Center/surface rewinder and winder

A winder for winding a web to produce a rolled product is provided. The winder includes a web transport apparatus that is used for conveying the web. Also included in one exemplary embodiment is a plurality of independent winding modules. The winding modules are independently positioned to independently engage the web as the web is conveyed by the web transport apparatus. The winding modules may be configured to wind the web to form a rolled product by center winding, surface winding, and combinations of center and surface winding. The winding modules are structurally and operationally independent of one another where if one module is disabled, another may still operate to produce the rolled product without shutting down the winder.

BACKGROUND

Winders are machines that roll lengths of paper, commonly known as paper webs, into rolls. These machines are capable of rolling lengths of web into rolls at high speeds through an automated process. Turret winders are well known in the art. Conventional turret winders comprise a rotating turret assembly which support a plurality of mandrels for rotation about a turret axis. The mandrels travel in a circular path at a fixed distance from the turret axis. The mandrels engage hollow cores upon which a paper web can be wound. Typically, the paper web is unwound from a parent roll in a continuous fashion, and the turret winder rewinds the paper web onto the cores supported on the mandrels to provide individual, relatively small diameter logs. The rolled product log is then cut to designated lengths into the final product. Final products typically created by these machines and processes are toilet tissue rolls, paper toweling rolls, paper rolls, and the like.

The winding technique used in turret winders is known as center winding. A center winding apparatus, for instance, is disclosed in U.S. Patent Reissue No. 28,353 to Nystrand, which is incorporated herein by reference. In center winding, a mandrel is rotated in order to wind a web into a roll/log, either with or without a core. Typically, the core is mounted on a mandrel that rotates at high speeds at the beginning of a winding cycle and then slows down as the size of the rolled product being wound increases, in order to maintain a constant surface speed, approximately matching web speed. Center winders work well when the web that is being wound has a printed, textured, or slippery surface. Also, typically, center winders are preferable for efficiently producing soft-wound, higher bulk rolled products.

A second type of winding is known in the art as surface winding. A machine that uses the technique of surface winding is disclosed in U.S. Pat. No. 4,583,698. Typically, in surface winding, the web is wound onto the core via contact and friction developed with rotating rollers. A nip is typically formed between two or more co-acting roller systems. In surface winding, the core and the web that is wound around the core are usually driven by rotating rollers that operate at approximately the same speed as the web speed. Surface winding is preferable for efficiently producing hard-wound, lower bulk rolled products.

A problem found in both center and surface winders involves the winder shutting down when a condition such as a core load fault or a web break fault occurs. If a core on a turret winder, for instance, is not properly loaded onto the mandrel, the machine must shut down for the fault to be corrected. Similarly, a web break fault in a surface winder will also result in shutting the machine down. This results in a production loss and the immediate requirement to obtain repair services. The present invention provides a way of eliminating such problems by allowing the machine to continue to produce rolled product even though a fault condition has occurred. Additionally, the invention incorporates the advantages of both center and surface winding to produce rolled products having various characteristics by using either center winding, surface winding, or a combination of center and surface winding.

In the prior art, a winder is typically known as an apparatus that performs the very first wind of that web, generally forming what is known as a parent roll. A rewinder, on the other hand, is an apparatus that winds the web from the parent roll onto a roll that is essentially the finished product. It is to be noted, the prior art is not consistent in designating what is and is not a winder or rewinder. For instance, rewinders are sometimes called winders, and winders are sometimes referred to as rewinders.

SUMMARY

Objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned from practice of the present invention.

As used herein, “winder” is generic to a machine for forming a parent roll, and a machine (rewinder) for forming a roll/log from a parent roll. In other words, the word “winder” is broad enough to cover both a “winder” and “rewinder”.

The present invention may include a web transport apparatus for conveying a web to a winder for winding the web to produce a rolled product. Also, a plurality of independent winding modules may be present. The winding modules are independently positioned to independently engage the web as it is conveyed by the web transport apparatus. The winding modules engage the web and wind the web to form a rolled product. The winding modules are configured to wind using center winding, surface winding, or a combination of center and surface winding. The winding modules are controlled and positioned independent of one another. Therefore, if one winding module is disabled another winding module may still operate to produce the rolled product without having to shut down the winder.

Also according to the present invention, a winder is disclosed as above where the plurality of independent winding modules may each have a core loading apparatus and a product stripping apparatus.

Also disclosed according to the present invention is a winder as set forth above where the plurality of independent winding modules each have a center driven mandrel onto which the web is wound to form the rolled product.

Also disclosed according to the present invention, is a method of producing a rolled product from a web. This method includes the step of conveying the web by a web transport apparatus. Another step in the method of the present invention may involve winding the web into the rolled product by using one or more winding modules. This may involve winding the web by one or more winding modules of the plurality of winding modules at any given time. The process that is used to wind the web may be center winding, surface winding, or a combination of both center and surface winding. The winding modules may act independently of one another to allow one or more winding modules to still wind the web to produce a rolled product without having to shut down the plurality of winding modules if any of the remaining winding modules fault or are disabled. The method according to the present invention also includes the step of transporting the rolled product from the winding module.

Another exemplary embodiment of the present invention may include a winder that is used for winding a web to produce a rolled product that has a web transport apparatus for conveying a web. This exemplary embodiment also has a plurality of independent winding modules mounted within a frame where each winding module has a positioning apparatus for moving the winding module into engagement with the web. Each winding module also has a mandrel that is rotated onto which the web is wound to form the rolled product. The winding modules are operationally independent of one another where if any of the winding modules are disabled, the remaining winding modules could continue to operate to produce the rolled product without having to shut down the winder. The rotational speed of the mandrel and the distance between the mandrel and the web transport apparatus may be controlled so as to produce a rolled product with desired characteristics. The winding modules are configured to wind the web by center winding, surface winding, and combinations of center and surface winding.

