U.S. patent number 3,813,053 [Application Number 05/215,896] was granted by the patent office on 1974-05-28 for web winding machines.
This patent grant is currently assigned to Butler Automatic, Inc.. Invention is credited to Joseph F. Bonarrigo, Richard A. Butler, Jr..
United States Patent |
3,813,053 |
Butler, Jr. , et
al. |
May 28, 1974 |
WEB WINDING MACHINES
Abstract
Web winding apparatus has a pair of roll core supports at first
and second winding stations, an accumulator upstream from the
winding stations for storing web and a splicer in the web path
between the winding stations and the accumulator. The splicer
includes a pair of nip rolls movable toward and away from one
another and means for moving the rolls. A guide guides running web
from the accumulator around one of the nip rolls to a core in one
of the winding stations while a web leader is retained at the other
nip roll, which leader is also attached to the other roll core. The
nip rolls are moved together to press the running web and leader
into adhering engagement to form a splice while the accumulator
stores the running web. The running web is then severed downstream
from the splice and the roll core at the second winding station is
accelerated up to running speed while the web stored in the
accumulator is reduced in preparation for the next splice.
Inventors: |
Butler, Jr.; Richard A.
(Brookline, MA), Bonarrigo; Joseph F. (Pembroke, MA) |
Assignee: |
Butler Automatic, Inc. (Canton,
MA)
|
Family
ID: |
26910481 |
Appl.
No.: |
05/215,896 |
Filed: |
January 6, 1972 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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809146 |
Mar 21, 1969 |
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Current U.S.
Class: |
242/412.3;
242/413.1; 242/413.2; 242/413.4; 242/417.2; 242/527; 242/532.1;
242/552; 242/556.1 |
Current CPC
Class: |
B65H
19/2207 (20130101); B65H 2301/4148 (20130101); B65H
2301/41486 (20130101) |
Current International
Class: |
B65H
19/22 (20060101); B65h 019/16 () |
Field of
Search: |
;242/58.1,58.2,58.3,58.4,56R,67.1R |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Huckert; John W.
Assistant Examiner: McCarthy; Edward J.
Attorney, Agent or Firm: Cesari and McKenna
Parent Case Text
RELATED APPLICATION
The present application is a continuation of application Ser. No.
809,146, filed Mar. 21, 1969, now abandoned.
Claims
We claim:
1. Web winding apparatus comprising
A. means for supporting a roll core at a first winding station,
B. means for supporting a roll core at a second winding
station,
C. means upstream from the winding stations for storing a quantity
of web,
D. splicing means disposed in the web path between the winding
station and the storage means, said splicing means including
1. a pair of nip rolls movable relatively between a first position
wherein the nip rolls have a gap between them and a second position
wherein the nip rolls contact one another to form a nip,
2. means for moving the rolls between said two positions,
3. means for guiding running web from the storage means around one
of the nip rolls to a core at one of the winding stations,
4. means for retaining an end of a web leader at the second nip
roll, means for attaching the leader to the other roll core,
5. means for moving the nip rolls to their second position so as to
press the running web and leader end into adhering engagement to
form a splice, while the storage means stores the running web,
6. means for severing the running web downstream from the splice,
and
E. means for accelerating the core at the second winding station up
to running web speed while the quantity of web stored by the
storage means is reduced in preparation for the next splice cycle
so that the web can proceed uninterruptedly through the storage
means to the first or second winding station.
2. Web winding apparatus as defined in claim 1 wherein the storage
means include means for pulling the running web in a direction
opposite the direction of web movement immediately after the nip
rolls are moved to their second position so that the splice makes
one pass through the nip in a direction opposite the direction of
normal running web movement and then makes a second pass through
the nip in the direction of running web movement when the roll at
the second winding station is accelerated.
3. Web winding apparatus as defined in claim 2 and further
including adhesive applied to the exposed face of said leader and
to facilitate bonding the leader to the running web.
4. Web winding apparatus as defined in claim 1
A. wherein the severing means comprise
1. a pair of knives pivotally mounted adjacent the pair of nip
rolls, each knife being swingable from a position wherein its blade
is spaced from the path of web trained around the associated roll
to a second position wherein the knife blade intercepts the path of
web trained around the associated roll, and
2. means for swinging the knives selectively between said two
positions, and
B. further including
1. a knife backup swingable between two positions, in one of which
positions the backup is disposed opposite the knife blade
associated with one nip roll and the other of which positions the
backup is disposed opposite the knife blade associated with the
other nip roll, and
2. means for swinging the knife backup between its two
positions.
5. Web winding apparatus as defined in claim 1 and further
including means for controlling the rate at which the amount of web
stored by the storage means is reduced following completion of the
splice.
6. Web winding apparatus ad defined in claim 5 and further
including means for initiating a splice cycle when the running web
reaches a predetermined maximum size.
