WO2008116311A1

WO2008116311A1 - Web processing system with adjustable multiple slit web separation and redirection system and/or with automatic rewind and/or automatic unwind roll transfer system

Info

Publication number: WO2008116311A1
Application number: PCT/CA2008/000573
Authority: WO
Inventors: Allan Prittie
Original assignee: Prittie Family Trust 89
Priority date: 2007-03-27
Filing date: 2008-03-27
Publication date: 2008-10-02
Also published as: WO2008116311A9

Abstract

Novel arrangements in a web processing system are described. One arrangement allows lateral separation of a multiplicity of split webs without the inducement of undesirable lateral force vectors and which overcomes the problems of the prior art. A second such embodiment allows roll transfers to be made without stopping production by the handsoff of supply of the motive force permitting the automatic offloading and exchange of rolls being processed at the exit end and/or input end of a roll fed to a web processing system.

Description

TITLE OF INVENTION

WEB PROCESSING SYSTEM WITH ADJUSTABLE MULTIPLE

SLIT WEB SEPARATION AND REDIRECTION SYSTEM

AND/OR WITH AUTOMATIC REWIND AND/OR AUTOMATIC

UNWIND ROLL TRANSFER SYSTEM

FIELD OF INVENTION

[0001] The present invention relates generally to web printing, imaging, inspection and converting machines, normally referred to as web processing systems, which are adapted to perform various process steps on an elongate web. The machine typically has an unwind mandrel and a rewind mandrel. The web is provided initially in the form of a coil or roll of web material which can be fitted onto the unwind mandrel. The web is then strung through various possible combinations of devices, such as idler rollers, error detectors, splicers, diecutters, printheads, imaging systems, web slitters and sheeters. Slitting the web may be required for a separation of images, when two or more images are located across the web. Inspection of the moving web can be done electronically or visually with the assistance of a stroboscope, or vision or video system that sequentially samples the moving web. The specific inventions relate to an apparatus and method for laterally separating a multiplicity of slit webs so that they may be rewound on one rewind mandrel, and to an apparatus and method for the automatic transferring of rewinding rolls and to an apparatus and method for the automatic transferring of unwinding rolls such that the machine need not be stopped for roll changing during a production run.

BACKGROUND TO THE INVENTION

[0002] In conventional web processing systems, especially those used to slit the web being processed into a multiplicity of webs for rewinding with high finished rewind roll hardness, two rewind mandrels are normally employed. Figure 1 shows such a rewind system in which alternate slit webs are being wound onto the two different mandrels. The main reason for the use of two rewind mandrels is to avoid the effects of any possible lateral interleaving of the slit webs as they pass from the slitting system into the rewinding system. Such interleaving when winding on one mandrel alone can be catastrophic to the finished product, in that the finished rolls can become laterally interlocked, one to its neighbour, as the slit webs interleave while the rewind mandrel rotates. Since this interleaving is occurring while the finished rolls are being tightly wound, it is most often impossible to break the finished rolls apart for packaging, shipping, and subsequent practical use in packaging applications, so the finished product is useless.

[0003] The introduction of a second rewind mandrel to a web processing machine, such as that depicted in Figure 1 in order to alternately wind slit webs into two finishing rewind locations, creates serious complications and restrictions:

1. The second rewind system requires expensive extra drive components and control technology.

2. The physical location of the two rewinds typically requires considerable extra space in the machine construction, and therefore, extra floorspace in the ultimate factory location.

3. There are often repetitive strain injuries to the operator since he or she must alternately work at too high a rewind location and then too low a rewind location when manipulating the heavy finished rolls for subsequent packaging prior to shipping.

4. If the rewind roll changing process is to be automated in order to dramatically reduce changeover time and scrap levels, the automatic changeover systems required to handle two different sets of rolls are extremely expensive, and complex to integrate and maintain, and use a very high volume of space on the factory floor at the delivery end of the machine. [0004] Various attempts have been made in the past to create lateral web separation, after slitting and before rewinding, so that a multiplicity of slit rolls may be wound on one mandrel. For example:

1. Mechanical devices, such as separating rings and/or plates, are placed laterally between the moving slit webs in order to physically force them to laterally separate, one from another. When such devices are employed, the web edges are often severely damaged by interference with the separators or "burned" through friction caused between the passing webs and their separators. This is especially so when high rewinding tensions are needed and are, therefore, imposed on the slit webs and then consequently on the rewinding rolls.

2. "Bowed rollers", which are essentially resiliently coated tubes which are mounted upon a multiplicity of bearings which are then mounted to a curved or bowed nonrotating round shaft, are introduced between the slitting section and the rewinding section of the machine. The slit webs are typically entrained around the periphery of the bowed roller for a wrap angle of between 30° and 55°. This entraining and wrapping of the slit webs around the laterally curved surface creates unbalanced cross web tension in each of the individually slit webs. Since, in each individual web, there is then also created (by the bow) the effect that tension is higher in one side than the other, the bowed roller has set up a lateral vector force on each web which tends to track the webs apart as they move around and beyond the bowed roller. However, this imposition of a lateral vector force on each passing web also creates a major practical operating deficiency when longitudinal web tensions are varying, for example during machine speed changes. Since each individual web which passes from the slitting system around the bowed roller and toward the rewind system is being pulled by the rewind system in a direction which is parallel, in each of two planes, to the main single web which is traveling into the slitting section, it will be evident that the varying torque being applied by the rewind system as the individual rewind rolls grow in diameter is such that the rewind system is trying to pull the web straight through each of the two planes. The bowed roller is trying to interrupt that lineal web flow by creating lateral vector forces as it unbalances the side-to-side tension in each passing web. The lateral vector forces are not quite at 90° to the individual passing webs and the consequence of this is that the right angle component to each of these lateral vector forces is not quite parallel to the lineal flow of the web into the slitting section. Therefore, in order the bowed roller to create a uniform and constant separation between any two webs as they subsequently flow into rewind, the lateral vector force variation in each web must be absolutely zero. This imposes the requirement, therefore, that the running lineal web tension variation in each passing web must also be absolutely zero. In practice, this cannot be accomplished since there are many factors which will cause instantaneous and long-term lineal tension variation. For example, the desired finished rewind roll tension and hardness profiles dictate that control algorithms and job engineering inputs to the tension control drives to be such that rewind tension is in fact automatically changed as the finished rolls grow in diameter. Also, there are major varying instantaneous and/or short-term effects on tension and roll hardness, such as those caused by variations in the Young's Modulus in the passing web, idler drag torque variations as the machine accelerates and decelerates, and varying air entrainment into the outer wraps of the rewinding rolls.

[0005] In the application of many conventional web processing systems, it is often desired that the printing and/or converting production be carried out, from the beginning to the end of the work on a complete production run, without stopping the machine. Since the processing of each job normally entails the use of web material pre-rewound and pre-stored and pre-shipped in lengths greater than one practical unwind roll size can accommodate, automatic or semi-automatic rewind and unwind roll changing subsystems are often added to the main web processing system. The fundamental requirement of these rewind and unwind roll changing subsystems is to then allow the "non-stop" production of a job such that all the unwind master or mother rolls are sequentially consumed and the rewinding web(s) is(are) transferred at the appropriate length or diameter to a new rewind mandrel(s) and all of these roll changing or roil transferring functions are accomplished throughout the job without stopping the machine during the production of that specific job. Various conventional methods of arranging these rewind and unwind roll transfer functions have historically been applied.

