GB2584200A

GB2584200A - Roll winding apparatus

Info

Publication number: GB2584200A
Application number: GB2004495.4A
Authority: GB
Inventors: Beynon David
Original assignee: Daco Solutions Ltd
Current assignee: Daco Solutions Ltd
Priority date: 2020-03-27
Filing date: 2020-03-27
Publication date: 2020-11-25
Anticipated expiration: 2040-03-27
Also published as: GB202004495D0; GB2584200B

Abstract

A roll winding apparatus (10 fig.1) for handling flexible web material 60 has a rotatable winding spindle 16a on which a winding core 62 is releasably mounted. A translation mechanism 18, such as a turret, moves the winding spindle about a closed loop path between an adhesive station 1 and a winding station 2. At the adhesive station a strip or line of adhesive (70 fig.10) is positioned on the winding core in a first core orientation. At the winding station the winding core is stationarily positioned in a second core orientation where a pressing mechanism 100 presses the already aligned flexible web material to the adhesive. A drive mechanism (28 fig.3) is arranged to rotate the winding spindle at the second station. The turret may be rotated to a third station to allow a wound roll to be unloaded whilst another is being wound. A sensor, such as a laser, may be used to determine if the winding core is in the predetermined second orientation.

Description

ROLL WINDING APPARATUS

FIELD

The present teachings relate to a roll winding apparatus. In addition, the present teachings relate to a method of operating a roll winding apparatus.

BACKGROUND

Turret winders are known for winding a continuous web of flexible web material, for example arrays of individual labels on a backing paper onto smaller diameter or narrower rolls for subsequent use. As such the turret winder may be downstream of other processes such as slitters that separate a wide web into multiple narrower webs, finishing processes, or a process to remove scrap material from around the array of labels.

Various arrangements are known to control the rewinders and allow full rolls to be removed, new cores that support the web to be placed on the winder, and the web to be adhered to the winder.

Some expensive machines are highly automated and wrap the web around the core frictionally. However, this high capital cost, and need for skilled operators is prohibitive for many potential customers. In addition, in certain circumstances it is known for the core to fall out of the roll after winding has taken place, which is undesirable.

Some lower cost winders partially immerse an empty core in a liquid hot melt adhesive that is then used to adhere a free end of the web to the core. Whilst these machines are generally reliable, one significant drawback is that the adhesive when still liquid may be transferred to an upper face of labels by the spinning of the core. Such labels are then often printed on by thermal printers and the like e.g. when being used by courier companies for despatch information, or for the printing of batch, use by, best before, or other information on the labels for food products. Further, hot melt adhesive poses a risk to the health and safety of an operator of the winder. This is because the hot melt adhesive has the potential to burn the operator and fumes emanating from the hot met adhesive may be toxic.

Such printers have expensive and delicate print heads that run close to the surface of the label. The print heads can therefore be damaged by the stray adhesive from the cores.

The heads are expensive to replace, and the downtime arising from their damage can lead to considerable costs through lost production.

Some winders require a strip of adhesive to be applied to a core before the winder positions the core adjacent to a leading edge of web material that is to be rolled onto the core. The core is then rotated whilst the leading edge of web material is pressed against the core. Once the leading edge contacts and adheres to the strip of adhesive, the web material may then be wound onto the core.

In such winders, the core must be initially rotated relatively slowly to ensure sufficient contact between the leading edge and the adhesive strip, adversely increasing the total winding time. Further, to avoid tearing the web material, a relatively light pressure must be applied to the leading edge of web material as it is pressed against the rotating core.

In some cases, this may lead to insufficient adhesion between the leading edge and the core, resulting in the web material disconnecting from the core during the initial stages of winding. This may require the winder to be stopped whilst it is reset.

The present teachings seek to overcome or at least mitigate the problems of the prior art. SUMMARY According to a first aspect of the present teachings, there is provided a roll winding apparatus for handling flexible web material. The apparatus comprises: at least one winding spindle supported for rotation and arranged to releasably mount a winding core thereon; a translation mechanism arranged to translate the at least one winding spindle about a closed loop path between at least a first station and a second station at which an operation may be performed, the first station being an adhesive station at which a strip or line of adhesive is positioned on a winding core in a first core orientation, and the second station being a winding station at which the winding spindle is configured to wind a web of flexible material onto the winding core; a drive mechanism arranged to rotate the at least one winding spindle at the second station; and a pressing mechanism arranged to movably press a portion of flexible web material against the winding core at the second station, wherein the apparatus is configured to stationarily position the winding core in a predetermined second core orientation at which the strip or line of adhesive on the winding core and a leading edge of flexible web material are aligned, actuate the pressing mechanism to press the leading edge of flexible web material against the line or strip of adhesive on the winding core, and commence winding thereon.

