Web winding method

Abstract

The present invention includes a method for winding a flexible web (15), for example, in the manufacture of tissue products, to facilitate a converting operation based on a web parent roll having a flexible web of paper or nonwoven material. The method includes rotating an engagement member (18) with a reel spool (26) to form a nip and advancing the web (15) into the nip, causing the web to move around the reel spool (26) to form a parent roll of increasing diameter. During advancing the web into the nip, one or more values ​​of the caliper (IWC) of the web wound onto the parent roll are determined. The reel spool (26) can be moved relative to the engagement member (18) based on the determined caliper values, or vice versa.

Description

[Technical Field]

[0001] The present invention relates to a method for winding a continuously produced flexible web, such as a web of paper or a web of nonwoven material, to form a parent roll. The present invention also relates to a controller for a flexible web winding apparatus, a computer program, a transport means including the computer program, and a flexible web winding apparatus. [Background technology]

[0002] In the manufacture of various tissue products, such as facial tissue, toilet paper, paper towels, and the like, the dried tissue web or sheet coming from the tissue machine is wound into a parent roll, which is temporarily stored for further processing. The parent roll can then be unwound and the sheet converted into the final product form. Such processes can also be used with other types of paper or nonwoven materials.

[0003] When tissue webs are wound into larger parent rolls, it is crucial to wind the parent roll in a manner that prevents significant defects in the parent roll and allows for efficient conversion of the parent roll into final products, whether that be boxed facial tissue sheets, toilet paper rolls, embossed paper towels, or the like. Ideally, a parent roll has an essentially cylindrical shape with a uniform cylindrical major surface and two smooth, parallel end surfaces. The cylindrical major surface and end surfaces should be free of small irregularities, dents, ripples, eccentricities, and wrinkles. In other words, the parent roll should be "dimensionally accurate." Similarly, the shape of the parent roll should be stable so that it does not lose its cylindrical shape during storage or routine handling. In other words, the parent roll should be "dimensionally stable." Defects that render the parent roll unsuitable for high-speed conversion could necessitate the scrapping of the entire parent roll.

[0004] To provide parent roll characteristics advantageous for converting operations, U.S. Patent No. 5,901,918A proposes engaging a tissue web with a reel spool that includes a transfer belt that traverses the unsupported section between two support rolls. When the parent roll is urged toward the sheet / transfer belt at a point within the unsupported section, the web is transferred from the transfer belt to the parent roll. The resulting deflection of the transfer belt is detected, and the position of the reel spool is altered in response to control the deflection to a desired level. As a result, a predetermined, light nip pressure can be applied to the parent roll as the tissue web is wound onto it, producing a large parent roll of high-bulk tissue with desirable properties upon unwinding.

[0005] Although the transport belt solution has proven very advantageous, it is desirable to further facilitate converting operations based on parent rolls having flexible webs of paper or nonwoven material. Summary of the Invention [Problem to be solved by the invention]

[0006] SUMMARY OF THE INVENTION It is an object of the present invention to facilitate converting operations based on parent rolls having flexible webs of paper or nonwoven material. [Means for solving the problem]

[0007] This object is achieved by a method for winding a flexible web to form a parent roll, said method comprising: engaging a rotatable engagement member with the first reel spool; rotating the first reel spool; rotating the engagement member with the first reel spool to form a nip; advancing a first web into the nip to move the first web around a first reel spool to form a first parent roll of increasing diameter; determining one or more values ​​of caliper (IWC) of the web wound on the first parent roll during the step of advancing the first web into the nip; Including, This method involves the following options (a) and (b): (a) moving at least one of the first reel spool and the engagement member relative to the other of the first reel spool and the engagement member based on the determined caliper value of the web wound on the first parent roll; (b) engaging a rotatable engagement member with the second reel spool, rotating the second reel spool, rotating the engagement member with the second reel spool to form a nip, advancing a second web into the nip, moving the second web around the second reel spool to form a second parent roll of increasing diameter, and moving at least one of the second reel spool and the engagement member relative to the other of the second reel spool and the engagement member based on the determined caliper value of the web wound on the first parent roll; It includes at least one of the following.

[0008] The web may be a web of paper or a web of nonwoven material.

