US20240002185A1 - Electronic Nip Adjustment and Pressure Measurement on Pull Station - Google Patents
Electronic Nip Adjustment and Pressure Measurement on Pull Station Download PDFInfo
- Publication number
- US20240002185A1 US20240002185A1 US18/200,849 US202318200849A US2024002185A1 US 20240002185 A1 US20240002185 A1 US 20240002185A1 US 202318200849 A US202318200849 A US 202318200849A US 2024002185 A1 US2024002185 A1 US 2024002185A1
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- US
- United States
- Prior art keywords
- continuous loop
- pull station
- webs
- frame
- conveyed
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H31/00—Pile receivers
- B65H31/30—Arrangements for removing completed piles
- B65H31/3027—Arrangements for removing completed piles by the nip between moving belts or rollers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H23/00—Registering, tensioning, smoothing or guiding webs
- B65H23/04—Registering, tensioning, smoothing or guiding webs longitudinally
- B65H23/18—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web
- B65H23/188—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web in connection with running-web
- B65H23/1888—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web in connection with running-web and controlling web tension
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H45/00—Folding thin material
- B65H45/12—Folding articles or webs with application of pressure to define or form crease lines
- B65H45/22—Longitudinal folders, i.e. for folding moving sheet material parallel to the direction of movement
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H45/00—Folding thin material
- B65H45/12—Folding articles or webs with application of pressure to define or form crease lines
- B65H45/28—Folding in combination with cutting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2301/00—Handling processes for sheets or webs
- B65H2301/40—Type of handling process
- B65H2301/42—Piling, depiling, handling piles
- B65H2301/422—Handling piles, sets or stacks of articles
- B65H2301/4229—Handling piles, sets or stacks of articles cutting piles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2404/00—Parts for transporting or guiding the handled material
- B65H2404/20—Belts
- B65H2404/26—Particular arrangement of belt, or belts
- B65H2404/261—Arrangement of belts, or belt(s) / roller(s) facing each other for forming a transport nip
- B65H2404/2614—Means for engaging or disengaging belts into or out of contact with opposite belts, rollers or balls
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2511/00—Dimensions; Position; Numbers; Identification; Occurrences
- B65H2511/10—Size; Dimensions
- B65H2511/11—Length
- B65H2511/112—Length of a loop, e.g. a free loop or a loop of dancer rollers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2513/00—Dynamic entities; Timing aspects
- B65H2513/10—Speed
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2515/00—Physical entities not provided for in groups B65H2511/00 or B65H2513/00
- B65H2515/30—Forces; Stresses
- B65H2515/31—Tensile forces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2555/00—Actuating means
- B65H2555/10—Actuating means linear
- B65H2555/11—Actuating means linear pneumatic, e.g. inflatable elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2701/00—Handled material; Storage means
- B65H2701/10—Handled articles or webs
- B65H2701/18—Form of handled article or web
- B65H2701/186—Several articles or webs processed together
- B65H2701/1864—Superposed webs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2701/00—Handled material; Storage means
- B65H2701/10—Handled articles or webs
- B65H2701/19—Specific article or web
- B65H2701/1924—Napkins or tissues, e.g. dressings, toweling, serviettes, kitchen paper and compresses
Definitions
- the disclosure is directed to an electronic nip adjustment for a pull station used in connection with a converting line.
- the pull station is used for processing multiple webs of material that are arranged in a vertically stacked arrangement.
- the pull station conveys the vertically stacked arrangement of webs from an entrance of the pull station through a discharge of the pull station.
- initial setup and adjustment of a pull station for each product substrate, sheet count, stack height, and (if applicable) liquid combination is an iterative process performed manually from within the line's protective guarding, with the line stopped each time an adjustment is needed.
- the setting of a pull station for each product combination can be saved in a recipe or product process, but the saved value is a number read from a scale, counter, or the like which must be returned to manually.
- the force applied to the stack of webs is unknown, as is the extent to which the force applied to the stack of webs is in excess of that needed to maintain control of the stack of webs and/or sufficient to cause liquid to be wrung from the stack of webs.
- the webs are unwound on an unwind station 12 and directed to a folding station 14 .
- the folding station 14 folds the webs W as needed and arranges them in an overlapping format to form a ribbon of webs that are arranged in a vertically stacked arrangement.
- the overlapping format may include any number of formats of folding, including C-folding, V-folding, W-folding and Z-Folding.
- a lotion may be injected onto each of the webs or into the ribbon of webs at the folding station 14 .
- the ribbon of webs W is then introduced into the pull station 16 before entering into a cutting and stacking station 18 .
- the pull station 16 is integral to the converting line in drawing the webs of material from the unwind station 12 and through the folding station 14 and to the cutting and stacking station 18 .
