Mandrel cupping assembly

A mandrel cupping assembly for releaseably engaging the unsupported ends of a plurality of mandrels supported on a web winding turret assembly is disclosed. Each of the mandrels is driven in a closed mandrel path about a web winding turret assembly axis. The mandrel cupping assembly has a cupping arm turret with a cupping arm turret central axis, a cupping arm cooperatively associated with each mandrel of the plurality of mandrels, and a first actuator for disposing the cupping arm from a hold-open position to a hold-closed position. Each of the cupping arms is disposed radially about the cupping arm turret and is carried in a radial orbital path about the cupping arm turret central axis while disposed in either of the hold-open position or the hold-closed position.

FIELD OF THE INVENTION

The present disclosure relates to automatic web rewinding machines where paper towel stock, bath tissue stock, or the like unwound from very large parent rolls is rewound into small individual rolls. In particular, the present disclosure relates to an apparatus that releaseably attaches a mandrel cup into and out of supporting engagement with the free end of a mandrel prior to the winding of the web material upon the mandrel and subsequently detaching the mandrel cup from the mandrel so that the wound web material can be removed from the mandrel for additional processing.

BACKGROUND OF THE INVENTION

Typical web rewinding machines provide a number of core supporting mandrels ranging anywhere from four to ten in number which are mounted on an indexingly rotatable turret. The mandrels extend parallel to the horizontal axis about which the turret rotates, and they are spaced at equal distances from the turret axis and at uniform intervals around that axis. By way of example, a typical six-mandrel turret moves through one-sixth of a revolution at each of its indexing movements and hence it carries each mandrel in turn to each of the six successive stations with a period of dwell at each station. By way of yet another example, an exemplary eight-mandrel turret moves through one-eighth of a revolution at each of its indexing movements and hence it carries each mandrel in turn to each of the eight successive stations with a period of dwell at each station. In any regard, it should be understood that the number of spindles disposed about any given turret used in a web rewinding machine would likely determine the number of successive stations in any such device.

In such a configuration, typically one station (sometimes called a first station) is a loading station at which a length of core stock is slid axially onto the mandrel. At the next station, the core stock has an adhesive or glue applied to the surface of the core. At the third station, the mandrel is brought up to winding speed. As the mandrel moves from the third to the fourth station, the web material is attached to the glued core disposed upon the mandrel for the beginning of the winding operation. Winding continues while the mandrel is at the fourth station. As the mandrel moves out of the fourth station, the web material is cut through across its width (or cross-machine direction) to sever it from the wound roll of web material (e.g., the source of the web material) and give it a new leading edge that is attached to a new core on the next mandrel moving into the winding station. At the fifth station, the rotation of the mandrel is decelerated to a stop, and at the sixth station a wound core or log is stripped off the mandrel. The mandrel then moves to the first station for a repetition of the cycle.

A conventional turret by which the mandrels are carried comprises a spider which is mounted for a rotation on a coaxial shaft that projects a substantial distance in one direction from the spider. The mandrels have rotating connections with the spider, and they project from it in the same direction as the turret shaft. The rotating connection of each mandrel with the spider must provide cantilevered support of the mandrel because when the mandrel is at the core loading station and the unloading station, the end of the mandrel that is remote from the spider has to be accessible to allow cores to be moved axially onto and off. It should be recognized that the mandrels tend to be heavy and very long—typically, 72 inches to 96 inches in length. Therefore, their free ends are typically supported whenever possible and certainly during winding.

To provide support of the free ends of the mandrels, there is conventionally an assembly of supporting arms or chucks on the end portion of the turret shaft that is remote from the spider. This is also known to those in the art as a mandrel cupping assembly. A mandrel cupping assembly is an assembly that is constrained to indexing rotation concurrent with the spider containing the individual mandrels. The mandrel cupping spider generally comprises a chuck arm (or cup) cooperatively associated with each mandrel. Each chuck arm is generally swingable about an axis which is near the turret axis and transverse thereto between a substantially radially extending closed position in which the free end of the chuck arm supportingly engages the free end portion of its associated mandrel and an open position in which the chuck arm is disengaged from its mandrel and is disposed in a more or less axial orientation alongside the turret shaft. Each chuck arm is operated automatically so that it is in its open position during loading and unloading of the mandrel and is in its closed position at least from the time the mandrel moves into the gluing station and moves out of the deceleration station mentioned supra.