7. Web winding apparatus as defined in claim 2 and further
including
A. first adhesive means affixed to the exposed face of the leader
near its said end, and
B. second adhesive means affixed to the exposed face of the leader
at a point spaced along the leader from the first adhesive means,
both said adhesive means being positioned so that both pass through
the nip on each said pass of the splice through the nip.
8. Web winding apparatus as defined in claim 2 and further
including means for controlling the rotational speed of the running
web roll in accordance with the amount of web stored by the storage
means.
Description
The present invention relates generally to improvements in web
winding machines and more particularly in at least one aspect to
such machines which are especially adapted for rewinding web which
has been unrolled, processed and is being rerolled in preparation
for storage or for further processing.
Several problems are encountered in the rewinding of web,
particularly when the apparatus employed for the rewinding
operation is adapted for handling web having wide variations in
properties which affect the winding characteristics. Among the
properties in addition to width and thickness are web material and
if a laminate or composite, the material of the various parts,
relative stiffness and hardness. The nature of the operation being
performed on the web between unwind and rewind positions also
effects the winding characteristics. The very large number of
variable factors all tend when cumulatively adverse to create
serious defects in rolls wound on conventional winding machines.
One of these called "telescoping", being the protrustion of the
core and adjacent web layers beyond the edge of outer layers of the
roll, may occur either during rolling or in a defectively wound
roll, during subsequent handling after the roll has been completely
wound. The results of telescoping are serious in that the edge of
the web is often damaged with the result that the roll must be
discarded, if not in whole, then at least in part. Even if the web
is salvagable, a telescoped roll must be handled with very special
care, is difficult to store, and in addition renders further
processing especially difficult.
Conventional winders have heretofore generally been very expensive
to construct because of the very nature of the winding operation.
Basically, when winding web, the roll being wound and driven from
its core starts with requirements of high rotational speed and low
torque. As the size of the roll increases with the progress of the
winding operation, if the linear winding speed is maintained
constant, the rotational speed decreases and the driving torque
requirement progressively increases. Conventional winding drives
have been designed with the speed capacity necessary for the start
of the winding operation and the torque capacity needed at the end
of the winding operation when the roll is up to full size. The
combination of both high speed and high torque capabilities in a
single drive has rendered such conventional drives unduly
expensive.
It is accordingly an object of the present invention to provide a
web winding machine having the required versatility to operate upon
webs having a a wide variety of properties.
A related object is to provide a web winding machine in which
defects in wound rolls, particularly "telescoping", are
avoided.
A further object is to provide a web winding machine having surer
and more precise control of tension of the web being wound and more
particularly without changing the web tension in a processing zone
between an unwinding and a rewinding machine.
A further and important object of the invention is to reduce the
cost of web winding machines while maintaining flexibility and
accuracy of control.
A subsidiary, but often important object is to provide a web
winding machine adapted for safe usage in an atmosphere containing
volatile solvents such as are used in inks employed in high-speed
presses.
In the achievement of the foregoing objects, a feature of the
invention relates to a variable speed hydraulic drive arranged to
drive the roll being wound through its core. The drive comprises a
variable volume hydraulic pump, the output of which is inversely
proportional to the size of the roll at any given time. Accoring to
a related feature, the diameter of the roll is continuously
measured and this measurement is translated into a signal for
controlling the output of the pump. A constant displacement
hydraulic motor is driven by fluid from the pump, coupled to a core
shaft and adapted to relatively high speed operation. The coupling
of the motor to the core shaft is through a speed reduction which
provides increased torque and lower speed suitable for the winding
operation.
According to another feature of the invention, the present machine
includes two tension control systems which may be used either
together or separately during a winding operation. Between the web
processing zone and the winding station, the web passes through a
storage festoon including dancer rolls which are urged away from
idler rolls under varying force conditions. This force, which is
regulated by changes in fluid pressure, applies a tension to the
web and determines the tightness of winding. According to one mode
of operation of the present machine, the fluid pressure at the
festoon and hence the tension of the web being rolled, is decreased
at a slow rate during the progress of winding operation. Typically
the difference between starting and ending tension is something on
the order of 5 per cent for typical webs but this may be varied to
suit the specific material being wound.
According to a related feature of the invention, the fluid pressure
and hence the tension applied to the web in the festoon remains
constant from the start to the finish of the winding operation.
However, additional tension essentially "in series" with the
festoon tension is applied to the web by a pair of nip rolls which
are used not only for forming a splice, but also for applying a
drag to the web just ahead of the winding station. Not only does
this feature simplify the control of dancer pressure, but it also
eliminates variations in web tension in a web processing zone ahead
of the festoon. In some cases, the process being carried on is
particularly sensitive to changes in web tension and the quality of
the process is adversely affected by such changes.
