System and method for winding web

Abstract

Various embodiments of the present disclosure provide a web winding system (30) that simultaneously employs separate multiple rolls of film (FR1, FR2) to simultaneously wind separate films around a single web as the web rotates about its longitudinal axis.

Description

Technical Field

[0001] The present disclosure relates to systems and methods for wrapping a web with a film. Background Art

[0002] Many steel manufacturers produce relatively large coils of steel plates or strip, which are then shipped to their customers for use or further processing. Figure 1 One such example coil C is shown. Coil C has a cylindrical outer surface OS, a relatively flat annular first side surface SS1, a relatively flat annular second side surface SS2 opposite the first side surface SS1, and a cylindrical inner surface IS extending between the side surfaces SS1 and SS2. The cylindrical inner surface IS defines a cylindrical central opening, which is referred to herein as the "eye" E of the coil C and extends between the opposite side surfaces SS1 and SS2. Coil C has a longitudinal axis LA extending through the center of the eye E.

[0003] In order to prevent the coil from unwinding, a circumferential band (not shown) is typically applied around the cylindrical outer surface OS of the coil C, and / or an eye-through band (not shown) is applied through the eye E and around the outer surface OS of the coil C so that they engage the inner surface IS and the outer surface OS of the coil C. Although these bands prevent the coil from unwinding, they do not protect the coil from damage during natural factors or transportation. If the customer expects this additional protection, the manufacturer typically wraps the coil with a plastic stretch film. For this reason, the manufacturer typically installs one of several known coil winding systems in the manufacturing line. These known systems all use a single roll of plastic stretch film to wrap the coil. And although these known systems are different, they typically pass the film roll through the eye of the coil and around its outer surface along a repeated loop, while rotating the coil along its longitudinal axis. These winding processes are relatively slow and may require the operator to replace the empty film roll with a replacement film roll during the coil winding process. Summary of the invention

[0004] Various embodiments of the present disclosure provide web winding systems and methods for simultaneously employing multiple separate film rolls to simultaneously wind separate films, such as plastic films, onto the web as it rotates about its longitudinal axis.

[0005] Various embodiments of the present disclosure provide mandrels for film rolls that help maintain tension on the film of the film rolls before, during, and after the winding process through a web winding system.

[0006] Various embodiments of the present disclosure provide mandrel grippers that receive, hold, and release a mandrel and a roll of film mounted on the mandrel.

[0007] Various embodiments of the present disclosure provide a film roll replacement system and associated methods for automatically replacing an empty film roll with a new film roll. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a perspective view of an example web that may be wound by the web winding system of the present disclosure.

[0009] Figure 1A is a top perspective view of a web winding system including a web winding apparatus and a film replacement system according to an example embodiment of the present disclosure.

[0010] Figure 1B yes Figure 1A Another top perspective view of a web winding system and a web positioned relative to the web winding system.

[0011] Figure 1C yes Figure 1A An end perspective view of a web winding system.

[0012] Figure 1D yes Figure 1A A top end perspective view of a web winding apparatus.

[0013] Figure 1E yes Figure 1A A top perspective view of a web winding device.

[0014] Figure 1F yes Figure 1A A bottom perspective view of a first winder of a web winding system.

[0015] Figure 1G yes Figure 1F A top perspective view of a first applicator arm of a first wrapper.

[0016] Figure 1H yes Figure 1A A three-dimensional view of a second winder of a web winding apparatus, a cutting, clamping and edge sealing system of the second winder, and a leading edge end retainer of the second winder.

[0017] Fig. 1I yes Figure 1H Rear perspective view of the cutting, clamping and edge sealing system of the second winder.

[0018] Figure 1J yes Figure 1A A rear perspective view of a second winder of a web winding apparatus and a cutting, clamping and edge sealing system of the second winder engaged with the web.

[0019] Figure 1K yes Figure 1ARear perspective view of the cutting, clamping and edge sealing system of the second winder of the web winding device.

[0020] Figure 1L It shows Figure 1A A block diagram of some components of a web winding system.

[0021] Figure 1M is a side view of the coil, and Figure 1A The coil winding device of the coil winding system determines the position of the film roll and the leading edge end of the film roll when the coil winding process starts.

[0022] Figure 1NA to Figure 1NI It shows that during the winding process Figure 1A A web (shown in cross-section) is wound around a film roll (shown in simplified form) carried by an applicator arm (shown in simplified form) of a web winding apparatus of a web winding system.

[0023] Figure 1NJ A fully wound coil is shown.

[0024] Fig.1O yes Figure 1A A top perspective view of a first winder and a second winder of a web winding apparatus of a web winding system of FIG. 1 , shown before starting to wind a web positioned between the first winder and the second winder.

[0025] Figure 1P yes Figure 1A A top perspective view of a first winder and a second winder of a web winding apparatus of a web winding system showing a point in the winding process when the first applicator arms and the third applicator arms of the first winder and the second winder are in their respective first film roll transfer positions.

[0026] Figure 1Q yes Figure 1A A top perspective view of a first winder and a second winder of a web winding apparatus of a web winding system showing a point in the winding process when the first applicator arms and the third applicator arms of the first winder and the second winder are in their respective second film roll transfer positions.

[0027] Figure 2A yes Figure 1A A perspective view of a first replacement film roll holder of a film changing system of a web winding system without any replacement film roll.

[0028] Figure 2B yes Figure 2A A perspective view of one of the replacement film roll supports of a first replacement film roll holder without a replacement film roll.

[0029] Figure 2C yes Figure 2A A perspective view of a first replacement film roll holder holding a replacement film roll.

[0030] Figure 2D yes Figure 2A An enlarged perspective view of one of the replacement film roll supports of a first replacement film roll holder holding a replacement film roll.

[0031] Figure 3A yes Figure 1A A perspective view of a first film roll supplier of a film changing system of a web winding system.

[0032] Figure 3B yes Figure 3A A partial perspective view of a first film roll supply showing its film roll mover.

[0033] Figure 3C is the first replacement film roll holder and Figure 3A A partial perspective view of a first film roll supply of a film replacement system of FIG. 1 , showing a film roll mover aligned with a position to remove a replacement roll from a support of a first replacement film roll holder.

[0034] Figure 3D is the first replacement film roll holder and Figure 3A An enlarged partial perspective view of a first film roll supply of a film changing system of FIG. 1 , showing the film roll mover at a starting point in the process of removing a replacement roll from a support of a first replacement film roll holder.

[0035] Figure 3E is the first replacement film roll holder and Figure 3A A perspective view of a first film roll supply of a film changing system of FIG. 1 , showing the film roll mover at a starting point in the process of removing a replacement roll from a support of a first replacement film roll holder.

[0036] Figure 3F is the first replacement film roll holder and Figure 3A An enlarged perspective view of a first film roll supply of a film changing system of FIG. 1 , showing the film roll mover after the replacement roll is removed from the support of the first replacement film roll holder.

[0037] Figure 4A is a top perspective view of an example mandrel of the present disclosure used as a mounting for a film roll.

[0038] Figure 4B yes Figure 4A A bottom perspective view of the mandrel.

[0039] Figure 4C yes Figure 4A A perspective view of the top of the mandrel.

[0040] Figure 4D yes Figure 4A A perspective view of the bottom mandrel.

[0041] Figure 4E yes Figure 4A A partially exploded view of the mandrel.

[0042] Figure 4F is along Figure 4B The line 4F-4F is intercepted Figure 4A A cross-sectional perspective view of a mandrel.

[0043] Figure 4G yes Figure 4A A cross-sectional side view of the bottom portion of the mandrel.

[0044] Figure 4H , Fig. 4I , Figure 4J , Figure 4K and Figure 4L are at different stages of membrane application Figure 4A A cross-sectional plan view of the spring housing of the mandrel.

[0045] Figure 5A yes Figure 1A An enlarged perspective view of the mandrel holder of the web winding system.

[0046] Figure 5C It is partially along Figure 5D The line 5C-5C is intercepted Figure 5A A cross-sectional perspective view of a portion of the upper mandrel jaws of a mandrel holder, the mandrel holder being mounted on Figure 4A The film roll is on the mandrel.

[0047] Figure 5D yes Figure 5A A partial view of a portion of the upper mandrel jaws of a mandrel holder which holds the mandrel holder mounted on Figure 4A The film roll is on the mandrel.

[0048] Figure 6 yes Figure 1 Schematic diagram of two mandrel grippers of a web winding system and showing the transfer of a film roll mounted on a mandrel from one of the mandrel grippers to the other of the mandrel grippers. DETAILED DESCRIPTION

[0049] Although the systems, devices, and methods described herein can be implemented in a variety of different forms, the drawings illustrate and the specification describes certain exemplary and non-limiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and some implementations may include additional, different, or fewer components. The arrangement and type of components, the shape, size, and material of the components, and the connection mode of the components may be changed without departing from the spirit or scope of the claims. Unless otherwise specified, any direction mentioned in the specification reflects the orientation of the components shown in the corresponding drawings and does not limit the scope of the present disclosure. Further, terms related to installation methods such as installation, connection, etc. are not intended to be limited to direct installation methods, but should be broadly interpreted as including indirect and operably installed, connected, and other installation methods. This specification is intended to be regarded as a whole and interpreted according to the principles of the present disclosure and as understood by ordinary technicians in the field.

[0050] Coil winding system

[0051] Various embodiments of the present disclosure provide a web winding system for wrapping a web, such as web C described above, with film by simultaneously moving multiple film rolls through eye E and around outer surface OS of web C as web C rotates about its longitudinal axis LA. Figure 1A , Figure 1B , Figure 1C and Figure 1L An example web winding system 20 and its components of the present disclosure are shown. The web winding system 20 includes: a web winding apparatus 30 for winding webs, such as the example web C (described above); infeed and outfeed web movers (not shown) for moving webs into the web winding apparatus 30 for winding and moving the webs out of the web winding apparatus 30 after winding; a web rotator 500 for supporting and rotating each web about its longitudinal axis during winding; a film roll replacement system 50 for receiving empty film rolls from the web winding apparatus 30 and for supplying new film rolls to the web winding apparatus 30; a plurality of sensors S; an operator interface OI; and a controller CR. For purposes of the present disclosure, an empty film roll may be a completely empty film roll (having no remaining film) or a nearly empty film roll (such as a film roll having insufficient film volume to be wound onto the next web).

[0052] The movement and components (described below) of the example coil winding system 20 that extend in the same direction as the longitudinal axis of the coil C as described above (e.g., parallel to the longitudinal axis LA) are sometimes described herein as longitudinal movement or longitudinal components, and the movement and components of the example coil winding system 20 that extend in a direction transverse to the longitudinal axis LA of the coil C (e.g., perpendicular to the longitudinal axis LA) are sometimes described herein as lateral movement or lateral components.

[0053] Coil Winding Equipment

[0054] Figure 1A , Figure 1B , Figure 1C , Figure 1D , Figure 1E and Figure 1L A web winding apparatus 30 and its components are shown, which are configured to simultaneously wind each web C with a plurality of film rolls, such as film rolls FR1 and FR2. The web winding apparatus 30 includes: a machine frame 60; a first winder 100 slidably mounted to the machine frame 60; a first carriage actuator 110 operably connected to the first winder 100 via a first transmission system 111 and configured to slide the first winder 100 vertically relative to the machine frame 60; a second winder 300 slidably mounted to the machine frame 60; and a second carriage actuator 310 operably connected to the second winder 300 via a second transmission system 311 and configured to slide the second winder 300 vertically relative to the machine frame 60.

[0055] Machine frame, coil rotator, and infeed and outfeed coil movers

[0056] like Figure 1D and Figure 1EThe machine frame 60, best shown in FIG. 1 , is formed of a plurality of tubular and / or solid members and other elements (not separately labeled) and supports certain components of the web winding apparatus 30 and, in particular, movably supports the first winder 100 and the second winder 300. The machine frame 60 includes four spaced apart upright legs 62, 64, 66 and 68 and four crossbars 72, 74, 76 and 78. Crossbar 72 connects leg 62 to leg 64, crossbar 74 connects leg 64 to leg 66, crossbar 76 connects leg 66 to leg 68, and crossbar 78 connects leg 68 to leg 62. Legs 62 and 64 and crossbar 72 support the first winder 100 (including its actuator 110 and its drive train 111). Specifically, opposing vertically extending rails (not labeled) are connected to the legs 62 and 64 and slidably support opposite ends of the first winder 100. Likewise, the legs 66 and 68 and the crossbar 76 support the second winder 300 (including its actuator 310 and its drive train 311 ). Specifically, opposing vertically extending rails (not shown) are connected to the legs 66 and 68 and slidably support the second winder 300 .

[0057] The machine frame 60 defines: (a) a rectangular inner web winding area (not shown) defined by four spaced-apart upright legs 62, 64, 66 and 68; (b) an outer web feed area (not shown) on one side of the frame 60 and particularly adjacent to the legs 62 and 64; and (c) an outer web discharge area (not shown) on an opposite side of the frame 60 and particularly adjacent to the legs 66 and 68. Figure 1B A first coil CA is shown in the outer coil feed area (waiting to be moved into the coil winding area), a second coil C is shown in the inner coil winding area (in position to be wound on the coil rotator 500), and a third coil CW is shown in the outer coil feed area (after being wound and moved out of the coil winding area).

[0058] The illustrated machine frame 60 is merely one example configuration, and any suitable configuration of a machine frame may be employed in accordance with the present disclosure.

[0059] like Figure 1A , Figure 1B , Figure 1C and Figure 1JThe coil rotator 500, best shown in FIG. 5 , includes a coil rotator frame 510 (partially shown), two cylindrical coil splicers 520 and 530 supported by the coil rotator frame 510, and one or more coil splicer actuators 540 supported by the coil rotator frame 510 and operably coupled to one or both of the coil splicers 520 and 530. Under the control of the controller CR, the coil rotator 500 causes the coil splicer actuators 540 to rotate the coil C positioned on the cylindrical coil splicers 520 and 530 at a desired speed about the longitudinal axis LA of the coil C during the winding process of the coil C.

[0060] The coil winding apparatus 30 includes or operates with an associated in-feed coil mover 550, which, under the control of the controller CR, moves each waiting coil (such as coil CA) that needs to be wound out from the outer coil in-feed area under the first coiler 100 and into the inner coil winding area and onto the coil splicers 520 and 530 of the coil rotator 500 for winding by the first coiler 100 and the second coiler 300, as discussed below. The coil winding apparatus 30 also includes or operates with an associated out-feed coil mover 560, which, under the control of the controller CR, moves the wound coil from the coil rotator 500 in the coil winding area to the outer coil out-feed area under the second coiler 300, after the coil C is wound, when the second coiler 300 is in the raised position (not shown but discussed below). The wound coil (eg, coil CW) may then be transported.

[0061] The first winder 100 and the second winder 300 are supported by the machine frame 60 in a manner that enables them to be independently moved vertically upward to their respective elevated positions to enable each coil to be moved under the winder (as described above), and vertically downward to their respective winding positions. More specifically, the first winder 100 is slidably mounted to the machine frame 60 and is vertically movable relative to the machine frame between the following positions: an elevated position (not shown) in which the first winder 100 is adjacent to the crossbar 72; a coil winding position below the elevated position (in Figures 1A to 1E); and a film replacement position below the raised position. When the first winder 100 is in the raised position, there is sufficient clearance below the first winder 100 to enable the feed roll mover 550 to move the roll onto the roll rotator 500. When the second winder 300 is in the roll winding position, the first winder 100 can be operated under the control of the controller CR and together with the second winder 300 to wind the roll C in the roll winding area (as described below). When the first winder 100 is in the film replacement position, the first winder 100 can be operated to pass an empty (or nearly empty) film roll to the film replacement device 50.

[0062] Likewise, the second winder 200 is slidably mounted to the machine frame 60 and is vertically movable relative to the machine frame between: a raised position (not shown) in which the second winder 300 is adjacent the crossbar 76; a web-winding position below the raised position (in which the second winder 300 is positioned adjacent the crossbar 76); Figures 1A to 1E ); and a film change position below the raised position. When the second winder 300 is in the raised position, there is sufficient clearance below the second winder 300 to enable the feed roll mover 560 to move the roll out of the roll rotator 500. When the second winder is in the roll winding position, the second winder 300 is operable under the control of the controller CR and in conjunction with the first winder 100 to wind the roll C in the roll winding area (as described below). When the second winder 300 is in the film change position, the second winder 300 is operable to receive a replacement film roll from the film change device 50.