In one embodiment, a conventional mechanism for actuating the mandrel supporting chuck arms is provided with a barrel cam that is fixed to the machine frame adjacent to the free ends of the mandrels and a lever and link arrangement for each chuck arm. Each arrangement is carried by the turret for rotation therewith and having a cam follower roller that rides in a groove in the periphery of the stationary barrel cam. Each chuck arm is actuated at appropriate times in consequence of indexing movement of the turret. The shape of the cam groove is provided so that the chuck arms move into engagement with their respective mandrels when the latter are generally adjacent the glue applicator wheels and retract when the mandrels move from the web material winding position.

In such an operation, the stripping of wound rolls off a mandrel is conventionally accomplished by means of a pusher that engages the log at only one side of the mandrel and provides a lateral force upon the cantilevered mandrel. This can set the mandrel into a vibration mode that may be aggravated by the indexing movement that follows unloading. With the mandrel unsupported at the loading station, its free end often wobbles so severely that the core may not be run onto it with automatic core loading equipment. Such an apparatus is described in U.S. Pat. No. 2,769,600.

It is believed that with such conventional machines, the failure to load a core creates a danger that the mandrel itself would be coated with glue at the gluing station necessitating a lengthy shutdown of the machine for cleaning. An operator, seeing that such an unloaded core was moving out of the unloading station, would be required to stop the machine and would find that there is no way to retract the chuck arm engaged with the empty mandrel to permit manual axial unloading of the core. This is because of the nature of the chuck arm actuating mechanism. One purported solution to this problem was to slit a core along its length and push it laterally onto a mandrel to protect the mandrel from glue. At the conclusion of the winding cycle the individual rolls wound onto the slitted core are then discarded.

It is also believed that wobble of an unsupported mandrel could cause a chuck arm to fail to engage the mandrel properly. One solution proposed was a U-shaped member on each chuck arm that tended to preliminarily engage the mandrel during closing movement of the chuck arm and steady the mandrel sufficiently to enable its conical free end to be received in the bearing socket disposed in the chuck arm. However, it is believed that this expedient is not always successful in practice because as the wobbling mandrel fails to enter the chuck arm socket, the chuck arm mechanism exerts as much force as the indexing mechanism can provide. This can result in the inevitable bending or breakage of the link and lever elements that translate any cam follower motion into swinging motion of the chuck arm. The repair of such damage would be necessarily difficult and time consuming.

It is also believed that another expedient that has been used to prevent damage to the chuck arm actuating mechanism is to mount the barrel cam for limited axial motion and pneumatically bias it towards one limit of such motion. When a chuck arm fails to close properly, the reaction force that is imposed upon the cam moves it against its bias to a position which actuates an emergency stop. However, it is believed that such an emergency shutdown arrangement merely relieves some of the effects of the problem rather than solving the problem itself. By way of example, it will not permit axial loading of a core onto an empty mandrel that had moved out of the loading position.

Other solutions provide an automatic web rewinding machine or an automatic mandrel chucking mechanism that does not employ force derived from the turret indexing to affect chuck arm actuation. The chuck arms move to and from their mandrel supporting positions only during periods of dwell to minimize the likelihood of mandrel vibration at the time chuck arm closing occurs. The mechanism is arranged to allow a chuck arm to be manually controlled for movement to its open position in any position of the turret so that a core can be axially loaded onto an empty mandrel or a defective core or roll can be axially stripped off the mandrel. Such a system is described in U.S. Pat. No. 4,266,735.

In any regard, attempts by the prior art to achieve an automatic web rewinding machines all provide for a single chuck arm and it associated equipment to be cooperatively associated with a respective mandrel. Further, the chuck arm and its associated equipment must cooperatively rotate with the mandrel about the turret axis. In other words, a chuck arm is constrained to rotate with the turret and is movable relative to and between a closed position (in which the chuck arm supportingly engages the other end of the mandrel) and an open position (in which the chuck arm is disengaged from the mandrel) to permit cores to be moved axially onto and off it. Clearly, the mechanism is unduly complex and requires numerous moving parts and associated ancillary equipment for it to perform its intended function.

Thus, it would be clearly advantageous to provide a turret system and in particular, a mandrel cupping assembly that is less complex and requires fewer moving parts to perform its intended function. In fact, such system would rotate only the mandrel cup with its respective mandrel free of any associated equipment necessary to load and unload the mandrel cup. Clearly, such systems would be appreciated by one of skill in the art because of their overall simplicity and ease of use.