Another aspect of the present invention includes an exemplary embodiment of the winder as immediately discussed where each winding module may have a core loading apparatus for loading a core onto the mandrel. This exemplary embodiment also has a rolled product stripping apparatus for removing the rolled product from the winding module.

For example, in one embodiment, the core loading apparatus may comprise a core loading assembly slidably mounted on a mandrel. The core loading assembly may include a gripping device and a stabilizer. The gripping device can include at least two gripping members that are movable towards and away from each other. For instance, the gripping members may be pneumatically or hydraulically actuated. The stabilizer, on the other hand, can be slidably engaged on the mandrel for stabilizing the mandrel as the gripping device pulls a core onto the mandrel. The stabilizer, for instance, may have a configuration similar to the gripping device. The stabilizer may include at least two stabilizing members that are movable towards and away from each other and that surround the mandrel. Similar to the gripping device, the stabilizing members can be pneumatically or hydraulically actuated.

The core loading assembly can be attached to an actuator that is configured to move the core loading assembly back and forth across the mandrel. In this embodiment, in order to load a core onto the mandrel, the gripping members of the gripping device engage a core at the first end of the mandrel while the actuator moves the core loading assembly towards the second end of the mandrel thereby pulling a core onto the mandrel. The actuator, for instance, may comprise a linear track that is powered by a servo motor.

In one embodiment, the gripping members have a shape that surrounds a substantial portion of the core as it is pulled across the mandrel. For instance, the gripping members may define a rectangular-like cross-sectional shape that is configured to engage a core without harming the core.

In one embodiment, a controller, such as a microprocessor, may be placed in communication with the actuator and the core loading assembly. The controller can be configured to load a core onto the mandrel according to a predetermined sequence for positioning the core at a particular location.

Once the core is loaded on the mandrel, a web of material is wound onto the core to form a roll. In one embodiment, the core loading assembly can be used also to push a formed roll off the mandrel.

Another aspect of the present disclosure is directed to an apparatus for breaking a moving web while the web is being wound onto the mandrels. In particular, the apparatus for breaking the web is particularly well suited to breaking the web in order to form a new leading edge without having to stop or slow down the web.

In one embodiment, for instance, the apparatus can include a first rotating arm and a second rotating arm that are positioned adjacent to a conveying surface. The first rotating arm can be spaced upstream from the second rotating arm. The first rotating arm defines a first contact surface that contacts the conveying surface when the arm is rotated and the second rotating arm defines a second contact surface that also contacts the conveying surface when the arm is rotated.

In order to break a moving web on the conveying surface, both arms are rotated causing each of the contact surfaces to contact the moving web on the conveying surface simultaneously. The second rotating arm, however, is rotated at a faster speed than the first rotating arm during contact with the moving web causing the moving web to break in between the first and second contact surfaces.

In one embodiment, for instance, a perforation line can be formed into the moving web that is generally perpendicular to the direction of movement. The perforation line can be positioned in between the first and second contact surfaces of the rotating arms during the breaking process causing the web to break along the perforation line.

The conveying surface in one embodiment can comprise a rotating roll that rotates at generally the same speed as the web is moving. For instance, in one particular embodiment, the conveying surface may comprise a vacuum roll that not only rotates but holds the web onto the conveying surface.

During the breaking process, the first contact surface can be moving at generally about the same speed as the moving web during contact. The second contact surface, on the other hand, can be moving from about 2% to about 200% faster than the first contact surface. When the contacting surfaces are simultaneously contacting the moving web, the contacting surfaces can be spaced any suitable distance apart. For instance, in one embodiment, the contact surfaces may be from about 2 inches to about 12 inches apart, such as from about 4 inches to about 8 inches apart.

Yet another exemplary embodiment of the present invention includes a winder as substantially discussed above where each of the winding modules has a center winding means, a surface winding means, and a combination center and surface winding means.

DETAILED DESCRIPTION

Reference will now be made in detail to exemplary embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one exemplary embodiment can be used with another exemplary embodiment to yield still a third exemplary embodiment. It is intended that the present invention include these and other modifications and variations.

A winder is provided in the present invention that is capable of winding web directly from a parent roll to form a rolled product. The winder may comprise a winding module that has a rotating mandrel that engages the leading edge of a moving web. Upon transfer of the leading edge of the web to the core, the winding mandrel is disengaged from the transport apparatus removing any nip pressure for the remainder of the wind. The web may be wound about the core through the rotation of the center driven mandrel. This type of winding is known as center winding. Additionally, the mandrel may be placed onto the web to form and maintain nip pressure between the winding mandrel and the web. The web may be wound about the core through the rotation of the surface driven mandrel. This type of winding is a form of surface winding. As such, the winding module of the present invention may wind web into a rolled product by center winding, surface winding, and combinations of center and surface winding. This allows for the production of rolled products with varying degrees of softness and hardness.

Also, the present invention provides for a winder that has a plurality of independent winding modules. Each individual winding module may wind the web such that if one or more modules are disabled, the remaining modules may continue to wind without interruption. This allows for operator servicing and routine maintenance or repairs of a module to be made without shutting down the winder. This configuration has particular advantages in that waste is eliminated and efficiency and speed of the production of the rolled product is improved.

The present invention makes use of a winding module12as shown inFIG. 1in order to wind a web36and form a rolled product22. Although a plurality of independent winding modules12may be used in the present invention to produce rolled products22, the explanation of the functioning of only one winding module12is necessary in order to understand the building process of the rolled product22.

Referring toFIG. 5, a web36is transported by a web transport apparatus34as shown. The web36is cut to a predetermined length by use of, for instance, a cut-off module60may be configured as a pinch bar as is disclosed in U.S. Pat. No. 6,056,229. However, any other suitable way to cut the web36to a desired length may be employed. For example, another embodiment of a cut-off module60made in accordance with the present disclosure is shown inFIG. 15which will be described in more detail below. Additionally, the web36may be perforated by a perforation module64and have adhesive applied thereto by a transfer/tail seal adhesive applicator module62as also shown inFIG. 5. Additionally, in other exemplary embodiments, adhesion may be applied to the core24as opposed to the web36. Referring back toFIG. 10, the mandrel26is accelerated so that the speed of the mandrel26matches the speed of the web36. Mandrel26has a core24located thereon. The mandrel26is lowered into a ready to wind position and awaits the web36. The core24is moved into contact with the leading edge of the web36. The web36is then wound onto core24and is attached to core24by, for instance, the adhesive previously applied or and by the contact between the core24and the web36.

