Abstract:
An improved web splicing apparatus that permits better handling of rolls of paper and other materials and the automatic splicing of the beginning of one roll of paper onto the approximate end of a second roll of paper without discontinuing the flow of paper to the utilizing device and without the use of core shafts. The apparatus utilizes two opposed pairs of independently controlled and positioned web roll support arms which are pivoted about spaced shafts and rotatably support cores of the paper rolls. This invention also allows sequential splicing of rolls having unequal web widths. This configuration also allows the right and left roll support arms to move the rolls upward in an overlapping path from a single loading position, thus providing a machine having considerably reduced dimensions and floor-space requirements. Another aspect of this invention is the automatic ejection of depleted roll-cores. A further aspect is the feasibility of configuring a stacked system of multiple splicers by rotating the splicers one quarter of a revolution, allowing machines to be stacked on top of one another to reduce floor space. Yet another aspect of this invention is the ability to remove partially depleted rolls without interrupting the feed of the web. Still another aspect is the use of the motor in conjunction with the brakes to expand the core chucks to grip the inside of the roll cores.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to apparatus and method to form a flying splice to a new roll from a web of material running from an expiring roll. Specifically, such splicers join together the leading end of a web from a new roll of material to a web which is being drawn from a substantially depleted roll, and which is being run, under tension, along a predetermined path of travel to a utilizing device. Examples of such splicing arrangements are seen on conventional turret splicers. 
     In the past, several different types of pivoting roll supports have been used in flying splicers, including “Three-Arm Turret Splicers” and “Two-Arm Turret Splicers” and several splicers by the present inventor which move the rolls in a linear path. The turret types have several significant disadvantages: means to sequentially accept rolls of unequal lengths and means to automatically expel empty roll cores are complex and costly, and they have a floor length in the direction web travel exceeding twice the maximum roll diameter and additionally require over a diameter between every-other machine for loading access, for a total length, on average, of three times the roll diameter. The linear path types are stackable vertically and therefore more compact than the turret types, but use coreshafts, and stacking requires platforms, ladders, and roll-lifting means. Although linear types are able to effectively expel the 90 pound core shafts with the depleted rolls still attached, the operator must manually lift the heavy depleted roll and core shaft down from the splicer, release and remove the coreshaft from the expired roll, reassemble the coreshaft into a new roll and re-engage the gripping mechanism within the coreshaft. 
     As commonly used on printing presses, the press itself is situated on the ground floor and beneath this floor are the splicers that feed up into the press. As each web may equal only 4 or 8 newspaper pages, multiple webs of paper are required. The minimum printing unit spacing is normally approximately 137 inches and the turret type splicers average three times the roll diameter, or 150 inches. Thus a newspaper of 16 units, producing a newspaper having 64 pages would have a splicer row in excess of 16 feet longer in the direction of web travel than the press row. Further, much engineering design is wasted in designing the interface between the splicers and the presses on a custom basis for each installation occasioned by their unequal lengths. Also, there are frequently length restrictions imposed by existing buildings and real-estate lots which preclude lengthening the buildings wherein the press rows are housed. 
     Sequentially loading rolls of different widths is desirable as it permits make-ready on scrap rolls of various widths and facilitates a rapid startup on subsequent press runs as a web width required for the next product to be printed may be already threaded, allowing the personnel customarily assigned to the duty of changing roll sizes and threading the press to be available for other duties involved in the changeover to a new product. As it is sometimes necessary to splice before the expiring roll is depleted, whether because of a problem with the roll of material, or because of a need to change web widths, the present invention teaches designing an opening in the frame side plate and means to move the arms away from the roll after the roll weight is transferred to the roll removing means, to allow axial removal of the previous partial roll. 
     Exemplary of patented continuous roll feeding devices are the following U.S. Patents: Schmidt, U.S. Pat. No. 1,932,642, and Looser U.S. Pat. No. 3,071,333 both teach four independently rotatable arms about a common pivot shaft, and Looser has the additional disadvantage of requiring core shafts. Positioning the arms on a common shaft precludes independent lateral positioning and also the automatic core ejection as described herein, which are both prime objects of the present invention. 