The foregoing objects, features, and numerous advantages of the
present invention will be more fully understood from a detailed
description of an illustrative embodiment taken in connection with
the accompanying drawings in which:
FIG. 1 is a view in right side elevation of a winding machine
according to the invention;
FIGS. 2 and 3 are views in front and rear elevation respectively of
the machine of FIG. 1;
FIG. 4 is a schematic view in perspective of mechanical connections
between a dancer yoke and a speed control device depicted with
frame portions of the machine eliminated for clarity;
FIG. 5 is a schematic detail view in perspective illustrating
machine connections for varying fluid pressure to the dancer yoke
in accordance with roll size;
FIG. 6 is a view in left side elevation of the machine of FIGS. 1
to 3 inclusive;
FIG. 7 is a simplified view of a combination of an unwind stand and
a rewinder according to the present invention together with a
generalized interposed processing zone illustrative of a typical
installation;
FIGS. 8 to 11 are progressive views showing the formation of a
splice and the movement of web during the formation of the splice
and at the start of a winding operation;
FIG. 12 is a fragmentary detail view in right side elevation
showing the mounting of a movable idler roll;
FIG. 13 is a fragmentary detail view in left side elevation showing
actuators for splice forming nip rollers;
FIG. 14 is a schematic diagram of electrical connections of the
machine;
FIG. 15 is a schematic diagram of pneumatic connections of the
machine; and
FIG. 16 is a schematic diagram of hydraulic connections of the
machine.
Turning now to the drawings particularly FIGS. 1, 2, and 3 it will
be seen that the illustrative machine comprises a frame including
vertical upright plates 20 and 22 maintained in parallel
relationship by appropriate horizontal stretchers one of which is
seen at 24. The machine includes two winding stations, an upper and
a lower one at which are positioned winding drives indicated
generally at 26 and 28 respectively. The two drives 26 and 28 are
identical in construction and are automatically brought into
operation by appropriate control devices which will later be
described in detail. At the rear of the machine, there is a dancer
assembly indicated generally at 30 for performing the dual
functions of controlling web tension and of providing storage for a
quantity of web in motion to permit stoppage of the web at a point
near the winding stations while web is delivered uninterruptedly
and absorbed by the festoon. The web may thus be stopped or slowed
when a roll has been completely wound so that a splice may be
formed and winding shifted from one winding station to the other.
While the web is stopped or moving very slowly, the splice is
formed between the running web and a leader secured to an empty
core at the alternate winding station after the formation of the
splice and cutting of the web to the full roll, winding is resumed
at the alternate station. During stoppage for formation of the
splice and while the core is being accelerated, web being fed to
the winder is accumulated in the festoon 30. As the winding speed
increases after the formation of the splice the quantity of web in
the festoon is reduced to provide available storage for a
subsequent reduction in winding speed.
Upon entry into the winder the web passes first to the dancer
assembly 30 which is similar in the general layout of dancer and
idler rollers to that described in U.S. Letters Patent No.
3,414,208 granted Dec. 3, 1968 upon application of Richard A.
Butler, Jr. et al. The dancer assembly 30 comprises a yoke 32
mounted for vertical movement and carrying six dancer rollers
numbered in order of contact with the web 34, 36, 38, 40, 42, and
44. For storing web, the yoke 32 is urged upwardly by a pair of air
actuated pistons 46 each contained in a cylinder 48 and having a
rod 50 as shown schematically in FIG. 12, one of the like cylinders
being depicted in FIGS. 1 and 4 together with its connections to
the yoke 32. The present machine includes two like cylinders 48 so
as to provide the necessary forces for a normally expected range of
web winding operations with readily available air pressure without
incuring the expense of very large cylinders which tend to be
limited in production and hence relatively costly. Web stored in
the dancer assembly 30 alternates between one of the dancer rollers
34, 36, 38, 40, 42 and 44 and an idler roller 52, 54, 56, 58, 60,
62 and 64. Thus the path of the web in the dancer assembly, as the
web comes in beneath the idler roller 52 is alternately in
engagement with idler and dancer rollers as follows: 52, 34, 54,
36, 56, 38, 58, 40, 60, 42, 62, 44 and 64. From the idler roller
64, the web is trained over a pair of overhead idler rollers 66 and
68 and down to a slitter indicated generally at 70 and later to be
described in some detail. From the slitter 70 the web passes over
idler rollers 72 and 74 and through a splicer assembly indicated
generally at 76 to either the upper or the lower winding
station.
The yoke 32 comprises a pair of spaced apart side plates vertically
slidable on guide columns 89 and urged upwardly by the force of the
pistons 46. As best shown in FIGS. 1, 3 and 4, each of the side
plates comprising the yoke 32 is connected to a roller chain loop
82 trained over idler sprockets 84, 86, and 88 rotatably mounted on
the machine frame and over a large active sprocket 90 keyed to a
shaft 92 journalled in the machine frame. There are also mounted on
the shaft 92 beside the pair of sprockets 90, one for each of the
chains 82, a pair of smaller sprockets 94 each keyed to the shaft
and over each of which is trained a looped roller chain 96 each
connected to one of the piston rods 50. When pressurized air is
supplied to the cylinders 48 so as to cause downward motion of the
rods 50, the shaft 92 is urged in a counterclockwise direction and
the yoke 32 upwardly to place the web in the festoon under tension.
