MXPA97009373A - Method for devaning pieces with different accounts of lam - Google Patents

Abstract

The present invention relates to a method for winding a continuous web of material on hollow cores to form individual pieces, the pieces having different lengths of material wound thereon, the method characterized in that it comprises the steps of: providing a turret assembly rotatably driven by supporting a plurality of rotationally driven mandrels for winding the weft of material onto cores supported on the mandrels; providing a rotatable table roller to transfer the weft of material to the rotatably driven turret assembly; table, rotating the turret assembly to bring the mandrels in a closed path, winding the material on the cores supported on the mandrels to form pieces having a first predetermined length, and changing the length of the material wound on the cores, while rotating the turret assembly for form pieces that have a second predetermined length of the material, wherein the first length is different from the second length

Description

METHOD FOR DEVANATING PIECES WITH DIFFERENT SHEET ACCOUNTS FIELD OF THE INVENTION This invention relates to a method for winding weft material such as tissue paper or paper to be wound as a towel into individual pieces. More particularly, the invention relates to a method for winding different stretches of weft material over hollow cores.

BACKGROUND OF THE INVENTION Turret winders are known in the art. Conventional turret rewinders comprise a rotating turret assembly, which supports a plurality of mandrels to rotate about a turret shaft. The mandrels travel in a circular path at a given distance from the turret axis. The mandrels couple hollow cores on which a paper web can be wound. Typically, the paper web is unrolled from a main roller in a continuous form, and the turret winder rewinds the paper web onto the cores supported on the mandrels to provide individual chunks of relatively small diameter. Since the turret windings can provide the winding of the weft material on the mandrels as the mandrels are carried around the axis of the turret assembly, the rotation of the turret assembly is indexed in a form of stop and start to provide the loading of the core and the unloading of the piece, while the mandrels are fixed. The turret windings are described in the following U.S. Patents: 2, 769 600, issued November 6, 1965 to Kwitek et al .; patent of E.U.A. 3,179,348, issued September 17, 1962, to Nystrand et al .; patent of E.U.A. 3,552,670, issued on June 12, 1968 to Hermán; and patent of E.U.A. 4,687,153, issued August 18, 1987 to McNeil. Indexing turret assemblies are commercially available in Series 150, 200 and 250 rewinders manufactured by Paper Coverting Machine Company of Green Bay, Wisconsin. The Paper Converting Machina Company's 250 Series Rewinding Machine Training Manual Pushbutton Change describes a frame winding system that has five servo axes controlled. The shafts are odd dosed winding, torque metered winding, core load hauled, roll band conveyor, and turret indexer. Product changes, such as count and sheet per piece, are said to be made through an operator via a terminal interface. The system is said to eliminate mechanical cams, cog change gears or pulley and toothed wheels. Various constructions for the core supports, including mandrel locking mechanisms for securing a core to a mandrel, are known in the art, the US patent. No. 4,635,871, issued January 13, 1987 to Jonhson et al. Describes a rewinder mandrel having pivoting core closure projections. The patent of E.U.A. No. 4,033,521, issued July 5, 1977 to De discloses an expandable sleeve of rubber or other elastic material, which can be expanded through compressed air, so that the projections hold a core on which the weft is wound. Other mandrel and core support constructions are shown in the U.S.A. 3,459,388; 4,230,286; and 4,174,077. The indexing of the turret assembly is undesirable, due to the resulting inertial forces and vibration caused by the acceleration and deceleration of a rotating turret assembly. In addition, it is desirable to accelerate conversion operations, such as rewinding, especially where rewinding is a bottleneck in the conversion operation. Accordingly, it is an object of the present invention to provide an improved method for winding a weft material on individual hollow cores. Another object of the present invention is to provide a method for changing the length of the material wound on the cores while they are rotating in a turret assembly.

BRIEF DESCRIPTION OF THE INVENTION The present invention comprises a method for winding a continuous web of material on hollow cores to form individual pieces, the pieces having different lengths of material wound on them. In one embodiment, the method comprises the steps of: providing a rotatably driven turret assembly supporting a plurality of rotationally driven mandrels for winding the web of material on cores supported on the mandrels; providing a rotatable table driven roller to transfer the web of material to the rotationally driven turret assembly; spinning the table roll; rotating the turret assembly to bring the mandrels in a closed path; winding the material on cores supported on the mandrels to form pieces having a first predetermined length of the material; and changing the length of the material wound on the cores while the turret assembly is rotating to form the pieces having a second predetermined length of material, wherein the first length is different from the second length.

The method may comprise the steps of continuously rotating the turret assembly before the step of changing the length of the wound material on the cores is initiated, and continuously rotating the turret assembly after the step of changing the length of the turret assembly. material wound on the cores has been completed. For example, the method may comprise continuously rotating the turret assembly at a generally constant first angular velocity, while the pieces are being formed having the first predetermined length of material, and continuously rotating the turret assembly at a second angular velocity generally constant, while the pieces are being formed having the second predetermined length of the material. In one embodiment of the present invention, the method may comprise the steps of: providing a rotatably driven turret assembly supporting a plurality of rotatably driven mandrels for winding the web of material on the cores supported on the mandrels; providing a rotatable table roller for transferring the web of material to the rotationally driven turret assembly; spinning the table roll; rotating the turret assembly to bring the mandrels in a closed path; winding a first length of the material on the cores supported on the mandrels to form pieces having the first length of the material; changing the rotational speed of the turret assembly relative to the rotating speed of the table knee, while the turret assembly is rotating; and winding a second length of material on the cores supported on the mandrels to form pieces having the second length of material, wherein the second length is different from the first length.

BRIEF DESCRIPTION OF THE DRAWINGS Since the specification concludes with the claims particularly pointing out and claiming the present invention differently, it is believed that the present invention will be better understood from the following description taken together with the accompanying drawings, in which: Figure 1 is a perspective view of a turret winder, core guiding apparatus, and a core loading apparatus of the present invention. Figure 2 is a partially cut-away front view of the turret winder of the present invention. Figure 3A is a side view showing the position of the closed mandrel path and the mandrel drive system of the turret winder of the present invention relative to a conventional upstream rewinder assembly.

Figure 3B is a partial front view of the mandrel system shown in Figure 3A taken at 3B-3B in Figure 3: Figure 4 is an elongated front visa of the rotatably driven turret assembly shown in Figure 2. Figure 5 is a schematic view taken along lines 5-5 in FIG. Figure 4. Figure 6 is a schematic illustration of a mandrel support bracket slidably supported on rotating mandrel support plates. Figure 7 is a sectional view taken along lines 7-7 of Figure 6 and showing an extended mandrel relative to a rotating mandrel support plate. Figure 8 is a view similar to that of Figure 7 showing the mandrel retracted relative to the rotating mandrel support plate. Figure 9 is an enlarged view of the chuck chuck assembly shown in Figure 2. Figure 10 is a side view taken along lines 10-10 in Figure 9 and showing a cocking arm extended relative to a support arm support plate. Figure 11 is a view similar to that of Figure 10 showing the take-up arm retracted relative to the rotating take-up arm support plate.

Figure 12 is a view taken along lines 12-12 in Figure 10, with the open, uncovered position of the cup arm shown in a faded form.

Figure 13 is a perspective view showing the placement of the cupping arms provided by the fixed cupping arm, closing, opening, holding and keeping closed the camming surfaces. Figure 14 is a view of a fixed mandrel positioning guide comprising detachable plate segments. Figure 15 is a side view showing the position of core driving rollers and a mandrel support relative to the closed mandrel path. Figure 16 is a view taken along lines 16-16 in Figure 15. Figure 17 is a front view of a cup assist mandrel support assembly. Figure 18 is a view taken along lines 18-18 in Figure 17. Figure 19 is a view taken along lines 19-19 of Figure 17: Figure 20A is a perspective view enlarged of the adhesive application assembly shown in Figure 1. Figure 20B is a side view of a core rotation assembly shown in Figure 20A. Figure 21 is a rear perspective view of the core loading apparatus in Figure 1. Figure 22 is a schematic view shown partially in cross section of the core loading apparatus shown in Figure 1. Figure 23 is a view schematic shown partially in cross-section of the core guide assembly shown in Figure 1. Figure 24 is a front perspective view of the core separation apparatus in Figure 1. Figures 25A, B and C are top visas showing a wound core being separated from a mandrel through the core separation apparatus. Figure 26 is a schematic side view of a mandrel shown partially in cross section. Figure 27 is a partial schematic side view of the mandrel shown partially in cross section, a cup arm assembly shown engaging the nose piece of the mandrel to move the nose piece towards the mandrel body, thus compressing the deformable ring of the mandrel . Figure 28 is an enlarged schematic side view of the second end of the mandrel of Figure 26 showing a cup arm assembly engaging the nose piece of the mandrel to move the nose piece towards the body of the mandrel.

Figure 29 is an enlarged schematic side view of the second end of the mandrel of Figure 26 showing the nose piece biased away from the mandrel body.

Figure 30 is a cross-sectional view of a deformable mandrel ring. Figure 31 is a schematic diagram showing a programmable drive control system for controlling the independently driven components of the weft winder apparatus. Figure 32 is a schematic diagram showing a programmable mandrel drive control system for controlling the drive motors of the mandrel.

DETAILED DESCRIPTION OF THE INVENTION Figure 1 is a perspective view showing the front part of a weft winder apparatus 90 according to the present invention. The weft winder apparatus 90 comprises a turret winder 100 having a fixed frame 110, a core loading apparatus 1000, and a core separation apparatus 2000. Figure 2 is a partial front view of the turret winder 100. Figure 3 is a partial side view of the turret winder 100 taken along lines 3-3 in Figure 2, showing a conventional weft rewinder assembly upstream of the turret winder 100.

Description of the Carcass, Winding and Core Separation Referring to Figures 1, 2 and 3A / B, the turret winder 100 supports a plurality of mandrels 300. The mandrels 300 couple cores 302, on which a paper web is wound. The mandrels 300 are driven in a closed mandrel path 320 about a central axis of the turret assembly 202. Each mandrel 300 extends along a mandrel shaft 314 generally parallel to the central axis of the turret assembly 202, from from a first end of mandrel 310 to a second end of mandrel 312. The mandrels 300 are supported at their first ends 310 by a rotatably driven turret assembly 200. The mandrels 300 are releasably supported at their second ends 312 through an assembly. chuck attachment 400. The turret winder 100 preferably supports at least three mandrels 300, most preferably at least 6 mandrels 300, and in one embodiment, the turret winder 100 supports ten mandrels 300. A turret winder 100 which supports at least 10 mandrels 300 may have a rotatably driven turret assembly 200, which is rotated at an angular velocity re loosely low to reduce vibration and inertial loads, while providing increased performance relative to an indexed turret winder, which is intermittently rotating at higher angular speeds. As shown in Figure 3A, the closed mandrel path 320 may be non-circular, and may include a core shroud segment 322, a frame-hauled segment 324, and a core separation segment 326. The load segment core 322 and core separation segment 326 each comprise a generally straight line portion. By the phrase "a generally straight line portion" is meant that a segment of a closed mandrel path 320 includes two points on the closed mandrel path, where the straight line distance between the two points is at least 25.4 cm, and wherein the maximum normal deviation of the closed mandrel path extending between the two points of a straight line drawn between the two points is no more than about 10%, and in one embodiment is not more than 5 %. The maximum normal deviation of the portion of the closed mandrel path extending between two points is calculated: constructing an imaginary line between the two points; determining the maximum distance from the imaginary straight line to the portion of the closed mandrel path between the two points, as measured perpendicular to the imaginary straight line; and dividing the maximum distance between the straight line distance between the two points (25.4 cm).

