Abstract:
A web winding apparatus includes a frame support having a horizontal track arrangement; a first mandrel rotatably mounted at a first fixed position on the frame support above the track arrangement, for removably holding a core thereon; a second mandrel rotatably mounted at a second fixed position on the frame support above the track arrangement, for removably holding a core thereon; a motor drive for rotating the first and second mandrels; a carriage movable between first and second carriage positions along the track arrangement below the first and second fixed positions, respectively, for guiding a web onto the core on the first mandrel at the first carriage position and cutting the web thereat, and for guiding a web onto the core on the second mandrel at the second carriage position and cutting the web thereat, the carriage including a first support, first guide rollers mounted to the first support for riding along the linear track arrangement, second guide rollers mounted to the first support, a second support for riding between said second rollers in a vertical direction, and pressure rollers, web guide rollers and knives mounted to the second support for movement therewith; a drive mechanism associated with each of the first and second carriage positions for moving the second support toward the respective first and second mandrels; and a drive arrangement secured to the first support for moving the carriage between the first and second carriage positions.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to web winding apparatus, and more particularly, is directed to web winding apparatus for alternately winding a web onto cores mounted on two mandrels at fixed positions. 
     In many instances, a silicone layer has a paper or plastic top layer adhesively mounted thereon. The top layer is printed with labels, and the top layer is die cut around the labels. Then, the silicone layer with labels thereon is wound on a core. During a labeling operation, the labels are removed and applied, for example, to containers. The remaining top layer therefore has a plurality of openings therein, and is called a skeleton or matrix, the latter term being used herein. 
     The matrix is wound onto a disposal or rewind core mounted on a mandrel. When the rewind roll (core plus matrix) acquires a predetermined diameter of matrix thereon, it must be removed, and a new rewind core mounted on the mandrel. However, this requires shutting down the machine, resulting in downtime. This becomes cumbersome in practice, and costly. 
     In U.S. Pat. No. 5,810,280 to Ryan et al and having a common assignee herewith, there is disclosed a matrix rewinder, in which a matrix or skeleton of a used web is wound onto a core on a mandrel for removal. In order to provide that the machine is not stopped, three mandrels are provided offset from each other by 120°, and are sequentially brought into position for rewinding the matrix. However, the device of this patent does not always work properly with some types of webs, since the webs do not break, but must be cut. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide a web winding apparatus that overcomes the problems with the aforementioned prior art. 
     It is another object of the present invention to provide a web winding apparatus that can be used with all types of webs. 
     It is still another object of the present invention to provide a web winding apparatus that does not require stopping the machine in order to change a fully wound core on a mandrel. 
     It is yet another object of the present invention to provide a web winding apparatus in which there are a plurality of mandrels at fixed positions, and a carriage that moves between the mandrels. 
     It is a further object of the present invention to provide a web winding apparatus that is greatly simplified in construction. 
     In accordance with an aspect of the present invention, a web winding apparatus includes a frame support; a first mandrel rotatably mounted at a first fixed position on the frame support, for removably holding a core thereon; a second mandrel rotatably mounted at a second fixed position on the frame support which is different from the first position, for removably holding a core thereon; a motor drive for rotating the first mandrel and the second mandrel; and a carriage movable between first and second carriage positions in close proximity to the first and second fixed positions, respectively, for guiding a web onto the core on the first mandrel at the first carriage position and cutting the web thereat, and for guiding a web onto the core on the second mandrel at the second carriage position and cutting the web thereat. 
     The carriage is movable in a linear manner between the first carriage position and the second carriage position. In this regard, a linear track arrangement is provided on the frame support, and the carriage includes a plurality of guide rollers for riding along the linear track arrangement between the first and second carriage positions such that the first carriage position is below the first mandrel, and the second carriage position is below the second mandrel. 
     The carriage is normally spaced from the cores on the first and second mandrels at the first and second carriage positions, respectively, and the carriage is further movable in a direction toward and away from the first and second mandrels at the first and second carriage positions. In this regard, the carriage includes at least one pressure roller for engaging the core on the first and second mandrels at the first and second carriage positions, respectively, when the carriage is moved in the direction toward the first and second mandrels at the first and second carriage positions, respectively. 
