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(11) | EP 2 589 557 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | A web splicing arrangement for a web winder and/or methods of splicing webs |
| (57) A web splicing arrangement for a web winder comprises a splicing table (1) which
is supported by one or more displaceable arms (3); said table (1) being displaceable
said web roll between a retracted position the table (1) is at least spaced from the
underside of a web and a cutting position the table is located in contact with the
underside of said web for facilitating the cutting of said web.
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Field of the Invention
[0001] The invention relates to web splicing arrangements for web winders and/or methods of splicing webs.
Background to the Invention and Prior Art Known to the Applicant
[0002] Splicing tables are common on slitter rewinding machines. Traditionally, splicing tables are fixed in a static position between the rewinding machine's side frames at the unwinding portion of the winder.
[0003] The facility to splice the web is a well established concept and as such, splicing methods that join webs together have changed very little over the years. The following prior art arrangements are known:
- Basic splice table - some splice tables are just a smooth solid board with a steel insert, such as a machined cutting groove, that traverses the width of the splice table. The machined cutting groove is a guide to assist the operator in masking a good clean cut and is a feature of the Applicant's own splicing tables;
- Splice table with web clamps - this configuration of splicing table has web clamps to hold the web in position when the cut is made. The web clamps operate on pneumatic pressure supplied from reservoir cylinders. The cylinders are fed pneumatic pressure from the main pneumatic system of the machine;
- Splice table with vacuum pumps - the body of the splice table is hollow. The hollow centre of the body is usually divided into an upper vacuum chamber and a lower vacuum chamber. Each vacuum chamber incorporates an array of hundreds of small holes that are machined through the splice table's upper surface. Pipes connect the vacuum chambers to the vacuum pumps. When the web lies across the small holes machined through the splice table's upper surface and the vacuum pumps are switched ON the suction generated pulls the web onto the splice table surface, thereby sealing the holes and creating a vacuum. The web can then be cut accurately along the machined cutting groove;
- Splice table with web clamps and vacuum pumps.
[0004] The disadvantages of these known splicing tables are at least the following:
- Fixed height - machines that currently have a splice table over the unwind roll have the splice table at a fixed height. It is usually accepted that this is probably the best place to position the splice table, however, it does have a problem. The splice table at a fixed height may be out of reach for some operators. This problem is compounded when a large unwind roll is fitted to the web rewinding machine, whereby a lifting device or steps are required to enable the operator to reach the splicing table. Furthermore, rewind machines with a fixed height splice table located over the unwinding roll have the hindrance of the splice table being an obstruction when loading a new unwind roll using an overhead crane;
- Fixed width - conventional splice tables are rigidly mounted between the rewind machine's side frames;
- Loss of vacuum when splicing narrow webs - the vacuum chambers are the full width of the splice table. Therefore, if a narrow web is being spliced, the uncovered holes through the splice table's upper surface will not be seated and this will prevent the requisite vacuum from being generated. Paper or similar substrate material is required to cover the holes not covered by the web for the vacuum to be created;
- Web clamps - conventional web clamps are two parallel bars that traverse the full width of the splice table and are operated by pneumatic cylinders. The web clamps trap the web against the surface of the splice table and therefore create a narrow channel for the operator to work in.
[0005] Furthermore, known web clamps can be very long, which means further expense and weight issues. Apart from the weight there is the complex method of adjustment. There is also a very slight risk of the operator getting his hands trapped if they are in the way, when the web clamps are lowered;
- threading procedure - a known splice table is preferably fitted as close as possible to the unwind roll, however, it still means that the operator will have to manually thread the web from the unwind roll to the splice table;
- danger of the web touching the splice table when the machine is running - in conventional use, the web will be only a few millimetres above the splice table and will be travelling up to the speed of 900 metres per minute. A sudden drop in web tension, caused by say, for example, an out-of-round unwind roll, can result in the web being damaged by coming into contact with the splice table.