[0006] A first method of accomplishing rewind transfer (which is shown in Figure 6 and Figure 7) involves providing a multiplicity of rewind mandrels which are fixed, at their common center of rotation, to a revolving or turretting assembly. As the diameters of the rewinding rolls grow the turret rotates to present a new rewind mandrel, typically loaded with properly located, rotationally locked and pre-adhesived rewind cores ready to accept web transfer once the presently rewinding rolls have grown to a preset length or diameter. It is then typical that a sharp serrated knife assembly move at high speed toward the new rewind mandrel and thereafter sever the webs which have are travelling onto the presently winding mandrel and coincidentally adhere them to the exposed adhesive which is on the cores on the new rewind mandrel. This new rewind mandrel then continues to rewind material and hence the automatic rewind roll transfer has taken place without stopping the machine.

[0007] Rewind transfer systems of this type have the serious limitation that they are typically only used for processing small diameter finished rolls. Those that have been designed for the processing of larger diameter rolls such as the system shown in Figure 8 using the turretting method are extremely expensive because of the large rigid mounting and turretting structures that are required, they are very hard to guard safely and they consume large floorspace area and volume at the rewind end of the processing machine. Most importantly they cannot slit and rewind a multiplicity of finished rolls side- by-side without interleaving and interlocking the individual webs as they wrap onto the rewind cores. There is also the serious limitation that the torque required (from the rewind drives, components, and motors) must be provided for a very large torque gamut, since the system is required to center wind from small to large diameters, often to a diameter ratio above 6:1 and sometimes up to 12 or 14:1. These high rewind drive ratios require very large, expensive, and power wasting equipment.

[0008] Rewind transfer systems of this type also have the serious limitation, when designed to produce small rolls, that there is severe lateral web interleaving and interlocking of rolls caused by the violent action and variable rigidity of the rewind transfer cut-off knife assembly, and also the long distances over which the pre-slit webs would have to travel from the slitting system to the entry point of the rewinding roll (s) if multi-web slitting is tried at all. Often the finished rolls cannot be broken apart. When such a turretting design is used in conjunction with the processing of large diameter rolls, virtually no slitting into a multiplicity of finished rolls can be accomplished reliably and without lateral interlocking so it is almost never done.

[0009] A second method of accomplishing rewind transfer which is shown in Figure 9 involves the use of two rewind mandrels, each of which can retract and extend laterally and which interchange rewinding positions in order to accomplish the required rewind roll transfer without stopping the machine. As the rewind roll is growing on one rewind mandrel, the second mandrel (on which a full finished rewind roll is now located) retracts laterally to strip and drop the finished roll to a platform or cart. This second shaft then moves, in its retracted orientation, past the now rewinding mandrel and roll. The now rewinding mandrel and roll effectively move to interchange positions along the subsystem transfer frame until the two shafts are essentially interchanged and position. The operator then loads a pre-adhesived core to the empty rewind mandrel. A serrated "flying knife" assembly is then used to transfer the outgoing and rewinding web to the new mandrel once the appropriate finished length or diameter has been achieved on the now rewinding mandrel.

[0010] The most severe limitation of this method of accomplishing automatic rewind transfer is that only one web at a time can be effectively rewound and transferred. Therefore, jobs requiring a multiplicity of finished slit rolls cannot be practically processed on such a system. Also, there is a very large floorspace requirement behind the rewind transfer subsystem since the rewind mandrels have to be mounted to assemblies that move laterally when they are retracting from the cores of the finished rolls.

[0011] Conventional automatic and semiautomatic unwind transfer systems, such as those depicted in Figure 10, Figure 11 and Figure 12, also exhibit virtually all of the major drawbacks described of the rewind transfer configurations in Figures 6, 7, 8, and 9.

SUMMARY OF INVENTION

[0012] With reference to paragraphs [0002], [0003] and [0004],the present development relates to a way in which to address and solve the main drawbacks of the typical webflow configuration and construction represented by the rewind system in Figure 1 and the main drawbacks of the conventional web separation described in paragraph [0004] . In view of the shortcomings of the prior art, as set forth above, it is an object of one aspect of this invention to pass a single elongate web through a slitting system which converts that single web into two or more narrower webs. These narrower webs are then positively separated laterally and then the lateral separation of these webs is maintained through the method herein disclosed such that the webs do not interleave and so that the multiplicity of narrower webs can be rewound side-by-side on just one rewinding mandrel.

[0013] The present invention further provides a method of handling pre-slit webs (emanating from a slitting system of a web processing system) such as to laterally separate them through the integration of a lateral multiple web separation system which does not induce into, or present undesirable lateral force vectors to, the multiplicity of slit webs as they travel from the slitting section to the rewinding section or other downstream process of the web processing system into which it is integrated. [0014] This invention, in one aspect, provides a method of laterally separating two or more slit webs for use in a web processing machine utilizing a lateral web redirection module and providing controlled and balanced lateral web strain, and which does not introduce undesirable lateral force vectors, the method including the steps of:

(a) stringing the web material from an unwind roll through the various processing steps and functions of the web processing machine and to a slitting system of the machine;

(b) tensioning and unwinding the roll of web material while passing it through the slitting system in order to create two or more slit webs which will be laterally separated and ultimately be either rewound separately onto cores or sheeted or further processed;

(c) entraining the slit webs through a multi-web redirection module;

(d) the first web being entrained through the module without being laterally redirected as it passes through the module;

(e) the second web being entrained onto and partially around a first idler which is substantially parallel, in three spatial planes, to the web as it comes into the slitting system;

(f) next entraining the second (or additional) web onto and around a second (or additional) idler, this second idler being constrained to be substantially parallel, in two spatial planes, to the web as it comes into the slitting system;

(g) substantially aligning the center of the lateral face of the second (or additional) idler to the center of the lateral face of the second (or additional) web;

(h) angularly adjusting the axis of rotation of the second (or additional) at right angles to the entry or contact point of the second (or additional) web being entrained onto and around that idler, using a method to constrain the center of rotation of the axis of rotation to be substantially tangent to and in line with the lateral centerline of the web as it is entrained onto and passes around that idler;

(i) using a method to assure the positioning of the entry point of each pre-slit web (subsequent to the first) to the second (or further) idler after that web has left the first idler and using a method to assure the positioning of the exit point of that web from the second (or further) idler and as it flows toward and contacts the third idler such that the web as it enters the second idler is parallel to itself as it exits the second idler, and using a method to assure that these entering and exiting web paths to and from the second idler are also at right angles to the angularly adjustable axis of rotation of the second idler, and also using a method to ensure that the entry point of rotation to the axis of rotation is substantially tangential to and in line with the centerline of the web as it is entrained onto and passes around the second (or further) idler, in such a fashion as to laterally displace the web from the entry point of the first idler to the exit point of the third idler without introducing undesirable lateral force vectors into that or any other of the passing webs as they flow from the slitting system through the redirection module and into subsequent downstream processes with all webs (but the first) now being laterally displaced.