FIG. 11shows the web36being wound onto the core24. The winding of the web36onto core24may be controlled by the pressing of the core24onto the web transport apparatus34to form a nip. The magnitude with which the core24is pressed onto the web transport apparatus34creates a nip pressure that can control the winding of the web36onto the core24. Additionally, the incoming tension of the web36can be controlled in order to effect the winding of the web36onto the core24. Another control that is possible to wind the web36onto the core24involves the torque of the mandrel26. Varying the torque on the mandrel26will cause a variance in the winding of the web36onto the core24. All three of these types of winding controls, “nip, tension, and torque differential”, can be employed in the present invention. Also, the winding of the web36may be affected by using simply one or two of these controls. The present invention therefore allows for any combination of winding controls to be employed in order to wind the web36.

If not done before, the web36may be cut once the desired length of web36has been rolled onto the core24. At this point, the leading edge of the next web36will be moved by the web transport apparatus34into contact with another winding module12.

FIG. 12shows the mandrel26being moved from a location immediately adjacent to the web transport apparatus34inFIG. 10to a position slightly above the web transport apparatus34. The wound length of web36is shown inFIG. 12as being a rolled product38with a core24. Now, a stripping function is carried out that moves the rolled product38with a core24off of the mandrel26. This mechanism is shown as a product stripping apparatus28inFIG. 2. The rolled product38with a core24is moved onto a rolled product transport apparatus20as shown inFIGS. 1 and 2.

Once the rolled product38with a core24is stripped from the mandrel26, the mandrel26is moved into a core loading position as shown inFIG. 13. The product stripping apparatus28is shown in more detail inFIG. 2. Once the product stripping apparatus28finishes stripping the rolled product38with a core24, the product stripping apparatus28is located at the end of the mandrel26. This location acts to stabilize the mandrel26and prevent it from moving due to the cantilevered configuration of mandrel26. In addition, the product stripping apparatus28helps to properly locate the end point of mandrel26for the loading of a core24.

FIG. 14shows one embodiment of a core24being loaded onto the mandrel26. The loading of the core24is affected by a core loading apparatus32. The product stripping apparatus may also serve as a core loading apparatus. The core loading apparatus32may be simply a frictional engagement between the core loading apparatus32and the core24. However, the core loading apparatus32can be configured in other ways known in the art. For example, another embodiment of a core loading apparatus made in accordance with the present disclosure is shown inFIGS. 16-24which will be described in more detail below. In one embodiment of the present invention, once the core24is loaded, a cupping arm70(shown inFIG. 6) closes. Upon loading of the core24onto the mandrel26, the mandrel26is moved into the ready to wind position as shown inFIG. 10. The cores24are located in a core supplying apparatus18as shown inFIGS. 1,2,3, and4.

FIG. 1shows an exemplary embodiment of a winder according to the invention as a “rewinder”10with a plurality of independent winding modules12arranged in a linear fashion with respect to one another. A frame14supports the plurality of independent winding modules12. A web transport apparatus34is present which transports the web36for eventual contact with the plurality of independent winding modules12. The frame14is composed of a plurality of posts16onto which the plurality of independent winding modules12are slidably engaged and supported. The frame14may also be comprised of modular frame sections that would engage each other to form a rigid structure. The number of modular frame sections would coincide with number of winding modules utilized.

Situated adjacent to the frame14are a series of core supplying apparatuses18. A plurality of cores24may be included within each core supplying apparatus18. These cores24may be used by the plurality of independent winding modules12to form rolled products22. Once formed, the rolled products22may be removed from the plurality of independent winding modules12and placed onto a rolled product transport apparatus20. The rolled product transport apparatus20is located proximate to the frame14and web transport apparatus34.

FIG. 2shows a rewinder10as substantially disclosed inFIG. 1but having the frame14and other parts removed for clarity. In this exemplary embodiment, the plurality of independent winding modules12are composed of six winding modules1-6. However, it is to be understood that the present invention includes exemplary embodiments having any number of independent winding modules12being other than six in number, for instance only one winding module12may be used in another exemplary embodiment.

Each winding module1-6is shown performing a different function. Winding module1is shown in the process of loading a core24thereon. The plurality of independent winding modules12are provided with a core loading apparatus for placing a core24onto a mandrel26of the plurality of independent winding modules12. Any number of variations of a core loading apparatus may be utilized in other exemplary embodiments of the present invention. For instance, the core loading apparatus may be a combination of a rod that extends into the core supplying apparatus18and pushes a core24partially onto the mandrel26and a mechanism attached to the linear actuator of the product stripping apparatus28that frictionally engages and pulls the core24the remaining distance onto the mandrel26. As shown inFIG. 2, winding module1is in the process of pulling a core24from the core supplying apparatus18and placing the core24on mandrel26.

Referring toFIGS. 16-24, one embodiment of a core loading apparatus that may be used in accordance with the present disclosure is shown. In particular,FIGS. 16-23illustrate a sequence of loading a core24onto a mandrel26in order to form a rolled product22which is then stripped off the mandrel26.

As shown inFIG. 16, the core loading apparatus includes a core loading assembly200that slides back and forth across the mandrel26. The core loading assembly200includes a gripping device202for engaging the core24and optionally a stabilizer204. The core loading assembly200is attached to an actuator208, such as a linear actuator as shown. In particular, the core loading assembly200is mounted to the linear actuator which is positioned parallel to the mandrel26. The actuator208includes a motor210that drives a track212. The track212is attached to the core loading assembly200such that the core loading assembly traverses back and forth across the mandrel26as the motor206drives the track212. The track212may comprise, for instance, a belt as shown or can be a chain or any other suitable device.

