WO2003010076A1

WO2003010076A1 - Method of web turn-up in a web winder and apparatus therefor

Info

Publication number: WO2003010076A1
Application number: PCT/CA2002/001167
Authority: WO
Inventors: Roman C. Caspar
Original assignee: Caspar Roman C
Priority date: 2001-07-26
Filing date: 2002-07-25
Publication date: 2003-02-06
Also published as: CA2354303A1

Abstract

A method and apparatus for cutting and transferring a web (12, 14) onto a new empty reel core (16) utilizing at least one water jet (46) cutter located immediately upstream and adjacent to a nip formed between a driving drum and the empty reel core (16) and that further utilizes twin water jet nozzle tail cutters located further upstream of the first water jet cutter (46). The twin cutters (42) cut a strip (44) into the web from the interior of the web which strip is directed downstream past the first water jet cutter (46). The first water jet cutter (46) is limited to cut across the strip (44) to completely sever the strip and form a leading tip (49) that is wrapped around the new empty core (16). Thereafter, the water jet tail cutters (42) move to the outside edges of the web (12, 14) widening the strip (44) to the complete width of the web which is then wound onto the new empty core (16).

Description

METHOD OF WEB TURN-UP IN A WEB WINDER AND APPARATUS THEREFOR

Field of the Invention

The present invention relates to a winder for continuously winding a web onto a core and in particular relates to web cutting system that severs the web and turns the severed web onto a new empty core. The web cutting system preferably utilizes a water jet tail cutting system that cuts a strip of paper web in advance of the turn-up station and a water jet tip cutter located immediately prior to the turn-up station to sever the strip and create a tip that turns up onto the new empty core.

Background of the Invention

In present day winding machines for winding a web onto a roll it is common practice to drive the web onto the new roll by using a reel driving drum in driving contact with the web and roll. These machines are typically equipped with a transfer arm mechanism for lowering an empty core or reel bar into driving engagement with the driving drum. The empty core can either be partially or fully accelerated up to a surface speed equivalent to the speed of movement of the web over the driving reel drum prior to engagement with the driving drum. When the empty core comes into driving relation with the driving reel drum, the web is cut and turns up onto the empty core. The existing roll is decelerated and removed from the winding machine. The empty core is typically then rotated around the driving reel drum by the transfer arm mechanism into its normal winding position. After the core is fully wound with paper, the loading process of a new empty core is repeated. The wound core is removed from the reeling station and is later unwound and slit into paper of reduced width and diameter.

Clearly, the successful transfer of the web onto the new empty core in the reel bar transfer station requires a successful severing of the web and turn-up of the severed web onto the empty core of the reel bar. This requires diverting the normal path of web travel from the existing winding roll. The other requirement is that the winding operation is a continuous non-stop operation and the transfer of the web to the new roll must consistently occur without resulting in the stoppage of the paper making machine. It should be understood that if the turn-up operation requires a stoppage in the travelling web, this effects the web travelling continuously upstream of the reeling station.

For the production of relatively lightweight paper moving at relatively fast speeds, the turn-up system presently utilized typically relies on an air jet attached to a goose neck located to transversally cut and redirect the web onto a new reel bar downstream of the nip formed between the driving roll and the new empty core reel bar. During the turnup operation, knife cutters in the form of rotary cutters or water jet cutters positioned upstream from the reel bar loading station are utilized to sever a tip in the web which tip must be moved a distance in the order of 15 meters to the reel bar turn-up station. The location of a tail cutter this distance upstream of the turn-up station is necessary since at the turn-up station there is no space for the placement for such a tail cutter which typically has rotating knives or water jet cutters that move transversally across the web on a support beam. Examples of such tail cutters used in the turn-up operation are disclosed in U.S. patent 4,444,362 issued April 24, 1984 to Gerald W. Karr and to U.S. patent 5,360,179 issued November 1, 1994 to Kalevi A. Vesterinen. In these devices, the tip of the paper must be blown up by the use of either a goose neck or a blowing device located downstsream of the nip formed between the driving drum and the new empty core reel. While such devices may meet the requirement of permitting successful turn-up onto a new empty core, these applications, particularly using air, are utilized typically for relatively low basis weight paper.