- the disclosure is directed to maximizing the efficiency of the pull station and the converting line, in general.
- the disclosure is directed to a control for controlling the pull station which enables the pull station to draw the webs from the unwind station without significantly altering the characteristics of the webs. For instance, in the fold station, a lotion or liquid may be applied to the webs or to the ribbon of webs.
- the control for controlling the pull station as described herein enables the ribbon of webs to be drawn through the converting line in an efficient manner that maintains the caliper of the respective webs and a required amount of liquid in the substrate.
- control controls the position of a top continuous loop of the pull station relative to a bottom continuous loop of the pull station so as to maintain a desired force or pressure on the ribbon of webs as the ribbon is conveyed from an entrance of the pull station to the discharge of the pull station.
- the control also allows an adjustment to set the minimum distance between the top continuous loop and the bottom continuous loop for each specific product format processed on the converting line, thus allowing automatic set up of the pull station depending upon the product format and manufacturing processing requirements of the product.
- control system allows for speed measurements to determine whether the ribbon is slipping as it is being conveyed from the entrance of the pull station to the discharge of the pull station. To the extent the ribbon is determined to be slipping, the force applied to the ribbon vis-à-vis the top continuous loop may be increased to eliminate the slipping condition while maintaining the required amount of liquid in the substrate.
- FIG. 1 A is a schematic block diagram of a converting line using a pull station.
- FIG. 1 B is an operator side view of a folding station, the pull station, and cutting and stacking stations of the converting line.
- FIG. 2 is an operator side perspective view of a pull station of a converting line.
- FIG. 3 is a drive side perspective view of the pull station of FIG. 2 .
- FIG. 4 is a partial, enlarged, operator side, perspective view of the pull station of FIG. 2 showing additional detail of a top continuous loop, a frame supporting the top continuous loop, and a frame actuator for positioning the frame and the top continuous loop.
- FIG. 5 is another partial, enlarged, operator side, perspective view of the pull station of FIG. 2 showing additional detail of the top continuous loop, the top frame and the frame actuator.
- FIG. 6 is a partial, front, operator side view of the pull station of FIG. 2 .
- FIG. 7 is a partial, discharge end view of the pull station of FIG. 2 showing the frame and the top continuous loop in a position away from the bottom continuous loop.
- FIG. 8 is a partial, discharge end view of the pull station of FIG. 2 showing the frame and the top continuous loop in a position toward the bottom continuous loop with a ribbon of webs between the top continuous loop and the bottom continuous loop.
- FIGS. 2 - 8 show the general structure of the pull station 16 .
- the pull station 16 comprises a structural framework 20 which supports the various components of the pull station.
- the pull station 16 comprises a top continuous loop 22 and a bottom continuous loop 24 that cooperate to draw the ribbon of webs W from an entrance 26 of the pull station to a discharge 28 of the pull station.
- the pull station draws the ribbon of webs W through the folding and unwind stations of the converting line and to the cutting and stacking station.
- the top continuous loop 22 and the bottom continuous loop 24 comprise one or more belts which define surfaces between the entrance 26 and the discharge 28 of the pull station that are arranged generally parallel to each other and spaced apart generally vertically based upon a height of the ribbon of webs W to be conveyed through the pull station.
- the top continuous loop 22 and bottom continuous loop 24 are generally parallel to each other from the entrance 26 of the pull station to the discharge 28 of the pull station.
- the top continuous loop and bottom continuous loop are driven by a transmission which includes a belt drive system 30 and motor 32 .
- the motor 32 drives a main belt 34 that engages a first pulley 36 on a drive shaft 38 of the bottom continuous loop 24 for movement of the bottom continuous loop.
- An auxiliary belt 40 extends between a second pulley 42 on the bottom continuous loop drive shaft 38 and a pulley 44 on a drive shaft 46 of the top continuous loop 22 .
- the belt drive system 30 allows for synchronized motion of the top and bottom continuous loops 22 , 24 with one motor 32 . It is also possible to have the top continuous loop and bottom continuous loop driven by separate drive systems and separate motors.
- the top continuous loop 22 is supported by a frame 50 .
- the frame 50 is movable relative to the structural framework 20 of the pull station 16 so as to allow the top continuous loop 22 to move toward and away from the bottom continuous loop 24 .
- the frame 51 supporting the bottom continuous loop 24 is stationary on the structural framework 20 .
- the frame 50 is supported on a vertical slide 52 formed in the structural framework 20 of the pull station 16 so as to allow the frame to move upward and downward on the structural framework 20 of the pull station and move the top continuous loop 22 toward and away from the bottom continuous loop 24 .
- a frame actuator 54 is provided to effectuate motion of the frame 50 and thus the top continuous loop 22 .