In one embodiment of the present invention, the core load segment 322 and the core separation segment 326 each comprise a straight line portion having a maximum normal deviation of less than 5.0%. By way of example, the core load segment 322 may comprise a straight line portion having a maximum deviation of about 0.15-0.25%, and the core separation segment may comprise a straight line portion having a maximum deviation of about 0.5-5.0%. The straight line portions as the maximum deviations allow the cores to be accurately and easily aligned with moving mandrels during core loading and allow the separation of empty cores from the moving mandrels in the case in which the raster material Do not be wound on one of the cores. In contrast, for a conventional indexing turret having a circular closed mandrel path with a radius of about 25.4 cm, the normal deviation of the circular closed mandrel path of a straight rope with a length of 25.4 cm from the circular mandrel path it is e approximately 13.4%. The second ends 312 of the mandrels 300 are not coupled by, or otherwise supported by, the chuck chucking assembly 400 along the core loading segment 322. The core loading apparatus 1000 comprises one or more components core driven loads for transporting the cores 302 at least part over the mandrels 300 during movement of the mandrels 300 along the core loading segment 322. A pair of rotationally driven core drive rolls 505 disposed on the opposite sides of the core loading segment 322 cooperate to receive a core of the core loading apparatus 1000 and complete the driving of the core 302 on the mandrel 300. As shown in Figure 1, the loading of a core 302 on a mandrel 300 is initiated at the second mandrel end 312 before the loading of another core on the preceding adjacent mandrel is completed. Accordingly, the delay and inertial forces associated with the start and stop index of conventional turret assemblies are eliminated. Once the core loading is completed in a particular mandrel 300, the chuck attachment assembly 400 engages the second end 312 of the mandrel 300 as the mandrel moves from the load segment 322 to the frame winder segment 324, thus providing support to the second end 312 of the mandrel 300. The cores 302 loaded onto the mandrels 300 are brought to the weave winder segment 324 of the closed mandrel path 320. Intermediate to the core load segment 322 and to the weft winder segment 324, a band assurance adhesive can be applied to the core 302 through an adhesive application apparatus 800 as the associated core and mandrel are carried along the closed mandrel path. As the core 302 is carried along the weft winder segment 324 of the closed mandrel path 320, a frame 50 is directed to the core 302 through a rewinder assembly 60 disposed upstream of the turret winder 100. The rewinder assembly 60 is shown in Figure 3, and includes feed rollers 52 to bring the weft 50 to a punch roller 54, a weft cutter table roller 56 and a shredder roll 58 and a table roll 59 The perforating roller 54 provides lines of perforations extending along the width of the weft 50. Adjacent lines of perforations are spaced a predetermined distance along the length of the weft 50 to provide individual sheets joined in the perforations. The length of the sheet of the individual sheets is the distance between the adjacent lines of perforations. The crumb roller 58 of the table roll 59 cuts the weft 50 at the end of a piece winding cycle, when the winding of the weft is completed in the core 302. The table roll 59 also provides transfer of the free end of the weft 50 to the next core 302 advancing along the closed mandrel path 320. Said rewinding assembly 60, including the feed rollers 52, the perforating roller 54, the roller of the weft cutting table 56, and the crumb roller and the table roller 58 and 59m are well known in the art. The table roll 59 may have plural radially movable members having barriers and pins extending radially outwardly, and radially movable sheaths, as is well known in the art. The crumb roller may have a blade and damper extending radially outward, as is known in the art. The patent of E.U.A. No. 4,687,153, issued August 18, 1987 to McNeil is hereby incorporated by reference for the purpose of generally describing the operation of the table roll and the shredder roll to provide frame transfer. A suitable rewinder assembly 60 including the rollers 52, 54, 56, 58 and 59 can be supported on a frame 61 and is manufactured by Paper Converting Machine Company of Green Bay Wisconsin as a Series 150 rewinder system. The table roll includes a shredding solenoid to activate the radial moving members. The solenoid activates the radial moving members to cut the web at the end of a chute winder cycle, so that the web can be transferred to wind up in a new empty core. The solenoid activation time control can be varied to change the length interval at which the web is cut by the table roll and the shred roll. Accordingly, if a change in the sheet count per piece is desired, the time control of the activation of the solenoid may be varied to change the length of the material wound on a piece. A mandrel drive apparatus 330 provides for the rotation of each mandrel 300 and its associated core 302 about the axis of the mandrel 314 during movement of the mandrel and the core along the weft winder segment 324. The mandrel drive apparatus 330 thus it provides the winding of the weft 50 on the core 302 supported on the mandrel 300 to form a piece 51 of the weft material wound around the core 302 (a weft-wound core). The mandrel drive apparatus 330 provides a central winding of the paper web 50 over the cores 302 (i.e., connecting the mandrel to an impeller, which rotates the mandrel 300 about its axis 314, so that the frame is pulled on the core), as opposed to the winding surface, wherein a portion of the outer surface on the piece 51 is in contact by rotating the winder drum so that the frame is pushed, by friction, on the mandrel. The central winding mandrel drive apparatus 330 may comprise a pair of mandrel drive motors 332A and 332B, a pair of mandrel drive bands 334A and 334B, and tensioning pulleys 336A and 336B. Referring to Figures 3A B and 4, the first and second mandrel drive motors 332A and 332B drive the first and second mandrel drive bands 334A and 334B, respectively, around the tensioning pulleys 336A and 336B. The first and second driving belts 334A and 334B transfer the torque to alternate the mandrels 300. In Figure 3A, the engine 332A, the engine 332B, the band 334A and the pulleys 336A are opposite the engine 332B, the band 334B and the pulleys 336B, respectively. In Figures 3A / B, a mandrel 300A (an "even" mandrel) supporting a core 302 just prior to receiving the table roll from the table 59, is driven by the mandrel drive band 334A, and an adjacent mandrel 300B (an "odd" mandrel) supporting a core 302B on which the winding is almost complete, is driven by mandrel drive belt 334B. A mandrel 300 is urged about its axis 314 relatively rapidly just before and during the initial transfer of the weft 50 to the associated core of the mandrel. The rotation speed of the mandrel provided by the mandrel drive apparatus 330 is reduced as the diameter of the weft wound on the mandrel core increases. Accordingly, adjacent mandrels 300A and 300B are driven through alternating drive bands 334A and 334B, so that the rotation speed of a mandrel can be controlled independently of the rotation speed of an adjacent mandrel. The mandrel drive motors 332A and 332B can be controlled in accordance with a winding speed schedule of the mandrel, which provides the desired rotational speed of a mandrel 300 as a function of the angular position of the turret assembly 200.

Accordingly, the speed of rotation of the mandrels around their axes during the winding of a piece is synchronized with the angular position of the mandrels 300 on the turret assembly 200. It is known to control the rotational speed with a mandrel speed schedule. in conventional rewinders. Each mandrel 300 has a toothed mandrel drive pulley 338 and a smooth surface free running tension pulley 339, both arranged near the first end 310 of the mandrel, as shown in Figure 2. The positions of the drive pulley 338 and the tension pulley 339 alternate every two mandrels 300, so that the alternating mandrels 300 are driven by the mandrel drive bands 334A and 334B, respectively. For example, when the mandrel drive belt 334A engages the mandrel drive pulley 338 in the mandrel 300A, the mandrel drive belt 334B travels over the smooth surface of the tension pulley 339 on that same mandrel 300A, so that only the drive motor 332A provides rotation of that mandrel 300A about its axis 314. Similarly, when the mandrel drive belt 334B couples the mandrel drive pulley 338 onto an adjacent mandrel 300B, the mandrel drive belt 334A it travels on the smooth surface of the tension pulley 339 on that mandrel 300B, so that only the drive motor 332B provides the rotation of the mandrel 300B about its axis 314. Accordingly, each drive pulley on a mandrel 300 engages over the bands 334A / 334B for transferring the torque to the mandrel 300, and the tensioner pulley 339 engages the other of the bands 334A / 334B, but does not transfer the torque of the drive belt to the mandrel. The band that winds the cores is carried along the closed mandrel path 320 to the core cutting segment 326 of the closed mandrel path 320. Intermediate to the weft retractor segment 324 and the core separation segment 326, a portion of the chuck attachment assembly 400 is uncoupled from the second end 312 of the mandrel 300 to allow separation of the chunk 51 from the mandrel 300. The core separation apparatus 2000 is positioned along the core separation segment 326. The core separation apparatus 000 comprises a driven core separation component, such as an endless conveyor belt 2010, which is continuously driven around the pulleys 2012. The conveyor belt 2010 carries a plurality of separate 2014 flights on the conveyor belt 2010. Each flight 2014 couples the end of a piece 51 supported on a mandrel 300 as the mandrel moves along of the core separation segment 326. The flight conveyor belt 2010 can be angled with respect to the axes of the mandrel 314 as the mandrels are carried along a generally straight line portion of the core separation segment 326 of the closed mandrel path, so that the flights 2014 couple each piece 51 with the first speed component generally parallel to the mandrel axis 314, and a second speed component generally parallel to the straight line portion of the separation segment of 326. The core separation apparatus 2000 is described in detail below. Once the piece 51 is separated from the mandrel 300, the mandrel 300 is carried along the closed mandrel path towards the core load segment 322 to receive another core 302. having described the core charge, the winding and the separation generally, the individual elements of the frame winding apparatus 90 and their functions will now be described in more detail.

Turret Feeder: Mandrel Support Referring to Figures 1-4, the rotatably driven turret assembly 200 is supported on the fixed frame 110 to rotate about the center axis 202 of the turret assembly. The frame 1 10 is preferably separated from the rewinder assembly frame 61 to isolate the turret assembly 200 from the vibrations caused by the rewinder assembly 60. The rotatably driven turret assembly 200 supports each mandrel 300 adjacent the first end 310 of the mandrel 300.

Each mandrel 300 is supported on the rotatably driven turret assembly 200 for independent rotation of the mandrel 300 about its axis 314, and each mandrel is carried on the turret assembly rotatably driven along the closed mandrel path 320. Preferably , at least a portion of the mandrel path 320 is non-circular, and the distance between the mandrel shaft 314 and the central axis 202 of the turret assembly varies as a function of the position of the mandrel 300 along the path Closed mandrel 320. With reference to Figures 2 and 4, the fixed turret winder frame 110 comprises a fixed support 120 horizontally in extension, extending intermediate to the straight frame ends 132 and 134. The rotatably driven turret assembly 200 comprises a turret hub 220, which is rotatably supported on the support 120 adjacent the straight frame end 132 through is of bearings 221. The portions of the assembly are shown cut in Figures 2 and 4 for clarity. A turret hub drive servo motor 222 mounted on the frame 110 delivers the torque to the turret hub 220 through a band or chain 224 and a gear 226 to rotationally drive the turret hub 220 about the axis turret assembly center 202. The servo motor 222 is controlled to form phase with the rotational position of the turret assembly 200 with respect to a reference position. The reference position can be a function of the angular position of the table roll 59 about its axis of rotation, and a function of an accumulated number of revolutions of the table roll 59. In particular, the position of the turret assembly 200 may be formed in phase with respect to the position of the table roll 59 within the piece winding cycle, as fully described below. In one embodiment, the turret hub 220 can be driven continuously, in a non-stop, non-indexed manner, so that the turret assembly 200 rotates continuously. By "continuously rotating" is meant that the turret assembly 200 makes multiple complete revolutions about its axis 202 without stopping. The turret hub 220 can be driven at a generally constant angular velocity, so that the turret assembly 200 rotates at a generally constant angular velocity. By "driven at a generally constant angular velocity" is meant that the turret assembly 200 is driven to rotate continuously, and that the rotational speed of the turret assembly 200 varies less than about 5%, and preferably less than around 1%, of a baseline value. The turret assembly 200 can support 10 mandrels 300, and the turret hub 220 can be driven at a baseline angular velocity of between about 2-4 RPM, to wind between about 20-40 pieces 51 per minute. For example, the turret hub 220 can be driven at a baseline angular velocity of approximately 4 RPM during winding of approximately 40 pieces per minute, with the angular velocity of the turret assembly varying from less than about 0.04 RPM. Referring to Figures 2, 4, 5, 6, 7, and 8, a mandrel support extends from the turret hub 220. In the embodiment shown, the rotation mandrel support comprises first and second support plates. rotation mandrel 230, rigidly attached to the hub for rotation with the hub about the axis 202. The rotation mandrel support plates 230 are spaced apart from one another along the axis 202. Each rotation mandrel support plate 230 may have a plurality of elongated slots 232 (Figure 5) extending therethrough. Each slot 232 extends along a path having a radial component and a tangential relative to the axis 202. A plurality of transverse members 234 (Figures 4 and 6-8) extend intermediate and are rigidly attached to the rotation mandrel support plates 230. Each transverse member 234 is associated with and extends along an elongated slot on the first and second rotation mandrel support plates 230. The first and second rotation mandrel support plates 230 are disposed intermediate the first and second fixed mandrel guide plates 142 and 144. The first and second mandrel guide plates 142 and 144 are attached to a portion of the frame 110., so that the frame end 132 or the support 120, or alternatively, can be supported independently of the frame 110. In the embodiment shown, the mandrel guide plate 142 can be supported through the frame end 132 and the second one. mandrel guide plate 144 may be supported on the support 120. The first mandrel support guide plate 142 comprises a first camming surface, such as a cam surface groove 143, and the second mandrel guide plate 144. it comprises a second cam surface, such as a cam surface groove 145. The first and second cam surface grooves 143 and 145 are disposed on the opposing facing surfaces of the first and second mandrel guide plates 142 and 144. , and are spaced from one another along the axis 202. Each of the slots 143 and 145 define a closed path around the central axis of the turret assembly 202. The slots of Cam surface 143 and 145 can, but do not need to be, mirror images of each other. In the embodiment shown, the cam surfaces are slots 143 and 145, but it will be understood that other cam surfaces, such as external cam surfaces, may be used. The mandrel guide plates 142 and 144 act as a mandrel guide for positioning the mandrels 300 along the closed mandrel path 320 as the mandrels are carried on the rotary mandrel support plates 230. Each mandrel 300 is supported for rotation about its mandrel shaft 314 on a mandrel bearing support assembly 350. The mandrel bearing support assembly 350 may comprise a first bearing housing 352 and a second bearing housing 354 rigidly attached to a chuck slide plate 356.

