GB2311774A

GB2311774A - Combining webs into a single multi-ply wound web

Info

Publication number: GB2311774A
Application number: GB9606956A
Authority: GB
Inventors: Neemat Georges Frem
Original assignee: Indevco Ltd
Current assignee: Indevco Ltd
Priority date: 1996-04-02
Filing date: 1996-04-02
Publication date: 1997-10-08
Also published as: GB9606956D0; WO1997036816A1

Abstract

Individual webs are unwound from spools 1-3 and combined into a multi-ply web 22, which may be processed at 6/7 before being wound on spool 4, spindles of the spools being slidingly and rotatably mounted on rails 5 so that a drive 14 to one of the spools is frictionally transmitted to the other spools. The friction may operate directly between the wound rolls of web, or via rollers between adjacent rolls, or may operate between friction wheels associated with the respective spools. The angle of the rails is adjustable at 8. The spools may be urged together by means 11.

Description

Winding Unit for combining multiple Plies into a Single Multi- > ly Web This invention relates to a winding unit for combining multiple webs into a single multi-ply web, and in particular to a winding unit for combining multiple webs of tissue into a single multi-ply tissue.

Winding units are found in many manufacturing processes. Materials requiring winding units in their manufacture include tissue, paper, carpets, cloth, sheet metals (tin foil), and plastics (cling film) and laminates.

Often two or more webs require combining into a single multi-ply web. These two or more webs may be made of the same material, or of different materials.

Machines for combining multiple single ply webs into a single multi-ply web currently use winding units to unwind rolls of single ply webs. These individual webs are then co-aligned into a single multi-ply web. This multi-ply web is then rewound onto a single roll by a final winding unit.

In tissue mills where two or more rolls of tissues are combined into a single multi-ply tissue, one winding unit is used for each roll of tissue. One further winding unit is required to wind the combined multi-ply tissue. This means that for a three ply tissue, four winding units are required. Each winding unit has a separate drive means to enable the roll to wind or unwind the roll of tissue. The winding units are mounted on the floor in a single line with their own foundations and mounting points built into the foundations. The foundation construction is complex, but critical since if the winding units are out of line then the multiple webs will not align together.

Each winding unit is typically 3m wide, and requires 4m between the roll centres to enable the drive means, control circuits, and other moving component parts to be accessible for servicing. The 4m between roll centres also provides sufficient room for loading and unloading means to replace the rolls when the process of combining the multiple webs has depleted the single ply rolls. This is usually achieved by lifting the empty roll off the winding unit by crane, swinging the crane away from the winding unit with the empty roll, returning the crane to the winding unit with a full roll of tissue, and lowering the roll into place on the winding unit.

Between the winding unit that rewinds the combined single multi-ply tissue and the winding units that unwind the single ply tissue, calendering units, printing units, cutting units, crimping units and any further processing units are situated. All these units are required to be in line to prevent unnecessary twisting or folding of the tissue. The length of such a tissue mill line is typically at least 21m.

Each unit requires a separate driving means to assist in the feeding of the tissue through the tissue mill. The speed at which each winding unit turns must be independently controllable, since the thickness of each web may not be the same, and especially since the combined single multi-ply web will be thicker than each of the single ply webs. A complex control system is required to control these independent winding speeds and also to enable any tears, folds, holes or misalignments to be identified or prevented.

The present invention seeks to provide a single winding unit that achieves the tasks of unwinding multiple single-ply webs, combining the single-ply webs into a multi-ply web, optionally processing the multi-ply web and then rewinding the multi-ply web. The present invention also seeks to simplify the installation of the winding unit, and in particular to simplifying the foundations and mounting points built into the foundations and to reduce the floor area required for the winding unit. A further aim of the present invention is to provide a single winding unit that achieves the tasks listed above without the need for a complex drive control system. Another aim of the present invention is to provide a winding unit where the loading and unloading of the rolls can be achieved easily.

In accordance with the present invention, we provide a winding or unwinding unit comprising a rewinding spool, a first unwinding spool, a second unwinding spool, and a driving means for rotating one of the spools, wherein the spools are mounted on a rail means. By an unwinding spool is meant a spool from which at least one web is to be unwound, and by a winding spool is meant a spool onto which one or more webs unwound from one or more unwinding spool is to be wound.