The relative sizes of the sprockets 90 and 94 are so chosen that
they enable the stroke of the pistons 46 to match the travel of the
yoke 32. During the total travel of the yoke 32 from its lowermost
to its uppermost position, the shaft 92 and the sprockets 90 turn
slightly less than a complete revolution.
The turning of the shaft 92 is employed for regulating the output
of a pump, shown schematically at 98 in FIG. 16, through a
mechanism now to be described. For this purpose, as best seen in
FIG. 4, there is keyed to the outboard end of the shaft 92, a
pinion 100 meshing with a gear 102 keyed to a stub shaft 104 which
is journalled in the frame. A cam 106 is also keyed to the shaft
104 and the periphery of the cam is engaged by a follower roll 108
mounted near one end of a lever 10 pivoted near its center at 112
upon the machine frame. Connected to the end of the lever 110
opposite the follower roll 108 is a cable 114 which is coupled to
the delivery volume control of the pump 98. The cam 106 is so
shaped that as the storage capacity of the dancer assembly 30
diminishes with the rise of the yoke 32, the lever 110 is pivoted
in a clockwise direction as seen in FIG. 4 pulling the cable 114
upwardly and increasing the delivery of the pump 98 to increase the
winding speed and cause the yoke 32 to descend thereby increasing
the storage capacity of the festoon 30. Conversely, if the yoke 32
is near the lower extreme of its travel, the contact of the
follower roll 108 with the contour of the cam 106 causes the lever
110 to swing in a counterclockwise direction allowing the cable 114
to slacken downwardly and thereby decreasing the delivery rate of
the pump 98 and the web winding speed so that the yoke 32
rises.
As shown in FIGS. 1 and 5, there is provided in the present winding
machine apparatus for continuously measuring the size of the roll
being wound for two different purposes. The first of these,
according to a mode of operation of the machine, is to regulate the
tension in the web in accordance with the size of the roll at any
given moment. The second purpose is to permit the automatic
termination of the winding operation at one winding station and the
initiation of a winding operation at the alternate winding station
when the roll being wound has reached a predetermined size. For
these purposes there is provided at each winding station an arcuate
arm 116 affixed to a shaft 118 and carrying at its distal end a
roller 120 which is maintained in contact with the outside of the
roll being wound. The shaft 118 which is journalled in the machine
frame also carries a second arm 122 to the distal end of which is
connected a spring loaded chain 124 trained over a sprocket 126
affixed to one end of a control shaft 128 which is also journalled
in the frame. The shaft 128 has affixed to it cams 130 and 132, the
peripheries of which are engaged by follower rolls respectively
associated with a control valve 134 and a switch 136. The contour
of the cam 130 is such that as the roll being wound increases in
size, the output pressure of the valve 134 decreases. The cam 132
is formed to allow the switch 136 to close when a predetermined web
roll size has been reached.
Both winding drives 26 and 28 are alike and accordingly the
following description will be equally applicable to both. Each
drive 26 and 28 comprises a hydraulic motor designated as 138 and
139 respectively as best seen in FIGS. 1 and 2. A cogged belt 140
passes over a driving pulley 142 of each motor 138 and 139 and also
over an intermediate driven pulley 144 mounted on a common shaft
with an intermediate driving pulley 146. A second cogged belt 148
passes over the pulley 146 and also over a large driven pulley 150
keyed to the cutboard end of stub winding shaft 152. At its inboard
end, the shaft 152 also has keyed to it a chuck 154 by which it is
coupled to a core shaft 156 which grips the interior of the web
roll core for imparting rotary motion to the roll. The combination
of belts 140 and 148 and the pulleys 142 and 144, 146 and 150 which
these belts engage provide a speed reduction between the pulley 142
of the core shaft 156, of approximately six to one with a resultant
increase in torque. Both the motors 138 and 139 are driven from the
same pump 98 through appropriate control circuitry later to be
described.
