Automated unwind system with auto-splice

• US 7,980,504 B2
• Filed: 04/16/2010
• Issued: 07/19/2011
• Est. Priority Date: 04/17/2009
• Status: Active Grant

• Current Assignee: C.G. Bretting Manufacturing Co., Inc.
• Original Assignee: C.G. Bretting Manufacturing Co., Inc.
• Inventors: Butterworth, Tad T.
• Primary Examiner(s): Kim; Sang
• Application Number:
  US12/761,529
• Publication Number:
  US 20100264248A1
• Time in Patent Office: 459 Days
• Field of Search: 242/552, 242/554, 242/544.3, 242/555, 2425551-5553, 2425555-5557, 242/556, 242/556.1
• US Class Current: 242/554
• CPC Class Codes: B65H 19/1847 taking place on the replacement roll
• CPC Class Codes: B65H 2301/41361 sequentially used roll supports for the same web roll
• CPC Class Codes: B65H 2301/41732 by crane
• CPC Class Codes: B65H 2301/41734 involving rail
• CPC Class Codes: B65H 2301/41892 Cutting knife located in winding or guiding roller and protruding therefrom
• CPC Class Codes: B65H 2301/46172 cutting expiring web only
• CPC Class Codes: B65H 2301/4621 Overlapping article or web portions
• CPC Class Codes: B65H 2301/46312 double-sided
• CPC Class Codes: B65H 2301/4633 Glue
• CPC Class Codes: B65H 2403/942 Bidirectional powered handling device
• CPC Class Codes: B65H 2406/33 Rotary suction means, e.g. roller, cylinder or drum
• CPC Class Codes: B65H 2408/216 roller with accumulated material wound around it (scrap roll)
• CPC Class Codes: B65H 2408/2171 the position of the movable roller(s), i.e. the web loop, being positively actuated

Abstract

A splice is made, between a tail end of first web and a lead end of a second web coiled about an unwind axis, by winding a portion of the first web adjacent the tail end of the first web about a splicing roll mounted for rotation about a splice roll axis oriented substantially parallel to the unwind axis, and then joining the tail end to the lead end by compressing an adhesive between an inside surface of the tail end and an outer surface of the second web. Compression of the adhesive is accomplished by urging the splice roll against the coiled second web while the coiled second web is rotating about the unwind axis in an unwind direction and the splicing roll is rolling about the splice roll axis in a direction opposite to the unwind direction.

Claims

1. A splicing arrangement for splicing a tail end of a first web, having an uncoiled section thereof extending in an out-feed direction along a web path from a coiled section thereof coiled in a winding direction opposite the out-feed direction about an unwind axis into a first coil, to a lead end of a second web coiled in the winding direction about the unwind axis into a second coil, wherein the webs define outer and inner surfaces thereof, and the outer surfaces of respective outer layers of the first and second webs of each of the first and second coils defines respective outer surfaces of each of the first and second coils, the splicing arrangement comprising, a splice roll and a splice roll drive arrangement:

the splice roll defining a periphery thereof and mounted for rotation about a splice roll axis oriented substantially parallel to the unwind axis, configured for winding a portion of the uncoiled section of the first web adjacent the tail end of first web about the periphery of the splice roll by attaching the outer surface of the portion of the uncoiled section adjacent the tail end of the first web to the splice roll and rotating the splice roll about the splice roll axis in a direction opposite the winding direction of the coils; and

the splice roll drive arrangement operatively connected between the splice roll axis and the unwind axis for selectively translating the splice roll axis to urge the tail end of the first web wound around the periphery of the splice roll into rolling contact with the outer surface of the second coil and for pressing the tail end of the first web against the outer surface of the second coil when the second coil is mounted for rotation about the unwind axis, for joining the tail end of the first coil to the lead end of the second coil through compressing an adhesive between the inside surface of the tail end of the first coil and the outer surface of the second coil by urging the splice roll against the second coil while the second coil is rotating about the unwind axis in the unwind direction and the splice roll is rolling about the splice roll axis in a direction opposite to the unwind direction.

2. The splicing arrangement of claim 1, wherein, the splice roll drive arrangement selectively drives the splice roll about the splice roll axis in the direction opposite to the winding direction of the coils and also alternatively in the winding direction.

