Mandrel-less winder

Abstract

A machine for continuously winding on a mandrel-less core primarily small packages of material, wherein the wound package is continuously in contact with at least one of the driving drums during the winding operation.

Description

BACKGROUND OF INVENTION

Extensive use is made in the textile industry of winders for winding web material into rolls for packaging or subsequent textile operations. Such winders are shown for instance in U.S. Pat. Nos. 3,045,940 and 3,061,221.

These winders include a type having a mandrel which is in effect a supporting metal shaft which extends through a core of heavy cardboard or plastic tubing, upon which the material is wound, wherein the mandrel is supported or journalled at the ends to support and control the wound package. Such mandrel type winders are generally used where the packages are extensive in size and weight; for instance, up to 6 feet in diameter and weighing for instance up to 4000 pounds. Another type of winder is one in which no mandrel is used, but rather the core upon which the material is wound is supported or otherwise positioned within a winder. Such mandrel-less winders are generally used for relatively small packages of for instance up to 24 inches in diameter and for instance up to 150 pounds in weight. The advantages of a mandrel-less winder are that there is no need to insert and withdraw a relatively heavy mandrel into the core tube and hence a faster and less cumbersome operation ensues. However, such mandrel-less winders are limited since the mandrel is necessary where weights and, or, material widths become excessive.

In the past virtually all winding was done on mandrel type winders since weights were relatively heavy and there were serious problems with the mandrel-less type even for lightweight packages. For instance, in one prior art type of mandrel-less winder it is necessary to stop the winding operation to cut the continuous web and to rethread the cut end about a new core tube. Such rethreading has been done manually. Such interruption of operation was necessary since the cutter mechanism was positioned after the doffing or rear drum, and the beginning of the windup took place between the entering and center drum of the multiple drum arrangement.

SUMMARY OF PRESENT INVENTION

In the present invention a package can be wound on a core in a mandrel-less winder while the web material is being fed continuously to the winder, without the necessity of shutdown to cut and rethread onto a new core. In operation, the web material is initially wound about a core which is in turn held against a rotating driven front drum. After the wound package reaches a predetermined size, the package is moved in a positive manner from contact with the entering drum to a center drum and then to a position between the center and doffing drum for final winding. The package is moved in a positive manner during winding by means of hubs inserted in the core ends. The hubs are supported from a transfer mechanism.

When the package being wound reaches a predetermined end size, the web is automatically severed and the entering free end is in turn automatically started about a new core which has been fed into position by mechanical means. The new core is positioned adjacent to, and in contact with, the entering, rotating, driven drum. The winding continues and the process repeats itself.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the machine of the invention.

FIG. 2 is a sectional elevation of the machine of FIG. 1 taken on the line 2--2 of FIG. 1, taken at the start of windup.

FIG. 3 is a view similar to FIG. 2 showing a drum during winding being transferred between the front, or entering and middle drums.

FIG. 4 is a view similar to views 2 and 3 showing the completion of the winding of one drum and the start of winding of another drum.

FIG. 5 is a partial elevational view of the slide and track assembly of the invention.

FIG. 6 is a partial sectional elevation taken on the line 6--6 in FIG. 5.

FIG. 7 is a sectional elevation of the left hand assembly of the hub slide.

FIG. 8 is a view taken on the line 8--8 of FIG. 7.

FIG. 9 is a plan view of the left hand assembly of the slide mounting.

FIG. 10 is a view taken on the line 10--10 in FIG. 9.

BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENT

The machine of the invention consists essentially of a frame 40, driven drums 45, 46 and 47 journalled within the frame, a cutter mechanism 51, a transfer assembly 60, and a hub assembly 75.

Frame 40 has positioned at both sides of the machine a fabricated housing 40' which is about 60 inches high, 251/2 inches wide at the top and 40 inches in width at the bottom, and about six inches thick. The plates forming the housing 40' are for instance 1/4 inch thick and are reinforced with ribs fashioned by bending. The housing 40' includes therein the winder electrical wiring and pneumatic valving. Tie rods and crosspieces, including channels and plates, extend across the frame ends to provide rigidity. There are journalled in the end frames 40' driven shafts 41, 42 and 43 which have keyed thereon respectively, rear, doffing, or let-off drum 45, middle or center drum 46 and front, or entering drum 47. These drums are for instance of an 8 inch diameter, but they may go up to 81/2 inch diameter. The drums are driven at the same rotational speed by a sprocket chain drive connected to a driving motor.