     The Pato U.S. Pat. No. 3,637,155 shows two pairs of arms mounted on two parallel shafts but specifically states the one set of arms is “spaced laterally outwardly from the support arms of the second pair . . . ” whereas the objectives of the present invention require independent lateral positioning of the pairs of support arms. In addition, the claims of the Pato patent specifically state that the arms be of different lengths, whereas in the present invention, it is not necessary that the pairs of arms bear any length relationship to one another whatsoever. 
     The McDonald U.S. Pat. No. 3,740,296 teaches the use of two pairs of arms mounted on separate parallel shafts, but the configuration is such that the horizontal distance required for a splicer exceeds twice the roll diameter whereas the present invention requires less than one and one-half times the roll diameter. Furthermore, the McDonald design requires two splicing mechanisms and two separate load positions. 
     The Phelps et. al. U.S. Pat. No. 3,831,876 teaches supporting of the rolls having roll core shafts with four arms on a common arm support shaft. 
     The Tafel U.S. Pat. No. 4,729,522 requires roll core-shafts, and even if it were feasible to adequately support moving and retractable core chucks on an endless chain, it would still not be feasible to splice sequential rolls of different length as permitted in the present invention because the chucks would have to be on separate endless chains which would interfere with one another. 
     The Moore U.S. Pat. No. 5,697,575 teaches a splicer having an overall width of less than twice the maximum roll diameter wherein two core chucks traverse opposite sides of the same vertical rail on both the operating and drive sides. Because both chucks are on the same vertical rail, and thus horizontally spaced the same distances as their opposing chuck, this design precludes splicing rolls of varying width. To avoid this problem, four separate vertical rails might be used, one for each of the four chucks, two on the operator side and two on the drive side. However, interference between said vertical rails and the ends of the rolls would occur if the roll widths were unequal as permitted in the present invention. 
     To integrate sequential splicing of rolls of varying width into the prior art requires either (a) the use of core shafts longer than the widest roll, which would defeat one of the prime objects of the present invention, the elimination of core shafts, or (b) independent axial positioning of the roll support arms, which precludes positioning said arms on a common shaft, as it is necessary for each pair of arms to carry rolls having a length that either is less than or surpasses the length of the other pair. A common roll support arm shaft also precludes the automatic core ejection as described herein, which is another prime object of the present invention. 
     SUMMARY OF THE INVENTION 
     Definition of Terms 
     It will be useful to define certain terms: the term “splicehead” refers collectively to the resilient roll, its supporting frame, the severing knife and its actuator. The term “splicer” refers collectively to the entire roll unwinding, tension control mechanism and splicehead. The term “chucking means” refers collectively to the internal core supports, located parallel to the pivot shafts on which the arms rotate, and rotatably mounted on the end away from said shafts, which are operatively expandable to grip the insides of the roll cores and rotate therewith. The term “butt roll” refers to a core having only a reduced amount of paper remaining wound upon it. The term “arm” refers collectively to a rigid structure having parallel holes in each end, one end pivoting on a shaft parallel to the axis of the rolls and the other end having a chuck support shaft on bearing means contained therein rotatably supporting its chuck, means to apply torque to the chuck, and sensing means located thereon to determine the position of the surface of the roll and to confirm the completion of mechanical motions. The term “computer” refers to a control device, either an analog or preferably a digital device for speed and economy, which provides control signals to operatively regulate the motions of the splicer elements logically responsive to manual and automatic sensor signals. The term “new roll” refers to the most recently loaded roll onto which the end of the expiring roll will be joined. The term “roll cores” refers to a tube of length substantially equal the width of the web onto which the web is wound. The term “operator side” refers to that side of the machine closest to the operator into which the roll is preferably loaded. The term “drive side” refers to the side farthest away from the operator. The term “non-driven side” refers to the side of the splicer opposite the core driving motor. The term “driven side” refers to the side of the splicer that has the chuck rotatably driven by the motor. The term “linear actuator” refers to an operative means activating a screw or rack assembly which is operatively contractible or extensible responsive to operative means connected thereto, or a pneumatic or hydraulic cylinder to provide a lifting means for said arms. The term “web” refers to a thin ribbon of flexible martial, such as paper, cardboard, plastic, foil, fabric or the like. The term “dancer” refers to a roller mounted between swinging arms which are adjustably biased by spring, pneumatic or electrical actuators, said actuators so disposed as to resist rotation of said arms by a web wrapped around said roller, the rotational position of said arms producing an electrical signal responsive to the angular position which is indicative of the tension force of said webs. The term “core shaft” refers to a commercially available device consisting of a tube having a diameter smaller than the inside diameter of the roll core into which it is inserted, journaled ends, and a length exceeding the length of the roll of material it supports, and which is provided with expansion means to forcibly engage the interior of said core. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the detailed description of the invention which follows, reference will be made to the accompanying drawings composed of the following figures: 
     FIG. 1 is a pictorial view showing the splicer in its preferred embodiment with a “linear splicehead” located above the roll and with part of the operator side frame cut away to reveal the internal mechanisms. 