At the completion of a roll winding operation the web is spliced to
a leader such as that shown at 162 in FIGS. 8 through 11 and then
cut between the leader and the full roll. In these FIGS. there is
depicted the end of the winding operation for a roll at the lower
winding station and the start of winding at the upper station. A
web 164 is shown in FIG. 8 being drawn downwardly toward the lower
winding station and in FIG. 9 being cut as the web is being spliced
to the leader 162. For forming the splice, the leader 162, which is
securely anchored to a core mounted on the upper core shaft 156, is
provided with adhesive strips 166 and 168 typically in the form of
double faced adhesive tape. The splice is formed by pressure from a
pair of nip rollers consisting of a lower and an upper one 170 and
172 respectively. The rollers 170 and 172 are moved into splicing
engagement with the web by air cylinders 174 and 176 respectively
as shown in FIG. 13. The nip rollers 170 and 172 are hollow,
rubber-covered, perforated and connected to a vacuum source for
holding the leader in readiness for the splicing operation as shown
in FIG. 8 in which the free end of the leader 162 is supported by
vacuum on the upper nip roller 172. Also associated with the nip
rollers are knives 178 and 180 mounted on pivoted arms and movable
into engagement with the web running to the lower and upper rewind
stations respectively. The knife blades 178 extends across the web
running from the roller 170 to the lower winding station and is
mounted on arms 182 while the knife which is arranged to engage the
web running upwardly from the roll 172 is similarly mounted on arms
184 as shown in FIG. 11. A brush 186 is pivotable to either of two
positions to back the web for cutting by the appropriate knife. The
splicing operation is initiated by actuating the nip roller which
is supporting the leading end of the leader toward the running web
passing over the other nip roller when the roll being wound has
reached an appropriate diameter. Thus, as seen in FIGS. 8 and 9,
the roller 172 which is supporting the leader 162 is pressed
downwardly toward the web 164 at a point where the web is passing
over the nip roller 170. As the adhesive band 166 is secured to the
web 164, the knife 178 is actuated to cut the web 164 between the
nip roller 170 and the lower winding station. The web 164 ahead of
the nip rollers 170 and 172 to the left as seen in FIG. 9, is under
tension from the festoon 30. The result of the tension is that the
leader 162 is thereby drawn through the nip between the rollers 170
and 172 and to the left toward the festoon as indicated by an arrow
in FIG. 10. This is in effect a reverse or unwinding motion of the
web which is no longer being pulled in the winding direction after
having been severed by the knife 178 as seen in FIG. 9. The effect
of the reverse motion of the web 164 and the leader 162 is to
splice both bands of adhesive 166 and 168 to the web 164. After the
leader 162 has been drawn a sufficient distance in the reverse
direction to splice both adhesive bands to the web 164, rotary
motion is imparted to the new core and the splice is thereby drawn
toward the upper winding station as shown in FIG. 11. This view is
largely schematic in nature since it shows the nip rollers 170 and
172 spread apart and a leader 188 is shown ready on the lower nip
roller 170 for the next splice which occurs only after the web roll
at the upper unwind station has been wound to its full size. In
practice, as will be seen, the nip rollers 170 and 172 may remain
closed upon the running web for an appreciable period of time to
provide additional web tension for winding a tight core. As will
later be explained, the leader 188 can be applied to the nip roller
170 at a later time so long as it is ready for the formation of the
next splice.
It is thus seen from the foregoing that the splice is formed in the
present machine in a novel manner to assure reliability of splice
formation. When the adhesive band 166 is pressed into engagement
with the running web 164 as shown in FIG. 9, the running web is
either moving very slowly or stopped as will later be explained.
The tension on the web 164 originating in the festoon 30 which is
to the left of the nip rolls 170 and 172 as shown in FIG. 9, draws
the splice backwardly or in an unwinding direction between the nip
rolls for a first pass which presses both adhesive bands 166 and
168 into secure contact with the web 164. When the rotary motion is
imparted to the upper core shaft 156 so that the web 164 begins to
move in a winding direction, both adhesive bands 168 and 166 are
again pressed against the web 164 by a second pass between the nip
rolls 170 and 172 as seen in FIG. 10 with the result that a secure
and reliable splice is formed between the leader 162 and the web
164.
The operation of the machine will be better understood from a
description of the electrical schematic diagram, FIG. 14, which
includes a transformer indicated at 200 whose primary winding is
connected to the power line and whose secondary is connected to
main machine lines 202 and 204, the connections between the
secondary of the transformer 200 and the main line 204 being made
through a fuse 206. For setting the machine in operation, there is
a main on-switch 208 of the momentary contact type. The main switch
208 is in series with a normally closed electrical interlock switch
210 which is opened when an access door is opened and also with a
normally-closed main off-switch 212. When the switch 208 is
momentarily closed a motor controller solenoid 214 is energized and
causes a pair of normally open holding contacts 216 to close and
also causes the closure of a pair of normally open contacts (not
shown) for switching on a motor 218 which drives the pump 98 as
shown schematically in FIG. 16. At the same time a signal light 220
is lit to indicate that the pump 98 is in operation. After the pump
98 has been started and in preparation for the formation of a
splice, a splicing cycle on-switch 222, of the momentary contact
type is closed to energize circuits prior to the triggering of a
splice. The switch 222 is in series with a normally closed
off-switch 224 interposed between the one switch and auxiliary line
226 connected to the main line 204 through the contacts 216 when
the controller solenoid 214 is energized, the contacts 216 serving
as holding contacts for the solenoid 214. When the switch 222 is
momentarily closed, a motor controller solenoid 228 is energized
closing normally open holding contacts 230 and another pair of
contacts not shown which provides power to a vacuum pump motor for
supplying vacuum to the nip rolls for holding a leader 162 or 188
upon the appropriate nip roll in preparation for the formation of a
splice. When the solenoid 228 is energized and the contacts 230
closed, a signal light 232 is lit to indicate the availability of
vacuum at the nip rolls and the readiness of the splicing apparatus
of the machine.