SUMMARY OF THE INVENTION

An exemplary embodiment of the present disclosure provides a mandrel cupping assembly for releaseably engaging the ends of a plurality of mandrels supported on a web winding turret assembly having a web winding turret assembly axis. Each of the mandrels is driven in a closed mandrel path about the turret assembly axis. The mandrel cupping assembly has a cupping arm turret with a cupping arm turret central axis, a cupping arm cooperatively associated with each mandrel of the plurality of mandrels, and a first actuator for disposing the cupping arm from a hold-open position to a hold-closed position. Each of the cupping arms is disposed radially about the cupping arm turret and has a mandrel cup for releaseably engaging the unsupported end of the mandrel. Each cupping arm is carried in a radial orbital path about the cupping arm turret central axis while disposed in either of the hold-open position or the hold-closed position.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-3of the present disclosure depict various perspective and planar views of an exemplary web rewinding machine10and the relevant portion of an exemplary, non-limiting embodiment of a turret assembly20suitable for use as an automatic web rewinding machine. As would be appreciated by one of skill in the art, a plurality of rotatable core supporting mandrels22are carried in an indexable, orbital motion about the axis of turret assembly20as well as for rotation about their own respective axes. A turret assembly20of the present disclosure provides a spider (not shown) by which the respective mandrels22are carried and a shaft (not shown) by which the spider (not shown) is supported for rotation. The turret shaft (not shown) projects a substantial distance in one direction from the spider (not shown) and the mandrels22disposed thereupon project from the spider (not shown) a somewhat smaller distance in the same direction. One of skill in the art will appreciate that since the rotatable connection between the spider (not shown) and each of the long, relatively heavy mandrels22is near one end of the mandrel22and the other end of the mandrel22will be unsupported at times, the spider (not shown) will typically be provided with two axially spaced apart bearings (not shown) for each mandrel so that the cantilevered connection of the mandrel22with the spider (not shown) can, by itself, hold the mandrel22reasonably steady. As will be appreciated by one of skill in the art, it is preferred that each mandrel22be provided equidistant from the axis of the turret and are uniformly spaced about that axis.

Each mandrel22can be driven to provide the required rotation in any conventional manner. One form of a mandrel drive apparatus can provide rotation of each mandrel22and its associated core disposed thereabout the mandrel axis during movement of the mandrel22and core combination. The mandrel drive apparatus can provide winding of a web material upon the core supported on the mandrel22to form a log of web material wound around the core (a web wound core). This form of mandrel drive apparatus can provide center winding of the web material upon the cores (that is, by connecting the mandrel with a drive which rotates the mandrel22about its axis, so that the web material is pulled onto the core. The mandrel22can be provided with a profiled rotation that provides a constant rotational speed throughout the winding cycle. Alternatively, the mandrel22can be provided with a winding profile that provides a differential rotational speed throughout the winding cycle.

As one of skill in the art will appreciate, each mandrel22can be connected at its end adjacent to the spider (not shown) with a form of coaxial clutch that provides a disengageable driving connection between the mandrel22and a coaxial sheave. Typically, the sheave is connected by means of a belt with a pulley and is rotatable on the turret shaft and in turn a belt drivingly connects the pulley with a motor which can be provided at a fixed location relative to the frame of the turret assembly20. Such assemblies are described in U.S. patent application Ser. No. 06/113,465.

Further, one of skill in the art will appreciate that a turret assembly20having a turret (not shown) is typically indexingly rotated to carry each of the mandrels22to each of a succession of fixed stations at each of which the mandrel dwells for a time during the performance of an operation distinctive to the particular station. The arrangement of the stations, the operation or operations at each, and the apparatus provided at the several stations for the performance of their function are all generally known to those of skill in the art familiar with web rewinding machines.