     FIG. 2 is a pictorial view showing the splicer in an alternate embodiment with a “pivoting splicehead” with part of the operator side frame cut away to reveal the internal mechanisms. 
     FIG. 3 is a pictorial view showing the splicer with the “pivoting” splicehead, a new roll loaded and part of the operator side frame and part of the left-hand roll cut away to reveal the internal mechanisms. 
     FIG. 4 shows diagrammatically the splicer in FIG. 1 at the beginning of the run with a new roll just loaded and still supported on a roll-dolly, with the “linear” splicehead retracted and with the roll in the right-hand pair of arms partly depleted. 
     FIG. 5 shows diagrammatically the roll in the right hand pair of arms nearly expired with the “linear” splicehead positioned to splice the end of that roll onto the new roll which is supported by the left-hand pair of arms. 
     FIG. 6 shows diagrammatically the position of the left-hand roll as a new roll is being loaded into the right-hand arms from a roll-dolly. 
     FIG. 7 shows diagrammatically the rolls in their preferred splicing position, and the “linear” splicing mechanism extended near the new roll just prior to splice. 
     FIG. 8 is an end elevation showing the butt roll extending out through an opening in the frame, and being removed from the chuck and ejected. 
     FIG. 9 is a side view of a plurality of machines according to the preferred embodiment with the “linear” splicehead, as configured for side loading in a vertically stacked arrangement, and a roll loading device. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention relates to methods and apparatus to form a flying splice wherein the new and expiring rolls of material are supported on a roll unwind stand, where the expiring roll is rotatably supported between a first pair of support arms, and where a new roll with an adhesive pattern is rotatably supported between a second pair of support arms such that the plane of the path of the expiring roll is above, but not touching, the surface of the new roll. When the expiring roll is depleted to a predetermined diameter, the running web is pressed against the surface of the revolving new roll he splicehead, joining the adhesive areas to the running web. The web leading from the expiring roll is severed by a knife which is part of the splicehead. The knife on the splicehead is responsive to a signal from the computer means. 
     Further, the present invention relates to an improved apparatus and method supplying a continuous web of material at substantially constant speed and tension from a succession of web supply rolls. While reference is made to rolls of paper, it will be understood that the webs may be formed of any thin flexible material, such as paper, plastics, textiles, metal foils and the like, and while reference is made to printing, other web processing devices may be substituted. 
     More particularly, the present invention relates to an improved splicing machine having the following advantages: 
     (1) improved structures for loading and rotatably supporting rolls having unequal widths, without the use of core shafts 
     (2) reduced overall dimensions, specifically, a length less than twice the roll diameter. 
     (3) an economical and simple way of removing rolls that are rejected after being only partially depleted from the splicer without interrupting the web supply. 
     (4) a design of such a general nature that it is adapted to being rotated on its side and the rolls introduced into the splicer horizontally from a roll lifting and transport system. 
     (5) a procedure whereby the chucks may be operatively expanded by a combination of braking torque applied on one chuck and a driving torque applied to the chuck on the other end, thereby actuating the internal mechanisms of a chuck designed to be torque-activated. 
     Referring now to the drawings, the present invention in its preferred embodiment with a linear splicehead and rolls loaded off of floor roll-dollies is shown in FIGS. 1, and  4 - 8 . FIGS. 2 and 3 show the alternate pivoting splicehead, and FIG. 9 is shown as configured to be bottom loaded. 
