U.S. patent number RE29,365 [Application Number 05/687,260] was granted by the patent office on 1977-08-23 for web supply apparatus.
This patent grant is currently assigned to Butler Automatic, Inc.. Invention is credited to Richard A. Butler Jr..
United States Patent |
RE29,365 |
Butler Jr. |
August 23, 1977 |
Web supply apparatus
Abstract
Web supply apparatus for supplying relatively stiff web material
such as liner board for a corrugator serves the web from one of two
supply rolls. The running web passes through a splicing station and
a festoon on its way to the web-consuming machine. The leading end
of the ready web is prepared on a web positioning bar away from the
splicing station and then carried by the bar to the splicing
station while the running web is being consumed. When the roll of
running web expires, a control system automatically stops the roll
of running web and special pressure pads at the splicing station
press the running web and ready web together to make a strong
splice between them. Immediately thereafter, a knive fires directly
behind the splice, thereby cutting the trailing end of the running
web. The pressure pads firmly grip the webs above and below the
line of the cut so that the knife slices cleanly through the web.
Following this, the roll of ready web is accelerated and the
trailing end of the running web pulls the ready web into the
festoon which then refills to complete the splicing cycle. When the
apparatus incorporates roll stands of the rollout type, the web
positioning bars are affixed directly to the roll stands and move
in and out of the splicing station with them. When the roll stands
are of the fixed type, the positioning bars are moved from a remote
loading station to the splicing station by a special transport
assembly. Also, the positioning bars can be moved manually from the
preparation site to the splicing station if the situation demands
it. Thus, the splicing is accomplished at zero speed with maximum
reliability, yet the stiff web proceeds uninterruptedly and at
constant speed to the corrugator.
Inventors: |
Butler Jr.; Richard A.
(Chestnut Hill, MA) |
Assignee: |
Butler Automatic, Inc. (Canton,
MA)
|
Family
ID: |
26971365 |
Appl.
No.: |
05/687,260 |
Filed: |
May 17, 1976 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
Reissue of: |
299713 |
Oct 24, 1972 |
03858819 |
Jan 7, 1975 |
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Current U.S.
Class: |
242/552;
242/556.1; 156/504; 242/559 |
Current CPC
Class: |
B65H
19/1852 (20130101); B65H 19/1873 (20130101); B65H
2301/4621 (20130101); B65H 2301/46412 (20130101); B65H
2408/2211 (20130101); B65H 2701/1762 (20130101) |
Current International
Class: |
B65H
19/18 (20060101); B65H 019/14 (); B65H
019/20 () |
Field of
Search: |
;242/58,58.1-58.6
;156/502,504,505,506,507,510 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Gilreath; Stanley N.
Assistant Examiner: Jillions; John M.
Attorney, Agent or Firm: Cesari and McKenna
Claims
I claim:
1. Web supply apparatus comprising
A. a first source of web,
B. a second source of web,
C. an inaccessible splicing station through which web travels
alternately from the first and second sources, said splicing
station including
1 . a first pressure pad,
2. a second pressure pad, said pads being movable toward and away
from one another,
3. means for moving the pressure pads toward and away from one
another in response to a command,
4. a first knife assembly associated with the first pressure pad,
said knife assembly including a first blade movable from a
retracted position out of the path of web from the first source
through the splicing station to an extended position wherein it
projects through the path of web from the first source through the
splicing station,
5. a second knife assembly associated with the second pressure pad,
said second knife assembly including a second blade movable from a
retracted position out of the path of web from the second source
through the splicing station to an extended position wherein it
projects through the path of web from the second source through the
splicing station, each said pressure pad extending above and below
the corresponding knife assembly so that when the two pads come
toward one another, they retain the web on both sides of the
cutting knife blade, and
6. means for moving the two blades between their two positions,
D. means for guiding web from one of the sources through the
splicing station between the two pads,
E. a loading station remote from the splicing station at a location
accessible to an operator,
F. means for moving the leading end of the web from the other
source from the loading station to a position at the splicing
station between the two pressure pads,
G. control means for commanding the pressure pad moving means to
move the pressure pads toward one another so that the web from the
one source is pressed against the leading edge of the web from the
other source so that the two become joined, and
H. means for commanding the blade moving means which moves the
blade adjacent the path of the web from the one source to move to
its second position while the pads are moved toward one another so
that said blade severs the web from the one source just behind its
joint to the web from the other source.
2. The web supply apparatus defined in claim 1 and further
including a knife backup positioned directly between the two knife
assemblies against which the cutting knife blade acts when cutting
the web from the one source, said knife backup also shielding the
web from the other source from said cutting knife blade during the
cutting operation.
3. Web supply apparatus as defined in claim 2 wherein the backup is
comprised of a rail extending parallel to the knife blades, said
rail having
A. a first blade receiving slot directly opposite the first knife
blade and a second blade receiving slot directly opposite the
second knife blade, said first and second knife blades and their
slots being offset relative to one another.
4. Web supply apparatus as defined in claim 1 and further including
a web accumulator located downstream from the splicing station and
further including means for stopping the one source of web so that
a joint can be formed at zero web speed, the accumulator providing
the web required by a downstream web-consuming machine while the
incoming web is stopped.
5. The web supply apparatus defined in claim 1 wherein the means
for moving the leading end of the web from the other source from
its loading station to the splicing station is comprised of
A. a bar to which said leading end is affixed, and
B. means for removably locating the bar at the splicing station
between the pressure pads.