[0063] First carriage actuator and first drive train for a first winder

[0064] like Figure 1E and Figure 1FThe first carriage actuator 110 and the first drive train 111 best shown in the drawings are operably connected to the first winder 100 and are configured to move the first winder 100 between its raised position, web winding position and film changing position relative to the machine frame 60. In this example embodiment, the first carriage actuator 110 includes an electric motor, but in other embodiments it may include any other suitable actuator. The first transmission system 111 includes: drive shafts 112a and 112b, each of which has one end connected to the first bracket actuator 110; spaced apart drive wheels 116a and 116b, which are respectively connected to opposite ends of the drive shafts 112a and 112b and are rotatably supported by the machine frame 60; spaced apart driven wheels 116a and 116b, which are respectively connected to the machine frame 60 and are rotatably supported by the machine frame; spaced apart follower wheels 118a and 118b, which are respectively connected to the machine frame 60 and are rotatably supported by the machine frame; and a transmission belt. 120a, which is wrapped around wheels 116a and 118a and extends between them; a drive belt 120b, which is wrapped around wheels 116b and 118b and extends between them; first bracket connectors 122a and 124a (numbered but not shown for clarity) that connect the drive belt 120a to a first end of the bracket 102 of the first winder 100; and bracket connectors 122b and 124b (numbered but not shown for clarity) that connect the drive belt 120b to a second end of the bracket 102 of the first winder 100. In operation, to raise the first winder 100, under the control of the controller CR, the first carriage actuator 110 simultaneously rotates each of the drive shafts 112a and 112b, causing each of the spaced upper wheels 116a and 116b to rotate, which causes each of the drive belts 120a and 120b to rotate. The rotation of the drive belts 120a and 120b causes the first carriage connectors 122a and 124a to move upward, and the carriage connectors 122b and 124b cause the first carriage 102 of the first winder 100 to move upward. This process is reversed to cause the first carriage 102 of the first winder 100 to move downward.

[0065] First Winder

[0066] like Figure 1D , Figure 1E , Figure 1F and Figure 1GThe first winder 100 best shown in the figure includes: a first bracket 102; a first applicator arm 130 slidably mounted to the first bracket 102; longitudinal and transverse first applicator arm actuators 150a and 150b, which are supported by the first bracket 102 and are operably connected to the first applicator arm 130 via a transmission system (described below), and are configured to move the first applicator arm 130 in the longitudinal and transverse directions relative to the roll C on the roll rotator 500; a second applicator arm 180 slidably mounted to the first bracket 102; and longitudinal and transverse second applicator arm actuators 200a and 200b, which are supported by the first bracket 102 and are operably connected to the second applicator arm 180 via a transmission system (described below), and are configured to move the second applicator arm 180 in the longitudinal and transverse directions relative to the roll C on the roll rotator 500.

[0067] First bracket of the first winder

[0068] like Figure 1F 100, the first carriage 102 of the winder 100 has a carriage frame 104 having a first end 103a, an opposite second end 103b, an inner side 103c and an outer side 103d. The carriage 102 extends transversely from the first end 103a (relative to the longitudinal axis LA of the coil C on the coil rotator 500) to the second end 103b. The carriage 102 extends longitudinally from the inner side 103c (relative to the longitudinal axis of the coil) to the outer side 103d. The carriage frame 104 supports the first applicator arm 130 and the associated first applicator arm actuators 150a and 150b and the second applicator arm 180 and the associated second applicator arm actuators 200a and 200b. The carriage 102 includes two spaced apart transversely extending tracks 106 and 108, which are connected to the bottom of the carriage frame 104. The first applicator arm 130 and the second applicator arm 180 are each slidably coupled to the tracks 106 and 108, respectively, and are each independently movable laterally along the tracks 106 and 108, as described below.

[0069] First applicator arm of first winder

[0070] like Figure 1F and Figure 1G, the first applicator arm 130 includes an elongated frame 132, an elongated track 134 connected to the top of the elongated frame 132, and a holder 5000 (described in detail below) connected to the inner end of the elongated frame 132. The first applicator arm 130 is slidably mounted to the carriage 102 via a cart 160. Specifically, the cart 160 is slidably mounted to the tracks 106 and 108 so that the cart 160 can slide laterally relative to the carriage frame 104. The cart 160 is slidably mounted to the track 134 so that the first applicator arm 130 can slide longitudinally relative to the tracks 104 and 106.

[0071] A transverse first applicator arm actuator 150b is connected to the bottom of the carriage frame 104 and is operably coupled to the first applicator arm 130. Under control of the controller CR, the transverse first applicator arm actuator 150b moves the first applicator arm 130 transversely (relative to the web being wound) on the rails 106 and 108 between an outer position adjacent to the first end 103a of the carriage 102 and an eye position aligned with the longitudinal rotation axis of the web. In other words, under control of the controller CR, the transverse first applicator arm actuator 150b moves the first applicator arm 130 transversely to the web between an outer position adjacent to the first end 103a of the carriage 102 and an eye position adjacent to the central longitudinal axis of the web.

[0072] Although not shown, the lateral first applicator arm actuator 150b is similar to that in Figure 1F The lateral second applicator arm actuator 200b is shown in more detail in FIG.

[0073] Under control of controller CR, longitudinal first applicator arm actuator 150a moves first applicator arm 130 longitudinally relative to the longitudinal axis of web C on web rotator 500 and carriage 102 between a transfer position and a retracted position relative to carriage 102. In other words, longitudinal first applicator arm actuator 150a moves arm 130 longitudinally relative to web and carriage 102 between a transfer position and a retracted position at each of the outer position, the eye position, and at each position therebetween.

[0074] More specifically, if Figure 1G1 and 15. The longitudinal first applicator arm actuator 150a, best shown in FIG. 1 , includes an actuator 152a controlled by a controller CR and operably connected to a cart 160 that is slidably connected to the carriage 102; a drive pulley 154a controlled by the actuator 152a; two control pulleys 155a and 156a; and a belt 158a connected to the frame 132 of the applicator arm 130. In operation, to move the applicator arm 130 longitudinally, the actuator 152a, under the control of the controller CR, rotates the drive pulley 154a to engage the belt 158a, thereby causing the first applicator arm 130 to move longitudinally relative to the cart 160. This rotation of the drive pulley 154a is reversed to cause longitudinal movement of the applicator arm 130 in the opposite direction.

[0075] Second applicator arm of the first winder

[0076] Similarly, if Figure 1F The movable second applicator arm 180, best shown in FIG. 1 , includes an elongated frame 182, an elongated track 184 connected to the top of the elongated frame 182, and a holder 5000 connected to the inner end of the elongated frame 182. The second applicator arm 180 is slidably mounted to the carriage 102 via a cart (not shown) that is slidably mounted to the track (not shown) so that the cart can slide laterally relative to the carriage frame 104. The cart is slidably mounted to the track 184 so that the second applicator arm 180 can slide longitudinally relative to the tracks 104 and 106.

[0077] The transverse second applicator arm actuator 200b is stationary and connected to the bottom of the carriage frame 104 and supported by the carriage frame 104 of the carriage 102. Under the control of the controller CR, the transverse applicator arm actuator 200b moves the second applicator arm 180 transversely on the rails 106 and 108 relative to the web on the web rotator 500 and the carriage 102 between an outer position adjacent to the second end 103b of the carriage 102 and an eye position aligned with the longitudinal rotational axis of the web. In other words, under the control of the controller CR, the transverse second applicator arm actuator 200b moves the second applicator arm 180 transverse to the longitudinal axis of the web and transverse to the carriage 102 and between an outer position adjacent to the second end 103b of the carriage 102 and an eye position aligned with the central longitudinal axis of the web.

[0078] More specifically, if Figure 1FThe lateral second applicator arm actuator 200b, best shown in FIG. 1 , includes an actuator 202b connected to the carriage frame 104 and controlled by the controller CR; a first pulley 204b connected to the actuator 202b; a second pulley 206b connected to the carriage frame 104; a drive belt 208b wrapped around and extending between the pulleys 204b and 206b; and a cart 210 connected to the drive belt 208a and coupled to the track 184 of the second arm 180. Thus, the cart 210 movably supports the applicator arm 180 for lateral movement while facilitating independent longitudinal movement of the second applicator arm 180. In operation, to cause the applicator arm 180 to move laterally, the actuator 202b, under the control of the controller CR, rotates the pulley 204b, thereby causing the drive belt 208b to rotate, causing the cart 210 to move laterally, and thus causing the second applicator arm 180 to move laterally. This rotation of the pulley 204b and drive belt 208b reverses direction, causing the cart 210 and second applicator arm 180 to move laterally in opposite directions.

[0079] Under control of controller CR, longitudinal second applicator arm actuator 200a moves second applicator arm 180 longitudinally relative to carriage 102 between a transfer position relative to inner side 103c of carriage 102 and a retracted position relative to inner side 103c of carriage 102. In other words, under control of controller, longitudinal second applicator arm actuator 200a moves arm 180 perpendicular to (and therefore longitudinal to) carriage 102 between the transfer position and the retracted position at each of the outer position, the eye position, and at each position therebetween.

[0080] In an alternative embodiment, the first applicator arm 130 and the second applicator arm 180 are movably connected to two or more separate carriages, rather than a single carriage 102 .

[0081] A second winder, a second bracket of the second winder, and a second bracket actuator for the second winder

[0082] Similar to the first bracket 102, as Figure 1D , Figure 1E , Figure 1H and Figure 1JAs best shown in FIG. 3 , the second bracket 302 of the wrapper 300 has a first end (not shown), an opposite second end (not shown), an inner side (not shown), and an outer side (not shown). The bracket 302 extends transversely from the first end to the second end. The bracket 302 extends longitudinally from the inner side to the outer side. The bracket 302 includes a bracket frame 304, which supports the third applicator arm 330 and the third applicator arm actuators 350a and 350b in the longitudinal and transverse directions, and the fourth applicator arm 380 and the fourth applicator arm actuators 400a and 400b in the longitudinal and transverse directions. The bracket 302 includes two spaced apart transversely extending tracks 306 and 308, which are connected to the bottom of the frame 304. The third applicator arm 330 and the fourth applicator arm 380 are movably connected to the tracks 306 and 308, respectively, and can be independently moved laterally along the tracks 306 and 308.

[0083] Similar to the first winder 100, the second winder 300 is vertically movable between a web winding position and an elevated position above the web winding position. Similar to what is described above for the first winder 100 and the first carriage actuator 110, under the operation of the controller CR, the second carriage actuator 310 moves the second winder 300 upward and downward to these respective positions.

[0084] Similar to the first bracket actuator 110, as Figure 1E and Figure 1FAs best shown in FIG. 1 , the second carriage actuator 310 and the second drive train 311 are operably connected to the second winder 300 and are configured to move the second winder 300 between its raised position, the web winding position, and the film changing position relative to the machine frame 60. In this example embodiment, the second carriage actuator 310 includes an electric motor, but in other embodiments, it may include any other suitable actuator. The second drive train 311 includes drive shafts 312a and 312b, which are connected to the crossbar 76 of the frame 60 and have inner ends connected to the second carriage actuator 310; spaced-apart upper drive wheels 316a and 316b, which are respectively connected to opposite ends of the drive shafts 312a and 312b and are connected to and rotatably supported by the crossbar 76; spaced-apart lower follower wheels 318a and 318b, which are respectively connected to and rotatably supported by the legs 68 and 66; a drive belt 320a, which is wrapped around the wheels 316a and 316b. 318a and 318a; a drive belt 320b wrapped around and extending between the wheels 316b and 318b; carriage connectors 322a and 324a (numbered but not shown for clarity) connecting the drive belt 320a to a first end of the carriage 302 of the second winder 300; and carriage connectors 322b and 324b (numbered but not shown for clarity) connecting the drive belt 320b to a second end of the carriage 302 of the second winder 300. Similar to the first carriage actuator 110, in operation, under the control of the controller CR, the actuator 310 causes the drive shafts 312a and 312b to rotate simultaneously, which causes the spaced-apart upper wheels 316a and 316b to rotate, which causes each of the drive belts 320a and 320b to rotate. The rotation of the drive belts 320a and 320b causes the upward movement of the first bracket connectors 322a and 324a and the bracket connectors 322b and 324b, which causes the second bracket 302 of the second winder 300 to move upward. This process is reversed to cause the second bracket 302 of the second winder 300 to move downward.

[0085] Similar to the first winder 100, as Figure 1D , Figure 1E and Figure 1HThe second winder 300 best shown in the figure includes: a third applicator arm 330 slidably mounted to the second bracket 302; longitudinal and transverse third applicator arm actuators 350a and 350b, which are supported by the second bracket 302 and are operably connected to the third applicator arm 330 via a transmission system (described below), and are configured to move the third applicator arm 330 in the longitudinal and transverse directions relative to the roll C on the roll rotator 500; a fourth applicator arm 380 slidably mounted to the second bracket 302; and longitudinal and transverse fourth applicator arm actuators 400a and 400b, which are supported by the second bracket 202 and are operably connected to the fourth applicator arm 380 via a transmission system (described below), and are configured to move the fourth applicator arm 380 in the longitudinal and transverse directions relative to the roll C on the roll rotator 500.

[0086] Third applicator arm of the second winder

[0087] like Figure 1D , 1E and Figure 1H , the third applicator arm 330 includes an elongated frame 332, an elongated track 334 connected to the top of the elongated frame 332, and a holder 5000 (described in detail below) connected to the inner end of the elongated frame 332. The third applicator arm 330 is slidably mounted to the second bracket 302 via a trolley (not shown). Specifically, the trolley is slidably mounted to the track (not shown) so that the trolley can slide laterally relative to the bracket frame 304. The trolley is slidably mounted to the track 334 so that the third applicator arm 330 can slide longitudinally relative to the track.

[0088] A third transverse applicator arm actuator 350b is connected to the bottom of the carriage 302 and is operably coupled to the third applicator arm 130. Under control of the controller CR, the third transverse applicator arm actuator 350b moves the third applicator arm 330 transversely (relative to the wound web) between an outer position adjacent to the first end of the carriage 302 and an eye position aligned with the longitudinal axis of rotation of the web (in a manner similar to that described above). In other words, under control of the controller CR, the third transverse applicator arm actuator 350b moves the third applicator arm 330 transversely to the web C on the web rotator 500 between an outer position adjacent to the first end of the carriage 302 and an eye position adjacent to the central longitudinal axis of the web C.

[0089] Under control of controller CR, longitudinal third applicator arm actuator 350a moves third applicator arm 330 longitudinally relative to the longitudinal axis of web C on web rotator 500 and carriage 302 between a transfer position and a retracted position relative to carriage 302. In other words, under control of controller, longitudinal third applicator arm actuator 350a moves arm 330 longitudinally relative to web and carriage 302 between a transfer position and a retracted position at each of the outer position, the eye position, and at each position therebetween.

[0090] Fourth applicator arm of the second winder

[0091] Similarly, if Figure 1D and Figure 1E The movable fourth applicator arm 380, best shown in FIG. 3 , includes an elongated frame 382, ​​an elongated track 384 connected to the top of the elongated frame 382, ​​and a clamp 5000 connected to the inner end of the elongated frame 382. The fourth applicator arm 380 is slidably mounted to the second bracket 302 via a cart (not shown). Specifically, the cart is slidably mounted to the track (not shown) so that the cart can slide laterally relative to the bracket frame 304. The cart is slidably mounted to the track 384 so that the fourth applicator arm 380 can slide longitudinally relative to the track.

[0092] The transverse fourth applicator arm actuator 400b is stationary and connected to the bottom of the carriage 302 and supported by its carriage frame (not shown or numbered). Under the control of the controller CR, the transverse applicator arm actuator 400b moves the fourth applicator arm 380 transversely relative to the web C on the web rotator 500 and the carriage 102 between an outer position adjacent to the second end of the carriage 302 and an eye position aligned with the longitudinal rotation axis of the web C. In other words, under the control of the controller CR, the transverse fourth applicator arm actuator 400b moves the fourth applicator arm 380 transverse to the longitudinal axis of the web C and transverse to the carriage 302 and between an outer position adjacent to the second end of the carriage 302 and an eye position aligned with the central longitudinal axis of the web.

[0093] Under control of the controller CR, the fourth longitudinal applicator arm actuator 400a moves the fourth applicator arm 380 longitudinally relative to the carriage 302 between a transfer position relative to the inside of the carriage 302 and a retracted position relative to the inside of the carriage 302. In other words, under control of the controller, the fourth longitudinal applicator arm actuator 400a moves the arm 380 perpendicular to (and therefore longitudinal to) the carriage 302 between the transfer position and the retracted position at each of the outer position, the eye position, and at each position therebetween.