     FIG. 1 illustrates the apparatus in its preferred embodiment comprising frame plates  1  and  2 , loading aperture  50 , spaced apart by cross members  3  and  4  to provide a rigid box-like structure or frame supporting four main splicer components: the pivot shafts  9  and  10 ; the actuators  16 ,  17 ,  18  and  19 ; the preferred embodiment includes a linear splicehead comprising side plate  11 , shaft  12 , resilient roller  13 , severing knife  14 , a supporting track,  20 , and an idler roller  23  and the dancer  15 . The pivot shafts are adjustably supported within the frame plates  1  and  2  by pairs of eccentrics  21  and  22 . The actuators are slidably supported on rails extending across the length of, and attached to, cross members  3  and  4 , so disposed that they slide in unison with the roll support arms beneath them. New roll  32  is rotatably supported on each end by the chucks on arms  5  and  6  operatively swingable about shaft  10  by linear actuators  18  and  19 . Expiring roll  30  is rotatably supported on each end by the chucks on arms  7  (and  8  shown in FIG. 3) which are swingable about shaft  9  by linear actuators  16  and  17 . Each of the pair of arms has opposed and rotatable chucks at one end of each arm and is pivoted about a shaft at the other end, said rotatable chucks extending into and expandibly engaging each end of the tubular roll-core on which rolls are commonly wound. On a first end of rolls  30  and  32 , rotation of the chuck is controllably restrained by friction brake assemblies  36  and  38  respectively, and by friction brake assemblies  35  and  37  respectively on the second end, said friction brakes acting collectively and in unison with regenerative braking from roll core drive motors  31 , to restrain roll rotation, the collective amount of said braking being responsive to signals from the computer to the brake actuating means and to the motor controller, said computer being responsive to a position transducer connected to dancer  15  to provide a constant, predetermined web tension in the exiting web  29 . Thus, braking means are located on both ends of the roll, whereas the driving means, which requires substantially less torque, is preferable located on only one end. The driving motor is preferably, but not necessarily located on the side away from the operator. 
     When the roll  30  is depleted to less than approximately one third its maximum diameter as shown, and said expiring roll is rotating at a high speed, said roll speed accelerates rapidly and may cause an increase in the web tension beyond its predetermined value, even though the brakes are totally released, due to collective inertial mass of the roll core, chuck assemblies and rotating drive components. During this time when the roll is depleted to less than one-third of the maximum diameter, the control of the web tension is normally accomplished solely by the torque of the variable-speed drive motor, which may be used to restrain or accelerate the roll responsive to the position of dancer roll  15  or according to a digitally predictive rate, thereby preventing any variation in the exiting web tension. In the event that it becomes necessary to stop the rolls very rapidly, such as in the case of a web-break or the like, every brake may be applied, to the amount necessary, to assist the drive motors in overcoming the inertia of the rotating rolls so as to rapidly arrest rotation of the rolls. A rapid stop of the expired roll is also required after the splice, to limit the amount of material being unwound after it is cut from the running web and spewing onto the splicer. 
     Dancer roll  15  is rotatably mounted between the frames and serves to sense the web tension. A pair of load cells, supporting web leading roller  49  and mounted on the frames  1  and  2  may be substituted for the dancer to provide a signal to the computer means which is responsive to the exiting web tension; however, the small movements of dancer have the advantage of absorbing minor transient tension fluctuations, such as those caused by an out-of-round roll, whereas the load cells have only a minute amount of movement. 
     Linear actuators  18  and  19  rotatably position arms  5  and  6  respectively, and actuators  16  and  17  rotatably position arms  7  and  8  respectively (shown in FIG.  3 ). Positioning screws  24 ,  25 ,  26  (and an additional positioning screw not shown), laterally position arms  5 ,  6 , 7  (and  8  shown in FIG. 3) respectively to accommodate rolls of varying widths. Another function of said positioning screws is positioning the exiting web  29  from side to side by simultaneous motion of the arms on both ends of a roll, said motion causing axial roll movement without affecting the engagement of the chucks in the roll cores. 
