GB2387837A

GB2387837A - System for producing coreless fabric rolls

Info

Publication number: GB2387837A
Application number: GB0317011A
Authority: GB
Inventors: Balbir Singh
Original assignee: Ethicon Inc
Current assignee: Ethicon Inc
Priority date: 1999-08-31
Filing date: 2000-08-17
Publication date: 2003-10-29
Anticipated expiration: 2020-08-17
Also published as: GB0317011D0; GB2387837B

Abstract

A system for producing coreless fabric rolls includes a feed station 12 operable to supply a leading edge of a fabric web 24 from a parent roll 18. The system includes a first tucking station 132 operable to position the leading edge of the fabric web 24 adjacent one of a plurality of spindles 48,50,52 coupled to a turret 46. The system also includes a winding station 38 comprising a winding roller 36. The winding station 38 is operable to receive the leading edge in a nip defined by the spindle and the winding roller and wind the fabric web into a fabric roll about the spindle. The system also includes a cutting station 40 operable to separate the fabric roll from a remaining portion of the fabric web 24. The system also includes a second tucking station 42 operable to receive the spindle from the winding station and wind a trailing edge of the fabric roll about the fabric roll. The spindle is transferred along a generally hypocycloidal path.

Description

SYST ==OD FOR-PRODUCING CORE=SS FABRIC ROLLS

TECHNICAL FIELD OF THE INVENTION

The present invention relates generally to the field

of fabric or paper converting processes andmachinery, and more particularly, to a system and method for producing 5 careless fabric rolls.

BACKGROUND OF THE INVENTION

Fabric rewind systems are generally used to unwind paper or fabric from a large parent roll and conduct the 10 fabric through a finishing or converting operation. For example, the converting operation may include rewinding.the fabric into a roll of a:-specific size which is generally smaller than the-size of the parent roll. For,example, the system may be used to produce products such as rolls of 15 sanitary' or tissue paper.

An example of a fabric rewind system may include:-a plurality of mandrels coupled to a rotatable;turret. The mandrels rotate in a circular path a fixed distance,froman axis- of the turret. As the turret rotates,. cores. are 20 placed on each mandrel, adhesive or glue is applied to the cores, and then the fabric is brought into contact with the cores. The cores are then driven in rotation by rotating the mandrels to wind the fabric.about the cores.

An example of a coreess fabric rewind system may 25 include a pair of winding rollers and an actuator to-adjust the position Of one. winding roller relative to The other winding:roller. Th,e: Winding rollers are brought Onto contact- with each other.to-s-,eve:.r fabric -disposed --, bet,e,en the winding rollers.-,A-s the winding rollers rotat,e:-in the 30; 'same'directi-o.n-j--'t-.he-;-severd-e.ndof fabric óur\8,on--.itself

to begin the formation of a fabric roll. The actuator controls the position of one of the winding rollers to allow for an increase in diameter of the fabric roll during formation. 5 Prior systems suffer several disadvantages. For example, systems including rotating turrets may require actuators to adjust the position of either winding rollers or the turret prior to, during, and/or after the winding process to avoid interference between the fabric rolls, winding rollers, or 10 other system components during rotation of the turret.

Additionally, turret systems do not generally accommodate surface winding of the roll.

Coreless winding systems generally initiate winding by compressing the severed end of the fabric to roll the severed 15 end back on itself to begin the fabric roll. Thus, this process compresses and flattens the fabric, thereby creating a hard center portion of the fabric roll.

SUMMARY OF THE INVENTION

20 Accordingly, a need has arisen for a system and method for producing coreless fabric rolls that increases the efficiency and reduces the amount of movement of system components. The present invention provides a system and method for producing coreless fabric rolls that address the 25 shortcomings of prior systems and methods.

According to a first aspect of the present invention, a method for producing coreless fabric rolls is provided, comprising: winding a fabric web onto one of a plurality of spindles to form a coreless fabric roll at a first station, 30 the spindles coupled to a turret; transferring the spindle from the first station to a second station along a generally hypocycloidal path; separating the coreless fabric roll from the fabric web; forming a leading edge of the fabric web and a trailing edge of the coreless fabric roll; winding the 35 trailing edge about the coreless fabric roll at the second station; transferring the spindle from the second station to

a third station; and removing the coreless fabric roll from the spindle at the third station.

According to a second aspect of the present invention, a system for producing coreless fabric rolls is provided, 5 comprising: a hypocycloidal turret having a plurality of spindles; a winding station operable to wind a fabric web onto one of the spindles to form a coreless fabric roll; a cutting station operable to separate the coreless fabric roll from the fabric web to form a leading edge of the fabric web 10 and a trailing edge of the coreless fabric roll; a tucking station operable to wind the trailing edge about the coreless fabric roll; a stripping station operable to remove the coreless fabric roll from the spindle, and a control system operable to transfer each of the spindles to the winding, 15 tucking, and stripping stations along a generally hypocycloidal path.