Preferably, spindles of the spools support the spools on the rail means, and the first unwinding spool sits on the rail means next to the rewinding spool, with the second unwinding spool sitting on the rail means next to the first unwinding spool. Preferably the driving means rotates the rewinding spool. The rail means is preferably inclined at an angle which is sufficiently steep to permit a force between the spools to create friction between adjacent spools such that a driving force of the rewinding spool is transmitted to the subsequent unwinding spools in turn.

The webs are preferably entrained through the winding unit by first entraining the web which is unwound from the first unwinding spool over substantially one half of the second unwinding spool so that the web of the first unwinding spool is aligned with the web of the second unwinding spool. When the web on the second unwinding spool is unwound the two webs remain aligned. The two aligned webs are further entrained through the winding unit over further unwinding spools, if present, adding third or fourth aligned webs to make the multi-ply web. This multi-ply web is then passed over guide rollers around the winding unit, through further processing units if desired where the multiply web can be further processed by cutting units, calendering units, printing units, gluing units and other further processing units, prior to finally being entrained over further guide rollers and onto the rewinding spool where it is rewound.

Preferably the angle of inclination of the rail means is variable, whereby the force between neighbouring spools can be maintained for different spool weights.

Alternatively or additionally, a force applying means can provide a force between the neighbouring spools.

The winding unit described above fulfils the aims of the invention in that it combines single plies into multi-ply webs, and provides the possibility of further processing the web prior to rewinding it. It also simplifies the installation of the complete unit, reduces the amount of floor space required, reduces the number of foundation blocks required, and reduces the need for a complex drive control means. The procedure for unloading and loading of the spools when the unwinding spools are empty can also be accomplished much more simply than in the prior art. The variable angle of inclination of the rail means permits the rail means to be angled such that when the bottom most spool is removed from the rail means, the next spool rolls down into its place. For loading, the rail means can be angled nearly level so that the previous spool placed on the rail means can be pushed along the rail means by the spool about to be loaded onto the rail means, thus creating the space for the spool being loaded onto the rail means. The variable angle of inclination of the rail means therefore enables all the spools on the rail means to be unloaded and loaded onto the rail means at the same point.

Preferably, the rail means is pivotably supported about a central region under the control of a hydraulic ram.

Preferably, the rail means are two spaced rails between which the spools lie with end portions of their spindles supported thereon.

While it is envisaged that drive from spool to spool will be by virtue of friction between webs wound on the spools, it is envisaged that free resting rollers may be located between the webs on each spool to transmit friction drive between spools, or alternatively, it is envisaged that a friction drive could be provided by mounting drive wheels on each spindle which are in engagement with each other.

This would result in a constant speed of rotation of the spools regardless of the amount of web on the spools.

In an alternative embodiment, the rail means may be arranged vertically (but preferably adjustable in inclination) with the spools resting one above another.

A preferred embodiment of a winding unit according to the present invention is now described by way of example with reference to the accompanying drawings, in which: Figure 1 is a side view of a winding unit, containing three unwinding spools and one rewinding spool.

Figure 2 is an enlarged scale view of a lower part of the unit of figure 1, and Figure 3 is an enlarged scale view of an upper part of the unit of figure 1.

Referring to figure 1, a winding unit 10 according to the invention has three unwinding spools 1, 2 & 3, each for a single web of tissue, and one rewinding spool 4, all of which have central spindles 48 which are rotatably and slidably mounted on rail means comprising a pair of spaced rails 5 (only one of which is shown). The rails 5 are arranged at an angle of inclination 17 from the horizontal.

This inclination causes the spools 1, 2, 3 & 4 to be in rolling contact with their adjacent spool(s) under the influence of their own weight.

The invention is designed to cause three webs of tissue wound respectively on the unwinding spools 1, 2 & 3 to be unwound from those spools, combined into a three ply tissue, and then to be rewound onto the rewinding spool 4.

To achieve this, the spools 1, 2, 3 & 4 are loaded onto the rail means 5 so that tissue on the unwinding spools 1, 2 & 3 can be unwound by rotating the respective spools in the respective directions shown by arrows A, B and C, and rewound as a three ply tissue by winding onto the rewinding spool 4 by rotating the latter in the direction indicated by the arrow D.

