Single web automatic splicing unwind machine and method

A converting line comprising:

• a control for the converting line, the control including a controller having a processor and a memory, the control including a load sensor downstream of an unwind machine, the load sensor being adapted and configured to sense a tension in the web downstream of the unwind machine and generate signal corresponding thereto;
• the unwind machine adapted and configured to deliver a web of material to downstream equipment in the converting line, the unwind machine comprising:
• a stand for supporting components of the unwind machine;
• a load station assembly operatively coupled to the stand, the load station assembly being adapted and configured to receive a roll of the web material, the load station assembly being configured to rotatably support the roll as the web material is unwound from the unwind machine during a first portion of the unwind cycle;
• a vertical movement assembly operatively coupled to the stand, the vertical movement assembly adapted and configured to receive the roll from the load station assembly, the vertical movement assembly including a vertical movement actuator, the vertical movement actuator being configured to move the vertical movement assembly between a lowered position adjacent the load station assembly and a raised position away from the load station assembly, the vertical movement assembly being configured to rotatably support the roll as the vertical movement assembly moves the roll between the lowered position and the raised position as the web material is unwound from the unwind machine during a second portion of the unwind cycle;
• a lower brake assembly operatively coupled to the stand, the lower brake assembly being adapted and configured to control rotation of the roll in the load station assembly during the first portion of the unwind cycle;
• an upper brake assembly operatively coupled to the vertical movement assembly, the upper brake assembly being adapted and configured to control rotation of the roll with the roll in the vertical movement assembly during the second portion of the wind cycle;
• wherein with the roll rotatably supported in the load station assembly during the first portion of the unwind cycle, the control is adapted and configured to generate signals for the lower brake assembly to control a rate of rotation of the roll in the load station assembly;
• wherein with the roll rotatably supported by the vertical movement assembly during the second portion of the unwind cycle, the control is adapted and configured to generate signals for the upper brake assembly to control a rate of rotation of the roll in the vertical movement assembly;
• and
• a splice box assembly, the splice box assembly being configured to splice and join the web material from the roll with web material of a further roll.