6. The web supply apparatus defined in claim 5 wherein the locating
means includes a pair of retainers at the splicing station for
retaining the opposite ends of the bar between the pressure
pads.
7. The web supply apparatus defined in claim 6 wherein the
retainers are movable along with the associated pressure pads.
8. The web supply apparatus defined in claim 5 wherein
A. the first and second web sources are mounted on roll stands of
the rollout type, and
B. the bar locating means is comprised of means on each roll stand
for supporting the bar to which the leading end of the web from the
other source is affixed so that when the roll stand supporting the
other source is moved to its normal position for feeding web, the
positioning bar supported by that stand properly locates the
leading edge of the web at the splicing station beween the
pads.
9. The web supply apparatus defined in claim 5 wherein the bar
locating means includes
A. transport means connected to each web positioning bar, said
transport means communicating between the web loading station and
the splicing station, and
B. means for driving the transport means so as to move the
positioning bar between its two stations.
10. Web supply apparatus comprising
A. a first source of web,
B. a second source of web,
C. a splicing station not conveniently accessible to an operator,
said splicing station including
1. first pressure applying means,
2. second pressure applying means, said pressure applying means
being movable toward and away from one another,
3. a first knife assembly associated with the first pressure
applying means, said first knife assembly including a first blade
movable from a retracted position to an extended position wherein
it projects beyond the first pressure applying means toward the
second pressure applying means,
4. .Iadd.a .Iaddend.second knife assembly associated with the
second pressure applying means, said second knife assembly
including a second blade movable from a retracted position to an
extended position wherein it projects beyond the second pressure
applying means toward the first pressure applying means,
D. means for moving the leading end of the web from one of the
sources from an .[.inaccessible.]. .Iadd.accessible
.Iaddend.loading station to a position at the splicing station
between the two pressure applying means, said means for moving the
leading .[.eand.]. .Iadd.end .Iaddend.of the web from each source
from its loading station to the splicing station being comprised
of
1. a .[.movable.]. bar to which said leading end is affixed,
and
2. means for removably locating the bar at the splicing station
between the pressure applying means,
E. means for moving the pressure applying means toward and away
from one another to splice webs trained between them, and
F. means for moving the first and second blades between their two
positions.
11. The web supply apparatus defined in claim 10 wherein the
locating means are comprised of retainers at the splicing station
for supporting the bar between the pressure applying means.
12. The web supply apparatus defined in claim 10 wherein
A. the first and second web sources are mounted on roll stands of
the roll-out type, and
B. the bar locating means are comprised of means on each roll stand
for supporting the bar to which the leading end of the web from a
source is affixed so that when the roll stand supporting that web
end is moved to its normal position for feeding the web, the
positioning bar supported by that stand properly locates the
leading end of that web at the splicing station between the
pressure applying means.
13. The web supply apparatus defined in claim 10 wherein the bar
locating means include
A. transport means connected to each .[.web positioning.]. bar,
said transport means communicating between each web loading station
and the splicing station, and
B. means for moving the transport means so as to carry each
.[.positioning.]. bar between its two stations.
14. The web supply apparatus defined in claim 10 wherein the
pressure applying means extend above and below the corresponding
knife blade so that when the pressure applying means come together,
they grip the web between them on both sides of the blade.
15. The web supply apparatus defined in claim 13 and further
including means for controlling the transport means so as to locate
each .[.positioning.]. bar at one of its two stations.
16. The web supply apparatus defined in claim 13 wherein the
transport means are comprised of
A. a chain loop extending between one said loading station and the
splicing station, and
B. means for driving the chain so that the .[.positioning.]. bar
connected thereto is carried by the chain between the two
stations.
17. The web supply apparatus defined in claim 11 wherein the bar
includes a pair of flexible, resilient end extensions secured to
the retainers to permit the bar to flex relative to the
retainers.
18. The web supply apparatus defined in claim 13 and further
including means for adjusting the path of the transport means to
compensate for the change in said path which occurs when the
pressure applying means are moved.
19. Web supply apparatus comprising
A. a first source of web,
B. a second source of web,
C. a splicing station through which web travels alternately from
the first and second sources, said station including,
1. first pressure applying means, and
2. second pressure applying means, said pressure applying means
being movable toward and away from one another,
D. a first knife assembly, said first knife assembly including a
first blade movable from a retracted position out of the path of
the web from the first source through the splicing station to an
extended position wherein it projects into the path of the web from
the first source through the splicing station,
E. a second knife assembly, said second knife assembly including a
second blade movable from a retracted position wherein it is out of
the path of the web from the second source through the splicing
station to an extended position wherein it projects into the path
of the web from the second source through the splicing station,
said pressure applying means extending upstream and downstream
relative to their corresponding knife blades so that when the
pressure applying means are moved to their extended positions, they
grip the web between them on both sides of the blades,
F. means for moving the pressure applying means toward and away
from one another to splice webs trained between them,
G. means for moving the first and second blades between their two
positions, and
H. a web accumulator located downstream from the splicing station,
said accumulator providing the web required by a downstream
web-consuming machine while the incoming web is temporarily gripped
by the pressure applying means. .Iadd. 20. Web supply apparatus
comprising
A. a web accumulator;
B. a splicing station located directly underneath the accumulator
that is not readily accessible to an operator;
C. a pair of roll stands of the roll-out type for supporting a pair
of web rolls one of which is expiring into the accumulator, the
other of which is at the ready, each said stand being movable
generally parallel to the axes of the rolls between said splicing
station and a loading station adjacent the accumulator that is
readily accessible to the operator,
D. positioning means supported on each roll stand for positioning
the leading edge of the ready web when the roll stand supporting
the ready web is located at its loading station;
E. means supporting the roll stand containing the ready web for
movement to the splicing station so that the leading edge of the
ready web is positioned directly opposite the expiring web, and
F. means permanently suspended from the overhead accumulator at the
splicing station for pressing the expiring web and ready web
together to splice them so that web can proceed continuously into
the overhead accumulator. .Iaddend..Iadd. 21. The web supply
apparatus defined in claim 20 and further including means
permanently suspended from the overhead accumulator for severing
the trailing end of the expiring web upstream from said splice.
