Abstract:
Systems, apparatuses and methods for cutting and spooling paper are described. In one embodiment, a system for cutting a traveling web of paper that is being wound onto a first spool and transferring the paper web onto a second spool by feeding turn-up tape into a nip between the second spool and the paper web, comprises a transfer track for transporting the turn-up tape beneath the paper web and to a position adjacent to the nip, and a drive assembly capable of driving the turn-up tape along the transfer track toward the nip, wherein the drive is capable of being powered by manual power or motor power.

Description:
RELATED APPLICATION 
   This application claims priority to U.S. Provisional Patent Application Ser. No. 60/441,951 filed Jan. 23, 2003, which is hereby incorporated in its entirety by this reference. 

   FIELD OF THE INVENTION 
   The field of this invention is systems related to paper producing and methods of operating the same. More specifically, this invention relates to systems, apparatuses and methods for cutting and spooling a traveling web of paper. 
   BACKGROUND OF THE INVENTION 
   Paper is typically produced in wide, continuous sheets or webs. As the web is produced, it is wound onto a spool. As each spool is filled it is necessary to transfer the web to an empty spool. However, because of the manner in which paper producing machines operate, it is difficult and expensive to shut down the machine while the web is cut and transferred to a new spool. Thus, methods for transferring the paper web from a full to an empty spool without interrupting the paper producing machines have been developed. For example, U.S. Pat. No. 4,414,258 to Corbin (“Corbin”), entitled “Turn-up Tape,” discloses the manual application of a paper ribbon or “turn-up tape” to a spinning empty spool that is positioned above the moving web of paper. The trailing end of the turn-up tape is positioned underneath the web. As the turn-up tape is wound onto the spinning empty spool, it cuts across the moving web, thereby tearing the web and simultaneously holding the cut end of the web against the empty spool. In this manner, the web is transferred to the empty spool with no interruption or interference with the continuous production of the paper web. 
   Manual application of turn-up tape to empty spools presents certain disadvantages. For instance, the operator responsible for applying the turn-up tape is exposed to dangerous, high-speed equipment. Moreover, manual application is prone to errors in positioning and timing. Thus, machines for applying the turn-up tape to the empty spools have been developed. For example, U.S. Pat. No. 4,659,029 to Rodriguez, entitled “Apparatus and Method for Cutting and Spooling a Web of Paper,” discloses a turn-up tape machine having a hand driven tape drive, a tape-cutting mechanism, an open guideway and a brake. The turn-up tape is propelled into and along the guideway by the tape drive manually powered by a hand crank. It is also known to propel the turn-up tape through the guideway via a motor powered tape drive. The guideway travels under the paper web and curves up and around so that the exit of the guideway is positioned adjacent to the “nip” or the point where the paper web is tangent to the empty spool. The turn-up tape is forced through the guideway and into the nip. When the turn-up tape is pushed into the nip, it sticks to the spool, is pulled out of the guideway and tears the paper web as described above. An example of such a motor-powered system is described in U.S. Pat. No. 6,416,012 entitled “Apparatuses and Methods for Cutting and Spooling Paper.” Various methods are known for introducing the end of the turn-up tape into the nip. 
   Many current systems for cutting and spooling paper are highly automated and utilize a computer to control much of the operation. However, these systems do not provide for a manual back-up if there is an electrical system failure or other failure that results in the non-functioning of the automatic operation of the system. As a result, operators may have to resort to dangerous and primitive techniques to transfer a paper web to a new spool. 
   SUMMARY 
   Systems, apparatuses and methods are described for cutting a traveling web of paper that is being spooled on a first spool and transferring the paper web to spool on a second spool by driving turn-up tape into a nip between the second spool and the paper web. The systems, apparatuses and methods provide for a switch between automatic operation and manual operation and provide a drive assembly that allows for a switch between motor power and manual power. In one embodiment, a system for cutting a traveling web of paper that is being wound onto a first spool and transferring the paper web onto a second spool by feeding turn-up tape into a nip between the second spool and the paper web, comprises a transfer track for transporting the turn-up tape beneath the paper web and to a position adjacent to the nip, and a drive assembly capable of driving the turn-up tape along the transfer track toward the nip, wherein the drive is capable of being powered by manual power or motor power. In one embodiment, the transfer track comprises at least in part a V-shaped groove capable of containing the turn-up tape. The V-shaped groove can comprise a first side wall and a second side wall at an acute angle from the first side wall and the second side wall can comprise a concave portion. 