Extending upwardly from the frame base is a pneumatic cylinder 48 which has extending therefrom a rod 50 carrying thereon a cutter mechanism 51. The cutter mechanism which is of a prior art type, has journalled thereon a plurality of circular blades which rotate on the cutter mechanism when the cutter is moved up into position. The blades are driven by a motor 49 through a gear drive and sprocket chain arrangement. A hold-down bar 52 is driven downwardly by a pair of pneumatic air cylinders 53 during the cutting operation. Such cutting mechanism is shown in detail in U.S. Pat. Nos. 2,723,717 and 3,614,010 and such disclosure is incorporated therewith by way of reference.

Mounted on cutter mechanism 51 is a transversely extending pipe 55 which has therein holes which enable air under pressure within the pipe to be jetted upwardly during the cutting operation. The function of this upward air jet is to blow the severed end of the web about the new core tube to begin the wrapup for the new wind.

The core tubes on which the packages are wound are of the well known prior art type and are for instance from 36 inches up to 100 inches in length, and of, for instance, 21/2inches in diameter. The cores are made of heavy cardboard or plastic. The cores are fed through a chute arrangement 57. The chute is essentially opposing channels 57' which face each other to provide a guide arrangement for the tubes.

The channels 57' are fixed on transfer mechanism assembly 60. The transfer assembly mechanism 60 comprises opposing mirror image, left hand and right hand sections keyed on shaft 61. The mechanism 60 is rotated by a pneumatic cylinder which controls the movement to provide the action later described.

A screw thread shaft 63, as seen for instance in FIGS. 5 and 6, forms part of the means for adjusting the spacing between opposing sections, that is, the left hand section and the right hand section, of the transfer mechanism assembly 60 to provide for an adjustment to conform to the core tube length, from for instance 36 inches up to 100 inches. Shaft 63 has a left hand thread on one end of the shaft and a right hand thread at the other end of the shaft.

The adjusting means includes collar 64 secured to threaded sleeve 68 engaging shaft 63 as best seen in FIGS. 5 and 6. Collar 64 straddles shoulder 64' fixed on sliding sleeve 64.sup.2. Sleeve 64.sup.2 is fixed to and supports transfer assembly 60. It should be understood sleeve 64.sup.2 is free to slide longitudinally along shaft 61, but is rotationally fixed to shaft 61 by key 61'. Collar 64 is of a Y configuration as seen in FIG. 5 so that shaft 61 can rotate transfer assembly 60 without interference with collar 64.

Likewise the transfer mechanism assembly plates 60' can slide longitudinally along shaft 61 and also along key 61'. Hence, the transfer mechanism is locked rotationally to shaft 61, but it may be adjusted longitudinally along said shaft by rotating adjusting screw 63.

An air cylinder 70 is mounted on the plate 60 to activate an escape mechanism 71 which selectively allows a core tube to be moved into position while retaining the upper core tubes in the chute 57. Such escape mechanism is shown in FIG. 5.

Escape mechanism 71 includes prongs 71' and 71.sup.2 on plate 71.sup.3 which selectively are brought into engagement and disengagement with a core tube when plate 71.sup.3 is rotated about pivot 71.sup.4. Plate 71.sup.3 is selectively oscillated by piston rod 70' extending from cylinder 70 and connected at 70.sup.2, as best seen in FIG. 5.

In FIGS. 7 and 8 there are shown details of the left hand section of the hub slide assembly, there being a similar, mirror-image, right hand assembly on the opposite side of the machine. Hub slide assembly 75 has a hub 79 which has a tapering end adapted to fit into, and support the end of a core tube. It will be seen that a core tube can be firmly supported by means of opposing hubs inserted into the ends of the core tube. Hub 79 is rotatably journalled on shaft 78 which is secured to piston rod 80 which extends from pneumatic cylinder 77. Shaft 78 is slidably supported in journal 82 which is fixed on slide plate 84. Cylinder 77 is fixedly supported from slide plate 84 by bracket 86 held to plate 84 by suitable bolts. Screws 88 secure stop blocks 88' to slide plate 84, used to limit the travel of slide plate 84. A stripper 90 is also fixed to plate 84 and permits hub 79 to shift as indicated at 76 without pulling the tube 124 when it is to be released. Slide plate 84 has bevels 92 thereon along its edges. A rack 94 is affixed to plate 84 by suitable bolts.