.Iaddend. .Iadd. 22. The web supply apparatus defined in claim 20
wherein each positioning means comprises an elongated rigid bar
extending the full width of the web proceeding into the
accumulator. .Iaddend.
Description
BACKGROUND OF THE INVENTION
This invention relates to web splicing apparatus. It relates more
particularly to apparatus of this type which automatically splices
and cuts relatively stiff web material such as liner board for
making corrugated cardboard. It is designed particularly to splice
the leading edge of a ready web of stiff material to the trailing
edge of a running web while the web proceeds uninterruptedly and at
substantially uniform speed and tension to a web-consuming machine,
e.g., a corrugator, printer, etc.
Web supply apparatus which supplies web uninterruptedly to a
web-consuming machine is, of course, not new. Examples of such
machines are shown in U.S. Pat. Nos. 3,305,189 and 3,414,208. While
these prior machines are able to handle relatively limp webs quite
easily, making a strong, accurate splice with little or no tail,
they are not so successful with the stiffer webs such as liner
board. Sometimes the splice between the trailing end of the running
web and the leading end of the ready web may not take or remain
secure all across the web, with the result that the two webs
sometimes come apart on the way to the web-consuming machine. Also,
at times, the prior machines of this type do not cut cleanly all
the way through the expiring end of the ready web, with the result
that the splice has a very long tail which may be pulled into the
web-consuming machine and interfere with its proper operation.
Another problem with the prior web supply apparatus is that it is
difficult to incorporate them into an existing web processing setup
because they are rather large and, therefore, cannot fit into the
available space. In other words, the web supply and splicing
apparatus is just one of a series of machines in a production line.
All of the machines in the line are extremely large and massive
and, therefore, extremely difficult and costly to move. Thus, many
existing web processing setups cannot be retrofitted with
conventional web supply apparatus having a splicing capability
without having to move one or more of the massive machines in the
line in order to accommodate the web supply apparatus.
SUMMARY OF THE INVENTION
The present invention aims to provide web supply apparatus which
delivers even relatively stiff web such as liner board
uninterruptedly and at a substantially constant speed to a
consuming machine such as a corrugator.
Another object of the invention is to provide web supply apparatus
which is able to splice even stiff webs in a reliable and
consistent manner.
Still another object of the invention is to provide a web supply
apparatus of the above type which can make a strong, neat splice at
zero web speed, yet still deliver the web uninterruptedly to a
web-consuming machine.
Still another object of the invention is to provide web supply
apparatus of the above type which consistently cuts cleanly through
the expiring end of the running web after the splice is made and
leaves a small tail.
Still another object of the invention is to provide web supply
apparatus of the above type which can be incorporated into many web
processing lines without having to substantially rearrange other
machines in that line.
Other objects will in part be obvious and will in part appear
hereinafter.
The invention accordingly comprises the features of construction,
combination of elements and arrangement of parts which will be
exemplified in the construction hereinafter set forth, and the
scope of the invention will be indicated in the claims.
In general, the present web supply apparatus delivers web such as
liner board for making corrugated cardboard from one of two rolls,
one of which is running and one of which is at the ready. The web
from the running roll travels through a splicing station to be
described in more detail later which is located more or less above
and between the two rolls. From there, the web travels to a festoon
or accumulator which is positioned in a generally horizontal plane
directly above the two rolls and the splicing station and thence to
the web-consuming machine. With the elements of the apparatus
arranged thusly, the entire machine occupies a relatively small
amount of space as compared with prior apparatus of this type.
Consequently, it can be incorporated into an existing web
processing line, for example, under the bridge of a corrugator,
without requiring movement of the other heavy machinery in the
line.
While web from the running roll is being consumed, the leading edge
of the ready roll is prepared by securing it to a mounting bar by
means of a suitable adhesive or the like and applying a strip of
double-faced adhesive tape to the edge. Then the mounting bar is
carried to the splicing station in a manner to be described in
complete detail later to await depletion of the running roll.
When the running roll reaches a predetermined minimum diameter, the
splicing cycle commences. First, the roll of running web is braked
to a smooth stop. As soon as the roll stops, a pair of spaced-apart
opposed pressure pads at the splicing station are projected toward
each other. One pad extends directly behind the mounting bar
holding the leading edge of the ready web. The other pad is located
behind the running web passing through the splicing station. As the
two pads are urged toward one another, the running web and ready
web are pressed together and adhere by virtue of the double-faced,
pressure-sensitive tape on the ready web.
A knife is associated with each pressure pad at the splicing
station, each knife extending the full width of the web. The knife
associated with the pad behind the running web is actuated
automatically immediately following the splice so that it is
propelled through the running web and into a special knife backup
which allows the blade to sever the running web, but shields the
ready web. The pressure pads are arranged so that, during the
cutting operation, the pads securely grasp the ready and running
webs both above and below the line of the cut. Since the running
web is held firmly at both sides of the knife blade, it is under
tension when the cut is made. Consequently, the blade cuts quickly
and cleanly and surely through even stiff web material, such as
liner board.