[0094] In an alternative embodiment, the third applicator arm 330 and the fourth applicator arm 380 are movably connected to two or more separate carriages, rather than a single carriage 302 .

[0095] Cutting, clamping and edge sealing system for the second winder

[0096] The second winder 300 further includes a cutting, clamping and edge sealing system 420 (and associated cutting, clamping and edge sealing system actuators, not shown) operably connected to the second bracket 302. Figure 1H , Fig. 1I , Figure 1J and Figure 1K The cutting, clamping and edge sealing system 420 best shown in FIG. 1 is connected to the second bracket 302 of the second winder 300 and clamps, seals and cuts the film of the film roll at the end of the web winding process under the control of the controller CR. The cutting, clamping and edge sealing system 420 includes: (i) a sealer / cutter frame 422 connected to and supported by the bracket 302; (ii) a first sealer / cutter 430 movably connected to the sealer / cutter frame 422; (iii) a second sealer / cutter 440 movably connected to the sealer / cutter frame 422; (iv) a first actuator (not shown) operably connected to the sealer / cutter frame 422 and coupled to the first sealer / cutter 430; and (v) a second actuator (not shown) operably connected to the second sealer / cutter frame 422 and coupled to the second cutter / sealer 440. The first sealer / cutter 430 includes a first arm 432, a first web splicer 434 connected to an inner end of the first arm 432, and a first sealing / cutting hand 436 pivotally connected to the first web splicer 434. Similarly, the second sealer / cutter 430 includes a second arm 442, a second web splicer 444 connected to an inner end of the second arm 442, and a second sealing / cutting hand 446 pivotally connected to the second web splicer 444.

[0097] At the end of the web winding process, as described below, when the respective films F1 and F2 of the film rolls FR1 and FR2 are ready to be clamped, sealed and cut, under the control of the controller CR, the first and second actuators of the cutting, clamping and edge sealing system 420 move the first sealer / cutter 430 and the second sealer / cutter 440 to respectively engage with the first film F1 and the second film F2 adjacent to the side surface SS1 of the web C. The films will then surround the first web splicer 434 and the second web splicer 444. Under the control of the controller CR, the first and second actuators of the cutting, clamping and edge sealing system 420 pivot the first sealer / cutting hand 436 and pivot the second sealer / cutting hand 446 to respectively engage with the first film F1 and the second film F2 adjacent to the side surface SS1 of the web C wrapped around the first web splicer 434 and the second web splicer 444 to seal and cut such films F1 and F2 to seal and cut such films.

[0098] First film end holder and second film end holder of second winder

[0099] The second wrapper 300 further includes a first film end retainer 450a and a second film end retainer 450b (and associated actuators (not shown)) mounted to the second bracket 302. The first film end retainer 450a and the second film end retainer 450b of the second wrapper 300 (such as Figure 1H ) respectively grips the leading edge end of the film of any replacement film roll received from film roll suppliers 900 and 1900 for subsequent web winding.

[0100] The first film end retainer 450a includes: (i) a first track mount 452a slidably mounted on a laterally extending track 305 of the second bracket 302; (ii) a first film end retainer arm 454a connected to the first track mount 452a; (iii) a first inner film coupler 456a connected to the first film end retainer arm 454a; (iv) a first outer film coupler 458a pivotally connected to the first film end retainer arm 454a; (v) a first arm actuator (vi) a first film joint actuator (not shown) operably connected to the film end retainer arm 454a and causing the first film end retainer arm 454a to move laterally on the track 452a under the control of the controller CR; and (vi) a first film joint actuator (not shown) operably connected to the external film joint 458a and causing the first external film joint 458a to pivot to open the first external film joint 458a under the control of the controller CR, thereby releasing the leading edge end of the film. In this example embodiment, the first external film joint 458a is configured to pivotally move to engage with the first internal film joint 456a to hold the leading edge end of the film. In an alternative embodiment, one or both of the first internal film joint 456a and the first external film joint 458a include one or more magnets (not shown) that attract the first external film joint 458a to the first internal film joint 456a and hold these joints together to hold the leading edge end of the film. In such an embodiment, the first film end retainer 450a is therefore a magnetic retainer of the leading edge end of the film of the film roll.

[0101] Similarly, the second film end retainer 450b includes: (i) a second track mount 452b slidably mounted on the laterally extending track 307 of the second bracket 302; (ii) a second film end retainer arm 454b connected to the second track mount 452b; (iii) a second inner film adapter 456b connected to the first film end retainer arm 454b; (iv) a second outer film adapter 458b pivotally connected to the second film end retainer arm 454b; (v) A second arm actuator (not shown) operably connected to the second film end retainer arm 454b and causing the second film end retainer arm 454b to move longitudinally on the track 452b under the control of the controller CR; and (vi) a second film joint actuator actuator (not shown) operably connected to the second external film joint 458b and causing the second external film joint 458b to pivot between the film engagement position engagement and the film release position under the control of the controller CR. In this example embodiment, the second external film joint 458b is configured to pivotally move to engage with the second internal film joint 456b to hold the leading edge end of the film. In an alternative embodiment, one or both of the second internal film joint 456b and the second external film joint 458b include one or more magnets (not shown) that attract the second external film joint 458b to the second internal film joint 456b and hold the joints together to hold the leading edge end of the film. In these embodiments, the second film end retainer 450b is therefore a magnetic retainer of the leading edge end of the film of the film roll.

[0102] Coil winding method and winding operation of coil winding system

[0103] Under the control of the controller CR, the web winders 100 and 300 of the web winding apparatus 30 of the web winding system 20 work together to simultaneously wind a single web C using two separate film rolls FR1 and FR2 while the web C is rotated about its longitudinal axis LA by the web rotator 500. During the winding process, as shown in FIG. Figure 1NA to Figure 1NIAs generally shown in the figure, under the control of the controller CR, for each winding cycle, the web winding device 30: (i) moves the first film roll FR1 longitudinally to the outside of the eye E of the web C, while the second film roll FR2 is longitudinally moved through the eye E of the web C, (ii) then moves the first film roll FR1 laterally to the outside of the eye E of the web C, while the second film roll FR2 is laterally moved to the outside of the eye E of the web C, (iii) then moves the first film roll FR1 longitudinally through the eye E of the web C, while the second film roll FR2 is longitudinally moved to the outside of the eye E of the web C, and (iv) then moves the first film roll FR1 laterally to the outside of the eye E of the web C, while the second film roll FR2 is laterally moved to the outside of the eye E of the web C. Under the control of the controller CR, the web winding system 50 repeats this process, causing the film rolls FR1 and FR2 to alternately pass longitudinally through the eye E of the web C, while causing each film F1 and F2 from each film roll FR1 and FR2 to be wound on the corresponding outer surface, side surface and inner surface of the web C, so that each of the first film roll FR1 and the second film roll FR2 is used to wind approximately half of the web C. This simultaneous winding of the web C with the two film rolls FR1 and FR2 significantly reduces the amount of time required to wind each web C, and reduces the amount of film used by each roll to wind each web, so that each roll lasts a longer amount of time before it needs to be replaced.

[0104] The web winding method includes the following general steps (and, in various embodiments, subsequently described specific sub-steps of each of these general steps): (1) positioning a web C in a web winding area and positioning a first winder 100 and a second winder 300 to wind the web C; (2) initially positioning film rolls FR1 and FR2 held by a third applicator arm 330 and a fourth applicator arm 380 of the second winder 300 and the corresponding separated films of the separated film rolls FR1 and FR2 relative to the web C; (3) using the first applicator arm 130, the second applicator arm 180, the third applicator arm 330 and the fourth applicator arm 380 of the first winder 100 and the second winder 300 respectively to simultaneously wrap the web C with the separate films F1 and F2 from the two film rolls FR1 and FR2; (4) using the cutting, clamping and edge sealing system 420 to simultaneously seal, clamp and cut the separate films F1 and F2 from the two film rolls FR1 and FR2; and (5) removing the wound web C from the web area. This method can further include preparing to wrap the next web, as further described below.

[0105] Positioning the coil in the coil winding area

[0106] The steps of positioning the coil C in the coil winding area and positioning the first winder 100 and the second winder 300 to wind the coil C include: (a) lifting the first winder 100 to its raised position; (b) moving the unwound coil C longitudinally from the coil feeding area below the first winder 100 to the coil rotator 500 (thereby positioning the unwound coil on the coil rotator 500 in the coil winding area); and (c) lowering the first winder 100 to its coil winding position (and if not previously done, lowering the second winder 300 to its coil winding position). In this position, the applicator arms 130, 180, 330 and 380 are each at a certain vertical height so that the corresponding gripper 5000 of each of the arms 130, 180, 330 and 380 is vertically aligned with the longitudinal axis of the coil C on the coil rotator 500 in the coil winding area.

[0107] Positioning the film roll and the leading edge of the film on the film roll

[0108] Each step of positioning each of the applicator arms 130, 180, 330 and 380 of the first and second wrappers 100, 300 described below includes: a longitudinal movement of the applicator arm caused by a corresponding longitudinal applicator arm actuator for the corresponding applicator arm; and a lateral movement of the applicator arm caused by a corresponding lateral applicator arm actuator for the corresponding applicator arm. All of these movements are controlled by the controller CR based on a specific point in the coil winding process. In addition, one or more of these movements can be monitored by one or more sensors S, and one or more of these movements can be caused by the controller CR based on feedback from one or more sensors in the sensor S.

[0109] The following describes this winding process after the film roll has been replaced (such as described below). Figure 1M , Figure 1NA and Fig.1OAs best shown in the figure, the steps of positioning the film rolls FR1 and FR2 initially held by the third applicator arm 330 and the fourth applicator arm 380 of the second winder 300 and the leading edge ends LE1 and LE2 of the films F1 and F2 of the film rolls FR1 and FR2 relative to the roll C include: (a) positioning the fourth applicator arm 380 longitudinally and transversely at a first starting winding position so that the leading edge end LE1 of the film F1 of the film roll FR1 held by the fourth applicator arm 380 is generally positioned adjacent to a first area FA1 of the side surface SS1 of the roll C (i.e., the side surface of the roll facing the second winder 300), which is on one side of the eye E of the roll C; and (b) positioning the third applicator arm 330 longitudinally and transversely at a second starting winding position so that the leading edge end LE2 of the film F2 of the film roll FR2 held by the third applicator arm 330 is generally positioned adjacent to a second area FA2 of the side surface SS1 of the roll C, which is on the other side of the eye E of the roll C. This includes: (c) causing the first film end retainer 450a to position the leading edge end LE2 of the film F2 of the film roll FR2 in the first area FA2 adjacent to the side surface SS1 of the web C; and (d) causing the second film end retainer 450b to position the leading edge end LE1 of the film F1 of the film roll FR1 adjacent to the second area FA1 of the side surface SS1 of the web C. Steps (a), (b), (c), and (d) may be performed simultaneously in the illustrated example embodiment.

[0110] This further includes: Figure 1NA and Fig.1O As best shown in FIG. 1 , (e) the first applicator arm 130 (at this time without holding any film roll) is longitudinally and transversely positioned adjacent to the side surface SS2 of the web C (i.e., the side surface of the web facing the first winder 100), and laterally aligned with the third applicator arm 330 of the second winder 300; and (f) the second applicator arm 180 (at this time without holding any film roll) is longitudinally and transversely positioned adjacent to the side surface SS2 of the web C, and laterally aligned with the fourth applicator arm 380 of the second winder. Steps (e) and (f) can be performed simultaneously in the illustrated example embodiment. Steps (e) and (f) can also be performed simultaneously with steps (a) and (b) and / or steps (c) and (d) in the illustrated example embodiment.

[0111] Wrapping a web with film from a film roll

[0112] The step of simultaneously winding the web C with the films F1 and F2 from the two film rolls FR1 and FR2 includes the following sets of steps.

[0113] The first set of steps includes: (a) causing the web rotator 500 to begin rotating the web C about its longitudinal axis LA (if not previously started); (b) causing the fourth applicator arm 380 and the film roll FR1 held by its gripper to move longitudinally inward in an area adjacent to the web C so that the film F1 of the film roll FR1 is applied to the area of ​​the outer surface OS of the web C; (c) causing the third applicator arm 330 and the film roll FR2 held by its gripper to move longitudinally inward into the eye E of the web C so that the film F2 of the film roll FR2 is applied to the area of ​​the inner surface IS of the web C; (d) causing the second applicator arm 180 (not holding any film roll at this time) to move longitudinally inward in an area adjacent to the outer surface OS of the web C; and (e) causing the first applicator arm 130 (not holding any film roll at this time) to move longitudinally inward into the eye E of the web C. Steps (b), (c), (d) and (e) can be performed simultaneously in the illustrated example embodiment.

[0114] like Figure 1NB The next set of steps best shown in FIG. 1 include: (f) continuing to move the fourth applicator arm 380 and the film roll FR1 held by its gripper longitudinally inward to a film roll transfer position (while continuing to apply film F1 of film roll FR1 to the area of ​​the outer surface OS of the web C); (g) continuing to move the third applicator arm 330 and the film roll FR2 held by its gripper longitudinally inward to a film roll transfer position in the eye E of the web C (while continuing to apply film F2 of film roll FR2 to the area of ​​the inner surface IS of the web C); (h) continuing to move the second applicator arm 180 (at this time without holding any film roll) longitudinally inward to a film roll transfer position in the area adjacent to the outer surface OS of the web C; and (i) continuing to move the first applicator arm 130 (at this time without holding any film roll) longitudinally inward to a film roll transfer position in the eye E of the web C. These applicator arms and film roll transfer positions are also in FIG. Figure 1P Steps (f), (g), (h) and (i) can be performed simultaneously in the illustrated exemplary embodiment.

[0115] like Figure 1NC The next set of steps, best shown in FIG. 1 , include: (j) transferring the film roll FR1 held by the gripper of the fourth applicator arm 380 to the gripper of the second applicator arm 180 at a film roll transfer location at the region of the outer surface OS of the web C; (k) transferring the film roll FR2 held by the gripper of the third applicator arm 330 to the gripper of the first applicator arm 130 at a film roll transfer location in the eye E of the web C. Steps (j) and (k) may be performed simultaneously in the illustrated example embodiment.

[0116] like Figure 1NDThe next set of steps, best shown in FIG. 1 , include: (1) moving the second applicator arm 180 and the film roll FR1 now held by its gripper longitudinally outward in an area adjacent to the web C so that the film F1 of the film roll FR1 continues to be applied to an area of ​​the outer surface of the web C; (m) moving the first applicator arm 130 and the film roll FR2 now held by its gripper longitudinally outward of the eye E of the web C so that the film F2 of the film roll FR2 continues to be applied to an area of ​​the inner surface IS of the web C; (n) moving the fourth applicator arm 380 longitudinally outward in an area adjacent to the outer surface OS of the web C; (o) moving the third applicator arm 330 longitudinally outward of the eye E of the web C. Steps (1), (m), (n), and (o) may be performed simultaneously in the illustrated example embodiment.

[0117] like Figure 1NE The next set of steps best shown in the figure include: (p) moving the second applicator arm 180 and the film roll FR1 held by its gripper laterally adjacent to the side surface SS2 of the web C so that the film F1 of the film roll FR1 is applied to the area of ​​the side surface SS2 of the web C, and stopping this lateral movement when the film roll FR1 held by the gripper is in a plane longitudinally aligned with the eye E of the web C; (q) moving the first applicator arm 130 and the film roll FR2 held by its gripper laterally adjacent to the side surface SS2 of the web C so that the film F2 of the film roll FR2 is applied to the web (r) move the fourth applicator arm 380 laterally adjacent to the side surface SS1 of the roll C and stop such lateral movement when its gripper is in a plane longitudinally aligned with the eye E of the roll C; and (s) move the third applicator arm 330 laterally adjacent to the side surface SS1 of the roll C and stop such lateral movement when its gripper is in a plane longitudinally adjacent to the outer surface OS of the roll C. Steps (p), (q), (r) and (s) can be performed simultaneously in the illustrated exemplary embodiment.

