Automatic tape crossover

• US 6,481,664 B1
• Filed: 10/02/2000
• Issued: 11/19/2002
• Est. Priority Date: 10/02/2000
• Status: Expired due to Term

• Current Assignee: Dynamex Incorporated (TFI International, Inc.)
• Original Assignee: Dynamex Incorporated (TFI International, Inc.)
• Inventors: Bravin, Ben
• Primary Examiner(s): Jillions, John M.
• Application Number:
  US09/678,057
• Time in Patent Office: 778 Days
• Field of Search: 242/552, 242/554.2, 242/555.1, 156/502, 156/504
• US Class Current: 242/552
• CPC Class Codes: B65H 19/1852 taking place at a distance from the replacement roll
• CPC Class Codes: B65H 19/1873 with two stationary roll supports carrying alternately the replacement and the expiring roll
• CPC Class Codes: B65H 2301/46174 cutting both spliced webs separately
• CPC Class Codes: B65H 2301/4621 Overlapping article or web portions
• CPC Class Codes: B65H 2301/46312 double-sided
• CPC Class Codes: B65H 2301/46414 by nipping rollers
• CPC Class Codes: B65H 2701/1944 Wrapping or packing material

Abstract

An automatic tape crossover machine having two feeding mechanisms to supply running and new tapes, respectively. A powered cutter is provided through which the running tape is to pass and be cut in response to a cut signal, where the cutter is positioned downstream of the first tape feeding mechanism. The machine also includes a joining mechanism at which a portion of a new tape is to be joined to the running tape in response to a join signal. Control circuitry automatically determines whether a tape exhaustion condition has been reached and asserts the join and cut signals to join the running and new tapes and to cut the running tape, before the tape feeding mechanism is emptied of the running tape. The machine thus allows the automatic transition from the running tape to the new tape, i.e. without requiring the presence or manual assistance of a human operator when joining the two tapes. In addition, the process line speed need not be altered for the crossover, thereby reducing the probability of inconsistencies in product quality.

Claims

1. An automatic tape crossover machine comprising:

first and second tape feeding mechanisms to supply running and new tapes, respectively;

a first powered cutter through which the running tape is to pass and be cut in response to a cut signal, the first cutter being positioned downstream of the first tape feeding mechanism along the first tape;

a powered joining mechanism in which an end portion of the new tape is to be joined, at a position downstream, of the first cutter, to the running tape in response to a join signal wherein the joining mechanism further provides an essentially inertia-free accumulation of the new tape and further includes a pusher mechanism downstream of the accumulation and having at least one pusher and another surface between which the portion of the new tape and the running tape are to be sandwiched and passed in response to the join signal;

a friction surface to which a pinch roller is coupled, to provide a pinch point on the running tape, the pinch point being positioned downstream of the pusher mechanism, and wherein the essentially inertia-free accumulation is at least as long as a tape path between the pinch point and the point at which the new tape and the running tape are to be sandwiched; and

control circuitry to automatically determine whether a tape exhaustion condition has been reached and assert the join and cut signals to (1) join the running and new tapes and (2) cut the running tape, before the first tape feeding mechanism is emptied of the running tape.

2. The machine of claim 1 wherein the joining mechanism includes a first clamp to (1) hold the end portion of the new tape in position for joining to the running tape, and (2) release the new tape in response to a clamp release signal asserted by the control circuitry.

3. The machine of claim 2 wherein the clamp is to hold an upstream portion and a downstream portion of the new tape so that the essentially inertia-free accumulation of the new tape is provided between these two held portions.

4. The machine of claim 2 further comprising:

a second powered cutter through which the new tape is to pass and be cut in response to a cut signal, the second cutter being positioned downstream of the second tape feeding mechanism along the new tape.

5. The machine of claim 4 wherein the joining mechanism further includes a second clamp to (1) hold a portion of a third tape in position for joining to the new tape when the new tape is running, and (2) release the third tape in response to a clamp release signal asserted by the control circuitry.

6. The machine of claim 5 wherein the second clamp is to hold an upstream portion and a downstream portion of the third tape so that an essentially inertia-free accumulation of the third tape is provided between these held portions.

7. The machine of claim 1 wherein the control circuitry is to determine the tape exhaustion condition by determining a length of the running tape remaining in the first tape feeding mechanism.

8. A longitudinal tape payoff machine to be positioned upstream of and to feed tape to a cable manufacturing process comprising:

a pair of motor-driven shafts, each to receive a roll of running tape and a roll of new tape, respectively, that are suitable for making at least one of electrical and optical cable;

a pair of accumulator sections positioned downstream of the shafts in the paths of the running and new tapes, to provide accumulation for the running and new tapes, respectively, and to provide feedback to control the driving of the shafts;

first and second powered cutter-clamps and cutting blades positioned downstream of the accumulator to clamp and cut the running tape and the new tape, respectively;

first and second blocks positioned downstream of the clamps and cutting blades, each block having a powered pusher, at least one of the blocks being movable between a preparation position and an operating position, the preparation position allows a human operator to position an end portion of the new tape across one of the pushers, the operating position brings the pushers near each other and allows the new tape and the running tape to be joined by moving at least one of the pushers;

a rotatable friction surface to which a pinch roller is coupled to provide a pinch point at a location downstream of the blocks on the running tape, an essentially inertia-free accumulation of the new tape to be provided by one of the first and second blocks and that is at least as long as a tape path between the pinch point and the point at which the running and new tapes are to be joined when the block is in the operating position; and

a controller to automatically determine whether a tape exhaustion condition has been reached and signal the actuation of (1) at least one of the pushers to join the end portion of the new tape to the running tape, and (2) the first powered cutter clamp and cutting blades to clamp and cut the running tape.