- the frame actuator 54 may comprise a pneumatic cylinder with an end effector 56 that is operatively connected to a yoke 58 extending across the frame 50 .
- the frame actuator may be configured to apply a desired amount of force on the ribbon of webs W as the ribbon is conveyed from the entrance 26 of the pull station to the discharge 28 of the pull station.
- a pneumatic cylinder may be arranged with a pressure sufficient to apply a desired force to the ribbon of webs W.
- the frame actuator may also be another type of linear actuator, including a ball screw or acme lead screw driven by a motor, which may supply sufficient torque and pressure to the ribbon of webs.
- the frame actuator 54 may have a position sensor 60 that is adapted and configured to sense the position of the end effector 56 of the frame actuator and thus the position of the frame and top continuous loop 22 relative to the structural framework 20 of the pull station and the bottom continuous loop 24 .
- the output of the frame actuator position sensor 60 may be directed to a controller that will be described in greater detail below.
- the pull station 16 may further include a stop 70 and a shoulder 72 .
- the stop 70 and the shoulder 72 cooperate to set the minimum distance between the top continuous loop 22 and the bottom continuous loop 24 .
- the stop 70 may be connected to the structural framework 20 of the pull station and the shoulder 72 may be operatively connected to or formed as part of the frame As best shown in FIGS. 3 and 7 - 8 , the stop 70 may be provided on the drive side of the pull station, and may comprise a stop actuator 74 for adjustably positioning the stop.
- the shoulder 72 may be formed as part of the frame or operatively connected to the frame.
- the stop actuator 74 may adjustably position the stop 70 so the stop engages the shoulder 72 at a desired position corresponding to the minimum distance between the top continuous loop 22 and the bottom continuous loop 24 for a particular product format and product manufacturing process.
- the stop actuator 74 may comprise a jackscrew and motor, for example, a stepper motor.
- the stop actuator 74 may include a right angle head connected to the jackscrew that is driven by the motor. This allows adjustments to be made to the pull station 16 from outside the protective guarding of the converting line 10 , including while the pull station is running in operation, with push button controls provided in a human machine interface (HMI) 76 for the pull station and/or converting line.
- HMI human machine interface
- the stop actuator 74 is shown in a withdrawn position and the frame 50 is shown in a withdrawn position with the top continuous loop 22 away from the bottom continuous loop 24 .
- the frame 50 is lowered via the frame actuator 54 so the shoulder 72 of the frame engages the stop 70 and the top continuous loop 22 is spaced from the bottom continuous loop 24 at a minimum height corresponding to the desired position for the product format and product manufacturing process.
- the stop 70 may include a load sensor 80 .
- the load sensor may be a button-style load cell, for example a Honeywell Model 53 .
- the load sensor 80 may be positioned on a distal end of the stop as shown in the drawing. Alternatively, the load sensor may be incorporated into the shoulder.
- the load sensor 80 may be adapted and configured to sense a load applied against the load sensor when the frame 50 engages the stop 70 , for instance, when the shoulder 72 of the frame engages the stop, and more in particular, when the shoulder of the frame engages the load sensor.
- the stop actuator 74 may also include a position sensor 82 that is adapted and configured to sense the position of the stop actuator 74 relative to the structural framework 20 of the pull station.
- the pull station may be provided with a control 90 .
- the control 90 may include a controller 92 that includes a processor 94 with a memory 96 .
- the frame actuator position sensor 60 , the stop actuator position sensor 82 , and the stop load sensor 80 may all provide inputs to the control 90 and controller 92 for generating signals for controlling the pull station.
- the control 90 may include at least one speed sensor 100 , 102 for a respective one or both of the top and bottom continuous loops for sensing the speeds of the respective top and bottom continuous loops.
- the control 90 may also include a speed sensor 104 ( FIG. 2 ) for determining the speed of ribbon or of the plurality of webs as they are drawn from the entrance 26 of the pull station to the discharge 28 of the pull station.
- setpoints and operating parameters relating to the product format and product manufacturing process, as well as inputs to the controller may be stored in the memory 96 of the controller 90 so as to facilitate set up and operation of the pull station, provide real-time dynamic control of the pull station, and data to assess the efficiency and operational characteristics of the pull station which may assist in maintenance of the pull station.
- the controller 92 is configured to determine a distance measurement D between the top continuous loop 22 and the bottom continuous loop 24 based upon the frame actuator position sensor 60 as the plurality of webs W are conveyed from the entrance 26 of the pull station to the discharge 28 of the pull station. In another aspect, the controller 92 is configured to determine a force imparted to the plurality of webs based on the stop load sensor 80 , the weight of the frame 50 and the top continuous loop 22 , and a force imparted to the top continuous loop 22 by the frame actuator 54 . For instance, the stop load sensor 80 may sense the amount of pressure exerted by the frame 50 via the shoulder 72 against the stop 70 .