[0015] More particularly, this invention provides, in another aspect, for use in a web processing system, a multi-web redirection module, an embodiment of which is shown in Figure 2 to be embedded in a typical web processing machine. Also, Figure 3, Figure 4, and Figure 5 show the multi-web redirection module of Figure 2 in side elevation and isometric views. The application of this redirection module to a typical web processing system provides lateral separation of webs using a series of lateral position redirecting assemblies which introduce substantially zero unbalanced axial vector force on each of the webs requiring lateral separation, the redirection module comprising:

(a) front and back support frames mounted to a web processing system;

(b) a first idler mounted to the support frames for rotation about a first axis fixed with respect to the support frames, said first idler being constrained to be substantially parallel in three planes to the web as it flows into the slitting system and to the slit and separated webs as they flow downstream from the redirection module;

(c) a second (or additional) idler which is mounted for laterally constrained positioning across the face of (or faces of ) the web (or webs) as they pass through the redirection module, means to substantially align the center of the lateral face of each idler to the center of the lateral face of each passing web, said second (or additional) idler being equipped with support means which allow it to be constrained to be substantially parallel in two planes to the web as it flows into the slitting system and to the slit and separated webs as they flow downstream from the redirection module;

(d) means to angularly adjust the axis of rotation (the third spatial plane) of the second (or additional) idler at right angles to the entry or contact point of the particular web being entrained onto and partially around that idler, and in such a way as to constrain the center of rotation of the axis of rotation to be substantially tangent to and in line with the lateral centerline of the web as it is entrained onto and passes around that idler;

(e) a third idler mounted to the support frames for rotation about a third axis fixed with respect to the support frames, and means to constrain said third idler to be parallel in three planes to the web as it passes through the upstream printing or converting functions of the web processing system; (f) means to assure the positioning of the entry point of a web to the second (or further) idler after that web has left the first idler and means to assure the positioning of the exit point of that web from the second (or further) idler and as it flows toward and contacts the third idler such that the web ( as it enters the second idler) is parallel to itself as it exits the second idler, and means to assure that these entering and exiting web paths to and from the second idler are also at right angles to the angularly adjustable axis of rotation of the second idler, and also means to ensure that the entry point of rotation to the axis of rotation is substantially tangent to and in line with the centerline of the web as it is entrained onto and passes around the second (or further) idler, in such a fashion as to laterally displace the web from the entry point of the first idler to the exit point of the third idler without introducing unwanted lateral force vectors into the passing web.

[0016] In a further aspect of the present invention, there is provided for use in an apparatus for handling web, a cylinder module providing for the lateral displacement or redirection of a multiplicity of webs, each web flowing at controlled, laterally balanced web strain, the module comprising: a frame, a first cylinder mounted on the frame for rotation about a first axis fixed with respect to the frame, a second cylinder mounted on the frame for rotation about a second axis fixed with respect to the frame, the second cylinder at all times being parallel in two planes with respect to the first cylinder, further cylinders, up to the number of the multiplicity of webs being processed ( minus one), each cylinder mounted on individual subframes for rotation about each of their respective axes, each further cylinder having an outside diameter and a constrained spatial location provided by its individual subframe such that a web, when passing partially around the periphery of the first cylinder, thence to and partially around the periphery of that further cylinder, thence to and partially around the periphery of the second cylinder, the cylinders being disposed such that the web span from the first cylinder to that further cylinder is substantially parallel to the span from that further cylinder to the second cylinder, each further cylinder's subframe being mounted for constrained arcuate adjustment perpendicular to each of the incoming and the outgoing webspans, and locating the center of rotation of each further cylinder's arcuate adjustment as to be substantially identical to the center of the path of the webspan which approaches that further cylinder, in two planes.

[0017] In an additional aspect of the present invention, there is provided a method of handling web, utilising a cylinder module providing for the lateral displacement or redirection of a multiplicity of webs, each web flowing at controlled, laterally balanced web strain, the module comprising: a frame, a first cylinder mounted on the frame for rotation about a first axis fixed with respect to the frame, a second cylinder mounted on the frame for rotation about a second axis fixed with respect to the frame, the second cylinder at all times being parallel in two planes with respect to the first cylinder, further cylinders, up to the number of the multiplicity of webs being processed (minus one), each cylinder mounted on individual subframes for rotation about each of their respective axes, each further cylinder having an outside diameter and a constrained spatial location provided by its individual subframe such that a web, when passing partially around the periphery of the first cylinder, thence to and partially around the periphery of that further cylinder, thence to and partially around the periphery of the second cylinder, the cylinders being disposed such that the web span from the first cylinder to that further cylinder is substantially parallel to the span from that further cylinder to the second cylinder, each further cylinder's subframe being mounted for constrained arcuate adjustment perpendicular to each of the incoming and the outgoing webspans to and from that further cylinder, locating the center of rotation of each further cylinder's arcuate adjustment as to be substantially identical to the center of the path of the webspan which approaches that further cylinder, in two planes, said method comprising the steps: passing the multiplicity of webs partially around the periphery of the first cylinder, thence passing each of the multiplicity of webs (minus one) to and partially around the individual peripheries of each further cylinder, adjusting each of such further cylinder's arcuate positioning as to laterally displace the outgoing web path of the web from that further cylinder with respect to the webs emanating from the immediately neighbouring further cylinder or further cylinders, thence entraining each of the webs around the second cylinder, each of the paths of the each of the multiplicity of webs (minus one) now being substantially parallel to one another as they move toward and away from their respective further cylinders, the webs now emanating from the module having been laterally displaced for further processing through the web handling machine in which this method has been employed.

[0018] In various embodiments of this invention, one or more (the further) means may be provided between the first idler and the third idler, substantially in the form, positioning, and constraining of the second idler to assure the redirection of one ( or more) further web (or webs) beyond that entrained onto and around the second idler.

[0019] In various embodiments of the invention one or more means of providing an unwind mandrel, a converting process or function such as image printing or diecutting, inspection, slitting, and a rewind mandrel or a sheet creating system may be included.

[0020] With reference to paragraphs [0005], [0006], [0007], [0008], [0009], [0010] and [0011] , the present development also relates to a way in which to solve the main drawbacks of the prior art automatic and semi-automatic rewind and unwind roll transfer systems represented in Figures 6, 7, 8, 9, 10, 11 and 12. It is an object of one aspect of this invention to provide substantially continuous webflow motion throughout a complete production run, at either the rewind section or the unwind section (or both) of a web processing machine.

[0021] Considering firstly the rewind section, there are provided two moving rewind mandrel support systems, a first which is equipped to a rewind small roll (or rolls) up to a preset diameter, and a second which is equipped to accept that (or those) roll (s) just having been wound (on the first moving rewind mandrel support system) and to wind it (or them) to a final predetermined length or diameter.

[0022] One embodiment of this invention provides a method and means to rotationally align the mandrel drive axis of the small roll rewind mandrel support system and to rotationally align the mandrel drive axis such that these two axes co-align.