3. The splicing arrangement of claim 1, wherein:

the splice roll drive arrangement further comprises an articulated member having a proximal end and a distal end thereof;

the proximal end of the articulated member being mounted for pivotable motion about an articulated member axis extending substantially parallel to the unwind axis; and

the splice roll being rotatably mounted to the distal end of the articulated member for rotation about the splice roll axis.

4. The splicing arrangement of claim 3, wherein, the splice roll drive arrangement is configured for pivotably moving the articulated member about the articulated member axis, for translating the splice roll axis with respect to the unwind axis.

5. The splicing arrangement of claim 4, wherein:

the splice roll drive arrangement is configured for pivotably moving the articulated member about the articulated member axis in first and second modes of pivotable motion;

the first mode of pivotable motion comprising pivoting the articulated member to place the splice roll in a desired position thereof with respect to the unwind axis; and

the second mode of pivotable motion comprising urging the splice roll toward the outer surface of the second coil.

6. The splicing arrangement of claim 5, wherein, the splice roll drive arrangement is configured for rotatably driving the splice roll about the splice roll axis in the direction opposite to the unwind direction and also alternatively in the winding direction.

7. The splicing arrangement of claim 1, wherein, the splice roll further comprises vacuum elements for attaching the outer surface of the portion of the uncoiled section adjacent the tail end of the first web to the splice roll.

8. The splicing arrangement of claim 1, further configured for cooperatively interfacing with a cutting arrangement for severing the first web of material when the first web of material is brought into contact with the cutting arrangement by the splice roll.

9. The splicing arrangement of claim 8, wherein:

the cutting arrangement comprises a blade; and

the splice roll further comprises one or more grooves therein for receiving the blade.

10. The splicing arrangement of claim 9, wherein, the cutting arrangement comprises a pair of nip rollers disposed on opposite sides of the blade, and the splice roll drive arrangement is configured for urging the splice roll into contact with the nip rollers.

11. The splicing arrangement of claim 9, wherein the splice roll drive arrangement is configured for selectively rotating the splice roll to an angular position with respect to the blade where one of the grooves in the splice roll is aligned to receive the blade, and for actuating the blade to sever the web.

12. A method for splicing a tail end of a first web, having an uncoiled section thereof extending in an out-feed direction along a web path from a coiled section thereof coiled in a winding direction opposite the out-feed direction about an unwind axis into a first coil, to a lead end of a second web coiled in the winding direction about the unwind axis into a second coil, wherein the webs define outer and inner surfaces thereof, and the outer surfaces of respective outer layers of the first and second webs of each of the first and second coils defines respective outer surfaces of each of the first and second coils, the method comprising:

winding a portion of the uncoiled section of the first web adjacent the tail end of first web about a splicing roll mounted for rotation about a splice roll axis oriented substantially parallel to the unwind axis, by attaching the outer surface of the portion of the uncoiled section adjacent the tail end of the first web to the splice roll and rotating the splicing roll about the splice roll axis in a direction opposite the winding direction of the coils, so that the inside surface of a portion of the tail end of the first web faces outward from the splice roll axis; and

joining the tail end of the first coil to the lead end of the second coil through compressing an adhesive between the inside surface of the tail end of the first coil and the outer surface of the second coil by urging the splice roll against the second coil while the second coil is rotating about the unwind axis in the unwind direction and the splice roll is rolling about the splice roll axis in a direction opposite to the second coil.

13. The method of claim 12, further comprising, applying a pressure sensitive adhesive to at least one of the outside surface of the first coil upstream from the lead end of the first coil and the inside surface of second coil downstream from the tail end of the second coil in such a manner that the pressure sensitive adhesive will be compressed between the inside surface of the tail end of the first coil and the outer surface of the second coil.

14. The method of claim 13, further comprising, applying the pressure sensitive adhesive in the form of a double-sided tape.

15. The method of claim 13, further comprising, applying the pressure sensitive adhesive by spraying an adhesive pattern of the pressure sensitive adhesive onto at least one of the outside surface of the first coil upstream from the lead end of the first coil and the inside surface of second coil downstream from the tail end of the second coil.

16. The method of claim 13, further comprising, orienting the second coil about the unwind axis to place the lead end of the second web in a predetermined pre-splicing position about the unwind axis.