[0118] like Figure 1NFThe next set of steps best shown in FIG. 1 include: (t) moving the first applicator arm 130 and the film roll FR2 held by its gripper longitudinally inward to a film roll transfer position while applying the film F2 of the film roll FR2 to an area adjacent to the outer surface OS of the web C; (u) moving the second applicator arm 180 and the film roll FR1 held by its gripper longitudinally inward to a film roll transfer position in the eye E of the web C while applying the film F1 of the film roll FR1 to an area adjacent to the inner surface IS of the web C; (v) moving the fourth applicator arm 380 (at this time without holding any film roll) longitudinally inward to a film roll transfer position in the eye E of the web C; (w) moving the third applicator arm 330 (at this time without holding any film roll) longitudinally inward to a film roll transfer position in an area adjacent to the outer surface OS of the web C. These applicator arms and film roll transfer positions are also shown in FIG. Figure 1Q Steps (t), (u), (v) and (w) may be performed simultaneously in the illustrated exemplary embodiment.

[0119] like Figure 1NG The next set of steps, best shown in FIG. 1 , include: (x) transferring the film roll FR2 held by the gripper of the first applicator arm 130 to the gripper of the third applicator arm 330 at a film roll transfer location at the region of the outer surface OS of the web C; (y) transferring the film roll FR1 held by the gripper of the second applicator arm 180 to the gripper of the fourth applicator arm 380 at a film roll transfer location in the eye E of the web C. These steps (x) and (y) can be performed simultaneously in the illustrated example embodiment.

[0120] like Figure 1NH The next set of steps, best shown in FIG. 1 , include: (z) moving the third applicator arm 330 and the film roll FR2 now held by its gripper longitudinally outward in an area outside the eye E of the web C such that film F2 of the film roll FR2 continues to be applied to an area of ​​the outer surface of the web C; (aa) moving the fourth applicator arm 380 and the film roll FR1 now held by the gripper longitudinally outward of the eye E of the web C such that film F1 of the film roll FR1 continues to be applied to an area of ​​the inner surface IS of the web C; (bb) moving the first applicator arm 130 longitudinally outward in an area adjacent to the outer surface OS of the web C; and (cc) moving the second applicator arm 180 longitudinally outward of the eye E of the web C. Steps (z), (aa), (bb), and (cc) may be performed simultaneously in the illustrated example embodiment.

[0121] like Figure 1NIThe next set of steps best shown in the figure include: (dd) moving the fourth applicator arm 380 and the film roll FR1 held by its clamp adjacent to the side surface SS1 of the web C laterally so that the film F1 of the film roll FR1 is applied to the area of ​​the side surface SS2 of the web C, and stopping this lateral movement when the film roll FR1 held by the clamp is in a plane longitudinally adjacent to the outer surface OS of the web C; (ee) moving the fourth third applicator arm 330 and the film roll FR2 held by its clamp adjacent to the side surface SS1 of the web C laterally so that the film F2 of the film roll FR2 is applied (ff) the second applicator arm 180 is moved laterally adjacent to the side surface SS2 of the roll C, and this lateral movement is stopped when the film roll FR2 held by the clamp is in a plane longitudinally aligned with the eye E of the roll C; (gg) the first applicator arm 130 is moved laterally adjacent to the side surface SS2 of the roll C, and this lateral movement is stopped when its clamp is in a plane longitudinally adjacent to the outer surface OS of the roll C. Steps (dd), (ee), (ff) and (gg) can be performed simultaneously in the exemplary embodiment shown. Figure 1NI As slightly shown in FIG. 1 , at this point, films F1 and F2 overlap themselves.

[0122] Then the corresponding set of steps (b) to (gg) is repeated while the web C continues to rotate about its longitudinal axis until about half of the web C is wrapped with the film F1 and about the other half is wrapped with the film F2. After repeating steps (b) to (gg) a suitable number of times (e.g., two or three times), the films F1 and F2 are able to hold the corresponding leading edge ends LE1 and LE2 of the films F1 and F2, so that the film end retainers 450a and 450b can release the leading edge ends LE1 and LE2 of the films F1 and F2.

[0123] Sealing, clamping and cutting of two films from two film rolls

[0124] After the above process is repeated several times so that the web C is completely wrapped with the two films F1 and F2, the steps of sealing, clamping and cutting the two films F1 and F2 from the two film rolls FR1 and FR2 are started. After the last execution of steps (dd), (ee), (ff) and (gg), the method includes positioning the cutting, clamping and edge sealing system 420 in an active position adjacent to the side surface SS2 of the web C, such as Figure 1J and Figure 1K shown.

[0125] More specifically, this includes: (i) positioning the first web splicer 434 in a first sealing / cutting position such that the first web splicer 434 engages the film F2 of the film roll FR2 positioned on a first area of ​​the side surface SS1 of the web C, the first area being adjacent to the eye E of the web C, and wherein the sealer / cutter 436 is in an open position, such as Figure 1J and Figure 1K and (ii) positioning the second web splicer 444 in a second sealing / cutting position so that the second web splicer 444 engages the film F1 of the film roll FR1 positioned on a second region of the side surface SS1 of the web C, the second region being adjacent to the eye E of the web C, and wherein the sealer / cutter 446 is in an open position, such as Figure 1J and Figure 1K In the exemplary embodiment shown, steps (i) and (ii) can be performed simultaneously.

[0126] This further includes: (iii) causing the first sealer / cutter 436 to pivot inwardly and engage, seal and cut the film F2 of the film roll FR2 positioned on a first area of ​​the side surface SS1 of the web C, the first area being adjacent to the eye E of the web C; and (iv) causing the second sealer / cutter 446 to pivot inwardly and engage, seal and cut the film F1 of the film roll FR1 positioned on a first area of ​​the side surface SS1 of the web C, the first area being adjacent to the eye E of the web C. This further includes: (v) holding the leading edge end of the film F2 of the film roll FR2; and (vi) holding the leading edge end of the film F1 of the film roll FR1. Steps (v) and (vi) can be performed simultaneously in the illustrated example embodiment. Steps (iii) and (iv) can be performed simultaneously in the illustrated example embodiment. Steps (v) and (vi) are performed before or simultaneously with steps (iii) and (iv).

[0127] This process may include raising the second winder 300 so that the wound web can move under the second winder 300. This process also includes or alternatively includes: (vii) retracting the first web splicer 434 from the first sealing / cutting position; and (viii) retracting the second web splicer 444 from the second sealing / cutting position. These steps (vii) and (viii) can be performed simultaneously in the illustrated example embodiment. At this point, the ends of the films F1 and F2 are retained for application to subsequent webs.

[0128] Figure 1NJ The coil is shown after it has been completely wound.

[0129] Removing the wound coil from the coil winding area

[0130] The method of removing a wound coil from the coil winding area comprises: (a) causing the coil rotator 500 to stop rotating coil C (if not previously done); (b) raising the second winder 300 to its raised position; (c) moving the fully wound coil longitudinally from the coil rotator 500 in the coil winding area and below the second winder 300 to the coil outfeed area (and thereafter enabling the wound coil to be transported as needed); and (d) lowering the second winder 300 to its coil winding position for winding the next coil.

[0131] An example film roll changing system 50, an example method for preparing to wind the next roll, an example mandrel 4000, and an example mandrel holder 5000 of this illustrated example embodiment of the present disclosure are now described.

[0132] Film roll replacement system

[0133] The film roll replacement system 50 removes empty or nearly empty film rolls from the web winding device 30 and supplies new film rolls to the web winding device 30. Figure 1A , Figure 1B , Figure 1C , FIG. 2A to FIG. 2D as well as FIG. 3A to FIG. 3F The film roll replacement system 50 shown in the drawing includes a first replacement film roll holder 600, a first replacement film roll holder track 610, a first empty film roll holder 800, a first empty film roll holder track 810, a first film roll supply 900, a first empty film roll remover 1000, a second replacement film roll holder 1600, a second replacement film roll holder track 1610, a second empty film roll holder 1800, a second empty film roll holder track 1810, a second film roll supply 1900, and a second empty film roll remover 2000.

[0134] The first replacement roll holder track 610 and the first empty roll holder track 810 are positioned adjacent to the first outer region of the machine frame 60 and each extend transversely to the web rotator 500. The first replacement roll holder track 610 is aligned with the second winder 300, and the first empty roll holder track 810 is generally aligned transversely with the first winder 100. The first replacement roll holder 600 is slidably mounted on the first replacement roll holder track 610 and can be moved thereon from a supply position ( Figure 1A ) moves laterally to the reloading position ( Figure 1B ). Figure 1B After the replacement roll has been loaded onto the first replacement film roll holder 600 and after the first replacement film roll holder 600 has been returned to Figure 1AAs shown in the supply position shown previously, the first empty film roll holder 800 is slidably mounted on the first empty film roll holder track 810 and receives an empty film roll from the empty film roll receiving position ( Figure 1A ) moves laterally to the empty film roll unloading position ( Figure 1B ).

[0135] Likewise, the second replacement roll holder track 1610 and the second empty roll holder track 1810 are positioned adjacent to the opposite second exterior region of the machine frame 60 and each extend transversely to the web rotator 500. The second replacement roll holder track 1610 is generally aligned with the second winder 300, and the second empty roll holder track 1810 is laterally aligned with the first winder 100. The second replacement roll holder 1600 is slidably mounted on the second replacement roll holder track 1610 and can be moved thereon from a supply position ( Figure 1A ) moves laterally to the reloading position ( Figure 1B ). The second empty film roll holder 1800 is slidably mounted on the second empty film roll holder track 1810 and receives the empty film roll from the empty film roll receiving position ( Figure 1A ) moves laterally to the empty film roll unloading position ( Figure 1B ).

[0136] Suitable protective structures such as fences (not shown) may be employed around the components of the web winding system 20 to form protective barriers around the various components thereof to restrict access to the working area of ​​the web winding system 20. The loading and unloading positions described above may be outside such protective structures to enable operators to load replacement film rolls onto corresponding replacement film roll holders 600 and 1600 and unload empty film rolls from corresponding empty film roll holders 800 and 1800 without entering such protected working areas.

[0137] Each of the first replacement film roll holder 600, the first empty film roll holder 800, the second replacement film roll holder 1600 and the second empty film roll holder 1800 can be respectively: (i) manually movable toward and away from the corresponding winder 100 and 300 and moved and locked on the corresponding track 610, 810, 1610 and 1810 inside / outside the protective structure, or (ii) automatically movable toward and away from the corresponding winder 100 and 300 and moved and locked on the corresponding track 610, 810, 1610 and 1810 inside / outside the protective structure via the corresponding actuator (such as by the example actuator described below) under the control of the controller CR. Each of the first replacement film roll holder 600, the first empty film roll holder 800, the second replacement film roll holder 1600 and the second empty film roll holder 1800 can be manually locked in a corresponding position on the corresponding track 610, 810, 1610 and 1810, or can be automatically locked via a corresponding actuator (such as by the example actuator described below) under the control of the controller CR.

[0138] The first film roll supply 900 and the first empty film roll remover 1000 are positioned adjacent to the first outer region of the machine frame 60 and each extend transversely to the web rotator 500. The first film roll supply 900 and the first empty film roll remover 1000 are positioned between the first replacement film roll holder track 610 and the first empty film roll holder track 810, and thus between the first replacement film roll holder 600 and the first empty film roll holder 800 (when those holders are positioned in their respective supply position and empty film roll receiving position), as shown in FIG. Figure 1A and Figure 1CAs shown. The first film roll supplier 900 is also aligned with the first replacement film roll holder 600 (when the holder is in the film roll supply position), so that under the control of the controller CR, the first film roll supplier 900 can obtain the replacement film roll (on the spindle 4000) from the first replacement film roll holder 600 and provide the replacement film roll (on the spindle 4000) to the third applicator arm 330 of the second winder 300. The first empty film roll remover 1000 is also aligned with the first empty film roll holder 800 (when the holder is in the empty film roll receiving position), so that under the control of the controller CR, the first empty film roll remover 1000 can obtain the empty film roll (on the spindle 4000) from the first applicator arm 130 of the first winder 100 and provide the empty film roll (on the spindle 4000) to the first empty film roll holder 800. Since the first empty film roll remover 1000 obtains the empty film roll from the first applicator arm 130 of the first winder 100, in response to the controller CR determining that the film roll held by the third applicator arm 330 is empty, the controller CR causes the third applicator arm 330 to transfer the empty film roll to the first applicator arm 130 of the first winder 100 for removal as described below.

[0139] Likewise, the second film roll supply 1900 and the second empty film roll remover 2000 are positioned adjacent to the second outer region of the machine frame 60 and each extend transversely to the web rotator 500. The second film roll supply 1900 and the second empty film roll remover 2000 are positioned between the second replacement film roll holder track 1610 and the second empty film roll holder track 1810, and are therefore positioned between the second replacement film roll holder 1600 and the second empty film roll holder 1800 (when those holders are positioned in their respective supply positions and empty film roll receiving positions), as shown in FIG. Figure 1A and Figure 1CAs shown. The second film roll supplier 1900 is also aligned with the second replacement film roll holder 1600 (when the holder is in the film roll supply position), so that under the control of the controller CR, the second film roll supplier 1900 can obtain the replacement film roll (on the spindle 4000) from the second replacement film roll holder 1600 and provide the replacement film roll (on the spindle 4000) to the fourth applicator arm 380 of the second winder 300. The second empty film roll remover 2000 is also aligned with the second empty film roll holder 1800 (when the holder is in the empty film roll receiving position), so that under the control of the controller CR, the second empty film roll remover 2000 can obtain the empty film roll (on the spindle 4000) from the second applicator arm 180 of the first winder 100 and provide the empty film roll (on the spindle 4000) to the second empty film roll holder 1800. Since the second empty film roll remover 2000 obtains the empty film roll from the second applicator arm 180 of the first winder 100, in response to the controller CR determining that the film roll held by the fourth applicator arm 380 is empty, the controller CR causes the fourth applicator arm 380 to transfer the empty film roll to the second applicator arm 180 of the first winder 100 for removal.

[0140] First replacement film roll holder

[0141] More specifically, if Figure 2A , Figure 2B , Figure 2C and Figure 2D The first replacement film roll holder 600 best shown in FIG. 1 is configured to hold replacement film rolls RFR, which can be individually and separately provided to the third applicator arm 330 of the second winder 300 by the first film roll supplier 900 when the controller CR determines to replace each empty film roll held by the third applicator arm 330 of the second winder 300 (and transferred to the first applicator arm 130 of the first winder 100 for removal). The first replacement film roll holder 600 includes a replacement film roll holder frame 620 movably coupled to the track 610. The replacement film roll holder frame 620 includes a lower portion 630 and an upper portion 640. The lower portion 630 includes a plurality of legs (not labeled) having feet (not labeled) coupled to the track 610 and slidably movable on the track 610. The upper portion 640 includes a plurality of upright and longitudinal frame members (not labeled) supporting a plurality of film roll holders 700 as described below. The track 610 is fixed in position on a support surface, such as a floor, and as mentioned above, extends laterally outward in a first region adjacent the machine frame 60 and is laterally aligned with the second winder 300. The replacement film roll holder frame 620 can be moved outwardly from a supply position on the track 610 by the replacement film roll holder actuator 650 under the control of the controller CR. Figure 1A The supply position shown moves to Figure 1B The reloading position shown. In the supply position, the replacement film roll holder 600 is configured to supply the replacement film roll on the mandrel to the third applicator arm 330 of the second winder 300 via the first film roll supplier 900 when needed. In the reloading position, the replacement film roll holder 600 is configured to reload another replacement film roll on the mandrel. The replacement film roll holder actuator 650 is connected to the replacement film roll holder frame 620. The replacement film roll holder actuator 650, under the control of the controller CR, causes the replacement film roll holder frame 620 to move between the supply position and the reloading position on the track 610. This example embodiment additionally includes a replacement film roll holder locking actuator 660 connected to the replacement film roll holder frame 620. The replacement film roll holder locking actuator 660 is configured to move the locking pin 665 to engage with the track 610 under the control of the controller CR to lock the replacement film roll holder frame 620 in the supply position or the reloading position.

[0142] Figure 2A Twelve film roll holders 700 are shown without holding any film rolls. Figure 2C A film roll holder 700 is shown holding twelve replacement film rolls, each mounted on one of the mandrels 4000. In this example embodiment, the twelve film roll holders 700 are arranged in two rows, with each row having six film roll holders. Thus, the first replacement film roll holder 600 is capable of holding twelve replacement film rolls, such as 12 rolls, before having to be reloaded with additional replacement film rolls. Figure 2C The number and arrangement of the film roll holders may vary.