According to a third aspect of the present invention, a method for producing fabric rolls is provided, comprising: providing a fabric web at a substantially constant feed rate; 20 moving a first spindle of a turret to a first station; accumulating a reserve portion of the fabric web during movement of the first spindle to the first station; and discharging the reserve portion to the first station to form a fabric roll about the first spindle; transferring the first 25 spindle from the first station to a second station; accumulating a next reserve portion of the fabric web during transfer of the first spindle from the first station to the second station; moving a second spindle of the turret to the first station; and discharging the next reserve portion to 30 the first station to form another fabric roll about the second spindle.

According to a fourth aspect of the present invention, a method for producing fabric rolls, comprises: disposing a spindle of a turret in a winding station; providing a fabric

web from a feed station to an accumulator at a first feed rate; providing the fabric web from the accumulator to the winding station at a second feed rate; winding the fabric web about the spindle at the winding station to form a fabric 5 roll; and accumulating a reserve portion of the fabric web at the accumulator when the second feed rate is less than the first feed rate.

According to a fifth aspect of the present invention, a system for producing a fabric roll is provided, comprising: a 10 feed station operable to provide a fabric web at a substantially constant feed rate; a turret operable to intermittently move each of a plurality of spindles into a winding station; the winding station operable to wind the fabric web about one of the spindles; and an accumulator 15 operable to accumulate a reserve portion of the web during movement of the spindles relative to the winding station, the accumulator is further operable to discharge the reserve portion of the fabric web to the winding station after another of the spindles is positioned at the winding station.

20 According to a sixth aspect of the present invention, a system for producing a fabric roll, comprises: a turret having a plurality of spindles; a feed station operable to provide a fabric web at a first feed rate; a winding station operable to receive the fabric web at a second feed rate and 25 wind the fabric web about the spindles; and an accumulator operable to receive the fabric web from the feed station and transfer the fabric web to the winding station, the accumulator further operable to accumulate a reserve portion of the fabric web when the second feed rate is less than the 30 first feed rate.

The technical advantages of the present invention include providing a system and method for producing wound articles with increased efficiency over prior systems and methods.

4= Preferably, the rotating turret transfers the plurality of spindles through different stations to produce a fabric roll. Thus, the present invention provides an increased cycle I rate for producing fabric rolls. 3 5 Preferred embodiments of the present invention reduce movement of system components, thereby increasing efficiency and decreasing the amount of time required to form fabric rolls. For example, the rotating turret preferably transfers a plurality of spindles through different stations along a 10 generally hypocycloidal path, thereby substantially eliminating interference between the fabric rolls and other system components. Additionally, preferred embodiments of the present invention substantially eliminate any requirement to translate various system components toward or away from the 15 fabric roll during formation of the fabric roll or to transfer the spindles between different stations.

Other technical advantages of the present invention will be readily apparent to one skilled in the art from the following figures, descriptions and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in connection with the;

25 accompanying drawings, in which: FIG. 1 is a diagram illustrating a system for producing careless fabric rolls in accordance with an embodiment of the present invention; FIG. 2 is a diagram illustrating a control system for 30 the system for producing careless fabric rolls in accordance with the an embodiment of the present invention; FIG. 3 is a diagram illustrating a differential of an accumulator for the system in accordance with an embodiment of the present invention;

FIGS. 4A-4D are diagrams illustrating a turret of the system in accordance with the embodiment of the present invention; and I FIGS. 5A- 5H are diagrams illustrating the production of 3 5 careless fabric rolls in accordance with an embodiment of the: present invention. i

DETAILED DESCRIPTION OF All; INVENTION

Embodiments of the present invention and the advantages thereof are best understood by referring to the following descriptions and drawings, wherein like numerals

are used for like and corresponding parts of the drawings.

FIGURE 1 is a diagram illustrating a system 10 for producing careless fabric rolls in accordance with:an embodiment of the present invention. System 10 includes a feed station 12, and accumulator 14 And a rewind station 10 16. Feed station 12 comprises a parent roll of fabric 18 rotatably mounted to an unwind support (not explicitly shown). Parent roll 18 may comprise paper, woven material, non-woven material or -other :suitable materials. for producing careless fabric rolls:. For example, parent roll IS 18 may ind:ude-woven or non-:wovencotto,n or rayon/polyester fabric: which may be used for-producing rolled bandages.

Parent roll 18 may also comprise one or more roll units 20 of fabric....

: Feed station 12 also comprises unwind:r.ollers 22 for 20 feeding a fabric web 24 downstream from parent roll 18, Unwind rollers 22 rotate in the direction indicated, by arrows 26 to control the feed rate of Fabric web 24 downstream from parent roll 18. Thus, in operation, fabric web 24 is unwound from parent roll:18 by rotating parent 25 roll i'8 in a direction indicated by arrow 28. As used throughout this description downstream" relates To the

direction-of:fabric travel though system 10, whereas, the term upstream refers to a direction opposite that of fabric travel.. -- -:: 30 Fabric web 24 is fed downstream to feed:>,rollers:3Q and accumulator i4;. ::'Accumulat.or 14-:co.mprises: fe,st,oon-rollers 3-2:that-move-^towar,d or.away From eachother to..disc,harg-or accumulate, respectively, a reserve portion of fabric 24.