For application in cutting paper having a relatively higher basis weight, such as paperboard, and for light weight papers in slower speed applications, the use of an adhesive tape has been employed to cut the web. In present tape systems, the adhesive tape has a tip portion that is glued against the new roll and has a strip that extends below the web held in a receiving slot. In this turn-up operation, the tip portion of the tape applicator is glued in one end to the empty core of the reel and is drawn tight and snaps in a fashion to break through the web attaching itself on one side to the web to hold the web in contact with the new reel. This form of tape applicator has been successfully in use for over twenty years and finds particular application with slower moving heavier basis weight paper.

While the aforementioned re-direction of the cut tip by the use of air nozzles attached to goose necks downstream of the nip, or by the use of tape applied to the web upstream of the nip has resulted in successful turn- up, it should be understood that these processes cause several initial layers of paper wound onto the new reel to become wrinkled and unusable. Clearly the effect of the tape adhered to the web will create an uneven surface starting from one extremity of the reel spool that provides a wrinkling effect and an imprint on the paper which results in wastage. With respect to turn-ups by means of air jets mounted to goose neck devices, the paper is ripped by these devices and is blown around the nip forming an air pocket between the paper web and the reel which results in wrinkling of a plurality of layers of paper web. This wrinkled paper has resulted in significant wastage of paper. It should be understood that this wastage or wrinkling effect is further compounded when the completed wound roll is removed from the transfer station and subsequently moved to an unwinding station where the roll is wound into paper having smaller widths. In the unwinding operation, due to the large size of the wound paper web roll, significant torque must be applied to overcome the inertia of the roll and to get the roll up to speed. This wrinkled section of the paper has a creeping effect which results in further surface damage of layers of unwrinkled paper wound over and immediately adjacent to layers of the wrinkled paper. Hence, the wastage in the paper plants extends beyond that which is visible because the wrinkled section has a compounding effect on layers immediately adjacent to it during the unwinding and slitting operation. Consequently, paper making facilities have had to accept that existing processes used to cut the web at turn-up results in considerable amounts of wastage. Hence, anything that can be done to reduce the amount of wrinkling during the turn-up of the web onto new empty reel core in the reel transfer station will have a significant cost improvement in paper production.

While the foregoing discussion relates to current commercially available turn-up systems, it should be understood that other patents have issued or applications published disclosing turn-up systems for the reel bar transfer station that do not appear to have enjoyed wide commercial implementation. One such patent is U.S. patent 5,314,312 issued May 24, 1994 to Ando et al. This patent application relates to the use of a goose neck type device located downstream of the nip which breaks the web or a strip portion of the web downstream of the nip and causes it to turn-up onto the reel. To facilitate this turn-up, immediately prior to entering the nip, a strip of adhesive tape is applied to this ribbon or strip passing through the nip which causes the strip to adhere to the new reel when it is cut downstream of the nip. While this practice does not appear to be common in the industry, it is believed that if a turn-up device could be manufactured in accordance with the teachings of this patent, it would still be subject to the wrinkling problems due to both the entrapment of air between the reel core and web and the use of tape.

Another patent application which discloses turn-up without the use of a subsequent air shower or tape is disclosed in my Canadian patent application serial number 2,227,113 which was published July 15, 1999. This patent application relates to the use of a tail cutter located immediately upstream of the nip formed by the new reel bar loader and the driving roll in the web transfer station. The problem with this particular transfer device that has now been encountered relates to the positioning of such a turn-up device immediately adjacent the nip. The placement of the turn-up tail cutter in this location is not commercially feasible in many instances because the space requirements immediately upstream of the nip are usually used for arms to lower the reel bar into temporary engagement vertically above the reel driving drum. Hence, the turn-up beam of this patent application cannot be located in this position and still permit operation of common transfer arm mechanisms that lower the new empty reel core onto the driving reel drum.

Hence, there is a need for a turn-up apparatus and method for use with a reel bar loading station that reduces the number of wrinkled layers of web would about the reel bar core.

