Two known reeling apparatus of this type are Beloit Corporation's TNTz and ATR reels. The former is disclosed in U. S Patent No.

5,370,327, and the latter is disclosed in U. S Patent No. 5,560,566.

The ATR (Advanced Tissue Reel) reel was developed with a view to apply all the advantages of the TNT (Tension, Nip and Torque) reel to high bulk grades of paper, especially tissue. These grades of paper require winding at little or no nip pressure so that as much of their inherent bulk can be retained as possible. In order to attain control of very low nips, the ATR reel utilizes a large diameter reel drum on a fixed stand. The ATR reel differs from the TNT reel in that with the TNT reel, the reel drum can be raised or lowered in elevation. This allows the paper to be transferred to the new reel spool on the wet-end side of the reel drum (upstream in the paper machine process). After winding of the paper begins, the reel spool/winding roll of paper is moved downstream by its guiding carriages.

This movement causes the reel drum to move downwards to allow the winding roll of paper over the top of the reel drum.

SUMMARY OF THE INVENTION The invention provides a machine for the winding of a continuous web of material onto a spool or mandrel. The machine comprises a winding drum, support arms front and back sides, support rails, turn-up devices and motors to drive the winding drum and the spool. The winding drum provides one of the nips and main support for the wound roll. The support arms provide the desired amount of nip between the winding drum and the winding roll. The support rails support the spool when the roll reaches a determined diameter. The turn-up devices are used to transfer the web from the finished reel to the new spool.

The machine is also designed to allow for centerwind assist from turn-up through finished reel. There are several ways this could be accomplished. One way is to have two separate drives. One could be used to wind from turn-up through to when the roll is rotated into its final winding orientation. Then the second larger centerwind drive would engage and continue to apply centerwind torque throughout roll build-up.

Another way is to utilize a set of motors for every set of arms. Each motor set would apply centerwind assist throughout roll buildup.

More particularly, the invention provides a winding apparatus comprising a winding drum rotatable about a winding drum axis extending in the cross-machine direction, the winding drum having axially spaced first and second ends. The apparatus also comprises first and second support members supported adjacent the first and second ends, respectively, of the winding drum, the first and second support members being pivotable about the winding drum axis and relative to the winding drum. A spool is rotatable about a spool axis parallel to the winding drum axis, the spool having axially spaced first and second ends supportable by the first and second support members, respectively. A support member drive mechanism simultaneously moves the first and second support members-so that the spool, when the first and second ends of the spool are respectively supported by the first and second support members, is moved between angularly spaced first and second positions with the web passing between the winding drum and the spool such that the winding drum and the spool exert a nip pressure on the web while the web is wound onto the spool.

The invention also provides a winding apparatus comprising a winding drum as described above, and first and second support surfaces adjacent the first and second ends, respectively, of the winding drum, the first and second support surfaces being oriented at a non-vertical and non- horizontal angle. The apparatus also comprises a spool as described above, and a spool drive mechanism operable to rotatably drive the spool so that, when the first and second ends of the spool are respectively supported by the first and second support surfaces, the web is wound onto the spool with the web passing between the winding drum and the spool such that the winding drum and the spool exert a nip pressure on the web, and such that the first and second support surfaces reduce the nip pressure on the web.

The invention also provides a method of winding a paper web in a papermaking machine, the method comprising the steps of: (a) providing a winding drum rotatable about a winding drum axis extending in the cross- machine direction, the winding drum being supported such that, except for rotational movement, the winding drum is stationary; (b) providing a spool rotatable about a spool axis parallel to the winding drum axis; (c) placing the spool in a first position such that the spool is supported by the winding drum and such that the spool axis is located on one side of a substantially vertical plane through the winding drum axis; (d) winding the web onto the spool so that the web passes between the winding drum and the spool such that the winding drum and the spool exert a nip pressure on the web; and (e) during step (d), moving the spool to a second position such that the spool axis is located on the opposite side of the vertical plane through the winding drum axis.