Motorised rollers 14 provide a friction driving means to rotate the rewinding spool 4. It is preferred that the drive for the rollers comprises air motors to provide a constant driving force. Tissue on the rewinding spool 4 is in frictional contact with tissue on the first unwinding spool 1 due to gravitational forces and this frictional contact causes the first unwinding spool 1 to rotate with the same surface velocity as the said rewinding spool 4.

The tissue on the second unwinding spool 2 has frictional contact with the tissue on the first unwinding spool 1, and the tissue on the third unwinding spool 3 has frictional contact with the tissue on the second unwinding spool 2.

These frictional contacts cause the second unwinding spool to rotate with the same surface velocity as the first unwinding spool 1, and the third unwinding spool 3 to rotate with the same surface velocity as the other three spools 1, 2 & 4.

The three unwinding spools unwind their webs of tissue whilst rotating. The webs of tissue are fed through the winding machine passing between the contact points of the neighbouring spools such that the web unwinding off the first unwinding spool 1 is aligned with the web unwinding off the second unwinding spool 2. The two aligned webs form a two ply web on substantially the top half of the second unwinding spool 2. The two ply web is then aligned with the web unwinding from the third unwinding spool 3 forming a three ply web 22 passing over part of the bottom half of the third unwinding spool 3. This feeding path causes the single web unwinding off the first unwinding spool 1 to be sandwiched between the webs unwinding off the second and third unwinding spools 2 & 3. The three ply web 22 is then entrained over a first guide roller 23 supported on the end of rails 5, a second guide roller 24 supported on an upper end of a frame 50, a third guide roller 25 at the base of the frame 50, a fourth guide roller 26 beneath the rewinding spool 4, and then between a lower one of the motorised rollers 14 and the rewinding spool 4 and is then rewound onto rewinding spool 4.

In order to maintain the frictional contact between the webs on the spools 1, 2, 3 & 4 as the unwinding spools 1, 2 & 3 lessen in diameter and hence in weight due to the unwinding action of the webs, the winding unit 10 has a force applying means 11 to provide a squeezing action between the spools 1, 2, 3 & 4 to keep them in frictional contact. Referring now to figure 3, the force applying means 11 comprises a threaded bar 13 attached to a drive shaft of a motor 12, and a nut-like follower 53 threadably engaged on the threaded bar 13. The follower 53 supports a pressure arm 27 which engages the spindle 45 of the third unwinding spool 3. By rotating the threaded bar 13, the position of the arm 27 can be altered, thus allowing a variable squeezing force to be applied to the spools 1, 2, 3 & 4. The provision of this mechanism is optional.

As can be seen from figures 1, 2 & 3, the rails 5 are pivotally connected by hinges 9 near the mid length of the rails 5 to an upstanding support column 30. An adjusting means 8 for varying the angle of inclination 17 of the rails 5 is provided to enable the force between the neighbouring spools1 due to the weight of the spools 1, 2, 3 & 4, that provides the frictional contact between the neighbouring spools, to be controlled. The adjusting means 8 is shown as a hydraulic ram 20 pivotally mounted between two mounting brackets 15 & 16 located respectively on the rails 5 and column 30. By making the angle of inclination steeper, a larger component part of the weight of the spools acts to provide the frictional force between the neighbouring spools. Alternative forms of adjusting means 8 could be provided.

A secondary use for the adjusting means 8 is to lessen the angle of inclination 17 to enable a simple replacement, i.e. loading/unloading of any one or more of the spools 1, 2, 3 & 4 when the one or more of the unwinding spools 1, 2 & 3 is empty and/or the rewinding spool 4 is full. These occurrences do not necessarily occur at the same time. When the rails 5 are moved to a substantially horizontal position, it is relatively simple to move the spools on the rails 5. For example, the rewinding spool 4 can be moved clear of the driving rollers 14, and the spool 4 can then be removed from the winding machine 10 by a lifting means such as a crane or a fork lift truck. The force applying means 11 can then push the subsequent spools 1, 2 & 3 into the position previously occupied by the removed spool, thus enabling each spool to be removed one by one from the same place. However, this is not essential. One or more fresh spools can then be loaded onto the rails 5, by winding back the force applying means 11 (to allow the subsequent fresh spool(s) to be placed onto the rails 5). Once loaded, the adjusting means 8 is operated to return the angle of inclination 17 to a preferred angle (15 ) at which the ends 19 of the rails 5 rest on supports 18.