[0023] This invention in a further aspect provides, in a web processing system, a method of transferring and delivering of finished rewind rolls without having to stop the webflow processing during upstream operations, through the use of an automatic roll transferring system, the system including:

(a) a small roll rewind mandrel support system,

(b) a large roll rewind mandrel support system,

(c) supplying rewind torque to one side of the small roll rewind mandrel support system, and hence to one end of the new rewind mandrel,

(d) supplying rewind torque to the opposite side of a large roll rewind mandrel support system (relative to the side on which the small roll torque supply system is mounted to the small roll rewind mandrel support system), and hence to the other end of the new rewind mandrel, (e) co-aligning the axes of the small roll rewind mandrel support system and the large roll rewind mandrel support system,

(f) directing the first control means to cause the small roll rewind torque supply to be engaged and transferred to a new rewind mandrel, and removing and disengaging from that mandrel,

(g) directing the second control means to cause the large roll rewind torque supply to be engaged and transferring to said new rewind mandrel, and removing and disengaging from that mandrel,

(h) moving the axis of the small roll rewind mandrel support system from a "start rewinding" spatial orientation to a "co- aligned" orientation,

(i) moving the axis of the large roll rewind mandrel support system from the "co-aligned" orientation to a finished diameter (or roll length) location and then to a large roll unloading location, and

(j) severing the webs as they are traveling into the large rewinding rolls, and transferring them to the new rewind mandrel (which is mounted in the small roll rewind mandrel support system and is oriented to the "start rewinding" position).

[0024] In one embodiment of the invention, one or more converting processes, such as image printing or diecutting may be effected on the web upstream of the severing system, and within the web processing system.

[0025] Rewind drive torque supply means are provided at one side of the small roll rewind mandrel support system, and at the opposite side of the large roll rewind mandrel support system. Thereby it is provided that drive torque can be supplied to the presently rewinding mandrel by either the small rewind torque supply means or the large rewind torque supply means.

[0026] (Firstly assuming that the small roll torque supply means are being used to supply motive power to the small roll rewind system and that it is in motion, and that the two rewind drive torque support means are co-aligned), when the machine automatically (or the operator) decides to transfer the rewinding of the small roll(s) from the small roll moving rewind support and drive system to the large roll moving rewind support and drive system the torque supply is automatically transferred from the small roll rewind torque supply means to the large roll rewind torque supply means.

[0027] Next the small roll rewind torque supply means are disengaged from the presently rewinding mandrel, the axes of the small rewind mandrel support system and the large rewind mandrel support system leave co- alignment, and the large roll rewind torque supply means now continued to supply motive power as the large rolls grow to their finished diameter or length.

[0028] This invention permits, through the use of torque supply to one end of a rewinding mandrel (when rewinding small rolls) and the transferred use of a second torque supply to the other end of that same rewinding mandrel, the accomplishment of the following objectives:

(a) the rewinding of a single or a multiplicity of pre-slit webs such that the path length separation of the web from the exit point of a slitting system to the entry point to rewinding roll throughout a rewinding cycle which progresses from small rolls at the beginning to large rolls at the end,

(b) the minimizing of floorspace requirements at the delivery end of a web processing system, (c) the maximization of flexibility with respect to producing large multi-slit rolls side-by-side on one rewind mandrel,

(d) the minimizing of rewind roll damage, and

(e) the ability to smoothly and economically supply an automatic torque ratio change between a small roll torque supply means and a large roll torque supply means which also minimizes energy costs and drive component costs.

[0029] Accordingly, another aspect of the present invention provides, in a web processing system allowing the transfer and delivery of finished rewind rolls without having to stop the webflow processing during upstream operations, and automatic roll transferring system, the system including:

(a) a small roll rewind mandrel support system,

(b) a large roll rewind mandrel support system,

(c) rewind torque supply means mounted to one side of the small roll rewind mandrel support system,

(d) rewind torque supply means mounted to the opposite side of the large roll rewind mandrel support system (relative to the side on which the small roll torque supply means are mounted to the small roll rewind mandrel support system),

(e) means to co-align the axes of the small roll rewind mandrel support system and the large roll rewind mandrel support system,

(f) first control means for causing the small roll rewind torque supply to be engaged and transferred to a new rewind mandrel, and to be removed and disengaged from that mandrel,

(g) second control means for causing the large roll rewind torque supply to be engaged and transferred to said new rewind mandrel, and to be removed and disengaged from that mandrel,

(h) means to move the axis of the small roll rewind mandrel support system from a "start rewinding" spatial orientation to a "co-aligned" orientation,

(i) means to move the axis of the large roll rewind mandrel support system from the "co-aligned" orientation to a finished diameter (or roll length) location and then to a large roll unloading location,

0) means to sever the webs as they are traveling into the large rewinding rolls, and to transfer them to the new rewind mandrel (which is mounted in the small roll rewind mandrel support system and is oriented to the "start rewinding" position).