In one exemplary, but non-limiting embodiment, each mandrel22can be provided with a toothed mandrel drive pulley38and a smooth surfaced, free wheeling idler pulley, both disposed near the at its end adjacent to the spider (not shown). The positions of the drive pulley and idler pulley alternate on every other mandrel22, so that alternate mandrels22are driven by their respective mandrel drive belts. For instance, when a mandrel drive belt engages the mandrel drive pulley on its associated mandrel22, the mandrel drive belt can ride over the smooth surface of the idler pulley on that same mandrel22, so that only the respective drive motor provides rotation of that mandrel22about its axis. Similarly, when the mandrel drive belt engages the mandrel drive pulley on an adjacent mandrel22, the mandrel drive belt can ride over the smooth surface of the idler pulley on that respective mandrel22, so that only that drive motor provides rotation of the mandrel about its axis. Accordingly, each drive pulley on an associated mandrel22engages one of the belts to transfer torque to the mandrel, and the idler pulley engages the other of the belts, but does not transfer torque from the drive belt to the mandrel.

As would also be understood by one of skill in the art, a length of tubular core stock from a supply thereof is advanced axially by known mechanisms to be loaded onto a particular mandrel22. Typically, a mandrel22has a conical or “bullet”-shaped nose free end portion to assist in guidance of the cores into a coaxial relationship thereto.

Similarly, after the winding of a web material into a wound product46upon a core disposed upon an associated mandrel22, it was found that a generally conventional mandrel unloading mechanism can provide the individual rolls of wound product to be stripped off a particular mandrel22at an unload station. In one embodiment, the unloading mechanism may comprise an endless belt arranged to have a long, straight stretch which extends parallel to the mandrel22at the unloading station at a small distance to one side of that mandrel22. A pusher can be secured to the belt and can project laterally therefrom to engage from behind a log of wound product46and drive it off the mandrel22as the pusher moves away from the spider along a straight stretch.

Alternatively, a core stripping apparatus can be positioned along the unload station. An exemplary core stripping apparatus can comprise a driven core stripping component, such as an endless conveyor belt. The conveyor belt preferably carries a plurality of flights spaced apart on the conveyor belt. Each flight can engage the end of a log supported on a mandrel22as the mandrel22enters the unload station.

A flighted conveyor belt can be angled with respect to a respective mandrel22axis as the mandrels22are carried along a generally straight line portion of the core unload station so that the flights engage each log disposed about a mandrel22with a first velocity component generally parallel to the mandrel22axis, and a second velocity component generally parallel to the straight line portion of the unload station. Once the log is stripped from the respective mandrel22, the mandrel22can be carried along the closed mandrel path to the core loading station to receive another core.

As shown generally inFIGS. 1-3, one of skill in the art will recognize that during both unloading and loading of a mandrel22, the end of a mandrel22that is remote from the spider must be unsupported. However, as the mandrel22moves through the portion of its orbit about the axis of turret assembly20that takes it from the loading station around to an unloading station, its free end portion is preferably supported by means of a cupping assembly24having cupping arms28disposed about a cupping spider26that are placed into contacting and un-contacting engagement with the free end of the mandrel22. In other words, a cupping arm28releaseably engages the unsupported end of a mandrel22and supports the mandrel22for rotation of the mandrel22about its own rotational axis as well as its rotation (i.e., orbit) about the axis of turret assembly20. In this embodiment, the cupping arm28is in a passive configuration for movement (i.e., orbit) about cupping spider26. In a passive configuration, it is envisioned that the inertia of a particular spindle22due to its rotation about the axis of turret assembly20, once in mating engagement with a corresponding cupping arm28, will be sufficient to cause the corresponding cupping arm28to orbit about cupping spider26in a cooperative manner coincident with the mandrel22cooperatively associated thereto.

In a preferred embodiment, a particular cupping arm28is cooperatively associated with each mandrel22. A cupping arm28of mandrel cupping assembly24releaseably engages the unsupported end of a mandrel22intermediate the core loading segment and the core stripping segment of the closed mandrel path as the mandrels22are driven around the turret assembly (not shown) axis by the rotating turret assembly (not shown).

In certain embodiments, when a turret assembly comprises four mandrels22, naturally there will be four cupping arms28disposed radially about cupping spider26—each cupping arm28providing cooperative engagement with each respective mandrel22. Similarly, a turret assembly20having six, eight, or ten mandrels22disposed thereabout, a cupping assembly24will have respectively six, eight, or ten respective cupping arms28disposed radially about cupping spider26.

