said
core having a longitudinally extending slot for receiving said
longitudinally extending lug, and means for locking said driving
collars against said core on each end of said shaft.
15. A foil separator and rewind machine comprising a front section
and a rear section, each section having a pair of rewind arms
adapted to support at their outer ends a rewind shaft on which
shaft a web of foil material is to be wound into a rewind roll, the
inner ends of each pair of rewind arms being fixedly mounted on a
rewind arm supporting pivot shaft, a fluid piston and cylinder
assembly engaging at least one of said rewind arms to pivot said
rewind roll during buildup, a pair of ironing roll arms adapted to
support at their outer ends an ironing roll in engagement with said
rewind roll, means mounting said ironing roll arms for pivotal
movement, a servo valve actuatable by said means mounting said
ironing roll arms for actuating said rewind arm to index said
rewind roll outwardly in a direction away from said ironing roll
for accommodating buildup of foil on said rewind roll, a separating
roll mounted between and closely adjacent said rewind rolls, said
ironing rolls being mounted substantially between said separating
roll and said rewind rolls respectively, and said rewind rolls
being rotatable in both directions respectively for winding the
foil with the desired side thereof facing outwardly, the linear
distance between said separating roll and each of said rewind rolls
being substantially constant throughout a cycle of operation, said
ironing rolls engaging said rewind rolls substantially adjacent the
contact points of said foils with respect to said rewind rolls
respectively, a mill supply roll, said separator roll being mounted
adjacent said rewind rolls, a dancer roll mounted between said mill
supply roll and said separator roll, a fluid piston and cylinder
assembly for dampening the movement of said dancer roll, a
coupling, motive means for driving said coupling, said rewind shaft
being driven by said coupling, said coupling comprising a first
member mounted on the end of said rewind shaft, a pair of
diametrically opposed cam rollers carried by said first member
adjacent the periphery thereof, a second coupling member fixedly
attached to the end of said motive means, a pair of diametrically
opposed cam rollers carried by said second member adjacent the
periphery thereof, an intermediate member mounted on said second
member, said intermediate member being free for radial movement,
said intermediate member having a diametrical slot for receiving
the cam rollers carried by said first member, said intermediate
member having recesses for receiving the cam rollers carried by
said second member, a core interposed between said rewind shaft and
said rewind roll, said rewind shaft having a plurality of spaced
longitudinally extending slots, a driving collar having a
corresponding plurality of spaced wedge-shaped lugs mounted at each
end of said core, said lugs fitting in said slots and acting as a
wedge between said core and said rewind shaft, and a locking nut
threadably mounted on the shaft at each end thereof outwardly of
said collars for locking said collars against the ends of said
core.
Description
This invention relates to a foil separator and rewind machine and
more particularly to apparatus for receiving a relatively wide
two-ply mill supply roll, separating the plies and rewinding each
ply into a separate rewind roll. Prior art apparatus of this
general type have not been completely successful in controlling all
of the factors required for producing a high quality rewind roll,
particularly with such foil materials as are of a non-uniform
caliper over the sheet width, or with certain very thin foils.
Applicants have discovered a novel combination of elements combined
in such a way as to afford a very economical, efficient and
practical solution of the difficulties in the prior art, as will
become apparent as the description proceeds.
In one form, the present invention contemplates the provision of a
new and improved foil separator and rewind machine having a front
section and a rear section. The rear section is upwardly and
rearwardly disposed with respect to the front section, and each
section has a pair of rewind arms pivotally supported at their
inner ends. Each pair of rewind arms is adapted to support a driven
rewind shaft at their outer ends on which a web of foil material is
to be wound into rewind roll. Ironing rolls are adapted to
resiliently engage the peripheries of the rewind rolls
respectively, and means are provided for actuately moving the
rewind arms in response to the buildup of the rewind rolls
respectively. A separating roll is mounted between and closely
adjacent the rewind rolls, and the ironing rolls are mounted
substantially between the separating roll and the rewind rolls,
respectively. The rewind rolls are rotatable in both directions,
respectively, for winding the foil with the desired side thereof
facing outwardly.