Advantageously, the apparatus allows for a faster adhesion between the leading edge of flexible web material and the strip of adhesive, since the apparatus may automatically align the leading edge and strip of material before pressing them together. This negates the need to rotate the core until the leading edge catches the strip of adhesive. Further, since the assembly may automatically align the leading edge and strip of adhesive, a higher pressing pressure can be provided, which helps to ensure a stronger adhesion. This is in comparison to the prior art in which a lower pressing pressure is required to ensure that the web material does not tear whilst attempting to adhere the leading edge to the strip of adhesive on the rotating core.

The roll winding apparatus may further comprise a sensor arrangement configured to determine whether the winding core is in the predetermined second core orientation.

This provides the apparatus with feedback to help automatically align the strip of adhesive and leading edge of the web material.

The roll winding apparatus may be configured to rotate the winding core at the second station until the sensor arrangement determines that the winding core is in the predetermined second core orientation.

This allows the apparatus to more accurately align the strip of adhesive and the leading edge of web material.

The sensor arrangement may comprise a sensor component, such as an inductivity proximity sensor or an optical sensor, located at the second station.

This provides a simple and accurate means for sensing the orientation of the winding spindle and the winding core.

The first station may comprise a spindle brake configured to inhibit the winding spindle from rotating on engagement therewith.

This helps to ensure that the spindle remains in a fixed orientation when the strip of adhesive is applied to the core.

The spindle brake and the winding spindle may be mutually configured such that the winding spindle is in a predetermined spindle orientation on engagement with the spindle brake, the predetermined spindle orientation corresponding to the first core orientation of the winding core.

Arranging the winding spindle to be in the predetermined spindle orientation at the first station may help the apparatus to determine the position of the line of adhesive on the core when it reaches the second station.

The roll winding apparatus may be configured to rotate the winding spindle until the spindle brake engages the winding spindle at the first station.

This speeds up the winding process, since it negates the need for an operator to manually rotate the winding spindle at the first station.

The winding spindle may comprise a first planar surface and a curved surface joining first and second edges of the first planar surface.

The spindle brake may comprise a second planar surface arranged to movably engage the first planar surface.

This allows the curved portion of the winding spindle to rotate adjacent to the spindle brake until the first and second planar surfaces engage, at which time the winding spindle is inhibited from rotating.

The sensor component may be configured to detect a corner of the winding spindle at which the curved surface joins the first edge of the first planar surface.

This allows an easily identifiable region of the winding spindle to act as a datum for determining the predetermined spindle orientation.

The first station may comprise a marker arrangement to indicate a predetermined angular position on the winding core at which the strip or line of adhesive strip is applied to permit the application of adhesive to the winding core in situ on the spindle.

If the adhesive strip is manually applied, the marker arrangement assists in achieving accurate alignment.

The marker arrangement may comprise a light, preferably a laser light, projected onto the winding core in a particular location.

A marker arrangement that projects a light on the core may allow the alignment to be easier to achieve by an operator of the apparatus.

The roll winding apparatus may be configured such that the leading edge of flexible web material is substantially static immediately prior to actuation of the pressing mechanism.

Configuring the apparatus such that the leading edge of flexible web material is static immediately prior to actuation of the pressing mechanism may provide a more accurate alignment between the strip of adhesive and the leading edge of flexible material.

The roll winding apparatus may be configured to accelerate the winding spindle at the second station from a zero rotational speed to a non-zero operational winding speed to wind the web of flexible material onto the winding core.

The second station may comprise a cutting mechanism arranged to cut the flexible web material to define a trailing cut edge of a first web portion and a leading cut edge of a second web portion.

This allows the apparatus to unload a fully wound core and begin to wind a separate core.

The roll winding apparatus may comprise two spindles.

The roll winding apparatus may comprise a third station, the third station being an unloading station.

The third station may be at a different location to both the first and second stations, and the apparatus may comprise three spindles.

This speeds up the winding process since a first core can be unloaded at the third station whilst a second core is being wound at the second station and adhesive is being applied to a third core at the first station.

The strip of adhesive may be a strip of double sided adhesive tape.

According to a second aspect of the present teachings, there is provided a method of operating a roll winding apparatus. The method comprises the steps of: a) providing a strip or line of adhesive to a winding core in a first core orientation, the winding core releasably mounted on a winding spindle at a first station; b) stationarily positioning the winding core in a predetermined second core orientation in which the strip or line of adhesive and a leading edge of flexible web material are aligned at a second station; c) pressing the leading edge of flexible web material against the line or strip of adhesive on the winding core at the second station, and commencing winding thereon.