In any regard, each mandrel22associated with the turret assembly (not shown) is provided with a corresponding cupping arm28that is disposed radially about cupping spider26of cupping assembly24. Each cupping arm28orbits about cupping spider26in a cooperative motion with a respective mandrel22. Such rotary motion carries a respective cupping arm28to rotate or orbit about the axis of cupping assembly24in a singular track40. As used herein a “track” is to be broadly construed to provide a path or line for travel or motion for sliding or rolling a part or parts. As such, a “track” may include any device, apparatus, or assembly that prevents the unwanted movement from one portion of a device or assembly to another. Non-limiting examples of various tracks may include a race, a cam, a trace, a channel, groove, a rail, or the like all of which are used interchangeably and combineably herein without limitation.

It should be noted that track40is capable of providing the cupping arm28in a “closed” operative position in which the respective cupping arm28supportingly engages the free end portion of a cooperatively associated mandrel22of the turret assembly (not shown) and extends substantially radially to the shaft supporting the turret assembly (not shown). Further, the track40is capable of facilitating orbital motion of each cupping arm28about cupping assembly24in an “open” position in which the cupping arm28is disengaged (i.e., in non-contacting engagement) from its respective mandrel22cooperatively associated thereto.

Generally, cupping arm28remains in a radially up-right position relative to track40when in contacting engagement with a respective mandrel22of turret assembly (not shown). In a preferred embodiment, when cupping arm28is not in contacting engagement with a respective mandrel22of turret assembly (not shown), cupping arm28remains in a radially up-right position relative to track40. However, it should be realized that cupping arm28may reside in any position relative to track40including any position that is disposed radially away from a respective mandrel22when cupping arm28is not in contacting engagement with a respective mandrel22. Such an embodiment may relieve the need for offsetting the hold-open portion44of track40from the hold-closed portion42of track40as shown. In this way track40can be provided as a singular track40having a generally constant distance from the turret supporting the mandrels22.

Each cupping arm28is generally provided with a ring at an end distal from cupping spider26and preferably comprises a bearing socket in which the generally conical end portion of the mandrel22is receivable. The ring can provide locking engagement with the unsupported end of mandrel22. Such locking engagement can be provided through the use of locking pins, a ‘snap-lock’, magnets, gears, deformable rings, and the like. In any regard, it is preferred that the unsupported end of a corresponding mandrel22be capable of rotation within the engaged portion of cupping arm28while not being able to withdraw from the ‘locked’ position while the cupping arm28is in the hold-closed portion42of track40.

The disposition of each cupping arm28into contacting or non-contacting engagement with a respective mandrel22is defined by cupping actuator32or un-cupping actuator34, respectively, through a respective chucking lever30. It is surprising to note that the cupping assembly24of the present disclosure only requires the use of only two actuators in order to provide engagement and disengagement of a respective cupping arm28with a mandrel22cooperatively associated thereto. It is also important to understand that the cupping actuator32, the un-cupping actuator34, and the associated ancillary equipment such as the respective chucking lever30of the present cupping assembly24do not rotate with a respective cupping arm28.

The cupping assembly24is designed to be utilized with a single cupping actuator32and a single un-cupping actuator34that transfers each respective cupping arm28from the hold-open portion44of track40to the hold-closed portion42of track40and from the hold-closed portion42of track40to the hold-open portion44of track40respectively. In a preferred but non-limiting embodiment, the respective cupping actuator32or un-cupping actuator34can push/pull on a linkage cooperatively associated with the respective cupping arm28. Alternatively, the respective cupping actuator32or un-cupping actuator34can push/pull directly upon cupping arm28upon engagement of the cupping actuator32or un-cupping actuator34directly upon cupping arm28. Hold-open portion44of track40can provide a region suitable for the removal of the respective cupping arm28from the respective mandrel22and to provide the clearance necessary to facilitate removal of the material (e.g., core, core and material, etc.) disposed upon mandrel22.

One of skill in the art will readily appreciate the fact that using only two actuating devices (cupping actuator32and un-cupping actuator34) greatly reduces the need for having a respective activation device for each cupping arm28that may be associated with a cupping assembly of the prior art. Further, it will be readily appreciated by one of skill in the art as clearly advantageous in having such a cupping assembly24having only two actuating devices (cupping actuator32and un-cupping actuator34) in that such a system can allow cupping and un-cupping actions to occur at virtually any point of the rotation of turret assembly20as well as the respective cupping arms28orbiting about cupping assembly24. This can include, but clearly not be limited to, turret assembly20dwell, turret assembly index, or any combination of the two. This is clearly advantageous over conventional cam track systems that require cupping and un-cupping actions to occur only while the turret is in motion. Clearly, one of skill in the art will appreciate that the system of the present invention provides less complexity by allowing increased product turn-over rates, reduced maintenance and repair times, as well as reduced maintenance and repair costs.

