Winder Laurel Hill - Can-Am Machinery · operation on the Winder and on the Combining Calender. SPARE PARTS The availability of spare parts at mill site is essential to ensure the

COMBINING WINDER

(WINDER with COMBINING CALENDER)

Maintenance and Instruction Manual

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I N D E X

WINDER SECTION............................................................................................ 5

1.00 Unwind stand ......................................................................................... 6

1.01 Supporting frame ............................................................................... 71.02 Sheet centering device – lengthwise ................................................. 81.03 Sheet centering device - crosswise ................................................... 91.04 Empty reel spools ejection system................................................... 101.05 Arm movement with belt .................................................................. 111.06 Disc brake........................................................................................ 121.07 Sheet leading rolls ........................................................................... 131.08 Drive system.................................................................................... 14

2.00 Power-operated spreader roll .............................................................. 15

3.00 Slitting system....................................................................................... 16

3.01 Knives - holding beam ..................................................................... 173.02 Knives - holding cylinder.................................................................. 18

4.00 Winding station ..................................................................................... 19

4.01 Supporting frame ............................................................................. 204.02 Reel ejector ..................................................................................... 214.03 Bowed spreader roll......................................................................... 224.04 Drum Rolls (first/second) ................................................................. 234.05 Rider Roll Lifting Device .................................................................. 24

4.05.1 Side bearing housings................................................................ 254.05.2 Rider Roll ................................................................................... 26

4.06 Core - chucks................................................................................... 274.07 Core - chucks carriages................................................................... 284.08 Core - chucks carriages movement device...................................... 294.09 Core - chucks synchronism ............................................................. 304.10 Reel diameter indicator and position transducer.............................. 314.11 Core - chuck stop control device ..................................................... 324.12 Reel lowering table .......................................................................... 334.13 Winder drive .................................................................................... 344.14 Driving pulley ................................................................................... 364.15 Driving shaft for counter knives holding cylinder.............................. 374.16 Guards............................................................................................. 38

4.16.1 Safety guards for unwind stands................................................ 384.16.2 Winder guards............................................................................ 40

COMBINING CALENDER SECTION ............................................................... 41


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1.01 Double-cam device .......................................................................... 421.02 Combining calender rolls with bearing housings.............................. 431.03 Oscillating Doctors........................................................................... 441.04 Drive and guards combining calender ............................................. 45


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OPERATION INSTRUCTIONS

Introduction

These instructions have been prepared to serve as a guide to ensure proper

operation on the Winder and on the Combining Calender.

SPARE PARTS

The availability of spare parts at mill site is essential to ensure the continuous

operation of the machinery.

Genuine spare parts are supplied only and exclusively by Over Meccanica

S.p.A. – The end user of Over Meccanica’s paper machinery should keep in

mind that the installation or the use of spare parts not manufactured and/or

supplied by Over Meccanica may negatively affect the performance and the

safety of Over Meccanica’s machinery.

Over Meccanica disclaims all responsibilities and liabilities for any damage

caused by the use of non-genuine spare parts.


5

WINDER SECTION

The winder function is to receive the reels coming from the unwind stand and

wind them on board cores thus making them saleable.

The winder section is made of the following main units that, on their turn, are

divided into sub-sections:

1. Unwind stands;

2. Power-operated spreader roll;

3. Slitting system;

4. Winding station.

A combining calender (5) is interposed between the unwind stands and the

slitting station.


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1.00 Unwind stand

The unwind stand accommodates the jumbo reels dia. 2500 mm coming frompope reel. This unit is made of the following sub-sections:

1.01 – Supporting frame1.02 – Sheet centering device - lengthwise1.03 – Sheet centering device - crosswise1.04 – Empty reel spools ejection system1.05 – Arm movement with belt1.06 – Disc brake1.07 – Sheet leading roll1.08 – Drive system


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1.01 Supporting frame

The supporting frame, as shown in the figure below, is the base on which all thesub-assemblies are fixed.It is made of:- Front side and rear side basements (1) on which the unwind stand is secured;- Front side and rear side basements (2) connected by the primary (3) and

secondary (4) cross beams;- Brackets (5) welded to the cross beam (3) holding the bearing housings for

the motion of the arms with belt;- Cross beams (6) on which the air cylinder is hinged;- Bracket supporting the shaft with pulleys (7) on rear side.

