System and method for storage and temporary installation of secondary flooring surface
Systems and methods of rolling and unrolling secondary flooring surfaces, such as tall pile polyethylene turf, are provided. The system includes a drive system that allows for the conversion of a primary surface into a secondary flooring surface in a relatively short period of time. The drive system includes core adjustable speed drive units for controlling the speed and torque of the motors that drive the core, as well as roller adjustable speed drive units for controlling the speed of the front roller. The core adjustable speed drive units control the torque of the core motors during roll up and control the speed of the core motors during roll out.
1. A conversion system for installing a secondary flooring surface over a primary flooring surface, comprising:
a core for storing the secondary flooring surface when not in use, wherein the core is driven by at least one core motor and the at least one core motor is controlled by a core drive unit;
a first roller for supporting the secondary flooring surface on the core and guiding the secondary flooring surface on and off the core, wherein the first roller is free spinning;
a second roller for supporting the secondary flooring surface on the core and guiding the secondary flooring surface on and off the core, wherein the second roller is driven by at least one roller motor and the at least one roller motor is controlled by a roller drive unit; and
a transducer for determining a relative position of the core,
wherein the core motor drive unit controls a torque of the at least one core motor while the secondary flooring surface is rolling onto the core and the core motor drive unit controls a speed of the at least one core motor while the secondary flooring surface is rolling off of the core based on information received from the transducer, and
wherein the roller drive unit controls a speed of the at least one roller motor.
2. The system of claim 1 , further comprising a frame for supporting the core and the secondary flooring surface, wherein the frame moves vertically along a pair of end shafts as the secondary flooring surface rolls on or off the core.
3. The system of claim 2 , wherein the transducer determines the relative position of the core by determining the relative position of the frame.
4. The system of claim 2 , further comprising a hydraulic lift connected to the frame that assists with the vertical movement of the frame supporting the core.
5. The system of claim 1 , wherein at least part of the conversion system is located in a pit.
6. The system of claim 1 , wherein at least part of the conversion system is located in a partial pit.
7. The system of claim 1 , wherein at least part of the conversion system is a Mezzanine mounted system.
8. The system of claim 1 , wherein at least part of the conversion system is a surface mounted system.
9. The system of claim 1 , further comprising a winch and cable system that assists with the installation of the secondary flooring surface over the primary flooring surface.
10. The system of claim 9 , wherein the winch and cable system includes wheels.
11. The system of claim 9 , wherein the winch and cable system further comprises a steering mechanism.
12. The system of claim 11 , wherein the steering mechanism is capable of being manually operated by only one operator.
13. The system of claim 11 , wherein the steering mechanism is capable of being automatically operated.
14. A system for installing a secondary flooring surface, comprising:
a core for storing the secondary flooring surface when not in use, wherein the core is driven by at least one core motor and the at least one core motor is controlled by a core motor drive unit;
a first roller for supporting the secondary flooring surface on the core and guiding the secondary flooring surface on and off the core, wherein the first roller is free spinning; and
a second roller for supporting the secondary flooring surface on the core and guiding the secondary flooring surface on and off the core, wherein the second roller is driven by at least one roller motor and the at least one roller motor is controlled by a roller drive unit;
wherein the core drive unit controls a torque of the at least one core motor while the secondary flooring surface is rolling onto the core and the core motor drive unit controls a speed of the at least one core motor while the secondary flooring surface is rolling off the core, and
wherein the roller drive unit controls a speed of the at least one roller motor.
15. The system of claim 14 , further comprising a frame for supporting the core and the secondary flooring surface, wherein the frame moves vertically along a pair of end shafts as the secondary flooring surface rolls on or off the core.
16. The system of claim 14 , further comprising a transducer, which determines the relative position of the core.
17. The system of claim 14 , wherein the secondary flooring rolls through a front of the system and the second roller is located between the first roller and the front of the system.
18. A method for rolling up a secondary flooring surface, comprising:
controlling a core motor to operate at a predefined torque, wherein the core motor controls the rotation of a core as the secondary flooring surface rolls onto the core;
allowing a first roller to spin freely, wherein the first roller guides the secondary flooring surface as it rolls onto the core and supports the secondary flooring surface on the core;
controlling a roller motor to operate at a predefined speed, wherein the roller motor controls the rotation of a second roller and the second roller guides the secondary flooring surface as it rolls onto the core and supports the secondary flooring surface on the core; and
wherein the predefined speed is based on a length of the secondary flooring surface and a time allocated to roll up the secondary flooring surface.
19. The method of claim 18 , wherein the predefined torque is maintained as the secondary flooring surface rolls onto the core.
20. The method of claim 18 , wherein the core motor and the roller motor have similar acceleration times and deceleration times.
21. A method for rolling out a secondary flooring surface, comprising:
controlling a speed of a core motor, wherein the core motor controls the rotation of a core as the secondary flooring surface rolls off the core;
allowing a first roller to spin freely, wherein the first roller guides the secondary flooring surface as it rolls off the core and supports the secondary flooring surface on the core;
controlling a roller motor to operate at a predefined speed, wherein the roller motor controls the rotation of a second roller and the second roller guides the secondary flooring surface as it rolls off the core, and wherein the predefined speed is based on a length of the secondary flooring surface and a time allocated to roll out the secondary flooring surface and supports the secondary flooring surface on the core;
determining an amount of the secondary flooring surface on the core; and
using the amount of the secondary flooring surface on the core to adjust the speed of the core motor.
22. The method of claim 21 , wherein determining an amount of the secondary flooring surface on the core comprises determining a position of a frame that supports the core.
23. The method of claim 21 , wherein using the amount of the secondary flooring surface on the core to adjust the speed of the core motor comprises adjusting the speed in a linear manner.
24. The method of claim 21 , wherein controlling a roller motor to operate at a predefined speed comprises maintaining the predefined speed as the secondary flooring surface rolls off the core.
25. The method of claim 21 , further comprising a winch and cable system that assists with pulling the secondary flooring surface across a primary flooring surface as the secondary flooring surface rolls off the core.
26. A method for rolling out a secondary flooring surface, comprising:
controlling a speed of a core motor to operate at a first predefined speed, wherein the core motor controls the rotation of a core as the secondary flooring surface rolls off the core;
allowing a first roller to spin freely, wherein the first roller guides the secondary flooring surface as it rolls off the core and supports the secondary flooring surface on the core;
controlling a roller motor to operate at a second predefined speed, wherein the roller motor controls the rotation of a second roller and the second roller guides the secondary flooring surface as it rolls off the core and supports the secondary flooring surface on the core, and wherein the second predefined speed is based on a length of the secondary flooring surface and a time allocated to roll out the secondary flooring surface.
27. The method of claim 26 , wherein controlling a roller motor to operate at a predefined speed comprises maintaining the predefined speed as the secondary flooring surface rolls off the core.
28. The method of claim 26 , wherein controlling a speed of a core motor to operate at a first predefined speed, comprises maintaining the predefined speed as the secondary flooring surface rolls off the core.
29. The method of claim 26 , further comprising a winch and cable system that assists with pulling the secondary flooring surface across a primary flooring surface as the secondary flooring surface rolls off the core.