Referring toFIGS. 1 and 2, an incoming cupping arm28(i.e., a cupping arm28not engaged with a mandrel22) generally rides in hold-open portion44of track40. In a preferred embodiment and as shown inFIGS. 1-3, the section of track40comprising hold-open portion44can generally be off-set from the section of track40comprising hold-closed portion42. This ensures that the respective cupping arm28remains in the un-cupped position and remains distal from a corresponding mandrel22. One of skill in the art will appreciate that the cupping arm28should be in a fully retracted position before the cupping arm28proceeds past the position where the cupping actuator32via its chucking lever30engages the cupping arm28. This engagement between the respective chucking lever30and cupping arm28causes cupping arm28to be positioned in hold-closed portion42of track40and thus in contacting engagement with the unsupported end of a respective mandrel22. In a preferred embodiment, the cupping arm28eventually reaches a dwell position in hold-open portion44of track40where the cupping arm28is fully retracted. In such a dwell position, a core can be loaded onto the respective mandrel2. Then the cupping arm28can be directed inwardly toward the open end of the mandrel22in order to close the cup and fully support the previously unsupported end of the mandrel22. The geometry and/or location of hold-open portion44of track40is preferably designed to allow the turret assembly20to cup during dwell, turret index, or any combination of the two. Practically, it was found that this design allows more time to load a core onto a respective mandrel22and also facilitates higher turret assembly20turn-over speeds. The cupping arm28can begin to retract once the cupping arm28reaches a clear-out position. In this position, it is preferred that the cupping arm28be in a fully retracted position before the next incoming cupping arm28approaches a clear in position.

One of skill in the art will appreciate that cupping arm28could comprise a feature that utilizes the cupping motion to actuate means for locking a core onto respective mandrel22. By way of non-limiting example, the cupping motion may cause axial compression of a deformable ring disposed at the cupping end of respective mandrel22. This compression forces the ring to expand radially, thereby locking the core onto respective mandrel22. Further, the core can also be driven onto a core stop disposed proximate to the spider (not shown) end of turret assembly (not shown) prior to cupping. The core stop can be provided with tapered fins that are effectively wedged into the core wedged when loading. Effectively, such a tapered stop and expanding ring can combine to lock the core onto the respective mandrel22at both ends, providing a non-slipping drive engagement.

In another alternative, but non-limiting embodiment, the cupping motion could displace a moveable shaft disposed within the respective mandrel22. Axial movement of the shaft would then cause locking pins disposed within respective mandrel22to protrude outside the outer diameter of the respective mandrel22, thereby locking the core to the respective mandrel22.

Referring again toFIGS. 1 and 2, when the cupping arm28reaches the start of hold open portion44of track40, the un-cupping actuator34through chucking lever30engages cupping arm28and retracts to essentially un-cup the mandrel22and leave the end of the mandrel22unsupported. While the mandrel22is un-cupped in this position, the wound product (which now forms what is known to those of skill in the art as a log) can be stripped from the respective mandrel22. The track40and cupping arm28geometry and location is preferably designed to allow the turret assembly to un-cup during dwell, turret assembly index, or any combination of the two. The turret assembly (not shown) then begins to index and the un-cupping actuator34and chucking lever30begin to extend once the cupping arm28disposed within the hold-open portion44of track40reaches a clear-out position.

In a preferred embodiment, the hold-open portion44of track40is designed to maximize time to strip the log comprising wound product from the mandrel22and to maximize turn-over for the placement of a new core upon mandrel22. One of skill in the art will understand that the un-cupping actuator34and associated chucking lever30should be in the fully extended position before the next incoming cupping arm28disposed within the hold-closed portion42of track40gets beyond a clear-in position.