   Further details and advantages of the present invention are set forth below. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings, which are incorporated in and form a part of the specification, illustrate exemplary embodiments of the present invention and, together with the description, disclose principles of the invention. In the drawings: 
       FIG. 1  is an illustration of the turn-up tape system according to one embodiment of the present invention; 
       FIG. 2  is an illustration of a portion of the turn-up tape system according to one embodiment of the present invention; 
       FIG. 3  is an illustration of a portion of the turn-up tape system according to one embodiment of the present invention; 
       FIG. 4  is an exploded view of a drive portion of the drive assembly according to one embodiment of the present invention; 
       FIG. 5  is a cross sectional view of the drive portion of the drive assembly according to one embodiment of the present invention; 
       FIG. 6  is an exploded view of a driven pulley according to one embodiment of the present invention; 
       FIG. 7  is an illustration of the driven pulley according to one embodiment of the present invention; 
       FIG. 8  is an exploded view of a hand crank according to one embodiment of the present invention; 
       FIG. 9  is a cross sectional view of the hand crank according to one embodiment of the present invention; 
       FIG. 10  is a cross sectional view of the transfer track according to one embodiment of the present invention; 
       FIG. 11  illustrates a pneumatic control subsystem according to one embodiment of the present invention; 
       FIG. 12  illustrates a pneumatic control subsystem according to one embodiment of the present invention; and 
       FIG. 13  illustrates a flow diagram for switching between automatic operation and manual operation of the turn-up tape system according to one embodiment of the present invention. 
       FIG. 14  schematically illustrates components of a turn-up tape system In relations to other components involved in spooling a paper web in accordance with one embodiment of the present invention. 
   

   DETAILED DESCRIPTION 
     FIG. 1  illustrates one embodiment of an improved turn-up tape system  100  for spooling and cutting a paper web. The turn-up tape system  100  can comprise of a drive assembly  102 , a press wheel assembly  101 , a cutter assembly  103 , a loop assembly including a looper bin door assembly  105  and a looper bin  104 , a cam assembly  106 , a brake assembly  114  and a tape transfer track  107  with a horizontal section  108  and a turn-up section  109 . Other embodiments of the turn-up tape system  100  are possible.  FIGS. 2 and 3  also illustrate a portion of the turn-up tape system from the drive assembly  102  to the cam assembly  106  according to one embodiment of the turn-up tape system. In the embodiment shown in  FIG. 1 , the turn-up tape system  100  is positioned in relation to a paper web, empty spool (a second) and full (first) spool so that the paper web travels over the horizontal section of the transfer track and the turn-up section is positioned to deliver the turn-up tape to a nip between the paper web and empty spool. 
   The general operation of one embodiment of the turn-up tape system  100  in either automatic or manual mode will now be described with reference to  FIGS. 1-3 . First, turn-up tape can be inserted into the turn-up tape system. In order to do this, the press wheel assembly  101  can utilize an air cylinder to move a rubber coated engaging wheel  120  away from a drive wheel  122  of the drive assembly  102 . Once the turn-up tape is appropriately positioned in the turn-up tape system, the press wheel assembly  101  can utilize the air cylinder to move the rubber coated engaging wheel  120  in position such that the turn-up tape is clamped between the rubber coated engaging wheel  120  and the drive wheel  122 . 
   The drive assembly  102  can then move the turn-up tape along the system  100  over the looper bin door assembly  105 , through the cam assembly  106 , through the horizontal section  108  underneath the paper web and to the end of the turn-up section  109  toward the nip (not shown). The drive assembly  102  can be motor powered or manually powered. In one embodiment, adhesive can be applied to the forward end of the turn-up tape so that when placed in the nip it sticks to the new spool. This adhesive application can be done manually or can be done by a machine. The brake assembly  114  can then apply pressure to the turn-up tape by utilizing an air cylinder and a metal pad. The looper bin door assembly  105  can then utilize an air cylinder to open a looper bin door. This can allow turn-up tape to gather in the looper bin  104 . The brake assembly  114  ensures that the tape goes in the looper bin  104  and prevents turn-up tape from passing the looper bin door assembly  105 . 