The method may be carried out on an apparatus according to the first aspect of the present 25 teachings.

The method may further comprise the steps of determining whether the winding core is in the predetermined second core orientation via a sensor arrangement.

In step b) of the method, the winding spindle may be rotated at the second station until the sensor arrangement determines that the winding core is in the predetermined second core orientation.

In step a) of the method, the winding spindle may be in a predetermined spindle orientation as the line or strip of adhesive is provided to the winding core, the predetermined spindle orientation corresponding to the first core orientation of the winding core.

In step c) of the method, immediately prior to pressing the leading edge of flexible web material against the line or strip of adhesive on the winding core, the leading edge of flexible web material may be substantially static.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are now disclosed by way of example only with reference to the drawings, in which: Figure 1 is a front view of a roll winding apparatus according to a first aspect of the present teachings; Figure 2 is a front isometric view of the roll winding apparatus of Figure 1; Figure 3 is a rear view of the roll winding apparatus of Figure 1 with a number of components removed for clarity; Figure 4 is a rear isometric view of the roll winding apparatus of Figure 1 with a number of components removed for clarity; Figure 5 is a magnified view of a portion of Figure 1; Figure 6 is a magnified view of a portion of Figure 3; Figure 7 is a cross-sectional view of a rear portion of a spindle and a spindle brake for use in the apparatus of Figures 1 to 6; Figure 8 is a schematic representation of a controller for use in the apparatus of Figures 1 to 6; Figure 9 is a schematic representation of a step of a method according to a second aspect of the present teachings; Figure 10 is a schematic representation of a step of the method of Figure 9; Figure 10a is a magnified front isometric view of the method step shown in Figure 10; and Figures 11 to 13 are schematic representations of steps of the method of Figure 9.

DETAILED DESCRIPTION OF EMBODIMENT(S)

Figures 1 to 7 illustrate a roll winding apparatus indicated generally at 10 for handling flexible web material 60, such as webs of labels for packaging. The apparatus 10 is illustrated as a freestanding unit, but may in other embodiments be incorporated into a printing press or the like. As illustrated, the apparatus 10 comprises a structural chassis 12 in the form of a vertical plate on to which the components of the apparatus 10 are mounted.

Figures 1 and 2 show the components that handle the web material 60, whereas in Figures 3 and 4, the drive components of the apparatus 10 are visible. These components are described in more detail below. In Figure 2, a housing 14 for the drive components is present, but in Figure 4 this is omitted for improved clarity. Guards are provided on the front of the apparatus 10 for operator safety, but are also omitted for clarity.

In the illustrated embodiment, the apparatus 10 comprises three winding spindles 16 arranged as cylindrical members extending in a cantilevered arrangement away from the chassis 12. In other embodiments the number of spindles may differ. For example, one or two may be provided, although this may reduce the throughput of the apparatus.

Each spindle 16 is rotatable about its longitudinal axis. The spindles 16 are arranged to receive winding cores 62 thereon, e.g. one core or multiple cores arranged co-axially end to end. The spindles 16 have an arrangement (not shown) to releasably hold the cores 62 in a fixed axial and angular relationship to the spindles, e.g. using teeth that extend radially from the spindle or via an interference fit. The winding cores 62 used are typically cardboard tubes, but may also be formed of plastics or metallic material.

The spindles 16 are mounted on a translation mechanism arranged to translate the winding spindles 16 about a closed loop path between stations at which an operation may be performed. In this embodiment the spindles are mounted to turret 18 in the form of a rotatable disc. The angular and radial spacing of the spindles 16 about the centre of rotation is equal. The turret 18 is intended to rotate so that the spindles 16 are translated between three stations at which particular operations are to be performed as described in more detail below. A turret motor 34, which in this embodiment is an inverter driven AC induction motor, is provided to rotate the turret. In alternative embodiments (not shown), the turret motor 34 may be a servo motor.

In order for the spindles 16 to be able to rotate about their own individual axes, a drive mechanism indicated generally at 28 is arranged selectively and independently rotate the winding spindles at one of the stations as described in more detail below.

The first station 1 may be designated as a loading or an adhesive station at which a strip or line of adhesive 70 is positioned on a core 62 in a first core orientation.

