Automatic sleeving splicer

A system and method for automatic splicing of rolls of sleeve material used in various packaging markets is provided. The system will automatically splice the prepared end of a new roll onto the expiring end of the prior roll. The system performs an automatic cut and splice operation resulting in a butt splice of the two rolls with tape applied to both sides of the splice joint. The splice can be done in-registration to provide a consistent product repeat length between expiring and new rolls.

FIELD OF THE INVENTION

The present invention is directed to splicing systems and, more particularly, to sleeving splicers.

SUMMARY OF THE INVENTION

The disadvantages of the prior art are overcome by providing a system and method for automatic splicing of rolls of sleeve material used in various packaging markets. The system will automatically splice the prepared end of a new roll onto the expiring end of the prior roll. The system performs an automatic cut and splice operation resulting in a butt splice of the two rolls with tape applied to both sides of the splice joint. The splice can be done in-registration to provide a consistent product repeat length between expiring and new rolls.

DETAILED DESCRIPTION OF AN ILLUSTRATIVE EMBODIMENT

System Description

The present invention is designed to provide a non-stop supply of sleeve material to downstream application systems as is known in the art. The system illustratively comprises of a frame1(FIG. 1A) on which are operatively mounted opposing sub-frame assemblies2(as shown inFIG. 1B). Illustratively each sub-frame assembly2comprises of a guide roll6(FIG. 1D). One of the guide rolls on a first sub-assembly2is utilized for the currently running roll of material, while the second guide roll of the second sub-assembly2is utilized for the new roll. During operation, the two guide rolls will alternate between being associated with the currently running roll of material and with the new roll. That is, as one roll is completed, the new roll will become the currently running roll, while the operator will replace the completed roll so that it will become the new roll.

Illustratively, each sub-assembly comprises of a first moving nip bar3(FIG. 1C) and a second moving nip bar4(FIG. 1D). The first moving nip bar3illustratively performs a dual purpose. A first use is to provide a vacuum to hold a prepared slice for the new roll. The first nip bar3also is utilized to apply force to the opposing nip and running web for the purpose of adhering the new roll to the cut end of the expiring roll. Illustratively, the second moving nip bar4is utilized to use a vacuum to hold the tape to be applied to the opposite side of the splice joint. Further, the second moving nip bar4is also utilized to apply force to the opposing nip to adhere the splice tape to the second (opposite) side of the splice joint.

Each of the sub assemblies also illustratively comprises of a fixed metal preparation bar5(FIG. 1C). The metal preparation bar5illustratively includes vacuum capability to hold a prepared splice in place as well as a set of measurement scales for alignment of the prepared web with the running web. Further, an idler roller6is also included on each sub-assembly2for web guiding during the splice preparation.

FIG. 2is a perspective view of exemplary guiding mechanism11in accordance with an illustrative embodiment of the present invention. The guiding mechanism11illustratively comprises of a dual thread ball screw7that illustratively comprises a plurality of guide arms9attached for centering of the traverse wound sleeving web. The guide arms9are illustratively implemented as tapered plates to provide the centering of the sleeving web during a splicing operation. Illustratively two offset guide rods10pass through the guide plates9to provide a narrow space for web materials to pass through. The offset guide rods10also strengthen the web for edge guiding functionality. The mechanism11may also illustrative including a knob8for rotating the dual thread ball screw7to adjust the guide plates9. Illustratively the knob8is utilized to rotate the dual thread ball screw in a way that adjusts and centers the guide plates9in a single operation. However, in alternative embodiments, a plurality of knobs, or other adjustment mechanisms, may be utilized to center and adjust the guide plates9separately. Thus, the description of a single knob8should be taken as exemplary only. Further, it should be noted that while a knob is shown and disclosed in accordance with an illustrative embodiment of the present invention, other techniques for adjusting and centering the guide plates9may be utilized in accordance with alternative embodiments of the present invention. As such, the description of a knob8should be taken as exemplary only.

FIG. 3is a perspective view a further assembly in accordance with an illustrative embodiment of the present invention. The assembly comprises of a frame12that is operatively interconnecting a sub frame13. Illustratively, the subframe13is configured to support a nip bar14that isolates the supply rolls and the splice operation from a downstream process tension and material flow. Brackets (other means)15are utilized to actuate the nip bar in line with the web direction provided between the frame12in subframe13. The actuators15both actuate the nip bar as well as provide a fixed and repeatable advance of the web application of the second side splice tape. Travel stops16are operatively mounted between the frame12and subframe13and are configured to provide adjustability to the amount of the web advance prior to the application of the second side tape. Illustratively, sensors17are mounted to provide end of travel location feedback of the moving nip bar. An idler roll18is provided to provide a web path from the splice head through the moving nip and out to the accumulator (not shown).