17. The method of claim 13, further comprising, orienting the splice roll about the splice roll axis to place the tail end of the first coil in predetermined pre-splicing position about the splice roll axis.

18. The method of claim 12, further comprising, pulling the portion of the uncoiled section wound about the splice roll back along the web path in a direction opposite to the out-feed direction by rotating the splicing roll about the splice roll axis in the direction opposite the winding direction of the coils about the unwind axis.

19. The method of claim 18, further comprising, continuing to feed the uncoiled section of the first web along the web path in the out-feed direction while splicing the tail end of the first web to the lead end of the second web.

20. The method of claim 19, further comprising, reducing an out-feed speed of feeding the uncoiled section in the out-feed direction along the web path while splicing the tail end of the first web to the lead end of the second web.

21. The method of claim 20, further comprising, accumulating a stored portion of the uncoiled section of the first web along the web path prior to severing the uncoiled section of the first web.

22. The method of claim 18, further comprising, accumulating a stored portion of the uncoiled section of the first web along the web path prior to severing the uncoiled section of the first web, and pulling part of the stored portion of the uncoiled section back along the web path while winding the portion of the uncoiled section about the splice roll.

23. The method of claim 12, further comprising, bringing the splice roll into contact with the outer surface of the uncoiled section of the first web while the uncoiled section is attached to the coiled section of the first web, and severing the uncoiled section to form the tail end of the first web.

24. The method of claim 23, further comprising, prior to severing the uncoiled section, deflecting the uncoiled section from a running path thereof to a cutting position thereof through movement of the splice roll axis while the splice roll is bearing against the outer surface of the uncoiled section.

25. The method of claim 23, further comprising, rotating the splice roll into a predetermined cutting position prior to severing the first web.

26. The method of claim 25, further comprising, rotating the splice roll a predetermined distance about the splice roll axis after severing the first web.

27. The method of claim 12, further comprising, performing at least a portion of the method in an automated process wherein performing at least one step of the method automatically initiates at least a second step of the method according to a predetermined sequence of steps.

28. The method of claim 27, wherein, the first and second steps are selected from the list of steps consisting of:

mounting the first coil on the unwind axis;

feeding the uncoiled length of the first coil along the web path;

bringing the splice roll into contact with the outer surface of the uncoiled section first web while the uncoiled section is attached to the coiled section of the first web, and severing the uncoiled section to form the tail end of the first web;

prior to severing the uncoiled section, deflecting the uncoiled section from a running path thereof to a cutting position thereof through movement of the splice roll axis while the splice roll is bearing against the outer surface of the uncoiled section;

rotating the splice roll into a predetermined cutting position prior to severing the first web;

attaching the uncoiled section of the first web to the splice roll prior to severing the first web;

rotating the splice roll a predetermined distance about the splice roll axis after severing the first web;

accumulating a stored portion of the uncoiled section of the first web along the web path prior to severing the uncoiled section of the first web;

pulling part of the stored portion of the uncoiled section back along the web path while winding the portion of the uncoiled section about the splice roll;

removing the first coil from the unwind axis after severing the uncoiled section thereof, and mounting the second coil on the unwind axis with the lead end of the second web oriented toward the web path;

orienting the second coil about the unwind axis to place the lead end of the second web in a predetermined pre-splicing position about the unwind axis;

applying a pressure sensitive adhesive to at least one of the outside surface of the first coil upstream from the lead end of the first coil and the inside surface of second coil downstream from the tail end of the second coil in such a manner that the pressure sensitive adhesive will be compressed between the inside surface of the tail end of the first coil and the outer surface of the second coil;

continuing to feed the uncoiled section of the first web along the web path in the out-feed direction while splicing the tail end of the first web to the lead end of the second web; and

reducing an out-feed speed of feeding the uncoiled section in the out-feed direction along the web path while splicing the tail end of the first web to the lead end of the second web.