Summary of the Invention
[0006] In a first broad independent aspect, the invention provides a web splicing arrangement for a web winder comprising a splicing table which is supported by one or more displaceable arms; said table being displaceable over said web roll between a retracted position where the table is at least spaced from the underside of a web and a cutting position where the table is located in contact with the underside of said web for facilitating the cutting of said web.
[0007] This configuration is advantageous because the operator can select any comfortable working height eliminating the need to stretch to reach the splice table. When there is a need to splice the web the displaceable arms position the splicing table from its parked position, to a position where the splicing can be carried out by the operator at a comfortable height. In preferred embodiments, the movement can be stopped at any time resulting in achieving a range of working heights.
[0008] Preferably, the arms are attached for rotation about the axle of the unwind chuck support mechanism of said web winder. This ensures that the splicing table and the unwind web roll both rotate about a common axis.
[0009] Preferably, the table is displaced by a pneumatic actuator. This enables the displaceable arms to be moved by an actuator which is supplied by an existing pneumatic air circuit incorporated within the rewind machine.
[0010] Preferably, the arms are slideably attached to the table which in use, narrow or widen the support provided to the table to accommodate a range of web roll widths. This enables the supporting arms to provide maximum support for the splice table when either a narrow or wide web roll has been loaded onto the rewind machine.
[0011] Preferably, the table further comprises a plurality of attachment channels, whereby each one of said attachment channels facilitates the slideable attachment of each one of said arms to said table. This enables the slideable attachment of the supporting arms to the table to be carried out along pre-determined axes which reduces the possibilities of any deviation along its path.
[0012] Preferably, the attachment channels are located on the underside of table. This configuration provides a means of supporting the table whereby the whole of the upper surface of the table may be utilised without any obstruction from the supporting arms.
[0013] Preferably, one or more of said arms is indexed to a pre-determined position within the attachment channel. This enables the position adjustment of the table to set known increments which can be applied uniformly over the whole table.
[0014] Preferably, the arrangement incorporates a plurality of selectable vacuum chambers comprising a first array of selectable vacuum chambers which extend across the width of the table; and a second array of selectable vacuum chambers which extend across the width of the table, whereby the first array of selectable vacuum chambers is disposed above the second array of selectable vacuum chambers. This configuration provide a means of having an upper and lower vacuum chamber that may accommodate a variety of web widths, having a first array of vacuum chambers, typically three or more chambers and the second array of chambers typically with three chambers are provided to accommodate four different web widths. For narrow webs only the middle chamber array of both upper and lower vacuum chambers will be used. For full width web all the vacuum chambers within the upper and lower chamber arrays will be used.
[0015] Preferably, the table further comprises a plurality of slideably attached clamping members, wherein at least one clamping member comprises a body and a resilient spring member; when the clamping member is moved to a first position against the pressure of the spring member, the movement of the clamp is enabled; and when moved to a second position the clamp co-operates with the spring pressure of the spring member, which in use pulls the clamp member body down onto a web securing it against the table. This configuration has the advantage that it is not dependent upon any pneumatic or electrical supplies and will not obstruct the splicing operation. The clamping devices may be spring-loaded devices fitted on a slider that may be located on the table. The clamp is pulled up to enable the device to be slideably adjusted so that it is next to the web located on the splicing table. The spring forces the clamp down against the web and traps it against the upper surface of the splice table.
[0016] Clamp members further comprise a rotation means to facilitate the rotation of the device member body when moved to the second position. This enables the clamp to be rotated so that its body is over the web and when released it ensures that a portion of the body is clamped down against the web which then traps it against the upper surface of the table.
[0017] Preferably, the plurality of clamping members may be slideably attached to an edge of said table. This configuration enables the bodies of the clamping members to be reduced to a small size so that only the relevant portion may protrude and be used to clamp the web in place on the table's upper surface. The upper edge allows the clamping devices to be moved up and adjacent to the web which is located on the splicing table's upper surface.
[0018] In a second broad independent aspect, the invention provides a method of splicing a web in a web winder comprising the steps of displacing a splicing table over a web roll between a retracted position where the table is at least spaced from the underside of a web and a cutting position where the table is located in contact with the underside of said web; and cutting said web prior to returning said table to said retracted position.