Summary of The Invention

The present invention relates to a turn-up apparatus and method utilized in the web winding section of a paper making machine. In particular, the present invention is directed to the cutting and transferring of the web from an existing wound roll onto a new empty core reel to be wound in the winding section. The present invention utilizes two cutting devices located upstream in the direction of web or sheet movement relative to a nip formed between a driving drum and the new empty core in the winding section of the paper making machine. A first web cutting device preferably cuts into the web at two locations spaced apart from each other so as to cut a strip in the interior portion of the web. Alternatively a singular cutting device may be used to cut along a strip just inboard of an edge portion of the web. This first cutting device preferably comprises water jet nozzles that can cut the web at much greater speed in the lateral direction. A second cutting device in the form of a water jet nozzle is mounted downstream of the first cutting device and immediately upstream and adjacent to the nip. The purpose of the second cutting device is to provide a compact, low inertia cross cutter immediately prior to the nip to cut a leading tip by severing the pre-cut strip. This cutting or severing of the narrow strip is almost like a chopping action which results in formation of the leading tip. The tip is directed immediately into the nip and between the driving drum and the surface ofthe new empty reel core. lt should be understood that the reference to the water jet tip cutter being located immediately prior to the turn-up station or immediately upstream and prior to the nip formed between the driving drum and the new empty core means that the water jet of the tip cutter is postioned to direct a water jet to chop the strip in advance of the strip entering the nip and preferably at a location where the stip is supported in its travel over the driving drum in advance of the nip.

After the leading tip of the strip starts to follow the new empty surface of the reel, then the tail is cut by the first cutting device by the tail cutters preferably moving outwardly of the strip towards the edges of the web. As a consequence the strip now carried around the new empty reel core will widen to the full width of the web which will then pass around the new empty reel core.

In accordance with one aspect of the present invention there is provided a method for cutting and transferring a web driven by a reel driving drum in a winding station from a driven reel onto an empty core reel. The method comprises transferring the empty core reel into driven engagement with the web and the reel driving drum to provide a nip therebetween through which the web passes. The method includes cutting a strip in the web upstream from the driving reel drum by use of a tail cutter. Then this strip is severed downstream from the tail cutter and immediately upstream of the nip to form a leading tip in the strip that is pressed into the nip and turns onto the new empty core reel. The web is then severed upstream of the nip by the tail cutter which moves away from the strip across the web after the leading tip is cut from the strip such that the strip widens and winds onto the new empty core.

In accordance with another aspect of this method, the strip or the empty core, at least adjacent the strip, may be wetted by either water or an adhesive glue like material on the same side of the web as the empty core reel to facilitate the leading tip and the strip following and adhering to the curvature of the new empty core. Since the tip is at least slightly wet on the same side as the empty reel core and/or the new empty core is wetted, the tip follows the new empty core and wraps itself around the empty core. In some applications this may render unnecessary the use of a gooseneck or an air blowing device located downstream of the nip. Further, there is no requirement to use tape. The present invention therefore reduces the amount of wrinkled paper wound around the new empty reel core and significantly reduces the amount of paper damaged during turn-up and subsequent unwinding and slitting.

In accordance with another aspect of the present invention there is provided a winder for continuously winding a web into rolls on successive reels that comprises a reel driving drum over which the web travels for driving the successive reels. There is also included a roll changing apparatus for cutting and transferring the web from a full rolled reel to an empty reel core. The winder comprises a transfer mechanism for transferring the empty reel core into engagement with the web and the reel driving drum to provide a nip between the driving reel drum and the empty reel core through which the web passes onto the fully rolled reel. A tail cutting device or tail cutter is located upstream of the transfer mechanism and has a rail that extends across the width of the web and supports at least one cutting device which is adapted to initially cut a strip in the web which strip runs into and through the nip. A leading strip cutting device is further included and positioned adjacent to and immediately upstream of the nip to sever the strip downstream from the tail cutting device to form a leading tip in the strip that is pressed into the nip and turns onto the new empty core reel.

Brief Description of The Drawings

For a better understanding of the nature and objects of the present invention reference may be had to the accompanying diagrammatic drawings in which:

Figure 1 is a side view of a winding apparatus for winding a web into a roll including the water jet cutting devices of the present invention;

Figure 2 is a plan view showing the location of the cutting devices relative to the empty reel core and shows the strip cut from the web;

Figure 3 is a plan view similar to Figure 2 and shows the leading tip cut into the web; Figure 4 is a plan view similar to Figure 2 showing the widening of the strip; and,

Figure 5 is a general plan view of the cutting pattern in the web.

Detailed Description of The Drawings

Referring to Figure 1 there is shown a winder 10 of a paper making machine for winding a web 12 into rolls 14 from successive cores 16. The web 12 is preferably a paper web, coated paper or heavier paperboard. The roll 14 is supported by its core 16 on rails 18. As the diameter of the wound web on roll 14 increases, the core 16 moves along rails 18 in the direction of arrow 22. The web 12 is driven by driving reel drum 24 onto the core 16. The direction of rotation of driving reel drum 24 is shown by arrow 27 which results in the roll 14 rotating in the direction shown by arrow 28.