29. The method of claim 12, wherein, winding a portion of the uncoiled section of the first web adjacent the tail end of first web about a splicing roll further comprises the steps of:

bringing the splice roll into contact with the outer surface of the uncoiled section first web while the uncoiled section is attached to the coiled section of the first web, and severing the uncoiled section to form the tail end of the first web;

prior to severing the uncoiled section, deflecting the uncoiled section from a running path thereof to a cutting position thereof through movement of the splice roll axis while the splice roll is bearing against the outer surface of the uncoiled section;

rotating the splice roll into a predetermined cutting position prior to severing the first web;

attaching the uncoiled section of the first web to the splice roll prior to severing the first web;

rotating the splice roll a predetermined distance about the splice roll axis after severing the first web;

accumulating a stored portion of the uncoiled section of the first web along the web path prior to severing the uncoiled section of the first web; and

pulling part of the stored portion of the uncoiled section back along the web path while winding the portion of the uncoiled section about the splice roll.

30. The method of claim 29, wherein, joining the tail end of the first coil to the lead end of the second coil further comprises the steps of:

removing the first coil from the unwind axis after severing the uncoiled section thereof, and mounting the second coil on the unwind axis with the lead end of the second web oriented toward the web path;

orienting the second coil about the unwind axis to place the lead end of the second web in a predetermined pre-splicing position about the unwind axis; and

applying a pressure sensitive adhesive to at least one of the outside surface of the first coil upstream from the lead end of the first coil and the inside surface of second coil downstream from the tail end of the second coil in such a manner that the pressure sensitive adhesive will be compressed between the inside surface of the tail end of the first coil and the outer surface of the second coil.

31. The method of claim 30, further comprising, continuing to feed the uncoiled section of the first web along the web path in the out-feed direction while splicing the tail end of the first web to the lead end of the second web.

32. The method of claim 31, further comprising, reducing an out-feed speed of feeding the uncoiled section in the out-feed direction along the web path while splicing the tail end of the first web to the lead end of the second web.

33. The method of claim 12, wherein, joining the tail end of the first coil to the lead end of the second coil further comprises the steps of:

removing the first coil from the unwind axis after severing the uncoiled section thereof, and mounting the second coil on the unwind axis with the lead end of the second web oriented toward the web path;

orienting the second coil about the unwind axis to place the lead end of the second web in a predetermined pre-splicing position about the unwind axis; and

applying a pressure sensitive adhesive to at least one of the outside surface of the first coil upstream from the lead end of the first coil and the inside surface of second coil downstream from the tail end of the second coil in such a manner that the pressure sensitive adhesive will be compressed between the inside surface of the tail end of the first coil and the outer surface of the second coil.

34. The method of claim 33, further comprising, continuing to feed the uncoiled section of the first web along the web path in the out-feed direction while splicing the tail end of the first web to the lead end of the second web.

35. The method of claim 34, further comprising, reducing an out-feed speed of feeding the uncoiled section in the out-feed direction along the web path while splicing the tail end of the first web to the lead end of the second web.

36. An apparatus for splicing a tail end of a first web, having an uncoiled section thereof extending in an out-feed direction along a web path from a coiled section thereof coiled in a winding direction opposite the out-feed direction about an unwind axis into a first coil, to a lead end of a second web coiled in the winding direction about the unwind axis into a second coil, wherein the webs define outer and inner surfaces thereof, and the outer surfaces of respective outer layers of the first and second webs of each of the first and second coils defines respective outer surfaces of each of the first and second coils, the apparatus comprising:

a splicing arrangement having a splice roll and a splice roll drive arrangement;

the splice roll defining a periphery thereof and mounted for rotation about a splice roll axis oriented substantially parallel to the unwind axis, configured for winding a portion of the uncoiled section of the first web adjacent the tail end of first web about the periphery of the splice roll by attaching the outer surface of the portion of the uncoiled section adjacent the tail end of the first web to the splice roll and rotating the splice roll about the splice roll axis in a direction opposite the winding direction of the coils; and

the splice roll drive arrangement operatively connected between the splice roll axis and the unwind axis for selectively translating the splice roll axis to urge the tail end of the first web wound around the periphery of the splice roll into rolling contact with the outer surface of the second coil and for pressing the tail end of the first web against the outer surface of the second coil when the second coil is mounted for rotation about the unwind axis, for joining the tail end of the first coil to the lead end of the second coil through compressing an adhesive between the inside surface of the tail end of the first coil and the outer surface of the second coil by urging the splice roll against the second coil while the second coil is rotating about the unwind axis in the unwind direction and the splice roll is rolling about the splice roll axis in a direction opposite to the unwind direction.