According to one aspect of the invention, each pair of ironing roll
arms are adapted to support at their outer ends an ironing roll
which is resiliently urged against its corresponding rewind roll. A
servo valve is actuatable by movement of the ironing roll arms for
actuating the rewind arms to index its corresponding rewind roll
outwardly in a direction away from the ironing roll for
accommodating buildup of the foil.
According to another aspect of our invention, a coupling is
provided which drives the rewind shaft, and motive means, which may
include an electrical motor, are provided for driving the coupling.
The coupling is characterized by a first member mounted on the end
of the rewind shaft which carries a pair of diametrically opposed
cam rollers adjacent the periphery thereof. A second coupling
member is fixedly attached to the end of the motive means, and a
pair of diametrically opposed cam rollers are carried thereby,
adjacent the periphery thereof. An intermediate member is mounted
on the second member, and it is free for radial movement. The
intermediate member has a diametrical slot for receiving the cam
rollers carried by the first member, and it is also provided with
recesses for receiving the cam rollers which are carried by the
second member. This arrangement provides a new and improved drive
coupling which is substantially free from vibration and
backlash.
Another aspect of our invention resides in the provision of means
for driving the rewind shaft which, in effect, permits essentially
a full diameter shaft with tapered collar feature. A core is
interposed between the rewind shaft and the rewind roll. The rewind
shaft is provided with a plurality of spaced longitudinally
extending slots, and driving collars at each end of the rewind
shaft are provided each having a corresponding plurality of spaced
wedge-shaped lugs. The lugs are adapted to fit in the slots and act
as a wedge between the core and the rewind shaft. The driving
collars are secured to the shaft by means of set screws. In place
of the set screws a locking nut could be threadably mounted on the
shaft at each end thereof for locking the collars against the ends
of the core.
Foil separator and rewind machines constructed in accordance with
the concept of this invention are, among other possible uses,
particularly useful for high-speed, large capacity production
wherein exceptionally fine roll quality is a very important
consideration.
A feature of this invention resides in the provision of a new and
improved rewind machine which has a web path of substantially
constant length throughout the rewinding cycle of operation, which
has a relatively short draw length between the rewind roll and the
separating roll, which provides convenient space for conventional
ultrasonic welding splicing apparatus adjacent the rewind rolls,
which allows the operator to clearly view the rewinding operation,
which can readily be started and stopped. As another feature of the
invention, we contemplate the provision of a machine which can
rewind foil having either side of the foil disposed outwardly,
which separates the two foils on a common drum, which can rewind
rolls up to a large diameter, which has an ironing roll that
engages the rewind roll substantially adjacent the point where the
web enters the rewind roll.
As still another feature of this invention, we provide a new and
improved rewind machine which maintains positive control of the nip
pressure against each individual rewind roll, which compensates for
the caliber variation of the material being rewound, which
substantially eliminates tracking vibration, and which
substantially eliminates pounding of the ironing roll.
According to another feature, there is provided a foil separator
and rewind machine which substantially eliminates backlash in the
rewind roll shaft driving mechanism, and which provides rigidity in
the rewind roll shaft mounting means.
Assignee's own U.S. Pat. No. 3,291,412 dated Dec. 12, 1966, is
related to the rewinding art, but is not directed specifically to
the foil separating art.
There has thus been outlined rather broadly the more important
features of the invention in order that the detailed description
thereof that follows may be better understood, and in order that
the present contribution to the art may be better appreciated.
There are, of course, additional features of the invention that
will be described hereinafter which will form the subject of the
claims appended hereto. Those skilled in the art will appreciate
that the conception on which this disclosure is based may readily
be utilized as the basis for the designing of other structures for
carrying out the several purposes of the invention. It is
important, therefore, that this disclosure be regarded as including
such equivalent constructions as do not depart from the spirit and
scope of the invention.
One embodiment of the invention has been chosen for purposes of
illustration and description, and is shown in the accompanying
drawings, forming a part of the specification wherein:
FIG. 1 is an end elevation of a foil separator and rewind machine
constructed in accordance with the invention, and with portions
broken away to more clearly show certain features;
FIG. 2 is an enlarged perspective view showing the means for
supporting the rewind rolls and the ironing rolls;
FIG. 3 is an enlarged perspective view showing the means for
supporting the rewind rolls and the ironing rolls similar to FIG.