The second station 2 may be designated as a winding station at which the core 62 is stationarily positioned in a predetermined second core orientation 110 in which the strip or line of adhesive 70 is aligned with a leading edge 83 of flexible web material 60. The leading edge 83 is then pressed against the strip or line of adhesive 70, and the web of flexible web material 60 is wound onto the core 62 thereafter.

The third station 3 may be designated as an unloading station where fully wound rolls are removed from the apparatus.

Considering the features of each station in more detail: The adhesive station 1 comprises a marker arrangement to indicate a predetermined angular position of the adhesive strip 70 on the first core 62. This assists in the application of adhesive to the core in situ on the spindle, or if adhesive has been pre-applied, allows the core 62 to be rotated to the correct angular position for alignment to be achieved.

Whilst the marker may be a physical indicator at each end of the spindle 16 to show where the ends of the adhesive strip 70 are to be located, in this embodiment, the marker is a light, preferably a laser light from a laser light emitter 26, which is projected onto the spindle 16 in a particular location. This has been found to assist more accurate alignment.

To ensure that the alignment does not shift from this position whilst the adhesive is being applied, a spindle brake 22 is provided for the spindles at station 1.

With reference to Figure 7, which shows a rear portion of the spindle 16, it can be seen that the spindle 16 includes a first planar surface 48 and a curved surface 49 joining first 47a and second 47b corners of the first planar surface 48. The spindle brake 22 includes a second planar surface 24 that is arranged to movably engage the first planar surface 48.

Once the first planar surface 48 of the spindle 16 and the second planar surface 24 of the spindle brake 22 are engaged, the spindle 16 is inhibited from rotating about its longitudinal axis and is in a predetermined first spindle orientation 45 (discussed more below).

The second planar surface 24 is formed on a flat arm 25, which is supported at one end by a resilient support (a pneumatic cylinder 23 in this embodiment) mounted to the chassis 12 and acts as a ramp that engages the spindle 16 during rotation of the turret 18.

In alternative embodiments (not shown), the spindle brake may be achieved in numerous alternative ways.

For example, the spindle brake may be in the form of servo motor(s) configured to drive an individual spindle for winding and controlling its orientation. Each servo motor is also configured to inhibit the spindle 16 from rotating when the servo motor in a braking mode; i.e. when the servo motor is activated in a braking mode. In this embodiment a servo motor is provided for each spindle and the or each servo motor is mounted to the turret 18. Accordingly a slip ring arrangement may be provided to provide electrical power and control to the or each servo motor at whatever rotational position of the turret 18.

When the turret 18 is rotated, in the clockwise direction in Figure 7, the spindle 16 arriving at the first station 1 may be orientated such that the curved surface 49 engages the second planar surface 24 of the spindle brake 22; i.e. the spindle 16 is not in the predetermined first spindle orientation 45. As the turret 18 rotates, the friction between the second planar surface 24 and the curved surface 49 causes the spindle 16 to rotate about its axis, in an anti-clockwise direction in Figure 7, until the first planar surface 48 engages the second planar surface 24, after which the spindle 16 is in the predetermined first spindle orientation 45 and is inhibited from rotating further. The arm 25 is long enough to ensure that engagement will always occur irrespective of the starting orientation of the spindle 16.

The winding station 2 includes a cutting mechanism 20 and a pressing mechanism 100.

The cutting mechanism 20 is arranged to cut the flexible web material 60 to define a trailing cut edge 81 of a first web portion 80 and a leading cut edge 83 of a second web portion 82; see Figure 12. The cutting mechanism 20 includes a cutter (not shown) located above the path of the web 60 that lowers to cut the web 60.

In the illustrated embodiment, the cutting mechanism 20 is controlled via a controller 50, as shown in Figure 8. The controller 50 is configured to actuate the cutting mechanism 20 to cut the web 60 when the controller 50 determines that a predetermined length of web material 60 has been wound onto the core 62 at the second station 2, as will be discussed more below. The controller 50 is a suitable industrial microprocessor controller and is also linked to a display 52 and one or more user inputs 54 such as buttons of a touch screen interface. These are used to set up, control and monitor the apparatus 10.

The predetermined length of web material 60 to be wound onto the core 62 can be adjusted by the operator of the roll winding apparatus 10 via the user inputs 54. The predetermined length may be input in units of length such as in meters or feet, or may be input as the number of labels on the web material 60 to be wound onto the core 62.

The pressing mechanism 100 is arranged to movably press a portion of web material 60 against the core 62 in response to a signal sent by the controller 50. The pressing mechanism 100 includes a pressing surface 101 that moves linearly from a retracted position to an extended position (not shown) under the action of a pressing actuator 102. The pressing surface 101 is shown in its retracted position in the figures. In its extended position, the pressing surface 101 is able to abut and apply pressure to the web material 60 and the core 62 at the second station 2, which presses the web material 60 against the core 62.