The invention also provides a method of winding a paper web in a papermaking machine, the method comprising the steps of: (a) providing a winding drum rotatable about a winding drum axis extending in the cross- machine direction, the winding drum having axially spaced first and second ends; (b) providing first and second angled support surfaces respectively located adjacent the first and second ends of the winding drum, the first and second angled support surfaces being substantially co-planar and being oriented at a non-vertical and non-horizontal angle; (c) providing at least one spool rotatable about a spool axis parallel to the winding drum axis, the spool having axially spaced first and second ends; (d) winding the web onto the spool so that the web passes between the winding drum and the spool such that the winding drum and the spool exert a nip pressure on the web; and (e) during step (d), supporting the first and second ends of the spool on the first and second angled support surfaces, respectively, such that the ends of the spool move upward along the support surfaces as the diameter of the roll being wound on the spool increases, and such that the support surfaces reduce the nip pressure on the web.

This invention is a step towards having a true winder at the paper machine reel. For some grades, principally newsprint, tissue and linerboard, it may result in the elimination of the paper machine winder as it is known.

One advantage of the invention is that both the roll and the spool are supported during winding. This improves roll structure.

Another advantage of the invention is that the spool is supported on non-horizontal rails, which also improves roll structure. By winding up at some angle from horizontal, the force between the paper and the spool is reduced. Obviously the best position to wind at is vertically. But due to space considerations and bending of the spool, an angle of 30 degrees from vertical or 60 degrees from horizontal is preferred. This represents a 44%, 18% and 10% reduction in loading that the paper sees at the spool for tissue, newsprint and LWC respectively.

Another important feature of the invention is the use of nip relieving.

Previous designs were limited in roll diameter due to their lack of nip relieving mechanisms. There is a higher tendency to produce roll defects whenever the nip level exceeds 30 pli.

Another advantage of the invention is that the spool is moved, during winding, over the top of a stationary winding drum. This provides the advantages of a stationary drum without the disadvantages of having to start the spool on the downstream side of the drum.

Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings.

DESCRIPTION OF THE DRAWINGS Fig. 1 is a side elevational view of a winding apparatus embodying the invention.

Fig. 2 is a top plan view of the apparatus.

Figs. 3-6 are partial side elevational views showing the sequence of operation of the apparatus.

Before one embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of the construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

DESCRIPTION OF THE PREFERRED EMBODIMENT A winding apparatus 10 embodying the invention is partially illustrated in Fig. 1. The winding apparatus 10 is part of a papermaking machine (not otherwise shown) having a machine direction (left to right in Fig. 1) and a cross-machine direction (into and out of the paper in Fig. 1 and from top to bottom in Fig. 2). The papermaking machine makes a continuous web W of paper having an open end E (see Fig. 3). The web W moves in the direction of arrow 12 in Fig. 1. The winding apparatus 10 has front and rear sides (bottom and top sides in Fig. 2), the front side being visible in Fig. 1.

The winding apparatus 10 inclues (see Fig. 1) a cylindrical winding drum 14 which is rotatable in the direction of arrow 16 about a winding drum axis 18 extending in the cross-machine direction. The winding drum 14 is supported by a winding drum support (not shown) such that, except for rotational movement about the winding drum axis 18, the winding drum 14 is stationary and fixed. A substantially vertical plane 26 extends through the winding drum axis 18. The winding drum 14 has axially spaced first and second or front and rear ends (bottom and top ends in Fig.

2). The winding apparatus 10 also includes (see Fig. 2) a winding drum drive mechanism 34 operable to rotatably drive the winding drum 14.

The winding apparatus 10 also includes (see Figs. 1 and 2) first and second or front and rear support members 42 and 44. The support members 42 and 44 are supported adjacent the front and rear ends, respectively, of the winding drum 14. The support members 42 and 44 are substantially identical and, therefore, only the support member 42 will be described in detail. The support member 42 is shown in Figs. 1 and 2.

The support member 44 is shown in Figs. 2-6.