9. The machine of claim 8 wherein each block further includes a powered clamp to (1) hold a portion of the new tape in position for joining to the running tape, and (2) release the new tape in response to a signal from the controller.

10. The machine of claim 9 wherein the clamp is to hold an upstream portion and a downstream portion of the new tape so that said essentially inertia-free accumulation of the new tape is provided between these two held portions, and wherein the pushers are downstream of the accumulation.

11. The machine of claim 10 wherein each block further includes a cavity in which the essentially inertia-free accumulation of tape is kept.

12. The machine of claim 8 wherein each pusher has a roller at its outside surface to contact a surface of the new running tapes, respectively.

13. The machine of claim 8 wherein the controller is to determine the tape exhaustion condition by determining when a predetermined period of time as programmed by an operator has elapsed.

14. A method for paying off tape, comprising:

routing tape continuously from a first roll through a first cutter and through a joining mechanism and by a pinch roller and to a manufacturing process;

routing tape continuously from a second roll through a second cutter and then positioning an end portion of the second tape next to the first tape in the joining mechanism with an essentially inertia-free accumulation of the second tape being at least as long as a tape path from a pinch point of the pinch roller to a point at which the first and second tapes are joined by the joining mechanism;

running the manufacturing process to pull tape continuously from the first roll;

before the first roll is depleted and without stopping the running of the cable manufacturing process (1) automatically joining the end portion of the second tape with the first tape and (2) automatically cutting the first tape at a position on the first tape that is upstream of a joint between the first and second tapes; and

then

replacing the first roll with a third roll; and

then

routing tape continuously from the third roll through the first cutter and then positioning an end portion of the third tape next to the second tape in the joining mechanism.

15. The method of claim 14 further comprising:

before the second roll is depleted and without stopping the running of the cable manufacturing process, automatically (1) joining the end portion of the third tape with the second tape, and (2) cutting the second tape at a position on the second tape that is upstream of a joint between the second and third tapes.

16. The method of claim 15 wherein the manufacturing process is a cable manufacturing process.

17. The method of claim 14 wherein the joining and cutting are performed without slowing down the manufacturing process.

18. An apparatus comprising:

means for making a joint between a running first tape and an end portion of a stationary second tape;

means for cutting the first tape upstream of the joint;

means for strengthening the joint;

means for providing an inertia-free accumulation of the second tape that is at least as long as a distance between the joint making and strengthening locations; and

means for automatically controlling the cutting and joining means in response to detecting that the running first tape is near depletion.

19. The apparatus of claim 18 further comprising:

means for controlling a tension in the running first tape downstream of the strengthening means.

20. The apparatus of claim 19 further comprising:

means for providing the first tape;

means for accumulating the first tape downstream of the first tape providing means and upstream of the cutting and joint making means; and

means for controlling the first tape providing means in response to detecting an amount of accumulation remaining in the accumulation means.

21. The apparatus of claim 20 further comprising:

means for tension decoupling in the running first tape between a tension at the joint making means and a tension at the tension controlling means.

22. The apparatus of claim 21 further comprising:

means for controlling the tension decoupling means to maintain a predetermined amount of accumulation and tension downstream in the tension control means.

23. An apparatus comprising:

first and second tape feeding mechanisms to supply running and new tapes, respectively;

a first powered cutter through which the running tape is to pass and be cut, the first cutter being positioned downstream of the first tape feeding mechanism along the first tape;

a powered joining mechanism in which there is an essentially inertia-free accumulation of the new tape, and in which an end portion of the new tape is to be initially joined to the running tape at a position downstream of the cutter;

a moving surface with which a roller is engaged to provide a pinch point on the running tape, the pinch point being positioned downstream of the joining mechanism, wherein the accumulation is at least as long as a tape path between the pinch point and the point at which the new tape and the running tape are to be initially joined; and

control circuitry to automatically determine whether tape exhaustion condition has been reached, and to signal the cutter and joining mechanism to join the new and running tapes and cut the running tape before the first tape feeding mechanism runs out of the running tape.

24. The apparatus of claim 23 in combination with said new tape, wherein the end portion of said new tape has attached thereto a piece of double-sided adhesive tape.

25. The apparatus of claim 23 further comprising:

first and second accumulator sections positioned downstream of the first and second tape feeding mechanisms, respectively, and upstream of the joining mechanism, to provide accumulation for the running and new tapes and feedback to control the rate at which tape is fed by the first and second feeding mechanisms so that a constant running tape speed may be maintained downstream of the accumulator sections.

26. An apparatus comprising:

first and second tape feeding mechanisms to supply running and new tapes, respectively;

a first powered cutter by which the running tape is to be cut downstream of the first tape feeding mechanism;

a powered joining mechanism by which an end portion of the new tape is to be held stationary until the moment the end portion of the new tape is joined with the running tape at a position downstream of the first powered cutter, wherein the joining mechanism is to hold an essentially inertia-free accumulation of the new tape so that the new tape, upon being joined with the running tape, accelerates almost instantaneously to the speed of the running tape; and

control circuitry to automatically signal the first powered cutter and the powered joining mechanism to join the new and running tapes and cut the running tape before the first tape feeding mechanism runs out of the running tape.

27. The apparatus of claim 26 further comprising:

a movable surface with which a roller is engaged to provide a pinch point on the running tape, the pinch point being positioned downstream of a point at which the end portion of the new tape is joined with the running tape by the powered joining mechanism.

28. The apparatus of claim 27 wherein the essentially inertia-free accumulation is at least as long as a tape path between the pinch point and the point at which the end portion of the new tape is joined with the running tape.