All during the splicing operation, the web supply apparatus still
delivers web at constant speed and tension to the web-consuming
machine, drawing on the supply of web stored in the festoon. As
soon as the expiring end of the running web is severed as
aforesaid, the roll of ready web is accelerated until the festoon
is refilled with web from the new roll, thereby completing the
splice cycle.
The present web supply apparatus thus achieves an excellent seal
between the two webs. The joint is clean and uniform across the
entire web even when splicing together webs of different widths or
different grades. Furthermore, the splice overlap or "tail" is
relatively small, on the order of 6 inches, so that there are no
jams further downstream in the line and a printer can actually
print right over the splice.
With the present apparatus, there is minimum waste because the
system precisely controls the point of splice so that there is very
little web left on the expiring roll. In addition, because there
are no variations in the speed of the web fed to the web-consuming
machine, the quality of the stiff web such as liner board is
consistent, thereby minimizing its tendency to warp. This results
in fewer problems during the downstream stacking and finishing
operations.
The present web supply apparatus can be used with either the fixed
position or rollout type roll stands for supporting the web rolls.
The only major difference between the two embodiments involves the
specific means for moving the web mounting bars to the splicing
station as will be described later in greater detail.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the
invention, reference should be had to the following detailed
description taken in connection with the accompanying drawings, in
which:
FIG. 1 is a front elevation of web supply apparatus made in
accordance with this invention, and incorporating web stands of the
rollout type;
FIG. 2 is an end view thereof;
FIG. 3 is a sectional view on a larger scale showing splicing
station of FIG. 1 apparatus in greater detail;
FIG. 4 is a perspective view with parts broken away on a still
larger scale of the splicing station;
FIG. 5 is a view similar to FIG. 1 of an embodiment of the
apparatus incorporating fixed position type roll stands;
FIG. 6 is an end view thereof;
FIG. 7 is a front elevational view with parts cut away on a larger
scale showing the splicing station of the apparatus adapted for
manual handling of the web positioning bars; and
FIG. 8 is a perspective view with parts broken away showing the web
positioning bar used with the FIG. 7 apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Refer now to FIGS. 1 and 2 of the drawings which show the apparatus
of the present invention with roll stands of the rollout type. It
is shown positioned under the bridge 12 of a conventional
corrugator (not shown). One rollout stand indicated at 14 supports
a roll 16 of running web W. The other stand 18 supports a roll 22
of ready web W'. Both roll stands 14 and 18 are fitted with wheels
26 which ride on tracks 28 in the floor. Basically, the purpose of
the roll stands is to facilitate replenishing the web supply. When
roll 16 expires, the web W is spliced to web W' and the apparatus
draws on the web from roll 22. Roll stand 14 is rolled along tracks
28 away from the rest of the apparatus, i.e., out of the plane of
the drawing figure. Then the core of the expired roll is removed
from the roll stand 14 and replaced by a new roll of web. Following
this, the roll stand 14 is rolled back into position as shown in
the drawing figure to await depletion of the other web roll 22.
Roll stands of this general type are well-known and will not be
detailed here. They are shown, for example, in U.S. Pat. No.
3,488,014, French Pat. No. 7505004 and Belgian Pat. No.
763,032.
The present stands differ from the prior ones in that they include
a pair of upstanding, spaced-apart columns 32 at the ends of the
opposing sides of the stands. Three rollers 33a, 33b and 33c are
mounted at the upper end of each column (FIG. 4).Iadd..
.Iaddend.Roller 33a is generally horizontal, while rollers 33b and
33c are situated at the opposite ends of roller 33a and oriented
perpendicular to that roller. The two columns on each stand are
arranged to loosely horizontally support a long, rectangular web
positioning bar; to wit; stand 14 supports a bar 34 and stand 18
supports a bar 36 for reasons to be dwelt on later. The rollers 33
permit lengthwise and lateral movement of each bar relative to its
supports.
Directly above the roll stands and suspended from bridge 12 is a
web accumulator or festoon indicated generally at 38. Festoon 38
includes a pair of transverse, spaced-apart end beams 39 and 40
which, in turn, support a pair of spaced-apart upper rails 41 and a
pair of spaced-apart lower rails 42.
A selected number, i.e., three, of idler rolls 44 are rotatively
mounted between rails 42 near the left-hand end thereof. Also, a
guide roll 46 is rotatively supported from those rails midway
across the festoon. Additional idler rolls 48 are rotatively
mounted between rails 41. In the present instance, there are two
such rolls located above rolls 44.
Festoon 38 also includes a yoke 52 which carries three dancer rolls
54 arranged generally in a horizontal plane. Yoke 52 is movable
toward and away from the idler rolls 44 and 48 along a suitable
track (not shown).
Web from the running roll, i.e., roll 16, is fed to the festoon 38
by way of splicing station indicated generally at 58, to be
described in greater detail later. The web W is trained around the
guide roll 46 and then looped back and forth between the fixed
rolls 44 and 48 and the movable dancer rolls 54, thereby forming a
number of bights in the festoon. Upon leaving the festoon, the web
W is trained around a guide roll 61 rotatively supported by bridge
12 and thence passes on into the web-consuming machine, i.e., a
corrugator 63.