The winder 10 is shown with an empty core 30 loaded and supported by transfer arm mechanism 32 onto the driving reel drum 24 and forms a nip 34. It should be understood that for the purposes of illustration, only arm mechanism 32 is shown and that some other apparatus is usually required to lower the empty core 30 into the position shown. The empty core 30 is typically lowered into position prior to web turn-up. The transfer arm mechanism 32 is controlled to rotate in a clockwise direction to place the empty core 30 on the rails 18 after the web 12 has been cut and turned up onto the empty core 30. Prior to lowering the empty core 30 to its normal winding position onto rails 18, the full wound roll 14 is moved away from the driving reel drum 24. As the empty core 30 is lowered into the initial winding position shown in Figure 1, the empty core 30 is accelerated and brought into driving contact with the driving reel drum 24. Once the empty core 30 engages the driving reel drum 24 at nip 34, the cutting of the web 12 to bring about its tum-up onto the empty core 30 is initiated.

The apparatus of the present invention includes a tail cutting device 38 located upstream from the transfer mechanism 32 and downstream of spreader roll 47. The tail cutting device 38 has a rail 40 that extends across the width of the web 12 and supports at least one cutting device and in the preferred embodiment a pair of water jet cutting nozzles 42. The water jet cutting nozzles 42 are adapted to initially cut a strip 44 of narrow width shown in Fig. 2 between parallel lines at 45 in the web 12. The strip 44 is cut after the reel core 30 is lowered into engagement with the drum 24. The strip 44 may initially run through the nip 24.

The apparatus further includes a leading strip cutting device in the form of a water jet cutter 46 positioned adjacent to and immediately upstream of the nip 24. This water jet cutter 46 is a smaller compact device that may pivot or move on a smaller rail to sever the strip 44 downstream from the tail cutting device 38 to form a leading tip 48 (see Fig. 3) in the strip 44 by directing a high pressure water jet across the strip. The tip 48 is pressed into the nip 34 and turns onto the new empty core reel 30.

The water jet tail cutter 38 allows for the water jet nozzles 42 to be movably mounted to the rail 40 and to move away from the strip 44 and across to the outside edges of the web 12 to sever the web 12 after the leading tip 48 is cut from the strip 44 as shown in Fig. 4. This results in the tip 44 widening as shown at 54 in Figures 4 and 5. After the strip 44 has been widened at 54, the downstream web indicated as 12a in Figures 4 and 5 then rolls onto and around the empty core reel 30.

To facilitate the turn-up of the leading tip 48 onto the empty reel core 30, the apparatus may be provided with additional nozzles 50 and 52. Preferably nozzles 50 and 52 are atomizing spay nozzles. Nozzle 50 is located attached to the tail cutter rail 40 and directs a spray of water or adhesive onto the strip 44 immediately downstream from the tail cutter 38. This wetted strip may then be picked up more readily by the empty reel core 30 once the leading tip 48 is cut. Alternatively the nozzle 50 could be directed downwardly adjacent the portion where the leading tip is cut. It should be understood that by cutting the leading tip 48 with the water jet 46, the tip 48 is partially wetted at the time of cutting and this facilitates turn-up of the leading tip 48 onto the new reel core 30. In an alternate embodiment, an auxiliary nozzle 52 may be located close to the leading tip cutter 46 and direct a spray of water or an adhesive onto the outer surface of the empty core 30 immediately prior to the core surface coming into contact with the leading tip portion cut from the strip 44.

By allowing for the chopping or severing of the strip 44 immediately prior to the nip 24, there is no requirement for a leading tip 48 having to travel any significant un-supported distance from the location of the tail cutter 38 to the nip 24. Furthermore, because the tip and/or the new empty reel are wetted prior to the tip 48 entering the nip 34, turn-up of the tip 48 onto the empty core reel 30 is facilitated without the further use of any tape or without the further use of a blow cutting device located downstream of the nip 34 in the direction of the web 12 travel. Consequently, with the tip 48 being press fitted onto the empty core 30 , there is minimal wrinkling effect associated with this tip 48.

