Abstract:
Various method embodiments move web equipment from a first web processing station to a second web processing station. According to a method embodiment, the web equipment is raised away from the first web processing station, where raising includes rotating the web equipment about a rotary axis. The rotary axis is linearly moved along a linear axis. The web equipment is lowered toward the second web processing station, wherein lowering includes rotating the web equipment about the rotary axis. Various embodiments move a laser head from one web processing station into operational position at another web processing station.

Description:
TECHNICAL FIELD 
     This application relates generally to web processing machines and, more particularly, to machine-mountable positioning apparatus for web processing equipment on multi-station web processing machines. 
     BACKGROUND 
     Web processing refers to numerous operations related to manipulating a continuous stream of product. Web processing machines perform web processing to produce a finished product from a continuous flow of material often loaded onto the machine in the form of a roll of material. The value of a web processing machine is often measured by the versatility of the machine. Versatility is manifest in how quickly the machine can be converted to run a different product, the number of different products a machine can produce, the speed at which the machine produces a particular product or combination thereof. One of the limits to machine versatility is whether a particular piece of web processing equipment mounted on a machine is positioned correctly for variations of a product or different products not originally anticipated to be produced by the machine. Large web processing equipment can limit the versatility of a web processing machine because the equipment cannot be easily moved from one web processing station of a machine to another to produce other products. 
     SUMMARY 
     Various apparatus embodiments comprise a linear axis, a carriage, a rotary axis, and a mount. The linear axis is mounted to a web processing machine. The carriage is adapted to linearly move on the linear axis. The rotary axis is connected to the carriage. The mount is connected to the rotary axis, and is adapted to mount web processing equipment to process web. Various embodiments include a controller adapted to move the mount between at least two web processing stations on the web processing machine using the linear and rotary axes. 
     Various system embodiments guide a laser beam to a laser head to process web handled by a web processing machine. The system comprises a positioning apparatus mounted to the web machine and adapted to move the laser head from one web processing station into operational position at another web processing station. The positioning apparatus comprises a linearly movable carriage, a mount rotatably coupled to the carriage, and a mirror mounted to the carriage and in a path of the laser beam. The mirror is adapted to direct the laser beam to the mount, and the mount is adapted to direct the laser beam to the laser head coupled to the mount. 
     Various method embodiments move web equipment from a first web processing station to a second web processing station. According to a method embodiment, the web equipment is raised away from the first web processing station, where raising includes rotating the web equipment about a rotary axis. The rotary axis is linearly moved along a linear axis. The web equipment is lowered toward the second web processing station, wherein lowering includes rotating the web equipment about the rotary axis. 
     Various method embodiments disengage one or more axis brakes of a positioning apparatus having one or more axes, disengage a positioning pin to unlock one of the one or more axes, implement a motion profile to avoid interferences moving the web processing equipment from the first web processing station to the second web processing station, execute a plurality of moves of the one or more axes according to the motion profile, engage the positioning pin to lock one of the one or more axes, and engage one or more axis brakes of the positioning apparatus. 
     This Summary is an overview of some of the teachings of the present application and is not intended to be an exclusive or exhaustive treatment of the present subject matter. Further details about the present subject matter are found in the detailed description and the appended claims. The scope of the present invention is defined by the appended claims and their legal equivalents. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIGS. 1A-1G  illustrate a positioning apparatus for web processing equipment according to an embodiment of the present subject matter. 
         FIG. 2  illustrates a flow diagram for using a positioning apparatus to move web processing equipment from one web processing station to another station according to an embodiment of the present subject matter. 
         FIG. 3  illustrates a block diagram of a positioning apparatus for laser processing equipment mounted to a web machine according to an embodiment of the present subject matter. 
         FIGS. 4A-4B  illustrate a positioning apparatus according to an embodiment of the present subject matter. 
         FIG. 5  illustrates a positioning apparatus according to an embodiment of the present subject matter. 
         FIGS. 6A-6B  illustrate a carriage for a positioning apparatus according to an embodiment of the present subject matter. 
         FIGS. 7A-7B  illustrate a position pin assembly for a positioning apparatus according to an embodiment of the present subject matter. 
         FIG. 8  illustrates a position sensor assembly for a positioning apparatus according to an embodiment of the present subject matter. 
         FIG. 9  illustrates a mount for a positioning apparatus according to an embodiment of the present subject matter. 