A splicing cycle is started by momentary closure of a push button
switch 234 or alternatively by closure of the switch 136 also
depicted in FIG. 5. Momentary closure of either the switch 136 or
the switch 234 causes a relay solenoid 1CR to be energized from the
auxiliary line 226, through the normally closed switch 224 and the
closed contacts 230. When the relay coil 1CR is energized, normally
open contacts 1CR-A closes to latch the coil 1CR in energized
condition and to continue energization of the time delay relay
coils TD-1, TD-3 and TD-4. Each of the time delay relays TD-1, TD-3
and TD-4 has contacts for controlling subsequent operation of the
machine in sequence. Time delay relay TD1 is provided with two
pairs of normally open contacts TD1-A and TD1-B which are closed
following a predetermined time interval after relay coil TD1 is
energized by the momentary closure of either the switch 136 or the
switch 234. Switches 242 and 243 are coupled to a valve which
determines whether vacuum is supplied to the upper or lower nip
roll 170 or 172. AS shown in FIG. 14, the machine is prepared for
splicing to a leader from the lower winding station since the
switches 242 and 243 are arranged to energize solenoids 238 and 240
respectively in order to actuate the lower nip roll 170 and the
upper knife 180 in proper sequence. When the contacts TD4-A closes,
a time delay relay solenoid TD2 is energized in order to reset the
circuits at the termination of the splice operation. For this
purpose there is associated with the time delay relay TD2 a single
pair of normally closed contacts TD2-A which opens after a
predetermined time interval following the energization of the time
delay relay TD4. When the contact TD2-A opens, the motor control
solenoid 228 is de-energized and the holding contacts 230 open
thereby de-energizing relay solenoids 1CR, TD1, TD3, and TD4. The
de-energization of the solenoid 1CR causes the opening of the
contact 1CR-A thereby interrupting power to solenoids 236, 238,
239, and 240.
The time delay relay TD4 also includes a pair of normally closed
contacts TD4-B in series with a relay coil 2CR having a single pair
of normally closed contacts 2CR-4 for terminating the throttling of
the output of the pump 98 as will be seen. When the relay contacts
TD1-A close, one or the other of a pair of valve operating
solenoids 236 and 238 is energized. Similarly, when the time delay
relay contacts TD4-A close, one or the other of a pair of valve
operating solenoids 239 and 240 is energized. For determining which
of the pairs of solenoids will be energized upon closure of a relay
contact TD1-A and TD4-A, there is provided a pair of switches 242
and 243 coupled mechanically to a valve for controlling vacuum to
the nip rollers 170 and 172. When the switches 242 and 243 are in
the condition shown in FIG. 14, the solenoids 238 and 240 are
energized on closure of the contacts TD1-A and TD4-A respectively.
When the solenoid 238 is energized, the spool of a two way valve is
shifted to cause the lower nip roll to be raised. Similarly, when
the solenoid 240 is energized, a valve spool is shifted to cause
the upper knife to be actuated at the proper time sequence.
For electrically controlling the connection of the hydraulic motors
138 and 139 to the pump, there are provided push-button switches
244 and 246 respectively. The switch 244 is in series with a relay
coil 3CR having a single pair of normally open contacts 3CR-A
serving as holding contacts. The contacts 3CR-A are in parallel
with the switch 244 and in series with a pilot light 248. The
closure of contacts 3CR-A latches coil 3CR in energized condition,
turns on the pilot light 248 and energizes a relay coil 5CR, which
is provided with a single pair of normally open contacts 5CR-A in
series with a throttle control solenoid 250.
The switch 246 is in series with a relay coil 4CR which is
energized when the switch is momentarily closed. Closure of the
switch 246 and energization of the coil 4CR causes contacts 4CR-A
to close and thereby to latch the coil 4CR in energized condition,
also causing a pilot light 252 to be turned on and a relay coil 6CR
to be energized. The coil 6CR has a single pair of normally open
contacts 6CR-A in parallel with the contacts 5CR-A. A double pole
normally closed switch 254 having a pair of contacts interposed
between the relay contacts 3CR-A and the relay coil 3CR and a
second pair of contacts interposed between the relay contacts 4CR-A
and the coil 4CR serves as a stop switch for stopping both motors
138 and 139 in case of emergency.
A pair of normally open contacts TD1-B closed by the time delay
relay TD1 serves to make possible the energization of upper and
lower motor solenoids 266 and 268 as will later appear. The choice
of which of the hydraulic motors 138 or 139 is energized is
determined by a circuit including latching relay coils LR1 and LR2
provided respectively with pairs of contacts LR1-A and LR1-B and
LR2-A and LR2-B. As shown in FIG. 14, the contacts LR1 A and LR2-A
are closed and LR1-B and LR2-B are open. The construction of the
relay gangs of the latching relays is such that each time a coil is
pulsed, the then open contacts close and the closed contacts open.
For pulsing coils LR1 and LR2 there are provided coupled normally
open switches 262 and 264 in series across the line with the coils
LR1 and LR2 respectively.