The basements, made of steel, are secured to the foundation plates by meansof screws.


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1.02 Sheet centering device – lengthwise

The sheet centering operation, lengthwise, is performed through a lever (1)acting on an adjusting screw (2).The adjusting screw is lubricated by means of grease nipple (3).The sheet movement as to the central position is in the range of ± 25mm.


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1.03 Sheet centering device - crosswise

The sheet centering device, crosswise, is carried out by means of an electricgear motor (1) acting on an adjusting screw (2). The adjusting screw islubricated by means of grease nipple (3).The sheet movement as to the central position is in the range of ± 50 mm.Two safety limit switches (4) stop the gear motor before the reel reaches theposition of max. displacement in both directions.


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1.04 Empty reel spools ejection system

This unit consists of two supports, with arm and guides (1) and a pair of levers(2) pivoting on to the supports secured to the main framing by means ofscrews. Levers perform two functions: they lock the reels (pos. 3) and eject theempty reel spools (pos. 4). They are operated by air cylinders (5) synchronizedby control valves mounted on the cylinders and remote controlled by controlconsole.During ejection, when the lever is in pos. 4, the empty reel spool slides on theguide until it is stopped by a couple of shock absorbers (6) .


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1.05 Arm movement with belt

The unit is made of two arms on front and rear side (1) connected by a spacer(8) and linked to the journal housings by pulleys dia. 400 (2) and dia. 402 (3).The two pulleys are wrapped by a flat belt S3 size 5750x350 made by “Habasit”(4) and the actuation takes place directly on the journal (5) of the bottom pulley(see drive).The motion of the arms hinged to the journal (5) occurs through air cylinder (6)that is linked to the cross beams (7) and acts on the spacer (8).The cylinder that works under pressure and backpressure creates a nipbetween belt and reel enough to transmit the motion and to unwind it.The position transmitter (9), connected to the bearing housing of the journal (5),allows reading the diameter of the unwinding reel on the basis of the rotationangle.


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1.06 Disc brake

The unit is made of:- Brake supporting base (1)- Brake disc dia. 514 (2)- Disc supporting hub (3)- Pneumatic brake (4).

With 7 bar air pressure the braking torque is 950 Nm (see brake SPG/1diagram – Suppliers section – “Fairco”).


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1.07 Sheet leading rolls

Each sheet leading roll is made of one rolled steel shell (1) and two heads (2)that are forged integral with the journals, mounted with interference fit andwelded to the shell.The shell is provided with annular grooving to keep the web properly spreadacross its full width.Spherical roller bearings with adapter sleeve are mounted on the heads and arelocated inside the SNL bearing housings in two halves (3) secured to the shims(4) through screws (5).A pulley (6) is fitted at the end of the rear side head for the drive by belt.


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1.08 Drive system

The motor (1) is provided by Customer. Over Meccanica S.p.A., during designphase, examines the characteristics of the motor and if it meets therequirements for the intended use, approves it.Over Meccanica S.p.A. disclaims all responsibility in case of use of motors notexamined and approved by its Engineering Department.The drive system consists of:- Motor (1)- Bushing (2)- Universal joint shaft (3)- Shaft (4)- Fixed coupling (5)- Bottom pulley journal (6)- Safety guards (7): it is absolutely forbidden to remove them when the

machine is on the run.From the pulley (8) the motion is transmitted to the sheet leading roll (9) troughthe belt (10) and two guide pulleys (11).


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2.00 Power-operated spreader roll

The unit has the purpose to spread the two webs of paper coming from theunwind stands and entering the calender to be combined together.The spreader roll assembly is made of one bowed roll (1) actuated by the beltdrive supported by the front and rear side columns (2) secured to the soleplatesby “T” bolts (3).Two sensors (4) fastened on the F.S and R.S columns detect the presence ofthe arms of the combining calender.The drive consists of the following:- Motor (5)- Rigid coupling (6)- One-piece support (7)- Driving pulley (8)- Return pulley (9)- Bowed roll (1)- Belt stretcher (9)- V-belt (10)- Safety guards (11): it is absolutely forbidden to remove them when the

machine is running.