During normal operation, the yoke 52 is biased away from the fixed
rolls 44 and 48 pneumatically, hydraulically or by means of
suitable counterweights so that it tends to assume a position near
the right-hand side of the festoon. Accordingly, the festoon is
able to store a relatively large supply of web, typically on the
order of 60 feet or more. At some time while the running web is
being consumed, the roll stand 18 is rolled out and filled with
roll 22. The leading edge of web W' is adhered to the positioning
bar 36 on stand 18 and prepared with double-face,
pressure-sensitive tape. Then the stand 18 is rolled back into the
position shown in FIG. 1 to await depletion of roll 16. In this
position, the bar 36 and the leading edge of the ready web W' are
situated in the splicing station 58.
As soon as the diameter of the roll 16 of running web reaches a
predetermined minimum size, the apparatus automatically commences
its splice cycle, whereupon roll 16 is immediately braked to a stop
by conventional braking means such as shown in U.S. Pat. Nos.
3,305,189 and 3,414,208.
As soon as the running web roll 16 stops, the leading edge of the
ready web W' which has been prepared as aforesaid is bonded to the
running web in the splicing station 58 as will be described later
in detail and the running web W is severed just behind the splice.
Following this, the roll 22 of ready web is accelerated.
When the web entering the festoon 38 slows and stops as the splice
is being made, the yoke 52 and dancer rolls 54 move toward the
idler rolls 44 and 48 as the web-consuming machine uses up the
accumulation of web in the festoon. Then as the ready roll 22
accelerates after the splicing operation, the festoon 38 receives
more web than it loses so that the yoke 52 resumes its normal
position near the right-hand end of the festoon, thereby completing
the splice cycle.
With the apparatus now consuming the web W' from roll 22, the stand
14 can be rolled out and the core thereon replaced by a new roll of
web. In this case, the leading edge of that web is adhered to the
web positioning bar 34 on stand 14 and prepared with double-faced
adhesive. Then the roll stand 14 is moved back into its position
shown in FIG. 1 to await the expiry of roll 22 and the next splice
cycle.
The controls for detecting roll size to actuate the splice cycle,
for initiating the splice at the proper time, for braking and
accelerating the web rolls, and for controlling web speed and
tension generally are all disclosed in U.S. Pat. No. 3,822,838
entitled ELECTRONIC UNWIND CONTROL, which application is owned by
the assignee of the present application. Conventional web tension
control mechanisms which also can be used to control the above
aspects of the present system are shown in U.S. Pat. Nos. 3,305,189
and 3,414,208, also owned by said assignee.
Turning now to FIGS. 1, 3 and 4, the splicing station 58 is
comprised of a pair of front and rear depending plates 62 and 64
suspended from festoon rail 42 and connected by cross beams 65.
Each plate 62, 64 is notched at 66 and 68, respectively, to provide
clearance space through the centers of the plates. A pair of
geneally horizontal channels 72 (FIG. 1) and 74 (FIG. 3) are formed
on the front and rear plates, respectively, so that they oppose one
another inside the splicing station. These channels form tracks for
a pair of carriage assemblies indicated generally at 76 and 78.
Carriage assemblies 76 and 78 are substantially mirror images of
one another. Therefore, we will use the same identifying numerals
for their common components. Each carriage assembly includes a
depending front plate 82 (FIG. 1) and a depending rear plate 84
(FIG. 3) arranged just inside end plates 62 and 64, respectively. A
pair of rollers 86 on the outside of each plate 82 is arranged to
ride in channel 72 and a similar pair of rollers 88 on the outside
of each rear plate 84 are arranged to ride in the channel 74 on the
rear end plate 64. This enables the carriage assemblies to move
laterally in a generally horizontal plane toward and away from one
another.
Connected between the front and rear plates of each carriage
assembly is a long, rectangular bar 92. This bar 92 is spaced an
appreciable distance back from the notches 66 and 68 in the end
plates. Spaced in front and parallel to each bar 92 is a second bar
94 which is somewhat shorter vertically than bar 92. Each bar 94 is
positioned so that its opposing face is more or less adjacent the
edges of notches 66 and 68. Bars 92 and 94 are connected along
their lengths by a number of spaced-apart lateral plates 96 which
extend down to the lower edge of front plate 94. Further, a long,
rectangular, generally horizontal plate 98 is positioned directly
below plates 96 and secured to the front and rear plates 94 and 92
to provide an upper guide surface for a knife assembly indicated
generally at 102. The lower face of plate 98 is provided with a
wear surface 104. The lower guide for the knife assembly 102 is
provided by a similar rectangular plate 106 spaced below and
parallel to plate 98. Plate 106 has an upper wear surface 107 and
is also secured to the rear plate 92 as well as to depending
carriage plates 82 and 84.
The opposing edges of each lower knife guide 106 are provided with
a coextensive rectangular facing plate 110 of the same thickness as
plate 94. A pressure pad 112 made of rubber or other suitable
resilient material covers the entire exposed face of the plate 94.
A similar pad 114, somewhat thicker than pad 112, covers the
exposed face of each plate 110.
Each carriage assembly 76 and 78 is movable along its track by
suitable means illustrated here as a hydraulic piston shown
generally at 116. Each piston 116 includes a cyliner 117 secured to
the stationary beams 65 and a piston rod 120 whose free end is
connected to the carriage rear plate 92. Each piston 116 is of the
double-acting variety so that it can move its associated carriage
assembly between a first position wherein the pressure pads 112 and
114 are located substantially adjacent the edges of the notches 66
and 68 to a second position where the pads protrude appreciably
into the notches.