         FIG. 10  illustrates a operator terminal screen  1060  for controlling a positioning apparatus and attached web processing equipment according to one embodiment of the present subject matter. 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description of the present invention refers to subject matter in the accompanying drawings which show, by way of illustration, specific aspects and embodiments in which the present subject matter may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the present subject matter. References to “an”, “one”, or “various” embodiments in this disclosure are not necessarily to the same embodiment, and such references contemplate more than one embodiment. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope is defined only by the appended claims, along with the full scope of legal equivalents to which such claims are entitled. 
       FIGS. 1A-1G  illustrate a positioning apparatus  100  for web processing equipment according to an embodiment of the present subject matter. In various applications, the positioning apparatus  100  is mounted atop a web processing machine  101 . The positioning apparatus  100  provides horizontal positioning  102  of web processing equipment across the face of the web processing machine using a linear axis. The positioning apparatus allows web processing equipment normally fixed mounted to a web processing machine to be portable with respect to web processing stations positioned across the face of the web processing machine. In various embodiments, the positioning apparatus includes a rotational axis to rotate, as represented by arrows  103 , a mount for the web processing equipment, or a portion of the web processing equipment, vertically out of the way of interferences positioned across the face of the web machine. Once the mount/web processing equipment is raised (e.g.  FIG. 1D ), the mount/web processing equipment is horizontally moved toward the new station (e.g.  FIG. 1E ) and rotated to lower the mount/web processing equipment into operational position to process web at the new station (e.g.  FIG. 1G ). In various embodiments, a controller is preprogrammed with positions detailing areas of potential interference  104  for the positioning apparatus  100 . The controller includes programming to control the motion of the positioning apparatus between one or more web processing stations. In various embodiments, the controller includes programming to combine the movement of the horizontal motion and the rotational motion to avoid the preprogrammed areas of potential interference while moving the web processing equipment from one station to another. 
       FIG. 2  illustrates a flow diagram for using a positioning apparatus to move web processing equipment from one web processing station to another station according to an embodiment of the present subject matter. The illustrated process  280  includes disengaging linear axis motor brake  281 , disengaging a positioning pin (or other mechanical locking mechanism) to allow rotary motion of the positioning apparatus  282 , implementing a motion profile of the web processing equipment to avoid interferences  283 , executing one or more interpolated moves of a linear axis and a rotary axis to raise the web processing equipment from a first station  284 , executing a linear move to move the web processing equipment toward a second station  285 , executing one or more interpolated moves of the linear and rotary axes to lower the web processing equipment at the second station  286 , engaging the positioning pin  287  and engaging linear axis motor brake  288 . In various embodiments, implementing a motion profile  283  includes determining a motion path from previously mapped areas of potential interference. Some embodiment use sensor(s) adapted to sense potential interference, and control motion based on the sensed potential interference as determined using the sensor(s). 
       FIG. 3  illustrates a block diagram of a positioning apparatus  300  for laser processing equipment mounted to a web machine  301  according to an embodiment of the present subject matter. The positioning apparatus  300  includes a linear axis  305 , a carriage  306 , a rotational axis  307 , a mount  308  for mounting web processing equipment, a positioning pin  309  and a position sensor  310 . The positioning apparatus provides mobility to web processing equipment normally mounted in a fixed position on a web processing machine. In various embodiments, providing mobility to normally fixed web processing equipment allows a web processing machine to produce a greater variety of products, processes or combination thereof. 
     The linear axis  305  of the positioning apparatus  300  includes a fixed portion for mounting to a web processing machine  301 . The carriage  306  linearly moves along the linear axis. The rotary axis  307 , the positioning pin  309  and the position sensor  310  are coupled to the carriage. The mount  308  is coupled to the rotary axis  307 . In the illustrated embodiment, a laser galvo assembly  311  is coupled to the mount  308 . The laser galvo assembly  311  is a component of laser processing equipment for web processing. Various laser galvo assemblies can be mounted to the positioning apparatus. In general, a laser galvo assembly includes one or more galvanometer mechanisms for moving one or more mirrors to direct a laser beam in a predetermined pattern toward a target, such as web on a web processing machine. Laser web processing equipment can provide a variety of web processing functions, such as intricate cutting, control depth cutting, scoring, ablation or combinations thereof. In the illustrated embodiment, a laser  312  is fixed to the web processing machine. The positioning apparatus  100  guides the laser beam from the laser  312  to the galvo assembly  311  coupled to the mount  308  using a set of mirrors  313 . As the galvo assembly  311  is moved from one processing station  314  of the web processing machine to another, a controller  315  coordinates the motion of the linear  305  and rotary  307  axes to avoid other equipment mounted to the face of the web processing machine  301 . For example, web processing machines often include a plurality of web spindles and idler rolls, as well as other parts, mounted to the face of the web processing machine. 
