Technical field
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The invention relates generally to production of fiber webs and to producing parent rolls of fiber webs, especially in a reeler. The invention relates to an adhesive application device according to the preamble part of the independent adhesive application device claim. The invention also relates to a turn-up system according to the preamble part of the independent turn-up system claim and to a turn-up method according to the preamble part of the independent turn-up method claim.
Background
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As known, fiber webs, such as paper or board webs, are manufactured in machines together forming a fiber web manufacturing line, which may be hundreds of meters long. Modern paper machines may produce more than 450,000 tons of paper per year. The speed of a paper machine may exceed 2000 m/min and the width of a paper web may be more than 11 meters.
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As known from the prior art in fiber web producing processes typically comprise an assembly formed by a number of apparatuses arranged consecutively in the process line. A typical production and treatment line comprises a head box, a wire section and a press section as well as a subsequent drying section and a reeler. The production and treatment line can further comprise finishing devices, for example a sizer and /or a calender and / or a coater. The production and treatment line also comprises typically at least one slitter-winder for forming customer rolls as well as a roll packaging apparatus.
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In fiber web production lines, manufacturing operates as a continuous process. The finished fiber web being output from the machine is wound with a reeler around a reeling shaft, i.e. a reel spool, into a parent roll (a machine roll), the diameter of which may be more than 5 meters and which may weigh more than 160 tons. The purpose of the reeling is to transfer the fiber web from its planar manufacturing form into a form in which it can be handled more easily. At the reeler, which is located in the main production line, the continuous process of the production line is interrupted for the first time, after which the process continues in stages. Every attempt is made to interlink these stages as smoothly as possible so that the work already performed would not be wasted. Reelers are thus used in fiber web production for reeling the fiber web coming from the fiber web production line into a parent roll, but reelers are also used to reel fiber web coming from a coating machine, a calender or a corresponding finishing device.
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In the known methods and systems for turn-up several disadvantages and problems may occur: Often in connection with the methods and systems known from prior art a lot of space needed for the equipment and thus it might be difficult to find a cost-effective solution for the turn-up system to perform the turn-up fast and effectively.
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In the reeler the parent roll is formed around the reeling shaft operating as the reeling core i.e. the fiber web being on one parent roll has a start, i.e. a beginning end, and a final end, i.e. a tail. When a parent roll has been reeled to its full diameter and it is completed, a turn-up (a reel change, a parent roll change) is performed for finishing the reeling of the completed parent roll and for beginning of reeling of a new parent roll around a new reeling shaft or like reeling core. In the turn-up the fiber web is cut typically such that a wedge like tip is formed to the web by one or two cutting devices and the final end i.e. tail of the fiber web is attached on the surface of the completed parent roll and the beginning end i.e. tip of the fiber web is attached on the new reeling shaft. For attaching the tail of the fiber web onto the surface of the completed parent roll and the beginning end on the reeling shaft it is known from prior art to add adhesive, such as glue, on the surface of the parent roll or on the surface of the fiber web near the edges of the fiber web just before the turn-up, and respectively on the beginning end of the fiber web. For these purpose, adhesive application devices, respectively, have been arranged in connection with the turn-up system of the reel up. For attachment of the beginning end on the reeling shaft an adhesive application device is provided as well as another adhesive application device for attachment of the tail on the surface of the completed parent roll.
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In existing turn-up systems using hotmelt adhesives, the container for the hotmelt adhesive and the pump for pumping the hotmelt adhesive to adhesive nozzles has been located at a side of the fiber web machine, whereby long feed tubes from the container and the pump to the adhesive nozzles has been needed. This long distance between the hotmelt adhesive container and the nozzles and to the application point has caused that the hotmelt adhesive has cooled before the application point, which in turn has caused that the hotmelt adhesive has been, to be on the safe side, even overheated. The overwarming of the hotmelt decreases binding properties of the hotmelt adhesive.