- the weight of the frame and top continuous loop 22 may be a constant value with the remainder of the load applied against the stop load sensor 80 being a function of the position of the end effector 56 of the frame actuator 54 , and the frame 50 and top continuous loop 22 , and the position of the stop actuator 74 .
- the frame actuator 54 is configured as a pneumatic cylinder
- the pressure applied to pneumatic cylinder may also be measured as an input to the controller 92
- the frame actuator is configured as a servo motor drive
- the torque of the motor may also be measured as an input to the controller.
- the frame actuator is configured as a pneumatic cylinder
- the pneumatic cylinder may allow the ribbon to temporarily overcome the force of the pneumatic cylinder and temporarily move the top continuous loop away from the bottom continuous loop.
- the stop actuator 74 is configured as a servo motor drive, the torque of the motor may also be measured as an input to the controller 92 .
- the controller 92 may be adapted and configured to generate signals for controlling the pull station 16 based upon the distance measurements D and inputs to the controller. This may be useful in benchmarking different substrates and web materials for optimal settings and repeatability in processing. For instance, if certain material properties of a substrate comprising the web materials W are known and/or can be predicted, for instance, from prior product manufacturing processes in the converting line 10 , then initial settings of distance and force may be used to facilitate set-up, and operational parameters may be set, maintained and/or changed as necessary during processing to maximize efficiency and quality.
- the force applied by the top continuous loop 22 may be controlled so as to limit the amount of force to that which is necessary to prevent slipping of the ribbon while ensuring any liquid or lotion applied to the ribbon is not wrung out of the ribbon.
- the speed of one or both of the top continuous loop and bottom continuous loop may be measured via the respective loop speed sensors 100 , 102 and compared to a ribbon speed sensor 104 to determine a relative amount of slippage.
- the position of the frame 50 may be changed with the frame actuator 54 and/or the stop actuator 74 .
- the frame actuator 54 and/or stop actuator 74 may be operated so as to change the position of the frame 50 and top continuous loop 22 to apply additional pressure.
- the frame actuator sensor 60 and the stop actuator position sensor 82 along with stop load sensor 80 may provide signals to the controller 92 that trim control signals from the controller to the frame actuator 54 and/or stop actuator 74 to change the applied pressure.
- pressure and/or torque signals of the respective actuators that are directed the controller 92 may also be trimmed by signals from the frame actuator and stop actuator position sensors, and the stop load sensor.
- the processor 94 and the memory 96 of the controller 92 of the pull station may be configured to store a plurality of data structures in the memory of the controller.
- the data structures may comprise a plurality of data items associated together as at least one of: (i) the distance measurements between the top continuous loop and the bottom continuous loop as the plurality of webs are conveyed from the entrance of the pull station to the discharge of the pull station, (ii) the load measurements as the plurality of webs are conveyed from the entrance of the pull station to the discharge of the pull station, (iii) the speed of the plurality of webs being conveyed in the pull station, (iv) the speed of the at least one of the top continuous loop and bottom continuous loop as the plurality of webs are conveyed from the entrance of the pull station to the discharge of the pull station, and (v) one or more characteristics representative of the plurality of webs being conveyed in the pull station.
- the data may be used to assess operational functionality of the pull station and the converting line in general, efficiency of the
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Controlling Rewinding, Feeding, Winding, Or Abnormalities Of Webs (AREA)
- Registering, Tensioning, Guiding Webs, And Rollers Therefor (AREA)
Abstract
Description
- This application claims priority benefit to U.S. provisional application Ser. No. 63/357,088, filed Jun. 30, 2022, the disclosure of which is incorporated by reference herein.
- The disclosure is directed to an electronic nip adjustment for a pull station used in connection with a converting line. In particular, the pull station is used for processing multiple webs of material that are arranged in a vertically stacked arrangement. The pull station conveys the vertically stacked arrangement of webs from an entrance of the pull station through a discharge of the pull station.