[0019] Preferably, the method comprises the steps of:
displacing a splicing table over a used unwind web roll from said retracted position to a cutting position;
securing the contacting portion of said web to said table;
cutting the web width wise;
displacing said splicing table to a retracted position;
unloading said used unwind roll;
loading a new unwind roll;
displacing said splicing table from a retracted position to a splicing position, and splicing a web winder remaining portion of said used web with a web end portion of said new unwind roll.
[0020] Preferably, the method comprises the step of displacing the table about the perimeter of a web roll.
[0022] Preferably, the table is supported by at least two arms; and the method incorporates the step of varying the separation between the two arm dependent upon the width of the web roll,
[0023] Preferably, the table incorporates a plurality of distinct vacuum areas; and the method incorporates the step of selecting the activation of one or more of the plurality of distinct vacuum areas.
[0024] Preferably, the table incorporates a plurality of clamping members; and the method incorporates the step of slideably displacing at least one clamping member along at least a portion of the width of the table.
[0025] In further broad independent aspects, the invention provides a splicing table arrangement in a web winder with at least one of the following features:
- supporting arms and means for varying the separation between the two arms dependent upon the width of the web roll
- a plurality of distinct upper and/or lower vacuum areas; and means of activating two or more of said plurality of distinct vacuum areas in the upper and/or lower areas of the table; and
- clamping members which displace along at least a portion of the width of the table.
Brief Description of the Figures
[0026]
Figure 1 shows a side view of the rewind machine where the table is rotated to a splicing position and a side view where the table is rotated back to a parked position.
Figure 2 shows a top view of the splice table assembly and a cross-sectional view of the splice table assembly, along with a side view of the table located at the parked position on the rewind machine.
Figure 3 shows a side view of the rewind machine which has a spent unwind roll fitted.
Figure 4 shows a side view of the rewind machine where the splicing table is holding the remaining web portion of a spent web roll which is being unloaded from the machine.
Figure 5 shows a side view of the rewind machine where a new web roll has been loaded onto the machine and its web has been placed onto the splicing table.
Figure 6 shows a side view of the machine where the web of the new roll has been spliced onto the remaining web portion of the previous roll.
Figure 7A shows a front view of the rewind machine where the supporting arms are located at the maximum width position.
Figure 7B shows a rear view of a rewind machine the supporting arms have been adjusted to their maximum width position.
Figure 7C shows a side view where the web from the supported roll is threaded through the machine.
Figure 8A shows a front view of the rewind machine where the support arms are in a narrow position.
Figure 8B shows a rear view of the rewind machine where the support arms are adjusted into a narrow position.
Figure 8C is a side view of the rewind machine which has a web from a narrow web roll threaded through the machine.
Figure 9a shows a side view of the rewind machine with the splicing table in the parked position along with its associated web clamps.
Figure 9 illustrates the manual operation of the web clamps.
Figure 9C illustrates where the clamps retain the web onto the splicing table's upper surface.
Figure 10 shows a side view of the rewind machine incorporating a spent web roll and parked splicing table with associated web clamps.
Figure 11A shows the manual operation of the web clamps where the web clamped down onto the upper surface of the splicing table.
Figure 11B shows a a plan view of a clamped end portion of a web.
Figure 11C shows a side view of a unwind machine that has clamped a web from a spent web roll and has the roll removed from the machine.
Figure 12A shows a side view of a rewind machine where a new web roll has been attached to the machine and its web has been placed on the splicing table to be joined with the clamped existing web.
Figure 12B shows a plan view of the splicing table with web ends in the process of being spliced together.
Figure 13A shows the manual operation of the web clamping devices for the splicing table.
Figure 13 shows a plan view of a splicing table where web ends of identical width have been spliced together.
Figure 13C shows sidle view of an unwind machine where web ends of identical width have been spliced together.
Figure 14A shows the side view of an unwind machine that has a new web loaded onto the machine which has been attached to a clamped existing web.