     In various embodiments, the positioning pin  309  engages when the positioning apparatus  300  completes a positioning move and disengages just prior to beginning a positioning operation. The positioning pin  309  locks the mount  308  connected to the rotary axis  307  at the completion of a positioning operation. In various embodiments, the position sensor  310  provides a permissive signal to the controller verifying proper positioning of the rotary axis. In various embodiments, the position sensor provides a permissive signal to the attached web processing equipment verifying proper positioning of the rotary axis. In the illustrated embodiment, the sensor  310  is connected to both the controller  315  and the laser  312 . The controller  315  uses the permissive signal to enable or disable the web processing equipment moved using the positioning apparatus  300 . For example, in the illustrated embodiment, the position sensor signal is used to enable the laser  312  only when the rotary axis  307  is positioned within a limited range of motion detected using the sensor  310 . 
     In various embodiments, an operator terminal  316  is connected to the controller  315  and provides status information about the positioning apparatus  300  and the web processing equipment. Some operator terminal embodiments provide an interface for a user to control the positioning apparatus  300 , for example, to manually move the axes of the positioning apparatus, manually control the positioning pin, manually control one or more motor brakes, change the operating mode of the positioning apparatus or combination thereof. An example of an operator terminal screen is illustrated in  FIG. 10 . 
       FIGS. 4A-4B  illustrate a positioning apparatus according to an embodiment of the present subject matter. The illustrated positioning apparatus  400  is shown mounted to the top of a web processing machine  401 . In various embodiments, web processing equipment  417  (inside cover) is mounted to a mount of the positioning apparatus  400 . In various embodiments, the web processing machine  401  is adapted to use the web processing equipment  417  at one or more web processing stations  414 . In the illustrated embodiment, the web processing machine  401  includes seven web processing stations  414 . Three of the illustrated stations include web processing equipment including two modular die/nip stations  418  and a modular web cutting station  419  for use with laser web cutting equipment  417  mounted to the positioning apparatus  400 . The web processing machine is adapted to process web  419  in a variety of configurations and the positioning apparatus  400  is adapted to position the web processing equipment  417  at one or more of the web processing stations  414  across the face of the web processing machine. For example, in the illustrated embodiment, the positioning apparatus  400  is adapted to position the web processing equipment  417  to any one of the five leftmost web processing stations  414  on the web processing machine  401 . To position the web processing equipment  417  at a station, the positioning apparatus  400  includes a linear axis to move the equipment across the face of the machine and a rotary axis to rotate the apparatus in a vertical plane. In various embodiments, such as the one illustrated, the rotary axis allows the web processing equipment  417  to be rotated out of a path that would otherwise collide with other equipment mounted on the web processing machine. For example, in the illustrated embodiment, moving the web processing equipment  417  to the right from the illustrated position using only the linear axis would eventually cause the web processing equipment to interfere with one of the die/nip stations  418 . Using the rotary axis, the web processing equipment  417  is rotated toward the top of the web processing machine  401  to avoid interference with the die/nip station  418 . Web roll spindles and idlers rolls are examples of common web machine accessories mounted to the front of web processing machines in which a positioning apparatus according to the present subject matter uses the rotary axis to avoid when moving web processing equipment from one station to another. 
       FIG. 5  illustrates a positioning apparatus  500  according to an embodiment of the present subject matter. The positioning apparatus includes a linear axis  505 , a carriage  506 , a rotary axis  507  and a mount  508 . In the illustrated embodiment, the linear axis  505  includes a first  520  and second  521  linear rail coupled to a plurality of mounts  522 . A lead screw  523  is connected to two of the mounts  522  used to mount the positioning apparatus  500  to the web processing machine and positioned between the rails  520 ,  521 . In the illustrated embodiment, the lead screw  523  is connected to a linear axis motor  524 . 
     The carriage  506  is connected to a plurality of linear bearings  525  that ride along the rails  520 ,  521 . The carriage  506  is also connected to the lead screw using a nut (not shown). The carriage  506  moves along the rails when the linear axis motor  524  rotates the lead screw  523 . In various embodiments, the linear axis motor is a servo motor. Some embodiments use a linear servo motor connected to the carriage  506 . 