[0009] The caliper of the web wound onto the first parent roll is understood to be the caliper, or thickness, of the first web when wound onto the first parent roll. The caliper of the wound web is also sometimes referred to as the in-wound caliper (IWC). Preferably, one or more caliper values ​​of the wound web are determined while the first web moves around the first reel spool to form the first parent roll. The calipers can be determined iteratively, for example, in a control loop for the movement of the first reel spool. For example, one caliper value can be determined relative to another caliper value, and so on.

[0010] Moving at least one of the first reel spool and the engagement member relative to the other of the first reel spool and the engagement member may be based on the determined caliper value of the web wound onto the first parent roll as well as one or more target caliper values ​​for the web wound onto the first parent roll. Thus, the method may include comparing the determined caliper value of the wound web to the respective target values. In some embodiments, the target value for a portion of the web may depend on the radial position of the portion of the web on the first parent roll. Thus, the target value may vary with radial position. In other embodiments, the target value may be constant throughout the first parent roll.

[0011] Preferably, the step of moving at least one of the first reel spool and the engagement member relative to the other of the first reel spool and the engagement member occurs during the step of advancing the first web into the nip. Moving at least one of the first reel spool and the engagement member relative to the other based on the determined caliper value of the web wound onto the first parent roll can control the caliper of the web wound onto the first parent roll. For example, the determined caliper value or values ​​of the wound web can be used to calculate a set point or reference speed for at least one of the first reel spool and the engagement member. This can keep the caliper of the web wound onto the first parent roll constant or follow a preset shape of the caliper of the wound web throughout the complete winding of the first parent roll.

[0012] The caliper of the wound web is important for subsequent converting operations based on the first parent roll. Direct control of the caliper of the wound web, enabled by the present invention, facilitates subsequent converting operations based on the first parent roll. For example, comparing the caliper of the wound web to the thickness of the web before winding provides better control of the winding process. Determining the caliper of the wound web from the thickness of the web before winding requires knowledge of how the web behaves as it is wound. Tissue, in particular, is soft and undergoes a relatively large change in thickness as it is wound. Additionally, determining the thickness of the web before winding can require sensitive sensors that are exposed to the dusty environment surrounding the tissue machine.

[0013] Moving at least one of the first reel spool and the engagement member relative to the other of the first reel spool and the engagement member may include moving at least one of the first reel spool and the engagement member away from the other of the first reel spool and the engagement member.

[0014] In some embodiments, moving at least one of the first reel spool and the engagement member relative to the other of the first reel spool and the engagement member includes moving only the first reel spool. In other embodiments, only the engagement member is moved. In further embodiments, both the engagement member and the first reel spool are moved.

[0015] In some embodiments, the method includes determining a position relative to the first reel spool based on the determined caliper value of the wound web, such that the first reel spool is moved to reach the determined position. In some embodiments, the method includes determining a speed of the first reel spool based on the determined caliper value of the wound web, such that the first reel spool is moved to reach the determined speed.

[0016] In option (b) of the present invention, the second parent roll does not have to be the first parent roll. The second parent roll can be formed after the first parent roll is formed. The second roll can be formed on the same machine on which the first parent roll is formed. Thus, the engaging members used in forming the first parent roll can be the engaging members used in forming the second parent roll. However, in some embodiments, the engaging members used in forming the second parent roll are not the engaging members used in forming the first parent roll. The second parent roll can be formed by winding a second web onto the second parent roll.

[0017] In option (b), at least one of the second reel spool and the engagement member is moved relative to the other of the second reel spool and the engagement member based on the determined caliper value of the web wound on the first parent roll.

[0018] For example, during forming the first parent roll and determining the caliper value of the wound first web, at least one of the first parent roll and the engaging member is moved relative to the other of the first parent roll and the engaging member based on the determined caliper value of the wound first web. When the first parent roll is formed, the value of the roll diameter and the values ​​of the position of the first reel spool and / or the engaging member are also recorded. Furthermore, the recorded value of the roll diameter is correlated with the recorded values ​​of the position of the first parent roll and / or the engaging member. The correlated values ​​are stored.