Festoon rollers 32 may be driven by-a chain or timing belt 33 to control an amount of the reserve portion of fabric web 24 accumulated or discharged; however, other suitable devices or methods may be used to control the movement and 5 speed of festoon rollers 32.

In operation, unwind' rollers 22 and feedrollers 30 feed fabric web 24 from parent roll 18 to accumulator 14 at a substantially constant rate of speed, thereby maintaining a substantially constant amount of tension in fabric web 10 24. Unwind rollers 22 and feed-.rollers-- 30 may be electrically and/or mechanically coupled: much that unwind rollers 22-and feed rollers-30 operate at substantially the same speed. During winding of fabric rolls at rewind station 16, accumulator 14-accumulates the reserve portion 15 of fabric web 24 to Accommodate a: reduced feed rateof fabric web 24 to rewind: station 16. In response to an increase in the feed rate of;fabric web 24 to rewind station 16, accumulator 14 discharges the reserve portion of fabric web 24.: Thus, accumulator 14 accumulates the 20 reserve port ton of fabric web 24 when the feed rate to rewind station 16 is less than the feed:-rate of feed station I2 and discharges the reserve portion of fabric web 24 when the feed rate to rewind station 16-is greater than the feed rate of feed station 12.

25 -Fabric web-24 is {ed--downstream from accumulator 34 through draw rollers 34 to rewind rollers 36 of: rewind station 16. Draw rollers,.34 and -rewind rollers 36 maybe electricalyiand/or mechanically coupled such that draw rollers 34 and rewind rollers 36 operate at-:substantially 30 the same-;speed,: thereby::maintaining a substantially constant tension:: offabric -web-24. Addi.tionally,:;feed cruet- 30- and dr,aw-:rollers-' 34 - operate::to -isolate .:._...

accumNlator--14 to maintain a substantially constant tension of fabric web 24 Rewind station 16 comprises a winding station 38, a cutting station 40, a tucking-station 42, and a stripping 5 station 44. Rewind station 16 also includes a turret 46 comprising spindles 48, SO and 52. In operation, turret 46 transfers spindles 48, SO, and 52 in a three-cusp -: hypocycloidal path between stations 38, 42, and 44.

Briefly, fabric web 24 is wound about spindles 48, so,: and 10 52 at winding station 38 using winding rollers 36 as each spindle -48,- 50, and 52 is transferred through winding station 38. Cutting station 40 severs the wound fabric rolls from fabric web24 and tucking station 40 winds any remaining fabric -after severing about the wound fabric 15 rolls. The wound:fabric rolls are removed fromspindles 48, 50, and S2 at striipping.. station 44..

--:FI&RE-2-is--a:diagram illustrating a control system 54 -f -system 10:in accordance -with an embodiment of..the present invention.: control system 54 comprises.a 20 controller 56 and servo motors 58, 60, 62, and:64.

-Controller 56 comprises a computer, workstation, mini - computer, mainframe or other.computing device. Controller : S6 controls the operation of motors 58, 60, 62, and 64.

For example, motor 58 may:be slaved to motor 60, and 2s controller 56 may control the operation of motor 60 such that fabric web 24 is fed at a substantially constant rate of speed from parent-roll 18 to. accumulator 14...

-: Additionally,: for example, motor 64 may be slaved to -A - motor<-62-, and- controller 56 may control. the operation. of 30 motor-62 to control the feed-rate of fabric web 24 from acc-umulator 14 to rewindstation 16. Thus, motors 62 and -. 64: y;-.be controlled to. deliver.apredetermind. length of - - i..:. -. . . .. - - - 1 -;;

fabric web 24 to rewind station 16 for producing fabric rolls. As illustrated in FIGURE 2, accumulator 14 comprises a differential 66 to control operation of festoon rollers 5 32 to accumulate or discharge a reserve portion of fabric web-24. For example, differential 66 may be mechanically coupled to feed rollers 30 and draw rollers 34 to control timing belt 33. However, a servo motor or other suitable type-of.method or device may be used to control timing belt 10 33.

FIGURE 3 is a diagram illustrating differential.66,of system 10 in accordance with an embodiment of the present invention. Differential 66 comprises. an input gear 68,- an :input gear 70,: a spider.pinion-gear 72 and.a spider 74.

15 Differential 66 receives--input from feed.,roller,s 30 through input gear 68 in the:direc.tion.indicat.ed by- arrow 76.

Diferentia1't'6-6- also receives input from draw: rollers 34 -throughinput-gear 70 in the-direction indicated.by arrow 78.'-' In:operation, feed rollers 30 are operated atria 20 subs/anti-ally constant speed to provide a substantially constant feed rate of: fabric web 24 to accumulator. 14.

Input from draw rollers 34 is cyclic as fabric rollsare produced at rewind station 16. Thus, differential 66 Operates -to regulate the position of festoon rollers 32 25 - based on input speeds from feed rollers 32 and draw.rollers -34. -.-.