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3.00 Slitting system

The slitting station consists of:1) “Cotta” make slitters1) Knives holding beam2) Counter-knives holding cylinderThe walkway (4) enables the operator to cross the winder for a check of theslitters, if required.The bowed roll ahead of the slitting station (5) anchored to the F.S. and R.S.columns is the same as the one after the slitting station (see par. 4.03).


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3.01 Knives - holding beam

The knives-holding beam (1) is fixed by screws (2) inside the F.S./R.S. backcolumns (3) of the supporting frame.A dovetail (4) is welded to the beam and allows both the fixing and thecrosswise displacement of the slitting units (5):The sheet cut occurs by contact of the upper knives and the bottom oneslocated on the knives-holding cylinder (6).Two tubes blow air against the paper: the tube (7) across the full web widthwhile the tube (8) on the side trims.Sleeve-type cocks (9) adjust the air pressure.


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3.02 Knives - holding cylinder

The cylinder (1) is held by SNH feet-type housings (2) mounted on the brackets(3) fastened inside the F.S and R.S. basements. Inside the housings arelocated the roller bearings: their lubrication is by grease through nipples (4).The cylinder or expanding shaft serves to hold the 29 counter-knives dia.275/235 (5) necessary for sheet slitting.Through the coupling (6), located on the front side journal, the air is blowninside six perforated strips secured lengthwise to the chromium-plated shell.These strips are provided with rubber shims that are pushed in radial directionthus locking the counter-knives to the shell.On the rear side the journal ends with the tang (7) for the connection to thedrive shaft (see par. 4.15); while the head is equipped with pulley (8) for thetransmission of the motion to the stretcher roll through V-belt (par. 4.03).


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4.00 Winding station

The winding station is made of the following components:

1) Supporting frame2) Reel ejector3) Spreader roll4) Drums (first/second)5) Rider roll lifting system6) Core chucks7) Core chuck carriages8) Movement device for core chuck carriages9) Core chucks synchronism10) Reel diameter indicator and position transducer11) Control device for core chuck stop12) Reel lowering table13) Winder drive14) Driving pulley15) Driving shaft for counter-knives holding cylinder16) Guards


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4.01 Supporting frame

The supporting frame consists of two basements (1) supporting the frontcolumns (2); on these columns are welded the bases of the bearing housingbodies that hold the drums (4).The front side columns accommodate also the gibs (3), made of hardenedsteel, serving as a guide for the carriages of the core chucks.The supporting frame is fixed to the foundation plates (5) by means of screws.

The remaining components are the following:

(6) F.S. and R.S. bottom columns;(7) Front columns spacer;(8) Rear columns spacer;(9) Spacer between front and rear side columns.


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4.02 Reel ejector

When the pre-set diameter has been reached, the ejector throws the finishedreels out of the winder. This device is made of the following elements:- Ejecting roll- Arms- Levers- Air cylinders.

The ejecting roll consists of a shell (1), which - in contact with the reel - rotatesthrough roller bearings (2) and of a center pin (3) whose ends are secured toarms (4). The arms, on the same centerline of the ejector roll, hold a device forcore loading. This device is made of a core supporting section bar (5) and apipe (6) fitted to the gudgeon pin with split pins (7).The arms (4) are shrunk-on and welded to the levers (8) through gudgeon pins(9) which rotate inside the housings (11) with bushings (10). The nipples (12)enable the lubrication of the pivoting assembly. The actuation of the reel ejectoris through the air cylinders (13) on levers (8).


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4.03 Bowed spreader roll

The bowed roll at the outlet of the slitting station, that is identical to the onelocated at the inlet of the slitting station, serves to spread the sheet.The unit is made of the roll (1) supported by the housings fastened to the F.S.and R.S brackets (2). These brackets are provided with slots and are anchoredto the rear columns (3) of the framing. The sheet wrap can be adjusted bychanging the vertical position of the brackets through the adjusting screws (4).On the rear side the roll has the seating (5) for the V-belt drive: the drive is viathe counter-knives holding cylinder (see par. 3.02).