- In the current state of the art, initial setup and adjustment of a pull station for each product substrate, sheet count, stack height, and (if applicable) liquid combination is an iterative process performed manually from within the line's protective guarding, with the line stopped each time an adjustment is needed. In the current state of the art, the setting of a pull station for each product combination can be saved in a recipe or product process, but the saved value is a number read from a scale, counter, or the like which must be returned to manually. In the current state of the art, the force applied to the stack of webs is unknown, as is the extent to which the force applied to the stack of webs is in excess of that needed to maintain control of the stack of webs and/or sufficient to cause liquid to be wrung from the stack of webs. Making reference to
FIG. 1A and 1B , generally speaking, in the convertingline 10, the webs are unwound on anunwind station 12 and directed to afolding station 14. Depending upon the product format, thefolding station 14 folds the webs W as needed and arranges them in an overlapping format to form a ribbon of webs that are arranged in a vertically stacked arrangement. The overlapping format may include any number of formats of folding, including C-folding, V-folding, W-folding and Z-Folding. A lotion may be injected onto each of the webs or into the ribbon of webs at thefolding station 14. The ribbon of webs W is then introduced into thepull station 16 before entering into a cutting andstacking station 18. Thepull station 16 is integral to the converting line in drawing the webs of material from theunwind station 12 and through thefolding station 14 and to the cutting andstacking station 18. - The disclosure is directed to maximizing the efficiency of the pull station and the converting line, in general. In particular, the disclosure is directed to a control for controlling the pull station which enables the pull station to draw the webs from the unwind station without significantly altering the characteristics of the webs. For instance, in the fold station, a lotion or liquid may be applied to the webs or to the ribbon of webs. Accordingly, the control for controlling the pull station as described herein enables the ribbon of webs to be drawn through the converting line in an efficient manner that maintains the caliper of the respective webs and a required amount of liquid in the substrate.
- As will be described in greater detail below, the control controls the position of a top continuous loop of the pull station relative to a bottom continuous loop of the pull station so as to maintain a desired force or pressure on the ribbon of webs as the ribbon is conveyed from an entrance of the pull station to the discharge of the pull station. The control also allows an adjustment to set the minimum distance between the top continuous loop and the bottom continuous loop for each specific product format processed on the converting line, thus allowing automatic set up of the pull station depending upon the product format and manufacturing processing requirements of the product. Additionally, as will be described in greater detail below, the control system allows for speed measurements to determine whether the ribbon is slipping as it is being conveyed from the entrance of the pull station to the discharge of the pull station. To the extent the ribbon is determined to be slipping, the force applied to the ribbon vis-à-vis the top continuous loop may be increased to eliminate the slipping condition while maintaining the required amount of liquid in the substrate.
-
FIG. 1A is a schematic block diagram of a converting line using a pull station. -
FIG. 1B is an operator side view of a folding station, the pull station, and cutting and stacking stations of the converting line. -
FIG. 2 is an operator side perspective view of a pull station of a converting line. -
FIG. 3 is a drive side perspective view of the pull station ofFIG. 2 . -
FIG. 4 is a partial, enlarged, operator side, perspective view of the pull station ofFIG. 2 showing additional detail of a top continuous loop, a frame supporting the top continuous loop, and a frame actuator for positioning the frame and the top continuous loop. -
FIG. 5 is another partial, enlarged, operator side, perspective view of the pull station ofFIG. 2 showing additional detail of the top continuous loop, the top frame and the frame actuator. -
FIG. 6 is a partial, front, operator side view of the pull station ofFIG. 2 . -
FIG. 7 is a partial, discharge end view of the pull station ofFIG. 2 showing the frame and the top continuous loop in a position away from the bottom continuous loop. -
FIG. 8 is a partial, discharge end view of the pull station ofFIG. 2 showing the frame and the top continuous loop in a position toward the bottom continuous loop with a ribbon of webs between the top continuous loop and the bottom continuous loop. -
FIGS. 2-8 show the general structure of thepull station 16. Thepull station 16 comprises astructural framework 20 which supports the various components of the pull station. Thepull station 16 comprises a topcontinuous loop 22 and a bottomcontinuous loop 24 that cooperate to draw the ribbon of webs W from anentrance 26 of the pull station to adischarge 28 of the pull station. In general, the pull station draws the ribbon of webs W through the folding and unwind stations of the converting line and to the cutting and stacking station. The topcontinuous loop 22 and the bottomcontinuous loop 24 comprise one or more belts which define surfaces between theentrance 26 and thedischarge 28 of the pull station that are arranged generally parallel to each other and spaced apart generally vertically based upon a height of the ribbon of webs W to be conveyed through the pull station. Accordingly, the topcontinuous loop 22 and bottomcontinuous loop 24 are generally parallel to each other from theentrance 26 of the pull station to thedischarge 28 of the pull station. As shown inFIG. 3 , the top continuous loop and bottom continuous loop are driven by a transmission which includes abelt drive system 30 andmotor 32. In particular, as shown inFIG. 3 , themotor 32 drives amain belt 34 that engages afirst pulley 36 on adrive shaft 38 of the bottomcontinuous loop 24 for movement of the bottom continuous loop. Anauxiliary belt 40 extends between asecond pulley 42 on the bottom continuousloop drive shaft 38 and apulley 44 on adrive shaft 46 of the topcontinuous loop 22. Thus, thebelt drive system 30 allows for synchronized motion of the top and bottom 22,24 with onecontinuous loops motor 32. It is also possible to have the top continuous loop and bottom continuous loop driven by separate drive systems and separate motors. - The top