In operat-ion,-if the input from -feed rollers -30 is greater than the input f.rom.draw rollers 34, an output shaft 80 of spider Delivers output-to-.timi.n,g b,e,lt:.33.in 30 -'':the dJre-<c-tion- indicated:by arrow 82.. If the- i,n,put from -fee-d rollers 30-is less-than.the input from drawrr,l-lers :' 32','heoutpUt f-rmhaft-.;8Q o-f:sp.i.der'74 Irvin a-.:d, e.cn opposite that indicated by arrow 82. If the input from

J feed rollers 30 equals the input from draw rollers 32, festoon rollers 32 will remain in a substantially static condition. Thus, accumulator 14 accumulates or discharges I a reserve.portion of-:fabric web 24 using differential 66 5. based on the speeds of feed rollers 30 and draw rollers 34.

FIGURES 4A-4D are diagrams illustrating turret 46 of rewind station 16 in accordance with an embodiment of the present,invention. Turret 46 comprises a fixed sun gear .-84, a planet carrier:86, and planet gears 88 rotatably 10 -coupled to sun.gear 84. In operations planet carrier 86 is rotated about.the axis of shaft 90 of planet carrier 86.

-As planet..-carrier 86 notates, teeth knot explicitly shown) of planet gears 8B engage: teeth (not explici:tly shown) -of sun.gear.84, therebycaus'-n.g rotation of planet gears.88. i 15:-Planet gears 88.are-coupled to spindles 48, 50,: and 52 such.

that spindles 48, 50, and-52,-tr,aviel.in a generally three- I :- cusp hypocycloidal motions -: -.; Referring- to FIGURES 4 and 4C, spindles 48, 50, and S2 are coupled.to planet gears 88. by spindle carriers 92.

20 Spindle carriers-92 each comprise a yoke 94, a support 96,.

: end springs 98 disposed between: yoke 94-and, support 96.

.-Yoke 94 comprises an outwardly: extending pin lop,., Support 96 comprises an opening 102 for receiving one of spindles :.48, So, and 52. In operation, yoke 94 cooperates with 25: support 96 such that.spring,s. 98 bias a clamping surface 104 of yoke 94 towards a clamping sufac,e 106 of opening 102 of :...support 96.to seclude spindles: 48, 50, a.n,d 52 within opening 102.. Thus., spindle carriers g2 securejspndl,e,s,48, 50, and -':-.:.-52 Inca predetermined position:r.il,ati.v,^e.-to a;.center,.a;xis of 30 planet gears 88. no -.--^.. -.,,:,. I . iRe;ferring.to..FI. GURE.4D-,,as,-;spnd,l.es,,48, 5,.g,:,,-and 52 are --o-it;.ion.e.d. at., windi n..-.statio,,, 38,,'., dov,n,w,1-r,,l,y drec,ted: =forc!e -is. apple. t.pi,.;OO,*to.:-rs,z,,s..--he bia"..f.or.e,e =f

v springs 98 and direct yoke 94 downwardly relative to support 96, thereby releasing spindles 48, 50, Andre for movement within-epening ion. For example, the force may be applied to pin 100 from a pneumatically operated cylinder 5 (not explicitly shown) controlled by controller - 5 6; however, other suitable devices or methods may be used to apply a downwardly directed force to pin 100. As yoke g4 moves:downwardly relative tosupport 96, spindles 48, 50, and 52 also move- downwardlywithin opening-102 so that 10 spindles 4S,- 50:, and s2 are positioned in a nip defined by adjacent winding rollers 36- As- fabric web 2-4 s surface wound thou t spindles 48 j 50, and 52, spindles 48,:50, and 52 are operable- t move -upwardly within opening 102 ho accommodate an increasing diameter:-fabric roll-formed 15 about spindles 4B, 50-,and 52. Aftar-the fabric roll is formed to a-desired size, pin 100 may be released, thereby causing yoke 94 to be biased upwardly fromsprings 98 to secure spindles: 48,; 50, and 52.:Thus,::spindle carriers 92 releasably engage spindles 48, - 50,:: and 52 to locate 20 spindles -48, 50, and 52 icy a position for surface winding of spindles: 48, 50, and - 52, and to - acconunodate an increasing diameter of the fabric-;roll:= during forrnatio-n of the fabric rolls In the embodiment illustrated in -FIGURES 4B-4D, 25 spindle carriers In comprise p:nl-O:O:-fordirecting yoke 94 downwardly: relative to support--96 to releasably engage spindles 4S, 50, And 52. However,ther-suit-able methods or devices yore use-d trio relea- sably engage spindles 48 -50, nd;-52:t=iprovide'jpo-s-i;nal n-trol-of-- ::spi-ndles 4B, 30 50, and 52 relative to winding rollers 36. -ace-