     The splicehead, consisting of side plates  11  and shaft  12  which move linearly in slides  20 , supported on the insides of side plates  1  and  2 , serve to rotatably support resilient roller  13  and severing knife  14  constitute collectively what will be refereed hereafter as the “linear splicehead” The linear splicehead is shown in its extended position, ready to make a splice, wherein it positions resilient roller  13  a distance of ½ inch to 1½ inches from new roll  32 , said roll also deflecting web  29  being unwound from roll  30  to a position close to roll  32 . A photocell (not shown) is located on the splicehead angling inward toward the middle of the roll to sense the circumferential position of the adhesive pattern on the rotating new roll. When the expiring roll reaches a predetermined minimum value, the computer will issue a signal to splice immediately after the next adhesive pattern has passed the photocell. Upon receiving said signal from said computer means, said resilient roll is rapidly and forcibly pressed against the running web against the surface of roll  32 . When the new roll has revolved sufficiently so that adhesive areas  33  (shown in FIG. 3) have traveled under the point of contact of the resilient roller and the new roll, the running web and the leading edge of the web wound on the new roll are co-joined, which tears the tab  34  (shown in FIG. 3) which is used to fasten down the leading edge of the new web and prevent it from unwinding due to aerodynamic drag. At the moment said tabs tear apart, knife  14  severs the connection between the joined webs and the expired roll  30 , and said expired roll is then immediately braked to a stop by braking assembly  35  and  36  and motor means  31 . A computer means  57  controls most of the actions of the present invention. 
     FIG. 2 illustrates an alternate mechanism, which will be referred to as the Pivoting Splicehead replacing the preferred Linear Splicehead in the embodiment illustrated in FIG.  1 . The side plates  47  pivoting in splicer frame side plates  1  and  2  about shaft  12 , resilient roller  13 , and its supporting shaft,  42 , severing knife  14  and idler roller  23  collectively form a mechanism hereinafter referred to as the “Pivoting Splicehead”, which is shown rotated counter-clockwise into its retracted non-operating position. Operating side left-hand roll-supporting arm  7  (and drive side roll-supporting arm  8  shown in FIG. 3) are shown rotated in a counter-clockwise direction by linear actuators  16  and  17  sufficient to allow the right-hand positioning arms  5  and  6  to rotate counter-clockwise past them. Counterclockwise rotation down of arm  5  has been stopped at a point above the area required for the loading of the new roll. Actuator  19  has extended to rotate arm  6  counterclockwise down to the vertical height required for photocell  39  to sense the top of the smallest diameter roll. The operator, or suitable automatic means, will position an end of the new roll inside the frame  2  sufficient close to chuck  40  so that the top of the end face of the roll is sensed by photocell  39 . Actuator  19  will then retract causing arm  6  to rotate clockwise up until photocell  39  senses the top of the new roll. The computer control will then compute the location of the center of the roll core, based on the predetermined height of the roll-dolly and the position of said photocell, and issue a control signal to actuator  19  which will lower arm  6  counter-clockwise to a position wherein the centerline of chuck  40  is positioned vertically at the same height as the new roll core. The roll diameter so obtained will also be stored in the memory of the computer for later use. 
     The new roll is then aligned horizontally, either manually or by automatic means so that the centerline of said new roll and the centerline of chuck  40  are substantially coincident, whereupon the new roll is moved axially to engage onto the chuck. Conical element  41  of the chuck is larger than inside diameter of the roll core, and the axial flutes provided thereon forcibly expand and firmly engage the roll core, centering the roll core on the chuck concomitantly. Actuator  18  then extends to lower arm  5  counter-clockwise to a position wherein its chuck  42  is the same height as opposed chuck  40 . Operative means, such as screws  24  (and  25  shown in FIG.  3 ), then move the arms towards the center of the new roll, thereby forcibly engaging the chucks into the new roll core so disposed that flanges  28 , which are provided on all four chucks, contact the end face of the roll and prevent further engagement. 
     The “chucking means”  40  consists of chuck flange  28 , fluted conical element  41 , a rounded end element supported on an internal shaft, and between  41  and the rounded end is an expandable element  27  which is expandable responsive to relative motion between said conical element and said rounded end element. The expandable element of some commonly available chucks are comprised of an external sleeve of an outside diameter that may be easily inserted into standard roll cores, and having openings through which moveable elements protrude radially outward responsive to a central shaft having cam surfaces so disposed that movement of said shaft relative to the sleeve cams said moveable elements outward, thereby engaging a surrounding roll core. Similar devices having minor variations are commonly available from various manufacturers. For use in this invention, a releasable locking means will be added to selectively retain said chuck in its expanded condition, responsive to a signal from the computer by rotationally restraining relative motion between the exterior element of the chuck and the internal caming element. 