In addition to the linear actuator208as shown inFIG. 16, it should be understood that any suitable actuator may be used that is capable of moving the core loading assembly200along the mandrel26. For example, in other embodiments, a pneumatic or hydraulic actuator may be used. Alternatively, a ball screw or the like may be used as the actuator.

The mandrel26as shown is supported on one end by a bearing214. On the opposite end, the mandrel26is engagable with a cupping arm70. The cupping arm70is in communication with a motor206. The motor206causes the cupping arm to rotate thereby engaging and disengaging the end of the mandrel26. For example, inFIG. 20, the cupping arm70is shown in the engaged position for supporting the end of the mandrel26. The cupping arm70is used to engage and support the end of the mandrel26during winding. When loading the core24or when stripping a rolled product from the mandrel26, on the other hand, the cupping arm70disengages the mandrel26. When the cupping arm70is disengaged from the mandrel26, the stabilizer204of the core loading assembly engages the mandrel for supporting the mandrel while a core is being loaded.

As illustrated inFIG. 16, the gripping device202and the stabilizer204are contained within a housing216to form the core loading assembly200. An enlarged view of the gripping device202and the stabilizer204with the housing removed is shown inFIG. 18. A cross-sectional view of the gripping device202is also illustrated inFIG. 24. As shown inFIG. 24, the gripping device202includes gripping members218that are intended to surround and grip the core24. In the embodiment illustrated inFIG. 24, four gripping members218are shown. It should be understood, however, that a greater or lesser number of gripping members may be utilized. The gripping members are movable towards and away from each other for gripping and releasing the core24.

For example, in one embodiment, the gripping members218can be pneumatically or hydraulically actuated. In this regard, as shown inFIG. 18, the gripping device202includes a fluid inlet220and a fluid outlet222. The fluid inlet220and the fluid outlet222are for flowing a fluid into and out of the gripping device202for respectively moving the gripping members218towards and away from each other.

In the embodiment illustrated inFIG. 24, the gripping members218generally form a rectangular-like cross-sectional shape for engaging the core24. It should be understood, however, that any suitable cross-sectional shape capable of surrounding the core24for engaging the core can be utilized. For example, in an alternative embodiment, the gripping device202may only include two gripping members that have an arc-like shape.

The gripping members218of the gripping device202are intended to engage and hold the core24for pulling the core onto the mandrel26without damaging the core. For example, having the gripping members218be fluid controlled allows for fine adjustments in the amount of pressure being placed on the core24. In addition, the gripping members218can pivot which allows for the gripping members to accommodate for some misalignment.

For instance, as shown inFIG. 24, the gripping device202includes a first pivot member223defining a first pivot point224and a second pivot member225defining a second pivot point226. In addition, the gripping device202includes four springs228. More particularly, the pivot point224is surrounded by an upper and lower spring228, while the pivot point226is also surrounded by an upper and lower spring228. The pivot points and the springs allow the pivot members223and225and thus the gripping members218some flexibility in movement. More particularly, the right pair of gripping members218can pivot about the pivot point224while the left pair of gripping members218can pivot about the pivot point226. In this manner, when the core24is engaged by the gripping members, not only can the gripping members move back and forth but can also pivot for pulling the core onto the mandrel without misalignment and without damaging the core.

The gripping members218can be made from any suitable material capable of engaging the core24without damaging the core. The gripping members218, for instance, can be made for any suitable hard or soft material. In one particular embodiment, for instance, the gripping members218can be made from a metal.

As shown inFIG. 18, the core loading assembly200also includes the stabilizer204. The stabilizer204can be included in the assembly in order to stabilize the mandrel as the core is being loaded onto the mandrel. In one embodiment, as shown inFIG. 18, the stabilizer204can generally have the same construction as the gripping device202. For instance, the stabilizer204can include at least two stabilizing members that slidably engage the mandrel26and move towards and away from each other by flowing a fluid through a fluid inlet230and a fluid outlet232. In one embodiment, the stabilizer204can include four stabilizing members having the same exact configuration as the gripping members218. The stabilizing members, however, are for slidably engaging the mandrel26. In this regard, the stabilizing members can have a low friction surface made from a lubricating material, such as a polyolefin. The stabilizing members, for instance, can include a polyethylene or a polypropylene surface that slides among the mandrel26as the core24is loaded.

The core loading assembly200and the actuator208can be placed in communication with a controller, such as a microprocessor that is capable of actuating a sequence for loading a core onto the mandrel at a desired position and then stripping a rolled product from the mandrel. One sequence for loading a core onto the mandrel is illustrated inFIGS. 16-23.

For instance, as shown inFIG. 16, in order to load the core24onto the mandrel26, the cupping arm70is first disengaged from the mandrel26and the core loading assembly200is positioned at the open end of the mandrel26. In this manner, not only is the core loading assembly200at a position for engaging the core24but also stabilizes the mandrel26when the cupping arm70is disengaged.

As shown inFIGS. 17 and 18, the gripping device202surrounds an outer circumference of the core24for engaging the core. The core can be supplied to the gripping device from a core supplying apparatus.

Once the core is engaged, the core24is pulled onto the mandrel26as shown inFIG. 19using the actuator208. The actuator208can be configured to place the core24at a particular position on the mandrel26. Once the core24is positioned into a particular position, the gripping device202can release the core as shown inFIG. 20. The core loading assembly200is then moved further to the end of the mandrel to prevent interference with the core24as a web of material is wound onto the core. Also, as shown inFIG. 20, the cupping arm70is moved back into engagement with the mandrel26.

