Dual position automatic winder

Abstract

A winder for winding process webs on roll cores may include a first winding position configured for rotatably securing a first roll core and rotating the first roll core in a first rotational direction. The winder may also include a second winding position configured for rotatably securing a second roll core parallel to the first roll core and rotating the second roll core in the first rotational direction. The winder may also include a roll positioning assembly configured to move a portion of the web upstream of the second winding position from a first side of the first winding position to a second side of the first winding position.

What is claimed is: 
     
         1 . A winder for winding process webs on roll cores, the winder comprising:
 a first winding position configured for rotatably securing a first roll core and rotating the first roll core in a first rotational direction;   a second winding position configured for rotatably securing a second roll core parallel to the first roll core and rotating the second roll core in the first rotational direction;   a roll positioning assembly configured to move a portion of the web upstream of the second winding position from a first side of the first winding position to a second side of the first winding position.   
     
     
         2 . The winder of  claim 1 , further comprising a bump roll and cutoff knife assembly configured for pressing the web against the first roll core and cutting the web. 
     
     
         3 . The winder of  claim 2 , wherein the bump roll and cutoff knife assembly is pivotable to performer bump rolling and cutoff for the first winding position and the second winding position. 
     
     
         4 . The winder of  claim 1 , further comprising a tension control device and a controller configured to operate the motors at the first and second winding positions based on the tension in the web. 
     
     
         5 . The winder of  claim 1 , wherein the roll positioning assembly comprises a pivoting arm with a positioning roller and a roll core carrier and wherein the roll positioning assembly is configured to move the portion of the web upstream of the second winding position from a first side of the first winding position to a second side of the first winding position while simultaneously carrying the first roll core to the first winding position. 
     
     
         6 . The winder of  claim 5 , wherein the pivoting arm is arranged outboard of a main frame of the winder. 
     
     
         7 . The winder of  claim 1 , wherein each winding position comprises opposing actuators, spindles, and chucks for engaging respective ends of respective roll cores. 
     
     
         8 . The winder of  claim 2 , wherein the bump roll and cutoff knife assembly comprises a main rail and carriage assembly and a bump roll and cutoff knife carriage and rail assembly. 
     
     
         9 . The winder of  claim 1 , further comprising a plurality of idler rolls for controlling the contour of the web passing through the winder. 
     
     
         10 . The winder of  claim 1 , further comprising a main frame comprising support structures on each end of the winder for supporting one or more components thereof. 
     
     
         11 . A method of winding webs on rolls, comprising:
 accumulating a web onto a roll core at a lower winding position;   moving a portion of the web upstream of the roll core from a first side of an upper winding position to an opposite side of the upper winding position using a roll positioning assembly;   installing a new roll core in the upper winding position;   transferring the incoming web to the new roll core.   
     
     
         12 . The method of  claim 11 , wherein installing a new roll core comprises carrying the new roll core into position while moving the portion of the web. 
     
     
         13 . The method of  claim 11 , wherein transferring the incoming web to the new roll core comprises engaging the web with a bump roll from an upper bump roll and cutoff knife assembly by actuating a main carriage and moving the web to a position of close proximity to the new roll core. 
     
     
         14 . The method of  claim 13 , further comprising pressing on the web with the bump roll to cause the web to engage the new roll core and cutting the web. 
     
     
         15 . The method of  claim 14 , moving a portion of the web upstream of the upper winding position to a position of close proximity to the new roll core at the lower winding position with a main carriage of a lower bump roll and cutoff knife assembly. 
     
     
         16 . The method of  claim 15 , further comprising pressing on the web with the bump roll to cause the web to engage the new roll core and cutting the web. 
     
     
         17 . The method of  claim 2 , wherein the cutoff knife assembly comprises a tail-free cutter.