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In existing turn-up systems, especially in connection with reeling of heavy grades fiber webs, adhesive application devices utilizing hotmelt adhesives are used. When the adhesive is to be applied by the adhesive application device an application pulse is generated by pressure to apply the adhesive on the target surface. In the adhesive application devices known from prior art control of adhesive amount is challenging as the pressure decreases fast after the adhesive application pulse has been started. This results in uneven adhesive amount within application pulse due to the pressure decrease at the beginning high amount of adhesive is applied and as the pressure decreases the amount of the adhesive applied gradually decreases towards the end of the application pulse. Uncontrolled amount of adhesive easily leads to failed turn-up, because the pick-up of the beginning end and its attachment onto the reeling shaft fails as both too high and too low adhesive amount disturbs the pick-up of the beginning end. Furthermore, the attachment of the beginning end is done with hotmelt adhesive as high amount of adhesive tackiness is required to attach the beginning end of the fiber web onto the surface of the reeling shaft. Thus, there exists a need, especially in view of achieving high turn-up performance, for an adhesive application device, which provides for fully controlled adhesive amount at the beginning end, as both too high and too low adhesive amount disturbs the pick-up and attachment of the beginning end. If the amount of adhesive is too high, the adhesive spreads outside the edges of the beginning end and prevents adherence and thus pickup of the fiber web onto the reeling shaft. If the amount of the adhesive is too low, it is not enough to tack and attach the beginning end onto the reeling shaft. In the adhesive application devices known from prior art the control of adhesive amount is challenging as the adhesive application device loses its pressure fast after the adhesive application pulse is started and thus, the amount of adhesive at the beginning of the application pulse is much higher than at the end of application pulse. Fiber web production lines, paper or board production lines, having large basis weight and/or operating speed range are the most difficult cases as the requirement for adhesive amount changes according to produced grade.
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In existing turn-up systems, the attachment of the tail onto the surface of the completed parent roll is performed by using a separate adhesive application device, by which the attachment of the tail and thus, the parent roll surface binding is provided in the turn-up. In the adhesive application devices for the parent roll surface binding, used adhesive often dries on the nozzle tip of the adhesive application device and thus, periodic checks and maintenance are needed. It is known from prior art that trials using hotmelt adhesive utilizing adhesive application devices for parent roll surface binding have been done but these trials have failed due to lack of adhesive left for the parent roll surface binding after the pick-up and attachment of the beginning end due to the adhesive application device losing its pressure to provide the adhesive. The attachment of the tail onto the completed parent roll, i.e. the parent roll surface binding is needed to prevent surface layers from loosening after the turn-up. The adhesive application in attaching the tail onto the surface of the completed parent roll, the application of the adhesive is typically begun from the middle in cross direction of the fiber web and thus, it is important that the adhesive covers accurately the whole cross-sectional area of the tail, even the last corners, to prevent loosening and straggling of the tail. The existing surface binding system is an additional and separate adhesive application device from the beginning end adhesive application device as different adhesive is used for the attachment of the beginning end and for the attachment of the tail.
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In patent publication
CA2636423C is disclosed a reeling shaft of a fiber-web machine reeler, which reeling shaft comprises at least one smooth surface area, which smooth surface area comprises at least the surface area of the reeling shaft to which an adhesive material used in connection with a turn-up process in the reel-up for fastening the end of the web for starting the reeling of a new web roll is arranged to adhere, and the smooth surface area is smooth so that the adhesion of the adhesive material used in the turn-up is adequate for starting the reeling of a new web roll and the adhesive material is easily removable after unreeling.
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In patent publication
EP1946846B1 is disclosed an adhesive application device for a machine which processes paper or board, having a plurality of discharge modules distributed over a working width, each of which has an adhesive flow connection and an adhesive return connection, an adhesive chamber between the adhesive flow connection and the adhesive return connection, and a closable discharge opening out of the adhesive chamber, the adhesive return connections of a plurality of discharge modules being connected to a common return. In the return there is arranged a pressure setting device, with which a pressure can be generated in the return, this pressure being set in accordance with the pressure drop which arises when all the discharge openings are completely open.
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An object of the present invention is to create an adhesive application device, in which the problems and disadvantages of adhesive application devices for a turn-up system of a reeler of a fiber web production line known from prior art are eliminated or at least minimized.
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A particular object of the present invention is to provide an adhesive application device in which especially the problems relating to the attachment of the beginning end of the fiber web onto a reeling shaft of a reeler in the turn-up of a fiber web production line are eliminated or at least minimized.
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A particular object of the present invention is to create an adhesive application device for a turn-up system of a reeler of a fiber web production line in which especially the problems relating to disadvantageous temperature of the hotmelt adhesive at the application point.