37. The apparatus of claim 36, further comprising, a coil drive arrangement for receiving the second coil and driving the second coil in the unwind direction about the unwind axis.

38. The apparatus of claim 36, further comprising, an adhesive application arrangement, for applying a pressure sensitive adhesive to at least one of the outside surface of the first coil upstream from the lead end of the first coil and the inside surface of second coil downstream from the tail end of the second coil in such a manner that the pressure sensitive adhesive will be compressed between the inside surface of the tail end of the first coil and the outer surface of the second coil.

39. The apparatus of claim 38, wherein the adhesive application arrangement further comprises, an arrangement for applying the pressure sensitive adhesive in the form of a double-sided tape.

40. The apparatus of claim 38, wherein the adhesive application arrangement further comprises, an arrangement for applying the pressure sensitive adhesive by spraying an adhesive pattern of the pressure sensitive adhesive onto at least one of the outside surface of the first coil upstream from the lead end of the first coil and the inside surface of second coil downstream from the tail end of the second coil.

41. The apparatus of claim 36, further comprising, an accumulator arrangement for accumulating a stored portion of the uncoiled section of the first web along the web path prior to severing the uncoiled section of the first web.

42. The apparatus of claim 41, wherein, the accumulator arrangement comprises a festoon arrangement.

43. The apparatus of claim 36, wherein, the splice roll drive arrangement selectively drives the splice roll about the splice roll axis in the direction opposite to the winding direction of the coils and alternatively also in the winding direction.

44. The apparatus of claim 36, wherein:

the splice roll drive arrangement further comprises an articulated member having a proximal end and a distal end thereof;

the proximal end of the articulated member being mounted for pivotable motion about an articulated member axis extending substantially parallel to the unwind axis; and

the splice roll being rotatably mounted to the distal end of the articulated member for rotation about the splice roll axis.

45. The apparatus of claim 36, wherein, the splice roll further comprises vacuum elements for attaching the outer surface of the portion of the uncoiled section adjacent the tail end of the first web to the splice roll.

46. The apparatus of claim 36, further comprising a cutting arrangement for severing the first web of material when the first web of material is brought into contact with the cutting arrangement by the splice roll.

47. The apparatus of claim 46, wherein:

the cutting arrangement comprises a blade; and

the splice roll further comprises one or more grooves therein for receiving the blade.

48. The apparatus of claim 47, further comprising, a controller operatively connected between the cutting arrangement and the splice roll drive arrangement for rotating the splice roll to an angular position with respect to the blade whereat one of the grooves in the splice roll is aligned to receive the blade, and for actuating the blade to sever the web.

49. The apparatus of claim 48, wherein, the splice roll further comprises vacuum elements for attaching the outer surface of the portion of the uncoiled section adjacent the tail end of the first web to the splice roll, and the controller is operatively connected for selectively applying vacuum to the vacuum elements.

50. The apparatus of claim 36, further comprising, a controller operatively connected for controlling translation of the splice roll.

51. A computer readable medium having stored thereupon instructions for implementing a method for splicing a tail end of a first web, having an uncoiled section thereof extending in an out-feed direction along a web path from a coiled section thereof coiled in a winding direction opposite the out-feed direction about an unwind axis into a first coil, to a lead end of a second web coiled in the winding direction about the unwind axis into a second coil, wherein the webs define outer and inner surfaces thereof, and the outer surfaces of respective outer layers of the first and second webs of each of the first and second coils defines respective outer surfaces of each of the first and second coils, wherein the method comprises:

winding a portion of the uncoiled section of the first web adjacent the tail end of first web, about a splicing roll mounted for rotation about a splice roll axis oriented substantially parallel to the unwind axis, by attaching the outer surface of the portion of the uncoiled section adjacent the tail end of the first web to the splice roll and rotating the splicing roll about the splice roll axis in a direction opposite the winding direction of the coils, so that the inside surface of a portion of the tail end of the first web faces outward from the splice roll axis; and

joining the tail end of the first coil to the lead end of the second coil through compressing an adhesive between the inside surface of the tail end of the first coil and the outer surface of the second coil by urging the splice roll against the second coil while the second coil is rotating about the unwind axis in the unwind direction and the splice roll is rolling about the splice roll axis in a direction opposite to the second coil.