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4.04 Drum Rolls (first/second)

The drum rolls consist of a centricast steel shell (1) and two heads (2) that areforged integral with the journals, mounted with interference fit and welded to theshell.The rear side journal is provided with pulley (3) for belt drive.The bodies of the bearing housings, in two halves, consists of a bottom part(4), directly welded to the main column of the frame and of the caps (5)screwed on the top. Inside these bodies are located the spherical rollerbearings (6) locked on the roll journal by taper fit with lock nut (7) and safetywasher.On the F.S. the bearing is free to move on the external ring so as to allow theroll expansion.Bearings (13) are grease lubricated through the nipple (8) . The internal covers(9) and external covers (10) ensure the tightness.The duct (11) provided on the journal serves to inject pressurized oil whendismounting the bearing.


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4.05 Rider Roll Lifting Device

This unit is made of:1) Side housings2) Synchronizing shaft3) Arms4) Rider roll5) Air cylinders type P1E-T125MS07306) Anchor brackets7) Stop mechanism8) Cam for stop mechanism

The side housings, secured to the beam, bear the synchronizing shaft whereare mounted the arms holding the rider roll. Two air cylinders give the motion. Astop device, fitted on the rear side and in contact with the cam mounted on thesynchronizing shaft, permits the detachment of the rider roll in lifting phase. The“floating” of the rider roll on the winding reel [ A to B] serves to stabilize itsformation.


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4.05.1 Side bearing housings

Each bearing housing (1) is made of a steel central body with feet provided withmarked seat. The bearing housing is secured to the beam through screws (2)and accommodates a roller bearing (3). The inner ring of the bearing is axiallylocked though Seeger rings (4) mounted on the synchronizing shaft. The outerring is locked by the flange (5) on the rear side only whilst on front side it is freeto slide axially to allow for shaft expansion. Lubrication is by grease and theseals (6) ensure the tightness.


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4.05.2 Rider Roll

The Rider Roll is made of a rolled steel shell (1) and two heads (2) which,forged in one piece with the journals, are mounted with interference fit andwelded to the shell.The self-aligning roller bearings (3) are mounted on the heads, locked bywithdrawal sleeve (4) and ring nut (5) with safety washer.The bearings are seated inside the housings (6) welded on the arms (7).The bearings are grease lubricated through the nipple (8) located on the cover(9); the seals (10) ensure the tightness.


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4.06 Core - chucks

The core-chucks function is to support the board core on which paper windingis performed.The sheet width variation allowed on each side by the core-chucks is 100 mm.The manual sheet width adjustment is performed as follows: loosen the lockingwheel (3), adjust the sheet width by means of wheel (2) and finally lock thewheel (3).The core-chucks heads (4) are supported by special roller bearings.The core-chucks are lubricated by grease nipples (5). A graduated indicator (6)allows checking the core-chuck protrusion.The core-chucks are actuated by means of hydraulic cylinders (1).


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4.07 Core - chucks carriages

The core-chucks carriages (1) are mounted on roller bearings (2) sliding ondouble guides (3) made of hardened steel, perfectly machined.The roller bearings of the carriages indicated on the drawing with letter “E” areprovided with cams for allowances adjustment, whereas the bearings indicatedwith letter “A” are coaxial.All bearings are lubricated by means of grease nipples (4).Two limit switches (5) indicate the core-chucks position when they arecompletely lowered.Two limit switches (5), one on each side, are fixed to the framing F.S. and R.S.main column by means of screws (6).


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4.08 Core - chucks carriages movement device

The movement of the core-chucks carriages occurs through double-acting aircylinders.The device is composed of two air cylinders (1) arranged one on the front sideand one on the rear side inside the columns. In the upper part they areanchored to the plate (2) trough terminal (3), while in the bottom part by thefork (4) to the ball joint (5) fastened on the core chucks.


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4.09 Core - chucks synchronism

The movement of the core chuck carriages is synchronized on both sides bythe chain (1) . The ends of the chain are secured to the gibs (2) of the corechuck through stud bolt (3) left tie rod (4) and sleeve (5): this system enablesthe adjustment of the slacks. The movement of the chain is transmitted by thecrown wheels (6) shrunk on the idle journals (7) and on the synchronizing shaft(8). The idle journal and the synchronizing shaft are supported by the housingswith bearings (9) grease lubricated through nipples (10).