[0019] During formation of the second parent roll, the diameter of the second parent roll is determined, for example, based on the position of the second parent roll and using the correlated values, and at least one of the second parent roll and the engaging member is moved relative to the other of the second parent roll and the engaging member based on the determined diameter. The diameter of the first parent roll and the values ​​of the position of the first parent roll and / or the position of the engaging member during formation of the first parent roll are determined by the determined caliper value of the wound first web. Thus, in option (b), rather than determining one or more caliper values ​​of the web wound onto the second parent roll, the caliper of the web wound onto the second parent roll is controlled in response to the determined caliper value of the web wound onto the first parent roll.

[0020] In some embodiments, the method includes option (a) and option (b) of claim 1. In other embodiments, the method includes option (a) of claim 1, with or without option (b). In other embodiments, the method includes option (b) of claim 1, with or without option (a).

[0021] Preferably, the method includes determining a value of a diameter parameter indicative of a diameter of the first parent roll or a change in the diameter of the first parent roll, and determining a value of a web length parameter indicative of a length of the web to be wound around the first parent roll, wherein at least one caliper value of the wound web is determined based on the diameter parameter value and the web length parameter value. For example, multiple diameter parameter values ​​and multiple web length parameter values ​​can be determined when the first parent roll is formed, thereby allowing the caliper value of the wound web to be determined based on each of the diameter parameter values ​​and each of the web length parameter values.

[0022] For example, if a tissue web is engaged with a reel spool using a transfer belt, such as in U.S. Patent Application No. 5,901,918A, the diameter of the first parent roll can be determined by measuring the position of the first reel spool and the deflection of the transfer belt caused by the first parent roll. This preferably takes into account the angle between the direction of reel spool movement and the direction of deflection of the transfer belt. The length of the web wound around the first parent roll can be determined based on the integral of the rotational speed of the support roll for the transfer belt and the diameter of the support roll. For example, the length of the web wound around the first parent roll can be determined by integrating the rotational speed of the support roll and multiplying the integral by the radius of the support roll.

[0023] Similarly, in a machine in which the tissue web is engaged by a reel drum onto a reel spool, the diameter of the first parent roll can be determined from the position and diameter of the reel drum and by measuring the position of the first reel spool. The length of the web wound onto the first parent roll can be determined based on the integral of the rotational speed of the reel drum and the diameter of the reel drum. For example, the length of the web wound onto the first parent roll can be determined by integrating the rotational speed of the reel drum and multiplying the integral by the radius of the reel drum. The rotational speed can be determined from pulses counted by a tachometer on the reel drum.

[0024] Alternatives are possible. In some embodiments, the diameter of the first parent roll can be determined by a sensor, such as a laser sensor, measuring the position of the first reel spool and the position of the outer edge of the first parent roll. Additionally, the length of the web wound around the first parent roll can be determined based on the integral of the rotational speed of the first parent roll and the determined diameter of the parent roll. For example, the length of the web wound around the first parent roll can be determined by integrating the rotational speed of the first parent roll and multiplying the integral by the radius of the first parent roll.

[0025] In other embodiments, the length of the web wound on the first parent roll can be determined based on the rotational speed and diameter of the reel drum or belt support roll, and the diameter of the first parent roll can be determined based on the rotational speed of the first parent roll and the determined length of the web wound on the first parent roll. For example, the number of rotations of the first parent roll can be determined by integrating the rotational speed of the first parent roll, and the diameter of the first parent roll can be determined by dividing the length of the web wound on the first parent roll by π and the number of rotations of the first parent roll.

[0026] To calculate the caliper (IWC) of the web wound onto the first parent roll, two diameter values ​​D1 and D2 can be determined at different times during the winding process. The diameter values ​​can indicate the change in diameter. Furthermore, the length ΔL of the web wound onto the first parent roll during the time period between these times can be determined. The caliper (IWC) of the wound web can then be determined as follows:

[0027]

number

[0028] Preferably, the method further includes measuring a deflection of or a load on the engagement member, and at least one of the first reel spool and the engagement member is moved relative to the other based on the measured deflection of or load on the engagement member and based on at least one of said determined caliper values ​​of the wound web.

[0029] For example, as proposed, in some embodiments, the engagement member comprises a flexible endless belt supported by and rotating about a plurality of support rolls, thereby determining a predetermined path of travel that includes a free section between adjacent pairs of support rolls, thereby determining the amount of deflection of the flexible member from the predetermined path of travel. A sensing device can be mounted adjacent to the flexible member to measure the deflection, thereby moving a first reel spool relative to the flexible member based on the measured deflection and the determined caliper value of the wound web.