     Thus, the carriage includes a first support and a second support, and the at least one pressure roller is mounted on the second support. The apparatus further includes a first linear track arrangement on the frame support or the first support, a plurality of first guide rollers mounted to the other of the frame support and the first support, for engagement with the first linear track arrangement, such that the first support moves in a first direction along the first linear track arrangement between the first and second carriage positions, a plurality of second guide rollers mounted to the first support or the second support, and a second linear track arrangement provided on the other of the first support and the second support and along which the plurality of second guide rollers ride, such that the second support moves in a second direction substantially perpendicular to the first direction, toward and away from the first and second mandrels at the first and second carriage positions, with the at least one pressure roller mounted for movement with the second support. 
     Preferably, the first linear track arrangement is mounted on the frame support; the plurality of first guide rollers are mounted to the first support for riding in the first direction along the first linear track arrangement between the first and second carriage positions; the plurality of second guide rollers are mounted to the first support; and the second support is positioned between and guided by the plurality of second guide rollers, with side edges of the second support forming the second linear track arrangement, for movement of the second support in the second direction substantially perpendicular to the first direction, toward and away from the first and second mandrels at the first and second carriage positions. 
     The carriage further includes at least one web guide roller mounted for movement with the second support, for guiding a web to the core on the first or second mandrel, and at least one knife mounted for movement with the second support, such that the at least one knife cuts the web when the at least one pressure roller is moved into engagement with the core on the first or second mandrel. 
     The carriage further includes a frame assembly fixedly mounted to the second support and extending outwardly therefrom, with the at least one pressure roller, the at least one further guide roller and the at least one knife mounted to the frame assembly. 
     In this regard, each knife is secured to a side wall of the frame assembly by a spring biased assembly that permits the knife to deflect slightly. 
     Also, each pressure roller includes a roller shaft mounted in grooves in front and rear walls of the frame assembly, and the carriage further includes springs mounted between the front and rear walls and the roller shaft to bias the roller shaft in a direction toward the respective first or second mandrel. 
     A drive mechanism is associated with each of the first and second carriage positions for moving the second support toward the respective first and second mandrels. The drive mechanism includes a cylinder having a piston rod movable by the cylinder such that engagement of the piston rod with the second support moves the second support toward the respective first and second mandrels. 
     A drive arrangement is also secured to the first support for moving the carriage between the first and second carriage positions. The drive arrangement includes first and second pulleys rotatably mounted to the frame adjacent the first and second carriage positions; an endless chain wrapped about the first and second pulleys, and the endless chain connected to the first support; and a motor having a motor shaft drivingly connected with one of the pulleys for rotating the one pulley. 
     The above and other objects, features and advantages of the invention will become readily apparent from the following detailed description thereof which is to be read in connection with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front elevational view of a portion of a web winding apparatus according to the present invention; 
     FIG. 2 is an end elevational view of the web winding apparatus of FIG. 1; 
     FIG. 3 is an enlarged front elevational view of the carriage assembly of the web winding apparatus of FIG. 1; and 
     FIG. 4 is a top plan view of a portion of the carriage of FIG. 3, viewed from line  4 — 4  thereof, with the retainer plate removed. 
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings in detail, a web winding apparatus  10  according to the present invention includes a vertically oriented, planar frame plate  12  mounted on a support  14 , which in the present instance, is shown as a horizontally oriented top of a support table, although the present invention is not limited thereto. A first shaft  16  extends through an opening (not shown) in plate  12  and is rotatably mounted therein by bearing assemblies  18 . The portion of shaft  16  that extends to the front of plate  12  has a first mandrel  20 , preferably with an air chuck fixed thereon, and mandrel  20  is rotatable with shaft  16 . Mandrel  20 , as is conventional, is adapted to hold a core  22  (FIG. 1) around which a web of material can be wrapped, while also permitting easy replacement of core  22 . Thus, mandrel  20  is stationary, that is, fixed in position relative to frame plate  12 , but can rotate about its own axis. 