Claims

WHAT IS CLAIMED IS:

1. A method for cutting and transferring a web, wound onto a winding reel by a reel driving drum in a winding station, from a driven reel onto an empty core reel, the method comprising: transferring the empty core reel into driven engagement with the web and the reel driving drum to provide a nip therebetween through which the web passes; cutting a strip in the web upstream from the driving reel drum by use of a tail cutter, severing the strip downstream from the tail cutter and immediately upstream of the nip to form a leading tip in the strip that is pressed into the nip and turns onto the new empty core reel; and, widening the strip and severing the web by having the tail cutter move away from the strip across the web after the leading tip is cut from the strip whereby the strip winds onto the new empty core.

2. The method of claim 1 further including the step of wetting the strip on a side thereof that travels into contact with the empty core reel.

3. The method of claim 2 further including auxiliary nozzle located on the same side as the empty core reel for performing the step of wetting the strip.

4. The method of claim 2 wherein the strip is wetted adjacent the tail cutter.

5. The method of claim 2 further including the step of wetting the empty core.

6. The method of claim 2 wherein the strip is cut from a central portion of the web by dual cutters in the tail cutter that move to the outside edges of the web away from the strip during severing of the web.

7. The method of claim 2, wherein during the step of severing the strip at least one water jet nozzle temporarily emits a water jet to sever the strip to form the leading tip.

8. The method of claim 2 wherein during the step of severing the strip the at least one water jet nozzle pivots to direct the water jet across the strip to form the leading tip.

9. The method of claim 1 further including the step of wetting the empty core.

10. The method of claim 9 wherein the strip is cut from a central portion of the web by dual cutters in the tail cutter that move to the outside edges of the web away from the strip during severing of the web.

11. The method of claim 9, wherein during the step of severing the strip at least one water jet nozzle temporarily emits a water jet to sever the strip to form the leading tip.

12. The method of claim 9 wherein during the step of severing the strip the at least one water jet nozzle pivots to direct the water jet across the strip to form_, the leading tip.

13. A winder for continuously winding a web into rolls on successive reels comprising a reel driving drum over which the web travels for driving the successive reels, and roll changing apparatus for cutting and transferring the web from a full rolled reel to an empty reel core, comprising: a transfer mechanism for transferring the empty reel core into engagement with the web and the reel driving drum to provide a nip between the driving reel drum and the empty reel core through which the web passes onto the full rolled reel; a tail cutter located upstream of the transfer mechanism having a rail that extends across the width of the web and supports at least one cutting device adapted to initially cut a strip in the web which strip runs into and through the nip, and, a separate strip cutting device positioned adjacent to, and immediately upstream of, the nip and positioned downstream from the tail cutting device to sever the strip and form a leading tip in the strip that is pressed into the nip and turns onto the new empty core reel.

14. The winder of claim 13 further including a first auxiliary nozzle located on the same side as the empty core reel and directed towards the strip to wet the strip a side thereof that travels into contact with the empty core reel.

15. The winder of claim 14 wherein the first auxiliary nozzle is located adjacent the leading strip cutter to wet the strip prior to entering the nip.

16. The winder of claim 14 wherein the first auxiliary nozzle is located adjacent tail cutter to wet the strip.

17. The winder of claim 14 further including a second auxiliary nozzle is positioned adjacent the leading tip cutter and is directed toward the empty reel core to wet the empty reel core at least adjacent the strip.

18. The winder of claim 14 wherein the tail cutter includes at least two cutting devices moveable along the rail to cut the strip from a central portion of the web and to sever the web by moving to the outside edges of the web away from the strip.

19. The winder of claim 14 wherein the leading tip cutter comprises at least one water jet nozzle that temporarily emits a water jet to sever the strip to form the leading tip.

20. The winder of claim 14 wherein the at least one water jet nozzle of the leading tip cutter pivots to direct the water jet across the strip to form the leading tip.

21. The winder of claim 13 further including a second auxiliary nozzle is positioned adjacent the leading tip cutter and is directed toward the empty reel core to wet the empty reel core at least adjacent the strip.

22. The winder of claim 21 wherein the tail cutter includes at least two cutting devices moveable along the rail to cut the strip from a central portion of the web and to sever the web by moving to the outside edges of the web away from the strip.

23. The winder of claim 21 wherein the leading tip cutter comprises at least one water jet nozzle that temporarily emits a water jet to sever the strip to form the leading tip.

24. The winder of claim 21 wherein the at least one water jet nozzle of the leading tip cutter pivots to direct the water jet across the strip to form the leading tip.