2, but from a different angle.
FIG. 4 is a sectional view taken along the line indicated at 4--4
in FIG. 3 and showing the construction and operation of the means
for controlling the angle of inclination of the ironing rolls and
the rewind rolls;
FIG. 5 is a side elevation, partially in section, showing the
rewind roll mounted on the end of the rewind arms;
FIG. 6 is a side elevation, partially in section, similar to FIG. 5
but showing the rewind roll removed from the rewind arms;
FIG. 7 is an enlarged, exploded, perspective view showing the
driving coupling for the rewind shaft;
FIG. 8 is an enlarged sectional view taken along the line indicated
at 8--8 in FIG. 5;
FIG. 9 is an enlarged sectional view taken along the line indicated
at 9--9 in FIG. 5;
FIG. 10 is an enlarged exploded view of the means for mounting a
rewind roll core; and
FIG. 11 is an enlarged sectional view taken along the line
indicated at 11--11 of FIG. 5.
In the illustrated embodiment of the invention, the foil separator
and rewind machine comprises a front section and a rear section
designated generally at 10 and 12, respectively. As best seen in
FIG. 1, a two-ply web of foil material 14 is received from over or
under a mill or supply roll 16 and passes partially around various
rolls such as 18 and 20, from whence it passes to a dancer roll 22
which is mounted for horizontal movement against an air cylinder
and piston assembly 24. The dancer roll serves to take the pulses
out of the supply roll. The dancer roll movement, through a cam,
strokes an electrical device (not shown) which signals an electric
motor 28, connected to the supply roll 16, to motor or to generate
as required to maintain a given tension. The tension level is
established by the air pressure at the dancer roll cylinders 24.
The operating position of the dancer is mid-range of its stroke so
that movement fore or aft is sensed electrically, thereby providing
optimum strip control and handling characteristics particularly for
light gauge foils.
After the web 14 passes partially around the dancer roll 22, it
passes around a series of rolls 30, 32 and 34, which may include
razor blades or a backup roll for edge slitting means, and thence
to a separator roll 36. The plies of foil material are separated
and a first ply 38 passes directly to the front section 10 of the
rewind machine and a second ply 40 passes directly to the rear
section 12 of the machine. The ply 38 passes partially around a
steel tracking or ironing roll 42 and onto a rewind roll 44, and
the ply 40 passes partially around a steel tracking or steel
ironing roll 46 and onto a rewind roll 48. It will be appreciated
that foil material is normally fabricated with a shiny surface on
one side and a matte surface on the other. Accordingly, sometimes
it is desirable to rewind it with one side out and sometimes it is
desirable to rewind it with the other side out. The rewind rolls 44
and 48 may be rotated in either direction, and hence when one side
of the foil is on the outside the ply may pass around the ironing
roll 42 along the path indicated at 38, whereas if the other side
of the ply is to be on the outside the ply will follow the path
indicated at 38', and in like manner in the rear section 12 the ply
may follow the path indicated at 40 or the path indicated at 40',
as desired. For purposes of reducing the friction as much as
possible, the rolls 18, 20, 30, 32, 34 and 36 are all center
driven. Also, the rolls may be chrome-plated and ground steel.
As best seen in FIGS. 1 and 2, the rear section 12 is upwardly and
rearwardly disposed with respect to the front section 10. This
allows the operator to visually observe the operation of both
sections and keep the machine under better control. In addition,
such arrangement of the rewind rolls 44 and 48 provides space for a
conventional ultrasonic splicing means (not shown) to be interposed
therebetween for conveniently and rapidly splicing the webs of foil
material.