Each mandrel slide plate 356 is slidably supported on a transverse member 234 for relative translation with the transverse member 234 along a path having a radial component relative to the axis 202 and a tangential component relative to the axis 202. FIGS. and 8 show the translation of the mandrel slide plate 356 relative to the transverse member 234 to vary the distance from the mandrel shaft 314 to the central axis of the turret assembly 202. In one embodiment, the mandrel slide plate can be slidably supported on a transverse member 234 through a plurality of linear bearing and track bearing assemblies 358 and 359, commercially available. Accordingly, each mandrel 300 is supported on the rotation mandrel support plates 230 for relative translation to the rotary mandrel support plates along a path having a radial component and a tangential component relative to the assembly of turret central shaft 202. The slides 358 and the matching rails 359 are ACCUGLIDE CARRIAGES manufactured by Thomson Incorporated of Port Washington, NY Each chuck sliding plate 356 has first and second cylindrical cam followers 360 and 362. The first and second followers of cam 360 and 362 couple the cam surface grooves 143, 145, respectively, through the slots 232 in the first and second rotational chuck supporting plates 230. As the mandrel bearing support assemblies 350 are carried around the shaft 202 on the rotating mandrel support plates 230, the cam followers 360 and 362 follow the grooves 143 and 145 on the mandrel guide plates, thereby positioning the mandrels 300 along the closed mandrel path 320. The servo motor 222 can drive the rotatably driven turret assembly 200 continuously around the central axis 202 at an angular velocity generally constant. Accordingly, the rotating mandrel support plates 230 provide for the continuous movement of the mandrels 300 about the closed mandrel path 320. The linear velocity of the mandrels 300 around the closed path 320 will increase as the distance of the mandrel. Mandrel axis 314 from shaft 202 is increased. A suitable servo motor 222 is a hp servo motor Model HR2000 manufactured by Reliance Electric Company of Cleveland, Ohio.

The shape of the first and second cam surface grooves 143 and 145 can be varied to vary the closed mandrel path 320. In one embodiment, the first and second cam surface grooves 143 and 145 can comprise replaceable, replaceable sectors. , such as the closed mandrel path 320 comprises replaceable segments. Referring to Figure 5, the cam surface grooves 143 and 145 can enclose the shaft 202 along a path comprising non-circular segments. In one embodiment, each of the mandrel guide plates 142 and 144 may comprise a plurality of plate segments co-threaded together. Each plate sector may have a segment of the full cam follower surface groove 143 (145). Referring to Figure 14, the mandrel guide plate 142 may comprise a first plate sector 142A having a cam surface slot segment 143A, and a second plate sector 142B having a surface slot segment of cam 143B. By unscrewing a plate sector and inserting a different plate sector having a different shaped segment configured from the cam surface groove, a segment of the closed mandrel path 320 having a particular shape, can be replaced by another segment that have a different form. Said sectors of interchangeable plates can eliminate the problems encountered when winding pieces 51 having different diameter and / or sheet counts. For a given closed mandrel trajectory, a change in the diameter of the pieces may result in a corresponding change in the position of the tangent point, in which the weft leaves the surface of the table roll as the winding is complete on a core. If a mandrel path adapted for large diameter pieces is used to wind small diameter pieces, the pattern will leave the table roll at a tangent point, which is higher on the table roll than the tangent point desired to provide the appropriate transfer of the frame to the next core. This displacement of the weft to the tangent point of the table roll may result in an input core "running into" the frame, as the frame is being wound on the preceding core, and may result in a transfer premature of the plot towards the entrance nucleus. Prior art windings having circular mandrel paths can have air jet systems or mechanical dampers to prevent such premature transfer, when small diameter pieces are being wound. The air jet systems and the dampers intermittently bend the middle frame to the table roll and the preceding core to move the weft to the tangent point of the table roll as the input core approaches the roll of the table. table. The present invention provides the advantage that the winding of pieces of different diameter can be adapted by replacing the segments of the closed mandrel trajectory (and thus vary the trajectory of the mandrel), instead of bending the weft.

By providing the mandrel guide plates 142 and 144, which comprise two or more plate sectors screwed together, a portion of the closed mandrel path, such as the weft retractor segment, can be changed by unscrewing a plate sector and inserting a different plate sector having a different configuration segment of the cam surface. By way of illustrative example, table 1A lists coordinates for a cam surface slot segment 143A shown in Figure 14, Table 1 B lists the coordinates for a cam surface slot segment 143B to be used in the winding of relatively large diameter pieces, and Table 1C lists the coordinates for a suitable cam surface slot segment for the replacement of the segment 143B when relatively small diameter pieces are unwrapped, the coordinates are measured from the central axis 202. Suitable cam groove segments are not limited to those listed in Tables 1A-C, and it will be understood that the cam groove segments may be modified as necessary to define any desired mandrel trajectory 320. Tables 2A list the coordinates of the mandrel path 320 corresponding to the cam slot segments 143A and 143B described by the coordinates in Tables 1A and 1 B. When Table 1C is replaced by Table 1B, the resulting changes in the coordinates of the mandrel path 320 are listed in Table 2B.

Assembly Turret Feeder, Mandrel Attachment Mandrel Coupling Assembly 400 releasably couples the second ends 312 of the intermediate mandrels 300 to the core load segment 322 and the core separation segment 325 of the closed mandrel path 320, a As the mandrels are propelled around the central axis of turret assembly 202 through the turret assembly 200. Referring to Figures 2 and 9-12, the chuck attachment assembly 400 comprises a plurality of coping arms. 450 supported on a rotating cup arm bracket 410. Each of the cup arms 450 has a mandrel cup assembly 452 for releasably coupling the second end 312 of a mandrel 300. The mandrel cup assembly 452 rotatably supports a mandrel cup 454 on bearings 456. Chuck cup 454 releasably couples second end 312 of a mandrel 300, and s the mandrel 300 is urged for rotation of the mandrel about its axis 314. Each clamping arm 450 is pivotally supported on the rotating clamping arm holder 410 to allow rotation of the clamping arm 450 about a pivot shaft 451 from from a first cupped position, wherein the chuck cup 454 couples a mandrel 300, to a second uncovered position, wherein the chuck cup 454 is decoupled from the mandrel 300. The first cupped position and the second cupped position are shown in Figure 9. Each grr arm 450 is supported on the swivel grr arm holder in a path about the central axis of turret assembly 202, wherein the distance between the grr arm pivot shaft 451 and the shaft The turret assembly hub 202 varies as a function of the position of the pick-up arm 450 about the axis 202. Accordingly, each cup arm The associated mandrel cup and cup 454 may travel the second end 312 of its respective mandrel 300, as the mandrel is carried around the closed mandrel path 320 through the rotating turret assembly 200. The rotating cup arm holder 410 comprises a support arm support hub 420, which is rotatably supported on the support 120 adjacent to the end of the straight frame 134 through bearings 221. The portions of the assembly are shown cut in Figures 2 and 9 for clarity. A servo motor 422 mounted on or adjacent to the straight frame end 134 supplies the torque to the hub 420 through a band or chain 424 and a pulley or sprocket 426 to releasably drive the hub 420 about the central axis of assembly. of turret 202. The servo motor 422 is controlled to form phase with the rotational position of the pick-up arm holder 410 with respect to a reference that is a function of the angular position of the roll of the table 59 about its axis of rotation, and a function of an accumulated number of revolutions of the table roll 59. In particular, the position of the support 410 can be formed in phase with respect to the position of the table roll 59 within a cycle of cycle winding, thus synchronizing the rotation of the cup arm support 410 with the rotation of the turret assembly 200. The servo motors 222 and 422 are equipped with a brake. The brakes prevent relative rotation of the turret assembly 200 and the grip arm bracket 410, when the winder apparatus 90 is not working, thus preventing the twisting of the mandrels 300. The rotating cup bracket 410 further comprises a plate Rotation arm support bracket 430 rigidly attached to hub 420 and extending generally perpendicular to central axis of turret assembly 202. Turntable 430 is rotatably driven about shaft 202 on hub 420. A plurality of support members of clamping arm 460 are supported on the rotation plate 430 for relative movement to the rotation plate 430. Each clamping arm 450 is pivotally attached to a clamping arm support member 460 to allow rotation of the clamping arm 450 about the pivot shaft 451. Referring to Figures 10 and 11, each arm support member 460 is slidably supported on a portion of the plate 430, such as a bracket 432 screwed to the rotation plate 430, for relative translation to the rotation plate 430 along a path having a radial component and a tangential component relative to the central axis of turret assembly 202. In one embodiment, the sliding abutment arm support member 460 can be slidably supported on a bracket 432 through a plurality of linear bearing and track rail assemblies 358 and 359, commercially available. A slider 358 and a rail 359 can be fixed (such as by screwing) to each of the bracket 432 and the support member 460, so that a slider 358 fixed to the bracket 432 slidably couples a fixed rail 359 to the support member 460 , and a slider 358 fixed to the support member 460 slidably engages a rail 359 fixed to the bracket 432. The chuck attachment assembly 400 further comprises a pivot shaft positioning guide for positioning the arm pivot shafts 451 The pivot shaft positioning guide positions the cup arm pivot shafts 415 to vary the distance between each pivot shaft 451 and the shaft 202 as a function of the position of the cup arm 450 about the shaft 202. In the embodiment shown in Figures 2 and 9-12, the pivot shaft positioning guide comprises a fixed pivot shaft positioning guide plate 442. The pivot shaft positioning guide plate 442 extends from generally perpendicular to the shaft 202 and positioned adjacent the rotating cup arm support plate 430 along the axis 202. The positioning plate 442 can be rigidly attached to the support 120, so that the arm support plate of rotating cup 430 rotates relative to the positioning plate 442. The positioning plate 442 has a surface 444 facing the rotating support plate 430. A cam surface, such as a cam surface groove 443 is disposed in the surface 444 for facing the rotating support plate 430. Each sliding support arm support member 460 has an associated cam follower 462, which engages cam surface slot 443. Cam follower 462 follows slot 443 as the turntable 430 brings the support member 460 about the axis 202, and thus places the cocking shaft 451 relative to the shaft 202. The slot 443 can be configured to the groove shape 143 and 145, so that each clamping arm and each associated mandrel cup 454 can travel the second end 312 of their respective mandrel 300, as the mandrel is carried around the closed mandrel path 320 through the rotary mandrel holder 200. In one embodiment, the slot 443 may have the same shape as that of the slot 145 in the mandrel guide plate. 144 along the portion of the closed mandrel path, where the mandrel ends 312 are capped. The slot 443 may have a circular arc shape (or other suitable shape) along that portion of the closed mandrel path, where the mandrel ends 312 are not cocked.