As seen in FIGS. 9 and 10, slide plate 84 is slidably journalled within rollers 96 pivotally mounted on transfer assembly 60. Rollers 96 have grooves, and bevels 92 fit within these grooves. As shown in the drawings, three rollers, two on one side of the plate 84, and one on the other side of the plate, slidably support the plate 84.

The teeth of rack 94 engage pinion 100 keyed on the shaft of air motor 102 mounted on transfer assembly 60 by bracket 104. Air motor 102 has suitable air hoses connected there to selectively rotationally drive the motor in either a clockwise or counterclockwise direction, thus permitting slide plate 84 to be selectively extended or retracted along with hubs 78 and pneumatic cylinder 77.

Before operation of the winder of the invention, it is necessary to adjust the transfer mechanism 60 transversely of the machine to the length of core tubes 126 which will be used during the continuous wind. The length of these tubes, of course, will be selected to accommodate the width of the material intended to be wound.

Handwheel 138 on shaft 63 is rotated so as to bring opposing sections of transfer assembly closer together, or further apart, as desired. By rotating handwheel 138 and shaft 63, sleeve 68 is moved along shaft 63, causing collar 64 to drive shoulder 64' and sleeve 64.sup.2, which supports transfer assembly 60 along shaft 61.

Opposing side guide plates 154 are mounted on screw shaft 160, which is tied by means of sprockets and chain to screw 63.

Rotating handwheel 130 on screw 63 causes both screw 160 and screw 63 to rotate together. Screw 160 is of similar construction to screw 63.

Guide plates 154 are used to keep roll 128 (FIG. 4) positioned while winding.

In operation, the web 120 to be wound enters at 122 and, for the start up at the very beginning of winding, is wrapped on core tube 124, manually, a few turns. The posture of the machine, shortly after the initial startup, is seen in FIG. 2 wherein:

a. Cutting mechanism 51 is retracted, and in a downward position, with piston rod 50 withdrawn within pneumatic cylinder 48.

b. Pressure bar 52 is withdrawn upwardly by pneumatic cylinders 53.

c. Drums 45, 46 and 47 are rotating in a clockwise direction as seen in FIG. 2.

d. Transfer mechanism 60, keyed on shaft 61, is in its extreme clockwise position, wherein core tube chute 57, with its load of empty cores 126', having a bottommost core tube 126, is positioned, vertically over front, or entering drum 47.

e. Escape mechanism 71 is positioned by cylinder 70 so that prong 71' holds the lowestmost core 126 of core supply 126' in a restrained position.

f. Slide plate 84 is in an extended downward position so that hubs 79, which engage the ends of core tube 124, hold core 124 and the package material 128 being wound thereon under a slight force, for instance five pounds against rotating drum 47.

Package 128 continues to be wound on core tube 124 until package 128 achieves a diameter of approximately four to five inches. At this point, transfer medhanism 60 is rotated in a counterclockwise direction, as seen in FIG. 3. Package 128 continues to be wound on core 124, as it is continuously, in a controlled manner by the transfer mechanism 60, held against rotating front drum 47, then against rotating drum 47 and middle drum 46 simultaneously, and then against, up and over middle drum 46. During this second phase of the operation, the package 128 is continuously in contact with at least one of the drums, and at times two of the drums.

Transfer mechanism 60 is rotated in a counterclockwise direction by the operator actuating a manual switch which causes a pneumatic cylinder (not shown) connected to shaft 61, to rotationally drive shaft 61 in a counterclockwise direction. Since transfer mechanism 60 is keyed on shaft 61 through sleeve 64.sup.2 and key 61.sup.1, transfer assembly 60 is likewise driven counterclockwise. As this happens, package 128 is carried rearward in the winder toward and then into contact with middle drum 46, as seen in FIG. 3. Package 128 is kept in contact, during this movement, with first front drum 47, and then front drum 47 and middle drum 46 simultaneously, and then with middle drum 46.