The threading of the webs through the winding machine might be achieved simply by an automated threading system (methods for feeding webs through spool systems are known) or alternatively manually whilst the spools are being rotated slowly.

Further processing equipment identified generally at 6 & 7 is incorporated into the winding machine 10. This may comprise any of calendering rollers, cutting units, slitting units or any such other further processing unit required for completing the processing of the multi-ply web.

Preferably this further processing equipment is located as shown on the frame 50 between the second and third guide rollers 24 & 25 thus requiring only one foundation block for the units, or alternatively between the third and fourth guide rollers 25 & 26, which would require foundation blocks for each unit.

The foundation blocks required for the preferred embodiment comprise one block 21 for mounting the driving means 14, one block 56 for the frame 50, one block 60 for the fourth guide roller 26 and one block 58 supporting column 30.

In a second embodiment of the present invention, the rail means could comprise a pair of substantially vertical rails between which spindles of the spools are mounted, thus providing a vertical stack of spools. The spools would preferably be held on the rails by having C-sectioned rails between flanges of which the spool spindles are located. To change the spools, the spools can be lifted out of the stack.

Sensors (not shown) are preferably provided adjacent each spool (and optionally adjacent the further processing equipment) in order to maintain a good quality of final product. A machine operator could identify any faults in any of the webs, but it is preferred to have automated sensors, to detect tears, holes or other flaws.

The friction drive between the webs on neighbouring spools could occasionally require assistance because certain web materials are virtually friction free, or alternatively very delicate. Provision of separating rollers between webs on neighbouring spools such as to enable contact between webs on neighbouring spools over only part of the surface of the spools can prevent damage to the web material on the spools. These separating rollers could be toothed or formed of or covered with a rubber or other friction producing material. By providing friction gearing to the neighbouring spools, any desired or alternative speeds of rotation can be achieved, thus enabling a variety of tensions in the individual plies to be obtained. This could be useful for forming multi-ply rubber webs. In this arrangement, it is envisaged that drive between neighbouring spools would be by means of friction wheels, having larger diameters than the diameters of the spools themselves, mounted on the spindles 48 of the spools. These friction wheels would engage friction wheels of their neighbouring spools, thus ensuring a constant rotational speed of the spools, regardless of the amount of web material on the spools.

The rail means can be altered in length such as to incorporate the number of spools required for particular multi-ply webs.

For lightweight spools, the rail means could comprise only one rail to support the spool with the spools being supported in a cantilever fashion.

The angle of inclination 17 of the rails is preferably 15". If desired, the angle of inclination could be varied throughout the process so that the angle of inclination is steeper towards the end of the process. The spindles 48 may require attachment to the rail means to prevent them from falling or jumping off the rail means at steep angles.

The path that the webs take through the winding machine 10 can be varied. The three plies could all travel above the spools 1, 2 & 3 before passing over the first guide roller 23, for example.

When the single ply webs require processing prior to combining, such as with lamination which requires glue application on one or two sides of each web, it may be necessary for free rollers similar to rollers 24 and 25 to be installed for each web, for example between rollers 24 and 25, or next to rollers 24 and 25, or upstream (or downstream) from rollers 24 and 25. Each web can then be guided separately either through or past further processing units such as gluing machines prior to being combined for rewinding onto rewinding roller 4.

The webs passing over first free roller 23 require separating prior to being individually processed. The individual webs could be kept separated between being unwound from the spools 1, 2 and 3 and reaching the free rollers installed for each web by entraining the webs over sets of free rollers above the spools.

The winding machine could be run in reverse to provide a machine for separating a multi-ply web into single webs.

The order in which the rewinding and unwinding spools are placed onto the rail can be altered. For example the rewinding spool could be the uppermost spool. Alternatively the rewinding spool could be between two unwinding spools.

A further alternative would be for the rail means to be shaped such that the spools are not arranged in a straight line.

The driving means need not be by means of rollers 14.

For example, a belt or a direct drive to the spindle 48 of one of the spools, for example spool 4, could be provided.

Preferably, sensors are incorporated into the winding machine, for example vibration sensors to slow down the winding speed if vibration of the machine is detected, or tension sensors to detect a drop in tension, thus detecting a possible faulty web.

