Method and a machine for winding a web onto spools to form a succession of web reels
12325605 ยท 2025-06-10
Assignee
Inventors
Cpc classification
B65H18/26
PERFORMING OPERATIONS; TRANSPORTING
B65H18/20
PERFORMING OPERATIONS; TRANSPORTING
B65H19/26
PERFORMING OPERATIONS; TRANSPORTING
B65H2404/4211
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65H18/26
PERFORMING OPERATIONS; TRANSPORTING
B65H18/20
PERFORMING OPERATIONS; TRANSPORTING
B65H19/22
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A device and method of winding a web (W) of tissue paper or a non-woven material onto spools (2) to form a succession of web reels (3) on the spools (2) wherein the force in the winding nip (5) is measured and, as the diameter of the web reel (3) grows, the spool (2) on which the web reel (3) is wound is moved during winding along a horizontal plane such that, in the horizontal direction, the distance between the first supporting drum (4) and the spool (2) increases, and the second supporting drum (9) is moved vertically downwards to match the increasing size of the web reel (3) while maintaining contact with the web reel (3) to such an extent that a nip force between the web reel (3) and the second supporting drum (9) is maintained, and the first supporting drum (4) is moved vertically downwards as the diameter of the web reel (3) grows and moved to such an extent that the measured nip force in the winding nip (5) remains substantially at a set value or within the range of a predetermined upper and a predetermined lower value.
Claims
1. A method of winding a web (W) of tissue paper or a non-woven material onto spools (2) to form a succession of web reels (3) on the spools (2) and wherein, for each web reel (3) that is wound, the web (W) is guided over a part of the circumference of a first supporting drum (4) and through a winding nip (5) formed between the first supporting drum (4) and the web reel (3) that is being wound, the first supporting drum (4) acting against the web reel (3) such that a nip force is generated in the winding nip (5), and wherein the web reel (3) that is being wound is supported during winding by a second supporting drum (9) that is arranged to form a nip (10) with the web reel (3) that is being wound, the method comprising the steps of: measuring the force in the winding nip (5); as the diameter of the web reel (3) grows, moving the spool (2) on which the web reel (3) is wound during winding along a horizontal plane such that, in the horizontal direction, the distance between the first supporting drum (4) and the spool (2) increases; moving the second supporting drum (9) vertically downwards to match the increasing size of the web reel (3) while maintaining contact with the web reel (3) to such an extent that a nip force between the web reel (3) and the second supporting drum (9) is maintained; and moving the first supporting drum (4) vertically downwards as the diameter of the web reel (3) grows to such an extent that the measured nip force in the winding nip (5) remains substantially at a set value or within the range of a predetermined upper and a predetermined lower value.
2. The method according to claim 1, wherein, during the winding of each web reel (3), said set value or said predetermined upper and lower values are set to increase with an amount equal to or greater than 3% and equal to or less than 10% of the respective value at the beginning of the winding from the beginning of the winding of a web reel (3) until the web reel (3) is completed.
3. The method according to claim 1, wherein, during the winding of each web reel (3), said set value or said predetermined upper and lower values are set to decrease with an amount equal to or greater than 3% and equal to or less than 10% of the respective value at the beginning of the winding from the beginning of the winding of a web reel (3) until the web reel (3) is completed.
4. The method according to claim 1, wherein said predetermined upper and lower values are set in relation to a fixed set value.
5. The method according to claim 1, wherein, as the diameter of the web reel (3) grows, the first supporting drum (4) is moved downwards such that the winding nip force in the winding nip (5) remains within a range of 2% deviation from a fixed set value.
6. The method according to claim 1, wherein, from at least the point in time at which a web reel (3) has reached 20% of its final diameter until at least the point in time at which the same web reel (3) has reached 95% of its final diameter, the angle between the horizontal plane and a straight line from the axis of rotation of the first supporting drum (4) and the axis of rotation of the web reel (3) is kept constant.
7. The method according to claim 6, wherein the angle lies in the range equal to or greater than 40 and equal to or less than 50.
8. The method according to claim 1, wherein the nip force between the web reel (3) and the second supporting drum (9) is measured and compared to a set value and wherein the second supporting drum (9) is moved vertically in the direction necessary to correct any deviation from the set force if the measured nip force deviates from the set value and is moved until the measured nip force does not deviate from the set value by more than 4%.
9. The method according to claim 1, wherein the nip force in the nip (10) between the web reel (3) and the second supporting drum is caused to increase during winding by an amount which is equal to or greater than 15% and equal to or less than 30% of said nip force at the beginning of the winding from the beginning of the winding of a web reel (3) to the end of the winding when the web reel has reached its final diameter.