In a preferred embodiment, both cupping actuator32and un-cupping actuator34are provided as linear motors. However, one of skill in the art will understand that it would also be possible to provide an embodiment of the cupping assembly24where the cupping actuator32and un-cupping actuator34are provided as a four-port, two-position valve having an axially slideable valve element. In such an embodiment, both cupping actuator32and un-cupping actuator34can be operated by the use of compressed air or any other fluid suitable for use in such constructions. By providing cupping actuator32and un-cupping actuator34in a linear relationship with the cupping arms28, it is possible to provide a cupping assembly24that requires the use of only two actuators to provide the intended function of cooperatively associating or disassociating the unsupported end of the mandrel22with an individual cupping arm28. However, it should be recognized that the cupping arm28and any chucking lever30cooperatively associated thereto are disposed about the circumference of cupping spider26so that an individual cupping arm28is cooperatively associated with only one mandrel22of turret assembly20.

An unloading mechanism (not shown) can be started as soon as the cupping arm28associated with the mandrel22having wound product disposed thereon, has reached the start of hold open portion44of track40. Starting of the unloading mechanism can be coordinated with cupping arm28opening in any of several manners. For example, a start signal can be issued after a predetermined delay interval followed by the end of indexing motion. Alternatively, the unloading mechanism can be stopped at the end of each unloading operation in such a position that when restarted for the next operation, the pusher moves substantial distance before coming into engagement with wound product disposed about a mandrel22forming the outgoing log. In such a case, the unloading mechanism can be started in operation simultaneously with delivery of the opening input to the unloading station.

As shown inFIGS. 2 and 3, once the cupping arm28is engaged with the unsupported end of the mandrel22after loading of a core upon mandrel22in the loading position, it remains in that position until turret assembly20indexes to carry the mandrel22out of the loading position. Furthermore, as the mandrel22moves away from the loading position and its associated cupping arm28is engaged into the hold-closed portion42of track40, the cupping arm28is maintained in its engaged position with the now supported end of mandrel22. The turret assembly (not shown) then indexes the mandrel22and associated cupping arm28about its longitudinal axis until web product is contactingly engaged with the core disposed upon the mandrel22. At this point, mandrel22is spun up (i.e., rotational inertia is imparted) and as discussed supra coincides with the winding of a web material about the core disposed about mandrel22to form a wound product.

Upon reaching the unloading position disposed proximate to the start of hold-open portion44of track40, un-cupping actuator34can then be engaged to cupping arm28(with or without the use of a chucking lever30) to retract cupping arm28from contacting engagement with a corresponding mandrel22and depositing cupping arm28into the hold-open portion44of track40. Deposition of cupping arm28into the hold-open portion44of track40then facilitates the mandrel22having wound product disposed thereon to be removed from mandrel22. The cupping arm28for the mandrel22moving from the unloading position to the loading position remains open in order to clear any required supports. The cupping arm28can then freely orbit about the axis of cupping assembly24within hold open portion44of track40in preparation for movement of the next mandrel22into the unloading position and egress of ensuing wound product.

By reference, a core may be started onto the mandrel22at the loading position by means of a core loading apparatus (not shown) as would be known by those of skill in the art. After the core has run onto the mandrel22a known distance, the core can then be engaged by a rotating loading wheel known to those of skill in the art that initially cooperates with the core loading apparatus and moving the core onto the mandrel22but which takes over the propulsion of the core in the last part of movement onto the mandrel22.

Further, as would be known by those of skill in the art, when a core is properly positioned on the mandrel22, its front end preferably engages in an abutment located near the spider supporting the mandrels22. After it engages the abutment, the core cannot be advanced any further by the rotating core loading wheel which would then merely slip relative to the core. At about the time that the core engages the abutment, its front end portion moves under an arm that typically comprises a core detector. Such an apparatus may comprise a spring arm having a free end portion that is biased towards contacting engagement with the mandrel22at the loading station and a properly loaded core intervenes between the associated spring arm and the mandrel22to break contact between them and thus open an electric signal circuit through the spring arm.

As would be understood by those of skill in the art, interruption of the circuit typically comprising an output signifying core presence can cause rotation of the associated core loading wheel to be stopped and engagement of a cupping arm28upon the mandrel22by operation of the cupping actuator32causing the respective chucking lever30connected to cupping arm28to engage the unsupported end of mandrel22having the core disposed thereupon. Such a core presence signal can also be issued to a PCD, PLC, or other synchronizing mechanism for the apparatus and its issuance is in any case a condition or the condition for retraction of the cupping arm28at the appropriate position. Such retraction, as pointed out above, constitutes a closing input to the control element for the cupping arm28to be positioned back into contacting engagement with its respective mandrel22. Thus, the cupping arm28is in the closed position only if and when a core is present on the mandrel22at the loading station and before the mandrel22begins to move out of that station.