While the switches 262 and 264 are open, contacts of the time delay
relay TD3 and TD4 are employed for maintaining the energization of
the coils LR1 and LR2. Thus contacts TD3-A are in series with coil
LR1 and contacts TD4-A are in series with coil LR2.
A circuit for energizing upper and lower motor solenoids 266 and
268 respectively includes the contacts of the latching relays LR1
and LR2. In series with a pair of normally closed switches 270 and
272, a branch including the upper motor solenoid 266 includes the
latching relay, LR1-A and LR2-A together with normally open relay
contact 3CR-B. Another branch includes the lower motor solenoid
268, the latching relay contacts LR1-B and LR2-B together with
relay contact 4CR-B. The switches 270 and 272 are coupled to
devices which measure the size of the roll being wound in order to
interrupt the winding operation in the event that the roll is wound
to excessive size. This is done by opening the switch 270 and 272
in response to the measurement. In parallel with the solenoid 266
there is a solenoid 274 for actuating the valve to control the
tension regulating circuit for the upper unwind station. There is a
similar solenoid 276 in parallel with solenoid 268 for the tension
control at the lower unwind station. In order to permit inching or
jogging of the upper motor 138 there is a double pole momentary
contact switch 278 which, when closed, causes the solenoids 266 and
274 and a solenoid 282 to be energized. Similarly, for the motor
139 at the lower unwind station there is a switch 280 which, when
closed, energizes the solenoids 268, 276 and 282.
The pneumatic connections of the machine are shown in FIG. 15 and
include a main line 290 in which there is provided a filter 292 and
a lubricator 294. After the lubricator 294 there are provided
branch circuits, each controlled by a pressure regulator indicated
at 296, 298, 300 and 302. The pressure regulator 296 adjusts the
air pressure to the dancer cylinders 48 while the pressure
regulator 298 is employed to adjust loading of the cylinders 48.
The regulator 300 controls the pressure to the nip roller actuating
cylinders 174 and 176. Finally, the regulator 302 controls the
pressure of a throttle control cylinder 304 and of a jog control
cylinder 306. The output of the regulator 296 is connected to the
control valve 134 which is shown in FIG. 5 and associated with the
upper winding station and a like control valve 310. The function of
the valves 134 and 310 is to change the air pressure supplied to
the cylinder 48 to regulate the tension on the web which varies in
accordance with the size of the roll being wound. Connected to the
control valve 134 is a solenoid actuated valve including the
solenoid 252 and a spool 312 which blocks the output of the valve
134 from a shuttle valve 314 unless the solenoid is energized. When
the solenoid 252 is energized, communication is established through
the lower portion of the spool 312 between the control valve 134
and the valve 314. Similarly when the solenoid 254 is energized a
spool 316 rises as seen in FIG. 15 and thereby establishes
communication between the control valve 310 and the shuttle valve
314. In practice, only one of the solenoids 252 and 254 is
energized at any given time. The shuttle valve is provided with a
ball which moves in response to the greater pressure applied to it
so that it blocks off the lower pressure input. Thus, when the
solenoid 252 is energized, the lower chambers of the cylinders 48
are in communication with the control valve 134 through the valve
314. When the solenoid 252 is de-energized and the solenoid 254
energized, it is the output of the control valve 310 which
communicates through the valve spool 316 and the valve 314 with the
lower chambers of the cylinders 48.
From the regulator 298, there is a connection through a check valve
318, connected in parallel with a restriction 320, with the upper
chambers of the cylinders 48. The regulator 298 is always adjusted
to a pressure greater than that of the regulator 296 and the force
supplied by the rod 50 to the yoke 32 is dependent upon the
difference between the pressure of the regulator 298 and the output
of the control valve 134 or 310, whichever is active. It will also
be realized that the cam corresponding to the cam 132 in FIG. 5 may
be considerably varied in shape and also that the control valves
134 and 310 may be bipassed altogether. The line establishing
communication between the check valve 318 and the restrictions 320
with the upper chambers of the cylinders 48 is provided with a
pressure relief valve 322.
The output of the regulator 300 is connected to a pair of valves
respectively comprising spools 324 and 326 and actuated by
solenoids 236 and 238. While the solenoids 236 and 238 are
de-energized, air under pressure is admitted to the upper chamber
of both cylinders 176 and 174. The result is that the piston is
retracted in the cylinder 176 and projected outwardly in the
cylinder 174. When the solenoid 236 is energized the connections
are reversed and air under pressure is supplied to the lower
chamber of the cylinder 176 and exhausted from the upper chamber
through the lower portion of the spool 324 to atmosphere. Similarly
when the solenoid 338 is energized connections are reversed so that
the lower chamber of the cylinder 174 is in communication with air
under pressure and the upper chamber is exhausted. Motion of either
piston associated with the cylinder 176 or 174 causes travel of the
related nip roller into splice forming position. Thus, when the
solenoid 236 is energized, the roll 172 is moved downwardly into
splicing position. Similarly, when the solenoid 238 is energized,
the roll 170 is moved upwardly into splicing position.