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A further, non-binding, object of the present invention is to create an adhesive application device for a turn-up system of a reeler of a fiber web production line in which especially the problems relating to the need of periodic checks and maintenance due to adhesive drying on the nozzle tip of the adhesive application device are eliminated or at least minimized.
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A particular, non-binding object of the present invention is to provide an adhesive application device in which especially the problems relating to the need of two separate adhesive application devices in the turn-up of a reeler are eliminated or at least minimized.
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An object of the present invention is to create a turn-up system of a reeler, in which the disadvantages of prior art are eliminated or at least minimized.
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An object of the present invention is to create a turn-up method of a reeler, in which the disadvantages of prior art are eliminated or at least minimized.
Summary
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To achieve the above-mentioned objects and those which come out later, the adhesive application device according to the invention is mainly characterized by what is presented in the characterizing part of claim 1. The turn-up system according to the invention is mainly characterized by what is presented in the characterizing part of the independent turn-up system claim and the turn-up method according to the invention is mainly characterized by what is presented in the characterizing part of the independent turn-up method claim. Advantageous features and embodiments of the invention are defined in the claims.
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According to the invention the adhesive application device for a turn-up system of a reeler of a fiber web production line comprises a melter and an adhesive applicator, which adhesive applicator comprises nozzles, in which adhesive application device the melter is connected to the adhesive applicator via a feed channel for providing adhesive to the nozzles of the adhesive applicator, wherein,
- the melter is a hotmelt adhesive melter,
- the adhesive applicator is a high pressure hotmelt adhesive applicator comprising an applicator head, a high-pressure pump unit, a linear actuator and a linear actuator mover,
- and the high-pressure pump unit is driven by the linear actuator and the linear actuator mover.
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According to an advantageous feature the linear actuator mover is a servo drive. The linear actuator mover can also be a hydraulic drive.
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According to the invention the applicator head is configured to apply hot melt adhesive for attaching a beginning end of a fiber web in a turn up of a reeler. According to an advantageous feature of the invention the adhesive applicator is configured to be controlled by a position control of the servo drive.
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According to the invention the applicator head is configured to apply hot melt adhesive for attaching a tail of the fiber web in the turn-up of the reeler. According to an advantageous feature of the invention the adhesive applicator is configured to be controlled by a pressure control of the servo drive.
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According to an advantageous feature of the invention the high-pressure pump unit comprises a piston and a cylinder structure and that the piston is a high-pressure piston.
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According to an advantageous feature of the invention the applicator head is manufactured by 3D-printing technology.
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According to an advantageous feature of the invention the high pressure hotmelt adhesive applicator comprises a pressure relief valve for pressure relief and limitation. Advantageously, the pressure relief valve is a magnetic or a pneumatic pressure relief valve.
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According to an advantageous feature of the invention the high-pressure pump unit and the applicator head are temperature controlled by controllable heating resistors.
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According to an advantageous feature of the invention the high pressure hotmelt adhesive applicator comprising the applicator head, the high-pressure pump unit, the linear actuator and the servo drive is formed as one unity.
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According to the invention the turn-up system of a reeler for reeling fiber webs comprises an adhesive application device according to the invention.
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According to an advantageous feature of the invention the adhesive applicator of the adhesive application device is located at middle area in cross direction of the fiber web.
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According to an advantageous feature of the invention distance from the melter to the nozzles of the adhesive application device to the application point is about half of the length of a roll to be reeled in the reeler.
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According to an advantageous feature of the invention the applicator head is configured to apply hot melt adhesive for attaching a beginning end of a fiber web in a turn up of a reeler.
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According to an advantageous feature of the invention the applicator head is configured to apply hot melt adhesive for attaching a tail of the fiber web in the turn-up of the reeler.
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According to the invention in the turn-up method of a reeler for reeling fiber webs in the turn up a beginning end of a fiber web is attached to a reeling shaft and/or a tail of the fiber web is attached on a completed parent roll by an adhesive application device according to the invention.
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According to an advantageous feature of the invention in the method power of the adhesive applicator is adjusted to desired level before beginning of applying the adhesive onto the surface of the fiber web.