Once the core24is loaded onto the mandrel26as shown inFIG. 20, a rolled product22is formed on the mandrel as shown inFIG. 21. Of particular advantage, in this embodiment, the core loading assembly200can also be used to strip the rolled product22from the mandrel26. For instance, as shown inFIG. 22, once the rolled product22is formed, the actuator208can move the core loading assembly200into engagement with the rolled product for sliding the rolled product off the mandrel26as shown inFIG. 23. The rolled product22once stripped from the mandrel26can then be fed to a rolled product transfer apparatus. Of particular advantage, the core loading assembly200stabilizes the mandrel as it pushes the rolled product off of the mandrel. In particular, the core loading assembly200holds the open free end of the mandrel which reduces the whip of the mandrel and therefore prevents against misalignments. Further, once the rolled product is stripped from the mandrel, the core loading assembly200is in a position for engaging and pulling a new core onto the mandrel.

The core loading apparatus described above can provide various benefits and advantages when forming the rolled products. For example, the core loading apparatus as described above is capable of pulling the cores onto the mandrel into a fixed position. In addition, the mandrel is stabilized and held in position during the loading process. By minimizing positional changes of the core and of the mandrel, the likelihood of successful core loading is vastly improved, which maximizes productivity and minimizes waste with respect to core loading operations. Furthermore, the core loading apparatus as described above is conducive to various conditions of core material and rigidity. For example, limp or flaccid cores can be pulled onto mandrels instead of rigid paper material if desired. In addition, the core loading apparatus also serves as a log strip device after the rolled product is formed. This dual function is advantageous because it simplifies design and minimizes hardware.

Referring back toFIG. 2, winding module2is shown as having removed the rolled product22from its mandrel26. The rolled product22is placed onto a rolled product transport apparatus20. In this case, the rolled product22is a rolled product with a core38. Such a rolled product with a core38is a rolled product22that is formed by having the web36being spirally wrapped around a core24. It is to be understood that the rolled product22may also be a rolled product that does not have a core24and instead is simply a solid roll of wound web36. It may also be the case that the rolled product22formed by the present invention does not include a core24, but has a cavity in the center of the rolled product22. Various configurations of rolled product22may thus be formed in accordance with the present invention.

Each of the plurality of independent winding modules12is provided with a product stripping apparatus28that is used to remove the rolled product22from the winding modules1-6. Winding module3is shown as being in the process of stripping a rolled product22from the winding module3. The product stripping apparatus28is shown as being a flange which stabilizes the mandrel26and contacts an end of the rolled product22and pushes the rolled product22off of the mandrel26. Also, the product stripping apparatus28helps locate the end of the mandrel26in the proper position for the loading of a core24. The rolled product stripping apparatus28therefore is a mechanical apparatus that moves in the direction of the rolled product transport apparatus20. The product stripping apparatus28may be configured differently in other exemplary embodiments of the invention.

The winding module4is shown as being in the process of winding the web36in order to form the rolled product22. This winding process may be center winding, surface winding, or a combination of center and surface winding. These processes will be explained in greater detail below.

Winding module5is shown in a position where it is ready to wind the web36once the winding module4finishes winding the web36to produce a rolled product22. In other words, winding module5is in a “ready to wind” position.

Winding module6is shown inFIG. 1in a “racked out” position. It may be the case that winding module6has either faulted or is in need of routine maintenance and is therefore moved substantially out of frame14for access by maintenance or operations personnel. As such, winding module6is not in a position to wind the web36to produce rolled product22, but the other five winding modules1-5are still able to function without interruption to produce the rolled product22. By acting as individual winders, the plurality of independent winding modules12allow for uninterrupted production even when one or more of the winding modules becomes disabled.

Each winding module12may have a positioning apparatus56(FIG. 4). The positioning apparatus56moves the winding module perpendicularly with respect to web transport apparatus34, and in and out of engagement with web36. Although the modules12are shown as being moved in a substantially vertical direction, other exemplary embodiments of the invention may have the modules12moved horizontally or even rotated into position with respect to web36. Other ways of positioning the modules12can be envisioned.

Therefore, each of the plurality of independent winding modules12may be a self-contained unit and may perform the functions as described with respect to the winding modules1-6. Winding module1may load a core24onto the mandrel26if a core24is desired for the particular rolled product22being produced. Next, the winding module1may be linearly positioned so as to be in a “ready to wind” position. Further, the mandrel26may be rotated to a desired rotational speed and then positioned by the positioning apparatus56in order to initiate contact with the web36. The rotational speed of the mandrel26and the position of the winding module1with respect to the web36may be controlled during the building of the rolled product22. After completion of the wind, the position of the module1with respect to the web36will be varied so that the winding module1is in a position to effect removal of the rolled product22. The rolled product22may be removed by the product stripping apparatus28such that the rolled product22is placed on the rolled product transport apparatus20. Finally, the winding module1may be positioned such that it is capable of loading a core24onto the mandrel26if so desired. Again, if a coreless rolled product were to be produced as the rolled product22, the step of loading a core24would be skipped. It is to be understood that other exemplary embodiments of the present invention may have the core24loading operation and the core24stripping operation occur in the same or different positions with regard to the mandrel26.

The rewinder10of the present invention may form rolled products22that have varying characteristics by changing the type of winding process being utilized. The driven mandrel26allows for center winding of the web36in order to produce a low density, softer rolled product22. The positioning apparatus56in combination with the web transport apparatus34allow for surface winding of the web36and the production of a high density, harder wound rolled product22. Surface winding is induced by the contact between the core24and the web36to form a nip68(shown inFIG. 6) between the core24and the web transport apparatus34. Once started, the nip68will be formed between the rolled product22as it is built and the web transport apparatus34. As can be seen, the rewinder10of the present invention therefore allows for both center winding and surface winding in order to produce rolled products22. In addition, a combination of center winding and surface winding may be utilized in order to produce a rolled product22having varying characteristics. For instance, winding of the web36may be affected in part by rotation of the mandrel26(center winding) and in part by nip pressure applied by the positioning apparatus56onto the web36(surface winding). Therefore, the rewinder10may include an exemplary embodiment that allows for center winding, surface winding, and any combination in between. Additionally, as an option to using a motor to control the mandrel speed/torque a braking device (not shown) on the winding modules12may be present in order to further control the surface and center winding procedures.