In the illustrated embodiment, the pressing surface 101 is formed on a roller having a circular cross-section and a longitudinal length substantially equal to the longitudinal length of the core 62. The roller is mounted to the pressing actuator 102 such that it is able to rotate about its longitudinal axis. This helps to minimise shear forces imparted onto the web 60 by the pressing mechanism 100, and thus helps to ensure that the web 60 does not tear.

However, in alternative embodiments (not shown), the pressing surface 101 may be formed on a non-rotatable body. In such embodiments, the pressing surface 101 may be substantially planar or may be curved (e.g. a convex surface). Further, the pressing surface 101 may be formed from a low friction material such as PTFE.

In the illustrated embodiment, the pressing actuator 102 is a pneumatic actuator. However, in alternative embodiments (not shown), the pressing actuator 102 may be a linear electric actuator, a hydraulic actuator or any other suitable actuator for example.

To provide rotational drive to the spindle 16 at the second station 2, the rear of the apparatus 10 is provided with a drive transfer device in the form of a spindle drive belt 36 which is driven by a spindle drive motor 30. In this embodiment, the motor is a servo motor so as to provide accurate speed signals to the controller 50, and so that the controller is able to accurately control the drive.

In alternative embodiments (not shown), a spindle drive motor may drive the spindle 16 at the second station via an arrangement of gears.

The belt 36 extends over the top of the turret 18, so that when a spindle 16 moves to the second station 2 it automatically drivingly engages the belt 36.

The arrangement of the belt 36 described above always enables the motor 30 to independently drive the spindle 16 at the second station 2 irrespective of whether the spindle at the second station 2 is spindle 16a, 16b or 16c.

With reference to Figures 1 and 2, at an infeed to the apparatus 10, a nip drive 125 controls the speed of the web 60 by using a nip drive motor 127 driving a nip roller 129. The nip drive motor 127 is controlled by the controller 50 such that the speed of the web 60 traveling from the nip drive 125 towards the cutting mechanism 20 may be varied from a zero speed to a non-zero speed.

With reference to Figures 7, 8 and 10, the apparatus 10 includes a sensor arrangement 90, which is configured to determine whether or not the core 62 is in the predetermined second core orientation 110 (discussed more below) when the core 62 is at the second station 2.

The sensor arrangement 90 includes a sensor component 92 mounted to the rear of the chassis 12 proximate the rear of the spindle 16 at the second station 2. In the illustrated embodiment, the sensor component 92 is an inductivity proximity sensor.

However, in alternative embodiments (not shown), the sensor component 92 may be a Hall Effect type sensor.

The sensor component 92 is configured to detect the first corner 47a of the spindle 16, which is formed from a metallic material, by sensing the transition from the curved surface 49 to the first planar surface 48. The sensor arrangement 90 is arranged such that the sensor component 92 detects the first corner 47a when the spindle 16 is in a predetermined second spindle orientation. Since the core 62 is fixed relative to the spindle 16, the predetermined second spindle orientation is chosen to correspond to the predetermined second core orientation 110. The sensor arrangement 90 is configured to notify the controller 50 when the core 62 is in the predetermined second core orientation at the second station 2.

However, in alternative embodiments, the controller 50 may determine when the core 62 is in the predetermined second core orientation 110 at the second station 2 from signals received from the sensor arrangement 90.

In alternative embodiments (not shown), the sensor component 92 may be arranged to detect a metallic or magnetic element mounted to an external surface of the spindle 16 in order to determine when the core 62 is in the predetermined second core orientation 110.

In alternative embodiments (not shown), the sensor arrangement 90 may include an optical sensor, for example mounted to the chassis 12, that is configured to detect the strip or line of adhesive 70 on the core 62. In such embodiments, the sensor arrangement 90 may determine that the core 62 is in the predetermined second core orientation 110 at the second station 2 when the optical sensor detects the strip or line of adhesive 70 on the core 62.

The apparatus 10 is configured to rotate the spindle 16 at the second station 2 until the sensor arrangement 90 determines that the core 62 is in the predetermined second core orientation 110. In the illustrated embodiment, the apparatus 10 rotates the spindle 16 and therefore the core 62 at the second station 2 via the spindle drive motor 30 and the spindle drive belt 36.

The unloading station 3 allows wound core(s) 64 to be removed from the spindle 16 without interfering with the operation of the loading and winding.