It should be realized by one of skill in the art that engagement of the cupping arm28upon the mandrel22could also occur just prior to any core presence signal being detected. It should be recognized that the core should be clear of the cupping arm28before the cupping arm28moved toward the mandrel22.

In a preferred embodiment, since the cupping arm28can be moved into the closed position where contacting engagement occurs between the cupping arm28and the respective mandrel22and likely after the mandrel22has been subjected to vibration dampening, it is unlikely that the conical end portion typically associated with the mandrel22will fail to seat in the bearing socket of the cupping arm28. However, in the event of such a failure, the cupping actuator32can be merely programmed to stop short of its limit position where the cupping arm28is closed, thus eliminating damage that can result because the cupping arm28will be urged past the stationary mandrel22under yielding pressure from cupping actuator32.

FIGS. 4-6of the present disclosure depict various perspective and planar views of an alternative exemplary web rewinding machine10A and the relevant portion of an exemplary, non-limiting embodiment of a turret assembly20A suitable for use as an automatic web rewinding machine. Similar to the embodiment depicted inFIGS. 1-3and described supra, a plurality of rotatable core supporting mandrels22A are carried in an indexable, orbital motion about the axis of turret assembly20A as well as for rotation about their own respective axes. A typical turret assembly20A provides a spider (not shown) by which the respective mandrels22A are carried and a shaft (not shown) by which the spider (not shown) is supported for rotation.

The turret shaft (not shown) projects a substantial distance in one direction from the spider (not shown) and the mandrels22A disposed thereupon project from the spider (not shown) a somewhat smaller distance in the same direction. One of skill in the art will appreciate that since the rotatable connection between the spider (not shown) and each of the long, relatively heavy mandrels22A is near one end of the mandrel22A and the other end of the mandrel22A will be unsupported at times, the spider (not shown) will typically be provided with two axially spaced apart bearings (not shown) for each mandrel so that the cantilevered connection of the mandrel22A with the spider (not shown) can, by itself, hold the mandrel22A reasonably steady. As will be appreciated by one of skill in the art, it is preferred that each mandrel22A be provided equidistant from the axis of the turret and are uniformly spaced about that axis.

As shown generally inFIGS. 4-6, one of skill in the art will recognize that during both unloading and loading of a mandrel22A, the end that is remote from the spider must be unsupported. However, as the mandrel moves through the portion of its orbit that takes it from the loading station around to an unloading station, its free end portion is supported by means of a cupping assembly24A having cupping arm28A disposed about a cupping spider26A that are placed into contacting and un-contacting engagement with the free end of the mandrel22A. In other words, a mandrel cup28A releaseably engages the unsupported end of a mandrel22A, and supports the mandrel22A for rotation of the mandrel22A about its axis.

In this embodiment, the cupping arm28A is in an “active” configuration for orbital rotation about cupping spider26A. It is envisioned that inertia can be provided to a particular cupping arm28A to allow the cupping arm28A to orbit cupping spider26A in the track40disposed about cupping spider26A. By way of non-limiting example, a plurality of electromagnets50can be provided within or upon cupping spider26that can generate an electromotive force (EMF) sufficient to propel a mandrel28A to orbit about cupping spider26A within track40A. Naturally, one of skill in the art would recognize that other arrangements can be used to provide a particular cupping arm28A with a motion such as a belt drive, gear drive, and the like. If used, it is believed that the electromagnets50can be provided as a plurality of individual electromagnets50or as a single linear electromagnet50.

In any regard it would be possible to provide control programming to cause a particular series of individual electromagnets50or a single linear electromagnet50to provide the necessary and/or desired motion to each cupping arm28A necessary to maintain concerted and cooperative alignment with a particular mandrel22A cooperatively associated thereto while orbiting about cupping spider26A within track40A. Such a motion profile can be used to provide each cupping arm28A with a characteristic motion about cupping spider26A that may be required at a particular position and/or region of cupping spider26A.

Any dimensions and values disclosed herein are not to be understood as being strictly limited to the exact dimension and values recited. Instead, unless otherwise specified, each such dimension and/or value is intended to mean both the recited dimension and/or value and a functionally equivalent range surrounding that dimension and/or value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.