[0030] In a further aspect of the present invention, there is provided for use in a web processing system, an apparatus for handling rolls of web such as to provide rolls from or to the web processing system without stopping production, the apparatus comprising: a mandrel for winding or unwinding web material an alternate mandrel (its alternate) for winding or unwinding web material a first mandrel support module a second mandrel support module a first torque motive drive supply mounted to one end of the first mandrel support module, a second torque motive drive supply mounted to the opposite end of the second mandrel support module (relative to the end on which the first torque motive drive supply means is mounted to the first mandrel support module), means to co-align the winding (or unwinding) axes of the first mandrel support module and the second mandrel support module, first control means for causing the first torque motive drive supply to be engaged with either the mandrel or its alternate whichever has been mounted into the first mandrel support module and to later become disengaged from that mandrel or its alternate, second control means the second torque motive drive supply to be engaged with the mandrel or its alternate, and to later become disengaged from such mandrel, means to move the mandrel driving axis of the first mandrel support module from an initial spatial orientation to an orientation in which it will be co- aligned with the winding or unwinding axis of the second mandrel support module, means to move the mandrel driving axis of the second mandrel support module to and from a spatial orientation which allows co-alignment with the mandrel driving axis of the first mandrel support module and later movement to allow the mandrel or its alternate to be off-loaded or on-loaded, means to sever the webs and to transfer them to the mandrel or its alternate, whichever is mounted into the first mandrel support module and has been moved into the initial spatial orientation of that module. [0031] In a further aspect of the invention, there is provided a method of handling rolls of web such as to provide rolls from or to a web processing system without stopping production, comprising: a mandrel for winding or unwinding web material, an alternate mandrel (its alternate) for winding or unwinding web material, a first mandrel support module, a second mandrel support module, a first torque motive drive supply mounted to one end of the first mandrel support module, a second torque motive drive supply mounted to the opposite end of the second mandrel support module (relative to the end on which the first torque motive drive supply means is mounted to the first mandrel support module), means to co-align the winding or unwinding axes of the first mandrel support module and the second mandrel support module, first control means for causing the first torque motive drive supply to be engaged with the mandrel or its alternate, whichever has been mounted into the first mandrel support module and to later become disengaged from such mandrel, second control means for causing the second torque motive drive supply to be engaged with such mandrel, and to later become disengaged from that mandrel, moving the second mandrel support module until its winding or unwinding axis is in a predetermined spatial orientation for upcoming co- alignment with the winding or unwinding axis of the first mandrel support module, moving the winding or unwinding axis first mandrel support module (while its torque supply is causing the winding or unwinding of web or webs onto the mandrel which is in the first mandrel support module) to an angle which will allow the upcoming co-alignment of the first and second roll winding or unwinding axes, engaging the second mandrel torque drive with the rewind mandrel and bringing it up to proper angular winding or unwinding speed, transferring winding or unwinding torque from that being supplied by the first mandrel torque supply to that being supplied by the second mandrel torque supply, decelerating the first mandrel torque supply drive and disengaging it from the mandrel or its alternate, moving such axis of the first mandrel support module to the initial spatial orientation once again. [0032] In a further aspect of the present invention, there is provided a method of handling winding rolls of web such as to provide finished rewound rolls from web processing system without stopping production, comprising: a small roll rewind mandrel support module, a large roll rewind mandrel support module, a rewind torque motive drive supply mounted to one end of the small roll rewind mandrel support module, a rewind torque motive drive supply mounted to the opposite end of the large roll rewind mandrel support module (relative to the end on which the rewind torque motive drive supply means is mounted to the small roll rewind mandrel support module), a means to co-align the winding axes of the small roll rewind mandrel support module and the large roll rewind mandrel support module, first control means for causing the small roll rewind torque motive drive supply to be engaged with a new rewind mandrel which has been mounted into the small roll rewind mandrel support module and to later become disengaged from that mandrel, second control means for causing the large roll rewind torque motive drive supply to be engaged with the said rewind mandrel, and to later become disengaged from that mandrel, means to move the winding axis of the small roll rewind support module from an initial spatial orientation to an orientation which will be co-aligned with the winding axis of the large roll rewind support module, means to move the winding axis of the large roll rewind support module to and from a spatial orientation which allows co-alignment with the winding axis of the small roll rewind support module and later movement to allow the winding and offloading of large rolls, and means to sever the webs as they are travelling into the large rewinding rolls, and to transfer them to a new rewind mandrel (which is mounted into the small roll rewind support module and has been moved into the initial spatial orientation of that module, said method comprising the steps: moving with the winding axis of the small roll rewind support module to an initial spatial orientation, loading a rewind mandrel into the small roll rewind support module, engaging the small roll rewind torque motive drive to the rewind mandrel, accelerating the speed of the small rewind mandrel until its circumference is running the web speed as web or webs is /are being wound onto the rewind mandrel being driven by the large roll rewind torque drive supply, severing the webs as they are travelling into the large rewinding rolls, after a desired large rewind roll length has been achieved, transferring the lead ends of the just severed webs to the new rewind mandrel (which is mounted into the small roll rewind support module), stopping and disengaging the large roll rewind torque supply from the rewind mandrel which is in the large roll rewind support module, unloading the large finished rolls, moving the large roll rewind support module until its winding axis is in a predetermined spatial orientation for upcoming co-alignment with the winding axis of the small roll rewind support module, moving the winding axis all of the small roll support module ( while it's rewind torque supply is causing the winding of web or webs onto the mandrel which is in the small roll rewind support module) to an angle which will allow the upcoming co-alignment of the small roll and large roll winding axes, engaging the large roll rewind torque supply with the winding rewind mandrel and bringing it up to angular winding speed, transferring winding torque from that being supplied by the small roll rewind torque supply to that being supplied by the large roll rewind torque supply, decelerating the small roll rewinding torque supply drive and disengaging it from the rewinding mandrel, moving the winding axis of the small roll support module to the initial spatial orientation once again.

[0033] In one embodiment of this invention, one or more means may be provided upstream of the slitting system, and within the web processing system to effect one or more converting processes or functions, such as image printing or diecutting. BRIEF DESCRIPTION OF DRAWINGS

[0034] Figure 1 is an isometric view of a web processing system provided in accordance with conventional prior art showing a web being slit into a multiplicity of narrower webs and then alternately wound on two different sets of a rewind assemblies;

[0035] Figure 2 is an isometric view of a web processing system which incorporates a multi-web redirection module, in accordance with one embodiment of this invention. This module allows the web processing system to laterally separate pre-slit webs such that they can be wound on a common rewind mandrel without interleaving or interlocking;

[0036] Figure 3 is a schematic side-elevational view of one embodiment of a detail of Figure 2, shown as a multi-web redirection module;

[0037] Figure 4 is an isometric view of a detail of Figure 2, shown with one pre-slit web passing through the multi-web redirection module without being redirected. This view also shows two further narrow pre-slit webs, each neighbouring the first (one toward the front of the machine webflow, and the other toward the back of the machine webflow) and each of which are being redirected laterally using the invention herein described;

[0038] Figure 5 is a second isometric view of a detail of Figure 2 which shows the three webs, which are passing through the particular embodiment shown in Figure 4, being in lateral separation as they leave the module and travel downstream toward further processing, such as rewinding.

[0039] Figure 6 is a photograph of a conventional prior art machine which provides a multiplicity of rewind mandrels that are fixed, at their common center of rotation, to a revolving or turretting assembly. This machine conventionally provides non-stop production of small finished rolls;

[0040] Figure 7 is a schematic side-elevational view of the machine of Figure 6;

[0041] Figure 8 is a schematic side-elevational view of a conventional prior art machine equipped to provide non-stop production of single web finished rolls;

[0042] Figure 9 is a photograph of a prior art machine which is equipped with retractable rewind mandrels which inter change position to semiautomatically produce finished single web rewind rolls;

[0043] Figure 10 is a schematic side-elevational view of a prior art arrangement of an automatic unwind roll transfer system which incorporates a rotating or turretting method to put the master unwind rolls into position for non-stop exchange with a depleted mandrel;

[0044] Figure 11 is a photograph depicting a machine exemplifying a prior art method of non-stop transfer of large unwind rolls;

[0045] Figure 12 is a schematic side-elevational view of the machine of Figure 11 ; and

[0046] Figures 13 to 19 are isometric representations showing the major components of an automatic unwind roll transfer system according to another embodiment of the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0047] Attention is first directed to Figure 2, which is an isometric view showing the major components of one configuration of a typical web processing system to which one embodiment of the present invention has been applied. Figure 3, Figure 4, and Figure 5 are also included to be helpful in describing the webflow of the slit webs 15, 16, and 17 through the redirection module 43.

[0048] The mechanism shown generally at 10 in Figure 2 includes an unwind mandrel located at 12, a rewind mandrel located at 14, an inspection zone 25, a fault splicing area 26, a slitting system generally located at 42, and a preferred embodiment of the web redirection module generally located at 43. [0049] A unwind roll 20 of web material is mounted on the unwind mandrel at 12, with the web 21 being paid off the unwind roll of 20. The web 21 is then threaded sequentially through the machine until it reaches the slitting system 42 in which it is slit into two or more narrower webs.

[0050] The web 21 , for the purposes of this description, will be considered to be slit into three narrower webs. Web 15 is located closest to the front of the machine, web 16 is located approximately in the middle of the webflow of the machine and will, (for the purposes of this description) be considered as approximately being slit from the center of web 21. Web 17 is located closest to the support structure of the mechanism 10, and is being slit from the back portion of web 21.