By way of illustration, Tables 3A and 3B, together, list the coordinates for a slot 443, which is suitable for use with the cam follower slots 143A and 143B having coordinates listed in Tables 1A and 1B. Similarly , Tables 3A and 3C, together, list the coordinates for a slot 443, which is similar for use with the cam follower slots 143A and 143C having the coordinates listed in Tables 1A and 1C. Each pick-up arm 450 comprises a plurality of cam followers supported on the pick-up arm and pivotable about the pick-up arm pivot shaft 451. The cam followers supported on the pick-up arm couple the fixed cam surfaces to provide the rotation of the cup arm 450 between the cocked and uncovered positions. Referring to Figures 9-12, each clamp arm 450 comprises a first clamp arm extension 454 and a second clamp arm extension 455. The clamp arm extensions 453 and 455 extend generally perpendicular to each other from their clamping arm extensions 453 and 455. neighboring ends on the cup arm pivot shaft 451 at their distal ends. The cup arm 450 has a fork construction for attachment to the support member 460 at the location of the pivot shaft 451. The cup arm extensions 453 and 455 rotate as a rigid body about the pivot shaft 451. The cup of mandrel 454 is supported on the distal end of extension 453. At least one cam follower is supported on extension 453, and at least one cam follower is supported on extension 455. In the embodiment shown in the Figures 10-12, a pair of cylindrical cam followers 474A and 474B are supported on the intermediate extension 453 to the pivot shaft 451 and the chuck cup 454. The cam followers 474A and 474B are pivotable about the pivot shaft 451 with the extension 453. Cam followers 474A, B, are supported on extension 453 to rotate around axes 475A and 475B, which are parallel to each other. The axes 475A and 475B are parallel to the direction along which the cup arm support member 460 slides relative to the rotating cup arm support plate 430, when the cup cup is in the cupped position (Upper cup arm in Figure 9). The axes 475A and 475B are parallel to axis 202 when the mandrel cup is in the uncovered position (lower cup arm in Figure 9). Each clamp arm 450 also comprises a third cylindrical cam follower 476 supported on the distal end of the clamp arm extension 455. The cam follower 476 is pivotable about the pivot shaft 451 with extension 455. The third follower cam 476 is supported on the extension 455 to rotate about an axis 477, which is perpendicular to the axes 475A and 475B around which the followers 474A and B rotate. The axis 477 is parallel to the direction along the which the cup arm support member 460 slides relative to the rotating cup arm support plate 430, when the cup cup is in the uncovered position, and the shaft 477 is parallel to the shaft 202 when the cup mandrel is in the cupped position. The chuck chuck assembly 400 further comprises a plurality of cam follower members having follower surfaces. Each cam follower surface is engageable by one of the cam followers 474A, 474B and 476 to provide rotation of the cup arm 450 about the cup arm pivot axis 451 between the cupped and non-cupped positions, and to keep the cup arm 450 in the cocked and uncovered positions. Figure 13 is a somatic view showing four of the cocking arms 450A-D. The cup arm 450A is shown pivoting from a non-cupped position to a cupped; the holding arm 450B is in the cocked position; the cup arm 450C is shown pivoting from the cupped position to a non-cupped position; and the take-up arm 450D is shown in an uncovered position. Figure 13 shows the cam follower members, which provide the pivoting of the coupling arms 450 as the cam follower 462 on the cup arm support member 460 traverses the slot 443 in the positioning plate 442 The rotating support plate 430 is omitted from figure 13 for clarity. Referring to Figures 9 and 13, the chuck chuck assembly 400 can comprise an opening cam member 482 having an opening cam surface 483, a support opening cam member 484 having a cam surface of support opening 485 (Figure 9), a closing cam member 486 comprising a closing cam surface 487, and a closed support cam member 488 comprising a closed support cam surface 489. The cam surfaces 485 and 489 can be generally flat, parallel surfaces, which extend perpendicular to the axis 202. the surfaces 483 and 487 are generally three-dimensional cam surfaces. The cam members 482, 484, 486 and 488 are preferably fixed, and can be supported (supports not shown) on any rigid base including, but not limited to a frame 110. As the turntable 430 carries the cocking arms 450 around the shaft 202, the cam follower 474A couples the three-dimensional aperture cam surface 483 before the core separation segment 326, thereby rotating the gripper arms 450 (e.g., the gripper arm 450C in Figure 13 ) from the cocked position to the uncovered position so that the weft wound in the core can be separated from the mandrels 300 by the core separation apparatus 2000. The cam follower 476 on the rotating coaming arm 450 (e.g. , the clamping arm 450D in Figure 13) then engages the camming surface 485 to keep the clamping arm in the position not engaging until the empty core 302 can be loaded on the mandrel 300 along the segment 322 through the core loading apparatus 1000. Upstream of the weft winding segment 324, the cam follower 474A on the pick-up arm (e.g., the pick-up arm 450A in FIG. 13) engages the closing cam surface 487 to rotate the gripper arm 450 from the unbalanced position to the cupped position. The cam followers 474A and 474B on the pick-up arm (for example, the pick-up arm 450B in Figure 13) then engage the cam surface 489 to keep the pick-up arm 450 in the cupped position during the winding of the screen . The cam and cam surface follower arrangement shown in FIGS. 9 and 13 provides the advantage that the clamp arm 450 can be rotated to the cocked and uncovered positions as the radial position of the arm pivot shaft of clamp 451 moves relative to shaft 202. A typical barrel cam arrangement for clamping and non-clamping mandrels, as shown on page 1 of PCMC Manual Number 01-12-ST003, and page 3 of PCMC Manual Number 01-013-ST0011 for the PCMC 150 series turret winder, requires a joining system for coupling and non-coupling the mandrels, and does not adapt the coupling arms that have a pivot axis whose distance from an axis of turret 202 is variable.

Core Drive Roller Assembly and Mandrel Assist Assemblies Referring to FIGS. 1 and 15-19, the weft winding apparatus according to the present invention includes a core drive apparatus 500, and a mandrel load assist assembly 600, and a cup assist assembly. mandrel 700. The core drive apparatus 500 is positioned to drive cores 302 on the mandrels 300. The mandrel support assemblies 600 and 700 are positioned to support and position the uncoiled mandrels 300 during core loading and coping of mandril. Turret winders having a single core roller for driving a core on a mandrel, while the turret is fixed, are well known in the art. Said arrangements provide a line of contact between the mandrel and the individual drive roller to drive the core on the fixed mandrel. The drive apparatus 500 of the present invention comprises a pair of core drive rolls 505.

The core drive rolls 505 are disposed on opposite sides of the core load segment 322 of the closed mandrel path 320 along a generally straight line portion of the segment 322. One of the core drive rolls, roller 505A, is disposed outside the closed mandrel path 320, and the other of the core drive rollers, 505B, is disposed within the closed mandrel path 320, so that the mandrels are brought intermediate to the drive rollers. of core, 505A and 505B. The core drive rolls 505 cooperate to couple a core driven at least partially on the mandrel 300 through the core loading apparatus 1000. The core drive rolls 505 complete the driving of the core 302 on the mandrel 300.

The core drive rolls 505 are supported to rotate about parallel axes, and are rotationally driven through servo motors through belt and pulley arrangements. The core drive roller 505A and servo motor 510 are supported from a frame extension 515. The core drive roller 505B and its associated servo motor 511 (shown in Figure 17) are supported from an extension of the support 120. The core drive rollers 505 can be supported to rotate about the axes that are inclined with respect to the mandrel shafts 314 and the core load segment 322 of the mandrel path 320. Referring to Figures 16 and 17, the core drive rollers 505 are tilted to drive a core 302 with the velocity component generally parallel to a mandrel axis and a velocity component generally parallel to at least a portion of the core load segment . For example, the core drive roller 505A is supported to rotate around the shaft 615, which is inclined with respect to the mandrel shafts 314 and the core load segment 322, as shown in FIGS. 15 and 16. Accordingly, the core drive rollers 505 can drive the core 302 on the mandrel 300 during the movement of the mandrel along the core load segment 322. Referring to FIGS. 16 and 16, the mandrel support assembly 600 is supported outside of the closed mandrel path 320 and is positioned to support the uncovered mandrels 300 intermediate to the first and second mandrel ends 310 and 312. The mandrel support assembly 600 is not shown in FIG. 1. mandrel support assembly 600 comprises a rotatably driven mandrel support 610 positioned to support an uncoiled mandrel 300 along at least a portion of the core load segment 322 of the closed mandrel path 320. The mandrel holder 610 stabilizes the mandrel 300 and reduces the vibration of the mandrel 300. The mandrel holder 610 thus aligns the mandrel 300 with the core 302 being driven onto the second end 312 of the mandrel from the core loading apparatus 1000. The mandrel support 610 is supported to rotate around the shaft 615, which is inclined with respect to the mandrel shafts 314 and the core loading segment 322. The mandrel support 610 comprises a generally helical mandrel support surface 620. The mandrel support surface 620 has a variable pitch measured parallel to the axis 615, and a variable radius perpendicular to the axis 615. The pitch and radius of the surface Helical support 620 varies to support the mandrel along the closed mandrel path. In one embodiment, the pitch can be increased as the radius of the helical support surface 620 is reduced. Conventional mandrel brackets used in conventional index turret assemblies support mandrels, which are fixed during core loading. The variable pitch and radius of the support surface 620 allows the support surface 620 to contact and support a moving mandrel 300 along the non-linear path. since the mandrel bracket 610 is supported to rotate about the shaft 615, the mandrel bracket 610 can be driven from the same motor used to drive the core drive roller 505A. In Figure 16, the mandrel bracket 610 is rotatably driven through the drive train 630 through the same servo motor 510, which rotationally drives the core drive roller 505A. An arrow 530 driven by the engine 510 is attached to and extends through the roller 505A. The mandrel bracket 610 is rotatably supported on the arrow 530 through bearings 540 so as not to be driven by the arrow 530. The arrow 530 extends through the mandrel bracket 610 towards the drive train 630. The train 630 includes the pulley 634 driven through a pulley 632 through the web 631, and a pulley 638 driven through the pulley 636 through the web 633. The diameters of the pulleys 632, 634, 636 and 638 are selected to reduce the rotational speed of the mandrel support 610 approximately half that of the core drive roller 505A. The servo motor 510 is controlled to the phase formation of the rotational position of the mandrel holder 610 with respect to a reference that is a function of the angular position of the table roll 59 about its axis of rotation, and a function of an accumulated number of revolutions of the roll of the table 59. In particular, the rotational position of the support 610 can make in phase with respect to the position of the roll of the table 50 within a cycle of piece winding, thus synchronizing the position rotational of the support 160 with the rotational position of the turret assembly 200.

Referring to Figures 17-19, the chuck chuck assist assembly 700 is supported within the closed mandrel path 320 and is positioned to support the uncoiled mandrels 300 and align the chuck ends 312 with the chuck cups. 454 as the mandrels are abutting. The chuck chuck assist assembly 700 comprises a rotatably driven chuck support 710. The rotatably driven chuck support 710 is positioned to support a non-cocked mandrel 300 intermediate the first and second ends 310 and 312 of the chuck. The mandrel support 710 supports the mandrel 300 along at least a portion of a closed mandrel path intermediate the core loading segment 322 and the weft retractor segment 324 of the closed mandrel path 320. The rotationally driven mandrel 710 can be driven through a servo motor 711. The mandrel chuck assist assembly 700, including the mandrel support 710 and the servo motor 71 1, can be supported from the horizontally fixed support in extension 120, as it is shown in figures 17-19.