For controlling motion of the knives 178 and 180, there are
provided air cylinders actuated through valves including spools 328
and 330 actuated respectively by solenoids 240 and 239. When the
solenoids 239 and 240 are deenergized the spools are in the
position of FIG. 15 and the cylinders 332 and 334 have their upper
chambers in communication with the regulator 300. Under such
conditions a piston 336 slidable in the cylinder 332 and a piston
338 slidable in the cylinder 334 are both depressed. When the
solenoid 240 is energized, the spool 328 rises and communication is
established between the regulator 300 and the lower chamber of the
cylinder 332 forcing the piston 336 upwardly and venting the upper
chamber to atmosphere through the lower portion of the spool 328.
The effect is to actuate the upper knife 180 to web cutting
position. Similarly when the solenoid 239 is energized the spool
330 rises as seen in FIG. 15 with the result that the output of the
regulator 300 is communicated through the lower portion of the
spool 330 with the lower chamber of the cylinder 334 and the upper
chamber is exhausted through the spool. The result of the rise of
the piston 338 is to impart a web cutting motion to the lower knife
178.
The output of the regulator 302 is in communication with to the
throttle control cylinder 304 through a valve including a spool 340
actuated by the solenoid 250. The output of the regulator 302 is
also connected to the jog control cylinder 306 through a valve
including a spool 342 actuated by the solenoid 282. Under the
conditions depicted in FIG. 15, when both solenoids 250 and 282 are
de-energized, the upper chambers of the cylinders 304 and 306
communicate with the regulator 302 through the upper portion of the
spools 340 and 342 respectively. When the solenoid 250 is
energized, the connections are reversed and the lower chamber of
the cylinder 304 is in communication with the regulator 302 through
the lower portion of the spool 340 while the upper chamber is
vented to atmosphere through the spool. When the solenoid 282 is
energized, the connections to the cylinder 306 are also reversed so
that they are under pressure from the regulator 302 introduced into
the lower chamber whereas the upper chamber is vented to
atmosphere, both through the lower portion of the spool 342.
The hydraulic connections of the machine are shown in FIG. 16 in
which the pump 98 is seen having its inlet connected to a sump 350
through a line having a shut-off valve 352. The outlet of the pump
98 is through a check valve 354 connected in parallel with a
restriction 356 to a main machine line 358 which has its pressure
controlled by a regulator 360. From the line 358, the pressurized
hydraulic fluid is conducted to the motors 138 and 139 through
check valves 362 and 364 respectively. Between the inlet and the
outlet of the motor 138 there is a back flow circuit comprising a
check valve 366 in series with a restriction 368. Around the motor
139 there is a similar circuit comprising a check valve 370 in
series with a restriction 372. At the outlet of the motor 138 there
is an overload relief valve 374 and a similar valve 376 is at the
outlet of motor 139. The actuation of either motor 138 or 139 is
controlled by a three-way valve including a spool 378 shown in a
central position which causes both motors to be idle. When the
solenoid 248 is energized the spool 378 is shifted to the right as
seen in FIG. 16 and the result is that the outlet of the motor 138
is returned to the sump through the left portion of the spool 378
and a check valve 380. At such times, the outlet of the motor 139
is subjected to the pressure of the main machine line 358 also
through the left portion of the spool 378. When the solenoid 250 is
energized, connections are reversed and the outlet of the motor 138
is subjected to a full line pressure through the right portion of
the valve spool 378 while the motor 139 is exhausted through the
same portion of the valve 378 and the check valve 380.
In FIG. 7, there is shown a typical application of a winder
according to the present invention indicated generally at 390,
including a festoon indicated at 392 receiving web from a
processing zone 394 which may be a printing press or a converting
machine. The web is fed to the processing zone 394 from a supply
apparatus such as that disclosed in the above-identified Butler et
al patent. The unwinding apparatus indicated generally at 396
includes a running web roll 398 and a ready web roll 400. The web
is unwinding from the roll 398 through a festoon indicated at 402
and through the processing zone 394. After passing through the zone
394, web is directed through the festoon 392 of the winder 390 and
is rerolled at the lower station on a roll 404. When the roll 404
has reached its predetermined diameter, the web is spliced to a
leader from the upper unwind station including a hydraulic driving
motor 406 and the web is then severed from the roll 404 as the
winding operation continues at the upper unwind station.
When the roll 398 is depleted, the leading end of the roll 400 is
spliced to the running web and the web continues to pass
uninterruptedly through the festoon 402 in the processing zone 394
to the winder 390. The festoon 404 senses the input tension to the
zone 394 and the festoon 392 controls the tension during the
winding operation at the winder 390.
The illustrated combination of unwind and rewind apparatus thus
furnishes web uninterruptedly, continuously controls unwinding and
rewinding tension and finally rewinds the web uninterruptedly after
processing.
Having thus disclosed our invention, what we claim is new and
desire to secure by letters patent of the United States is:
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