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According to an advantageous feature of the invention pressure level in the high pressure adhesive applicator is 100 - 200 bar depending on running speed of the fiber web. In higher running speeds higher pressure is used and in lower running speeds lower pressure is used.
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According to an advantageous feature of the invention the nozzles are individually controllable.
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According to an advantageous feature of the invention in the high pressure hotmelt adhesive applicator the adhesive cylinder of the high-pressure pump unit is located close to the nozzles of the applicator head, the distance being advantageously about 100 mm, as the nozzles and the high-pressure pump unit being in the same structural component.
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According to one advantageous aspect of the invention the adhesive application device comprises a hotmelt adhesive melter with a low-pressure pump, and a high pressure hotmelt adhesive applicator. The construction of the hot melt adhesive melter is simple. The low-pressure pump of the melter provides adhesive for the high pressure hotmelt adhesive applicator. The melter with the low-pressure pump provides the heated adhesive to the high pressure hotmelt adhesive applicator. The high pressure hotmelt adhesive applicator comprises a high-pressure pump unit, which is driven, advantageously servo-driven, and an applicator head, which is advantageously manufactured by 3D-printing technology. The high-pressure pump unit and the applicator head are advantageously temperature controlled. The driven high-pressure pump unit allows various system pressure behaviors within the application pulse (constant, decreasing, increasing) as drive speed can be altered during the application pulse. Length of the application pulse is advantageously about 1 second and the invention provides that during one pulse even 100 control operations can be made. The possibility to control the system pressure during the application pulse enables improved performance in the picking up and attachment of the beginning end of the fiber web onto the surface of the reeling shaft due to controllable adhesive amount. The possibility to control the system pressure during the application pulse enables also usage of hotmelt adhesive for parent roll surface binding as sufficient adhesive amount is available after the attachment of the beginning end. Also, number of overall equipment in the turn-up system is decreased as both the attachment of the beginning end and the tail can be done with just one adhesive application device.
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The invention provides according to an advantageous aspect thereof that during attachment of the tail onto the surface of a complete roll, pressure of the adhesive stream is adjustable during application, for example the pressure can be increased towards the end of the application to ensure smooth and even adhesive film covering the whole desired location on the fiber web.
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According to an advantageous aspect of the invention in the adhesive application device, in connection with the nozzles at least one sensor is provided to monitor mass flow and/or pressure of the adhesive stream at the nozzle. Optionally, there is feedback from the nozzle/-s to the servo motor to keep the flow and/or the pressure desired.
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According to one advantageous aspect of the invention in high pressure hotmelt adhesive applicator of the adhesive application device the adhesive cylinder is located close to the nozzle of the adhesive application device, by which the dosing amount of the adhesive is controllable.
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According to one advantageous aspect of the invention in the high pressure hotmelt adhesive applicator of the adhesive application device the driven high-pressure pump unit provides for accurate control of the amount of the adhesive to be applied.
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According to one advantageous aspect of the invention the adhesive application device can be used also in the adhesive application for the parent roll surface binding by providing the applicator head with nozzles and thus, no separate application device is needed for this in the turn-up system.
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According to one advantageous aspect of the invention the applicator head is manufactured by 3D-printing technology, and thus the applicator head can be configured to provide for uniform and simultaneous operation of several nozzles as forming the feed channels for the adhesive can be produced with great variations by the 3D-printing technology. The 3D-printing technology provides that feed channels can be made of same length, whereby flow from the adhesive source for each nozzle is similar and thus, also same pressure at each of the nozzles is provided.
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According to one advantageous aspect of the invention in the high pressure hotmelt adhesive applicator of the adhesive application device the amount of the adhesive to be applied is controlled by controlling the servo motor on basis of the adhesive flow velocity (ml/s).
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According to one advantageous aspect of the invention the high pressure hotmelt adhesive applicator of the adhesive application device comprises a pressure relief valve providing for pressure relief and limitation. The pressure relief valve is advantageously a magnetic or a pneumatic pressure relief valve.
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According to one advantageous aspect of the invention the high pressure hotmelt adhesive applicator of the adhesive application device comprises a high-pressure piston, providing for first removing first received adhesive from the cylinder, even in cases where the stroke of the piston is not full.
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According to one advantageous aspect of the invention the adhesive application device provides for combination of thermal and fouling protection.