[0051] The web redirection module 43 is shown in Figure 2 to be located in this configuration generally between the slitting system 42 and a downstream process, in this configuration a rewinding system 44. The web redirection module 43 is shown as being mounted to the mechanism 10 using a front side frame 9 and a back side frame 9'. In this particular configuration, front side frame 9 and back side frame 9' are constrained to be locked together and are pivotally mounted about center of rotation 45 such that idler 3 rides on the rewinding rolls 15', 16', and 17' as they are being rewound. This feature of this particular description is not required to effect the redirection of pre-slit webs which is the subject of this invention.

[0052] Web 15, web 16, and web 17 are partially entrained around idler 1 which is substantially parallel in three planes to the slitting system 42 and generally to the web 21 as it flows through the previous processes being carried out in mechanism 10.

[0053] Web 16, which will not be laterally redirected as it leaves the web redirection module 43, is next partially entrained around idler 8 which is also substantially parallel in three planes to the slitting system 42 and to the flow of web 21.

[0054] Web 16 is next partially entrained around idler 3, which is also substantially parallel in three spatial planes to idler 1 , to idler 8, to the slitting system 43, and to the upstream processes which may be being carried out in mechanism 10 as web 21 flows through it.

[0055] Web 16 next enters the downstream process (from the web redirection module 43), in this case a rewind system generally at 44, which is constructed to be capable of rewinding a multiplicity of finished rolls side-by- side onto one rewinding mandrel 14. Figure 2 shows the rewinding mandrel 14 in the process of rewinding web 15, web 16, and web 17 side-by-side (as they become finished rolls 16', 17', and 18') onto smatter malls near rewind system 44.

[0056] After it leaves contact with idler 1 , web 15 is entrained around idler 2, then around idler 3 and into the rewind system 44.

[0057] After it leaves contact with idler 1 , web 17 is entrained around idler 2', then around idler 3 and into the rewind system 44.

[0058] The diameter of idler 2 is designed such that the segment of web 15 as it travels from idler 1 to idler 2 is parallel to the segment of web 15 as it travels from idler 2 to idler 3. Similarly, the diameter of idler 2' is designed such that the segment of web 17 as it travels between idler 1 and idler 2' is parallel to the segment of web 17 as it travels between idler 2' and idler 3.

[0059] Lateral positioning mounting plate 4 is adjustably secured to a mounting subsystem (not shown) such that it can be moved laterally and substantially at right angles to the web as it flows through the mechanism 10. Rotational positioning mounting plate 5 is adjustably secured to the mounting subsystem such that it can be moved angularly with respect to lateral positioning mounting plate 4 and at right angles to the contacting face of lateral positioning mounting plate for. The design of the rotation constraining system (not shown) within rotational positioning mounting plate 5 is such that the center of rotation is extrapolated to be substantially in line with, and at right angles to, the entry path of web 15 as it is entraining onto and around idler 2. The mounting surfaces of lateral positioning mounting plate 4 and rotational position mounting plate 5 are constrained to be substantially at right angles to the entry path of web 15 as it is about to be entrained onto idler 2 and also to the exit path of web 15 as it leaves idler 2 and travels toward idler 3. If the constrained lateral positioning of idler 2 is set (by the operator) such that the center of rotation of rotational positioning mounting plate 5 is approximately under the centerline of the path of web 15, there will be no undesirable unbalanced lateral vector forces applied to web 15 as it is entraining onto and around idler 2, leaves idler 2 and is subsequently entrained onto and partially around idler 3, thereafter into the downstream process or processes.

[0060] Lateral position locking fixture 6 and rotational position locking fixture 7 are used to secure the lateral positioning of idler 2 and the angular displacement of idler 2.

[0061] Idler 2 can, therefore, be constrained to remain parallel in two planes to the flow of web 21 through mechanism 10. The third spatial plane of idler 2 can be angularly adjusted to determine the amount of desired lateral displacement of web 15 with respect to web 16 as they both flow through and exit the web displacement module 43.

[0062] Attention is next directed to Figures 13, 14, 15, 16, 17, 18, 19 which are isometric representations showing the major components of an embodiment of an automatic rewind roll transfer system to which the present inventions have been applied.

[0063] The mechanism shown generally at 100 in Figure 13 is assumed, for purposes of this description, to have been placed in line with and parallel and three planes to a web processing system such as the mechanism 10 which is shown in Figure 2 of this disclosure.

[0064] A web 21 , which has been previously passed through the various upstream processes of mechanism 10, is entraining onto and around draw roll 105 which provides motive power using motor and control means (which are not shown) such as to tension the web 21 and to draw it under tension from the upstream processes of mechanism 10.

[0065] A web severing system (which is not shown) is located generally above draw roll 105 in position 106. This severing system is activated to cut off the web (or webs) travelling through the draw system when roll transfer is either automatically or manually performed.

[0066] A first, small moving rewind support system 108 is rotationally mounted to frames 100 and 100', and is fixed to moving mounting subframes 109 and 109' which are, in turn, each fixed to shaft 1 10 and rotate about axis

1 1 1. This rotation is from a starting angle, which places the small rewind support system 108 into close proximity with the draw roll 105, clockwise (in this embodiment) to a "co-aligning" location 140 as shown in Figure 16. This co-aligning location 140 of the small moving rewind system support system 108 allows the small rewind support system 108 to come into coaxial alignment with large rewind support system 120 when it is put into its co- aligning angle, also at location 140.

[0067] Mounted to subframe 109 are a torque transfer carriage 1 12 and drive motor 113 for the small moving rewind support system 108. Belt means are used to interconnect the drive motor 113 to the torque transfer carriage

112. Drive and control means for drive motor 1 13 are not shown. The torque transfer carriage 1 12 may be moved axially to engage, at the front side of the mechanism 100, either rewind mandrel 123 or rewind mandrel 123' (which are shown respectively in Figure 14 and in Figure 17).

[0068] A second, large moving rewind support system, generally shown at 120, is rotationally mounted to frames 100 and 100', and is fixed to mounting subframes 121 and 121 ' which are in turn each attached to a mounting subassembly 124 which is able to rotate about axis 125. This rotation is from a starting angle, which places the large rewind support system (in this embodiment) at the co-aligning location 140 as shown in Figure 16. The rotation may be gradually or quickly made, clockwise to a finished roll offloading angle 126 which is shown in Figure 17.

[0069] Mounted to subframe 121 ' are the torque transfer carriage 122 and drive motor 123 for the large moving rewind support system 120. Belt means are used to interconnect the drive motor 123 to the torque transfer carriage 122. Drive and control means for drive motor 123 are not shown. The torque transfer carriage 122 may be moved axially to engage, at the backside of the mechanism 100, either rewind mandrel 123 or rewind mandrel 123' (which are shown respectively in Figure 14 and in Figure 17).