FGRE 5--5H:r:d-iagams-illdtrat-ing:rewind station 6--in: accordance withes- ails emdimdbt.-of he.;present -nvnoni..? ei-;-tc>:i-; P't:T: A-7"' ' statiorl:..:l6

is comprises winding station 38, cutting' station 40, tucking station 42, and stripping station 44. As described above, turret 46' rotates about a central axis'to transfer spindles 48, 50, and 52 between winding station 38, tuc.king station 5 42, and stripping station 44 along generally threecusp hypocycloidal paths 108, 110, and 112' - '.:' As illustrated in FIGURE 5A, fabric web 24 is wound about spindle-48 using rewind rollers 36 of winding station 38 to form a fabric roll 114. For example,'fabric roll 114 10 may be surface wound about spindle 48 by-rotatingrewind rollers 3-6'in'the direction indicated: by arrows 135 As describedabove', spindle carrier 92- disengaged spindle '-4'8 at winding station 38 to positionspindle 48- in a nip defined by adjacent winding:'rollers 36'. 'Additionally, 15 spindle carrier 92 disengages spindle 48 to alowrotation of spindle 48 caused by the rotation 'of' wincing rollers 36 The speed and duration of wincing 'may be co:ntr-olled'usi-ng control 'system 54 to form fabric roll 114 t'o'a' desisted size. After fabric roll li4; has' been wound to the desired 20 size, rotation of winding rollers 36 and draw rollers 34'i's dwelled to prevent feeding additional fabric web' 24 'to winding station 38 Additionally, spindle -carrier 92 engages spindle 48 in preparation for indexing of turret :: 25 FIGURE '5B illustrates an' indexing-of turret 46 t'o transferspindles 48, 50, and 52 between stations 3'8,'42-, and 44. For example, spindle 4:8 and fabr'ic:'roll'':I14 are -transferred from winding station 3:8 to tuck'ingstation 42 along hypocycloidal path 108 '-Additionally, spindie:50 is 30 -transferred from-tucking stationed tostrippingstation:'44 along path- 110, and'' spindle '2' is - transf'erred: from Airs g'S'tatzon 44'tb win'ding''s3tabion 3'8i''alodg4'i:'.--2'.

T err spindles 48, 50,' and 5-2 between d'tat'ions::'3G',

42, and 44 along generally hypocycloidal paths 108, 110, and 112 prevents interference between components of rewind station 16 and-.alleviates additional movement of components of rewind station 16 to avoid. interference..

5 As illustrated in FIGURE 5C, turret 46 has.completed indexing and has positioned-spindle 48 and fabric roll 114 at tucking 'station 42 and spindle 50 at stripping station 44. Additionally, asdescribed above, pindle.carrier 92 disengages spindle 52, at winding station 38, thereby 10 allowingspindle 52 to be disposed within a nip defined by adjacent wounding rollers 36. As.turret 46 indexes, fabric web.24.is.positioned between.,spindljS2 and r,ewind,rollers ,36,such that fabricweb 24 becomes secured between rewind rolllr.s 36 and spindle. 5-2..as spindle 52 reaches winding 15 statin.38... ..:,.: Cutting station 40 com,prises,. shear blades 116.and-118 -to separate fabric roll 114 from.a rema,ining, po.,rtion,of fabric:.web.24..-As.illustratd in FIGURE SC, as spindle 52 reaches winding station..38, spindle 52 causes a tension in 20 a port-ion of, fabricweb.24 extending from winding station 38 to fabric roll 114:so that shear blades 116 and 118 may separate fabric web 24- from fabric roll 114. For example, e-hear blade 118 -may be moved in..a direction indicated by arrow 120 to cooperate with shear blades 116 to separate 25 - fabric web, 24 from fab.,r,ic roll:.114.. Controller 56 may be used,.to Control actpa.t.ion of shear blades 116 and 1,18 to separte:fabric-,web 24.f.om.fabricroll 114.,: Referr,-ng-t,o F.IGUgg 5D, s,h,ear,.,.blade ll,, Bengages..s,hear blqe..11;6.to= se.papat!e ft,ic web 24,from, f Tic roll. ll4, 30 the,b.y: fain, a leading -'e,dge 122 of fabric womb,24..a trail.-. .5ge 12;4 Of f4ric,.r.,qll, 114,. Tu.cking.statio,,n 42 50pie5.r,,a,,,!, \pckin.; ol+e.<,t.yin.,4. tpai,li.n.,=4g,,174 ,.ot;,qp;>,n4le!8-ad ha. roll 1l4- crexample;t

roller 126 may be operated in.a direction indicated by arrow 128, thereby causing fabric roll 114 to rotate in a direction indicated by arrow 130 to wind trailing edge 124 about fabric roll 114. Controller 56 may be used to 5 operate tucking roller 126 after separation of fabric roll 114 from.fabric web 24. Rewind station 16 also comprises a tucking station 132 to position leading edge 122 of fabric web 24--into a position to form another fabric roll about spindle 52.

10, Referring to FIGURE BE, shear blade 118 is retracted and tucking roller 126 continues rotation to wind trailing edge 124 about fabric roll 114. Tucking station 132 comprises an arm 133 to engage leading edge 122 of fabric Web 24 and position leading edge 122 about spindle 52 at 15 winding station 38 in preparation for forming another fabric roll. However, tucking station 132 may also comprise other suitable methods or devices for positioning leading edge 122 of fabric web 24 adjacent spindle 52, including, but not limited to, an air.jet.

20 Referring to FIGURE 5F, rewind rollers 36 are activated in the direction indicated by arrows llS to wind fabric web 24-about spindle 52 to form a fabric roll 134.