     The rotary axis  507  is connected between the carriage  506  and the mount  508  and is used to rotate the mount. The rotary axis  507  includes a gearbox  526 , a motor  527 , a sensor (not shown) and a locating pin assembly  528 . In various embodiments, the rotary axis motor  527  is a servo motor. The mount  508  is used to connect web processing equipment to the positioning apparatus  500 . In various embodiments, web equipment includes a mobile portion connected to the mount  508  of positioning apparatus and a fixed portion located elsewhere. The positioning apparatus includes flexible ducting  529  to connect the fixed portion of the web processing equipment to the mobile portion connected to the mount. In the illustrated embodiment, a plurality of mirrors  513  are located on the positioning apparatus to guide a laser beam from a laser mounted to or near the web processing machine to a galvo assembly coupled to the mount  508  of the positioning apparatus  500 . 
       FIGS. 6A-6B  illustrate a carriage  606  for a positioning apparatus according to an embodiment of the present subject matter.  FIG. 6A  is an isometric view of the carriage and  FIG. 6B  is a top view of the carriage.  FIGS. 6A and 6B  show a carriage base plate  630 , a rotary gearbox  626  connected to a motor  627 , a positioning pin assembly  628  and a position sensor assembly  631 . In the illustrated embodiment, clearance holes and bolts  632  are shown for fastening the carriage base plate  630  to one of four linear bearings of the linear axis. A set of bolts  633  located near the center of the carriage base plate  630  connect the base plate to a nut assembly adapted to provide linear motion in cooperation with the lead screw of the linear axis.  FIGS. 6A  and  6 B show an adapter plate  634  for attaching a mount to the rotary gearbox  626 . In the illustrated embodiment, the adapter plate  634  includes a pin receiver opening  635  adapted to receive a positioning pin when the adapter plate  634  is at or near a predetermined rotary position. In various embodiments, the adapter plate  634  includes a plurality of pin receiver openings to accommodate fixing the adapter plate and attached mount at various predetermined rotary positions. The illustrated embodiment includes a mirror assembly  613  to direct a laser beam through the rotary gearbox  626  and the adapter plate  634 . 
       FIGS. 7A-7B  illustrate a position pin assembly for a positioning apparatus according to an embodiment of the present subject matter. The position pin assembly  728  includes a pin  739 , a slide assembly  738  and a pneumatic cylinder  736  and cylinder mount  737  for moving a portion of the slide assembly to engage and disengage the positioning pin with a rotary adapter plate. 
       FIG. 8  illustrates a position sensor assembly for a positioning apparatus according to an embodiment of the present subject matter. The position sensor assembly includes a deflector  840 , an adjustable sensor mount  841  and a sensor  842 . The deflector  840  is mounted to and moves with a rotary adapter plate. The sensor  842  is mounted to the carriage of a positioning apparatus and is adjusted to trigger upon sensing the deflector  840 . In various embodiments, the position sensor assembly provides an electrical signal for enabling and disabling web processing equipment coupled to the mount. In the illustrated embodiment, the position sensor assembly includes a mechanical limit switch. It is understood that various embodiments of the position sensor assembly can use other types of sensors, for example an optical sensor or a proximity sensor, without departing from the scope of the present subject matter. 
       FIG. 9  illustrates a mount  908  for a positioning apparatus according to an embodiment of the present subject matter. The illustrated mount includes an adapter mount plate  943 , a equipment mount plate  944  and two support members  945  connecting the adapter mount plate  943  to the equipment mount plate  944 . The illustrated mount includes an attached galvo assembly  911  and laser beam guidance components  946 . The laser beam guidance components provide a laser beam path from the carriage to the galvo assembly. The equipment mount plate includes an opening  947  to provide utility access to the galvo assembly for electrical cabling and pneumatic tubing, for example. In various embodiments, the galvo assembly  911  provides multi-axis laser web cutting, web scoring, web ablation, control depth web cutting or combination thereof. The laser beam guidance components  946  guide a laser beam to the galvo assembly  911  from the carriage or a positioning apparatus. The illustrated embodiment includes guide tubes  946  and a mirror assembly  913 . The mirror assembly  913  reflects a laser beam from the carriage toward the galvo assembly  911 . The mirror assembly  913  includes adjustment controls to assist in directing the laser beam toward the galvo assembly  911 . 
       FIG. 10  illustrates a operator terminal screen  1060  for controlling a positioning apparatus and attached web processing equipment according to one embodiment of the present subject matter. The screen includes both display and control elements. Control elements include pushbuttons and data entry controls. In various embodiments, the control elements can be activated using a mouse, a keyboard or a mouse and a keyboard. In various embodiments, the illustrated screen is displayed on a touch screen terminal allowing activation of a control element by touching the screen at the location of the control element. 