10. The method according to claim 1, wherein each spool (2) rotates about an axis of rotation during winding and wherein the first supporting drum (4) rotates about an axis of rotation which, during the entire winding process, is located at a vertical level below that of the axis of rotation of the spool (2).
11. The method according to claim 1, wherein, as the web reel (3) moves along the horizontal plane, the second supporting drum (9) also moves horizontally to follow the web reel (3) such that the angle between the horizontal plane and a straight line from the axis of rotation of the second supporting drum (9) and the axis of rotation of the web reel (3) remains substantially constant at least from the point in time at which the web reel (3) has reached 25% of its final diameter until at least the point in time at which the web reel (3) has reached 95% of its final diameter.
12. The method according to claim 1, wherein, when a first web reel (3) that is being wound has reached a predetermined size and it is time to start winding of a second web reel, the first supporting drum (4) moves vertically upwards to engage a new spool (2), the web is cut at a point before it has reached the first web reel (3), and the second supporting drum (9) is caused to act as a brake against the first web reel (3) to reduce or stop the rotation of the web reel (3).
13. The method according to claim 12, wherein, after the second supporting drum (9) has acted as a brake against the first web reel (3), the second supporting drum (9) is caused to move horizontally and vertically until it comes into contact with the second web reel (3) and starts to support the second web reel (3).
14. The method according to claim 1, wherein, at least from the point in time at which the web reel (3) has reached 25% of its final diameter until at least the point in time at which the web reel (3) has reached 90% of its final diameter, the second supporting drum (9) is caused to move in the horizontal direction during winding as the spool (2) moves such that the position of the second supporting drum in the horizontal direction (9) remains constant in relation to that of the spool (2) of the web reel (3) that is being wound.
15. The method according to claim 14, wherein the spool (2) of the web reel (3) that is being wound rotates about an axis of rotation and the second supporting (9) drum rotates about an axis of rotation and wherein the axes of rotation of the spool (2) and the second supporting drum (9) are kept in the same vertical plane at least from the point in time at which the web reel (3) has reached 25% of its final diameter until at least the point in time at which the web reel (3) has reached 90% of its final diameter.
16. The method according to claim 1, wherein, when a first web reel (3) that is being wound has reached a predetermined size and it is time to start winding of a second web reel (3), the first supporting drum (4) is moved vertically upwards, a new reel spool (2) for the second web reel is caused to move into a position in which it is supported from below by the first supporting drum (4).
17. A winding machine (1) for winding a web (W) of tissue paper or a non-woven material onto spools (2) to form a succession of web reels on the spools (2), the winding machine (1) comprising: a first supporting drum (4) arranged to act against a web reel (3) in a winding nip (5), the first supporting drum (4) being moveable upwards and downwards in the vertical direction, a first actuator (6) functionally connected to the first supporting drum (4) to be capable of moving the first supporting drum (4) in the vertical direction, a guide rail structure (7) along which web reels (3) can move in a horizontal direction as their diameter increases, a second supporting drum (9) arranged to be capable of acting against the web reel (3) and form a nip (10) against the web reel (3), the second supporting drum (9) being moveable both horizontally and vertically, the second supporting drum (9) being either functionally connected to a second actuator (11) that is capable of causing the second supporting drum (9) to move vertically and horizontally or the second supporting drum (9) being functionally connected to the first actuator such that the first actuator (6) can cause the second supporting drum (9) to move vertically and horizontally, a logic control unit (13) connected to the first actuator (6) and capable of controlling the first actuator (6) and at least one winding nip force sensor (14) arranged to measure the force in the winding nip (5) and send a signal to the logic control unit (13) which is indicative of the force in the winding nip (5), wherein the logic control unit (13) comprises software with an instruction to compare a set value for the winding nip force in the winding nip (5) with the signal from the at least one winding nip force sensor (14) and send an instruction to the first actuator (6) to move the first supporting drum (4) in the direction necessary to correct any deviation from the set force if the signal from the winding force nip sensor (14) indicates that the winding nip force in the winding nip (5) deviates from set force or is outside the range of a predetermined lower value and a predetermined higher value for said winding force.
18. The winding machine (1) according to claim 17, wherein the predetermined lower and higher values are set in relation to a fixed set value for the force in the winding nip (5).
19. The winding machine (1) according to claim 17, wherein the predetermined upper and lower values for the force in the winding nip (5) change during winding as a function of the web diameter and wherein the diameter is calculated by the logic control unit (13) as a function of machine speed, time and web thickness.