With reference to Figures 9 to 13, the apparatus operates as follows: Turning to Figure 9, at the loading station 1, the spindle brake 22 engages the spindle 16a as shown in Figure 7, and hence the spindle 16a is in the predetermined first spindle orientation 45. An operator then slides one or more cores 62 onto the spindle 16a. The core(s) 62 are arranged such that they are fixed relative to the spindle 16a. Once received on the spindle 16a, the winding core(s) 62 are in the first core orientation which corresponds to the predetermined first spindle orientation 45.

A line of light is shone on to the cores 62 from the laser light emitter 26 parallel to the axis of the cores at a predetermined angular position on the core(s) 62. By angular position, it is meant a position on the circumference of the core(s) 62 which is fixed relative to the spindle 16a. Using a tape applicator, the operator applies a line of double sided adhesive tape 70 to the core(s) 62 in alignment with the light thereby providing a strip of adhesive 70 on the core(s) 62.

Turning to Figure 10, the turret 18 is rotated (anticlockwise in Figure 10) until the spindle 16a arrives at the winding station 2. The spindle 16a is free to rotate about its longitudinal axis with respect to the turret 18 as it travels from the loading station 1 to the winding station 2. Therefore, the orientation of the core(s) 62 with respect to the turret 18 may change as it moves from the loading station 1 to the winding station 2.

At the winding station 2, the spindle 16a is rotated (clockwise in Figure 10) until the sensor arrangement 90 determines that the core 62 is in the predetermined second core orientation 110. As shown in Figures 10 and 10a, in the predetermined second core orientation 110, the line of adhesive tape 70 on the core(s) is aligned with a leading edge 83 of web material 60 which is to be wound.

By virtue of the spindle brake 22 orientating the spindle 16a at the loading station 1 into the predetermined first spindle orientation 45, the adhesive tape 70 being provided onto the core(s) 62 at the predetermined angular position relative to the spindle, and the core(s) 62 being fixed relative to the spindle 16a, the predetermined second core orientation 110 is chosen such that the controller 50 knows that the adhesive tape 70 is aligned with the leading edge 83 when the core(s) 62 is in the predetermined second core orientation 110 at the winding station 2.

In alternative embodiments (not shown), for example in which the sensor arrangement includes an optical sensor mounted to the chassis 12 that is configured to detect the strip or line of adhesive 70 on the core(s) 62 at the second station 2, the orientations of the spindle 16a and the core(s) 62 and the angular position of the strip or line of adhesive 70 on the core(s) 62 at the first station 1 may not be predetermined, i.e. the strip or line of adhesive 70 may be located at any angular position on the core(s) 62 at the first station 1. In such embodiments, the apparatus 10 may not include the marker arrangement 26.

The pressing mechanism 100 is located above and is aligned with the leading edge 83 and the adhesive 70 when the core 62 is in the predetermined second core orientation 110 as shown in Figure 10. The pressing mechanism 100 is actuated such that the pressing surface 101 presses the leading edge 83 against the adhesive tape 70 on the core(s) 62.

Pressing of the leading edge 83 against the adhesive tape 70 causes the leading edge 83 to adhere to the core(s) 62.

Immediately prior to the pressing mechanism 100 being actuated, the leading edge 83 of the web material 60 and the spindle 16a are both substantially static. This aids in ensuring that the alignment between the leading edge 83 and the adhesive tape 70 is accurate and precise, as well as allowing a higher pressing force to applied by the pressing mechanism 100 since it has been found that the probability of the web material 60 tearing is low relative to if either the spindle 16 or the leading edge 83 were not static.

Advantageously, since the leading edge 83 and the adhesive 70 are automatically aligned prior to the pressing mechanism 100 being actuated, the need to press the leading edge 83 against the core 62 whilst the core 62 slowly rotates for a full rotation until the leading edge 83 catches the strip of adhesive 70 is negated. This helps to reduce unproductive time when no winding occurs and speeds up the winding process.

Further, the reliability of the initial phase of winding is improved relative to prior art machines. This is because the higher pressing force applied by the pressing mechanism 100 to the leading edge 83 provides stronger adhesion of the leading edge 83 to the core(s) 62. This reduces the likelihood that the leading edge 83 will detach from the core(s) 62 as winding commences.

Turning to Figure 11, the spindle 16a is rotated (clockwise in Figure 11) at the winding station 2 to wind the web material 60 onto the core(s) 62. To achieve this, the drive mechanism 28 accelerates the spindle 16a at the winding station 2 from a zero rotational speed to a non-zero operational winding speed. The acceleration may be higher than in known apparatuses in view of the greater adhesion due to higher pressing force, further improving productivity.