     The rear portion of shaft  16  has an adjustable slip clutch  23  thereon, which is connected with a pulley  24  through a shaft  25 . A motor  26  is mounted on a support shelf  28  secured to the rear of frame plate  12 , and has an output shaft  30  with a pulley  32  mounted thereon. An endless belt  34  extends between pulleys  24  and  32  for driving clutch  23  which in turn rotates shaft  16 , and thereby mandrel  20 . Further, to stop rotation of shaft  16 , a disc brake system  36  is also provided, and includes a disc  38  fixed on shaft  16  and a braking arrangement  40  which can be a magnetic brake, calipers, or any other suitable arrangement, mounted on a support bracket  41  fixed to the rear of plate  12 . Accordingly, accurate driving of mandrel  20  can be achieved, so as to obtain accurate tension on the web wound on a core  22 . 
     A second mandrel  42  is mounted on a second shaft  44  that is rotatably mounted in bearing assemblies and extends through plate  12 . The mounting and drive assembly for second shaft  44  is identical to that of first shaft  16 . Mandrel  42  is of the same construction as mandrel  20  and is adapted to hold a core  46  (FIG. 1) around which a web of material can be wrapped, while also permitting easy replacement of core  46  thereon. Mandrel  42 , like mandrel  20 , is stationary, that is, fixed in position relative to frame plate  12 , but can rotate about its own axis. 
     Second mandrel  42  is offset laterally from first mandrel  20 , but is at the same height so that both mandrels  20  and  42 , and cores  22  and  46 , can be accessed by a movable carriage to be described hereinafter. 
     In addition, a shaft  48  extends from the front of plate  12  at a position midway between shafts  16  and  44 , but at a slightly greater height thereon, and includes a roller  49  rotatably mounted thereon, the purpose for which will be understood from the description hereinafter. 
     A carriage  50  is movable from a first carriage position beneath first mandrel  20  to a second carriage position beneath second mandrel  42 , and back again to the first carriage position. 
     In this regard, upper and lower tracks  52  and  54  are secured in parallel, spaced apart relation at the front surface of frame plate  12 , so as to extend horizontally below mandrels  20  and  42 . Upper track  52  includes an inverted V-shaped upper surface  56 , while lower track  54  includes a V-shaped lower surface  58 , as shown in FIG.  2 . 
     Carriage  50  includes a vertically oriented, substantially square-shaped rear support plate  60  having four rollers  62  rotatably mounted to the rear surface at the four corners thereof. Each roller  62  has a V-shaped circumferential groove  64  therein for riding on either inverted V-shaped upper surface  56  or V-shaped lower surface  58 . Thus, rollers  62  are positioned so that there are two upper rollers  62  that ride on inverted V-shaped upper surface  56  of upper track  52  and two lower rollers  62  that ride on V-shaped lower surface  58  of lower track  54 , whereby rear support plate  60  is restrained to only move horizontally, that is, left and right in FIG.  1 . Of course, the opposite arrangement could be provided, that is, rollers  62  mounted to frame plate  12  and linear tracks  52  and  54  provided on rear support plate  60 , although this arrangement would not be as desirable in view of the large number of rollers  62  that would be required. 
     In order to move rear support plate  60  horizontally, there is provided a lower projection  66  secured to the lower edge of rear support plate  60 . A first pulley  68  is mounted on a shaft  70  that is rotatably mounted to a first lower corner of frame plate  12 , and a second pulley  72  is mounted on a motor shaft  74  of a motor  78 , with shaft  74  extending through an opening (not shown) in frame plate  12  at the opposite lower corner. An endless chain  80  rides over pulleys  68  and  72  and is fixed to lower projection  66 . Thus, as motor  78  rotates motor shaft  74 , and thereby pulley  72 , endless chain  80  is caused to move, thereby moving rear support plate  60  of carriage  50  to the left or right in FIG.  1 . 