The rotatably driven mandrel support 710 has a generally helical mandrel surface 720 having a variable radius and a variable pitch. The surface of support 720 engages mandrels 300 and positions them for attachment by mandrel cups 454. The rotatably driven mandrel support 710 is rotatably supported on a pivot arm 730 having a first fork end 732 and a second end 734. The support 710 is supported for rotation about a horizontal axis 715 adjacent to the first end 732 of the arm 730. The pivot arm 730 is pivotally supported at its second end 734 to rotate about a fixed horizontal axis 717 separated from the axis 715. The The position of the shaft 715 moves in an arc as the pivot arm 730 pivots about the axis 717. The pivot arm 730 includes a cam follower 731 extending from a surface of the intermediate pivot arm to the first and second ends 732 and 734. A rotating cam plate 740 having an eccentric cam surface groove 741 is rotatably driven about a fixed horizontal axis 741. 42. Cam follower 731 engages cam surface groove 741 on rotating cam plate 740, thereby periodically pivoting the arm 730 about the axis 717. The pivoting of the arm 730 and the rotatable support 710 about the axis 717 causes the mandrel support surface 720 of the rotational support 710 to periodically couple a mandrel 300 as the mandrel is carried along a predetermined portion of the closed mandrel path 320. The mandrel support surface 720 thus places the second unsupported end 312 of the mandrel 300 for engagement. The rotation of the mandrel support 710 and the rotating cam plate 740 is provided by the servo motor 711. The servo motor 711 drives a band 752 around a pulley 754, which is connected to a pulley 756 through an arrow 755 The pulley 756, in turn, drives the serpentine band 757 around the pulleys 762, 764 and the tension pulley 766. The rotation of the pulley 762 drives the continuous rotation of the cam plate 740. The rotation of the The pulley 764 drives the rotation of the mandrel support 710 about its axis 715. Since the rotating cam plate 740 shown in the Figures has a cam surface groove, in an alternative embodiment, the rotating cam plate 740 may have a outer cam surface to provide pivoting of arm 730. In the embodiment shown, servo motor 711 provides rotation of cam plate 740, thereby providing periodic pivoting of mandrel support 710 about axis 717. Servo motor 711 It is co controlled to form phase with the rotation of the mandrel support 710 and the periodic pivoting of the mandrel support 710 with respect to a reference that is a function of an angular position of the table roller 59 about its axis of rotation, and a function of an accumulated number of revolutions of the table roll 59. In particular, the pivoting of the mandrel support 710 and the rotation of the mandrel support 710 can be made in phase with respect to the position of the table roll 59 within one cycle of piece winding. The rotational position of the mandrel bracket 710 and the pivot position of the mandrel bracket 710 can thus be synchronized with the rotation of the turret assembly 200. Alternatively, one of the servo motors 22 or 422 can be used to drive the rotation of I 740 cam plate through a timing chain or other suitable gear coupling. In the embodiment shown, the coil band 757 drives both the rotation of the cam plate 740 and the rotation of the mandrel support 710 about its axis 715. In still another embodiment, the coil band 757 can be replaced by two bands. separated. For example, a first band can provide rotation of cam plate 740, and a second band can provide rotation of mandrel support 710 about its axis 715. The second band can be driven through the first band through of a pulley arrangement, or alternatively, each band can be driven by the servo motor 722 through separate pulley arrangements. Once the mandrel 30 is coupled through a mandrel cup 454, the mandrel is carried along the closed mandrel path to the weft winding segment 324. Intermediate to the core load segment 322 and the segment of weft winding 324, an adhesive application apparatus 800 applies to the core 302 supported on the moving mandrel 300. The adhesive application apparatus 800 comprises a plurality of adhesive application nozzles 810 on the adhesive nozzle holder 820 Each nozzle 810 is in communication with a pressurized source of liquid adhesive (not shown) through a supply conduit 812.

The adhesive nozzles have a check valve ball tip, which releases an adhesive effluent from the tip when the tip engages a surface with compression, such as the surface of a core 302. The adhesive nozzle holder 820 is pivotally supported at the ends of a pair of support arms 825. The support arms 825 extend from a frame transverse member 133. The transverse member 133 extends horizontally between the straight frame members 132 and 134. The nozzle holder of adhesive 820 is pivotable about an axis 828 through an actuator assembly 840. Shaft 828 is parallel to the central axis of turret assembly 202. Adhesive nozzle holder 820 has an arm 830 that bears a follow by cylindrical cam . The driven assembly 840 for pivoting the adhesive nozzle holder comprises a continuously rotating disc 842 and a servo motor 822, both of which can be supported on the frame transverse member 133. The cam follower carried on the arm 830 couples a groove of cam follower surface 844 disposed in the continuously rotating disk 842 of actuator assembly 840. Disk 842 is continuously rotated by servo motor 822. Actuator assembly 840 provides periodic pivoting of adhesive nozzle holder 820 around the axis 828 so that the adhesive nozzles 810 traverse the movement of each mandrel 300 as the mandrel 300 moves along the closed mandrel path 320. Accordingly, the adhesive can be applied to the cores 302 on the mandrels 300 without stopping movement of the mandrels 300 along the closed path 320. Each mandrel 300 is rotated around d and its shaft 314 through a core rotation assembly 860 as the nozzles 810 couple the core 302, thereby providing distribution of the adhesive around the core 302. The core rotation assembly 860 comprises a servo motor 862, the which provides the continuous movement of two mandrel rotation bands 834A and 834B. Referring to Figures 4, 20A and 20B, the core rotation assembly 860 can be supported on an extension 133A of the frame transverse member 133. The servo motor 862 continuously drives a band 864 around the pulleys 865 and 867. Pulley 867 drives the pulleys 836A and 836B, which in turn drive the driving belts 834A and 834B, respectively, the belts 834A and 834B engage the mandrel drive pulleys 338 and rotate the mandrels 300 as the mandrels 300 move along the closed mandrel path 320 behind the adhesive nozzles 810. Accordingly, each mandrel and its associated core 302 are moved along the closed mandrel path 320 and rotating around the axis of the mandrel. mandrel 314 as the core 302 couples the adhesive nozzles 810. The servo motor 822 is controlled to phase the periodic pivoting of the adhesive nozzle holder 820 with respect to a reference which is a function of the angular position of the table roll 59 about its axis of rotation, and a function of an accumulated number of revolutions of the table roll 59. In particular, the pivot position of the nozzle holder 820 can do phase with respect to the position of the table roll 59 within the piece winding cycle. The periodic pivoting of the adhesive nozzle holder 820 is thus synchronized with the rotation of the turret assembly 200. The pivoting of the adhesive nozzle holder 820 is synchronized with the rotation of the turret assembly 200, so that the nozzle holder adhesive 820 is pivoted about shaft 828 as each mandrel passes below adhesive nozzles 810. Adhesive nozzles 810 thus traverse the movement of each mandrel along a portion of the closed mandrel path 320 Alternately, the rotation cam plate 844 can be driven indirectly by one of the servo motors 222 or 422 through a time control chain or other suitable gear arrangement. In another embodiment, the adhesive can be applied to the moving cores through a rotating rotogravure roller positioned within the closed mandrel path. The rotogravure roller can be rotated about its axis, so that its surface is periodically submerged in a bath of the adhesive, and a razor can be used to control the thickness of the adhesive on the surface of the rotogravure roller. The axis of rotation of the rotogravure roll may be generally parallel to the axis 202. The closed mandrel path 320 may include a circular arc segment intermediate the core load segment 322 and the frame winding segment 324. The arc segment The circular of the closed mandrel path may be concentric with the surface of the rotogravure roller, so that the mandrels 300 carry their associated cores 302 to be in rolling contact with an arcuate portion of the adhesive coated surface of the rotogravure roller. The adhesive-coated cores 302 could then be brought from the surface of the rotogravure roller to the weft winding segment 324 of the closed mandrel path. Alternatively, a deviated engraving arrangement may be provided. The deviated engraving arrangement may include a first pickup roller at least partially submerged in an adhesive bath, and one or more transfer rolls for transferring the adhesive from the pickup roller to the cores 302. The core loading apparatus 1000 for transporting cores 302 on mandrels in motion 300 is shown in Figures 1 and 21-23. The core loading apparatus comprises a core hopper 1010, a core charge carousel 1100, and a core guide assembly 1500 disposed intermediate the turret winder 100 and the core load carousel 1100. Figure 21 is a perspective view of the rear part of the core charging apparatus 1000. FIG. 21 also shows a portion of the core separation apparatus 2000. FIG. 22 is an end view of the core loading apparatus 1000 shown partially cut and viewed parallel to the central axis of turret assembly 202. Figure 23 is an end view of the core guide assembly 1500 shown partially cut away. Referring to Figures 1 and 21-23, the core load carousel 1100 comprises a fixed frame 1 110. The fixed frame can include vertically straight frame ends 1132 and 1134, and a frame transverse support 1136 extending horizontally intermediate to the frame. the frame ends 1132 and 1 134. Alternatively, the core charge carousel 1100 may be supported at one end in a cantilever shape. In one embodiment shown, an endless belt 1200 is driven around a plurality of pulleys 1202 adjacent the frame end 1132. Likewise, an endless band 1210 is driven around a plurality of pulleys 1212 adjacent the frame end 1134. bands are driven around their respective pulleys through a servo motor 1222. A plurality of support rods 1230 pivotally connect core trays 1240 to the pieces 1232 attached to the bands 1200 and 1210. In one embodiment, a support beam 1230 it may extend from each end of a core tray 1240. In an alternative embodiment, the support bars 1230 may extend in a parallel cross-member shape between the pieces 1232 attached to the bands. 1200 and 1210, and each core tray 1240 can be hung from one of the support bars 1230. The trays 1240 extend intermediate to the endless bands 1200 and 1210, and are carried in a closed-core tray path 1241 to through the endless bands 1200 and 1210. The servo motor 1222 is controlled to the phase formation of the movement of the core trays with respect to a reference which is a function of the angular position of the table roll 59 around its axis of rotation, and a function of an accumulated number of revolutions of the table roll 59. In particular, the position of the core trays can be made in phase with respect to the position of the table roll 59 within a cycle of piece winding, thus synchronizing the movement of the core trays with rotation of the turret assembly 200.

The core hopper 1010 is supported vertically above the core carousel 1100 and supports a supply of cores 302. The cores 302 in the hopper 1010 are fed by gravity to a plurality of slotted rotation wheels 1020 positioned above the path of closed core tray. Slotted wheels 1020, which can be rotatably driven by servo motor 1222, provide a core 302 to each core tray 1240, which is used in place of slotted wheels 1020 to supply a core to each core tray 1240. Alternatively , you can use a band with ears instead of grooved wheels to pick up a core and place a core on each core tray. A core tray support surface 1250 (FIG. 22) places the core trays to receive a core of the slotted wheels 1020 as the core tray passes behind the slotted wheels 1020. The cores 302 supported on the trays core 1240 are carried around the closed-core tray path 1241. Referring to Fig. 22, the core 302 is carried on the trays 1240 along at least a portion of the closed tray path 1241, the which is aligned with the core load segment 322 of the closed mandrel path 320. A core load conveyor 1399 is positioned adjacent the portion of the closed tray path 1241, which is aligned with the load segment of the core. core 322. The core load conveyor 1300 comprises an endless band 1310 propelled around the pulleys 1312 through a servo motor 1322. The endless belt 13 10 has a plurality of flight elements 1314 for coupling the cores 302 held in the trays 1240. The flight element 1314 couples a core 302 held in the tray 1240 and pushes the core 302 at least part of the way away from the core. tray 1240, so that the core 302 at least partially engages a mandrel 300. The flight elements 1314 need not push the core 302 completely out of the tray 1240 and onto the mandrel 300, but only sufficiently so that the core 302 is coupled by the core drive rolls 505. The endless band 1310 is inclined so that the elements 1314 couple the cores 302 in the core trays 1240 with a speed component generally parallel to a mandrel shaft and a component of speed generally parallel to at least a portion of the core load segment 322 of the closed mandrel path 320. In the embodiment shown, the patent core cores 1240 carry the cores 302 vertically, and the flight elements 1314 of the core charge hauler 1300 couple the cores with a vertical velocity component and a horizontal velocity component. The servo motor 1322 is controlled to form phase to the position of the flight elements 1314 with respect to a reference which is a function of angular position of the table roll 59 about its axis of rotation, and a function of an accumulated number of revolutions of the roll of the table 59. In particular, the position of the flight elements 1314 can form phase with respect to the position of the table roll 59 within a cycle of piece winding . The movement of the molding elements 1314 can thus be synchronized with the position of the core trays 1240 and with the rotational position of the turret assembly 200. The core guide assembly 1500, disposed intermediate to the core loading carousel 1100 and the turret winder 100, comprises a plurality of core guides 1510. the core guides place the cores 302 with respect to the second ends 312 of the mandrel 300 as the cores 302 are driven from the core trays 1240 through the core load conveyor 1300. The core guides 1510 are supported on conveyors of endless belt 1512 driven around the pulleys 1514. The belt conveyors 1512 are driven by the servo motor 1222, through an arrow and coupling arrangement (not shown). The core guides 1510 thus maintain a register with the core trays 1240. The core guides 1510 extend in a parallel cross-member shape to the belt conveyors 1512, and are carried around a closed-core guide path 1541 by conveyors 1512. At least a portion of the closed core guide path 1541 is aligned with a portion of the closed core tray path 1241 and a portion of the core load segment 322 of the closed mandrel path 320 Each core guide 1510 comprises a core guide channel 1550, which extends from a first end of the core guide 1510 adjacent the core charge carousel 1100 to a second end of the core guide 1510 adjacent to the core guide 1510. torelet winder 100. The core guide channel 1550 converges as it extends from the first end of the core guide 1510 to the sec end of the core guide. The convergence of the core guide channel 1550 helps center the cores 302 with respect to the second ends 312 of the mandrels 300. In Figure 1, the core guide channels 1550 at the first ends of the adjacent core guides 1510 the core charge carousel are flexed to accommodate some misalignment of the cores 302 pushed from the core trays 1240.