As described.above, spindle carrier 92 disengages spindle 52 at windingstation 38 to allow movement of spindle 52 to 25 accommodate formation of fabric roll 134. As illustrated in FIGURE 5F, spindle 52 moves upwardly away from the nip of winding rollers 36 to accommodate an increase in diameter of fabric roll 134.., Referring to FIGURE 5G, turret 46 indexes, and 30 transfers spindle 48 and fabric roll 114 from tucking station 42 to strippingstation 44,a10ng hypocycloidal path ::ll.O,,p;hdle,:-.52.a.nd. fabric roll 134,from winding:staton 38 to tucking station 42 along hypocycloidal path 108, and

spindle SO from stripping station 44 to winding station 38 along hypocycloidal path 112. As illustrated in FIGURE 5G, shear blades 316 and 118 have been releasably engaged to separate fabric web 24 from fabric roll.134, thereby 5 forming leading edge 122 of fabric web 24 and trailing edge 124 of fabric roll 134. Trailing edge 124 may then be wound about spindle 52 and fabric roll 134 using tucking roller 126.

Referring to FIGURE SH, stripping station 44 comprises 10 one or more paddles 136 to remove fabric rolls formed on -spindles 48, 50, and 52. Paddles 136 each comprise fingers 138 that extend across and straddle spindles 48, SO, andi52 adjacent fabric rolls formed on spindles 48, 50, and-52.

In operation, paddles 136 are translated along spindles--48, 15 50, and SO to slide and remove the fabric rollsfrom spindles 48, 50, and 52.

Paddles 136 may be coupled to a belt 140 for repeated positioning and translating of paddles 136 in stripping station 44. For example, referring to FIGURE 1, belt -140 20 may be driven in a direction indicated by arrow 142 to remove fabric rolls from spindles 48, 50, and 52.: Belt 140 may be driven at a speed and with. various quantities of paddles 136 to correspond with indexing of turret 4-6.

However, other suitable methods or devices may be used for 25 repeated stripping of fabric rolls from spindles 48, 50, and S2. Fabric rolls may then be transferred to a conveyor 144 or other suitable transfer device or method:to transport the fabric rolls to additional processing stations.:-: 30 - Although the present invention and its advantaged have been described inidetail, it:shoula: be:-understod- Abet - varioue c es,9substitutons,and alt-eatzon"-cAbe)e . it.... ..,. ,v,. ,j.,,, go,:,,... I-: Em.;

therein without departing from the scope of the invention as defined by the appended claims ::

Claims

C7.1t EMS 1. A method for producing coreless fabric rolls comprising:

winding a fabric web onto one of a plurality of spindles to 5 form a coreless fabric roll at a first station, the spindles coupled to a turret; transferring the spindle from the first station to a second station along a generally hypocycloidal path; separating the coreless fabric roll from the fabric web; 10 forming a leading edge of the fabric web and a trailing edge of the coreless fabric roll; winding the trailing edge about the coreless fabric roll at the second station; transferring the spindle from the second station to a third 15 station; and removing the coreless fabric roll from the spindle at the third station.
2. The method of claim 1, further comprising: 20 securing the spindle in a first position relative to the turret; and releasing the spindle at the first station to provide movement of the spindle from the first position to a second position during forming of the coreless fabric roll.

25;
3. The method of claim 1 or claim 2, wherein the removing step comprises disposing a paddle adjacent an end of the coreless fabric roll and translating the paddle along the spindle.
4. The method of any one of claims 1 to 3, further comprising tucking the leading edge of the fabric web adjacent another spindle disposed at the first station.

lo
5. The method of any one of claims 1 to 4, wherein the separating step comprises activating a shear blade disposed between the first and second stations to sever the fabric web from the coreless fabric roll.
6. The method of any one claims 1 to 5, further comprising: providing the fabric web from a feed station at a substantially constant feed rate; and accumulating a reserve portion of the fabric web while 10 the spindle is transferred from the first station to the second station.
7. A system for producing coreless fabric rolls comprising: a hypocycloidal turret having a plurality of spindles; 15 a winding station operable to wind a fabric web onto one of the spindles to form a coreless fabric roll; a cutting station operable to separate the coreless fabric roll from the fabric web to form leading edge of the I fabric web and a trailing edge of the coreless fabric roll; 20 a tucking station operable to wind the trailing edge about the coreless fabric roll; a stripping station operable to remove the coreless fabric roll from the spindle, and a control system operable to transfer each of the 25 spindles to the winding, tucking, and stripping stations along a generally hypocycloidal path.
8. The system of claim 7, wherein the turret further comprises a spindle carrier coupled to each of the spindles 30 to secure each of the spindles in a first position, and wherein the control system is further operable to disengage the spindle carrier from the spindle to provide for movement of the spindle from the first position to a second position in response to forming the coreless fabric roll.

:w
9. The system of claim 7 or claim 8, further comprising: a feed station operable to provide the fabric web at a substantially constant feed rate; and 5 an accumulator operable to accumulate a reserve portion of the fabric web as the spindles are transferred between each of the winding, tucking, and stripping stations.
10. The system of claim 9, wherein the accumulator is 10 further operable to discharge the reserve portion of the web during forming of the careless fabric roll.
11. The system of any one of claims 7 to 10, wherein the stripping station comprises a paddle having a plurality of 15 fingers, the fingers operable to extend over the spindle, and wherein the control system is further operable to translate the paddle along the spindle to remove the careless fabric roll from the spindle.