20. The winding machine (1) according to claim 17, wherein the machine (1) further comprises at least one nip force sensor (15) arranged to measure the force in the nip (10) between the second supporting drum (9) and the web reel (3) and to send a signal to the logic control unit (13) which is indicative of the nip force between the second supporting drum (9) and the web reel (3), and wherein the logic control unit (13) comprises software with an instruction to compare a set value for the force in nip between with the signal from the at least one nip force sensor (15) and send an instruction to an actuator to move the second supporting drum (9) if the signal from the sensor (15) indicates that the nip force is outside the range of a predetermined lower value and a predetermined higher value.
21. The winding machine (1) according to claim 17, wherein the machine further comprises a cutting device (16) for cutting the web (W) when a new web reel (3) is to be wound.
22. The winding machine (1) according to claim 17, wherein the logic control unit (13) comprises software with an instruction to cause the nip force in the nip (10) between the web reel (3) and the second supporting drum (9) to increase during winding by an amount which is equal to or greater than 15% and equal to or less than 30% of the nip force at the beginning of the winding from the beginning of the winding of a web reel (3) to the end of the winding when the web reel has reached its final diameter.
Description
BRIEF DESCRIPTION OF THE FIGURES
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS
(16) With reference to
(17) The set value may be a fixed set value, but it may alternatively also be allowed to change during winding as a function of the web diameter and the diameter is calculated by the logic control unit 13 as a function of machine speed, time and web thickness.
(18) Preferably, the machine 1 further comprises at least one nip force sensor 15 that is arranged to measure the force in the nip 10 between the second supporting drum 9 and the web reel 3 and to send a signal to the logic control unit 13 which is indicative of the nip force between the second supporting drum 9 and the web reel 3. The logic control unit 13 may then comprise software with an instruction to compare a set value for the force in nip between with the signal from the at least one nip force sensor 15 and send an instruction to an actuator (for example the second actuator 11) to move the second supporting drum 9 in the direction necessary to correct any deviation from the set value if the signal from the sensor 15 indicates that the nip force deviates from a set value or is outside the range of a predetermined lower value and a predetermined higher value.
(19) The machine preferably also further comprises a cutting device 16 for cutting the web when a new web reel 3 is to be wound.
(20) A method according to the invention for winding a web W onto spools 2 to form a succession of web reels 3 on the spools 2 will now be explained with reference first to
(21) During the winding of each web reel 3, the predetermined upper and lower values may be set to follow a curve such that the increase by an amount equal to or greater than 3% and equal to or less than 10% from the beginning of the winding of a web reel 3 until the web reel 3 is completed or such that they decrease by an amount equal to or greater than 3% and equal to or less than 10% from the beginning of the winding of a web reel 3 until the web reel 3 is completed.
(22) During winding, the web reel 3 is carried by the guide rail structure 7. However, as the web reel 3 grows in size, the weight of the web reel 3 may cause bending of the spool 2 which may increase the load on the second supporting drum 9. To compensate for this, the force in the winding nip 5 may be allowed to change as the web reel 3 grows in size.
(23) However, the predetermined upper and lower values may also be set in relation to a fixed set value. This corresponds to a control in which it is attempted to correct the winding nip force as soon as it deviates from a fixed set value but in which minor deviations may be accepted.
(24) For example, as the diameter of the web reel 3 grows, the first supporting drum 4 can be moved downwards such that the winding nip force in the winding nip 5 remains within a range of 2% deviation from a fixed set value.
(25) As indicated in
(26) Preferably but not necessarily, the nip force between the web reel 3 and the second supporting drum 9 is measured and compared to a set value while the second supporting drum 9 is moved vertically if the measured nip force deviates from a set value and moved until the measured nip force does not deviate from the set value by more than 4%, preferably not by more than 2%. Since increasing weight of the web reel 3 during winding may result in bending of the spool 2, the nip force in the nip 10 between the web reel 3 and the second supporting drum may be allowed to increase during winding. In many practical cases, the nip force between the second supporting drum 9 and the web reel may be allowed to increase by an amount equal to or greater than 15% and equal to or less than or 30% or an amount equal to or greater than % and equal to or less than or 28% of the nip force at the beginning of the winding from the nip force at the beginning of the winding (when the weight of the web reel is small) to the end of the winding when the web reel has reached its final diameter. For example, it may be allowed to increase by 25% or about 25%. To this end, the logic control unit 13 may comprise software that, during operation of the winding machine, controls movement of the second supporting drum 9 such that the nip force in the nip 10 between the second supporting drum 9 and the web reel 3 to increase by an amount which is equal to or greater than 15% and equal to or less than 30% of the nip force at the beginning of the winding from the nip force the beginning of the winding to the end of the winding of a web reel 3. In that case, the nip force in the nip 10 between the second supporting drum 9 and the web reel 3 will follow a curve instead of being kept at a constant level. Therefore, the method may be carried out such that the nip force in the nip 10 between the web reel 3 and the second supporting drum 9 is caused to increase during winding by an amount which is equal to or greater than 15% and equal to or less than 30% of the nip force at the beginning of the winding from the nip force at the beginning of the winding of a web reel 3 to the end of the winding when the web reel has reached its final diameter and preferably caused to increase by an amount which is equal to or greater than 20% and equal to or less than 28% of said nip force at the beginning of the winding. This can be controlled by the logic control unit 13 and the logic control unit may thus comprise software with an instruction to cause the nip force in the nip 10 between the web reel 3 and the second supporting drum 9 to increase during winding by an amount which is equal to or greater than 15% and equal to or less than 30% of the nip force at the beginning of the winding from the nip force at the beginning of the winding of a web reel 3 to the end of the winding when the web reel has reached its final diameter. The logic control unit 13 can achieve this effect since it controls the vertical movement of the second supporting drum through the vertical component 11a of the second actuator 11.