   In one embodiment, after an appropriate amount of turn-up tape has collected in the looper bin  104 , the cutter assembly  103  can cut the turn-up tape by utilizing an air cylinder equipped with a sharp blade. The brake can then be released and the drive assembly can be stopped. The cam assembly  106  can, when signaled at the appropriate time, utilize two air cylinders working in tandem to cause the turn-up tape to move into a nip between the empty spool and the paper web. After operation of the cam assembly  106 , the brake of the brake assembly  114  can again be actuated to apply pressure to the turn-up tape. The turn-up tape can then be wound around the empty spool causing the tape to pull out of the track  107 , cut the paper web, and start the paper web spooling on the empty spool. 
     FIG. 10  illustrates a cross section of the track  107  according to one embodiment of the present invention. In the embodiment show in  FIG. 10 , the turn-up tape  1000  travels through groove  1004 . Groove  1004  can be covered by a flexible seal  1002 . The flexible seal  1002  can keep debris out of the groove  1004 , while still allowing the turn-up tape  1000  to pull out of the groove  1004 . In one embodiment, the flexible seal is made from urethane, but other suitable materials can be used. As shown in  FIG. 10 , the groove  1004  can be generally V-shaped with a first wall  1006  and a second wall  1008  at an acute angle to the first wall  1006 . In one embodiment, the first wall  1006  is substantially parallel with the cross section of the turn-up tape  1000  in the groove  1004 . As shown in  FIG. 10 , the second wall  1008  can be concave or have a concave portion. This can help to alleviate binding of the turn-up tape  1000  in the groove  1004  and can prevent any adhesive that may be on the turn-up tape  1000  from attaching to the groove  1004  or otherwise preventing the turn-up tape  1000  from traveling through the groove  1004 . A third wall  1010  can also form the groove  1004  that is substantially perpendicular with the cross section of the turn-up tape  1000  in the groove  1004 . Alternatively, the track  1007  can be also be configured a variety of different ways as known to those skilled in the art, such as, for example, like the track configurations shown in U.S. Pat. No. 6,416,012, which is incorporated in its entirety by this reference. 
   The drive assembly  102  can provide the rotational force that is responsible for moving the turn-up tape through the system  100 . The drive assembly  102  can be powered by either an electric motor  124  or a human powered hand crank  126 .  FIGS. 4-7  provide more detailed illustrations of portions of the drive assembly  102 .  FIG. 4  provides an exploded view of a drive portion of the drive assembly  102  according to one embodiment of the present invention.  FIG. 5  provides a cross sectional view of the drive portion of the drive assembly  102  according to one embodiment of the present invention.  FIG. 6  provides an exploded view of a driven pulley  130  and directional clutches  131 ,  132  and  FIG. 7  provides a perspective view of the driven pulley  130  and directional clutches  131 ,  132  of one embodiment of the present invention. 
   The driven pulley  130  shown in  FIGS. 4-7  can receive power from the drive motor  124  by way of a belt  127  (as shown in  FIGS. 1 and 3 ). In one embodiment, this driven pulley  130  has an inside diameter sufficient to allow the press fit of two directional clutches  131 ,  132  (as shown in  FIGS. 6 and 7 ). During electrically powered operations, these directional clutches  131 ,  132  can engage and rotate the drive shaft  134  when the pulley  130  is turned in a clockwise direction, for example, as shown in  FIG. 6 . The rotation of the drive shaft  134  causes the drive wheel to rotate, which when the engaging wheel  120  is in position drives the turn-up tape through the system  100 . In one embodiment, when the system is manually powered, the motor  124 , the belt  127 , the pulley  130  and the directional clutches  131 ,  132  are stationary. In the manually powered case, the directional clutches  131 ,  132  can allow the shaft  134  to rotate freely without interference from the motionless electric motor  124  and pulley  130 . 
   The hand crank  126  can transmit power from a human being to the drive shaft  134  during manual operation causing turn-up tape to be driven through the system  100  similar to the motor powered mode described above. In one embodiment, this transmission of power can be accomplished by employing the assembly shown in  FIGS. 8 and 9 , which consists of two directional clutches  141 ,  142  that have been pressed into a machined bore inside the crank handle. These clutches  141 ,  142  can function to transmit torque to the drive shaft  134  when the handle is rotated in the clockwise direction shown, for example, in  FIG. 8 . However, when the system utilizes the electrically driven motor  124 , the clutches  141 ,  142  and the hand crank  126  can be stationary. In the electrically powered case, the clutches  141 ,  142  can slip on the shaft  134  and allow the hand crank to remain essentially motionless while the shaft  134  rotates. 