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4.10 Reel diameter indicator and position transducer

The reel diameter indicator comprises a graduated scale (1) fixed to the framingcolumn and an indicator (2) secured to the core chucks carriage, indicating thereel diameter during winding operation.The position transducer (3) mounted close to the graduated scale, through amagnet (4) installed on the indicator transmits a variable signal to the systemfor the detection of the reel diameter. This signal arrives to the pressureregulator of the air cylinders for the core chucks relief (see diagram).


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4.11 Core - chuck stop control device

Each basement inside the columns of the framing is provided with a stopmechanism for the cores diameter 102/180 mm.The device is made of:- One stationary sleeve (1) welded to the basement- One sleeve for cores dia. 102 (2)- One sleeve for cores dia.180 (3)- Screw with nut (4) where the core chuck carriage is lying


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4.12 Reel lowering table

The reel, after reaching the desired diameter, is pushed by the ejector (seeparagraph 20.6) onto the platform (lowering table) (1) [A]. This platform, hingedto housings (2), is actuated by two hydraulic cylinders (3) that rotate it by 90°thus lowering the finished reel onto the floor [B].Two valves adjust the oil flow into the hydraulic cylinders to keep the speedconstant during the reel lowering phase. Two limit switches (4) mounted on thefront side housing, in contact with the cam (5), shrunk on the shaft of theplatform, interrupt the oil flow: in this way they prevent the movement of theplatform in the loading position [A] and loading position [B].The grease nozzles (6) enable the lubrication of the antifriction bearingslocated in the housings (2).Due mechanical stops (7) keep the platform safely (1) in loading position [A].


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4.13 Winder drive

The motor (1) is provided by Customer. Over Meccanica S.p.A., during designphase, examines the characteristics of the motor and approves it on conditionthat it meets the requested technical requirements.Over Meccanica S.p.A. declines all responsibility in case of use of motors notexamined and approved by its Engineering Department.Drive consists of:- Motor (1)- Bushing (2)- Universal joint shaft (3)- Driving pulley (4)

From the driving pulley (4) the drive is by flat belt (15) on the followingcomponents:- Drum (5)- Idle pulleys (6) - (7)- Bottom knives holding cylinder (8)- Main belt stretcher (9)- Drum (10)

On its turn, the bottom knives holding cylinder (8) transmits the motion toanother set of components through V-belt (16) :- Spreader roll (11)- Idle pulley (12)- Bowed roll (13)- Belt stretcher (14)


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4.14 Driving pulley

The universal joint shaft (1) transmits the motion to the flange (2) fastened tothe pulley. (3). This latter protrudes from the shaft (4) fastened to the basementof the framing.Antifriction roller bearings (5) are mounted on the shaft, locked throughwithdrawal sleeve (6) and ring nut (7) with safety washer. The inner ring of thebearings remains standstill while the outer one rotates with the pulley. Thespacers (8) lock the bearings axially against the shaft abutments.Bearings lubrication is by grease through nipple (9).


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4.15 Driving shaft for counter knives holding cylinder

The driving shaft (1) on which is mounted the pulley (2) transmits the motionfrom the flat belt (3) to the counter knives holding cylinders (4) through “Sapit”coupling (5). The shaft is supported by the housing body (6), shrunk -on insidethe column (7), through antifriction roller bearings (8). Lubrication is by greasethrough nipple (9).Inside the two flanges, internal one (10) and external one (11), the seals (12)ensure the tightness.


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4.16 Guards

Guards are divided into the following groups:

1) Safety guards for unwind stands2) Safety guards for winder

4.16.1 Safety guards for unwind stands

Their function is to prevent the access to this area when the machine isrunning.Safety guards consist of frames (1) fixed with brackets to the floor by means ofscrews and wired modular panels (anti-climbing) (2).Guards are composed of two single-wing doors (3) with limit switch (4)equipped with auxiliary unblocking device with fixed-code key allowing theaccess in case of emergency, maintenance and cleaning operations, etc.Two photoelectric barriers (5) are installed on the reel discharge side in order toprotect the access when winder is running.No guards removal when machine is in operation is permitted.Should guards be removed for maintenance operations, it is necessary to re-mount them before any machine start-ups.