As the transfer assembly 60 rotates as described above, slide plate 84 is extended, and then retracted so that wound package 128 is supported, and held in engagement with the driving drums, by hub assembly 75, which has hubs 79 engaged into the ends of core tube 124. Air motor 102, as seen in FIG. 10, through pinion 100, and rack 94, exerts a preset force to bias the package 128 against the drums. This force can be for instance 5 pounds, but this may vary to achieve a tighter roll, where the biasing force is more, or a looser wound roll, where the biasing force is less.

The package 128 continues to grow in diameter as winding takes place.

The transfer mechanism 60 carries package 128 to the crest of middle drum 46, and on over the crest of drum 46, at which time a limit switch on mechanism 60, activated by slide 84, stops movement of shaft 61, and transfer assembly 60. The limit switch also causes pneumatic cylinder 77 to retract piston rod 80 causing hub assembly 75 to retract, causing hubs 79 to disengage from core tube 124. Package 128 is now free to drop into the valley between middle drum 46 and rear drum 45 where it continues to be wound.

Slide plate 84 is fully retracted by air motor 102, such that hubs 79 are positioned opposite either end of tube 126 (see FIG. 2), while transfer mechanism 60 is rotated clock wise to its extreme position.

The action of cylinder 77 is delayed such that the hubs 79 remain in a retracted position after releasing the transferred roll 128, until slide 84 has been fully retracted. Cylinder 77 then extends rod 80 causing hubs 79 to extend into, and grip core tube 126 to support it in the position shown in FIG. 2.

When package 128 is of desired size, as shown in FIG. 4, the operator pushes a button to activate the cutting sequence.

Cylinder 70 is then activated to permit escape mechansim 71 to allow the bottommost core tube 126, in chute 52, to move into position on front, or entering drum 47, as shown in FIG. 4. Piston rod 50 extends from cylinder 48, carrying cutting mechanism 51, with its rotating blades, upward.

Hold-down bar 52 moves downward, and the fabric being wound is cut, as seen in FIG. 4.

Air under pressure escapes from spaced holes in pipe 55, which extends across the winder, and end 146 of web 120 is blown up and over core tube 126, which is rotating under the influence of front drum 47. This causes a new winding to begin on core tube 126, and a new cycle begins.

It should be understood that there is a continuous winding of web 120, and there is no interruption between the finishing of package 128, and the beginning of a new package on core tube 126.

Package 128 is then removed from the winder by the operator activating pneumatic cylinders 150 which drive roller 152 upward to lift package 128, effectively doffing, or removing, it from the winder. Guides 154 keep package 128 from shifting laterally in the machine.

The cycles keep repeating themselves until the source of web 120 is exhausted.

Core tubes 126' can be continuously loaded in chute 57.

In view of my invention and disclosure, variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art to obtain all or part of the benefits of my invention without copy the structure shown, and I, therefore, claim all such insofar as they fall within the reasonable spirit and scope of my claims.

Claims

Having thus described my invention what I claim as new and desire to secure by Letters Patent is:

1. A mandrel-less winder for continuously winding a web of sheet material into packages on core tubes comprising:

1. a frame having journalled therein a front, a middle drum and a rear drum, each of the drums being driven;

2. means for partially winding onto a first core tube a first package on the front drum;

3. means for transferring the first package from the front drum into a position between the middle and rear drums wherein the first package is continuously in contact with at least one of the drums;

4. means between the front and middle drums for cutting the continuously moving web; and

5. means for starting the cut web onto a second core tube to begin a second package on the front drum;

wherein the means for transferring the first package from the front drum into a position between the middle and rear drums includes (1) a hub assembly having hubs that engage the first core tube ends for supporting the first package, (2) a slide plate for supporting the hub assembly, and (3) a transfer assembly slidably supporting the slide plate wherein the transfer assembly rotates with reference to the frame, and the slide plate translates within the transfer assembly.

2. A winder of claim 1, wherein the hub assembly has hubs slidable longitudinally selectively engaging the first core tube ends.

3. A winder of claim 1, wherein the means for transferring the first package has opposing spaced portions in combination with means for varying the spacing between the opposing portions for adapting the transfer assembly to the length of the core tubes.

4. A winder of claim 1, in combination with chute means for selectively feeding core tubes into position over the front drum.