It can be seen in Figure 11 that a new core has been slid onto the spindle 16c at the loading station 1 ready for adhesive 70 to be applied to it.

Turning to Figure 12, once a predetermined length of web material 60 has been wound onto the core(s) 62, the drive mechanism 28 decelerates the spindle 16a at the second station 2 until the spindle 16a is stationary. Either immediately prior to or immediately after the spindle 16a has been decelerated to a zero rotational speed, the cutting mechanism 20 cuts the web material 60, to produce a leading edge 83 of a second web portion 82 of and a trailing edge 81 of a first web portion 80.

Either prior to or after the cutting mechanism 20 has cut the web material 60, an operator applies a layer of adhesive 112 at a predetermined location on the exterior of the wound core 64 whilst the spindle 16a is static. Once the adhesive 112 has been applied, the spindle 16a rotates until the trailing edge 81 contacts and adheres to the adhesive 112. This helps to ensure that the web material 60 remains wound around the core(s) 62. In some embodiments, the pressing mechanism 100 may press the trailing edge 81 against the adhesive 112.

In alternative embodiments (not shown), after the cutting mechanism 20 has cut the web material 60, a self-adhesive label is applied to the wound core 64 to adhere the trailing edge 81 to the exterior of the wound core 64 in order to ensure that the web material 60 remains wound around the core(s) 62. The self-adhesive label may be either manually applied by an operator of the apparatus 10 or by an automatic label applicator system.

After the cutting mechanism 20 has cut the web material 60, the nip drive 125 moves the leading edge 83 of the second web portion 82 to a predetermined location. In the illustrated embodiment, the predetermined location of the leading edge 83 is chosen such that the pressing mechanism 100, the leading edge 83 and the strip of adhesive 70 on the core 62 in the predetermined second core orientation 110 are in alignment, as shown in Figure 10.

The roll winding apparatus 10 may include a feedback arrangement in communication with the nip drive 125 to aid in accurately moving the leading edge 83 of the second web portion 82 to the predetermined location. For example, the nip drive 125 may include an encoder arranged to provide feedback corresponding to the length of web material 60 that has passed through the nip drive 125, or if the nip drive 125 is provided by a servo motor such an encoder is built into the servo motor itself. The predetermined location may be set by an operator based on the diameter of the spindles of the apparatus.

Turning to Figure 13, the turret 18 is rotated (anticlockwise in Figure 13) until the spindle 16a arrives at the unloading station 3, where the wound core(s) 64 may be unloaded either by an operator or by an automated unloading mechanism (not shown).

It can be seen in Figure 13, that whilst the wound core(s) 64 on the spindle 16a is at the unloading station 3, the core 62 on spindle 16c is being wound at the winding station 2 and a new core 62 has been loaded onto the spindle 16b at the loading station 1 ready for adhesive 70 to be applied to it. This process may be repeated as long as desired, with the operator adding and applying adhesive 70 to empty cores 62 at station 1 and unloading wound cores 64 at station 3 whilst the apparatus 10 operates.

As a spindle 16 transitions from the unloading station 3 to the loading station 1, the spindle brake 22 engages the spindle 16. If the first planar surface 48 is not aligned with the second planar surface 24, the spindle 16 rotates and if required the arm 25 pivots against the action of the pneumatic cylinder 23 until the first 48 and second 24 planar surfaces are aligned and further rotation of the spindle 16 is prevented. The arm 25 is long enough to ensure that alignment will always occur irrespective of the starting orientation of the spindle 16. This means that the starting orientation of the spindle during loading is always known as described above.

It will be understood that numerous changes may be made within the scope of the present teachings. For example other forms of adhesive strip 70 may be used, although hot melt adhesive is not preferred for the reasons discussed above. The adhesive may be applied before loading onto the spindles. The adhesive may be applied in an automated process (in which case no visual marker may be required for correct orientation of the adhesive). Loading and/or unloading of the cores may be automated. Alternative drive mechanisms may be used such as individual motors for each spindle.