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4.16.2 Winder guards

In this case too the peripheral guards are made of upright members (1) fastedby clamps both to the floor and to the framing columns, through screws andmodular panels provided with anti-climb net (2).Four swing-doors with stop, same as those of the unwind stand, permit theaccess for emergency cases, maintenance, cleaning etc. and are:- Mobile side guard (3)- Core-chuck inspection door (4)- F.S/R.S platform inspection door (5)

No guards removal when machine is in operation is permitted.Should guards be removed for maintenance operations, it is necessary to re-mount them before any machine start-ups.


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COMBINING CALENDER SECTION

The combining calender serves to combine the two webs coming from the

unwind stands before they enter the slitting station.

The calender is made of the following main assemblies, that in their turn are

made of subassemblies:

1) F.S/R.S supporting columns2) Arms3) Plates with shims for Torpress air bags4) Pneumatic actuators5) Top calender roll with bearing housings6) Top oscillating doctor7) Bottom calender roll with bearing housings8) Bottom oscillating doctor9) F.S./R.S. double-cam device


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The framing of the calender in electrowelded steel comprises the columns

fastened to the soleplates through “T” bolts. Arms, operated by pneumatic

actuators, are hinged to the columns through pins. The arms located the

bearing housings of the bottom roll while the bearing housings of the top roll are

fastened to the top of the columns. The nip between the two rolls is 20 kN/m

(see Diagram section).

1.01 Double-cam device

The double cam device serves to misalign one roll as to the other one in order

to obtain a sort a “ false crowning”. Practically it is applied to avoid to make the

roll crowning and, in any case, to have the possibility of adjusting their profile

without dismounting them.

The roll’s misalignment may be obtained by rotating, through 30 mm wrench,

the cam type pin (1) for the same number of turns but in opposite directions. In

this way the arm (2) will move and consequently also the bottom roll as to the

fulcrum.


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1.02 Combining calender rolls with bearing housings

The rolls of the combining calender are identical. They are made of CrNi chilled

cast iron with hardness > 550 HB. The shell (1) is ground with 0,2 µm finish to

smooth the paper properly.

The connection to the motor is through the drive tang (2) arranged the rear side

head.

The rolls are supported by G25 cast iron bearing housings; inside the body (3)

are located the self-aligning roller bearings (4) with 1:12 taper fit to the

journals (5). On the rear side the bearing is axially locked through the internal

cover (6) and external cover (7), whilst on the front side it is free to move to

allow for roll expansion.

The fixing of the bearings is by lock nut and washer (8). Lubrication is by

grease through ¼ nipples (9) and tightness is ensured by stop rings with seals

(10). One duct (11) is provided on the roll journal (11), to inject pressurized oil

for bearing dismounting, when required for maintenance purposes.


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1.03 Oscillating Doctors

Oscillating doctors are provided on both rolls of the combining calender. Their

function is to keep the roll shells clean.

The figure here below shows the doctor blade (1) touching the roll (2) with a

preset contact angle. The blade is mounted on a blade holder (3) fastened to

the blade body (4) and with front side journal (5) and rear side journal (6) fitted

to the ends. A geared motor (7) is connected to the journal that, through cam

(8), oscillates the doctor crosswise with a stroke of 20 mm. In this way the roll is

kept clean across the full width without having the blade insisting in the same

position and therefore prevent any possible grooving of the roll surface.

The bearing housings (9) support the doctor body; the ball joints (10) enable

their orientation while bushings (11) permit the axial sliding.

The ¼” nipple (12) permits the lubrication of the bearings with Merkel seals

(13), while the lubricant drainage is through holes φ2 (14).

The blade linear pressure, usually around 10-15 daN/m, is due to the own

weight of blade.


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1.04 Drive and guards combining calender

The drive, both for top and bottom roll, is constituted by:- Motor (1)- Bushing for universal joint shaft (2)- Universal joint shaft (3)

The guard system is made of:- Bracket for covering (4)- Bottom/top covering (5)- Guard with inspection doors (6)

No guards removal when machine is in operation is permitted.Should guards be removed for maintenance operations, it is necessary to re-mount them before any machine start-ups.

Documents

Winder Laurel Hill - Can-Am Machinery · operation on the Winder and on the Combining Calender. SPARE PARTS The availability of spare parts at mill site is essential to ensure the