[0070] The purpose of this construction, these devices, the orientation of the devices and their relative movements is to allow:

(a) web 21 (or a series of narrower webs which have been slit from web 21) to be taken from an upstream process performed by, for example, mechanism 10;

(b) these webs to then begin rewinding onto removable rewind mandrel 131 which is being supported by small moving rewind support system 108;

(c) these webs continuing to be rewound into rewinding rolls during which time the small moving rewind support system rotates about axis 111 toward and ultimately to co-aligning location 140 as shown in Figure 16;

(d) the torque supply to one end of rewind mandrel 131 (in this particular embodiment, the front end) is then to be transferred from that supplied by drive motor 113 and torque transfer carriage 112 smoothly to the torque supply being given by drive motor 123 and torque transfer carriage 122 to the other end (in this particular embodiment, the back end) of rewind mandrel 131 , when the large moving rewind support system 120 is substantially co-aligned with the small moving rewind support system 108 (as shown in co-aligned location 140 of Figure 16);

(e) the rewinding rolls 150 to continue to build in diameter as shown in Figure 16 and Figure 17; (f) the small moving rewind support system 108 then to index fully counterclockwise to its start angle;

(g) the rewind mandrel 131' then to be loaded to the small moving rewind support system 108 by the mandrel loading subsystem 130 (as shown in Figure 14);

(h) the rewind mandrel 131 ' to then be brought up to a moving surface speed which is relative to the speed of the passing web 21 (or the webs into which it has been slit) as they flow toward and onto rewind rolls ( this being best described by the orientation shown in Figure 17);

(i) the web severing system 106 to then be activated to cut off web 21 (or the webs into which it has been slit);

G) the lead ends of the webs connected back to web 21 to next be transferred by an indexing and pressuring system (which has not been shown) to removable rewind mandrel 131 ';

(k) the large finished rolls 150 to then be offloaded from the large moving rewind support system 120;

(I) the large moving rewind support system 120 next to be indexed ( by means not shown) back to its co-aligning angle 140; and

(m) the rewind mandrel 131 then to be removed by the operator from the finished large rolls and placed by the operator into the mandrel loading subsystem 130 and now ready to be used in the next cycle of this particular mechanism 100.

[0071] Using the above described method allows the automatic transferring of finished rolls for further packaging, without having stopped the upstream process.

[0072] This disclosure indicates that small rolls only are produced on the small moving rewind support system up to a predetermined diameter and that larger rolls (starting from that predetermined diameter) only are produced on the large moving rewind support system. This roll transferring using a method alternately supply torque to one end of a mandrel during part of the winding process and then supply torque to the other end of that mandrel during another part of the winding process allows the particular advantage of applying different winding (or "gearing") ratios to one set of rewind rolls being processed in order to produce finished rolls exhibiting acceptable rewind tension profiles. Therefore, energy costs are reduced, component costs are reduced, and the equipment can be significantly reduced in overall size.

SUMMARY OF DISCLOSURE

[0073] In summary of this disclosure, in one aspect, the present invention provides a novel arrangement in a web processing system which allows the lateral separation of a multiplicity of slit webs without the inducement of undesirable lateral vector forces and which overcomes the problems of the prior art. While one embodiment of this aspect of the invention has been illustrated in the accompanying Figures 2, 3, 4 and 5 and described hereinabove, it will be evident to those skilled in the art that changes and modifications may be made therein without departing from the essence of this aspect of the invention.

[0074] In further summary of this disclosure, in another aspect, the present invention provides a novel arrangement in a web processing system which allows roll transfers to be made without stopping production. These transfers are made by driving the winding mandrel using motive torques applied to one end of the mandrel and then to both ends of the mandrel through co- alignment of the motive torque drivers, and then to the other end of the mandrel. Using this invention allows the "handoff" of supply of roll motive power thus effecting and allowing the automatic offloading and/or exchange of rolls being processed at the exit end and and/or input end of a roll fed a web processing system. While one embodiment of this aspect of the invention has been illustrated in the accompanying Figures 13, 14, 15, 16, 17, 18, and 19 and described hereinabove, it will be evident to those skilled in the art that changes and modifications may be made therein without departing from the essence of this aspect of the invention.

Claims

Claims What is claimed is:

1 . For use in an apparatus for handling web, a cylinder module providing for the lateral displacement or redirection of a multiplicity of webs, each web flowing at controlled, laterally balanced web strain, the module comprising: a frame, a first cylinder mounted on the frame for rotation about a first axis fixed with respect to the frame, a second cylinder mounted on the frame for rotation about a second axis fixed with respect to the frame, the second cylinder at all times being parallel in two planes with respect to the first cylinder, further cylinders, up to the number of the multiplicity of webs being processed ( minus one), each cylinder mounted on individual subframes for rotation about each of their respective axes, each further cylinder having an outside diameter and a constrained spatial location provided by its individual subframe such that a web, when passing partially around the periphery of the first cylinder, thence to and partially around the periphery of that further cylinder, thence to and partially around the periphery of the second cylinder, the cylinders being disposed such that the web span from the first cylinder to that further cylinder is substantially parallel to the span from that further cylinder to the second cylinder, each further cylinder's subframe being mounted for constrained arcuate adjustment perpendicular to each of the incoming and the outgoing webspans, and locating the center of rotation of each further cylinder's arcuate adjustment as to be substantially identical to the center of the path of the webspan which approaches that further cylinder, in two planes.

2. A method of handling web, utilising a cylinder module providing for the lateral displacement or redirection of a multiplicity of webs, each web flowing at controlled, laterally balanced web strain, the module comprising: a frame, a first cylinder mounted on the frame for rotation about a first axis fixed with respect to the frame, a second cylinder mounted on the frame for rotation about a second axis fixed with respect to the frame, the second cylinder at all times being parallel in two planes with respect to the first cylinder, further cylinders, up to the number of the multiplicity of webs being processed (minus one), each cylinder mounted on individual subframes for rotation about each of their respective axes, each further cylinder having an outside diameter and a constrained spatial location provided by its individual subframe such that a web, when passing partially around the periphery of the first cylinder, thence to and partially around the periphery of that further cylinder, thence to and partially around the periphery of the second cylinder, the cylinders being disposed such that the web span from the first cylinder to that further cylinder is substantially parallel to the span from that further cylinder to the second cylinder, each further cylinder's subframe being mounted for constrained arcuate adjustment perpendicular to each of the incoming and the outgoing webspans to and from that further cylinder, locating the center of rotation of each further cylinder's arcuate adjustment as to be substantially identical to the center of the path of the webspan which approaches that further cylinder, in two planes, said method comprising the steps: passing the multiplicity of webs partially around the periphery of the first cylinder, thence passing each of the multiplicity of webs (minus one) to and partially around the individual peripheries of each further cylinder, adjusting each of such further cylinder's arcuate positioning as to laterally displace the outgoing web path of the web from that further cylinder with respect to the webs emanating from the immediately neighbouring further cylinder or further cylinders, thence entraining each of the webs around the second cylinder, each of the paths of the each of the multiplicity of webs (minus one) now being substantially parallel to one another as they move toward and away from their respective further cylinders, the webs now emanating from the module having been laterally displaced for further processing through the web handling machine in which this method has been employed.