The hinging point 9 on the rail means is preferably substantially near the mid point of the rail means.

However, the hinge 9 could be at any point on the rail means 5.

It will of course be understood that the present invention has been described above purely by way of example, and that modifications of detail can be made within the scope of the invention.

Claims

CLAIMS:

1. A winding unit comprising a rewinding spool, a first unwinding spool, a second unwinding spool, and a driving means for driving one of the spools, wherein the spools are mounted on a rail means.

2. A winding unit according to claim 1 wherein spindles of the spools support the spools on the rail means.

3. A winding unit according to claims 1 or 2 wherein the first unwinding spool sits on the rail means next to the rewinding spool.

4. A winding unit according to any one of claims 1 to 3 wherein the second unwinding spool sits on the rail means next to the first unwinding spool.

5. A winding unit according to any one of claims 1 to 4 wherein the driven spool transfers the driving force to a neighbouring spool by frictional contact of webs wound on the spools.

6. A winding unit according to any one of claims 1 to 5 wherein the rail means is inclined at an angle sufficiently steep to establish a force between neighbouring spools which in turn creates friction to transmit the driving force of one spool to a neighbouring spool.

7. A winding unit according to any one of claims 1 to 6 wherein there are more than two unwinding spools.

8. A winding unit according to any one of the preceding claims wherein a single web of material is unwound from each of the unwinding spools, said webs are aligned into a single multi-ply web which is then rewound onto the rewinding spool.

9. A winding unit according to claim 8 wherein the webs are entrained through the winding unit by first entraining the web which is unwound from the first unwinding spool over substantially one half of the second unwinding spool so that the web of the first unwinding spool is aligned with the web of the second unwinding spool.

10. A winding unit according to claims 8 or 9 wherein the web on the second unwinding spool is unwound from the second unwinding spool with the first web aligned with it.

11. A winding unit according to claim 8, 9 or 10 wherein the webs are entrained through the winding unit over further unwinding spools from which further webs are unwound and aligned with the webs unwound from the first and second unwinding spools.

12. The winding unit according to any one of the preceding claims 8-11 wherein the webs are entrained over guide rollers around the winding unit and onto the rewinding spool where the webs are rewound.

13. A winding unit according to any one of the preceding claims 8-12 wherein the single multi-ply web is further processed by one or more of cutting units, calendering units, printing units, gluing units or other further processing units.

14. A winding unit according to any one of the preceding claims wherein a friction force between neighbouring spools is maintained by a force applying means.

15. A winding unit according to claim 14 wherein the force applying means comprises a threaded bar attached to a drive shaft of a motor, a nut-like follower threadably engaged on the threaded bar and a pressure arm which engages a spindle of a spool.

16. A winding unit according to any one of the preceding claims wherein a separating roller is located between each pair of neighbouring spools.

17. A winding unit according claim 16 wherein the separating roller is toothed.

18. A winding unit according claim 16 wherein the separating roller has a friction generating surface.

19. A winding unit according to any one of the preceding claims 1-15 wherein drive is transferred from one spool to the next via friction wheels, having larger diameters than the diameters of the spools themselves, mounted on spindles of the spools.

20. A winding unit according to any one of the preceding claims wherein the driving means comprises motorised rollers.

21. A winding unit according to any one claims 1-19 wherein the driving means comprises a belt.

22. A winding unit according to any one claims 1-19 wherein the driving means comprises a direct drive to a spindle of one of the spools.

23. A winding unit according to any one of the preceding claims wherein the driving means is powered by an air motor.

24. A winding unit according to any one of claims 1-19 wherein the rail means is mounted substantially vertically.

25. A winding unit according to any one of the preceding claims wherein the angle of inclination of the rail means is variable.

26. A winding unit according to any one of the preceding claims wherein the rail means is pivotally mounted substantially at the mid-point of the rail means.

27. A winding unit according to any one of the preceding claims wherein one end of the rail means rests on supports when the rail means is at a preferred angle.

28. A winding unit according to any one of the preceding claims wherein the rail means comprises a pair of parallel spaced rails.

29. The winding unit according to any one of the preceding claims, wherein the winding unit is operated in reverse to separate a multiple ply web into separate webs.

30. A winding unit substantially as hereinbefore described with reference to the accompanying drawings.