The plurality of independent winding modules12may be adjusted in order to accommodate for the building of the rolled product22. For instance, if surface winding were desired, the pressure between the rolled product22as it is being built and the web transport apparatus34may be adjusted by the use of the positioning apparatus56during the building of the rolled product22.

Utilizing a plurality of independent winding modules12allows for a rewinder10that is capable of simultaneously producing rolled product22having varying attributes. For instance, the rolled products22that are produced may be made such that they have different sheet counts. Also, the rewinder10can be run at both high and low cycle rates with the modules12being set up in the most efficient manner for the rolled product22being built. The winding modules12of the present invention may have winding controls specific to each module12, with a common machine control. Real time changes may be made where different types of rolled products22are produced without having to significantly modify or stop the rewinder10. Real time roll attributes can be measured and controlled. The present invention includes exemplary embodiments that are not limited to the cycle rate. The present invention is also capable of producing a wide spectrum of rolled products22, and is not limited towards a specific width of the web36. Also, the plurality of independent winding modules12can be designed in such a way that maintenance may be performed on any one or more of the winding modules1-6without having to interrupt operation, as previously discussed with winding module6. A winding module12may be removed and worked on while the rest keep running. Further, having a plurality of independent winding modules12allows for an increase in the time intervals available for the core24loading functions and the rolled product22stripping functions. Allowing for an increase in these time intervals greatly reduces the occurrence of loading and stripping errors. Also, prior art apparatuses experiencing interruption of the winding operation will produce a rolled product22that is not complete. This waste along with the waste created by the changing of a parent roll or product format change will be reduced as a result of the rewinder10in accordance with the present invention. Waste may be removed from the rewinder10by use of a waste removal apparatus200(FIG. 5) as is known in the art.

FIG. 3shows a rewinder10having a frame14disposed about a plurality of independent winding modules12. The frame14has a plurality of cross members42transversing the ends of the frame14. The positioning apparatus56that communicates with the winding modules1-6is engaged on one end to the cross members42, as shown inFIG. 4. A vertical linear support member44is present on the plurality of independent winding modules12in order to provide an attachment mechanism for the positioning apparatus56and to provide for stability of the winding modules. The positioning apparatus56may be a driven roller screw actuator. However, other means of positioning the plurality of independent winding modules12may be utilized. The vertical support members44also may engage a vertical linear slide support58that is attached to posts16on frame14. Such a connection may be of various configurations, for instance a linear bearing or a sliding rail connection. Such a connection is shown as a vertical linear slide52that rides within the vertical linear slide support58inFIG. 4.

A horizontal linear support member46is also present in the plurality of independent winding modules12. The horizontal linear support member46may communicate with a horizontal linear slide54(as shown inFIG. 6) to allow some or all of the plurality of independent winding modules12to be moved outside of the frame14. The horizontal linear slide54may be a linear rail type connection. However, various configurations are envisioned under the present invention.

FIG. 6shows a close up view of an exemplary embodiment of a winding module in accordance with the present invention. The servomotor50can be supported by the module frame48onto which a mandrel cupping arm70is configured. The mandrel cupping arm70is used to engage and support the end of the mandrel26opposite the drive during winding. As can be seen, the positioning apparatus56may move the winding module for engagement onto the web36as the web36is transported by the web transport apparatus34. Doing so will produce a nip68at the point of contact between the mandrel26and the transport apparatus34, with the web36thereafter being wound onto the mandrel26to produce a rolled product22.

FIG. 7shows another exemplary embodiment of a winder module in accordance with the present invention. The exemplary embodiment inFIG. 7is substantially similar to the exemplary embodiment shown inFIG. 6with the exception of having the winding process being a pure surface procedure. A drum roll72is located at approximately the same location as the mandrel26ofFIG. 6. In addition, the exemplary embodiment shown inFIG. 7also has another drum roll74along with a vacuum roll76. In operation, the web36is conveyed by the web transport apparatus34in the direction of arrow A. The web transport apparatus34may be a vacuum conveyor or a vacuum roll. However, it is to be understood that a variety of web transport apparatus34may be utilized, and the present invention is not limited to one specific type. Another exemplary embodiment of the present invention employs a web transport apparatus34that is an electrostatic belt that uses an electrostatic charge to keep the web36on the belt. The vacuum roll76draws the web36from the web transport apparatus34and pulls it against the vacuum roll76. The web36is then rotated around the vacuum roll76until it reaches a location approximately equal distance from the drum roll72, drum roll74, and vacuum roll76. At such time, the web36is no longer pulled by the vacuum in the vacuum roll76and is thus able to be rolled into a rolled product22by way of surface winding by the drum roll72, drum roll74, and vacuum roll76. The rolled product22that is formed in the exemplary embodiment shown inFIG. 7is a coreless rolled product without a cavity78. The winding module may also be modified such that more than or fewer than three rolls are used to achieve the surface winding process. Further, the production of the rolled product22having a core24or a coreless cavity in the rolled product22can be achieved in other exemplary embodiments using a similar configuration as shown inFIG. 7.

The plurality of winding modules12may also be modified such that additional improvements are realized. For instance, a tail sealing apparatus30may be included on the plurality of independent winding modules12. As shown inFIG. 2, the tail sealing apparatus30is located on the underside of the plate48. The tail sealing apparatus30may be a series of holes from which an adhesive is sprayed onto the rolled product22as the final lengths of the web36are rolled onto the rolled product22. The adhesive causes the tailing end of the web36to be adhered to the rolled product22. It is therefore possible to seal the tail of the rolled product22before being unloaded to the rolled product transport apparatus20. Of course, it may also be possible to provide adhesive to the web36at a point other than at the plurality of independent winding modules12. As stated, for example, adhesive may be applied by the tail sealing module62as shown inFIG. 5. Also, it may also be the case that sealing of the tail of the web36onto the rolled product22may be done offline, beyond the winder.