Figure 14B shows in plan view the manual operation of clamping an existing web onto the splicing table.
Figure 14C shows the existing web clamped to the top surface of the splicing table and held in place by the mechanical clamps.
Figure 15A shows the side view of an unwind machine that has a new web loaded onto the machine which has been attached to a clamped existing web; the new web being narrower than the former web.
Figures 15 show views on arrows A and B respectively.
Figure 15C shows a plan view of a splicing table with a new web being narrower than a former web.
Figure 16A shows a plan view of a splicing table with its clamping mechanism when used with a former web with greater width than the new web.
Figure 16B shows a side view of an unwind machine with a new web roll loaded.
Figure 17A shows a side view of an unwind machine with a retracted splicing table.
Figure 17B shows a cross-sectional view of the splicing table with several chambers.
Figure 17C shows the sequence of manual operations for clamping an end portion of a web.
Figure 17D shows a plan view of splicing table with the end of a web secured by both vacuum and by clamping.
Figure 18 shows the side view of an unwind portion of a web rewinder with the unwind roll used up.
Figure 19A shows the sequence of manual operations for clamping an end portion of a web.
Figure 19B shows a a plan view of a splicing table which secures a portion of a web by both vacuum and mechanical means.
Figure 19C shows a side view of an unwind portion and the removal of a spent roll.
Figure 20A shows a side view of an unwind portion during the splicing phase of the operation.
Figure 20B shows a plan view during the splicing phase of the operation.
Figures 21A and 21B show the manual operation of clamping.
Figure 21C shows in side view the feeding of a new web following splicing.
Figure 22A shows the manual operation of clamping.
Figure 22B shows the manual operation of clamping in plan view.
Figure 22C shows the removal of a used roll.
Figure 23A shows a side view of the splicing of web ends of different widths.
Figures 23B show views on arrows A and B.
Figure 23C shows a plan view of the splicing of web ends of different widths.
Figure 24A shows a plan view of the splicing of web ends of different widths.
Figure 24B shows a side view of the splicing of web ends of different widths.
Detailed Description of an Embodiment
[0027] Embodiments of the invention may include one or a combination of the following: web clamps, and vacuum pumps. In preferred embodiments, the splicing table will have at least one cutting groove.
[0028] Overview of embodiments and one of their objectives:
- A) VARIABLE WORKING HEIGHT. The Operator can select any comfortable working height eliminating the need to stretch to reach the splice table. The splice table support arms are mounted on the axis of the unwind chucks support mechanism. A pneumatic cylinder mounted on each unwind arm attaches the corresponding splice table support arm. When there is the need to splice the web the pneumatic cylinders extend and rotate the Splice Table from its 'parked' position. The movement can be stopped at any time resulting in virtually infinite working heights being achieved.
- B) VARIABLE WEB WIDTH. The splice table support arms are mounted in slide channels attached to the underside of the splice table with numerous stop positions. When the unwind arms are moved inwards to chuck a narrow mill roll, or outwards to chuck a wide mill roll, the support arms slide in the channels to provide maximum support for the splice table where it is most needed.
- C) NO LOSS OF VACUUM WHEN SPLICING NARROW WEBS. Instead of having one upper and one lower vacuum chamber for all web widths, this splice table has three upper and three lower vacuum chambers to provide for different web widths. For narrow webs only the middle upper and lower vacuum chambers will be used. For full width webs all three upper and lower vacuum chambers will be used.
- D) WEB CLAMPS. The web clamps are small mechanical devices that require no pneumatic or electrical supplies, and do not get in the way of the splicing operation. The web clamps are spring loaded devices fitted on a slider that is mounted along the upper edge of the splice table. Each web clamp consists of a metal body and a spring loaded clamp. The clamp is pulled up against spring pressure. The web clamp is moved along the slider until it is next to the web. The clamp is turned through approximately 450 so that it is over the web and released. The spring extends and forces the clamp down against the web trapping it against the splice table upper surface.
- E) NO THREADING PROCEDURE - FASTER MILL ROLL SPLICE TIME. The splice table is directly over the mill roll. The web is unrolled from the mill roll and laid on the splice table.