20
12. The system of any one of claims 7 to 11, wherein the cutting station comprises a shear blade, and wherein the control system is further operable to activate the shear blade to separate the careless fabric roll from the fabric web while the spindle is disposed at the tucking station.
13. A method for producing fabric rolls, comprising: providing a fabric web at a substantially constant feed rate; moving a first spindle of a turret to a first station; 30 accumulating a reserve portion of the fabric web during movement of the first spindle to the first station; and discharging the reserve portion to the first station to form a fabric roll about the first spindle;

transferring the first spindle from the first station to a second station; accumulating a next reserve portion of the fabric web L during transfer of the first spindle from the first station 5 to the second station; moving a second spindle of the turret to the first station; and discharging the next reserve portion to the first station to form another fabric roll about the second spindle.

10!
14. The method of claim 13, further comprising: transferring the first spindle from the first station to a second station; separating the fabric roll from the fabric web; 15 winding a remaining portion of the fabric web about the L fabric roll at the second station; transferring the spindle from the second station to a] third station; and removing the fabric roll from the first spindle at the 20 third station.
15. The method of claim 13 or claim 14, wherein accumulating the reserve portion comprises: I receiving the fabric web from a feed station at a ' 25 plurality of festoon rollers; and moving the festoon rollers away from each other to accumulate the reserve portion.
16. The method of claim 15, wherein discharging the fabric 30 web comprises moving the festoon rollers toward each other to discharge the reserve portion.

*A so
17. The method of any one of claims 13 to 16, wherein moving the first spindle comprises moving the first spindle to the first station following a substantially hypocycloidal path.

5
18. The method of any one of claims 13 to 17, further comprising: receiving the reserve portion of the fabric web at a plurality of rollers of the first station; disposing a portion of the fabric web adjacent the first 10 spindle; and rotating the plurality of rollers to form the fabric roll about the first spindle.
19. A method for producing fabric rolls, comprising: 15 disposing a spindle of a turret in a winding station; providing a fabric web from a feed station to an accumulator at a first feed rate; providing the fabric web from the accumulator to the winding station at a second feed rate; 20 winding the fabric web about the spindle at the winding station to form a fabric roll; and accumulating a reserve portion of the fabric web at the accumulator when the second feed rate is less than the first feed rate.
20. The method of claim 19, further comprising discharging the reserve portion when the second feed rate is greater then the first feed rate.

30
21. The method of claim 19 or claim 20, wherein accumulating comprises: receiving the fabric web at a plurality of festoon rollers of the accumulator; and

:3 moving the festoon rollers away from each other to accumulate the reserve portion.
22. The method of claim 21, further comprising discharging 5 the reserve portion from the accumulator by moving the festoon rollers towards each other when the second feed rate is greater than the first feed rate.
23. The method of any one of claims 19 to 22, wherein 10 disposing the spindle comprises disposing the spindle! adjacent a plurality of rollers, and wherein winding -

comprises rotating the plurality of rollers to wind the fabric web about the spindle.

15
24. The method of any one of claims 19 to 23, further L comprising: transferring the spindle from the winding station to a] tucking station; and reducing the second feed rate to less than the first 20 feed rate during transfer of the spindle from the winding station to the tucking station.
25. The method of claim 24, wherein transferring the spindle I comprises transferring the spindle from the winding station 25 to the tucking station following a substantially hypocycloidal path.
26. The method of any one of claims 19 to 25, wherein winding comprises: 30 releasing the spindle to a first position adjacent a plurality of rollers in the winding station; rotating the rollers to wind the fabric web about the spindle, the spindle moving from the first position to a

second position in response to an increasing thickness of the fabric roll; and securing the spindle at the second location for transfer from the winding station.
27. A system for producing a fabric roll, comprising: a feed station operable to provide a fabric web at a substantially constant feed rate; a turret operable to intermittently move each of a 10 plurality of spindles into a winding station; the winding station operable to wind the fabric web about one of the spindles; and an accumulator operable to accumulate a reserve portion of the web during movement of the spindles relative to the 15 winding station, the accumulator is further operable to discharge the reserve portion of the fabric web to the winding station after another of the spindles is positioned at the winding station.

20
28. The system of claim 27, wherein the turret is operable to move the plurality of spindles through a substantially hypocycloidal path.
29. The system of claim 27 or claim 28, wherein the 25 accumulator comprises a plurality of festoon rollers, the festoon rollers operable to receive the fabric web from the feed station and move away from each other to accumulate the reserve portion.
30 30. The system of claim 29, wherein the festoon rollers are further operable to move towards each other to discharge the reserve portion to the winding station.
31. The system of any one of claims 27 to 30, wherein the winding station comprises a plurality of rollers operable to wind the fabric web about one of the spindles, and wherein the turret comprises a spindle carrier operable to disengage 5 one of the spindles to dispose one of the spindles into a first position adjacent the rollers, the spindle carrier operable to reengage the one spindle in a second position after forming the fabric roll, the one spindle moving from the first position to the second position in response to an 10 increasing diameter of the fabric roll.
32. A system for producing a fabric roll, comprising: a turret having a plurality of spindles; a feed station operable to provide a fabric web at a 15 first feed rate; a winding station operable to receive the fabric web at a second feed rate and wind the fabric web about the spindles; and an accumulator operable to receive the fabric web from 20 the feed station and transfer the fabric web to the winding station, the accumulator further operable to accumulate a reserve portion of the fabric web when the second feed rate is less than the first feed rate.