Claims

CLAIMS1. A roll winding apparatus for handling flexible web material, the apparatus comprising: at least one winding spindle supported for rotation and arranged to releasably mount a winding core thereon; a translation mechanism arranged to translate the at least one winding spindle about a closed loop path between at least a first station and a second station at which an operation may be performed, the first station being an adhesive station at which a strip or line of adhesive is positioned on a winding core in a first core orientation, and the second station being a winding station at which the at least one winding spindle is configured to wind a web of flexible material onto the winding core; a drive mechanism arranged to rotate the at least one winding spindle at the second station; and a pressing mechanism arranged to movably press a portion of flexible web material against the winding core at the second station, wherein the apparatus is configured to stationarily position the winding core in a predetermined second core orientation at which the strip or line of adhesive on the winding core and a leading edge of flexible web material are aligned, actuate the pressing mechanism to press the leading edge of flexible web material against the line or strip of adhesive on the winding core, and commence winding thereon.
2. The roll winding apparatus of claim 1 further comprising a sensor arrangement configured to determine whether the winding core is in the predetermined second core orientation.
3. The roll winding apparatus of claim 2, wherein the apparatus is configured to rotate the winding core at the second station until the sensor arrangement determines that the winding core is in the predetermined second core orientation.
4. The roll winding apparatus of claims 2 or 3, wherein the sensor arrangement comprises a sensor component, such as an inductivity proximity sensor or an optical sensor, located at the second station.
5. The roll winding apparatus of any preceding claim, wherein the first station comprises a spindle brake configured to inhibit the winding spindle from rotating on engagement therewith.
6. The roll winding apparatus of claim 5, wherein the spindle brake and the winding spindle are mutually configured such that the winding spindle is in a predetermined spindle orientation on engagement with the spindle brake, the predetermined spindle orientation corresponding to the first core orientation of the winding core.
7. The roll winding apparatus of claims 5 or 6, wherein the apparatus is configured to rotate the winding spindle until the spindle brake engages the winding spindle at the first station.
8. The roll winding apparatus of any preceding claim, wherein the winding spindle comprises a first planar surface and a curved surface joining first and second edges of the first planar surface.
9. The roll winding apparatus of claim 8 when dependent on any one of claims 5 to 7, wherein the spindle brake comprises a second planar surface arranged to movably engage the first planar surface.
10. The roll winding apparatus of claim 8 when dependent on claim 4, wherein the sensor component is configured to detect a corner of the winding spindle at which the curved surface joins the first edge of the first planar surface.
11. The roll winding apparatus of any preceding claim, wherein the first station comprises a marker arrangement to indicate a predetermined angular position on the winding core at which the strip or line of adhesive strip is applied to permit the application of adhesive to the winding core in situ on the spindle.
12. The roll winding apparatus of claim 11, wherein the marker arrangement comprises a light, preferably a laser light, projected onto the winding core in a particular location.
13. The roll winding apparatus of any preceding claim, wherein the apparatus is configured such that the leading edge of flexible web material is substantially static immediately prior to actuation of the pressing mechanism.
14. The roll winding apparatus of any preceding claim, wherein the apparatus is configured to accelerate the winding spindle at the second station from a zero rotational speed to a non-zero operational winding speed to wind the web of flexible material onto the winding core.
15. The roll winding apparatus of any preceding claim, wherein the second station comprises a cutting mechanism arranged to cut the flexible web material to define a trailing cut edge of a first web portion and a leading cut edge of a second web portion.
16. The roll winding apparatus of any preceding claim comprising two spindles.
17. The roll winding apparatus of any preceding claim further comprising a third station, the third station being an unloading station.
18. The roll winding apparatus of claim 17, wherein the third station is at a different location to both the first and second stations, and wherein the apparatus comprises three spindles.
19. The roll winding apparatus of any preceding claim, wherein the strip of adhesive is a strip of double sided adhesive tape.
20. A method of operating a roll winding apparatus, the method comprising the steps of: d) providing a strip or line of adhesive to a winding core in a first core orientation, the winding core releasably mounted on a winding spindle at a first station; e) stationarily positioning the winding core in a predetermined second core orientation in which the strip or line of adhesive and a leading edge of flexible web material are aligned at a second station; f) pressing the leading edge of flexible web material against the line or strip of adhesive on the winding core at the second station, and commencing winding thereon.
21. The method of claim 20 wherein the method is carried out on an apparatus according to any one of claims 1 to 19.
22. The method of claims 20 or 21 further comprising the steps of determining whether the winding core is in the predetermined second core orientation via a sensor arrangement.
23. The method of claim 22, wherein in step b) the winding spindle is rotated at the second station until the sensor arrangement determines that the winding core is in the predetermined second core orientation.
24. The method of any one of claims 20 to 23, wherein in step a) the winding spindle is in a predetermined spindle orientation as the line or strip of adhesive is provided to the winding core, the predetermined spindle orientation corresponding to the first core orientation of the winding core.
25. The method of any one of claims 20 to 24, wherein in step c) immediately prior to pressing the leading edge of flexible web material against the line or strip of adhesive on the winding core, the leading edge of flexible web material is substantially static.