[0143] Each film roll holder 700 includes a top spindle holder 710, a bottom spindle holder 740, and a film end holder 780. The top spindle holder 710 is connected to the upper portion 640 of the frame 620 and includes a bracket shaped and sized to receive, hold, and release the top handle 4116 of the top handle assembly 4110 of the spindle 4000 (described below). The bottom spindle holder 740 is connected to the upper portion 640 of the frame 620, located below the top spindle holder 710, aligned with and spaced apart from the top spindle holder. The bottom spindle holder 740 includes a bracket shaped and sized to receive, hold, and release the bottom handle 4156 of the bottom handle assembly 4150 of the spindle 4000. The bottom spindle holder 740 also includes one or more magnets (not shown) that hold the spindle in place. The film end retainer 780 is connected to the upper portion 640 of the frame 620, located at the same level as the top mandrel retainer 710, aligned with and spaced apart from the top mandrel retainer. The film end retainer 780 includes a first film adapter 782 connected to the frame 600 and a second film adapter 790 pivotally connected to the first film adapter 782. The second film adapter 790 can be Figure 2A , Figure 2B , Figure 2C , Figure 2D The second film engager 790 is pivoted between a film holding position (not shown) and a film releasing position (not shown). The second film engager 790 is biased toward the film holding position by a biasing member (not shown). In some embodiments, one or more magnets can hold the second film engager 790 in the closed position. The film end retainer 780 is configured to hold the leading edge end of the replacement film roll, such as Figure 2C and Figure 2D As shown, the replacement film roll is held by the first replacement film roll holder 600. The film end holder 780 is configured to release the leading edge end of the replacement film roll when the replacement film roll is removed from the first replacement film roll holder 600 by the first replacement film roll supplier 900.

[0144] Second replacement film roll holder

[0145] The second replacement film roll holder 1600 is a mirror image of the first replacement film roll holder 600 and therefore, for the sake of brevity, is not described in detail herein. Figure 1A , Figure 1B and Figure 1CThe second replacement film roll holder 1600 best shown in the figure is configured to hold replacement film rolls, which are individually provided by the second film roll supply 1900 to the fourth applicator arm 380 of the second winder 300 when the controller CR determines to replace the empty film roll held by the fourth applicator arm 380 (and then transferred to the second applicator arm 180 of the first winder 100 for removal). Similar to the above, the replacement film roll holder actuator (not shown) connected to the replacement film roll holder frame of the second replacement film roll holder 1600 is controlled by the controller CR to cause the replacement film roll holder frame to be in the supply position ( Figure 1A shown) and the reload position ( Figure 1B 1610). This example embodiment additionally includes a replacement film roll holder locking actuator (not shown) connected to the replacement film roll holder frame. The replacement film roll holder locking actuator is configured under the control of the controller CR to move a locking pin (not shown) into engagement with the track 1610 to lock the replacement film roll holder frame in the supply position or the reloading position.

[0146] First empty film roll holder

[0147] like Figure 1A , Figure 1B and Figure 1C The first empty film roll holder 800 best shown in the figure is configured to hold an empty film roll (on the mandrel 4000) that is obtained separately from the first applicator arm 130 of the first winder 100 by the first empty film roll remover 1000 when the controller CR determines to replace the empty film roll held by the third applicator arm 330 or the first applicator arm 130, as explained above. The first empty film roll holder 800 is essentially a mirror image of the empty first replacement film roll holder 600 (but it does not initially hold any replacement film roll on the mandrel), and therefore, for the sake of brevity, the first empty film roll holder 800 is not described in detail herein. The first replacement film roll holder 600 can include, but need not include, any film end holder (such as the film end holder 780 of the first replacement film roll holder 600) because the first empty film roll holder 800 does not need to hold the leading edge end of the film of such an empty film roll. Similar to the above, the empty film roll holder actuator (not shown) connected to the empty film roll holder frame is controlled by the controller CR to cause the empty film roll holder frame to move on the track 810 in the empty film roll receiving position ( Figure 1A shown) and the unloading position ( Figure 1B810). This example embodiment additionally includes an empty film roll holder locking actuator (not shown) connected to the empty film roll holder frame. The empty film roll holder locking actuator is configured under the control of the controller CR to move a locking pin (not shown) into engagement with the track 810 to lock the empty film roll holder frame in the empty film roll receiving position or the unloading position.

[0148] Second empty film roll holder

[0149] The second empty film roll holder 1800 is likewise a mirror image of the first empty film roll holder 1800 and is therefore not described herein for the sake of brevity. Figure 1A , Figure 1B and Figure 1C The second empty film roll holder 1800 best shown in the example is configured to hold empty film rolls that are individually obtained by the second empty film roll remover 2000 from the second applicator arm 180 of the first winder 100 when the controller CR determines to replace the empty film rolls held by the fourth applicator arm 380 and transferred to the second applicator arm 180 for removal, as explained above. Similar to the above, an empty film roll holder actuator (not shown) connected to the empty film roll holder frame causes the empty film roll holder frame to move between the empty film roll receiving position and the unloading position on the track 1810 under the control of the controller CR. This example embodiment additionally includes an empty film roll holder locking actuator (not shown) connected to the empty film roll holder frame. The empty film roll holder locking actuator is configured under the control of the controller CR to move a locking pin (not shown) to engage with the track 1810 to lock the empty film roll holder frame in the empty film roll receiving position or the unloading position.

[0150] First film roll supplier

[0151] like FIG. 3A to FIG. 3E The first film roll supplier 900, best shown in FIG. 1 , is positioned between the first replacement film roll holder 600 and the first empty film roll remover 1000 and extends laterally partially within the interior region of the machine frame 60. The first film roll supplier 900 includes a supplier frame 920 and a film roll mover 950 supported by the supplier frame 920.

[0152] The feeder frame 920 is stationary and includes a lower section 922 and a track 924 attached to the top of the lower section 922. The feeder frame 920 is aligned with the first replacement film roll holder 600 in the longitudinal direction so that the film roll mover 950 can reach each replacement film roll holder support position of the first replacement film roll holder 600. The feeder frame 920 also extends laterally into an area within the machine frame 60 so that the film roll mover 950 can be longitudinally aligned with the third applicator arm 330 of the second winder 300 to transfer the replacement film roll to the third applicator arm 330.

[0153] The film roll mover 950 includes an upright support arm 952 that is movably coupled to a track 924 attached to the feeder frame 920, and a support arm actuator 956 that is operably coupled to the support arm 952 and that is movable on the track 924. The support arm actuator 956, under the control of the controller CR, causes the support arm 952 (and the components supported by it as described herein) to move laterally along the track 924. This enables the film roll mover 950 to interact with the first replacement film roll holder 600, and to interact with the third applicator arm 330. Thus, the support arm actuator 956, under the control of the controller CR, causes the support arm 952 and the entire film roll mover 950 to move along the track 924 to align longitudinally with different film holder support positions of the first replacement film roll holder 600, and to align longitudinally with the third applicator arm 330 when the third applicator arm 330 is in a film roll receiving position, such as Figure 1A shown.

[0154] The film roll mover 950 further includes a longitudinally extending film roll transfer arm 960 and a transfer arm actuator 966, which is longitudinally movably connected to the support arm 952, and the transfer arm actuator is connected to the support arm 952 and operably connected to the transfer arm 960. The transfer arm actuator 966 longitudinally moves the film roll transfer arm 960 longitudinally inwardly and outwardly relative to the support arm 952 under the control of the controller CR. The film roll mover 950 further includes a clamp 5000 (described below) connected to the end of the film roll transfer arm 960. The film roll mover 950 further includes a film roll leading edge end retainer 980 and a film roll mover actuator 986, which is configured to pivot the finger-shaped portion 984 of the retainer 980. 950 further includes a film roll leading edge end retainer 980 fixedly connected to the film roll transfer arm 960. The film roll mover 950 further includes a film roll leading edge end retainer 980 and a film roll mover actuator 986, which is fixedly connected to the arm 960 by a bracket 981 and can therefore move longitudinally therewith. The film roll leading edge end retainer 980 is similar to the film roll leading edge end retainer 450a described above in other aspects, and therefore, for the sake of brevity, it is not described herein. The film roll mover 950 includes an actuator 976, which is configured to move the film roll transfer arm 960 and the film roll leading edge end retainer 980 up and down along the track 958 attached to the support arm 952.

[0155] The first film roll supplier 900 is configured to: in response to the controller CR determining that the film roll held by the third applicator arm 330 is empty and needs to be replaced, and after the empty film roll has been transferred from the third applicator arm 330 to the first applicator arm 130 for removal, under the control of the controller CR, obtain a replacement film roll from the first replacement film roll holder 600 and move the replacement film roll to the third applicator arm 330 of the second winder 300.

[0156] Second film roll supplier

[0157] The second film roll supplier 1900 is positioned between the second replacement film roll holder 1600 and the second empty film roll remover 2000 and extends laterally partially within the interior area of ​​the machine frame 60. The second film roll first film roll supplier 1900 includes a mirror image of the first film roll first film roll supplier 900 and is therefore not described herein for the sake of brevity.

[0158] The second film roll supplier 1900 is configured to: in response to the controller CR determining that the film roll held by the fourth applicator arm 380 is empty and needs to be replaced, and after the empty film roll has been transferred from the fourth applicator arm 380 to the second applicator arm 180 for removal, under the control of the controller CR, obtain a replacement film roll from the second replacement film roll holder 1600 and move the replacement film roll to the fourth applicator arm 380 of the second winder 300.

[0159] First empty film roll remover

[0160] The first empty film roll remover 1000 is substantially similar to the first film roll supplier 900 and therefore is only briefly described herein for the sake of brevity.

[0161] The second empty film roll remover 1000 includes a remover frame 1020 and a film roll mover 1050 ( Figure 1B and Figure 1C ). The remover frame 1010 is stationary and similar to the supplier frame 920. The remover frame 1020 is aligned with the first empty film roll holder 800 in the longitudinal direction so that the film roll mover 1050 can reach each empty film roll holder support position of the first empty film roll holder 800. The remover frame 1020 also extends laterally into the area within the machine frame 60 so that the film roll mover 1050 can be longitudinally aligned with the first applicator arm 130 of the first winder 100 so that the first applicator arm 130 can transfer the empty film roll to the film roll mover 1050. The film roll mover 1050 is substantially similar to the film roll mover 950, except that: its longitudinally extending film roll transfer arm can be longitudinally moved longitudinally inwardly and outwardly in opposite directions under the control of the controller CR; and it does not need to include a film roll leading edge end retainer.

[0162] Second empty film roll remover

[0163] The second empty film roll remover 2000 is substantially similar to the first empty film roll remover 1000 and therefore is only briefly described herein for the sake of brevity.

[0164] The second empty film roll remover 2000 includes a remover frame 2020 and a film roll mover 2050 ( Figure 1C). The remover frame 2010 is stationary and similar to the remover frame 1010. The remover frame 2020 is aligned with the second empty film roll holder 1800 in the longitudinal direction so that the film roll mover 2050 can reach each empty film roll holder support position of the second empty film roll holder 1800. The remover frame 2020 also extends laterally into the area within the machine frame 60 so that the film roll mover 2050 can be longitudinally aligned with the second applicator arm 180 of the first winder 100 so that the second applicator arm 180 can transfer the empty film roll to the film roll mover 2050. The film roll mover 2050 is substantially similar to the film roll mover 950, except that: its longitudinally extending film roll transfer arm can be longitudinally moved longitudinally inwardly and outwardly in opposite directions under the control of the controller CR; and it does not need to include a film roll leading edge end retainer.

[0165] Preparation for coil winding and film roll changing methods

[0166] The method for preparing a wound roll and replacing an empty film roll with a replacement film roll using the film roll replacement system 50 will now be described in more detail.

[0167] The method of preparing to wind the next coil (i.e., before the next coil winding process begins) includes the controller CR determining whether both the film rolls FR1 and FR2 to be used by the first winder 100 and the second winder 300 to wind the next coil have sufficient film for winding the next coil. If either of those film rolls FR1 or FR2 does not have sufficient film for winding the next coil, the controller CR causes the insufficient film roll to be replaced with a replacement film roll from a corresponding one of the replacement film roll holders 600 or 1600. As mentioned above, such an insufficient film roll is regarded or considered to be empty.

[0168] These determinations may be made based on data received by the controller CR from one or more sensors S and / or data relating to the time each film roll FR was previously replaced and the amount of coil C that has been wound since the start of use of each film roll FR. In a number of different embodiments, the controller CR makes determinations based on signals received from sensors S mounted on respective grippers 5000 of respective applicator arms 330 and 380 of the second winder 300, wherein these signals indicate readings of the amount of film F remaining on respective films F1 and F2 of film rolls FR1 and FR2 (after the previous coil C has been wound). In other embodiments, the controller CR makes these determinations based on usage data tracked and maintained by the controller CR regarding each of the currently employed film rolls FR1 and FR2 and the number and size of coils C previously wound using such currently employed film rolls FR1 and FR2 (as well as the amount or length of film of each film roll). In other embodiments, the controller CR makes these determinations based on signals received from sensors S and based on such usage data.

[0169] In response to the controller CR determining that the film roll FR2 held by the third applicator arm 330 is insufficient to wind the next web, the controller CR generally causes: (1) the third applicator arm 330 to transfer the empty film roll FR2 to the first applicator arm 130; (2) the first applicator arm 130 to transfer the empty film roll FR2 to the first empty film roll remover 1000; (3) the first empty film roll remover 1000 to transfer the empty film roll FR2 to the first empty film roll holder 800; (4) the first film roll supplier 900 obtains the replacement film roll RFR from the first replacement film roll holder 600; and (5) the first film roll supplier 900 transfers the obtained replacement film roll RFR to the third applicator arm 330. In this example embodiment, steps (2) and (3) can be performed simultaneously with steps (4) and (5).

[0170] Similarly, in response to the controller CR determining that the film roll FR1 held by the fourth applicator arm 380 is insufficient to wrap the next web, the controller CR generally causes: (A) the fourth applicator arm 380 to transfer the empty film roll FR1 to the second applicator arm 180; (B) the second applicator arm 180 to transfer the empty film roll FR1 to the second empty film roll remover 2000; (C) the second empty film roll remover 2000 to transfer the empty film roll FR1 to the second empty film roll holder 1800; (D) the second film roll supplier 1900 obtains the replacement film roll RFR from the second replacement film roll holder 1600; and (E) the second film roll supplier 1900 transfers the obtained replacement film roll to the fourth applicator arm 380. In this example embodiment, steps (B) and (C) can be performed simultaneously with steps (D) and (E). Additionally, in this exemplary embodiment, steps (B) and (C), (2) and (3), (C) and (D), and (4) and (5) may be performed simultaneously.

[0171] Since the method for replacing film rolls FR1 and FR2 is substantially the same in this example embodiment, for the sake of brevity, only the method for replacing empty film roll FR2 is described in more detail herein. The method for replacing empty film roll FR2 as described below includes positioning the first winder 100 and the second winder 300, the applicator arms 130 and 330 of the first winder 100 and the second winder 300, and each of the film roll movers 950 and 1050. This positioning may include any necessary vertical, longitudinal and / or lateral movement of these corresponding parts by the corresponding actuators described above. All of these movements are controlled by the controller CR based on a specific point in the film roll replacement process. In addition, one or more of these movements can be monitored by one or more sensors S, and one or more of these movements can be caused by the controller CR based on feedback from one or more sensors in the sensor S.

[0172] More specifically, the method of replacing the empty film roll FR2 first includes: if necessary, vertically moving each of the first winder 100 and the second winder 300 to their respective vertical film replacement positions. In these film replacement positions, the third applicator arm 330 is vertically aligned with the first applicator arm 130 (i.e., at the same vertical height), the third applicator arm 330 is vertically aligned with the film roll mover 950 (i.e., at the same vertical height), and the first applicator arm 130 is vertically aligned with the film roll mover 1050 (i.e., at the same vertical height).

[0173] The method then includes causing the third applicator arm 330 to transfer the empty film roll FR2 to the first applicator arm 130, which includes: (a) moving the third applicator arm 330 longitudinally inward to position its clamp 5000 and the film roll FR2 held by the clamp to a film roll transfer position; (b) moving the first applicator arm 130 longitudinally inward to position its clamp 5000 (which does not hold any film roll at this time) at the film roll transfer position; (c) transferring the film roll FR2 from the clamp 5000 of the third applicator arm 330 to the clamp 500 of the first applicator arm 130 at the film roll transfer position; (d) moving the third applicator arm 330 (whose clamp 5000 is now empty) longitudinally outward; (e) moving the first applicator arm 130 (whose clamp 5000 now holds the film roll FR2) longitudinally outward. In this embodiment, steps (a) and (b) may be performed simultaneously, and steps (d) and (e) may be performed simultaneously.