continuous loop 22 is supported by aframe 50. Theframe 50 is movable relative to thestructural framework 20 of thepull station 16 so as to allow the topcontinuous loop 22 to move toward and away from the bottomcontinuous loop 24. Theframe 51 supporting the bottomcontinuous loop 24 is stationary on thestructural framework 20. As best shown inFIGS. 6-8 , theframe 50 is supported on avertical slide 52 formed in thestructural framework 20 of thepull station 16 so as to allow the frame to move upward and downward on thestructural framework 20 of the pull station and move the topcontinuous loop 22 toward and away from the bottomcontinuous loop 24. To effectuate motion of theframe 50 and thus the topcontinuous loop 22, aframe actuator 54 is provided. In one aspect, theframe actuator 54 may comprise a pneumatic cylinder with anend effector 56 that is operatively connected to ayoke 58 extending across theframe 50. Depending upon the configuration of theframe actuator 54, the frame actuator may be configured to apply a desired amount of force on the ribbon of webs W as the ribbon is conveyed from theentrance 26 of the pull station to thedischarge 28 of the pull station. In one configuration of theframe actuator 54, a pneumatic cylinder may be arranged with a pressure sufficient to apply a desired force to the ribbon of webs W. The frame actuator may also be another type of linear actuator, including a ball screw or acme lead screw driven by a motor, which may supply sufficient torque and pressure to the ribbon of webs. - The
frame actuator 54 may have aposition sensor 60 that is adapted and configured to sense the position of theend effector 56 of the frame actuator and thus the position of the frame and topcontinuous loop 22 relative to thestructural framework 20 of the pull station and the bottomcontinuous loop 24. The output of the frameactuator position sensor 60 may be directed to a controller that will be described in greater detail below. - The
pull station 16 may further include astop 70 and ashoulder 72. Thestop 70 and theshoulder 72 cooperate to set the minimum distance between the topcontinuous loop 22 and the bottomcontinuous loop 24. Thestop 70 may be connected to thestructural framework 20 of the pull station and theshoulder 72 may be operatively connected to or formed as part of the frame As best shown inFIGS. 3 and 7-8 , thestop 70 may be provided on the drive side of the pull station, and may comprise astop actuator 74 for adjustably positioning the stop. As best shown inFIGS. 4, 7 and 8 , theshoulder 72 may be formed as part of the frame or operatively connected to the frame. Thestop actuator 74 may adjustably position thestop 70 so the stop engages theshoulder 72 at a desired position corresponding to the minimum distance between the topcontinuous loop 22 and the bottomcontinuous loop 24 for a particular product format and product manufacturing process. The stop actuator 74 may comprise a jackscrew and motor, for example, a stepper motor. For instance, thestop actuator 74 may include a right angle head connected to the jackscrew that is driven by the motor. This allows adjustments to be made to thepull station 16 from outside the protective guarding of the convertingline 10, including while the pull station is running in operation, with push button controls provided in a human machine interface (HMI) 76 for the pull station and/or converting line. This also allows for automatic control and the saving of setpoints and operating parameters for a specific product format and product manufacturing process. InFIG. 7 , thestop actuator 74 is shown in a withdrawn position and theframe 50 is shown in a withdrawn position with the topcontinuous loop 22 away from the bottomcontinuous loop 24. During operation, theframe 50 is lowered via theframe actuator 54 so theshoulder 72 of the frame engages thestop 70 and the topcontinuous loop 22 is spaced from the bottomcontinuous loop 24 at a minimum height corresponding to the desired position for the product format and product manufacturing process. - The
stop 70 may include aload sensor 80. The load sensor may be a button-style load cell, for example a Honeywell Model 53. Theload sensor 80 may be positioned on a distal end of the stop as shown in the drawing. Alternatively, the load sensor may be incorporated into the shoulder. Theload sensor 80 may be adapted and configured to sense a load applied against the load sensor when theframe 50 engages thestop 70, for instance, when theshoulder 72 of the frame engages the stop, and more in particular, when the shoulder of the frame engages the load sensor. The stop actuator 74 may also include aposition sensor 82 that is adapted and configured to sense the position of thestop actuator 74 relative to thestructural framework 20 of the pull station. - The pull station may be provided with a
control 90. Thecontrol 90 may include acontroller 92 that includes aprocessor 94 with amemory 96. The frameactuator position sensor 60, the stopactuator position sensor 82, and thestop load sensor 80 may all provide inputs to thecontrol 90 andcontroller 92 for generating signals for controlling the pull station. Additionally, thecontrol 90 may include at least one speed sensor 100,102 for a respective one or both of the top and bottom continuous loops for sensing the speeds of the respective top and bottom continuous loops. Thecontrol 90 may also include a speed sensor 104 (FIG. 2 ) for determining the speed of ribbon or of the plurality of webs as they are drawn from theentrance 26 of the pull station to thedischarge 28 of the pull station. As will be described in greater detail below, setpoints and operating parameters relating to the product format and product manufacturing process, as well as inputs to the controller, may be stored in thememory 96 of thecontroller 90 so as to facilitate set up and operation of the pull station, provide real-time dynamic control of the pull station, and data to assess the efficiency and operational characteristics of the pull station which may assist in maintenance of the pull station. - In one aspect, the