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The adhesive application device according to the invention provides, that the applied adhesive at the desired application point is smooth, the temperature of the adhesive is suitable for optimal adherence.
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In the adhesive application device according to the invention the distance between the melter and the application point is shorth, thus moderate warming of the hotmelt adhesive is provided for viscosity for good fluent of the hotmelt adhesive. Therefore, at the application point the hotmelt adhesive is at temperatures providing for good stickiness and adherence properties.
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The adhesive application device according to the invention also has improved suitability in respect of different speeds and grades, as improved adjustability of length and thickness of adhesive stripe on the application point is provided.
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The adhesive application device according to the invention also provides that the adhesive can be applied at a further distance from the winding nip as application of the adhesive very close to the nip may cause problems.
Brief description of the drawings
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Aspects of the invention, however, together with additional objects and advantages thereof, will be best understood from the following description of some example embodiments when read in connection with the accompanying drawings and in the following the invention is described in more detail referring to the accompanying drawing, in which
- In figures 1A-1B is schematically shown an advantageous example of an adhesive application device according to the invention and
- In figure 2 is schematically shown an example of a reeler in turn-up stage.
- In figures 3A-3B is shown an example of pressure at the nozzle; in figure 3A in a prior art arrangement of an adhesive application device and in figure 3B in an adhesive application device according to the invention.
- In figures 4A-4B is shown an example of adhesive mass out of nozzle; in figure 4A in a prior art arrangement of an adhesive application device and in figure 4B in an adhesive application device according to the invention.
- In figures 5A-5B is shown an example of adhesive film on the fiber web; in figure 5A in a prior art arrangement of an adhesive application device and in figure 5B in an adhesive application device according to the invention.
Detailed description
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In the following description same reference signs designate for similar components unless otherwise mentioned and it should be understood that the examples are susceptible of modification in order to adapt to different usages and conditions within the frames of the invention. Repetition of some reference signs may have been omitted in the figures for clarity reasons. In some of the figures an arrow has been used to indicate rotation direction of the respective main element of the construction.
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Figs. 1A-1B schematically show an exemplifying embodiment of the adhesive application device 50. The adhesive application device 50 comprises a melter 40, which is a hotmelt adhesive melter 40, and a high pressure hotmelt adhesive applicator 20 comprising an applicator head 21, a high-pressure unit 22, a linear actuator 23 and a linear actuator mover 24, which in this example of the figures is a servo drive 24, formed as one unity. The hotmelt adhesive melter 40 comprises a heater (not shown) and a low-pressure pump (not shown) for providing heated adhesive to the high pressure hotmelt adhesive applicator 20. The applicator head 21 is provided with nozzles 31 for applying the adhesive for attaching a beginning end of a fiber web in a turn up of a reeler 10 (fig. 2) and advantageously also nozzles (not shown) for applying the adhesive for attaching a tail of the fiber web in the turn-up of the reeler 10. The melter 40 provides adhesive for the high pressure hotmelt adhesive applicator 20 via a tubelike channel 42 connected to adhesive feed opening 41 of the applicator head 21. The applicator head 21 comprises channels (not shown) for feeding the hot melt adhesive from the feed opening 41 to the nozzles 31. The applicator head 21 is advantageously manufactured by 3D-printing technology. The high-pressure pump unit 22 and the applicator head 21 are advantageously temperature controlled by providing them with controllable heating resistors (not shown). In the high pressure hotmelt adhesive applicator 20 the adhesive cylinder 34 of the high-pressure pump unit 22 is located close to the nozzles 31 of the applicator head 21 and the servo-driven high-pressure pump unit 22 provides for accurate control of the amount of the adhesive to be applied by the movement of the piston 35 of the high-pressure pump unit 22. The distance between the nozzles 31 and the high-pressure pump unit 22 is only about 100 mm, these elements being in the same structural component. The high pressure hotmelt adhesive applicator 20 comprises a pressure relief valve 44 (inside the outer frame structure, indicated in the figure 1 by the arrow 44) providing for pressure relief and limitation. The pressure relief valve is advantageously a magnetic or pneumatic pressure relief valve. The piston 35 of the high-pressure pump unit 22 is advantageously a high-pressure piston 35.