Still referring to FIGS. 3 and 4, each knife assembly 102 is
comprised of a long, rectangular block 118 which is able to slide
laterally in the space between the wear surfaces 104 and 107
relative to its supportive carriage assembly. A long knife blade
122 is secured to the inner edge margin of the block. The
arrangement is such that when the block and knife blade are fully
retracted, the edge of the knife blade does not protrude beyond the
pressure pads 112 and 114. On the other hand, when the knife is
extended, its cutting edge extends out appreciably beyond those
pads.
A knife arrangement employing a special serrated knife and knife
backup which is particularly suitable for cutting stiff web such as
liner board is disclosed in U.S. application Ser. No. 273,717,
filed July 21, 1972, entitled WEB CUTTING KNIFE now abandoned, said
application being owned by the assignee of the present
application.
The knife block 118 and blade 122 are moved between their two
operative positions by means of a double-acting piston indicated
generally at 124 (FIG. 3). Each piston includes a cylinder 126
connected to rear plate 92 and a piston rod 128 extending through
an opening in that rear plate and connected to the rear of the
knife block 118.
A guide roll 132 is mounted horizontally between the depending
carriage plates 82 and 84. Each guide roll 132 is positioned at the
lower inside corners of the end plates so that it can guide web
from the adjacent supply rolls 16 and 22 into the splicing station
58 as best seen in FIG. 1.
Still referring to FIGS. 3 and 4, a special knife backup 134 is
centered in the notches 66 and 68. The backup is essentially a
long, rectangular rail which is oriented edge-up and suspended
horizontally from the front and rear end plates 62 and 64 by a pair
of straps 136 and 138. The backup 134 is formed with a pair of
long, generally rectangular slots 142 and 144, each being directly
opposite the adjacent knife blade 122. Each slot 142 and 144 is
just wide enough and deep enough to accommodate the knife blade in
its fully extended position.
Assume now that the web W is being consumed from the running roll
16 as shown in FIG. 3. At this point in time, the carriages 76 and
78 are in their fully retracted positions shown in solid lines in
FIG. 3 and the knife assemblies 102 are also in their fully
retracted positions. Assume, too, that both of the roll stands 14
and 18 are in their positions shown in FIG. 1. Thus, the running
web W passes up adjacent the knife backup 134 and between the web
positioning bars 34 and 36 to the guide roll 46. At the same point
in time, the leading end of the ready web W' is tacked to the
inside face of positioning bar 36 by means of small strips 152 of
double-faced, pressure-sensitive tape, Also, a relatively wide
(i.e., 2 inch), long strip 154 of similar tape is adhered to the
exposed leading edge margin of the ready web W'.
When the running roll 16 is about to expire, the splice cycle is
commenced as described above. As soon as the roll 16 comes to a
stop, the splicer's control system actuates the carriage assembly
pistons 116 causing the carriage assemblies 76 and 78 to come
together as shown in dotted lines in FIG. 3, so that their pressure
pads 112 engage and press the positioning bars 34 and 36 together
between straps 136 and 138. This, in turn, forces the web W against
the adhesive strip 154 affixed to the leading edge of the ready web
W', with the pressure on the two webs being sufficient to make a
strong, reliable bond between them. Immediately following this, the
knife piston 124 in the left-hand carriage assembly 76 is actuated
by the control system, causing the left-hand knife blade 122 to
project out momentarily beyond its corresponding pressure pads 112,
114 through the web W and into the slot 142 in the knife backup
134.
It is important to note that when this cutting action takes place,
the webs W and W' are grasped firmly between the two positioning
bars 34 and 36 above the knife. They are also held firmly below the
knife between the lower pressure pads 114 and the knife backup 134.
As noted above, these lower pads are somewhat thicker than the
upper pads 112 to compensate for the widths of the positioning bars
34 and 36 adjacent the pads 112. Since the webs are held firmly on
both sides of the line of cut, the knife blade is able to cut
surely and cleanly through the web W quite close to the joint.
Consequently, the splice is characterized by a relatively short
tail, on the order of 6 inches, including the 2 inch joint. In this
connection, it should be mentioned that the tail produced by the
left-hand assembly 76 is slightly longer than the one produced by
the right-hand assembly 78 because the two knife blades 122 and
their receiving slots 142 and 144 are slightly offset one above the
other. This offset arrangement and the special knife backup 134
allow the appropriate knife blade 122 to sever only the expiring
end of the running web; the backup completely shields the ready web
from the knife impact.
As soon as the web W is cut as aforesaid, carriage assemblies 76
and 78 retract automatically to their solid line positions shown in
FIG. 3 and the leading edge of the ready web W' is pulled by the
running web W to which it is attached out of the splicing station
58 and over the guide roll 46.
As soon as the festoon is refilled and the splice cycle is
completed, the roll stand 14 can be rolled out as described above,
thereby withdrawing the positioning bar 34 from the splicing
station 58 so that the leading edge of a new web roll can be
positioned in stand 14 and prepared on bar 34 far away from the
heat and congestion at the splicing station.
Turn now to FIGS. 5 and 6 of the drawings which show a slightly
different splicer embodiment incorporating fixed type roll stands.
Since most of the components of the FIGS. 1 to 4 embodiment of the
invention are found also in this embodiment, we will assign the
same identifying numerals to them. Aside from the roll stands
themselves, the only other major difference here involves the means
for carrying the positioning bars 34 and 36 from the location where
the leading end of the ready web is affixed to them to their
position at the splicing station 58.
A conventional fixed type roll stand indicated generally at 170 is
positioned directly below the festoon 38 and splicing station 58.