controller 92 is configured to determine a distance measurement D between the topcontinuous loop 22 and the bottomcontinuous loop 24 based upon the frameactuator position sensor 60 as the plurality of webs W are conveyed from theentrance 26 of the pull station to thedischarge 28 of the pull station. In another aspect, thecontroller 92 is configured to determine a force imparted to the plurality of webs based on thestop load sensor 80, the weight of theframe 50 and the topcontinuous loop 22, and a force imparted to the topcontinuous loop 22 by theframe actuator 54. For instance, thestop load sensor 80 may sense the amount of pressure exerted by theframe 50 via theshoulder 72 against thestop 70. The weight of the frame and topcontinuous loop 22 may be a constant value with the remainder of the load applied against thestop load sensor 80 being a function of the position of theend effector 56 of theframe actuator 54, and theframe 50 and topcontinuous loop 22, and the position of thestop actuator 74. To the extent theframe actuator 54 is configured as a pneumatic cylinder, the pressure applied to pneumatic cylinder may also be measured as an input to thecontroller 92, and to the extent the frame actuator is configured as a servo motor drive, the torque of the motor may also be measured as an input to the controller. To the extent the frame actuator is configured as a pneumatic cylinder, if the ribbon imparts a transient force to the top continuous loop, for example, from one or more sections of splice tape that were used to connect an expired parent roll to a new parent roll, or for example, from an unexpectedly thick web in the ribbon or an unexpectedly higher number of webs in the ribbon, the pneumatic cylinder may allow the ribbon to temporarily overcome the force of the pneumatic cylinder and temporarily move the top continuous loop away from the bottom continuous loop. To the extent thestop actuator 74 is configured as a servo motor drive, the torque of the motor may also be measured as an input to thecontroller 92. Thecontroller 92 may be adapted and configured to generate signals for controlling thepull station 16 based upon the distance measurements D and inputs to the controller. This may be useful in benchmarking different substrates and web materials for optimal settings and repeatability in processing. For instance, if certain material properties of a substrate comprising the web materials W are known and/or can be predicted, for instance, from prior product manufacturing processes in the convertingline 10, then initial settings of distance and force may be used to facilitate set-up, and operational parameters may be set, maintained and/or changed as necessary during processing to maximize efficiency and quality. In one example, the force applied by the topcontinuous loop 22 may be controlled so as to limit the amount of force to that which is necessary to prevent slipping of the ribbon while ensuring any liquid or lotion applied to the ribbon is not wrung out of the ribbon. In this respect, the speed of one or both of the top continuous loop and bottom continuous loop may be measured via the respective loop speed sensors 100,102 and compared to aribbon speed sensor 104 to determine a relative amount of slippage. Depending upon the comparison, the position of theframe 50 may be changed with theframe actuator 54 and/or thestop actuator 74. For instance, if the comparison of the speed of one or both of the topcontinuous loop 22 and bottomcontinuous loop 24 compared to the ribbon speed determines an undesirable amount of slippage, then theframe actuator 54 and/or stopactuator 74 may be operated so as to change the position of theframe 50 and topcontinuous loop 22 to apply additional pressure. Theframe actuator sensor 60 and the stopactuator position sensor 82 along withstop load sensor 80 may provide signals to thecontroller 92 that trim control signals from the controller to theframe actuator 54 and/or stopactuator 74 to change the applied pressure. Depending upon the arrangement of the stop actuator and the frame actuator, pressure and/or torque signals of the respective actuators that are directed thecontroller 92 may also be trimmed by signals from the frame actuator and stop actuator position sensors, and the stop load sensor. - The
processor 94 and thememory 96 of thecontroller 92 of the pull station may be configured to store a plurality of data structures in the memory of the controller. The data structures may comprise a plurality of data items associated together as at least one of: (i) the distance measurements between the top continuous loop and the bottom continuous loop as the plurality of webs are conveyed from the entrance of the pull station to the discharge of the pull station, (ii) the load measurements as the plurality of webs are conveyed from the entrance of the pull station to the discharge of the pull station, (iii) the speed of the plurality of webs being conveyed in the pull station, (iv) the speed of the at least one of the top continuous loop and bottom continuous loop as the plurality of webs are conveyed from the entrance of the pull station to the discharge of the pull station, and (v) one or more characteristics representative of the plurality of webs being conveyed in the pull station. The data may be used to assess operational functionality of the pull station and the converting line in general, efficiency of the pull station, product processing relative to previous product processing in the pull station, web material conditions, and maintenance of the pull station. - Further embodiments can be envisioned by one of ordinary skill in the art after reading this disclosure. In other embodiments, combinations or sub-combinations of the above-disclosed invention can be advantageously made. The example arrangements of components are shown for purposes of illustration and it should be understood that combinations, additions, re-arrangements, and the like are contemplated in alternative embodiments of the present invention. Thus, various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims and that the invention is intended to cover all modifications and equivalents within the scope of the following claims.