Core Separation Apparatus Figures 1, 24 and 25A-C illustrate the core separation apparatus 2000 for removing the pieces 51 from the uncoiled mandrels 300. The core separation apparatus 2000 comprises an endless conveyor belt 2010 and a Servo drive motor 2022 supported on a frame 2002. The conveyor belt 2010 is positioned vertically below the closed mandrel path adjacent to the core separation segment 326. The endless conveyor belt 2010 is continuously driven around the pulleys 2012 to through a drive belt 2034 and a servo motor 2022. The conveyor belt 2010 carries a plurality of 2014 flights spaced at equal intervals on the conveyor belt 2010 (two flights 2014 in Figure 24). The 2014 flights move with a linear speed V (figure 25A). Each flight 2014 couples the end of a piece 51 onto a mandrel 300 as the mandrel moves along the core separation segment 326. The servo motor 2022 is controlled to phase form with respect to the position of the flights 2014 with respect to a reference which is a function of the angular position of the roll of the table 59 about its axis of rotation, and a function of an accumulated number of revolutions of the table roll. In particular, the position of the flights 204 can be formed in phase with respect to the position of the roll of the table 59 within a cycle of piece winding. Accordingly, the movement of the flights 2014 can be synchronized with the rotation of the turret assembly 200. The conveyor belt in flight 2010 is angled with respect to mandrel shafts 314 as the mandrels 300 are carried along a portion in a straight line of the core separation segment 326 of the closed mandrel path. For a given mandrel speed along the core separation segment 326 and a given conveyor flight speed V, the included angle A between the conveyor 2010 and the mandrel shafts 314 is selected such that the 2014 flights dock each piece 51 with a first speed component V1 generally parallel to the mandrel shaft 314 for pushing the mandrel pieces 300, and a second velocity component V2 generally parallel to the straight line portion of the core separation segment 326. In one embodiment, the angle A may be about 4-7 degrees. As shown in Figures 25A-C, the 2014 flights are angled with respect to the conveyor belt 2010 to have a piece coupling face, which forms an included angle equal to A with the centerline of the 2010 band. The coupling face and angled piece of the flight 2014 is generally perpendicular to the mandrel shafts 314 so as to squarely couple the ends of the pieces 51. Once the piece 51 is separated from the mandrel 300, the mandrel 300 is brought to the length of the closed mandrel path towards the core load segment to receive another core 302. In some cases, it may be desirable to separate an empty core 302 from a mandrel. For example, it may be desirable to separate an empty core 302 from a mandrel during the start of the turret winder, or if no weft material is wound on the particular core 302. Therefore, the 2014 flights may each have a tip of deformable rubber 2015 for slidably engaging the mandrel as the weft wound core is pushed from the mandrel. Accordingly, the 2014 flights contact both the core 302 and the frame wound on the core 302, and have the ability to separate the empty cores (i.e., the core on which no frame is wound) of the mandrels .

Shred Rejection Apparatus Figure 21 illustrates a scrap reject apparatus 4000 placed downstream of the core separation apparatus 2000 to receive chunks 51 of the core separation apparatus 2000. A pair of drive rolls 2098A and 2098B couple the chunks 51 protruding from the mandrels 300, and urging the pieces 51 towards the piece reject apparatus 4000. The piece reject apparatus 4000 includes a servo motor 4022 and a selectively rotatable reject element 4030 supported on a frame 4010. the rotatable reject member 4030 supports a first group of piece engaging arms 4035A and a second group of piece engaging arms 4035B (three arms 4035A and three arms 4035B shown in Figure 21). During normal operation, the pieces 51 received by the piece rejecting apparatus 4000 are carried by the continuously driven rollers 4050 towards a first acceptance station, such as a storage tank or other suitable storage container. The rollers 4050 can be driven by the servo motor 2022 through a gear train or pulley arrangement to have a surface velocity at a fixed percentage higher than that of the 2014 flights. The rollers 4050 can thus engage the pieces 51 , and carry the pieces 51 at a higher speed than the one at which the pieces are driven by the 2014 flights.

In some cases, it is desirable to direct one or more pieces 51 toward a second reject station, such as a waste tank or recirculation tank. For example, one or more defective pieces 51 may be produced during the start of the weft winding apparatus 90, or alternatively, a piece defect detection device may be used to detect defective pieces 51 at any time during operation of the apparatus. 90. Servo motor 4022 can be controlled manually or automatically to intermittently rotate element 4030 in increments of approximately 180 degrees. Each time that the element 4030 is rotated 180 degrees, one of the groups of piece engaging arms 4035A or 4035B couples the piece 51 supported on the rolls 4050 at that instant. The piece is lifted from the rolls 4050, and directed to the reject station. At the end of the increment rotation of element 4030, the other group of arms 4035A or 4035B is in place to engage the next defective piece.

Description of the Mandrel Figure 26 is a partial cross-sectional view of a mandrel 300 according to the present invention. The mandrel 300 extends from the first end 310 towards the second end 312 along the mandrel longitudinal axis 314. Each mandrel includes a mandrel body 3000, a deformable core coupling member 3100 supported on the mandrel 300, and a mandrel nose piece 3200 disposed at the second end 312 of the mandrel. The mandrel body 3000 may include a steel tube 3010, an end piece of steel 3040, and a non-metallic composite mandrel tube 3030 extending intermediate the steel tube 3010 and the steel end piece 3040. At least a portion of the member 3100 is deformable from the first shape to a second form for coupling the inner surface of a hollow core 302 after the core 302 is placed on the mandrel 300 through the core shroud apparatus 1000. The The mandrel nose 3200 can be slidably supported on the mandrel 300, and is movable relative to the mandrel body 3000 to deform the deformable core coupling member 3100 from the first shape to the second shape. The mandrel nose piece is displaceable relative to the mandrel body 3000 through a cup 454. The deformable core coupling member 3100 may comprise one or more elastically deformable polymer rings 3110 (FIG. 30) radially supported on the nose piece. nose 3040. By "elastically deformable" it is meant that the member 3100 is deformed from the first shape to the second form under a load, and that after releasing the load member 3100 substantially returns to the first form. The mandrel nose piece can be displaced relative to the nose piece 3040 to compress the rings 3110, thereby causing the rings 3100 to be elastically wound in the radially outward direction to couple the inner diameter of the core 302. Figure 27 illustrates the deformation of the deformable core coupling member 3100. Figures 28 and 29 are enlarged views of a portion of the nose piece 3200 showing the movement of the nose piece 3200 relative to the nose piece of steel 3040. Referring to the components of the mandrel 300 in more detail, the first and second bearing housings 352 and 354 have bearings 352A and 354A to rotatably support the steel tube 3010 about the mandrel shaft 314. The mandrel drive pulley 338 and the Tension pulley 339 are placed on the steel tube 3010 intermediate the bearing housings 352 and 354. The mandrel drive pulley 338 is fixed to the steel tube 3010, and the tension pulley 339 can be rotatably supported on an extension of the bearing housing 352 by the tension pulley bearings 339A, so that the tension pulley 339 freewheels relative to the steel ring 3010. Steel tube 3010 includes a shoulder 3020 for coupling the end of a core 302 driven on the mandrel 300. The shoulder 3020 preferably has the shape of a truncated cone, as shown in Figure 26, and may have a textured surface for restricting the rotation of the core 302 relative to the mandrel body 3000. The surface of the truncated-shaped shoulder 3020 may be textured through a plurality of grooves 3022 axially and radially in extension. The ridges 3022 can be uniformly spaced around the circumference of the shoulder 3020. The flutes can be tapered as they extend axially from left to right in Figure 26, and each flute 3022 can have a generally triangular cross section at a given location along its length, with a relatively wide base junction to the shoulder 3020 and a relatively narrow apex for coupling the ends of the cores. The steel tube 3010 has a reduced diameter end 3012 (FIG. 26), which extends from the shoulder 3020. The composite mandrel tube 2030 extends from a first end 3032 to a second end 3034. The first end 3032 extends over the reduced diameter end 3012 of the steel tube 30101. The first end 3032 of the composite mandrel tube 3030 is attached to the reduced diameter end 3012, such as by bonding with adhesive. The composite mandrel tube 3030 may comprise a carbon composite construction. Referring to Figures 26 and 30, a second end 3034 of the composite mandrel tube 3030 is attached to the steel end piece 3040. The end piece 3040 has a first end 3042 and a second end 3044. The first end 3042 of the end piece 3040 fits within, and is attached to second end 3034 of compound mandrel tube 3030. Deformable core coupling member 3100 is spaced along mandrel axis 314 intermediate shoulder 3020 and nose piece 3200 The deformable core coupling member 3100 may comprise an annular ring having an outer diameter of a portion of the nose piece 3040, and may be radially supported on the end piece 3040. The deformable core coupling member 3100 may extend axially between a shoulder 3041 on the end piece 3040 and a shoulder 3205 on the nose piece 3200, as shown in Fig. 30. The preferred member 3100 It has a substantial circumferentially continuous surface for radially coupling a core. A suitable continuous surface may be provided through a ring-shaped member 3100. A substantial circumferentially continuous surface for radially coupling a core provides the advantage that the forces which restrict the core to the mandrel are distributed., instead of concentrated. Concentrated forces, such as those provided by conventional core closure projections, can cause the core to break or puncture. By "substantially and circumferentially continuous" it is meant that the surface of the member 3100 couples the inner surface of the core about at least about 51%, preferably about at least 75%, and most preferably about about less about 90% of the circumferential core. The deformable core coupling member 3100 may comprise two elastically deformable rings 3110A and 3110B formed of urethane of 40 durometers "A", and three rings 3130, 3140 and 3150 formed of durometer urethane "D" 60 relatively harder. The rings 31 10A and 3110B each have a circumferentially continuous, non-rotated surface 3112 for coupling the core. The rings 3130 and 3140 may have Z-shaped cross sections for coupling shoulders 3041 and 3205, respectively. The ring 3150 may have a T-shaped cross section. The ring 3110A extends between and is attached to the rings 3130 and 3150. The ring 3110B extends between and is attached to the rings 3150 and 3140. The nose piece 3200 it is slidably supported on bushings 3300 to allow axial displacement of nose piece 3200 relative to end piece 3040. Suitable bushings 3300 comprise a base material LEMPCOLOY with a revetment of LEMPCOART 15. These bushings are manufactured by LEMPCO Industries of Cleveland, Ohio. When the nose piece 3200 is displaced along the axis 314 towards the end piece 3040, the deformable core coupling member 3100 is compressed between the shoulders 3041 and 3205, causing the rings 311 B to twist radially outwards, as it is shown in figure 30 in faded form.

The axial movement of the nose piece 3200 relative to the end piece 3040 is limited by a threaded fastener 3060, as shown in Figs. 28 and 29. The fastener 3060 has a head 3062 and a threaded rod 3064. The threaded rod 3064 extends through the axially extended hole 3245 in the nose piece 3200, and is threaded into a tapered hole 3045 in the second end 3044 of the end piece 3040. The head 3062 is enlarged relative to the diameter of the hole 3245, limiting thus the axial displacement of the nose piece 3200 relative to the end piece 3040. A coil spring 3070 is disposed intermediate the end 3044 of the end piece 3040 and the nose piece 3200 to divert the nose piece from the mandrel body mandrel . Once the core is loaded onto the mandrel 300, the mandrel coupling assembly provides the driving force to compress the rings 3110A and 311 B. As shown in FIG. 28, a mandrel cup 454 engages the nose piece 3200 , thus compressing the spring 3070 and causing the nose piece to slide axially along the mandrel shaft 314 towards the end 3044. This movement of the nose piece 3200 relative to the end piece 3040 compresses the rings 311 A and 311 B, causing them to deform radially outwardly to have the generally convex surfaces 3112 to engage a core on the mandrel. Once the winding of the weft on the core is complete and the chuck cup 454 is retracted, the spring 3070 pushes the nose piece 3200 axially away from the end piece 3040, thus returning the rings 3110A and 3110B to their shape original, generally cylindrical, not deformed. The core can then be removed through the core separation apparatus. The mandrel 300 also comprises a counter-rotation member for restricting the rotation of the mandrel nose piece 3200 about the shaft 314, relative to the mandrel body 3000. The anti-rotation member may comprise a group of screws 3800. The group screw 3800 is screwed into a tapered hole, which is perpendicular to and crosses the tapered hole 3045 at the end 3044 of the end piece 3040. The group of screws 3800 abuts against the threaded fastener 3060 to prevent the fastener 3060 from being released from the end piece 3040. The group of screws 3800 extends from the end piece 3040, and is received in an axially extended slot 3850 in the workpiece. of nose 3200. The axial sliding of the nose piece 3200 relative to the end piece 3040 is adapted by the elongate slot 3850, while the nose piece 3200 relative to the end piece 3040 prevents the engagement of the group of screws 3800 with the sides of the slot 3850. Alternatively, the deformable core coupling member 3100 may comprise a metal component, which elastically deforms in a radially outward direction, such as elastic twist, when compressed. For example, the deformable core coupling member 3100 may comprise one or more metal rings having circumferentially spaced and axially extended grooves. The circumferentially spaced portions of an intermediate ring to each pair of adjacent slots deform radially outwardly when the ring is compressed by the movement of the sliding nose piece during the cocking of the second end of the mandrel.