[0030] In some embodiments, the movement associated with the other of the first reel spool and at least one of the engaging members is adapted to maintain a constant caliper of the wound web during creation of the parent roll, such that the movement associated with the other of the first reel spool and at least one of the engaging members can maintain a deflection or load on the engaging member between minimum and maximum boundaries.

[0031] The object is also achieved by a controller according to claim 4, a computer program according to claim 5, a conveying means according to claim 6, and an apparatus according to any one of claims 7 to 9.

[0032] Embodiments of the present invention are described below with reference to the drawings. [Brief explanation of the drawings]

[0033] [Figure 1] 1 is a schematic side view of a machine for softening high bulk tissue sheets. [Figure 2] FIG. 2 is a schematic side view of the winding section of the machine shown in FIG. 1; [Figure 3] FIG. 3 is an enlarged view of a portion of the winding section of FIG. 2. [Figure 4] FIG. 2 is a schematic block diagram of the controller of the machine of FIG. 1; [Figure 5]FIG. 1 is a flow diagram depicting steps in a method according to one embodiment of the present invention. [Figure 6] FIG. 10 is a view of a portion of the winding section of a machine in another embodiment of the present invention. [Figure 7] FIG. 4 is a flow diagram depicting steps in a method according to another embodiment of the present invention. [Figure 8] FIG. 4 is a flow diagram depicting steps in a method according to another embodiment of the present invention. [Figure 9] FIG. 9 is a view of a portion of the winding section of a machine used in the method depicted in FIGS. 7 and 8. DETAILED DESCRIPTION OF THE INVENTION

[0034] Figure 1 shows a schematic diagram of a machine for making tissue sheets, and although reference is made here to a tissue machine, it should be noted that the invention is equally applicable to machines making other types of paper, or machines making nonwoven materials.

[0035] The components of the machine in Figure 1 are described in U.S. Patent No. 5,901,918A, which is incorporated herein by reference. Shown is a headbox 1 that deposits an aqueous suspension of papermaking fibers onto the inner forming fabric 3 as it traverses forming rolls 4. An outer forming fabric 5 serves to contain the web 6 while it sheds some of the water as it passes through the forming rolls. The web 6 is transferred to a through-drying fabric 11 with the aid of a vacuum transfer roll 12.

[0036] The through-air drying fabric 11 carries the web over the through-air dryer 13, which blows hot air onto the web to dry it while maintaining its bulk. The web is then transferred to the Yankee 14.

[0037] After the Yankee, the web is transferred to a transfer belt 18, which returns to pick up the dried tissue sheet after passing two support rolls 21, 22. At a point between the two support rolls 21, 22, the sheet is transferred to a parent roll 25. The parent roll 25 is wound onto a reel spool 26, which is driven by a central drive motor 27 acting on the axis of the reel spool.

[0038] Imparting a predetermined amount of web tension to the subsequent web during winding, such as by programming the level of speed differential between the transport belt 18 and the outer surface of the parent roll 25 being produced, can help control the web properties of the web as it is unwound from the parent roll. In most cases, a positive draw (the percentage by which the surface speed of the parent roll exceeds the speed of the transport belt) is required on the parent roll to impart the web tension necessary to provide a stable parent roll.

[0039] On the other hand, too much positive draw can unacceptably reduce the machine direction elongation in the web. Therefore, the amount of positive draw depends on the properties of the web coming into the parent roll and the desired properties of the web unwound from the parent roll. Generally, the surface speed of the parent roll is up to about 10 percent faster than the speed of the transfer belt, more specifically about 0.5% to about 8% faster, and even more specifically about 1% to about 6% faster. Of course, a negative or zero draw may be desirable if the web already approaching the parent roll has been provided with sufficient tension by other means earlier in the tissue making process.

[0040] The sheet transport and winding is shown in more detail in FIG. 2. In the free section between the two support rolls 21, 22, the sheet 15 contacts and is transferred to the parent roll 25. Reference numerals 26, 26', and 26" indicate three positions of the reel spool during continuous operation. As shown, as the parent roll 25 is being built, a new reel spool 26" is ready to advance to position 26'. When the parent roll reaches its final predetermined diameter, the new reel spool is pushed down onto the next sheet by an arm 27 to position 26' at a point along the free section between the support rolls. Position 26' is generally relatively close to the first support roll 21, so that a strong nip between the support roll and the reel spool is avoided.