[0174] The method then includes causing the first applicator arm 130 to transfer the empty film roll FR2 to the first empty film roll remover 1000 , and causing the first empty film roll remover 1000 to transfer the empty film roll FR2 to the first empty film roll holder 800 . This includes: (f) moving the film roll mover 1050 of the first empty film roll remover 1000 laterally so that its gripper is longitudinally aligned with the first applicator arm 130; (g) moving the gripper 5000 of the film roll mover 1050 longitudinally outward to the film roll transfer position; (h) if necessary, moving the first applicator arm 130 longitudinally inward to position its gripper 5000 and the film roll FR2 at the film roll transfer position; (i) transferring the film roll FR2 from the gripper 5000 of the first applicator arm 130 to the gripper of the film roll mover 1050; (j) moving the first applicator arm 130 (whose gripper 5000 is now empty) longitudinally outward; (k) moving the film roll mover 1050 (whose gripper 5000 is now empty) longitudinally outward; (a) moving the film roll mover 1050 (whose clamp 5000 now holds the film roll FR2) longitudinally inward; (l) moving the film roll mover 1050 (whose clamp 5000 holds the film roll FR2) laterally (and, if necessary, vertically) to a position aligned with one of the empty film roll supports of the first empty film roll holder 800; (m) moving the film roll mover 1050 longitudinally outward to position its clamp to transfer the empty film roll FR2 to the selected empty film roll support of the first empty film roll holder 800; (n) transferring the empty film roll FR2 from the clamp of the film roll mover 1050 to the selected empty film roll support of the first empty film roll holder 800; and (o) moving the film roll mover 1050 (whose clamp is now empty) longitudinally inward.

[0175] The method also includes causing the first film roll supplier 900 to obtain a replacement film roll RFR from the first replacement film roll holder 600 and the first film roll supplier 900 to transfer the obtained replacement film roll to the third applicator arm 330. This includes: (q) moving the film roll transfer arm 960 of the film roll mover 950 and its gripper 5000 (which does not hold any film roll at this time) to a position longitudinally aligned with one of the film roll supports 700 of the replacement film roll holder 600 holding the replacement film roll RFR (this may also include moving the film roll transfer arm 960 vertically), such as Figure 3C As shown; (r) the film roll transfer arm 960 is moved longitudinally outward to position its clamp 5000 for transferring (here grabbing) the replacement film roll RFR of the film roll support from the first replacement film roll holder 600 (s), and the film roll leading edge end holder 980 attached to the film roll transfer arm 960 is moved longitudinally for transferring (here grabbing) the leading edge end of the replacement film roll from the first replacement film roll holder 600, such as Figure 3D or Figure 3E (s) transfer (here grab) the replacement film roll RFR from the first replacement film roll holder 600, and transfer (here grab) the leading edge end of the replacement film roll RFR from the leading edge end holder 780 of the first replacement film roll holder 800, such as Figure 3D or Figure 3E (t) the film roll transfer arm 960 (whose clamp 5000 now holds the replacement film roll RFR) is moved longitudinally inward, and the film roll leading edge end holder 980 that now holds the leading edge end of the replacement film roll RFR is simultaneously moved longitudinally inward, such as Figure 3FAs shown; (u) the film roll transfer arm 960 (whose clamp 5000 holds the replacement film roll RFR) is moved laterally, and the film roll leading edge end retainer 980 holding the leading edge end of the replacement film roll RFR is moved laterally to a position correspondingly aligned longitudinally with the third applicator arm 330 and the first leading edge end retainer 450a (if necessary, this can also include moving these components vertically); (v) if necessary, the third applicator arm 330 is moved longitudinally inward to position its clamp 5000 to the film roll transfer position; (w) if necessary, the first leading edge end retainer 450a is moved longitudinally inward to the film leading edge end transfer position; (x) the replacement film roll RFR is removed from the clamp of the film roll mover 950 (aa) move the film roll mover 950 (whose clamp 5000 and film roll holder 980 are now empty) longitudinally inwardly; and (bb) move the film roll mover 950 (whose clamp 5000 and film roll holder 980 are now empty) laterally.

[0176] Mandrel

[0177] FIG. 4A to FIG. 4L A mandrel 4000 configured to support a film roll according to an example embodiment of the present disclosure is shown. As indicated above, a number of film rolls are used for the roll winding system 50. Each film roll is mounted on a mandrel (such as mandrel 4000). Mandrel 4000 includes an internal mandrel assembly 4100 and an external mandrel assembly 4200. When the internal mandrel assembly 4100 and the external mandrel assembly 4200 can rotate relative to each other, when the internal mandrel assembly 4100 is held stationary by a mandrel clamp (the mandrel clamp 5000 described below), the external mandrel assembly 4200 and the film roll mounted on the external mandrel assembly 4200 can rotate under tension (as described below), thereby releasing the film from the film roll to the roll, such as in the manner described above. When the film is applied to the roll by the corresponding applicator arm, the mandrel 4000 keeps the film under tension. Mandrel 4000 is additionally configured to be held by a corresponding mandrel holder of an applicator arm and transferred from one applicator arm to another as described above.

[0178] Internal spindle assembly

[0179] The internal spindle assembly 4100 includes: a top handle assembly 4110, a shaft 4130, an internal rotation assembly 4140 and a bottom handle assembly 4150.

[0180] Top handle assembly

[0181] The top handle assembly 4110 includes: a top handle retaining screw 4112, a top handle retaining washer 4114, a top handle 4116, a top handle locking nut 4126 and a top handle locking washer 4128.

[0182] The top handle retaining screw 4112 and the top handle retaining washer 4114 secure the top handle 4116 to the shaft 4130 such that the top handle 4116 and the shaft 4130 are rotationally locked together.

[0183] The size, shape, location, orientation, and other aspects of the top handle 4116 are configured to be removably engaged by the upper spindle jaw 5210 of the spindle clamp 5000, as described below. The top handle 4116 is fixed to the shaft 4130 via a key connection so that the top handle 4116 and the shaft 4130 rotate together. The top handle 4116 includes: an outer handle cylinder 4118, an outer handle block 4120, an inner handle cylinder 4122, and an inner handle block 4124. The outer handle cylinder 4118 is cylindrical and aligned with the longitudinal axis 4130A of the shaft 4130. The size, shape, location, orientation, and other aspects of the outer handle cylinder 4118 are configured to be engaged by the spindle adapter 5230 of the upper spindle jaw 5210. The outer handle block 4120 is rectangular in shape and includes a top surface (not labeled) and a bottom surface (not labeled). The size, shape, location, orientation, and other aspects of the top surface are configured to engage with the fingers 5520 and 5520 of the upper spindle jaws 5210. The inner handle cylinder 4122 can be similar or identical to the outer handle cylinder 4118 in that it is cylindrical in shape and coaxial with the central axis of the shaft 4130. The size, shape, location, orientation, and other aspects of the inner handle cylinder are configured to be engaged by the upper spindle jaws 5210. The inner handle block 4124 can be similar or identical to the outer handle block 4120 in that it is square in shape and includes a top surface (not labeled) and a bottom surface (not labeled). The size, shape, location, orientation, and other aspects of the top surface are configured to engage with the fingers 5520 and 5520 of the upper spindle jaws 5210.

[0184] The top handle locking nut 4126 and the top handle locking washer 4128 secure the top handle 4116 to the shaft 4130 such that the top handle 4116 and the shaft 4130 are rotationally locked together.

[0185] When the mandrel 4000 is grasped by the mandrel holder 5000 , the top handle assembly 4110 is rotationally locked to the fingers 5520 and 5520 of the upper mandrel jaws 5210 of the mandrel holder 5000 .

[0186] axis

[0187] The shaft 4130 of the internal spindle assembly 4100 provides a central support structure to which the top handle assembly 4110, the internal rotating assembly 4140, and the bottom handle assembly 4140 are attached. The shaft 4130 is cylindrical. The shaft 4130 includes a top section, a middle section, and a bottom section having different diameters. The top diameter is smaller than the middle diameter, so that the transition between the top section and the middle section of the shaft 4130 defines a top shelf 4132. The top shelf 4132 is configured to engage the top handle assembly 4110. Similarly, the bottom diameter is smaller than the middle diameter, so that the transition between the bottom section and the middle section of the shaft 4130 defines a bottom shelf 4134. The bottom shelf 4134 is configured to engage the bottom handle assembly 4140. The shaft 4130 is fixed to the top handle assembly 4110, the internal rotating assembly 4140, and the bottom handle assembly 4140. The size, shape, positioning, orientation, and other aspects of the shaft 4130 are configured to engage the various bearings of the outer spindle assembly 4200 (including the top bearing 4240, the bottom bearing 4242, and the rotary axial bearing 4244).

[0188] Internal rotating assembly

[0189] The inner rotating assembly 4140 includes a fixed clutch disc 4142, a fixed disc docking plate 4144, and corresponding top and bottom disc springs 4146A, 4146B.

[0190] The fixed clutch plate 4142 is attached to the shaft 4130 via a key connection, a spline connection or other suitable connection so that they are both rotationally fixed to the top handle assembly 4110. The fixed clutch plate 4142 includes a top surface (not labeled) and a bottom surface (not labeled). The size, shape, positioning, orientation, and other aspects of the top surface of the fixed clutch plate 4142 are configured to engage the bottom surface of the rotating clutch plate 4238 of the outer spindle assembly 4200 to provide a force that resists the rotation of the outer spindle assembly 4200 relative to the inner spindle assembly 4100 about the longitudinal axis 4130A.

[0191] The fixed disc docking plate 4144 provides support for the fixed clutch disc 4142 and is sized, shaped, positioned, oriented, and otherwise configured to engage the bottom surface of the fixed clutch disc 4142. The fixed disc docking plate 4144 is attached to the shaft 4130 so that it is rotationally fixed to the top handle assembly 4110. The fixed disc docking plate 4144 includes a top surface (not labeled) that engages the fixed clutch disc 4142 and a bottom surface (not labeled) that is engaged by the top disc-type spring member 4146A.

[0192] The top disc spring 4146A and the bottom disc spring 4146B comprise two-part springs. The size, shape, location, orientation, and other aspects of the top disc spring 4146A are configured to engage the bottom surface of the fixed disc docking plate 4144, and the size, shape, location, orientation, and other aspects of the bottom disc spring 4146B are configured to be engaged by the bottom handle locking washer 4152.

[0193] During operation of the spindle 4000, the inner rotating assembly 4140 is rotationally fixed to the top handle assembly 4110. The size, shape, positioning, orientation, and other aspects of the inner rotating assembly 4140 are configured to engage with the outer spindle assembly 4200 via contact between the fixed clutch plate 4142 of the inner rotating assembly 4140 and the rotating clutch plate 4238 of the outer spindle assembly 4200, thereby providing a desired amount of resistance to rotation of the outer spindle assembly 4200 relative to the inner spindle assembly 4100.

[0194] Bottom handle assembly

[0195] The bottom handle assembly 4150 includes a bottom handle locking washer 4152 , a bottom handle locking nut 4154 , a bottom handle 4156 , a bottom handle retaining washer 4158 and a bottom handle retaining screw 4160 .

[0196] The size, shape, location, orientation, and other aspects of the bottom handle locking washer 4152 are configured to engage the bottom disc spring 4146B to provide a force transmitted through the disc springs 4146A and 4146B to the fixed clutch plate 4142. Together with the bottom handle locking nut 4154, the bottom handle locking washer 4152 secures the bottom handle 4156 to the shaft 4130 so that the bottom handle 4156 and the shaft 4130 are rotationally fixed to the top handle assembly 4110.

[0197] The bottom handle 4156 can be similar or identical to the top handle 4116. Therefore, for the sake of brevity, only the top handle is described in detail herein.

[0198] The bottom handle retaining washer 4158 and the bottom handle retaining screw 4160 secure the bottom handle 4156 to the shaft 4130 such that the bottom handle 4156 and the shaft 4130 are rotationally fixed to the top handle assembly 4110. To increase or decrease the tension on the disc springs 4146A and 4146B (and thus the tension on the fixed clutch plate 4142), the bottom handle retaining screw 4160 can be screwed in or out to increase or decrease the force on the disc springs 4146A and 4146B. This, in turn, can increase or decrease the friction between the fixed clutch plate 4142 and the rotating clutch plate 4238.

[0199] External spindle assembly

[0200] The external spindle assembly 4200 includes a film roll retainer assembly 4210, an external spindle body 4220, an external rotation assembly 4230, and a plurality of bearings and support structures (not shown).

[0201] External mandrel body

[0202] The outer spindle body 4220 includes a top surface 4222 and a lower lip 4224 , and defines a rotation stop groove 4226 .

[0203] The top surface 4222 is the surface of the outer mandrel body 4220 to which the retainer core 4216 is attached. A lower lip 4224 extends from the bottom of the outer mandrel body 4220 and provides a surface on which the bottom of the film roll rests. The lower lip 4224 prevents the film roll from sliding off the bottom of the mandrel 4000.

[0204] The rotation stop slot 4226 is an opening defined by the outer spindle housing 4220 that receives the rotation stop 4232 of the outer rotation assembly 4230, as described below.

[0205] The outer spindle body 4220 rotates relative to the inner spindle assembly 4100.

[0206] Film roll retainer assembly

[0207] The film roll retainer assembly 4210 includes: a retainer core screw 4212, a spring retaining pin 4214 and a retainer core 4216.

[0208] The retainer core screw 4212 rotatably secures the retainer core 4216 to the outer spindle body 4220, and in particular to the top surface (not shown) of the outer spindle body 4220. The size, shape, location, orientation, and other aspects of the spring retaining pin 4214 are configured to engage a first end (not shown) of a spring (not shown), wherein a second end of the spring (not shown) is attached to the outer spindle body 4220. The spring retaining pin 4214 is attached to the retainer core 4216. The retainer core 4216 is rotatably attached to the outer spindle body 4220 by the retainer core screw 4212 and is biased by a spring (not shown) to a first position extending radially from the outer spindle body 4220.

[0209] During operation, the retainer core screw 4212, spring retaining pin 4214, spring (not shown) and retainer core 4216 bias the retainer core 4216 to a first position extending radially outward from the outer mandrel body 4220. When a roll of film is positioned on the mandrel 4000, the bottom surface of the retainer core 4216 prevents the roll of film from sliding upward. To remove or add a roll of film from the mandrel 4000, the retainer core 4216 pivots to a second position in which the retainer core 4216 extends along the curve of the outer mandrel body 4220. In the second position, the retainer core 4216 rotates inward and does not prevent the roll from sliding on or off the mandrel 4000.

[0210] External rotating assembly

[0211] The external rotating assembly 4230 includes: a rotating stop 4232, a tension spring 4234, a spring housing 4236 and a rotating clutch plate 4238.

[0212] The rotation stopper 4232 is attached to the first end of the tension spring 4234 and is positioned in the rotation stopper slot 4226 of the outer mandrel body 4220. The positioning of the rotation stopper 4232 in the rotation stopper slot 4226 causes the rotation stopper 4232 to rotate as the outer mandrel body 4220 rotates.

[0213] The tension spring 4234 is attached to the rotation stop 4232 at a first end, extends within the spring housing 4236, and is attached to the spring housing 4236 at a second end. The tension spring 4234 provides a biasing force between the rotation stop 4232 and the spring housing 4236.

[0214] The spring housing 4236 defines an opening for the tension spring 4234 to extend circumferentially around the interior of the outer spindle body 4220. The spring housing 4236 includes a top surface (not labeled) that is sized, shaped, positioned, oriented, and otherwise configured to engage the rotating axial bearing 4244 and a bottom surface (not labeled) that is sized, shaped, positioned, oriented, and otherwise configured to engage the rotating clutch plate 4238.

[0215] The size, shape, location, orientation, and other aspects of the rotating clutch plate 4238 are configured to engage the fixed clutch plate 4142. The rotating clutch plate 4238 includes a top surface (not labeled) and a bottom surface (not labeled). The size, shape, location, orientation, and other aspects of the top surface of the rotating clutch plate 4238 are configured to engage the spring housing 4236. The size, shape, location, orientation, and other aspects of the bottom surface of the rotating clutch plate 4236 are configured to engage the fixed clutch plate 4142 to provide a force that resists the rotation of the outer spindle assembly 4200 relative to the inner spindle assembly 4100 about the longitudinal axis 4130A.