     The illustrated Laser Setup screen  1060  allows control and monitoring of a positioning apparatus with laser based web processing equipment attached to the mount. The Laser Control pushbutton  1061  toggles permissive signals enabling the laser. In various embodiments, the Laser Control pushbutton  1061  also enables and disables accessory equipment associated with the laser, such as, cooling equipment and exhaust equipment, for example. The Laser Mode pushbutton  1062  controls and displays the mode of laser with respect to the web processing machine with which the laser based web processing equipment is associate. In various embodiments, the Laser Mode is required to be in Auto mode before the web processing machine is allowed to begin processing web. In various embodiments, the Laser Mode is required to be in Manual mode before manual movement of the positioning apparatus is allowed. 
     The Current Station data display  1063 , Laser Station data entry control  1064  and the Move to Station pushbutton  1065  allow controlled movement of web processing equipment attached to the positioning apparatus from one station to another. The Current Station data display  1063  shows the current position of the positioning apparatus relative to web processing stations located across the face of a web processing machine. The Laser Station data entry control  1064  allows an user to enter a destination station number for the positioning apparatus to move the attached web processing equipment to. Entry of a valid station number does not initiate motion of the positioning apparatus. In various embodiments, station “0” represents a predetermined destination that upon movement of the positioning apparatus moves the web processing equipment away from any of the web processing stations, for example, to a vertical position above the web processing stations. The Move to Station pushbutton  1065  initiates motion of the positioning apparatus from the positioning apparatus&#39; current position to the position of the station entered using the Laser Station data entry control. 
     The Laser Setup screen  1060  includes displays and controls for individually operating the axes of the positioning apparatus. The illustrated Laser Setup screen  1060  allows individual operation of either the linear axis or the rotary, or “Arm”, axis. The screen includes a Motor Enable/Disable pushbutton  1066 ,  1067 , Position data display  1068 , 1069 , Jog Speed data entry control  1070 ,  1071 , reciprocal JOG pushbuttons  1072 ,  1073 ,  1074 ,  1075 , and a Brake control pushbutton  1076 ,  1077  for each axis. The Motor Enable/Disable pushbutton  1066 ,  1067  triggers the controller to enable the axis motor if the axis is not enabled or disable the axis motor if the axis is enabled. Enabling an axis includes enabling motor drive amplifiers and closing the feedback loop of position controllers associated with the axis. In various embodiments, the linear axis includes a brake and enabling the linear motor includes releasing the linear axis brake. In various embodiments, the rotational axis includes a brake and enabling the rotational axis includes releasing the rotational axis brake. The Position Data displays  1068 ,  1069  show the value of a position counter of a position controller associated with each axis. In various embodiments, the position displayed is referenced to a predetermined reference position of each axis. In various embodiments, the position of the linear axis is displayed in metric units. In various embodiments, the position of the linear axis is displayed in English units. In various embodiments, the controller allows a user to change the displayed units of the linear axis between one or more English and Metric units. 
     The Jog Speed data entry controls  1070 ,  1071  display current jog speed of each axis and allow a new jog speed to be entered. The units of the jog speed are displayed distance units per second where the distance units are the same as the units of the position. The reciprocating Jog pushbuttons  1072 ,  1073 ,  1074 ,  1075  initiate movement of the corresponding axis in the direction indicated by the button. Movement will begin and continue as long as the button is pushed or until the axis reaches an predetermined or physical extreme of the axis&#39; travel range. The Brake Control pushbuttons  1076 ,  1077  allow an axis brake to be disengaged without enabling the axis motor. In various situations, for example during setup, an technician may desire to move an axis by hand by pushing or pulling the axis. The Brake Control pushbutton  1076   1077  allows the technician to release the brake on an axis so the axis can be moved by hand. 
     The Zero Position pushbutton  1078  reset the position counter of all axes of the positioning apparatus to zero. The Zero Position pushbutton  1078  is used primarily during setup of the machine or in situation where the position counters are no longer accurate with respect to the web processing machine and mapped interference areas mapped thereon. Common where position counter inaccuracies an occur include replacement or repair of a position sensor. In various embodiments, one or more of the controls included on the Laser Setup screen  1060  are enabled based on a security setting associated with a user login. 
     This application is intended to cover adaptations and variations of the present subject matter. It is to be understood that the above description is intended to be illustrative, and not restrictive. The scope of the present subject matter should be determined with reference to the appended claim, along with the full scope of legal equivalents to which the claims are entitled.