[0041] The reel spool 26 is supported by a pair of carriages 37, one of which is shown in FIG. 3. As the parent roll 25 is being built, the reel spool moves toward the other support roll 22 and simultaneously away from the transfer belt 18. The reel spool 26 can be moved by an actuator 39, which in this example includes one or more hydraulic cylinders 39. The reel spool 26 can be moved in either direction, as indicated by the double-headed arrow. As a result, the nip of the parent roll substantially traverses the free section as the parent roll is built to its predetermined size. Once the sheet is transferred to a new reel spool, the sheet is broken, and the parent roll 25 is moved out so that the winding process can continue on the new reel spool.

[0042] The machine includes a non-contact detection device 35. The detection device 35 is focused on the inside of the transport belt, preferably at the midpoint M between the two support rolls 21, 22 shown in FIG.

[0043] Deflection D is understood herein to be the maximum distance of the transport belt 18 from its undeflected path of travel 36 in the free section between the support rolls 21, 22.

[0044] The detector 35 may be a laser detector 35. The detector 35 is preferably mounted in an air purge tube 38 that keeps air flowing around the laser to prevent dust from settling on the laser lens.

[0045] Although laser sensors are discussed above, any other suitable non-contact and contact detection devices can alternatively be used, including ultrasonic detection, microwave or radar wave reflection methods, camera stereo imaging for depth detection, or contact probes such as rollers, wheels, metal pieces, or other devices whose position or deflection is measured directly.

[0046] The sensing device 35 can be positioned to always measure the deflection of the transport belt 18 at the midpoint of the free section regardless of the position of the parent roll, so that the actual deflection at the parent roll nip point C can be calculated as a function of the position of the parent roll 25 during production as it traverses the open section from one end to the other on the carriage 37, as described, for example, in U.S. Pat. No. 5,901,918 A, which is incorporated herein by reference. Alternatively, the sensing device 35 can traverse the free section with the parent roll nip so that the laser always directly measures the deflection.

[0047] In some embodiments, two detection devices are spaced apart widthwise, one adjacent each edge of the transport belt 18. Thus, undesirable taper in the parent roll 25 can be minimized, or even a positive taper can be intentionally introduced to improve the winding parameters of the particular parent roll being wound.

[0048] See also FIG. 4. The machine includes a programmable controller 400. The controller 400 may be a computer, a processing device, an automated control, or the like. The controller 400 may include a processing module 401, which may be embodied in the form of one or more hardware modules and / or one or more software modules. Accordingly, the term "module" may refer to a circuit, a software block, or the like. The controller 400 may further include a memory 402. The memory may include, e.g., contain or store, instructions in the form of a computer program 403, which may include, e.g., computer-readable code units. The controller 400, e.g., its processing module 401, may be a processing circuit 404, which may be a hardware module. The instructions are executable by the processing circuit 404, thereby activating the controller 400 to perform the method of the embodiments described herein. FIG. 4 further illustrates a carrier 405, or program carrier, which provides the computer program 403 described above, e.g., includes, mediates, provides, and the like. The carrier 405 may be one of an electronic signal, an optical signal, a radio signal, or a computer-readable medium. Additionally, the controller 400, e.g., its processing module 401, may include an input / output module 406, which may be exemplified by a receiving module and / or a transmitting module, where applicable. The receiving module may receive commands and / or information from various devices, and the transmitting module may transmit commands and / or information to various devices.

[0049] As shown in Figure 3, the detection device 35 is connected to the controller, whereby the controller is configured to receive from the detection device 35 a signal representative of the position of the transport belt at the detection device 35. The machine further includes one or more position detectors 41 configured to detect the position of the carriage 37 relative to the reel spool 26, whereby the controller 400 is configured to receive from the position detector 41 a signal representative of the position of the carriage 37, whereby the controller is configured to determine the position of the reel spool 26. The position detector 41 can be provided in various forms, for example as a transducer attached to the rod of the hydraulic cylinder 39.

[0050] The controller 400 is further configured to control an actuator 39 for the reel spool 26 to control the position of the reel spool 26 .

[0051] The machine further comprises a rotational speed sensor 42 for measuring the rotational speed of one of the support rolls 21. The controller 400 is thereby arranged to receive from the rotational speed sensor 42 a signal representative of the rotational speed of the support roll 21.