It will be appreciated that the front section 10 and the rear
section 12 are of similar construction and operate in a similar
manner, and, therefore, some portions of one of these sections will
be described in detail hereinafter, it being understood that the
corresponding portions in the other section are of similar
construction and operate in a similar manner. As seen in FIGS. 1, 2
and 3, rewind roll 48 is mounted on rewind roll shaft 50, which is
carried by the outer ends of the rewind arms 52. The inner ends of
the rewind arms are secured to a rewind arm supporting pivot shaft
54, FIGS. 3 and 4, which in turn is mounted on the main frame 56. A
pivot arm 58 forms an extension of the rewind arm 52 and a piston
and fluid cylinder assembly 60 is connected thereto, as at 62, for
purposes of pivoting the rewind roll 48 in a clockwise direction,
as viewed in FIG. 1, during buildup.
Positive control of the nip pressure between the rewind roll 48 and
the ironing roll 46 is provided at the lowest possible value to
remove air from between adjacent layers of web being rewound and to
prevent slippage of the web and, thus, providing accurate tracking
of the web onto the rewind roll. Further, it will be appreciated
that the rewind torque is independent of the nip force, and hence
the nip force can be as heavy or light as desired without affecting
the rewind torque. Control of the nip force is very important.
Usually the web of metallic foil is annealed after rewinding to
remove the rolling oils on the surface thereof. If the nip force is
excessive, the layers of web will stick together during annealing.
If the nip force is not sufficient, then the web will go out of
control.
As best seen in FIGS. 3 and 4, the ironing roll 46 is supported at
its ends by ironing roll arms 64. The ironing roll support system
is a soft vibratory system to insure uniform ironing and
wrinkle-free operation at all speeds and with uniform pressure
across the strip. Each of the inner ends of the ironing roll arms
64 is in the form of an outer collar 68, FIG. 3, which is mounted
on an ironing roll pivot shaft 70 for pivotal movement. An inner
collar 72 is fixedly attached to the shaft 70, as by means of a pin
74, provided for the purpose. The inner collar 72 has an upstanding
projection 76 which is engaged by a pin or screw 78 attached to the
ironing roll arm 64. At one end of the pivot shaft 70 is a collar
80 having an arm 82 for engaging a rotary spool servo valve 84
which is connected to the piston and fluid cylinder assembly 60, as
at 86. That is, when the foil builds up a predetermined
infinitesimal amount, the pin 78 on the arm 64 on either the right
side or the left side, as viewed in FIG. 3, serves to rotate the
pivot shaft 70 to stroke the servo valve 84 to move the rewind arms
52 to pivot the rewind roll 48 in the direction away from the
ironing roll 46. However, momentary movement of the ironing roll,
such as passing over a slight bump, for example, does not provide
sufficient time for the servo valve to respond, and hence the
rewind arms are not indexed. The ironing roll is free to move
toward the rewind roll 48 without actuating the servo valve. During
normal operation, a steady state condition results wherein the
tracking or ironing roll maintains a basically constant position
and the rewind arms are moved outwardly in a steady uniform motion.
Rewind roll weight and ironing roll weight are isolated from the
ironing roll-rewind roll contact and, therefore, the ironing
pressure can be selected as desired through the pneumatic loading
of the ironing roll arms. If there is a bump on one side of the
rewind roll, the entire ironing roll is not pivoted because there
is no rigid cross support, and the support does not act like a
spring. One side does not bounce off with the other side and the
irregularities on either side are taken care of independently.
Basic pressure levels are easily established with consideration
given to the strip tension components and the desired ironing roll
nip pressures for the particular strip width, gauge and tension
level requirements. With this structure, rewind rolls which are not
perfectly circular or concentric may be rewound. Vibration or
pounding of the ironing roll is substantially eliminated, which
could otherwise cause sticking of the metal during annealing. Large
diameter rewind rolls may be wound. It will be appreciated that the
rewind roll can be free of wrinkles in one or two revolutions,
thereby reducing scrap. This is important because the foil may be
extremely thin, such as about 0.0002 inch, for example, and hence
it takes a long time, even at rapid speeds of 2,000 feet per minute
or more, to rewind a roll and the machine must be stopped
periodically during a cycle to splice the foil. Hence, deceleration
and acceleration are important considerations.
As best seen in FIG. 1, the draw length between the separating roll
36 and the rewind rolls 44 and 48 is as short as possible and it
remains constant throughout the rewind cycle regardless of the
diameter of the rewind rolls. In addition, the ironing rolls engage
the rewind rolls at substantially the point of contact of the web,
thereby improving the winding operation.