     Carriage  50  also has a component that can move vertically. Specifically, two pair of vertically aligned and horizontally spaced rollers  82  are rotatably mounted to the front surface of frame plate  12 . A center support plate  84  is held between rollers  82  so as to be vertically guided at opposite side edges thereof by rollers  82 , and thereby be vertically movable. In this regard, opposite side edges of center support plate  84  constitute linear tracks which ride along rollers  82 . of course, the opposite arrangement could be provided, that is, rollers  82  could be mounted to center support plate  84  and ride along linear tracks fixed to rear support plate  60 . A pneumatic or hydraulic cylinder  86  is mounted on the upper surface of the table top of support  14  below and slightly outwardly of each mandrel  20  and  42 , and includes a vertically movable piston rod  88 , the upper end of which is adapted to engage the lower edge of center support plate  84  in order to push center support plate  84  upwardly between rollers  82 . When a piston rod  88  is retracted or lowered, center support plate  84  falls vertically down by gravity. Stops  90  are secured to the front surface of rear support plate  60 , to limit the extent that center support plate  84  can travel downwardly when a piston rod  88  is retracted or lowered, as will be understood from the description hereinafter. 
     A frame assembly  92  is mounted to center support plate  84  and travels therewith. Frame assembly  92  includes a rear frame plate  94  fixedly secured to an upper end of center support plate  84 . Rear frame plate  94  preferably has a width similar to the width of rear support plate  60  and a height much less than that of center support plate  84 . Preferably, the upper edge of rear frame plate  94  is substantially coincident with the upper edge of rear support plate  60  when the respective piston rod  88  is at its uppermost position. The lower edge of rear frame plate  94  abuts against stops  90  during the downward travel of center support plate  84  so as to limit the downward travel thereof. Frame assembly  92  also includes two side frame plates  96  and  98  of similar height to rear frame plate  94  and secured at opposite edges thereof so as to extend forwardly, and a front frame plate  100  secured to the front edges of side frame plates  96  and  98 . Front frame plate  100  has been removed from FIG. 3 to better show the remaining structure. Accordingly, frame plates  94 ,  96 ,  98  and  100  form frame assembly  92  into a rectangular frame structure. 
     Two rollers  102  and  104  are rotatably mounted on shafts  106  and  108 , respectively, that extend between rear frame plate  94  and front frame plate  100 , at a center portion of frame assembly  92  and with a gap between rollers  102  and  104 . 
     A first pressure roller  110  is rotatably mounted on a shaft  112  that extends parallel to roller  102  and which is positioned slightly outwardly and upwardly therefrom. One end of shaft  112  is mounted in a vertical groove  114  in rear frame plate  94 , while the opposite end of shaft  112  is mounted in a vertical groove  116  in front frame plate  100 . A coil spring  118  is mounted in a wider portion of groove  114  while a coil spring  120  is mounted in a wider portion of groove  116 , so as to normally bias shaft  112  to an upward position as shown. A retainer plate  113  is positioned over vertical grooves  114  and  116  to prevent the shafts from exiting grooves  114  and  116 . 
     A second pressure roller  122  is rotatably mounted on a shaft  124  that extends parallel to roller  104  and which is positioned slightly outwardly and upwardly therefrom. One end of shaft  124  is mounted in a vertical groove  126  in rear frame plate  94 , while the opposite end of shaft  124  is mounted in a vertical groove  128  in front frame plate  100 . A coil spring  130  is mounted in a wider portion of groove  126  while a coil spring  132  is mounted in a wider portion of groove  128 , so as to normally bias shaft  124  to an upward position, with coil springs  130  and  132  being adapted to be compressed to the positions shown in FIGS. 1 and 3. A similar retainer plate  113  is positioned over vertical grooves  126  and  128  to prevent the shafts from exiting grooves  126  and  128 . 
     In addition, a first knife  134  is mounted to side frame plate  96  and extends substantially the entire length thereof. First knife  134  is vertically mounted to the inner surface of side frame plate  96  by a plurality of bolts  136  extending through side frame plate  96 , such that first knife  134  extends to a height above side frame plate  96 , with the sharp edge  138  of first knife  134  exposed at the upper free edge thereof. Coil springs  140  are wrapped about bolts  136  and extend between the bolt heads  142  and the outer surface of side frame plate  96 . This results in knife  134  serving to force the web onto the core so as to adhere the web thereto. In addition, if an excessive force is applied to first knife  134 , first knife  134  will deflect due to coil spring  140  to prevent breakage of the knife. 