[0052] Referring to Figure 5, an embodiment of a method for winding a web 15 of paper material to form a parent roll is described. The method aims to provide a caliper (IWC) of the wound web according to a predetermined IWC curve. The IWC curve provides desired values ​​of IWC as a function of the radial position of the wound web on the parent roll. The desired IWC can be constant or can vary with the radius of the parent roll.

[0053] The method includes (S1) engaging a transfer belt 18 with a reel spool 26 and rotating the reel spool 26 and the transfer belt to form a nip. The method further includes (S2) advancing a web 15 of paper material into the nip and moving the web around the reel spool 26 to form a parent roll of increasing diameter.

[0054] As the parent roll is formed, the deflection of the transport belt 18 is measured (S3a), for example, using the detector 35. Furthermore, the position of the reel spool is determined (S3b) using the position detector 41. Based on the deflection of the transport belt 18 and the position of the reel spool, the diameter of the parent roll is determined (S4a), for example, as exemplified in the "Summary of the Invention" above. Furthermore, the length of the web wound around the parent roll is determined (S4b). The length of the web wound around the parent roll can be determined based on the integral of the rotational speed of the backing roll 21 and the diameter of the backing roll.

[0055] Based on the determined diameter and web length, the caliper (IWC) value of the wound web is determined (S5), which can be done as exemplified in the "Summary of the Invention" above.

[0056] The method includes comparing (S6) the determined caliper of the wound web with a target caliper of the wound web according to the IWC curve. This allows for determining whether the determined caliper of the wound web is equal to the target caliper. The method further includes adjusting (S7) the position of the reel spool relative to the transport belt 18, as needed, so that the determined caliper of the wound web reaches the target caliper. For example, if the determined caliper of the wound web is equal to the target caliper, the reel spool can be moved relative to the transport belt 18 according to the IWC curve. If the determined caliper of the wound web is not equal to the target caliper, the position of the reel spool relative to the transport belt 18 can be adjusted to reach the target caliper. Moving the reel spool (S7) is performed by a hydraulic cylinder 39.

[0057] The method includes determining whether the parent roll is complete (S8), which may include determining whether the parent roll has achieved a predetermined final diameter. If the parent roll is not complete, the steps of measuring the belt deflection (S3a), determining the reel spool position (S3b), determining the diameter and web length (S4a, S4b), determining the caliper value of the wound web (S5), and moving the reel spool (S7a, S7b) are repeated. Thus, the steps of determining the diameter and web length (S4a, S4b), determining the caliper value of the wound web (S5), and moving the reel spool (S7a, S7b) are repeated multiple times while the parent roll diameter is increasing.

[0058] A control loop can be programmed to move the reel spool 26 to maintain a constant level of caliper on the wound web while creating the parent roll, which also moves the reel spool to maintain belt deflection between minimum and maximum boundaries.

[0059] When the parent roll is completed (S8), the reel spool 26 is removed from the carriage 37 (S9).

[0060] Note that in some embodiments, instead of using a position detector 41 to detect the position of the carriage 37 relative to the reel spool 26, the controller 400 uses a detector 35 configured to detect the deflection of the transport belt 18. Using the caliper value of the reeled web, the controller can correlate the desired transport belt deflection value with the target caliper value of the reeled web according to the IWC curve. The reel spool is then moved based on the determined caliper value of the reeled web (S7a, S7b).

[0061] In a further embodiment, instead of the position detector 41 for detecting the position of the carriage 37 relative to the reel spool 26, the machine includes one or more pressure sensors (not shown) configured to detect the pressure in one or more of the hydraulic cylinders 39. Accordingly, the controller 400 is configured to receive signals from the pressure sensors. The controller is configured to control the hydraulic cylinders 39 to move the reel spool 26 in a manner similar to that described with reference to FIGS. 1-5. Preferably, the controller 400 determines the pressure in the hydraulic cylinders when the hydraulic cylinders are not actuated. Using the caliper value of the wound web, the controller can correlate the desired pressure value with a target caliper value of the wound web according to the IWC curve. The reel spool is then moved based on the determined caliper value of the wound web (S7a, S7b).