In order to get the web36onto the mandrel26, the mandrel26as shown inFIG. 6, may be a vacuum supplied mandrel. Such a vacuum mandrel26will pull the web36onto the mandrel26by means of a vacuum supplied through all or parts of the vacuum mandrel26. Other ways of assisting the transfer of the web36onto the mandrel26are also possible. For instance, an air blast may be provided under the surface of the web transport apparatus34or a caming apparatus may be placed under the web transport apparatus34to propel the web36into contact with the mandrel26. Further, the positioning apparatus56may be used to push the winding module down onto the web36to effect the winding. Again, the rewinder10of the present invention is thus capable of producing a rolled product22which has a core, which is solid without a core or cavity therethrough, or which does not have a core but does have a cavity therethrough. Such a rolled product22that is produced without a core24, yet having a cavity therethrough could be produced by using a vacuum supplied mandrel26.

FIG. 5shows an exemplary embodiment of a rewinder10that makes use of several modules upstream from the plurality of independent winding modules12. For instance, a cut-off module60is utilized that severs the web36once a desired amount of web36is transported for the production of a rolled product22. This severing creates a new leading edge for the next available winding module1-6to engage. However, it is to be understood that a cut-off module60may be utilized at locations immediately adjacent to or at the nip68of the plurality of independent winding modules12. Also,FIG. 5shows an adhesive application module62on the web transport apparatus34. This adhesive application module62may be an apparatus for applying adhesive or an adhesive tape onto the web36in such a fashion that the adhesive would be applied to the tail end of the rolled product22sheet. The adhesive application module62may apply adhesive to the web36so that both the rolled product22will be sealed upon completion and the leading edge of the web36will have a source of adhesion to transfer to the core of the next successive module. A perforation module64is also provided in order to perforate the web36such that individual sheets may be more easily removed therefrom.

One particular embodiment of a cut-off module60that is particularly well suited to breaking the web36while moving is shown inFIG. 15. In particular, the cut-off module60as illustrated inFIG. 15can form a break in the web36without having to stop or decelerate the web during the winding process.

As shown, the cut-off module60includes a rotating roll300, such as a vacuum roll that rotates with the web36and defines a conveying surface302. In this embodiment, the vacuum roll300is placed adjacent to a guide roll304which can receive the web36from a parent roll or directly from a papermaking process. Not shown is a perforation module64. The web36, however, can be perforated as it is unwound or can be pre-perforated.

As shown inFIG. 15, the cut-off module60includes a first rotating arm306spaced upstream from a second rotating arm308. The first rotating arm306defines a first contact surface310while the second rotating arm308defines a second contact surface312. As shown, the contact surfaces310and312simultaneously contact the moving web36while on the conveying surface302when the arms are rotated. In order to rotate the arms306and308, the arms can be mounted onto a bearing and driven by any suitable driving device, such as a motor.

In the embodiment illustrated inFIG. 15, the rotating arms306and308are shown in an engagement position for breaking the moving web36and forming a new leading edge. When the web36is being fed into the process, the arms306and308can be rotated so as to not interfere with the unwinding of the web from the parent roll304. In particular, the arms306and308in one embodiment may have a rest position just out of engagement clockwise with the moving web.

When it is desirable to form a break in the web, however, each of the arms306and308can be rotationally accelerated so that both contact surfaces310and312contact the moving web on the conveying surface302simultaneously. In order for the web to break, however, the second rotating arm308is rotated slightly faster than the first rotating arm306. In this manner, the first rotating arm306serves to hold the web against the conveying surface while the second arm308pulls and breaks the web. In one embodiment, the arms are spaced a distance and the process is timed so that both contact surfaces310and312contact the web36when there is a perforation line located in between the two contact surfaces. In this manner, the break occurs along the perforation line.

More particularly, in order to form a break in the web, the first arm306is accelerated to a speed such that the contact surface310contacts the web36at a speed that is either slower or at substantially the same speed at which the web is moving.

As described above, the second arm308is rotated at a speed such that the contact surface312contacts the moving web at a speed greater than at which the first contact surface310is moving. For instance, in one embodiment, the second contact surface312can be moving at a speed that is from about 2% to about 200% faster than the speed at which the first contact surface310is moving. For example, in one particular embodiment, the second contact surface312can be moving at a speed that is from about 5% to about 30% faster than the speed at which the first contact surface310is moving when contact with the web occurs.

The contact surface312of the second arm308, for instance, can be traveling at a speed that is substantially the same speed at which the web is moving when the speed of the first contact surface310is slower than the speed of the web. Alternatively, the second contact surface312may be moving at a speed faster than that at which the web is moving.

When the contact surfaces310and312contact the moving web, in one embodiment, the first contact surface310contacts the web prior to the second contact surface312. Both contact surfaces310and312, however, are generally both in contact with the web as the web is being broken. During the breaking process, the first contact surface310holds the web for a brief moment of time while the second contact surface312pulls on the web with sufficient force for the break to occur.

The spacing between the first arm306and the second arm308during contact with the web can vary greatly depending upon the particular type of web material being conveyed and various other factors. For instance, in one embodiment, the contact surfaces310and312can be spaced from about 1 inch to about 20 inches apart. When processing bath tissue, the contact surfaces, for instance, can be spaced from about 2 inches to about 12 inches apart, such as from about 4 inches to about 8 inches apart, during contact with the web. The spacing, for instance, can be set so that the arms do not interfere with each other and allows for accuracy in placing a perforation line in between the two contact surfaces.

The contact surfaces310and312can be made from the same material or from different materials. In one embodiment, for instance, the second contact surface312can have a higher coefficient of friction than the first contact surface310. For instance, the second contact surface312can be made from a rubber-like material that better grips the web during the breaking process. The first contact surface310, on the other hand, can be a low friction material that prevents interference with the moving web. For instance, in one embodiment, the first contact material310can be made from a textile material, such as a loop material.