(27) Each spool 2 rotates about an axis of rotation during winding. Preferably, the winding process is carried out such that the first supporting drum 4 rotates about an axis of rotation which, during the entire winding process, is located at a vertical level below that of the axis of rotation of the spool 2. The first supporting drum 4 will then be supporting the web reel at least partially from below during the entire winding process.
(28) Preferably, a method according to the invention is carried out such that, as the web reel 3 moves along the horizontal plane, the second supporting drum 9 also moves horizontally to follow the web reel 3 such that a straight line from the axis of rotation of the second supporting drum 9 and the axis of rotation of the web reel 3 remains at a constant angle to the horizontal plane at least from the point in time at which the web reel 3 has reached 25% of its final diameter until at least the point in time at which the web reel 3 has reached 95% of its final diameter. The final diameter may vary depending on a number of factors such as, for example, the material of the web or the intended final product. In many typical cases, the final diameter may be on in the range of 3-4 m for a web reel formed by a tissue paper web but the value of the final diameter may also take other numerical values, both less than 3 m and more than 4 m. Often, the final diameter could be 3.5 m or 3.6 m. If the web material is a non-woven material, the final diameter may be in the range of 1 m-3 m. A typical value could be, for example, 1.2 m or 1.5 m. However, both for tissue paper and for non-wovens, the final diameter may deviate from the values given here and those values should only be understood as some typical examples. The axial width of a web reel made from a tissue paper web may be 5.6 m-6.0 m but other widths are also possible, both widths less than 5.6 m and widths greater than 6 m. The axial width of a web reel made from a non-woven material may take many different numerical values, but typical values would often be in the range of 2.2 m-5 m. It should be understood that the axial width of the web reel may take other numerical values.
(29)
(30)
(31)
(32) The angle between the horizontal plane and a straight line from the axis of rotation of the first supporting drum 4 and the axis of rotation of the web reel 3 can be kept constant, for example 45 but, for some applications, it may be suitable to change the angle during the winding operation such that it decreases or increases during operation. The logic control unit can then comprise software that is designed to control the angle during winding such that it changes according to a predetermined curve which is increasing or decreasing. This can be made dependent on the diameter of the web reel 3.
(33) Doffing according to the invention, i.e. change of spool to make a new web reel 3 will now be explained with reference to
(34) In
(35) In
(36) In
(37) In
(38) In connection with doffing, the second supporting drum will change its position in the horizontal direction relative to the web reel 3 that is being wound. However, at least from the point in time at which the web reel 3 has reached 25% of its final diameter until at least the point in time at which the web reel 3 has reached 90% of its final diameter, the second supporting drum 4 should preferably be caused to move in the horizontal direction during winding as the spool 2 moves such that the position of the second supporting drum 9 in the horizontal direction remains constant in relation to that of the spool 2 of the web reel 3 that is being wound. Preferably, the axis of rotation of the spool 2 of the web reel 3 that is being wound and the axis of rotation of the second supporting 9 drum should be kept in the same vertical plane at least from the point in time at which the web reel 3 has reached 25% of its final diameter until at least the point in time at which the web reel 3 has reached 90% of its final diameter.
(39) The inventive method and the inventive winding machine may be used both for on-line winding and off-line winding.
(40) Thanks to the invention, the winding can be carried out with a high stability during the winding process. Different configurations of the machine are possible which allows the machine to be suitable for many different products.
(41) Although the invention has been described above in terms of a method of winding and a winding machine, it should be understood that those categories only reflect different aspects of one and the same invention. The machine is thus designed to carry out the inventive method.