[0062] Another embodiment of the present invention will now be described with reference to Figure 6. In this embodiment, the web is transported to a nip between a parent roll 25 and an engagement member in the form of a reel drum 18. The reel drum may form part of a Pope reel. At the reel drum, the sheet is transferred to the parent roll 25. The reel drum is biased against the parent roll using a biasing device 43, which may include one or more hydraulic actuators. A load sensor 35 is configured to measure the load of the reel drum relative to the parent roll.

[0063] The machine further includes a rotational speed sensor 42 that measures the rotational speed of the reel drum 18. The controller 400 is thereby configured to receive from the rotational speed sensor 42 a signal representative of the rotational speed of the reel drum 18.

[0064] As the parent roll is formed, the diameter of the parent roll and the length of the web wound around the parent roll are determined. The diameter of the parent roll can be determined by determining the position of the reel spool using the position detector 41 and determining the position and diameter of the reel drum 18. The length of the web wound around the parent roll can be determined based on the integral of the rotational speed of the reel drum 18 and the diameter of the reel drum 18.

[0065] Based on the determined diameter and web length, the caliper (IWC) value of the wound web is determined. This can be done as exemplified in the "Summary of the Invention" above. Additionally, the load of the reel drum relative to the parent roll is measured using load sensor 35.

[0066] The reel spool 26 is moved relative to the reel drum 18 in response to the determined caliper value of the wound web and the measured load of the reel drum relative to the parent roll.

[0067] A control loop can be programmed to move the reel spool 26 to maintain a constant level of caliper on the wound web while the parent roll is being built, which also moves the reel spool to maintain the reel drum load on the parent roll between minimum and maximum boundaries.

[0068] Reference is now made to Figures 7-9. In another embodiment of the present invention, the steps described above with reference to Figure 5 are carried out using what is referred to herein as a first reel spool 26 to form what is referred to herein as a first parent roll. Thus, during the formation of the first parent roll and the determination of the caliper value of the first web wound onto the first parent roll, the first parent roll is moved to follow a predetermined IWC curve based on the determined caliper value of the wound first web.

[0069] Additionally, the method includes correlating and storing the determined diameter value of the first parent roll and the determined position value of the first reel spool (S51). Once the first parent roll is completed, the first parent roll is removed (S9).

[0070] 8 and 9, the method includes engaging the transfer belt 18 with the second reel spool 262 and rotating the second reel spool 262 and the transfer belt to form a nip when removing the first parent roll (S10). The method further includes advancing a second web of paper material into the nip and moving the second web around the second reel spool 262 to form a second parent roll 252 of increasing diameter (S22).

[0071] When the second parent roll 252 is formed, the deflection of the transport belt 18 is measured using, for example, the detection device 35 (S3a2). Furthermore, the position of the second reel spool 262 is determined using the position detector 41 (S3b2). The diameter of the second parent roll 252 is determined based on the deflection of the transport belt 18 and the position of the second reel spool (S4a2).

[0072] Using the correlated diameter value of the first parent roll and the position of the first reel spool (S51) stored when the first parent roll was formed, a target position of the second reel spool 262 is determined as the position of the first reel spool correlated with the determined diameter of the second parent roll 252 (S52).

[0073] The method includes determining whether the determined position of the second reel spool is equal to the target position of the second reel spool (S62). If the determined position of the second reel spool is not equal to the target position of the second reel spool, the second reel spool is moved (S7b2) to reach the target position of the second reel spool.

[0074] The method includes determining whether the second parent roll is complete (S82). If the second parent roll is not complete, the steps of measuring the belt deflection (S3a2), determining the position of the second reel spool (S3b2), determining the diameter of the second parent roll (S4a2), determining a target position for the second reel spool (S52), and moving the second reel spool as needed (S7b2) are repeated.

[0075] Thus, the stored first reel spool position value is determined by the determined caliper value of the first web wound onto the first parent roll, and the second reel spool 262 is moved according to the stored first reel spool position value, and the second reel spool 262 is moved according to the determined caliper value of the first web wound onto the first parent roll.