- F) DANGER OF THE WEB TOUCHING THE SPLICE TABLE WHEN THE MACHINE IS RUNNING IS ELIMINATED. (see figure 1) When the splice table is rotated to its 'parked' position it is completely out of the way of the web. The height of the web above the splice table removes any possibility of contact between the two surfaces unless the web snaps.
[0029] As shown in figure 2, the splice table assembly consists of a splicing table 1 with a support arm assembly 2.
[0030] The splicing table has three vacuum chambers 3 mounted on a backplate 4. Each vacuum chamber is fitted with (typical) suction connectors 5 for the pipes that connect from the splice table to the vacuum pumps. The outer surface of the vacuum chambers is porous. The support arm assembly is mounted on the unwind chuck axis.
[0032] As shown in figure 4, the splice table is rotated to a convenient position for the Operator to work. The upper and lower vacuum pumps are switched ON and the web is cut along the cutting groove. The lower vacuum chambers are switched OFF and the splice table is rotated back to the "parked" position. The used unwind roll is unloaded.
[0033] As shown in figure 5, a new unwind roll is loaded and the splice table is rotated to the "splice" position. A new web is pulled off the unwind roll and laid on the splice table overlapping the tail of the threaded web. The lower vacuum chambers are switched ON and the splice is made.
[0034] As shown in figure 6, the upper and lower vacuum chambers are switched OFF and the splice table is rotated back to its "parked" position. The machine may then be restarted.
[0035] With regard to reducing the web width, as shown in figure 7, the (wide) unwind roll fitted in the unwind is used up and the machine has been stopped. The splice table is rotated to a convenient position for the Operator. The upper and lower vacuum chambers are switched ON and the web is cut along the cutting groove. The unwind arms and the support arm assemblies are at the maximum width position.
[0036] The lower vacuum chambers are switched OFF. The splice table is rotated back to the "parked" position. The wide unwind roll is unloaded.
[0037] The unwind arms are moved inward to chuck the narrow unwind roll. The narrow unwind roll is fitted to the unwind and the splice table is rotated to the "splice" position. The new web is pulled off the unwind roll and laid on the splice table overlapping the tail of the threaded web. The lower centre Vacuum Chamber is switched ON. (The lower outer vacuum chambers are not needed). The splice is made (X).
[0038] The upper and lower vacuum chambers are switched OFF and the splice table is rotated back to the "parked" position.
[0039] The machine is started in crawl (jog, inch) speed to thread the narrow web through to the rewinds where the rewound rolls are cut free from the new web.
[0040] With regard to the splice table with web clamps and referring to Figure 9, the splice table assembly consists of a splicing table 1 with mechanical web clamps 2 and a support arm assembly 3. The support arm assembly is mounted on the unwind chuck axis.
[0041] The Web Clamps are spring loaded devices fitted on a slider that is mounted along the upper edge of the splice table. Each web clamp consists of a body and a spring loaded clamp. Spring pressure keeps the clamp down on the outer surface of the splice table. Figure 9b shows the following modes of operation:
- A) The web clamps are 'parked' at the ends of the slider.
- B) The clamp is pulled up and turned through approximately 45 degrees whilst being slid into position beside the threaded web.
- C) When the web clamp is in position beside the web and clamp is released.
[0043] The splice table is rotated to a convenient position for the Operator to work. The web clamps are pulled up and moved into position along side the web. The web clamps are released and they clamp DOWN to hold the web. The web is cut along the cutting groove. The splice table is rotated back to the "parked" position. The used unwind roll is unloaded as shown in figure 11.
[0044] As shown in figure 12, a new unwind roll is loaded and the splice table is rotated to the "splice" position. The new web is pulled off the unwind roll and laid on the splice table. The splice is made.
[0045] As shown in figure 13, the web clamps are pulled up and moved to the end of the splice table and released. The splice table is rotated back to its "parked" position. The machine its then restarted.