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In the operation of the adhesive application device 50 the adhesive is fed from the melter 40 via the channel 42 to the feed opening 41 in the applicator head 21 of the high pressure hotmelt adhesive applicator 20. In the applicator head 21 the adhesive is transferred via channels to nozzles 31. The application is controlled by the cylinder 34 - piston 35 structure of the high-pressure pump unit 22 operated by the linear actuator 23 and the servo drive 24. In pick-up of the beginning end adhesive is applied in the middle in cross direction of the fiber web. When attaching the tail of the fiber web onto surface of a complete roll adhesive film stripes are provided on surface of the fiber web, typically the adhesive applicators are provided in a water jet turn up device in connection with the cutting devices located at arms of the water jet turn up device. Typically different types of nozzles are used in connection with the pick-up and in the tail binding.
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In figure 2 a reeler 10 is shown in the turn-up stage in which the reeling of a parent roll 14 has reached the stage in which the diameter of the parent roll 14 is desired and thus, the parent roll 14 is completed. The reeling will be finished around this parent roll and changed to be around the next reeling shaft 11. The adhesive application device 50 is provided to attach the beginning end of the fiber web to the new reeling shaft 11 and the tail on the completed parent roll 14 for binding the surface thereof. In the turn-up the fiber web W is cut and the tail of the cut web W is directed around the completed parent roll 14 with desired diameter and the beginning end of the cut fiber web W is directed around the new reeling shaft 11 that has been moved from a reeling shaft storage or from a waiting position to be in contact with the reeling cylinder 15 to the beginning position of the reeling. The reeling is begun with the reeling shaft in this change position and as the reeling progresses the reeling shaft is lowered to the reeling position.
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In figures 3A-3B is shown an example of pressure at the nozzle; in figure 3A in a prior art arrangement of an adhesive application device and in figure 3B in an adhesive application device according to the invention. In the figures in X direction is indicated time (s) and in Y direction pressure (bar). As can be seen from the pressure curve P1 of figure 3A in the known arrangement as the adhesive application time, i.e. the application pulse, passes the pressure at the nozzle drops significantly. Instead in the arrangement according to the invention the pressure at the nozzle is uniform throughout the application of the adhesive, i.e. during the whole application pulse, as can be seen from the pressure curve P2 in figure 3B.
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In figures 4A-4B is shown an example of adhesive mass out of nozzle; in figure 4A in a prior art arrangement of an adhesive application device and in figure 4B in an adhesive application device according to the invention. In the figures in X direction is indicated time (s) and in Y direction adhesive mass (g). As can be seen from the adhesive mass curve GM1 of figure 4A in the known arrangement as the adhesive application time, i.e. the application pulse, passes the amount of applied adhesive out of the nozzle drops significantly. Instead in the arrangement according to the invention the adhesive mass out of the nozzle is uniform throughout the application of the adhesive, i.e. during the whole application pulse, as can be seen from the adhesive mass curve GM2 in figure 4B.
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In figures 5A-5B is shown an example of adhesive film on the fiber web; in figure 5A in a prior art arrangement of an adhesive application device and in figure 5B in an adhesive application device according to the invention. In the figures in X direction is indicated time (s) and in Y direction adhesive film width (mm) and by shading thickness of the adhesive film (the darker shading is the thicker adhesive film). As can be seen from the adhesive film areas S1-Sn of figure 5A in the known arrangement as the adhesive application time, i.e. the application pulse, passes the adhesive film width at areas S1-Sn vary and decrease significantly. There might even be partial areas NG without adhesive film. Instead in the arrangement according to the invention the adhesive film width is uniform and even throughout the application of the adhesive, i.e. during the whole application pulse, as can be seen from figure 5B. Further, as can be seen from figure 5A by shading, the thickness of the adhesive film decreased as the application time, i.e. the application pulse, passes. Instead, in the arrangement of the invention the thickness of the adhesive film remains even throughout the application, as can be seen from figure 5B.
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In the description in the foregoing, although some functions have been described with reference to certain features, those functions may be performable by other features whether described or not. Although features have been described with reference to certain embodiments or examples, those features may also be present in other embodiments or examples whether described or not. Above the invention has been described by referring to some advantageous examples only to which the invention is not to be narrowly limited. Many modifications and alterations are possible within the invention as defined in the following claims.