Rewinder web chop with early detection and web diversion to eliminate equipment damage
View Patent ↗Generally, the present disclosure is directed to, in one embodiment, a process for controlling a converting line web. More specifically, a sheet material is provided on the converting line. A loss of control is detected in the sheet material web and the sheet material web is broken at a location upstream from the converting line web rewinder. The broken sheet material web is redirected.
1. A process for controlling a converting line web, comprising the steps of:
providing a sheet material web on said converting line, said converting line comprising a parent roll and a rewinder;
detecting a loss of control in said sheet material web prior to a complete break in said sheet material web, the loss of control being determined by a controller;
breaking said sheet material web at a location upstream from the converting line web rewinder; and
redirecting the broken sheet material web.
2. A process as in claim 1 , wherein said loss of control in said sheet material web comprises detecting sheet deflection of said sheet material web.
3. A process as in claim 2 , wherein said sheet deflection is greater than 1 inch.
4. A process as in claim 1 , wherein said loss of control in said sheet material web comprises detecting a partial break in said sheet material web.
5. A process as in claim 1 , wherein said loss of control in said sheet material web comprises detecting a change in average tension in said sheet material web.
6. A process as in claim 5 , wherein said change in average tension is less than 4 lbs.
7. A process as in claim 5 , wherein said change in average tension is less than 10 lbs.
8. A process as in claim 1 , wherein said sheet material web is broken by a rotating web chop.
9. A process as in claim 1 , wherein said sheet material web is broken at a location less than 2 feet upstream from said rewinder.
10. A process as in claim 1 , wherein said broken sheet material web is redirected by subjecting said broken sheet material web to a high pressure gas.
11. A process as in claim 1 , further comprising the step of rethreading the broken sheet material web.
12. A process as in claim 1 , further comprising the step of maintaining control of said sheet material web upstream from said location of said sheet material web break.
13. A converting line web control system comprising:
a converting line, said converting line comprising a parent roll and a rewinder, said parent roll comprising a sheet material web;
at least one detection device capable of detecting a loss of web control prior to a complete break in said sheet material web;
a controller configured to determine a loss of web control;
a web cut-off mechanism located upstream from said rewinder; and
a web control mechanism for redirecting said web.
14. A system as in claim 13 , wherein at least one said detection device comprises a displacement sensor.
15. A system as in claim 13 , wherein at least one said detection device comprises a photo-eye.
16. A system as in claim 13 , wherein at least one said detection device comprises a load cell.
17. A system as in claim 13 , wherein said web cut-off mechanism comprises a rotating web chop.
18. A system as in claim 13 , wherein said web cut-off mechanism is at least 10 feet upstream from said rewinder.
19. A system as in claim 13 , wherein said web cut-off mechanism is at least 5 feet upstream from said rewinder.
20. A system as in claim 13 , wherein said web cut-off mechanism is at least 2 feet upstream from said rewinder.
21. A system as in claim 13 , wherein said web control mechanism comprises an air knife.
22. A system as in claim 13 , wherein said detection device provides data, said controller collecting, analyzing, and acting upon data from at least one said detection device.
23. A system as in claim 22 , wherein said controller initiates said web cut-off mechanism.
24. A system as in claim 22 , wherein said controller initiates said web control mechanism.