     A second knife  144  is mounted to side frame plate  98  and extends substantially the entire length thereof. Second knife  136  is vertically mounted to the inner surface of side frame plate  98  by a plurality of bolts  146  extending through side frame plate  98 , such that second knife  144  extends to a height above side frame plate  98 , with the sharp edge  148  of second knife  144  exposed at the upper free edge thereof. Coil springs  150  are wrapped about bolts  146  and extend between the bolt heads  152  and the outer surface of side frame plate  98 . This results in knife  144  serving to force the web onto the core so as to adhere the web thereto. In addition, if an excessive force is applied to second knife  144 , second knife  144  will deflect due to coil spring  150  to prevent breakage of the knife. 
     FIG. 1 shows a web  154  coming from a larger machine, with web  154  extending around a lower stationary roller  156  secured to the underside of support  14 , and then to a stationary roller  158  rotatably mounted on posts  160  at the upper surface of support  14  at a mid-point between mandrels  20  and  42 . Web  154  can be a matrix or skeleton, as discussed above, but is not limited thereto. From roller  158 , web  154  travels through carriage  50 , and in particular, about roller  104 , is then engaged at the underside of roller  49  and is wrapped about core  22  on first mandrel  20 . The core  22  on first mandrel  20  can have tape thereon for engagement with the start of web  154 , or alternatively, web  154  can have an adhesive surface that automatically adheres onto core  22 , as with a matrix or skeleton of a web. At this time, first mandrel  20  is rotated to wind web  154  thereon. 
     In the condition, with web  154  being wound on core  22 , center support plate  84  is at a lowered position and in the second carriage position at the left of FIG. 1 to a position beneath mandrel  42 . Further, in this condition, a new core  46  is positioned on mandrel  42  and held thereon. 
     When the roll (core  22  plus web  154  wound thereon) reaches a predetermined diameter, as detected by a sensor (not shown), as is conventional, center support plate  84  is moved upwardly by piston rod  88  at the second carriage position. As a result, pressure roller  122  moves web  154  into adhesive engagement with core  46 . This results in pressure roller  122  being pushed down against the force of coil springs  130  and  132  in order to ensure that there is a pressing force against core  46 . At the same time, mandrel  42  is caused to rotate, and knife  144  simultaneously is moved upward to cut web  154  extending to core  22  and press web  154  onto core  46 . As a result, the new free end of web  154  begins winding about core  46 . This can be the result of adhesive on core  46  or adhesive on web  154  itself. 
     Thereafter, center support plate  84  is lowered, whereby roller  122  disengages from web  154  and knife  144  is also lowered. This occurs by gravity when the respective piston rod  88  is retracted or lowered. The lowermost position is achieved when rear frame plate  94  abuts against stops  90 . 
     Then, the roll (core  22  with the web  154  thereon) on first mandrel  20 , is removed from mandrel  20  and a new core  22  is placed thereon. Thereafter, carriage  50  is moved to the right of FIG. 1 by endless chain  80 , to a position below mandrel  20  and the new core  22 . At this time, there is a shift of web  154  from roller  104  to roller  102 . 
     This operation continues by the horizontal and vertical movements of carriage  50  each time that web  154  reaches a predetermined diameter on core  22  or  46 . 
     Because of the use of knives  134  and  144 , web winding apparatus  10  can be used with all types of webs, and also, because of the use of carriage  50 , does not require stopping the machine in order to change a full core. In addition, because mandrels  20  and  42  are not moved, the apparatus becomes much simpler, since movement of a full core  22  and  46  requires relatively bulky, heavy and complicated machinery. Rather, the present invention provides an arrangement in which there are a plurality of stationary mandrels  20  and  42 , and a carriage  50  that moves between mandrels  20  and  42 . 
     Having described a specific preferred embodiment of the invention with reference to the accompanying drawings, it will be appreciated that the present invention is not limited to that precise embodiment and that various changes and modifications can be effected therein by one of ordinary skill in the art without departing from the scope or spirit of the invention as defined by the appended claims.