   In one embodiment, the operation of the turn-up tape system  100 , except for the drive assembly  102 , is controlled by a pneumatic system that can be controlled automatically, such as by a computer or can be controlled manually. The pneumatic system can include three sub-systems, the Turn-Up Control sub-system, which controls the cam assembly  106  and the brake assembly  114 , the Loop Control sub-system, which controls the looper bin door assembly  105  and the brake assembly  114  and the String-Up Control sub-system, which controls the press wheel assembly  101  and the cutter assembly  103 . 
   In one embodiment, the use of both manual controls as well as automated controls in a pneumatic system can be facilitated by the placement of both electrically actuated and manually actuated types of controls in a series configuration.  FIG. 11  provides a schematic diagram of one embodiment of how this principal can be used in a pneumatic system  1100  that has a manually actuated, pneumatic type selector switch as its manual control. The pneumatic system  1100  shown in  FIG. 11  can utilize a pressure source  1102 , a selector switch type manually actuated pneumatic valve  1106 , an electrically actuated pneumatic valve  1104  and a Pneumatic Main System  1108 . In this embodiment, if the manual selector valve  1106  is turned to a position where air can flow freely through the manual valve  1106  in the airflow direction A control of the system is relinquished to the electrically controlled valve  1104  further up stream of the manual valve. A programmed computer can now control the Pneumatic Main System  1108  with a minimum of human interactions. The electrically actuated valve  1104  can be used such that without the presence of an electrical signal the valve  1104  allows the unrestricted flow of air through the valve in the air flow direction A. In this embodiment, the manual valve  1106  can be manipulated to control the system. This principal allows the turn-up tape system  100  to be controlled as both an automated turn-up system as well as a manual turn-up system. This type of pneumatic subsystem is used by the Loop Control and String-up Control Subsystems of the turn-up tape system. 
     FIG. 12  illustrates another embodiment of a pneumatic system  1200 . The pneumatic system  1200  of  FIG. 12  can utilize a normally closed, manually actuated, pneumatic, pushbutton valve as its manual control. This system  1200  can utilize a pressure source  1202 , a pushbutton type manually actuated pneumatic valve  1204 , an electrically actuated pneumatic valve  1206  and a Pneumatic Main System  1208 . In one embodiment, when this pneumatic system  1200  is used with the Turn-up Control Type Subsystem, the Turn-up Control Type Subsystem can source its air pressure from both an external pressure source as well as from a source within the Pneumatic Main System  1208 . In one embodiment, the system  1200  utilizes a manual pushbutton valve  1204  that has a normally closed flow position. Thus, the valve  1204  cannot be set to a position where air can flow freely through the valve  1204 . Because of this a second external air source can be utilized to supply the electrically actuated valve  1206  during automatic operations. To facilitate manual operations, an electrically actuated valve  1206  can be selected such that without the presence of an electrical signal the valve allows the unrestricted flow of air in the direction B through the valve. In this embodiment, the system  1200  can be operated manually. This type of pneumatic subsystem is used by the Turn-up Subsystem. 
   Each of the control subsystems can be responsible for dispersing pressurized air to either work in a single Pneumatic Main System or provide pneumatic signaling to additional pneumatic powered controls located in the Pneumatic Main System. 
   The String-up Control, Loop Control and Turn-up Control subsystems can be utilized to control the mechanical assemblies of the turn-up tape system with the exception of the drive assembly. Manual controls can be associated with each subsystem, for example, a the Turn-up Control button, a Loop Control selector switch, and a String-up Control selector switch. 
     FIG. 13  illustrates an exemplary method  1300  of switching from automatic (computer controlled) operation to manual operation according to one embodiment of the present invention. In block  1302 , an electric selector switch that can be located at a control panel associated with a controlling computer is turned to a manual position. The electric selector switch can indicate to the computer that the operator is now operating in manual mode. The computer can respond to such indication by removing the electrical voltages from the electrically actuated pneumatic valves of the control subsystems and the electric motor. This can place the electric actuated control valves into a configuration where air is allowed to flow through without obstruction. 
   In block  1304 , a looper control switch is turned to a closed position and a string-up control switch is turned to an armed position. The actions in block  1304  can prepare the turn-up tape system to receive a piece of turn-up tape. When the looper control switch is turned to the “closed” position the Pneumatic Main System can apply air pressure to the air cylinder located on the looper assembly. This action can close the looper bin door not allowing the accumulation of turn-up tape in the looper bin and remove pressure from the brake assembly, which can allow turn-up tape to pass by the metal pad without interference. 