3. For use in a web processing system, an apparatus for handling rolls of web such as to provide rolls from or to the web processing system without stopping production, the apparatus comprising: a mandrel for winding or unwinding web material an alternate mandrel (its alternate) for winding or unwinding web material a first mandrel support module a second mandrel support module a first torque motive drive supply mounted to one end of the first mandrel support module, a second torque motive drive supply mounted to the opposite end of the second mandrel support module (relative to the end on which the first torque motive drive supply means is mounted to the first mandrel support module), means to co-align the winding (or unwinding) axes of the first mandrel support module and the second mandrel support module, first control means for causing the first torque motive drive supply to be engaged with either the mandrel or its alternate whichever has been mounted into the first mandrel support module and to later become disengaged from that mandrel or its alternate, second control means the second torque motive drive supply to be engaged with the mandrel or its alternate, and to later become disengaged from such mandrel, means to move the mandrel driving axis of the first mandrel support module from an initial spatial orientation to an orientation in which it will be co- aligned with the winding or unwinding axis of the second mandrel support module, means to move the mandrel driving axis of the second mandrel support module to and from a spatial orientation which allows co-alignment with the mandrel driving axis of the first mandrel support module and later movement to allow the mandrel or its alternate to be off-loaded or on-loaded, means to sever the webs and to transfer them to the mandrel or its alternate, whichever is mounted into the first mandrel support module and has been moved into the initial spatial orientation of that module.

4. For use in a web processing system, an apparatus for handling winding rolls of web such as to provide finished rewound rolls from the web processing system without stopping production, the apparatus comprising: a small roll rewind mandrel support module, a large roll rewind mandrel support module, a rewind torque motive drive supply mounted to one end of the small roll rewind mandrel support module, a rewind torque motive drive supply mounted to the opposite end of the large roll rewind mandrel support module (relative to the end on which the rewind torque motive drive supply means is mounted to the small roll rewind mandrel support module), a means to co-align the winding axes of the small roll rewind mandrel support module and the large roll rewind mandrel , first control means for causing the small roll rewind torque motive drive supply to be engaged with a new rewind mandrel which has been mounted into the small roll rewind mandrel support module and to later become disengaged from that mandrel, second control means for causing the large roll rewind torque motive drive supply to be engaged with the said rewind mandrel, and to later become disengaged from that mandrel, means to move the winding axis of the small roll rewind support module from an initial spatial orientation to an orientation which will be co-aligned with the winding axis of the large roll rewind support module, means to move the winding axis of the large roll rewind support module to and from a spatial orientation which allows co-alignment with the winding axis of the small roll rewind support module and later movement to allow the winding and offloading of large rolls, and means to sever the webs as they are travelling into the large rewinding rolls, and to transfer them to a new rewind mandrel (which is mounted into the small roll rewind support module and has been moved into the initial spatial orientation of that module.

5. A method of handling rolls of web such as to provide rolls from or to a web processing system without stopping production, comprising: a mandrel for winding or unwinding web material, an alternate mandrel (its alternate) for winding or unwinding web material, a first mandrel support module, a second mandrel support module, a first torque motive drive supply mounted to one end of the first mandrel support module, a second torque motive drive supply mounted to the opposite end of the second mandrel support module (relative to the end on which the first torque motive drive supply means is mounted to the first mandrel support module), means to co-align the winding or unwinding axes of the first mandrel support module and the second mandrel support module, first control means for causing the first torque motive drive supply to be engaged with the mandrel or its alternate, whichever has been mounted into the first mandrel support module and to later become disengaged from such mandrel, second control means for causing the second torque motive drive supply to be engaged with such mandrel, and to later become disengaged from that mandrel, moving the second mandrel support module until its winding or unwinding axis is in a predetermined spatial orientation for upcoming co- alignment with the winding or unwinding axis of the first mandrel support module, moving the winding or unwinding axis first mandrel support module (while its torque supply is causing the winding or unwinding of web or webs onto the mandrel which is in the first mandrel support module) to an angle which will allow the upcoming co-alignment of the first and second roll winding or unwinding axes, engaging the second mandrel torque drive with the rewind mandrel and bringing it up to proper angular winding or unwinding speed, transferring winding or unwinding torque from that being supplied by the first mandrel torque supply to that being supplied by the second mandrel torque supply, decelerating the first mandrel torque supply drive and disengaging it from the mandrel or its alternate, moving such axis of the first mandrel support module to the initial spatial orientation once again.

6. A method of handling winding rolls of web such as to provide finished rewound rolls from web processing system without stopping production, comprising: a small roll rewind mandrel support module, a large roll rewind mandrel support module, a rewind torque motive drive supply mounted to one end of the small roll rewind mandrel support module, a rewind torque motive drive supply mounted to the opposite end of the large roll rewind mandrel support module (relative to the end on which the rewind torque motive drive supply means is mounted to the small roll rewind mandrel support module), a means to co-align the winding axes of the small roll rewind mandrel support module and the large roll rewind mandrel support module, first control means for causing the small roll rewind torque motive drive supply to be engaged with a new rewind mandrel which has been mounted into the small roll rewind mandrel support module and to later become disengaged from that mandrel, second control means for causing the large roll rewind torque motive drive supply to be engaged with the said rewind mandrel, and to later become disengaged from that mandrel, means to move the winding axis of the small roll rewind support module from an initial spatial orientation to an orientation which will be co-aligned with the winding axis of the large roll rewind support module, means to move the winding axis of the large roll rewind support module to and from a spatial orientation which allows co-alignment with the winding axis of the small roll rewind support module and later movement to allow the winding and offloading of large rolls, and means to sever the webs as they are travelling into the large rewinding rolls, and to transfer them to a new rewind mandrel (which is mounted into the small roll rewind support module and has been moved into the initial spatial orientation of that module, said method comprising the steps: moving with the winding axis of the small roll rewind support module to an initial spatial orientation, loading a rewind mandrel into the small roll rewind support module, engaging the small roll rewind torque motive drive to the rewind mandrel, accelerating the speed of the small rewind mandrel until its circumference is running the web speed as web or webs is /are being wound onto the rewind mandrel being driven by the large roll rewind torque drive supply, severing the webs as they are travelling into the large rewinding rolls, after a desired large rewind roll length has been achieved, transferring the lead ends of the just severed webs to the new rewind mandrel (which is mounted into the small roll rewind support module), stopping and disengaging the large roll rewind torque supply from the rewind mandrel which is in the large roll rewind support module, unloading the large finished rolls, moving the large roll rewind support module until its winding axis is in a predetermined spatial orientation for upcoming co-alignment with the winding axis of the small roll rewind support module, moving the winding axis all of the small roll support module ( while it's rewind torque supply is causing the winding of web or webs onto the mandrel which is in the small roll rewind support module) to an angle which will allow the upcoming co-alignment of the small roll and large roll winding axes, engaging the large roll rewind torque supply with the winding rewind mandrel and bringing it up to angular winding speed, transferring winding torque from that being supplied by the small roll rewind torque supply to that being supplied by the large roll rewind torque supply, decelerating the small roll rewinding torque supply drive and disengaging it from the rewinding mandrel, moving the winding axis of the small roll support module to the initial spatial orientation once again.