     Referring now to FIG. 3, roll  32  is then raised off its supporting dolly at the roll loading position (shown in FIGS. 4 and 6) by a simultaneous and equal retraction of actuators  18  and  19  causing clockwise rotation of arms  5  and  6  until the roll reaches a splicing position responsive to its diameter, which was stored in the memory of the computer. 
     FIG. 3 shows the splicer as customarily disposed during operation, with the exiting web  29  being fed from roll  30 , after having traversed a plurality of idler rollers  49 . The new roll  32  is now shown raised sufficiently to allow removal of the dolly from the roll loading position. One of the numerous common ways of preparing the outer wrap of a new roll for splicing is illustrated, which will be familiar to those versed in the operations of splicers. The leading end of the outer wrap of the new roll  32  is retained during the time that the roll is being rotated prior to splice by breakable tab  34  and the leading edges prepared by the addition of adhesive areas  33   
     FIG. 4 shows diagrammatically a side view of the splicer with roll  32  beginning to unwind. New roll  48  was inserted into the roll loading position and is still supported on roll-dolly  43 . Next, the left-hand arms will move together axially, thereby engaging their chucks into the core of roll  48  prior to raising the roll into the position shown in FIG.  5 . 
     Referring now to FIG. 5, the unwinding roll  32  will soon be expired. The new roll  48  is positioned a predetermined distance from resilient roller  13  in preparation for the splicing operation, and is accelerated to a speed such that the surface velocity of the roll surface equals the running web velocity. At a predetermined size for expiring roll  32  the splice will be initiated as heretofore described for roll  32 . 
     FIG. 6 shows the preferred embodiment with the Linear Splicehead in its retracted position. The roll  48  in the left-hand pair of arms is raised sufficiently to allow the right-hand pair of arms to bypass them on the way downward to engage the new roll  61 , which is supported by dolly  43 . 
     In FIG. 7, the linear splicehead has been extended in preparation for splicing, and the running roll  48  is nearly depleted. The new roll  46  has been lifted from the dolly and positioned for splicing. When the diameter of roll  48  is reduced to a predetermined size, a splice will be made as heretofore described. 
     Referring to FIG. 8, after a splice has been made, chuck  40  on the operator side is shown disengaged from roll core  55 . The roll core continues to be supported by its opposed chuck, which is driven by motor  31  on the driven side. The roll support arms are then deliberately miss-aligned, and the arm still supporting the core  55  is rotated to a position where the roll core extends between rollers  44  and  45 , and is gripped thereby. Drive means  31  then rotates the butt roll wound on core  55  in the direction which causes the butt roll to unwind, and the web remaining thereon  54  to be drawn off by the rotation of rolls  44  and  45 . Assisting in the removing of said web is a suction and shredding fan located in duct  53 . After removal of said remaining web, the core is operatively disengaged from the chuck, and rollers  44  and  45  grip the core and continue to rotate to draw the core off of the chuck and expel it through the frame into a suitable accumulating means. Covers  51  and  52  enclose actuators  16 , 17 , 18 , and  19 . 
     Yet another aspect of this invention is shown in FIG. 9 wherein the entire splicing machine may be rotated a quarter of a revolution to produce machines which may be stacked vertically to reduce the floor length of the press row. Two stacks of four machines each with a central roll-lifting mechanism are shown, with the new roll illustrated in the position to load into the top right-hand splicer. This configuration for side-loading requires a special horizontally traversing cradle support arm  59  supporting roll cradle  56  and vertically moveable support by elevating structure and mechanism  58 . The new roll is rolled into said roll cradle at a central position in line with  58 , with its axis parallel to the direction of web travel. It is then prepared for splicing by the addition of the aforementioned adhesive and tab, rotated one-quarter of a revolution, and raised to the appropriate level to be loaded into the desired stacked splicer, where it is positioned side-to-side by arm  59  so disposed that its roll core may then be engaged by the chuck in the roll support arm  7 .