The support member 42 is pivotable about the winding drum axis 18 and relative to the winding drum 14. As explained below, the support member 42 pivots in the direction of the arrow 45 in Fig. 1. The support member 42 inclues (see Fig. 1) four sets 46,47,48 and 49 of support arms angularly spaced apart at approximately 90° intervals. In other embodiments, however, the support member 42 may include fewer than four or more than four sets of support arms. Each set of support arms includes generally parallel leading and trailing support arms 50 and 54, respectively. The leading and trailing arms 50 and 54 of the four sets 46, 47,48 and 49 define therebetween respective slots 56,57,58 and 59 that extend radially with respect to the winding drum axis 18. Each leading arm 50 inclues a support surface 74, the purpose for which is explained below.

The winding apparatus 10 also includes (see Figs. 1 and 2) first and second or front and rear generally parallel support rails 78 and 80 associated with the support members 42 and 44, respectively. The support rails 78 and 80 are substantially identical and, therefore, only the support rail 78 (shown in Fig. 1) will be described in detail.

The support rail 78 includes a horizontal portion 82 having a substantially horizontal, generally planar, upwardly facing support surface 86. The support surfaces 86 of the support rails 78 and 80 are substantially co-planar. The support rail 78 also includes an angled portion 90 extending downwardly from the horizontal portion at a non-vertical and non-horizontal angle. Viewed from the winding drum axis 18, the angled portion 90 extends upwardly toward the horizontal portion 82. The angled portion 90 inclues a generally planar, upwardly facing support surface 92.

The support surfaces 92 of the support rails 78 and 80 are substantially co-planar. In the illustrated construction, the surfaces 92 extend at an angle of thirty degrees from vertical or sixty degrees from horizontal. The surfaces 92 could extend at different angles in alternative embodiments of the invention.

The winding apparatus 10 also includes (see Figs. 1 and 2) cylindrical spools 94 and 96 onto which the web W is wound. The number of spools is based upon the operational requirements of the winding apparatus 10. The winding apparatus 10 actually uses more than two spools, but only two are shown for purposes of illustration.

The spool 94 is rotatable about a spool axis 98 which extends parallel to the winding drum axis 18. The spool 94 rotates in the direction of arrow 100 in Fig. 1. The spool 94 inclues axially spaced first and second or front and rear ends 102 and 106 (bottom and top ends in Fig. 2).

The ends 102 and 106 of the spool 94 are supportable and movable in the slots 56 of the support members 42 and 44, respectively. The winding apparatus 10 also includes (see Fig. 2) a spool drive mechanism 110 operable to rotatably drive the spool 94 about the spool axis 98, as explained below in more detail.

Similarly, as shown in Figs. 1 and 2, the spool 96 is rotatable about a spool axis 118 which extends parallel to the winding drum axis 18. The spool 96 includes axially spaced first and second or front and rear ends 122 and 126 (bottom and top ends in Fig. 2). The ends 122 and 126 of the spool 96 are supportable and movable in the slots 57 of the support members 42 and 44, respectively. The winding apparatus 10 also includes (see Fig. 2) a spool drive mechanism 130 operable to rotatably drive the spool 96 about the axis 118, as explained below in more detail.

The winding apparatus 10 also includes (see Fig. 2) a support member drive mechanism 134 (shown schematically in Figs. 1 and 2) for simultaneously moving the support members 42 and 44 so that the spools 94 and 96, when supported in the respective slots 56 and 57, are each moved between angularly spaced first and second or turn-up and winding positions. The spool 94 is shown in the turn-up position in Fig. 3 and in the winding position in Fig. 4. These positions, which are on opposite sides of the vertical plane 26, are explained below in more detail.

The winding apparatus 10 also includes a turn-up mechanism 136 (shown schematically in Fig. 3) for selectively winding the open end E of the web W onto a spool when the spool is in the turn-up position.

The winding apparatus 10 also includes (see Figs. 1 and 2) first and second or front and rear devices 138 and 142 (bottom and top in Fig. 2) for selectively exerting forces on the ends of a spool when the spool is in the winding position. The devices 138 and 142 are substantially identical and, therefore, only the device 138 (shown in Fig. 1) will be described in detail.

The device 138 exerts a force which is directed radially outwardly with respect to the winding drum axis 18, in a direction along the support surface 92 of the rail 78. While any suitable device can be employed, in the illustrated construction the device 138 is a hydraulic cylinder/piston apparatus extending parallel to the angled portion 90 of the support rail 78.