[0216] Bearings and support structures

[0217] The outer spindle assembly 4200 includes several bearings and support structures, including: a top bearing 4240, a bottom bearing 4242, a rotary axial bearing 4244, a plurality of leaf springs 4246A-H, and a retainer ring 4248.

[0218] The top bearing 4240 and the bottom bearing 4242 each include a ball bearing disposed between the shaft 4130 and the outer spindle body 4220. The top bearing 4240 and the bottom bearing 4242 enable the outer spindle assembly 4200 to rotate relative to the inner spindle assembly 4100.

[0219] A rotary axial bearing 4244 is positioned between the shaft 4130 and the outer spindle body 4220. The rotary axial bearing 4244 enables the outer spindle assembly 4200 to rotate relative to the inner spindle assembly 4100. The rotary axial bearing 4244 also provides vertical support for the outer spindle body 4220 relative to the shaft 4130.

[0220] The leaf springs 4246A-H are each attached to the outer surface of the outer mandrel body 4220. The leaf springs 4246A-H are vertically positioned in pairs and are spaced apart around the circumference of the outer mandrel body 4220. This illustrated example embodiment includes eight leaf springs, however more or fewer leaf springs may be employed. Additionally, other types of springs may be used when employed. The leaf springs 4246A-H push outward against the inner surface of the film roll to rotationally secure the film roll to the outer mandrel body 4220.

[0221] The size, shape, positioning, orientation, and other aspects of the retainer ring 4248 are configured to engage the bottom bearing 4242 and secure the bottom bearing 4242 in the appropriate position relative to the outer spindle body 4220.

[0222] Together, the inner mandrel assembly 4100 and the outer mandrel assembly 4200 provide a rotational force to the film relative to the film roll so that the film can be applied to and wound onto the web at a relatively constant tension (or tension within a specified range).

[0223] The spring housing 4236 is rotationally fixed to the rotating clutch plate 4238, which ensures that the spring housing 4236 (and the second end of the tension spring 4234 attached thereto) rotates together with the rotating clutch plate 4238. The first end of the tension spring 4234 is fixed to the rotation stop 4232, and the rotation stop 4232 is positioned in the rotation stop slot 4226 of the outer spindle housing 4220, so that the first end of the tension spring 4234, the rotation stop 4232 and the outer spindle housing 4220 are all rotationally fixed to each other.

[0224] Thus, there are three separate groupings of components that are rotationally fixed to the other components within their respective groupings: (1) the inner spindle assembly 4100, which can be rotationally held by the upper spindle jaws 5210 and the lower spindle jaws 5250 of the spindle holder 5000; (2) the rotating clutch plate 4238 and the spring housing 4236; and (3) the remaining components of the outer spindle assembly 4200. There are also three bearings, each connected to two of the three groupings, including: (1) a top bearing 4240 disposed between the shaft 4130 of the inner spindle assembly 4100 and the outer spindle body 4220; (2) a bottom bearing 4242 disposed between the shaft 4130 of the inner spindle assembly 4100 and the outer spindle body 4220; and (3) a slewing axial bearing 4244 disposed between the spring housing 4236 and the outer spindle body 4210.

[0225] Figure 4H , Fig. 4I , Figure 4J , Figure 4K and Figure 4L A cross section of the rotation stop 4232, tension spring 4234 and spring housing 4236 is shown. Figure 4H , Fig. 4I , Figure 4J , Figure 4K and Figure 4L The positions of the parts are shown both at rest and during the process of wrapping the film around a web.

[0226] Figure 4H The rotation stop 4232, tension spring 4234 and spring housing 4236 are shown at rest. The film roll can be mounted on the mandrel in this resting state. No external rotational force is applied. In this state, the spring housing 4236 is held in place and prevented from rotating by the rotating clutch plate 4238. The tension spring 4234 is in a balanced state, forcing the rotation stop 4232 to a position such as Figure 4H The resting position is shown.

[0227] Fig. 4I The position of the rotation stop 4232 is shown after the rotation stop 4232 has been rotated counterclockwise. The counterclockwise rotation of the rotation stop 4232 is caused by the film being pulled away from the film roll as the film is wrapped around the web. Fig. 4I As can be seen in FIG. 4 , the spring housing 4236 remains stationary while the tension spring 4234 and the rotation stop 4232 extend and move in a counterclockwise direction in response to the external torque.

[0228] Figure 4J The position of the rotation stop 4232 is shown when the external torque continues to be applied. The rotation stop 4232 reaches the end of the spring housing 4236, causing the rotation stop 4232 to stop moving. The spring housing 4236 is still held stationary by the rotating clutch plate 4238.

[0229] Figure 4K The positions of the rotation stop 4232, the extension spring 4234, and the spring housing 4236 are shown as the external torque continues to be applied after the rotation stop 4232 has reached the end of the spring housing 4236. The spring housing 4236 begins to rotate counterclockwise. The rotation stop 4232 remains in contact with the end of the spring housing 4236, and the extension spring 4234 remains fully extended. Rather than causing the rotation stop 4232 and the extension spring 4234 to continue to extend, the external torque causes the spring housing 4236, the extension spring 4234, and the rotation stop 4232 to all rotate counterclockwise simultaneously.

[0230] During the process of winding the web, the positioning of the film roll relative to the web follows a path that causes inconsistent forces on the film roll. For example, as the film roll moves from the outside of the wound web to the surface of the eye of the wound web, the path taken by the film roll causes slack to be introduced into the film that has been pulled off the film roll. To ensure that consistent tension is applied to the film roll, the mandrel is configured to rotate clockwise to rewind the slack film (i.e., to rotate in the opposite direction to that which causes the film to be pulled off the film roll).

[0231] Figure 4L The positions of the rotation stop 4232, tension spring 4234 and spring housing 4236 are shown after the external torque is reduced and the membrane has become relaxed. The spring housing 4236 remains in contact with the Figure 4K 4238. The tension spring 4234 pulls the rotation stop 4232 in a clockwise direction. The clockwise rotation of the rotation stop 4232 causes the outer mandrel body 4220 to also rotate in a clockwise direction, thereby rewinding the slack film onto the film roll.

[0232] In this example, the extension spring 4234 has a spring constant that causes a threshold force that must be overcome to extend the extension spring. The rotating clutch plate 4238 also has a threshold torque that must be applied to cause the spring housing 4236 to rotate. In this example, the rotating clutch plate torque is greater than the spring force. Therefore, the external torque caused by the film being pulled off the film roll first overcomes the spring force and causes the spring to extend, and then overcomes the rotating clutch plate 4238 torque and causes the spring housing 4236 to rotate.

[0233] In some examples, the travel distance of the tension spring 4234 can be approximately 90 to 100 degrees of rotation around the spring housing 4236. This rotation enables approximately 90 to 100 degrees of clockwise rotation (i.e., rewinding the slack film back onto the film roll 90 to 100 degrees).

[0234] Mandrel holder

[0235] Each mandrel gripper 5000 is connected to a respective frame of a respective applicator arm, such as frame 132 of applicator arm 130, and is configured to hold and release a mandrel, such as mandrel 4000 described above and on which a film roll is mounted. The grippers may alternatively be configured in accordance with the present disclosure.

[0236] Figure 5A , Figure 5C and Figure 5D A mandrel holder 5000 is shown of an example embodiment of the present disclosure that is configured to receive, hold, and release a mandrel, such as mandrel 4000 . Figure 6The transfer of the mandrel 4000 (and the roll of film thereon) from a first mandrel holder 5000 to a second mandrel holder 5000 is shown, as further described below.

[0237] The mandrel clamp 5000 includes a base 5100, an actuator 5130 attached to the base 5100, and a mandrel adapter 5200. The size, shape, positioning, orientation, and other aspects of the base 5100 are configured to be connected to a corresponding frame of a corresponding applicator arm so that the applicator arm can move the mandrel clamp 5000 as needed to perform the various functions described herein. The mandrel adapter 5200 includes an upper mandrel jaw 5210 and a lower mandrel jaw 5250, which work together under the control of a controller to clamp a mandrel, such as the mandrel 4000 described above.

[0238] More specifically, the base 5100 includes an arm connecting bracket 5110 .

[0239] The arm connection bracket 5110 includes: a first side panel 5112, a second side panel 5114 and a center panel 5116. The size, shape, location, orientation, and other aspects of each of the first side panel 5112 and the second side panel 5114 are configured to be connected to a corresponding frame of a corresponding applicator arm that moves the mandrel holder 5000. The first side panel 5112 and the second side panel 5114 are parallel to each other and are also each connected to the center panel 5116.

[0240] The center panel 5116 defines an upper spindle jaw opening 5118, a lower spindle jaw opening 5120, and includes an upper spindle jaw track 5122 and a lower spindle jaw track 5124. The upper spindle jaw opening 5118 and the lower spindle jaw opening 5120 are each an elongated opening extending in the direction of movement of the upper spindle jaw 5210 and the lower spindle jaw 5250 during operation. The upper spindle jaw opening 5118 and the lower spindle jaw opening 5120 enable a portion of the upper spindle jaw 5210 and the lower spindle jaw 5250 to extend therethrough, respectively, for operably connecting to the actuator 5130, as described below. The upper spindle jaw track 5122 and the lower spindle jaw track 5124 are respectively positioned above and below the upper spindle jaw opening 5118 and the lower spindle jaw opening 5120, as shown in FIG. Figure 5A The size, shape, location, orientation, and other aspects of the upper spindle claw track 5122 are configured to engage the track engagement support member 5216 of the upper spindle claw 5210. Similarly, the size, shape, location, orientation, and other aspects of the lower spindle claw track 5124 are configured to engage the track engagement support member of the lower spindle claw 5250.

[0241] In the illustrated figures, the actuator 5130 is attached to the base 5100 and is positioned between the first side panel 5112 and the second side panel 5114 on the side of the center panel 5116 opposite to the mandrel adapter 5200. Alternatively, the actuator 5130 can be attached to the applicator arm or another component. The actuator 5130 operably engages the upper mandrel claw 5210 and the lower mandrel claw 5250 and enables the upper mandrel claw and the lower mandrel claw to move. The actuator 5130 enables the upper mandrel claw 5210 and the lower mandrel claw 5250 to maintain a central positioning in an upright direction so that the vertical center point between the upper mandrel claw 5210 and the lower mandrel claw 5250 remains unchanged. The actuator 5130 enables the upper mandrel claw 5210 and the lower mandrel claw 5250 to move in a mirror image so that these claws move away from each other or toward each other.

[0242] The upper mandrel jaw 5210 and the lower mandrel jaw 5250 are mirror images similar or identical to each other. Therefore, for the sake of brevity, only the upper mandrel jaw 5210 is described in detail herein.

[0243] The upper spindle jaw 5210 includes: an actuator engagement arm 5212, a vertical support bracket 5214, a track engagement support member 5216 and a lateral spindle engagement member 5218.

[0244] The actuator engagement arm 5212 extends through the upper spindle jaw opening 5118 and is sized, shaped, positioned, oriented, and otherwise configured to engage the actuator 5130 at a first end of the actuator engagement arm 5212. The second end of the actuator engagement arm 5212 is connected to the vertical support bracket 5214. The vertical support bracket 5214 is connected to the actuator engagement arm 5212 on a first end. The vertical support bracket 5214 extends upwardly and is connected to the track engagement support member 5216 on a second end.

[0245] The size, shape, positioning, orientation, and other aspects of the track engagement support member 5216 are configured to engage the upper spindle claw track 5122, which together provide lateral support for the upper spindle claw 5210. The track engagement support member 5216 and the upper spindle claw track 5122 also enable the upper spindle claw 5210 to move smoothly in the vertical direction. The track engagement support member 5216 is also connected to the lateral spindle engagement member 5218.

[0246] The lateral spindle engagement member 5218 includes: a first finger 5220, a second finger 5222, a finger connecting rod 5224, and a U-shaped spindle engager 5230. The first finger 5220 and the second finger 5222 are shaped and sized to engage one of the outer handle block 4120 or the inner handle block 5124 of the spindle 4000. The finger connecting rod 5224 extends between the first finger 220 and the second finger 5222 and connects the first finger to the second finger.

[0247] The U-shaped spindle adapter 5230 extends inwardly from the first finger 5220 and the second finger 5222. The U-shaped spindle adapter 5230 is positioned so that the open end of the U-shape is oriented away from the base 5100. The U-shaped spindle adapter includes a spindle-facing surface 5232, a first handle lock catch 5234 and a second handle lock catch 5236. The spindle-facing surface 5232 extends along the inside of the U-shaped spindle adapter 5230 and is sized, shaped, positioned, oriented, and otherwise configured to engage the outer handle cylinder 4118 or the inner handle cylinder 4122 of the spindle 4000. The first handle lock catch 5234 and the second handle lock catch 5235 are positioned on the lower side of the U-shaped spindle adapter 5230, respectively close to the first finger 5220 and the second finger 5222. The size, shape, positioning, orientation, and other aspects of both the first handle locking catch 5234 and the second handle locking catch 5236 are configured to engage / receive the outer handle block 4120 or the inner handle block 4124 when the spindle 4000 is positioned so that it is held by the clamp 5000.

[0248] To move the upper spindle jaw 5210 and the lower spindle jaw 5250, the actuator 5130 actuates the two jaws simultaneously and in opposite directions. To move the jaws apart, the actuator is actuated in a first direction, causing the upper spindle jaw 5210 to move upward and simultaneously causing the lower spindle jaw 5250 to move downward. To move the jaws together, the actuator is actuated in a second direction opposite to the first direction, causing the upper spindle jaw 5210 to move downward and simultaneously causing the lower spindle jaw 5250 to move upward. The actuator may include a piston or other mechanism configured to cause the jaws to move, as indicated herein.

[0249] Mandrel Holder Operation

[0250] When the clamp 5000 is operated, the size, shape, positioning, orientation, and other aspects of each of the upper spindle jaws 5210 and the lower spindle jaws 5250 are configured to respectively engage the top handle 4116 and the bottom handle 4156 of the spindle 4000. As described above, the top handle 4116 and the bottom handle 4156 each include an inner handle block and an outer handle block. Each spindle jaw can engage one of the two handle blocks (i.e., the inner handle block or the outer handle block) at a time. Therefore, there are several combinations of engagement between the upper spindle jaws 5210 and the lower spindle jaws 5250 and the handle blocks of the spindle 4000. These combinations include: (i) the upper spindle jaw 5210 engages the external handle block 4120, and the lower spindle jaw 5250 engages the corresponding external handle block of the bottom handle 4156; (ii) the upper spindle jaw 5210 engages the internal handle block 4124, and the lower spindle jaw 5250 engages the corresponding internal handle block of the bottom handle 4156; (iii) the upper spindle jaw 5210 engages the external handle block 4120, and the lower spindle jaw 5250 engages the internal handle block of the bottom handle 4156; and (iv) the upper spindle jaw 5210 engages the internal handle block 4124, and the lower spindle jaw 5250 engages the external handle block of the bottom handle 4156.

[0251] Thus, the mandrel holder 5000 enables several actions to be performed, including: receiving the mandrel 4000 and the film roll mounted thereon; transferring the mandrel and the film roll thereon to another mandrel holder 5000; and removing the mandrel and the film roll thereon from the mandrel holder 5000.

[0252] More specifically, although every combination of engagement between the upper and lower spindle jaws 5210, 5250 and the outer and inner handle blocks of the spindle may occur, for the sake of brevity, only the engagement of the upper and lower spindle jaws 5210, 5250 with the corresponding outer handle blocks of the spindle 4000 is described below.

[0253] As an initial step, the actuator 5130 is activated by the controller, thereby causing the upper and lower spindle jaws 5210, 5250 to move apart in opposite directions.

[0254] The mandrel holder 5000 is moved into position relative to the mandrel 4000 such that the top handle 4116 and the bottom handle 4156 of the mandrel 4000 are positioned between the first and second fingers of the upper and lower mandrel jaws 5210, 5250, respectively.

[0255] The size, shape, positioning, orientation, and other aspects of the spindle-facing surface 5232 of the U-shaped spindle coupler 5230 of the upper spindle claw 5210 are configured to engage the external handle cylinder 4118 of the top handle 4116, and the corresponding U-shaped spindle coupler of the lower spindle claw 5250 is mirror-engaged with the external handle cylinder of the bottom handle 4156.

[0256] The actuator 5130 is again activated by the controller, causing the upper spindle jaw 5210 and the lower spindle jaw 5250 to move toward each other. The movement of the upper spindle jaw 5210 and the lower spindle jaw 5250 continues until the first handle lock catch 5234 and the second handle lock catch 5236 of the upper spindle jaw 5210 receive and engage the outer handle block 4120 of the top handle 4116. On the bottom side, similar engagement occurs between the first and second handle lock catches of the lower spindle jaw 5250 and the outer handle block of the bottom handle 4156.