Servo Motor Control System The frame winding apparatus 90 may comprise a control system for phase form relative to the position of a number of independently driven components with respect to a common position reference, so that the position of one of the components can be synchronized with the position of one or more of the other components. By "independently driven" is meant that the positions of the components are not mechanically coupled, such as by mechanical gear trains, mechanical pulley arrangements, mechanical links, mechanical cam mechanisms, or other mechanical means. In one embodiment, the position of each of the independently driven components can be electronically formed in phase with respect to one or more of the other components, such as through the use of electronic gear ratios or electronic cams. In one embodiment, the positions of the independently driven components are made in phase with respect to a common reference that is a function of the angular position of the roller in the table 59 about its axis of rotation, and a function of an accumulator number of revolutions of the table roller 59. In particular, the positions of the independently driven components can be formed in phase with respect to the position of the table roll 59 within a cycle of piece winding. Each revolution of the table roll 59 corresponds to a fraction of a roll-up cycle. A piece winding cycle can be defined as 360 degree equalization increments. For example, if there are 64 sheets of 11% of inches on each piece of frame 51, and if the circumference of the table roll is of 45 inches, then four sheets will be wound by roll revolution on the table, and one cycle of piece will be completed (a piece 51 will be wound) for every 16 revolutions of the table roll. Accordingly, each revolution of the table roll 59 will correspond to 22.5 degrees of a 360 degree piece winding cycle. Independently driven components may include: the turret assembly 200 driven by the engine 222 (e.g., a 4 HP servo motor); the swivel chuck chuck arm bracket 410 driven by the engine 422 (e.g., a 4 HP servo motor); the roller 505A and a mandrel support 610 driven by a 2 HP servo motor (the roller 505A and the mandrel support 610 are mechanically coupled); the chuck chuck support 710 driven by the engine 711 (for example a 2 HP servo motor); the adhesive nozzle support actuator assembly 840 driven by the motor 822 (for example a 2 HP servo motor); the core carousel 1100 and a core guide assembly 1500 driven by a 2 HP servo motor (rotation of the core carousel 1 100) and the core guide assembly 1500 are mechanically coupled); the core load conveyor 1300 driven by the engine 132 (e.g., a 2 HP servo motor); and a core separation conveyor 2010 driven by the 2022 engine (for example a 4 HP servo motor). Other components, such as a core drive roller 505B / motor 511 and a core adhesive rotation assembly 860 / motor 862, can be independently driven, but do not require phase forming with the roller on table 59. independently driven components and their associated drive motors are shown schematically with a programmable control system 5000 in FIG. 31. The table roll 59 has an associated near breaker. The near switch contacts once for each revolution of the table roll 59, at an angular site and roll of the given table. The programmable control system 5000 can count and store the number of times the table roll 59 has completed one revolution (the number of times the near table roll switch has made contact), since the winding term of the last piece 51. Each of the independently driven components may also have a near breaker to define a rest position of the component. The phase formation of the position of independently driven components with respect to a common reference, such as the position of the table roll within a piece winding cycle, can be achieved in a closed loop form. The phase formation of the position of the independently driven components with respect to the position of the table roll within a piece winding cycle may include the steps of: determining the rotational position of the table roll within a cycle of piece winding, determining the actual position of a component relative to the rotational position of the table roll within the piece winding cycle; calculating the desired position of the component relative to the rotational position of the table roll within the piece winding cycle; calculating a position error for the component of the real and desired positions of the component with respect to the rotational position of the table roll within the roll-to-roll cycle; and reduce the calculated position error of the component. In one embodiment, the positional error of each component can be calculated once the raster winding apparatus 90 has been started. When a first contact is made by the near roller switch of the table, the position of the roller of the The table with respect to the piece winding cycle can be calculated based on the information stored in the random access memory of the programmable control system 5000. Also, when the near switch associated with the table roll counts first during the start , the actual position for each component relative to the rotational position of the table roll within the chunk cycle is determined by a suitable transducer, such as an encoder associated with the motor that drives the component. The desired position of the component relative to the rotational position of the table roll within the piece winding cycle can be calculated using an electronic gear ratio for each component stored in the random access memory of the programmable control system 5000.

When the near table roll switch first makes contact at the start of the winding apparatus 90, the cumulative number of rotations of the table roll until the end of the last piece winding cycle, the sheet count per piece, the length of the sheet, and the circumference of the table roll can be read from the random access memory of the programmable control system 5000. For example, assume that the table roll has completed seven rotations in a piece winding cycle when the winding apparatus 90 was stopped (e.g., stop for maintenance). When the near table roller switch contacts first after re-starting the winding apparatus 90, the table roller completes its eighth full rotation since the last piece winding cycle has been completed. Accordingly, the table roll at that time, is in the 180 degree (average) position of the piece winding cycle, due to the given sheet count, length of sheet and circumference of the table roll, each rotation of the roll of the table corresponds to 4 sheets of a 64-sheet slab, and 16 revolutions of the table roll are required to wind a complete piece. When contact is made first through the nearest roller switch of the table at the start, the desired position of each of the independently driven components with respect to the position of the table roll in the piece winding cycle is calculated based on in the electronic gear ratio for that component and the position of the table roll within the winding cycle. The calculated, desired position of each independently driven component with respect to the piece winding cycle can then be compared to the actual position of the component measured by a transducer, such as an associated encoder with respect to the roll position of the table in the The piece winding cycle is compared with the actual position of the component with respect to the roll position in the piece winding cycle to provide a component position error. The motor that drives the component can then be adjusted, such as by adjusting the speed of the motors with a motor controller, to drive the position error of the component to zero. For example, when the near switch associated with the first table roller makes contact first at the start, the desired angular position of the rotating turret assembly 200 with respect to the position of the table roll in the piece winding cycle can be calculated based on the number of revolutions of the roller in the table that has made during the cycle of piece winding, sheet count, sheet length, the circumference of the table roll, and an electronic gear ratio for the assembly of turret 200. The actual angular position of the turret assembly 200 is measured using a suitable transducer. Referring to Figure 31, a suitable transducer is an encoder 5222 associated with the servo motor 222. The difference between the actual position of the turret assembly 200 and its desired position relative to the position of the table roll within the winding cycle The stub is then used to control the speed of the motor 222, such as with a controller 503B, and thus driving the positioning error of the turret assembly 200 to zero. The position of the chuck chuck arm bracket 410 can be controlled in a similar manner, so that the rotation of the bracket 410 is synchronized with the rotation of the turret assembly 200. An encoder 5422 associated with the engine 422 driving the chuck chuck assembly 400 can be used to measure the actual position of the chuck 410 relative to the position of the table roll in the chute winding cycle. The speed of the servo motor 422 can be varied, such as with a 5030A motor controller, to drive the positioning error of the support 410 to zero. By forming the phase of the angular positions of both the turret assembly 200 and the support 410 relative to a common reference, such as the position of the table roll 59 within the chord winding cycle, the rotation of the cocking arm support The mandrel 410 is synchronized with that of the turret assembly 200, and the twisting of the mandrels 300 is prevented. Alternatively, the position of the independently driven components can be formed in phase with respect to a reference other than the position of the roller. table within a piece winding cycle.

The position error of an independently driven component can be reduced to zero by controlling the speed of the motor driving that particular component. In one embodiment, the value of the position error is used to determine whether the component can be driven to form the phase with the table roller more quickly by increasing the speed of the drive motor, or by reducing the speed of the motor. If the value of the position error is positive (the actual position of the component is "above" the desired position of the component), the drive motor speed is reduced. If the value of the position error is negative (the actual position of the component is "below" the desired position of the component), the speed of the drive motor increases. In one embodiment, the position error is calculated for each component when the near switch of the table roller makes contact first at the start, and a linear variation in the speed of the associated drive motor is determined to drive the position error to zero about the remaining portion of the piece winding cycle. Normally, the position of a component in degrees of the piece winding cycle must correspond to the position of the table roll in degrees of chunk cycle (for example, the position of a component in degrees of a piece winding cycle must be zero when the roll position of the table in degrees of winding cycle is zero). For example, when the near table roll switch contacts at the beginning of a winding cycle (degrees of zero winding cycle), the motor 22 and the turret assembly 200 must be in the angular position so that the position The actual assembly of the turret 200 as measured by the encoder 522 corresponds to a calculated, desired position of winding cycle degrees of zero. However, if the band 224 that drives the turret assembly 200 slides, or if the motor shaft 222 otherwise moves relative to the turret assembly 200, the encoder will no longer provide the actual correct position of the turret assembly. 200. In one mode of the programmable control system can be programmed to allow an operator to provide a deviation for the particular component, the deviation can be entered into the random access memory of the programmable control system in increments of approximately 1/10 of one cycle degree of piece winding. Accordingly, when the actual position of the component coincides with the desired, calculated position of the component modified by the deviation it is considered to be in phase with respect to the position of the table roll in the piece winding cycle. Said deflection capability allows the continuous operation of the winder 90 until mechanical adjustments are made. In one embodiment, a suitable programmable control system 500 for forming the position phase of the independently driven components comprises a programmable electronic drive control system having a programmable random access memory, such as a programmable drive control system AUTOMAX manufactured by Reliance Electric Company of Cleveland, Ohio. The AUTOMAX programmable drive system can be operated using the following manuals, which are incorporated here by reference: AUTOMAX System Operation Manual version 3.0 J2-3005; AUTOMAX programming reference manual J-3686; and AUTOMAX Hardware Reference Manual J-3656,3658. However, it will be understood that in other embodiments of the present invention, other control systems may also be tuned, such as those available from Emerson Electronic Company, Giddings and Lewis, and General Electric Company. Referring to Figure 31, the AUTOMAX programmable drive control system includes one or more 5010 power supply, a common memory module 5012, two model microprocessors 7010, 5014, a network connection module 5016, a plurality of dual axis programmable cards 5018 (each axis corresponding to one of the motor drive components of the independently driven components), resolution input modules 5020, general input / output cards 5022, a VAC 5024 digital output card. The AUTOMAX system also includes a plurality of HR2000, 5030A-K motor controllers. Each motor controller is associated with a particular drive motor. For example, the motor controller 5030B is associated with the servo motor 222, which drives the rotation of the turret assembly 200.