The lower end of the device 138 is supported adjacent the front end of the winding drum 18. The upper end of the device 138 is engageable with the front end of a spool in the winding position (i. e., the end 102 of the spool 94 in Fig. 1). The purpose for the device 138 is explained below.

The operation of the winding apparatus 10 is partially illustrated in Figs. 3-6. Initially (see Fig. 3), the spool 94 is supported in the slots 56 of the support members 42 and 44 in the turn-up position. With the spool 94 in this position, the turn-up mechanism 136 winds the open end E of the web W onto the spool 94. The winding drum drive mechanism 38 rotatably drives the winding drum 14, and the spool drive mechanism 110 rotatably drives the spool 94. The web W passes between the outer surface of the winding drum 14 and the outer surface of spool 94 such that the winding drum 14 and the spool 94 exert a nip pressure on the web W at the point identified by N.

Once the open end E of the web W is wound onto the spool 94, the support member drive mechanism 134 moves the support members 42 and 44 so that the spool 94 is moved to the winding position (shown in Figs. 1, 4 and 5). As the spool 94 moves to the winding position, the spool axis 98 moves past the plane 26 and up over the highest point of the winding drum 14.

When the spool 94 is in the slots 56 and in the winding position, the slots 56 of the support members 42 and 44 are aligned with the angled portions 90 of the support rails 78 and 80, respectively. Viewed in another manner, and referring to the support member 42, the leading arm 50 of the set 46 of support arms supporting the spool 94 is aligned with the angled portion 90 of the support rail 78 so that the support surface 74 of the leading arm 50 is aligned with the support surface 92 of the angled portion 90. This aligns the front end 102 of the spool 94 with the support surface 94. The support member 44 is aligned with the support rail 80 in the same way, so that the rear end 106 of the spool 94 is aligned with the support surface 92 of the angled portion 90 of support rail 80.

When the spool 94 is in the winding position, the web W continues to be wound onto the spool 94. As shown by the change of the position of the spool 94 between Figs. 4 and 5, the increasing diameter of the wound roll causes the spool 94 to move radially outwardly with respect to the winding drum axis 18 along the support surfaces 74 of the leading arms 50 and, thereafter, along the support surfaces 92 of the support rails 78 and 80. The support surfaces 74 and the support surfaces 92 support the ends of the spool 94 and thereby reduce the nip pressure on the web W. In addition, the devices 138 and 142 can be engaged with the ends 102 and 106 of the spool 94 to force the spool 94 upwardly and away from the winding drum 14, thereby further reducing the nip pressure on the web W.

The web W continues to be wound onto the spool 94 until the spool 94 is fully wound or, in other words, is carrying the amount of web W as required by the operational parameters of the winding apparatus 10. At this point, the ends of the spool 94 move onto the support surfaces 86 of the horizontal portions 82 of the support rails 78 and 80, as shown in Fig.

6, for transport away from the papermaking machine. The web W is broken and another open end E of the web W is started.

As shown in Fig. 5, while the web is being wound onto the spool 94, the spool 96 is placed in the slots 57 of the support members 42 and 44. As shown in Fig. 6, after the web W is broken away from the spool 94, the spool 96 is moved to the turn-up position and the turn-up mechanism 136 winds the new open end E of the web W onto the spool 96. The support member drive mechanism 134 then moves the support members 42 and 44 so that the spool 96 moves to the winding position.

The winding apparatus 10 continues to operate in the above-described manner for the spool 96 and for any additional spools. Eventually, a third spool (not shown) is placed in the slots 58, a fourth spool (not shown) is placed in the slots 59, a fifth spool (not shown) is placed in the slots 56, and so on.

In the illustrated construction, the spool drive mechanism 110 is a single drive mechanism which rotatably drives the spool 94 in both the turn-up and winding positions, as required. In other constructions, however, the spool drive mechanism could include one mechanism for driving the spool 94 in the turn-up position and a second mechanism for driving the spool 94 in the winding position. The same is true for the spool drive mechanism 130.

Various features of the invention are set forth in the following claims.