Claims

1. 1. A method for winding a flexible web (15) to form a parent roll, the method comprising: engaging a rotatable engagement member (18) with a first reel spool (26); rotating the first reel spool (26); rotating the engagement member with the first reel spool (26) to form a nip; advancing a first web (15) into the nip and causing the first web to move around the first reel spool (26) to form a first parent roll of increasing diameter; determining one or more values ​​of caliper (IWC) of the web wound on the first parent roll during the step of advancing the first web into the nip; Including, The method comprises the following options (a) and (b): (a) moving at least one of the first reel spool (26) and the engagement member (18) relative to the other of the first reel spool (26) and the engagement member (18) based on the determined value of the caliper of the web wound on the first parent roll; (b) engaging a rotatable engagement member (18) with a second reel spool (262), rotating the second reel spool (262), rotating the engagement member with the second reel spool (262) to form a nip, advancing a second web into the nip, moving the second web around the second reel spool (262) to form a second parent roll (252) of increasing diameter, and moving at least one of the second reel spool (262) and the engagement member (18) relative to the other of the second reel spool (262) and the engagement member (18) based on the determined value of the caliper of the web wound on the first parent roll; The method includes at least one of the following:

2. 2. The method of claim 1, comprising determining a value of a diameter parameter indicative of the diameter of the first parent roll or a change in the diameter of the first parent roll, and determining a value of a web length parameter indicative of a length of a web wound around the first parent roll, wherein at least one of a caliper value of the wound web is determined based on the diameter parameter value and the web length parameter value.

3. 3. The method of claim 1, further comprising measuring a deflection of or a load on the engaging member (18), and wherein at least one of the first reel spool (26) and the engaging member (18) is moved relative to the other based on at least one of the measured deflection of the engaging member and the load on the engaging member and the determined caliper value of the wound web.

4. 1. A controller (400) for an apparatus for winding a flexible web (15) into a parent roll, the apparatus comprising: a rotatably mounted first reel spool (26); a drive motor (27) for rotating the first reel spool (26) to wind the first web (15) onto the first reel spool (26) to create a first parent roll of increasing diameter; a rotatable engagement member (18) disposed adjacent the first reel spool (26) for engaging the first web (15) to the first reel spool (26) during the winding; and an actuator (39) for positioning the first reel spool (26) and the engagement member (18) relative to one another, the controller being configured to determine one or more values ​​of a caliper (IWC) of the web wound onto the first parent roll during the winding, the controller being configured to select one or more of the following options (a) and (b): (a) the controller is configured to control the actuator (39) based on the determined value of the caliper (IWC) of the web wound onto the first parent roll during the winding of the first web; (b) the controller is configured to control the actuator (39) based on the determined value of the caliper (IWC) of the web wound onto the first parent roll while winding a second web onto a rotatably mounted second reel spool rotated by the drive motor (27) to create a second parent roll (252) of increasing diameter; wherein the engagement member (18) is positioned adjacent to the second reel spool (262) to engage the second web to the second reel spool (262) during the winding of the second web, and the actuator (39) is configured to position the second reel spool (262) and the engagement member (18) relative to each other.

5. 5. A computer program comprising computer-readable code units that, when executed on a controller according to claim 4, cause the controller to determine a caliper (IWC) value of the wound web during winding and to control the actuator (39) based on the determined caliper value of the wound web during winding.

6. 6. A carrier containing the computer program of claim 5, wherein the carrier (405) is one of an electronic signal, an optical signal, a radio signal, and a computer readable medium.

7. An apparatus for winding a flexible web (15) into a parent roll, comprising: a rotatably mounted reel spool (26); a drive motor (27) for rotating the reel spool (26) and winding the web (15) onto the reel spool (26) to create a parent roll of increasing diameter; a rotatable engagement member (18) disposed adjacent the reel spool (26) for engaging the web (15) to the parent roll during winding; an actuation device (39) for positioning the reel spool (26) and the engagement member (18) relative to one another; A controller according to claim 4; 1. An apparatus comprising:

8. 8. The apparatus of claim 7, wherein the controller is configured to: determine a value of a diameter parameter indicative of the diameter of the parent roll or a change in the diameter of the parent roll; determine a value of a web length parameter indicative of a length of the web wound around the parent roll; and determine at least one of a caliper value of the wound web based on the diameter parameter value and the web length parameter value.

9. 9. The apparatus according to any one of claims 7 to 8, wherein the apparatus includes a detection device (35) configured to measure a deflection of or a load on the engagement member (18), and the controller is configured to control the actuation device (39) based on the measured deflection or load and a determined caliper value of the wound web during winding.

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