   When the string-up control switch is turned to the “turn-up armed” position the Pneumatic Main System can apply air pressure to the portion of the presswheel assembly&#39;s air cylinder that will cause the engaging wheel of the presswheel assembly to move away from the drive wheel of the drive assembly. This action can allow turn-up tape to be inserted into the machine without the interference of the presswheel assembly&#39;s engaging wheel. Simultaneously, the Pneumatic Main System can apply the appropriate air pressure configuration to the cutter assembly to cause the cutter blade to move into the position where the inserted turn-up tape will strike the cutter blade thus limiting the amount of turn-up tape that can be inserted into the machine. 
   In block  1306 , turn-up tape is fed into the turn-up tape system until the turn-up tape comes into contact with the cutter blade from the cutter assembly. An operator can also add adhesive to the end of the turn-up tape before feeding the turn-up tape into the turn-up tape system. 
   In block  1308 , the string-up control switch is switched to a “string-up” position. This can reverses the actions of the previous movement of this control to the armed position. In one embodiment, switching the string-up control switch to the string-up position can cause the Pneumatic Main System to apply the appropriate air configuration to the presswheel assembly to cause the engaging wheel to clamp the turn-up tape previously inserted into the machine against the drive assembly&#39;s drive wheel. Additionally, the Pneumatic Main System can cause the cutter Assembly to remove the cutter blade from in front of the inserted turn-up tape, which allows turn-up tape to be further inserted into the turn-up tape system. 
   In block  1310 , the hand crank is turned a predetermined number of turns. The number of turns can be the number of turns necessary to dispense turn-up tape into the turn-up tape system to a specified quantity. For example, the hand crank is turned until the end of the turn-up tape is in position at the end of the track  107  to enter the nip. 
   In block  1312 , the looper control switch is switched to the looper open position. The movement of the loop control switch to the “looper open” position can cause the Pneumatic Main System to apply the appropriate air pressure configuration to the looper assembly air cylinder. This application of air causes the cylinder to open the looper bin door and allow the accumulation of turn-up tape. Additionally, the Pneumatic Main System can apply the appropriate air pressure configuration to the brake assembly to cause the metal pad of the brake assembly to be pressed against the turn-up tape stopping any further collection of turn-up tape into the system past the brake assembly. 
   In block  1314 , the hand crank is turned a predetermined number of times in a clockwise direction. This can cause the accumulation of turn-up tape in the looper bin, because the looper bin door is open and the brake assembly secures the turn-up tape at a point beyond the looper assembly. The number of turns of the hand crank can be the number necessary to accumulate a measured quantity of turn-up tape in the looper bin. 
   In block  1316 , the string-up control switch is switched to the armed position. Turning the string-up control switch to this position can cause the Pneumatic Main System to cause the presswheel assembly to release the clamping pressure applied to the turn-up tape by the engaging wheel and cause the cutter assembly to move the cutter blade so as to cut the turn-up tape. In addition, the Pneumatic Main System can apply the appropriate air pressure configuration to cause the brake assembly to apply the appropriate air pressure configuration to cause the metal pad to be retracted from its previous position where it isolated the turn-up tape from motion. At this point, a measured quantity of turn-up tape can be contained in the turn-up tape system. 
   In block  1318 , the turn up control button is depressed after the spool contacts the reel drum. Pressing the turn-up control button can signal the Pneumatic Main System to apply the appropriate air pressure configuration to the air cylinders contained in the cam assembly, which causes the cam assembly to feed a measured amount of turn-up tape, for example, eleven inches, to advance and travel into the nip of the paper production machinery. After the operation of the cam assembly, the brake assembly is activated so that it applies pressure to the turn-up tape. This constitutes the beginning of the turn-up process. At this point all turn-up tape in the turn-up tape system is removed from the machine by the paper production equipment. After the removal of the turn-up tape from the machine is complete the operator can return to block  1304  and begin the process again. 
   The foregoing description of exemplary embodiments of the invention has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to explain the principles of the invention and their practical applications so as to enable others skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. 
     FIG. 14  schematically illustrates a first spool  2002  and a second spool  2004  of a system for collecting a paper web  2006  in relation to a transfer track  2008  for directing a turn-up tape Into a nip  2010  between the second spool  2004  and the paper web  2006  in accordance with certain embodiments of the present Invention.  FIG. 14  also shows a computer  2012  for controlling the pneumatic system of certain embodiments of the present invention.