The roll stand 170 has a pair of spaced-apart chuck supporting arms
172 for holding the running web roll 16. The arms 172 can be
lowered when loading a new roll onto the arms 172, after which the
arms can be raised to lift the roll off the floor. A second similar
pair of arms 174 are positioned at the opposite side of the roll
stand supporting the ready web roll 22.
In this embodiment of the invention, each positioning bar carrying
the leading end of the ready web is moved from a web loading
position away from the splicing station 58 to the splicing station
by positioning bar transport assembly. The transport assembly
associated with the roll 16 is indicated generally at 176, the
transport assembly associated with roll 22 is shown generally at
178. The two transport assemblies are substantially mirror images
of one another. Accordingly, the same components of each assembly
will be denoted by the same identifying numeral.
Each web positioning bar 34, 36 is supported at its opposite ends
by a pair of endless chains 182. FIG. 5 shows the chain and its
supporting mechanism which is situated at the front of the
apparatus. An identical chain 182 and supporting mechanism is
located at the rear of the apparatus, both chains moving in unison.
The lower reach of each chain 182 in assembly 176 is trained around
a pair of idler sprockets 184 and 186 rotatively mounted at the
bottoms of depending carriage assembly plates 82 and 84. Each chain
182 extends up through the splicing station 58 and is trained over
a sprocket 188 mounted near the top of plate 62 or 64. The
sprockets 188 are driven by means of a suitable electric motor
drive system 189.
The upper and lower reaches of each chain extend out generally
horizontally away from the splicing station 58. The upper reach of
each chain in assembly 176 passes over an idler sprocket 192
mounted on a depending plate 194 secured to the festoon rail 42.
From there, the upper reach passes over a pair of guides 196 and
198 secured on a plate 202 also suspended from rail 42. The lower
reach of each chain 182, on the other hand, passes over an idler
sprocket 204 affixed to plate 194 and both reaches join at a chain
tensioning assembly shown generally at 206, there being one at the
front of assembly 176 and one at the rear thereof.
Each tensioning assembly 206 is comprised essentially of a pair of
idler sprockets 208, 210 mounted on a fixed base 211 and supporting
the upper and lower reaches of the chain, respectively. The chain
loop beyond these sprockets passes around a third idler sprocket
212 on a fixture 213 which is slidable on a rail 215 toward and
away from the fixed sprockets. A compression spring 214 acting
between the fixed base supporting the sprockets 208 and 210 and the
movable fixture 213 biases sprocket 214 downward so as to keep the
endless chain 182 in a taut condition. The travel of the movable
sprocket 214 also allows the path of the chain 182 to be altered
for reasons to be discussed presently.
The two endless chains 182 in transport assembly 176 are moved in
unison by the driven sprockets 188. By actuating the drive system
189 at the appropriate time either manually or automatically, the
chains 182 are moved counterclockwise to advance the positioning
bar 34 from a loading position shown at point A in FIG. 5 wherein
the bar is shown in dotted lines to a ready position at the
splicing station 58 wherein the bar is shown in solid lines.
The web positioning bar 36 associated with the right-hand roll in
FIG. 5 is moved in exactly the same way by the chains in assembly
178. The chains are moved clockwise to advance the bar from a
loading position at point B wherein the bar 36 is shown in solid
lines to a ready position at splicer station 58 wherein the bar is
shown in dotted lines. In actual practice, the driven sprockets 188
in each transport assembly 176, 178 are driven in opposite
directions in unison by the same drive system 189. However, the two
assemblies are 180.degree. out-of-phase so that when the
positioning bar 34 is in its ready position at the splicing station
58, the positioning bar 36 is in its loading position at point B,
and vice-versa. A switch 222 is mounted on a bracket 202 in
transport assembly 178. This switch is arranged to be tripped by a
finger 224 projecting out laterally from the chain 182 when the web
positioning bar 36 reaches its loading position at point B. Of
course, this also means that the positioning bar 34 is in its ready
position at the splicing station 58. A similar switch 222 and
actuator 224 is associated with the transport assembly 176 to stop
the bar 34 at its loading position at point A. Thus, each of the
switches 222 turns off the drive system 189 at just the right times
to properly locate the positioning bars 34 and 36.
Still referring to FIGS. 5 and 6, assume that the roll 16 is active
and that the running web W is proceeding through the splicing
station 58 and over the guide roll 46 and that a new roll has just
been loaded onto the roll stand arms 174. At this point, the
positioning bar 34 is located at splicing station 58, while the
positioning bar 36 is located at its ready position at point B at
the extreme right-hand side of the apparatus. The operator now
takes the leading end of the fresh roll and attaches it to the
positioning bar 36 as described above. He then places the strip 154
of double-faced tape over the exposed face of the leading edge
margin. Next, he energizes the drive system 189 manually, or this
may be done automatically at the proper time with relation to the
completion of the previous splicing cycle. When the sprockets 188
are driven, the chains 182 carrying positioning bar 36 carry the
leading edge of the ready web W' along the paths of the chains
around the guide roll 132 and to the ready position at splicing
station 58. At the same time, the empty positioning bar 34 is
carried counterclockwise by the transport assembly 176 to its
loading position at point A at the extreme left-hand side of the
apparatus. The two bars stop at the proper places because the
switch 222 in the transport assembly 176 is tripped at the right
time and turns off the drive system 189.