FIG. 4Ais a perspective view of a frame19in accordance with an illustrative embodiment of the present invention. The frame19illustratively comprises a guiding system20, such as that described above in reference toFIG. 3, that is operatively connected to a first idler roll21and a second idler roll22. The first idler roll21is utilized to guide the web through the splice head and alignment assembly of the automatic sleeve splicer. The second idler roll22is illustratively configured to provide a large wrap angle around the idler roll21. Further, the idler roll22works to guide the web vertically into the nip/advance module.

An encoder23is operatively connected to the first idler roll21. A fixed sensor24is operatively interconnected with the encoder23to provide feedback of the web speed from the supply roll into the accumulator. There is further a mount for an optical registration sensor25(FIG. 4B) that is integrated into the upper alignment system.

FIG. 5is an exploded perspective view of an exemplary guide plate system in accordance with an illustrative embodiment of the present invention. The guide plate system comprises a pair of opposing sub-plates26that provide a plenum for air under pressure. Air is provided by air intake nozzles from a pressurized air source (not shown). Perforated surface plates27are mounted to each plenum from which air flows to create a low friction surface upon which the web (not shown) passes. A self centering edge guide plate system28provides guiding action to the web.

It should be noted that the system hardware description contained above is in relation to an exemplary embodiment. Thus, variations and modifications may be made from the description contained herein without departing from the spirit or scope of the present invention.

System Operation

A description of the operation of the novel automatic sleeving splicer is provided herein. As will be appreciated by one skilled in the art, the system operation description should be read in conjunction with the above system hardware description. In operation, the splicer is loaded with the material which is webbed through the guiding system, splice head, nip advance, and accumulator and provided to the downstream process equipment. The upper and lower guides are adjusted to suit the width of the material being run on the machine.

Using encoders before and after the accumulators, the control system drives the core-driven roll shafts at the appropriate speed to maintain a pre-defined level of storage in the accumulator. The speed at which the core is driven is calculated based on feedback from the encoders on the drive system and the encoders before and after the accumulator. An estimated time before the running roll expires is provided on the user interface and is based upon the speed-related control items and user-input caliper of the web.

While the running roll is supplying material to the process, the operator loads the next roll of material onto the opposite core drive shaft. The material is webbed through the system and to the splice head. The non-running side of the splice head is opened, upon which vacuum is turned on automatically to only the preparation and nip bars. The operator webs the new material through the associated side of the lower guide system and over the idler roll on the head to the preparation bar. The splice is prepared using the cutting edge guides and lateral alignment scales provided on the preparation bar. The vacuum to the preparation and nip bars hold the splice in place. The non-running side of the head is then closed.

The operator then opens the running side of the head where the vacuum has been automatically turned on to the second side tape application nip bars. The operator places a piece of tape, adhesive side up, over the vacuum holes, using the alignment scales provided to ensure proper positioning relative to the running web. The operator then closes the running side of the head. Using line speed data collected from the encoders on the system and the user-input material caliper, the system will initiate an automatic splice when the calculated outside diameter of the running roll becomes less than a user-defined minimum value.

If in-registration splice mode has been selected on the user interface, the system will automatically slow the drives down to a pre-defined scan speed. Using an optical sensor, the system will find a registration mark on the running material. Once the mark is located, the system will advance the web a user-defined distance such that the splice takes place at the desired location on the web. If in-registration is not selected, the drive will decelerate to zero speed at the predetermined minimum outer roll diameter.

During the deceleration, scan, and splice sequences the downstream process will continue to be supplied material at the process-defined line speed by consuming material stored within the accumulator. When the web is properly positioned for the splice and the drives have decelerated to zero speed, the accumulator/web advance nip will close on the web thereby isolating the splicing activities from the downstream process tension and material flow.

The splice head will then fire the primary nip on the running side of the head, thereby compressing the running web against the exposed tape on the prepared splice to join the two webs of material. A knife on a moving shuttle then cuts the expiring web in a precise location to provide a butt splice at the user-specified location. With the expiring web cut and the running web now adhered to the new roll, the primary nip will retract.

The upper accumulator/web advance nip will then advance the web by moving a predefined distance in the in-web direction. Sensors in the nip advance provide confirmation of the completed motion. Upon completion of the web advance the second side tape nip bars extend from both sides of the head to apply the tape and backing force for the opposite side of the web. The second side tape nip bars then retract to complete the splice and two-side tape application process.

The accumulator/web advance nip then opens and the new running roll is accelerated to a value higher than the calculated line speed until the accumulator has returned to a pre-defined fill state, as indicated by sensors within the accumulator that monitor the position of the moving dancer. Once the pre-defined fill state is achieved the drive speed returns to a value that matches the process line speed. The operator would then remove the expired roll from the roll drive, replace it with new material, and repeat the process noted above to provide a non-stop supply of material to the downstream processes.

The above description is directed to exemplary embodiments of the present invention. As will be appreciated by those skilled in the art various modifications may be made to the description contained herein without departing from the spirit or scope of the invention.