As pointed out hereinbefore, vibration in the machine causes uneven
rewind roll buildup. Therefore, backlash has been substantially
eliminated in the driving mechanism. As best seen in FIG. 5, the
rewind roll shaft is rotatably mounted on the rewind roll arms 52
as by means of bearings 88. The shaft overhangs at one end, and a
flexible coupling, indicated generally at 90, is mounted thereon.
The coupling is mounted on one end of a drive shaft 92 and a pulley
94 is mounted on the other end thereof. A drive belt 96 having
teeth thereon connects the pulley 94 to a pulley 98, which is
mounted on a shaft 100 on the main frame 56, FIG. 1. The shaft 100
is driven by an electric motor 101, FIG. 2. The coupling 90
comprises a first coupling member 102, which is mounted on the end
of the rewind shaft 50 by means of a plate 104 and a screw 106,
FIG. 9. A pair of diametrically opposed cam rollers 108 is carried
by the member 102. The drive shaft 92 has a second coupling member
110, fixedly attached to the end thereof. The coupling member 110
carries diametrically opposed cam rollers 112 as seen in FIGS. 7
and 8. A center piece or intermediate member 114, FIG. 5, is
mounted on the second member 110 by means of a shoulder screw 116.
The intermediate member is free for radial movement and, in
addition, it is provided with a slot 118 for receiving the cam
rollers 108. It is noted that the ends of the slot are slightly
narrower, thereby providing a close fit with the cam rollers 108,
as at 120, FIG. 8. The intermediate member 114 has a pair of
diametrically disposed recesses 121 for receiving the cam rollers
112. In operation, for purposes of removing a rewind roll such as
when it is completed, the rewind shaft may be lifted upwardly from
the machine from its position as seen in FIG. 5, to its position as
seen in FIG. 6. This is done by means of removing the bearing caps
122, FIG. 5, and lifting the shaft upwardly, rollers 108 sliding up
and out through the slot 118 in the intermediate member 114. It
will be appreciated that in this manner the rewind shaft may be
removed or installed without axial movement, thereby reducing the
mechanical difficulties. Accordingly, a flexible coupling is
provided having only backlash between the rollers and their
respective grooves. However, such backlash is substantially
negligible because the rollers are mounted at a relatively large
radius with respect to the rewind shaft. In this manner vibration
in the driving mechanism is substantially eliminated.
As best seen in FIG. 5, the rewind roll 48 is mounted on the rewind
shaft 50 by means of a rewind roll core 124. Conventionally the
core is fabricated from aluminum tubing or steel with a wall
thickness of the order of between about one-eighth inch and
three-sixteenths inch. In prior art structures the rewind roll
shaft had a reduced diameter with respect to the inside diameter of
the core and collar-shaped wedges were used at the ends to center
the core and to provide a driving connection. Such a small diameter
shaft tended to spring and bounce during operation. According to
the present invention, as best seen in FIGS. 10 and 11, the rewind
shaft 50 is of increased diameter and is provided with three spaced
grooves or slots 126. A cap or driving collar 128 has three spaced
wedge-shaped lugs 130 which, when the driving collar is placed on
the shaft 50, fit in the slots 126 and act as a wedge between the
core 124 and the shaft 50. The width of the slots 126 are of the
order of about three-eighth inch, for example. The driving collar
128 carries a lug 132 which is disposed adjacent one of the lugs 30
for strength purposes. The core 124 has a slot 134 for receiving
the lug 132. Set screws 135 secure the driving collar 128 to the
shaft 50 and, thereby, lock the core 124 to the shaft 50. If
desired, a locking nut 136 could be threadably mounted on the shaft
50 for the same purpose.
It will thus be seen that the present invention does indeed provide
an improved foil separator and rewind machine which is superior in
simplicity, economy and efficiency as compared to prior art such
devices.
Although a particular embodiment of the invention is herein
disclosed for purposes of explanation, various modifications
thereof after study of this specification, will be apparent to
those skilled in the art to which the invention pertains.
* * * * *