Claims (21)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US18/200,849 US20240002185A1 (en) | 2022-06-30 | 2023-05-23 | Electronic Nip Adjustment and Pressure Measurement on Pull Station |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US202263357088P | 2022-06-30 | 2022-06-30 | |
| US18/200,849 US20240002185A1 (en) | 2022-06-30 | 2023-05-23 | Electronic Nip Adjustment and Pressure Measurement on Pull Station |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20240002185A1 true US20240002185A1 (en) | 2024-01-04 |
Family
ID=86903954
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US18/200,849 Pending US20240002185A1 (en) | 2022-06-30 | 2023-05-23 | Electronic Nip Adjustment and Pressure Measurement on Pull Station |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US20240002185A1 (en) |
| EP (1) | EP4536574A1 (en) |
| MX (1) | MX2024015000A (en) |
| WO (1) | WO2024005995A1 (en) |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20040051059A1 (en) * | 2002-09-17 | 2004-03-18 | Kimberly-Clark Worldwide, Inc. | Web velocity-based registration control system |
| US20040188909A1 (en) * | 2001-08-09 | 2004-09-30 | Dornbusch Gerold Emil | Former for a folding unit |
| US20060081179A1 (en) * | 2001-05-23 | 2006-04-20 | Voith Paper Patent Gmbh | Device, method and arrangement for pressing two axis-parallel rollers approachable to one another in a device for producing and/or treating a web of material |
| US20160228303A1 (en) * | 2013-09-30 | 2016-08-11 | Zuiko Corporation | Device for producing disposable wearable article and method for producing disposable wearable article |
| US20190008697A1 (en) * | 2015-12-23 | 2019-01-10 | Ontex Bvba | Nonwoven Unit |
| US20210009299A1 (en) * | 2018-02-14 | 2021-01-14 | Essity Hygiene And Health Aktiebolag | Method and apparatus for compressing an elongate stack of folded tissues |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP5697360B2 (en) * | 2010-04-12 | 2015-04-08 | ユニ・チャーム株式会社 | Wet wipes manufacturing method and manufacturing apparatus |
-
2023
- 2023-05-23 WO PCT/US2023/023236 patent/WO2024005995A1/en not_active Ceased
- 2023-05-23 EP EP23733497.4A patent/EP4536574A1/en active Pending
- 2023-05-23 US US18/200,849 patent/US20240002185A1/en active Pending
-
2024
- 2024-12-03 MX MX2024015000A patent/MX2024015000A/en unknown
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20060081179A1 (en) * | 2001-05-23 | 2006-04-20 | Voith Paper Patent Gmbh | Device, method and arrangement for pressing two axis-parallel rollers approachable to one another in a device for producing and/or treating a web of material |
| US20040188909A1 (en) * | 2001-08-09 | 2004-09-30 | Dornbusch Gerold Emil | Former for a folding unit |
| US20040051059A1 (en) * | 2002-09-17 | 2004-03-18 | Kimberly-Clark Worldwide, Inc. | Web velocity-based registration control system |
| US20160228303A1 (en) * | 2013-09-30 | 2016-08-11 | Zuiko Corporation | Device for producing disposable wearable article and method for producing disposable wearable article |
| US20190008697A1 (en) * | 2015-12-23 | 2019-01-10 | Ontex Bvba | Nonwoven Unit |
| US20210009299A1 (en) * | 2018-02-14 | 2021-01-14 | Essity Hygiene And Health Aktiebolag | Method and apparatus for compressing an elongate stack of folded tissues |
Also Published As
| Publication number | Publication date |
|---|---|
| EP4536574A1 (en) | 2025-04-16 |
| MX2024015000A (en) | 2025-01-09 |
| WO2024005995A1 (en) | 2024-01-04 |
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