[0257] The mandrel 4000 is then locked into the mandrel holder 5000. The first handle locking catch 5234 and the second handle locking catch 5236 engage an outside surface of the outer handle block 4120 (e.g., a surface facing away from the holder 5000), thereby preventing the mandrel 4000 and the film roll thereon from being removed from the mandrel holder 5000 without the jaws moving away from each other. The tolerances and geometry of the first handle locking catch 5234, the second handle locking catch 5236, and the handle of the mandrel 4000 positioned therebetween prevent rotation of the handle of the mandrel 4000, prevent rotation of the internal mandrel assembly 4100 of the mandrel 4000 (by preventing rotation of the handles), and prevent the mandrel 4000 from pivoting or tilting during operation.

[0258] Although every combination of engagement between the upper and lower spindle jaws 5210, 5250 and the outer and inner handle blocks of the spindle is possible, for the sake of brevity, only the embodiments of the present invention will now be described. Figure 6 The transfer of a spindle from a first spindle holder engaged with a corresponding outer handle block to a second spindle holder engaged with a corresponding inner handle block is described herein.

[0259] In the initial state, the first spindle clamp 5000F engages the corresponding outer handle blocks of the top handle 4116 and the bottom handle 4156 of the spindle 4000. At this point, the spindle clamp 5000 has the sole control of the spindle 4000.

[0260] The actuator of the second spindle clamp 5000S is then activated by the controller CR to cause its upper and lower spindle jaws to move apart so that they are properly spaced to engage the inner handle block of the spindle 4000.

[0261] The second mandrel holder 5000S is moved into position around the mandrel 4000 so that the top handle 4116 and the bottom handle 4156 of the mandrel 4000 are positioned respectively between the first and second fingers of the upper and lower mandrel jaws 5210, 5250 of the second mandrel holder 5000S.

[0262] The spindle-facing surface 5232 of the upper spindle jaw of the second spindle clamp 5000S engages the inner handle cylinder 4122 of the spindle 4000 , and the U-shaped spindle engager of the lower spindle jaw of the second spindle clamp 5000S engages in a mirror-image engagement with the inner handle cylinder of the bottom handle 4156 .

[0263] The actuator of the second spindle clamp 5000S is then enabled by the controller CR, causing the upper and lower spindle jaws of the second spindle clamp 5000S to move toward each other. This movement continues until both the first handle locking catch and the second handle locking catch of the upper spindle jaw of the second spindle clamp 5000S engage the inner handle block 4120 of the top handle 4116, and the first handle locking catch and the second handle locking catch of the lower spindle jaw of the second spindle clamp 5000S engage the inner handle block 4156 of the bottom handle 4156. The first and second handle locking catches of the clamps engage the inner handle block 4120, so that the spindle is locked in place to the second spindle clamp 5000S.

[0264] At this point in the transfer process, both the first mandrel clamp 5000F and the second mandrel clamp 5000S are engaged with the mandrel holding the film roll. To complete the transfer to the second mandrel clamp 5000S, the actuator of the first mandrel clamp 5000F is then enabled by the controller CF to move the upper and lower mandrel jaws of the first mandrel clamp 5000F out of engagement with the outer handle block of the mandrel 4000. The second mandrel clamp 5000S then has sole control over the mandrel 4000.

[0265] sensor

[0266] The web winding system 20 includes a plurality of sensors S configured to sense various states of the web winding system 20, positions of components of the web winding system 20, and the amount of remaining film on each film roll held by the gripper of the applicator arm. The sensors S are communicatively connected to the controller CR. The sensors S may be any suitable sensors.

[0267] Operator interface

[0268] The coil winding system 20 includes an operator interface OI, which is configured to receive input from an operator and output information to the operator in some embodiments. The operator interface OI includes one or more input devices configured to receive input from an operator. In a number of different embodiments, the one or more input devices include one or more buttons (such as hard keys or soft keys), one or more switches, and / or a touch panel. In a number of different embodiments, the operator interface OI includes a display device, which is configured to display information to the operator, such as information about the coil, the state of the winding operation, or the settings of the coil winding system 200. The operator interface may include other output devices such as one or more speakers and / or one or more lights instead of or in addition to the display device. In some embodiments, the operator interface is formed as a part of the coil winding system 20 and is, for example, mounted to a machine frame 60. In other embodiments, the operator interface is away from the frame 60.

[0269] Controller

[0270] The coil winding system 20 includes a controller CR, which includes a processing device that is communicatively connected to a memory device. The processing device may include any suitable processing device, such as but not limited to a general-purpose processor, a special-purpose processor, a digital signal processor, one or more microprocessors, one or more microprocessors associated with a digital signal processor core, one or more application-specific integrated circuits, one or more field programmable gate array circuits, one or more integrated circuits, and / or a state machine. The memory device may include any suitable memory device, such as but not limited to a read-only memory, a random access memory, one or more digital registers, a cache memory, one or more semiconductor memory devices, such as magnetic media such as integrated hard disks and / or removable memories, magneto-optical media, and / or optical media. The memory device stores instructions that can be executed by the processing device to control the operation of the coil winding system 10 (such as executing the coil moving process, coil rotating process, bracket moving process, film supply roll loading process, coil winding process, and film roll unloading described herein). The controller CR is communicatively and operably connected to: an operator interface OI; a plurality of sensors S; actuators for moving the first winding bracket 100 and components thereof, the second winding bracket 300 and components thereof, the coil rotator 500, the first replacement film roll holder 600, the first empty film roll holder 800, components of the first replacement film roll supplier 900, components of the first empty film roll remover 1000, the second replacement film roll holder 1600, the second empty film roll holder 1800, components of the second film roll supplier 1900, and components of the second empty film roll remover 2000; and an infeed coil mover 550 and an outfeed coil mover 560.

Claims

1. A coil winding device, comprising: Machine frame; a first winder supported by the machine frame; a second winder supported by the machine frame opposite the first winder, wherein a web winding area is defined between the first winder and the second winder; as well as A controller is operably connected to the first winder and the second winder and is configured to cause the first winder and the second winder to simultaneously use the first film roll and the second film roll to simultaneously wind the first film and the second film from the first film roll and the second film roll onto the web when the web positioned in the web winding area rotates around the longitudinal axis of the web.

2. The web winding apparatus of claim 1, wherein: The first winder is vertically movable relative to the machine frame to a raised position so that the coil can be moved under the first winder and into the coil winding area.

3. The web winding system of claim 1, wherein: The second winder is vertically movable relative to the machine frame to a raised position so that after the coil is wound, the coil can move under the second winder and away from the coil winding area.

4. The web winding system of claim 1, wherein: The first winder includes a first applicator arm and a second applicator arm; the second wrapper includes a third applicator arm and a fourth applicator arm; and The controller is operably connected to the first applicator arm, the second applicator arm, the third applicator arm, and the fourth applicator arm and is configured to simultaneously: causing the first applicator arm and the fourth applicator arm to move the first film roll along a plurality of loops through the eye of the web and around the outer surface of the web to wind the first film onto the web as the web rotates about its longitudinal axis; and As the web rotates about its longitudinal axis, the second and third applicator arms are caused to move the second film roll along a plurality of loops through the eye of the web and around the outer surface of the web to wind the second film onto the web.

5. The web winding apparatus of claim 4, wherein: Each loop of the first film roll includes a generally rectangular path, wherein each loop of the second film roll includes a generally rectangular path.

6. The web winding apparatus of claim 5, wherein: When one of the first film roll and the second film roll is inside the eye of the web, the other of the first film roll and the second film roll is outside the eye of the web.

7. The web winding apparatus of claim 4, wherein: The controller is configured to cause the first winder and the second winder to move the first film roll and the second film roll together in a longitudinal direction during winding.

8. The web winding apparatus of claim 4, wherein: The controller is configured to cause the first winder and the second winder to move the first film roll and the second film roll such that a spacing between the first film roll and the second film roll in a transverse direction during winding remains substantially the same.

9. The web winding apparatus of claim 8, wherein: The controller is configured to cause the first winder and the second winder to move the first film roll and the second film roll together in a longitudinal direction during winding.

10. The web winding apparatus of claim 4, wherein: The controller is configured to cause the first applicator arm and the fourth applicator arm to, during one loop in the loop of the first film roll: while the first applicator arm holds the first film roll and while the first applicator arm and the fourth applicator arm are generally aligned with the longitudinal axis of the web, moving the first applicator arm and the fourth applicator arm into the eye of the web and toward each other to apply the first film to a portion of the interior surface of the web; transferring the first film roll to the fourth applicator arm within the eye of the web; moving the first and fourth applicator arms away from each other and away from the eye of the web to apply the first film to another portion of the interior surface of the web; moving the first applicator arm and the fourth applicator arm in a transverse direction to apply the first film to a portion of the first side surface of the web; moving the first applicator arm and the fourth applicator arm toward each other to apply the first film to a portion of the outer surface of the web; transferring the first film roll to the first applicator arm; moving the first applicator arm and the fourth applicator arm away from each other to apply the first film to another portion of the outer surface of the web; and The first and fourth applicator arms are moved in the transverse direction until the first and fourth applicator arms are generally aligned with the longitudinal axis of the web to apply the first film to a portion of the second side surface of the web.

11. The web winding apparatus of claim 10, wherein: The controller is configured to cause the second applicator arm and the third applicator arm to, during one loop in the loop of the second film roll: while the second applicator arm holds the second film roll and while the second applicator arm and the third applicator arm are spaced laterally from the longitudinal axis of the web, moving the second applicator arm and the third applicator arm toward each other to apply the second film to a portion of the outer surface of the web; transferring the second film roll to the third applicator arm; moving the second applicator arm and the third applicator arm away from each other to apply the second film to another portion of the outer surface of the web; moving the second applicator arm and the third applicator arm in the transverse direction until the second applicator arm and the third applicator arm are generally aligned with the longitudinal axis of the web to apply the second film to a portion of the first side surface of the web; moving the second applicator arm and the third applicator arm into the eye of the web and toward each other to apply the second film to a portion of the interior surface of the web; transferring the second film roll to the second applicator arm within the eye of the web; moving the second applicator arm and the third applicator arm away from each other and away from the eye of the web to apply the second film to another portion of the interior surface of the web; The second applicator arm and the third applicator arm are moved in a transverse direction to apply the second film to a portion of the second side surface of the web.

12. The web winding apparatus of claim 1, further comprising a web rotator positioned in the web winding area, wherein: The controller is operably connected to the web rotator and is configured to cause the web rotator to rotate the web about its longitudinal axis.

13. A method of winding a web using a first film from a first film roll and a second film from a second film roll, the method comprising: rotating the coil about the longitudinal axis of the coil; as well as While the web is rotating about its longitudinal axis, the first film and the second film are wound onto the web by simultaneously using the first film roll and the second film roll in the following manner: moving the first film roll along a plurality of loops through the eye of the web and around the outer surface of the web to wind the first film onto the web; and The second film roll is moved along a plurality of loops through the eye of the web and around the outer surface of the web to wind the second film onto the web.

14. The method of claim 13, wherein: Each loop of the first film roll includes a generally rectangular path, wherein each loop of the second film roll includes a generally rectangular path.

15. A film roll replacement system for a web winding device, the film roll replacement system comprising: a first replacement film roll holder; a first empty film roll holder; a first film roll supplier; a first empty film roll remover; a second replacement film roll holder; a second empty film roll holder; a second film roll supplier; as well as Second empty film roll remover.

16. The film roll replacement system according to claim 15, comprising: a first replacement film roll holder track, wherein the first replacement film roll holder is movable on the first replacement film roll holder track; a first empty film roll holder track, wherein the first empty film roll holder is movable on the first empty film roll holder track; a second replacement film roll holder track, wherein the second replacement film roll holder is movable on the second replacement film roll holder track; and A second empty film roll holder track, wherein the second empty film roll holder is movable on the second empty film roll holder track.

17. A mandrel comprising: An internal spindle assembly, the internal spindle assembly comprising: a top handle assembly capable of being clamped by the mandrel clamp; a bottom handle assembly capable of being clamped by the spindle clamp; a shaft coupled to the top handle assembly and the bottom handle assembly; and an inner rotating assembly including a stationary clutch plate; and an outer spindle assembly rotatable relative to the inner spindle assembly, the outer spindle assembly comprising: an outer mandrel body engageable with the film roll; a film roll retainer assembly attached to the outer mandrel body and securing the film roll to the outer mandrel body; an outer rotating assembly having a rotating clutch plate engageable with the inner rotating assembly; and One or more bearings are positioned to enable the outer spindle assembly to rotate relative to the inner spindle assembly.

18. The mandrel of claim 17, wherein: A top handle assembly and a bottom handle assembly are rotatably secured to the shaft and to each other.

19. The spindle assembly of claim 18, wherein: The top handle assembly includes a top handle having (1) an outer handle cylinder, (2) an outer handle block, (3) an inner handle cylinder, and (4) an inner handle block.

20. The spindle assembly of claim 19, wherein: The outer handle block and the inner handle block of the top handle are engageable by fingers of a spindle clamp, thereby preventing the top handle assembly from rotating.

21. The mandrel of claim 17, wherein: The shaft includes (1) a top section having a first diameter, (2) a middle section having a second diameter, and (3) a bottom section having a third diameter, wherein a first transition portion between the top section and the middle section defines a top shelf engageable by the top handle assembly, and wherein a second transition portion between the middle section and the bottom section defines a bottom shelf engageable by the bottom handle assembly.

22. The mandrel of claim 17, wherein: The inner rotating assembly is rotatably fixed to the shaft, the top handle assembly, and the bottom handle assembly.

23. The mandrel of claim 17, wherein: The inner rotating assembly further includes: (1) a disc docking plate configured to engage the stationary clutch disc; and (2) a pair of Belleville springs configured to apply a force to the disc docking plate.

24. The mandrel of claim 17, wherein: The outer mandrel assembly further includes a plurality of leaf springs attached to the outer mandrel body and configured to engage the film roll.

25. The mandrel of claim 17, wherein: The film roll retainer assembly includes a retainer core configured to pivot between a first position that enables a film roll to be added to or removed from the mandrel and a second position that locks the film roll on the mandrel.

26. The mandrel of claim 17, wherein: The outer rotating assembly includes: (1) the rotating clutch plate engaged with the inner rotating assembly; (2) a spring housing fixed to the rotating clutch plate; (3) a rotating stop engaged with the outer spindle body; and (4) a tension spring fixed to the spring housing at a first end and to the rotating stop at a second end.

27. The mandrel of claim 26, wherein: The spring housing and the extension spring enable the rotation stop to rotate approximately 90 to 100 degrees around the circumference of the spring housing.

28. A mandrel holder, comprising: a base attachable to an applicator arm; an actuator attached to the base and activatable by a controller; as well as A spindle adapter is movable by the actuator and engageable with the top and bottom handles of the spindle.

29. The mandrel of claim 28, wherein: The base includes an arm connecting bracket including a first side panel, a second side panel, and a center panel connected to the first side panel and the second side panel.

30. The mandrel of claim 28, wherein: The mandrel adapter includes an upper mandrel jaw and a lower mandrel jaw.

31. The mandrel of claim 28, wherein: The center panel defines an upper mandrel jaw opening and a lower mandrel jaw opening.

32. The mandrel of claim 28, wherein: The center panel further includes an upper mandrel claw track and a lower mandrel claw track.

33. The mandrel of claim 28, wherein: The upper spindle jaw and the lower spindle jaw engage the upper spindle jaw track and the lower spindle jaw track.

34. The mandrel of claim 28, wherein: The actuator is configured to move both the upper spindle jaw and the lower spindle jaw simultaneously in opposite directions.

35. The mandrel of claim 28, wherein: The upper spindle jaw includes an actuator engager arm, a vertical support bracket, a track engaging support member, and a lateral spindle engaging member.

36. The mandrel of claim 35, wherein: The lateral mandrel engaging member includes: (1) a first finger; (2) a second finger; (3) a finger connecting rod connecting the first finger to the second finger; and (4) a U-shaped mandrel engager.

37. The mandrel of claim 36, wherein: The U-shaped spindle coupler includes: (1) a surface facing the spindle; a first handle locking clamp configured to engage the handle of the spindle and prevent the handle from rotating; and a second handle locking clamp configured to engage the handle of the spindle and prevent the handle from rotating.

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