The common memory module 5012 provides an interface between the multiple microprocessors. The two model 7010 microprocessors run the software programs, which control the independently driven components. The connection module 5016 transmits the control and status data between an operator interface and other components of the programmable control system 5000, as well as between the programmable control system 5000 and a programmable mandrel drive control system 6000 discussed further ahead. The 5018 dual axis programmable cards provide individual control of each of the components independently of drive. The signal from the near roller switch of the table is counted with a rigid cable to each of the dual axis 5018 programmable cards. The 5020 resolution input modules convert the angular displacement of resolutions 5200 and 5400 (discussed below) to digital data, the general input / output cards 5022 provide a data exchange path between the different components of the control system 5000. The digital output card VAC 5024 provides output to the brakes 5224 and 5424 associated with the motors 222 and 422, respectively. In one embodiment, the mandrel drive motors 332A and 332B are controlled by a programmable mandrel drive control system, shown schematically in FIG. 32. The motors 332A and 332B can be 460 volt, 30 HP AC motors. The programmable mandrel drive control system 600 may include an AUTOMAX system including a power supply 6010, a common memory module 6012 having a random access memory, two central processing units 6014, a 6016 network communication card to provide communication between the programmable mandrel control system 6000 and the programmable control system 5000, the 6020A-6020D resolution input cards, and 602A and 6022B dual serial port cards. The programmable chuck drive control system 6000 can also include AC motor controllers 6030A and 6030B, each having current feedback inputs 6032 and speed controller 6034. The 6020A and 6020B resolution input cards receive the inputs from the resolutions 6200A and 6200B, which provide a signal related to the rotational position of the mandrel drive motors 332A and 332B, respectively. The 6020C resolution input card receives an input of a resolution 6200C, which provides a signal related to the angular position of the resulting turret assembly 200. In one embodiment, the resolution 6200C and the resolution 5200 in FIG. 31 may be a and the same. The 6020D resolution input card receives the input of a resolution 6200D, which provides a signal related to the angular position of the table roll 59. An operator interface (not shown), which may include a keyboard and a screen of presentation, can be used to enter the data into, and present the data of the programmable drive system 5000. A suitable operator interface is the XYCOM 8000 Industrial Workstation series manufactured by Xycon Corporation of Saline, Michigan. The software of the operator interface to be used with the workstation XYCOM 8000 series is interaction software available from Computer techonology of Mildford, Ohio. The individually driven components can be moved forward or backward, individually or together with the operator. In addition, the operator can write in a desired deviation, as described above, from the keyboard. The ability to verify the position, speed, and current associated with each drive motor is developed on (in the rigid cable) the dual axis 5018 programmable cards. The position, speed, and current associated with each drive motor., it is measured and compared with the associated position, velocity and current limits, respectively. The programmable control system 5000 stops the operation of all drive motors if any of the position, speed or current limits are exceeded. In Fig. 2, the rotatably driven turret assembly 200 and the rotating take-up arm support plate 430 are rotatably driven by the separate servo motors 222 and 422, respectively. The motors 222 and 422 can continuously rotate the central axis 202, at a generally constant angular velocity. The angular position of the turret assembly 200 and the angular position of the cup arm support plate 430 are verified through the position resolutions 5200 and 5400, respectively, shown schematically in Figure 31. The programmable drive system 5000 stops the operation of all motors if the angular position of the turret assembly 200 changes more than a predetermined number of angular degrees with respect to the angular position of the support plate 430, as measured by the position resolutions 5200 and 5400. In In one embodiment, the rotatably driven turret assembly 200 and the cup arm support plate 430 can be mounted on a common hub and driven through an individual drive motor. Said arrangement has the disadvantage that the torque of the common hub interconnecting the rotating turntable support and arm support assemblies can result in vibration or deflection of the mandrel cups relative to the mandrel ends, if the connection hub does not become sufficiently massive and sticky. The weft winding apparatus of the present invention drives the independently supported rotary turret assembly 200 and the cup arm support plate 430 with separate drive motors which are controlled to maintain positional phase formation of the turret assembly 200 and the chuck clamping arms 450 with a common reference, thus mechanically decoupling the rotation of the turret assembly 200 and the clamping arm support plate 430.

In the described embodiment, the motor that drives the roller on the table 59 is separated from the motor that drives the rotating turret assembly 200 to mechanically decouple the rotation of the turret assembly 200 from the rotation of the table roll 59, thus isolating the turret assembly 200 from the vibrations caused by the upstream winding equipment. The drive of the rotating turret assembly 200 separately from the table roll 59 also allows the ratio of revolutions of the turret assembly 200 to the revolutions of the table roll 59 that will be changed electronically, instead of changing the mechanical gear trains. Changing the ratio of the rotations of the turret assembly to the roll rotations of the table can be used to change the length of the weft wound on each core, and, therefore, the number of perforated sheets of the weave changes, the which are wound in each nucleus. For example, if the ratio of the rotations of the turret assembly to the rotations of the roll on the table increases, fewer sheets of a given length will be wound on each core. The sheet count per piece can be changed, while the turret assembly 200 is rotating, changing the ratio of the rotational speed of the turret assembly to the ratio of the rotational speed of the table roll, while the turret assembly 20 It is spinning. In one embodiment according to the present invention, two or more mandrel winding speed schedules, or mandrel speed curves, can be stored in a random access memory, which is accessible to the 5000 programmable control system. example, two or more speed curves can be used in the common memory 6012 of the programmable mandrel drive control system 6000. Each of the mandrel speed curves stored in the random access memory can correspond to a piece of size different (different sheet count per piece). Each mandrel speed curve can provide the mandrel winding speed as a function of the regular position of the turret assembly 200 for a particular sheet count per piece, the weft can be cut as a function of the desired sheet count by piece by changing the time control of the shred solenoid activation. In one embodiment, the sheet count per piece can be changed while the turret assembly 200 is rotated: 1) by storing at least two mandrel speed curves in the address memory, such as a random access memory accessible to the 5000 programmable control system; 2) providing a desired change in the count of the sheet per piece via an operator interface; 3) selected a mandrel speed curve of the memory, based on the desired change in the sheet count per piece; 4) calculating a desired change in the ratio of the rotational speeds of the turret assembly 200 and the chuck attachment assembly 400 to the rotational speed of the table roll 59 as a function of the desired change in sheet count per piece; 5) calculating a desired change in the ratios of the speeds of the core drive roller 505A and the mandrel support 610 driven by the motor 510: the mandrel support 710 driven by the motor 711; the adhesive nozzle holder actuator assembly 840 driven by the motor 822; the core carousel 1100 and the core guide assembly 1500 driven by the engine 1222; the 1300 core load conveyor driven by the 1322 motor; and the core separation apparatus 2000 driven by the motor 2022; with respect to the rotational speed of the roller in the table 59 as a function of the desired change in the sheet count per piece; 6) by changing the electronic gear ratios of the turret assembly 200 and the chuck collet assembly 400 with respect to the table roll 59 in order to change the ratio of the rotational speeds of the turret assembly 200 and the coupling assembly of mandrel 400 at the rotational speed of the table roll 59; 7) changing the electronic gear ratios of the following components relative to the table roll 59; the core drive roller 505A and the mandrel support 610 driven by the motor 510; mandrel support 710 driven by motor 711; and the adhesive nozzle holder actuator assembly 840 driven by the motor 822; the core carousel 1100 and the core guide assembly 1500 driven by the engine 1222; the 1300 core load conveyor driven by the 1322 motor; and the core separation apparatus 2000 driven by the motor 2022 relative to the rotational speed of the table roll 59; and 8) cutting the screen as a function of the desired change in the sheet count per piece, such as by varying the control time of the shred solenoid. Each time the sheet count is changed per piece, the position of the independently driven components can be re-formed in phase with respect to the position of the table roll within a piece winding cycle: determining a winding cycle of updated piece based on the desired change in the sheet count per piece; determining the rotational position of the table roll within the updated piece winding cycle; determining the actual position of a component relative to the rotational position of the table roll within the updated piece winding cycle; calculating the desired position of the component in relation to the rotational position of the table roll within the updated piece winding cycle; calculating a positional error for the component of the actual and desired positions of the component with respect to the position of the table roll within the updated piece winding cycle; and reducing the calculated position error of the component. Since particular embodiments of the present invention have been illustrated and described, various changes and modifications can be made without departing from the spirit and scope of the invention. For example, the central axis of the turret assembly is shown extending horizontally in the figures, but it will be understood that the turret assembly axis 202 and the mandrels can be oriented in other directions, including but not limited to vertically. It is intended to cover, in the aerial claims, all these modifications and intended uses. or CN p / i CONTINUATION TABLE IÍA ? : 0TINUACI0N CUADRO ITTA -l CONTINLIATION TABLE IIIA OR)

Claims (3)

1. - A method for winding a continuous web of material on hollow cores to form individual pieces, the pieces having different lengths of the material wound thereon, the method characterized in that it comprises the steps of: providing a rotatably driven turret assembly supporting a plurality of rotating mandrels driven for the winding of the web of material on cores supported on the mandrels; providing a rotatable table roller for transferring the web of material to the turnably driven turret assembly; spinning the table roll; rotating the turret assembly to bring the mandrels in a closed path; winding the material on the cores supported on the mandrels to form pieces having a first predetermined length; and changing the length of the material wound on the cores, while the turret assembly is rotating to form pieces having a second predetermined length of the material, wherein the first length is different from the second length.

2. The method according to claim 1, wherein it comprises the step of continuously rotating the turret assembly; wherein the step of continuously rotating the turret assembly preferably comprises the step of continuously rotating the turret assembly after the step of changing the length of the wound material on the cores has been completed; and wherein the step of continuously rotating the turret assembly preferably comprises the step of continuously rotating the turret assembly before starting the step of changing the length of the material wound on the core.

3. The method according to claim 1 or 2, comprising the steps of: continuously rotating the turret assembly at a first generally constant speed, while forming the pieces having the first predetermined length of the material; and continuously rotating the turret assembly at a second generally constant angular velocity, while forming the second predetermined length of the material. 4 - A method for winding a continuous web of material on hollow cores to form individual pieces, the pieces having different lengths of material wound thereon, the method characterized in that it comprises the steps of: providing a rotatably driven turret assembly supporting a plurality of mandrels rotatably driven for winding the web of material on cores supported on the mandrels; providing a rotatable table roller for transferring the web of material to the turnably driven turret assembly; spinning the table roll; rotating the turret assembly to bring the mandrels in a closed path; winding a first length of the material on cores supported on the mandrels to form pieces having the first length the material; change the rotation speed of the turret assembly relative to the rotation speed of the table roll, while the turret assembly is rotating; and winding a second length of material over the cores supported in the mandrels to form the pieces having the second length of material, wherein the second length is different from the first length. 5. The method according to claim 4, wherein the steps of winding the material on the cores comprise: varying a winding speed of the mandrels according to a first speed schedule to wind the first length of the material on the cores; and varying the winding speed of the materials according to a second speed schedule to wind the second length of the material over the cores, where the first speed schedule is different from the second speed schedule,. 6. The method according to claim 4 or 5, wherein the step of changing the rotation speed of the turret assembly relative to the rotation speed of the table roll, while the turret assembly is rotating, it comprises the step of forming a phase in the position of the turret assembly with respect to the position of the table roll within a piece winding cycle. 7. The method according to claim 6, wherein the step with the position of the turret assembly with respect to the position of the table roll within the piece winding cycle comprises the steps of: determining a chunk winding cycle updated as a function of the difference between the first and second lengths; determining the rotational position of the table roll within the updated winding cycle; determining the actual position of the turret assembly relative to the rotational position of the table roll within the updated chunk winding cycle; determining the desired position of the turret assembly relative to the rotational position of the table roll within the updated chunk winding cycle; calculating a positional error for the turret assembly of the actual and desired positions of the turret assembly relative to the rotational position of the table roll within the roll-on-roll cycle; and reduce the calculated position error of the turret assembly. 8. The method according to claims 4, 5, 6, or 7, wherein it comprises the steps of: continuously rotating the turret assembly at a generally constant first angular speed, while the pieces are being formed having the first predetermined length of material, and continuously rotating the turret assembly at a second generally constant angular velocity, while the pieces are being formed having the second predetermined length of the material. 9. A method for winding a continuous web of material on the hollow core to form individual pieces, the pieces having different lengths of material wound thereon, the method comprises the steps of: providing at least two independently driven components, the position of each independently driven component being mechanically decoupled from the positions of the other independently driven components, wherein at least one of the independently driven components comprises a rotatably driven turret assembly supporting a plurality of rotatably driven mandrels for winding the pieces; providing a rotatable table roller for transferring the web of material to the rotatably driven turret assembly, wherein the position of the table roll is mechanically decoupled from the positions of the independently driven components; provide a programmable control system to control the position of independently driven components; provide an accessible memory to the programmable control system; providing a first mandrel winding speed schedule and a second mandrel winding speed schedule in the memory accessible to the programmable control system, wherein the first mandrel winding speed schedule corresponds to a stub having a first length of mandrel, and wherein the second mandrel winding speed schedule corresponds to a piece having a second length of the material; spinning the table roll; driving the independently driven components, wherein the turret assembly is rotated to bring the mandrels in a closed path: vary the winding speed of the mandrels according to the first mandrel winding speed schedule to wind chunks having a first length of the material; changing the speeds of the individually driven components relative to the rotational speed of the table roll, while the turret assembly is being rotated; and varying the winding speed of the mandrels according to the second mandrel winding speed schedule to wind up pieces having the second length of the material. 10. The method according to claim 9, wherein the step of changing the speeds of the individually driven components with respect to the rotation speed of the table roll comprises the step of shaping the position of the individually driven component with with respect to the position of the table roll within a piece winding cycle.