The cut-off module60as shown inFIG. 15can provide various advantages and benefits. For instance, by using two contact surfaces310and312, the web36can be efficiently and effectively broken and severed over a wide range of web properties and processing conditions. In addition, the two rotating arms as described above place tension only on a short length of the web36during the break. In particular, the web is only under tension in between the two contact points of the arms which prevents the moving web from wrinkling, folding or otherwise falling out of misalignment. The cut-off module also provides web control upstream and downstream from the cut-off edge, which minimizes slack in the web in the winding roll that is being finished as well as in the leading portion of the new web for the new roll to be wound. The apparatus also prevents the web from sliding upstream and enables a robust break at high or low speed and at high or low web tension.

Also shown inFIG. 5is a waste removal apparatus200for removing extra web36that results from faults such, as web breaks, and machine start ups. This waste is moved to the end of the web transfer apparatus34and then removed. The use of a plurality of individual modules12reduces the amount of waste because once a fault is detected, the affected module12is shut down before the rolled product is completely wound. The web is severed on the fly and a new leading edge is transferred to the next available module. Any waste is moved to the end of the web transfer apparatus34and then removed.

It is believed that using a web transport apparatus34that has a vacuum conveyor or a vacuum roll will aid in damping the mandrel26vibrations that occur during transfer of the web36onto the mandrel and also during the winding of the mandrel26to form a rolled product22. Doing so will allow for higher machine speeds and hence improve the output of the rewinder10.

Each of the winder modules1-6of the plurality of independent winding modules12do not rely on the successful operation of any of the other modules1-6. This allows the rewinder10to operate whenever commonly occurring problems during the winding process arise. Such problems could include for instance web breaks, ballooned rolls, missed transfers, and core loading errors. The rewinder10therefore will not have to shut down whenever one or more of these problems occurs because the winding modules1-6can be programmed to sense a problem and work around the particular problem without shutting down. For instance, if a web break problem occurred, the rewinder10may perform a web cut by a cut-off module60and then initiate a new transfer sequence in order to start a new winding about the next available winding module1-6. Any portion of the web36that was not wound would travel to the end of the web transport apparatus34where a waste removal apparatus200could be used to remove and transport the waste to a location remote from the rewinder10. The waste removal apparatus200could be for instance an air conveying system. The winding module1-6whose winding cycle was interrupted due to the web break could then be positioned accordingly and initiate removal of the improperly formed rolled product22. Subsequently, the winding module1-6could resume normal operation. During this entire time, the rewinder10would not have to shut down.

Another exemplary embodiment of the present invention involves the use of a slit web. Here, the web36is cut one or more times in the machine direction and each slit section is routed to a plurality of winding modules12. It is therefore possible to wind the web36by two or more modules12at the same time.

Exemplary embodiments of the present invention can allow for the winding process to be performed at the back end of a tissue machine. In this way, the tissue web36could be directly converted to product sized rolls22which in turn would bypass the need to first wind a parent roll during the manufacturing and subsequent rewinding process. Still another exemplary embodiment of the present invention makes use of only a single winding module12, instead of a plurality of winding modules12.

The exemplary embodiment of the rewinder shown inFIG. 5is one possible configuration for the movement of the plurality of independent winding modules12. A positioning apparatus member66is present and is attached to the frame14. The positioning apparatus member66extends down to a location proximate to the winding location of the web36. The plurality of independent winding modules12are slidably engaged with the positioning apparatus member66so that the center, surface, or center/surface winding procedure can be accomplished. It is to be understood that alternative ways of mounting and sliding the plurality of independent winding modules12in a vertical direction can be accomplished by those skilled in the art. The plurality of independent winding modules12ofFIG. 5are arranged in a substantially linear direction. In addition, the web transport apparatus34is also linear in orientation at the location proximate to the plurality of independent winding modules12. The embodiments depicted are of an orientation of the web transport device in a substantially horizontal plane. However, it should be realized that any orientation other than horizontal could be utilized. Furthermore, the embodiments depicted utilize modules that only engage one side of the web transport apparatus. It should be understood that a winder could be configured where the winding modules engage more than one side of the web transport apparatus.

FIG. 8shows an alternative configuration of both the web transport apparatus34and the plurality of independent winding modules12. The exemplary embodiment shown inFIG. 8is a plurality of winding modules12that are radially disposed with respect to one another, and a web transport apparatus34that is cylindrical in shape. The web transport apparatus34in this case can be, for instance, a vacuum roll. Each of the winding modules1-6are arranged about the web transport apparatus34such that the winding modules1-6are moved towards and away from the web transport apparatus34by the positioning apparatus56.

The operation of the exemplary embodiment shown inFIG. 8is substantially similar to that as previously discussed. Winding module1is shown in the process of loading a core24. The mandrel26of winding module1has a distance from the center of the web transport apparatus34designated as a core loading position100. Winding module3is shown in the process of stripping a rolled product22. The center of the mandrel26of winding module3is located at a stripping position102from the center of the web transport apparatus34. Winding module4is shown in the process of engaging the web36and winding the web36onto the core24, that is loaded on the driven mandrel26, to form a rolled product22. A nip68is formed between the core24, that is loaded on mandrel26, and the web transport apparatus34. The nip68is located at a winding position104at a distance from the center of the web transport apparatus34.

Winding modules2and6are located at the core loading position100. However, these modules may be positioned such that maintenance can be performed on them, or be in the “ready to wind” position. Module5is at the stripping position102. However, module5may also be in the process of just completing the stripping of a rolled product22.

FIG. 9discloses an exemplary embodiment of a winding module that is used in the configuration disclosed inFIG. 8. The winding module ofFIG. 9is substantially the same as the winding module shown inFIG. 6, although configured for a circular array configuration as opposed to a linear array configuration.

It should be understood that the invention includes various modifications that can be made to the exemplary embodiments of the center/surface rewinder/winder described herein as come within the scope of the appended claims and their equivalents. Further, it is to be understood that the term “winder” as used in the claims is broad enough to cover both a winder and a rewinder.