25
33. The system of claim 32, wherein the accumulator is further operable to discharge the reserve portion to the winding station when the second feed rate is greater than the first feed rate.

30
34. The system of claim 32 or claim 33, wherein the accumulator comprises a plurality of festoon rollers operable to move away from each other to accumulate the reserve portion.
35. The system of claim 34, wherein the festoon rollers are further operable to move toward each other to discharge the reserve portion to the winding station.

5
36. The system of any one of claims 32 to 35, wherein the turret further comprises a spindle carrier coupled to each of the spindles, each spindle carrier operable to provide for movement of the spindle during formation of the fabric roll in response to an increasing size of the fabric roll.
37. The system of any one of claims 32 to 36, wherein the turret is further operable to move each of the spindles to the winding station following a substantially hypocycloidal path.
38. The system of any one of claims 32 to 37, wherein the winding station comprises a plurality of rollers operable to rotate relative to one of the spindles to wind the fabric web about the one spindle.
39. A system for producing careless fabric rolls comprising: a turret having a plurality of spindles; a feed station operable to supply a fabric web from a parent roll; 25 a winding station comprising a winding roller; a tucking element adjacent the winding roller, the tucking element operable to position a portion of the fabric web proximate a nip defined by one of the plurality of spindles and the winding roller; 30 the winding station operable to wind the fabric web onto the spindle into a careless fabric roll; and a cutting station operable to separate the careless fabric roll from a remaining portion of the fabric web.
40. The system of claim 39, further comprising a stripping station operable to receive the spindle and remove the careless fabric roll from the spindle.

5
41. The system of claim 39 or claim 40, further comprising a control system operable to control rotation of the turret to transfer each of the plurality of spindles to the winding station. 10
42. The system of any one of claims 39 to 41, further comprising a spindle carrier operable to secure the spindle in a first position relative to the turret, the spindle carrier further operable to allow movement of the spindle from the first position to a second position during forming 15 of the careless fabric roll.
43. The system of claim 42, wherein the spindle carrier comprises a yoke operable to secure the spindle at the first position, the yoke further operable to release the spindle at 20 the winding station to provide for movement of the spindle during forming of the careless fabric roll.
44. The system of claim 41, wherein the control system is operable to transfer the spindle to the winding station 25 following a generally hypocycloidal path.
45. The system of any preceding claim, wherein the feed station supplies the fabric web at a substantially constant feed rate, and further comprising an accumulator operable to 30 accumulate a reserve portion of the fabric web as the spindle is transferred to the winding station.
46. The system of any preceding claim, wherein the tucking station comprises an arm operable to position the portion of 35 the fabric web in the nip of the spindle and the winding roller.
47. A method for producing careless fabric rolls comprising: providing a fabric web to a winding station having a winding roller; 5rotating a turret having a plurality of spindles to dispose one of the spindles at the winding station; positioning a portion of the fabric web proximate a nip defined by the spindle and the winding roller; rotating the winding roller to wind the fabric web onto 10 the spindle at the winding station to form a careless fabric roll; separating the careless fabric roll from the fabric web; and removing the careless fabric roll from the spindle.
48. The method of claim 47, wherein providing the fabric web comprises providing the fabric web at a substantially constant feed rate, and further comprising accumulating a reserve portion of the fabric web during rotation of the 20 turret.
49. The method of claim 48, further comprising discharging the reserve portion to the winding station after positioning one of the plurality of spindles at the winding station.
50. The method of any one of claims 47 to 49, wherein removing the fabric roll comprises disposing a paddle adjacent the fabric roll and translating the paddle along the 30 one spindle.
51. The method of any one of claims 47 to 50, further comprising: disengaging the one spindle to position the one spindle 35 in a first position adjacent the roller; and

reengaging the one spindle at a second location after formation of the fabric roll, the one spindle moving from the first location to the second location in response to an increasing size of the fabric roll.
52. The method of any one of claims 47 to 51, wherein rotating the roller comprises rotating the roller to form a plurality of careless fabric rolls on the one spindle, and wherein removing comprises removing each of the plurality of 10 fabric rolls from the one spindle.
53. A method for producing careless fabric rolls, substantially as hereinbefore described with reference to the accompanying drawings.;
54. A system for producing careless fabric rolls, substantially as hereinbefore described with reference to the accompanying drawings.

20
55. A method for producing fabric rolls, substantially as hereinbefore described with reference to the accompanying drawings.
56. A system for producing a fabric roll, substantially as 25 hereinbefore described with reference to the accompanying drawings.