As soon as the roll 16 is depleted, the splicing cycle commences
automatically as described above, the carriage assemblies 76 and 78
moving toward each other as described above. Since these assemblies
carry the chains 182, the movable sprockets 212 in the tensioning
assemblies 206 move up accordingly. In this embodiment, there is
only one positioning bar at the splicing station 58 at any given
time, e.g., bar 36. Accordingly, the pressure pad 112 on carriage
assembly 76 presses directly against the running web W, while the
pressure pad 112 on assembly 78 pushes the positioning bar 36
carrying the ready web against the running web so that a firm seal
is formed between the two webs. As before, the knife blade 122 on
carriage 76 is actuated to sever the ready web W just behind the
splice, following which the carriage assemblies are retracted and
the web W' accelerated up to speed.
It should be mentioned also that since there is only one
positioning bar at station 58, the pressure pads 112 on the
carriage assemblies are made somewhat thicker than those depicted
in FIGS. 3 and 4. Actually, they can be about the same thickness as
the pressure pads 114 shown in those figures.
On completion of the splice cycle, the core of the expired roll is
removed from the stand arms 172 and a fresh roll installed. The
leading end of that roll is then affixed to the positioning bar 34
which is now located at the left-hand loading station at point A,
to await depletion of the roll 22. Thus, the loading of the web and
preparation of its leading end can be done at a location
considerably away from the heat and confinement associated with the
splicing station. Therefore, the web can be prepared more carefully
and better splices obtained.
FIG. 7 illustrates still another embodiment of the apparatus which
can be used in conjunction with most types of roll stands. In this
embodiment, the positioning bar carrying the leading edge of the
ready web is moved manually to the splicing station 58. A typical
positioning bar is illustrated in FIG. 8. It is comprised of a
hollow, generally rectangular box frame 260. The front face of the
box frame is faced with a resilient pad 262 of rubber or the like.
Attached to the opposite ends of the frame are a pair of relatively
long, generally rectangular straps 264 and 266 which project out
from the ends of the frame. These straps are made of a berylium
copper alloy which is quite strong yet quite flexible so that they
will allow the bars to be pressed together to make a splice. A pair
of elongated slots 274 and 276 are formed in the straps to support
the bar at splicing station 58 as will be described presently and a
pair of handles 268 and 272 are affixed to the free ends of the
straps so that it can be carried easily. This same type of bar
without the handles can be used with the FIGS. 1-4 embodiment of
the apparatus.
Splicing station 58 is more or less the same as the one depicted in
connection with the FIGS. 1-4 embodiment of the invention, except
that provision is made for supporting the positioning bars which
are carried manually to the splicing station 58. More particularly,
a pair of identical, horizontally oriented slides 282 are mounted
on the outside of front end plate 62 at the opposite edges of notch
66. Each slide slidably supports a strap or retainer 284. The end
of the strap 284 facing the notch has a cutout or notch 286
extending down from its top edge. Each strap is arranged to project
through the slot 274 in the web positioning bar shown in FIG. 8
with the top edge of the slot seating in the notch 286. Each strap
284 is biased away from notch 266 by a compression spring 288
acting between the slide 282 and a washer 292 mounted on the end of
the strap and retained there by a pin 294 extending through the end
of the strap. The straps 284 affixed to plate 62 are designed to
support one end of a pair of positioning bars 34 and 36 and an
identical arrangement affixed to the outside of the rear end plate
64 supports the other ends of these bars in exactly the same
way.
FIG. 7 shows one positioning bar 34 supported by straps 284 at the
left-hand side of the splicing station 58. The running web W which
was originally carried by this bar passes up through the station
and over roll 46. The leading end of the ready web W' has already
been affixed to the other positioning bar 36 and that bar has been
carried by two men standing in front of and behind the apparatus to
the splicing station 58.
To facilitate mounting the bar, a pair of guide plates 298 are
affixed to end plates 62 and 64 opposite the ends of the knife
backup 134. Additional guide plates 302 are attached to plates 62
and 64 adjacent the edges of the notches 66 and 68. The web
positioning bar 36 is slid up into the space between the guide
plates 298 and 302 and the bar is hooked up onto the notched straps
284 to position the bar so that the leading end of the ready web is
in position for the next splice. A top horizontal guide plate 304
is attached to plates 62 and 64 at the tops of each notch 66 and 68
to provide a guide for the positioning bars so that they cannot
cock.
When the running web W is depleted, the web W stops and the
carriage assemblies 76 and 78 are moved toward each other as
described above. This pushes the positioning bars 34 and 36
together, this movement being accommodated by the slidable straps
284 to which the bars are connected. As soon as the bars press
together, the running web is adhered to the ready web W', whereupon
the running web is cut just behind the splice. Following this, the
carriage assemblies retract, as do the positioning bars, due to the
return bias afforded by the compression springs 288. The ready web
W' is now pulled out of the splicing station 58 by the trailing end
of the running web. Finally, the ready web roll is accelerated up
to speed, completing the splicing cycle.
At any time after this, the positioning bar 34 can be removed
manually from the splicing station 58 and outfitted with the
leading end of a new ready web and returned to its position at
station 58 to await the next splice. Except for the handling of the
positioning bars then, the FIG. 7 apparatus is more or less the
same as the other two embodiments. Therefore, it affords the same
advantages in terms of the speed and reliability of the splice.
Further, this embodiment is especially suitable when retrofitting
existing apparatus where working space is at a minimum.
It will thus be seen that the objects set forth above, among those
made apparent from the preceding description, are efficiently
attained and, since certain changes may be made in the above
construction without departing from the scope of the invention, it
will be intended that all matter contained in the above description
or shown in the accompanying drawings be interpreted as
illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended
to cover all of the generic and specific features of the invention
herein described .
* * * * *