[0046] With regard to a reducing web width, the (wide) unwind roll is used up and the machine has been stopped. The splice table is rotated to a convenient position for the Operator to work. The web clamps are pulled up and moved into position along side the web. The web clamps are released and they clamp DOWN to hold the web as shown in figure 14. The web is cut along the cutting groove. The splice table is rotated back to the "parked" position. The used unwind roll is unloaded.
[0047] The unwind arms are moved inward to chuck the narrow unwind roll. The narrow unwind roll is fitted to the unwind and the splice table is rotated to the "splice" position. The new web is pulled off the unwind roll and laid on the splice table overlapping the tail of the threaded web. The splice is made as shown in Figure 15.
[0048] The web clamps are pulled up and moved to the end of the splice table and released. The splice table is rotated back to its "parked" position as shown in figure 16.
[0049] The machine is then started in crawl (jog, inch) speed to thread the narrow web through to the rewinds where the rewound rolls are cut free from the new web.
[0050] With regard to a splice table with vacuum and web clamps embodiment, the splice table assembly consists of a splicing table 1 fitted with three vacuum chambers 2 and mechanical web clamps 3 mounted to a back plate 4 that is fixed to the support arm assembly 5. The support arm assembly is mounted on the unwind chuck axis. Each vacuum chamber is fitted with (typical) suction connectors 6 for the pipes that connect from the splice table to the vacuum pumps. The outer surface of the vacuum chambers is porous.
[0051] As shown in figure 17, the web clamps 7 are spring loaded devices fitted on a slider that is mounted along the upper edge of the splice table. Each web clamp consists of a body and a spring loaded clamp 8. Spring pressure keeps the clamp down on the outer surface of the splice table.
- A) The web clamps are 'parked' at the ends of the slider.
- B) The clamp is pulled up and turned through approximately 45 degrees whilst being slid into position beside the threaded web.
- C) When the web clamp is in position beside the web and the clamp is released.
[0052] With regard to maintaining web width, the unwind roll fitted in the unwind is used up as shown in figure 18 and the machine has been stopped.
[0053] The splice table is rotated to a convenient position for the operator to work. The upper and lower vacuum pumps are switched ON and the web clamps are pulled up and moved into position along side the web. The web clamps are released and they clamp DOWN to hold the web. The web is cut along the cutting groove. The vacuum pumps are switched OFF. The splice table is rotated back to the "parked" position. The used unwind roll is unloaded as shown in figure 19.
[0054] As shown in figure 20, a new unwind roll is loaded and the splice table is rotated to the "splice" position. New web is pulled off the unwind roll and laid on the splice web. The vacuum pumps are switched ON. The splice is made.
[0055] The vacuum pumps are switched OFF and the web clamps are selected UP. The web clamps are pulled up and moved to the end of the splice table and released. The splice table is rotated back to its "parked" position as shown in figure 21. The machine is then restarted.
[0056] With regard to an embodiment of reducing web width, the (wide) unwind roll is used up and the machine has been stopped. The splice table is rotated to a convenient position for the operator. The middle vacuum pumps are switched ON. The web clamps are pulled up and moved into position along side the web. The web clamps are released and they clamp DOWN to hold the web. The web is cut along the cutting groove. The vacuum pumps are switched OFF. The splice table is rotated back to the "parked" position. The used unwind roll is unloaded as shown in figure 22.
[0057] The unwind arms are moved inward to chuck the narrow unwind roll. The narrow unwind roll is fitted to the unwind and the splice table is rotated to the "splice" position. A new web is pulled off the unwind roll and laid on the splice table overlapping the tail of the threaded web. The lower middle vacuum pump is switched ON to hold the web in position. The splice is made as shown in figure 23.
• displacing a splicing table over a used unwind web roll from said retracted position to a cutting position;
• securing the contacting portion of said web to said table;
• cutting the web width wise;
• displacing said splicing table to a retracted position;
• unloading said used unwind roll;
• loading a new unwind roll;
• displacing said splicing table from a retracted position to a splicing position; and
• splicing a web winder remaining portion of said used web with a web end portion of said new unwind roll.