Apparatus and method for winding paper

An apparatus for winding a web of paper material into a roll comprising:

• a rotatably mounted reel spool;
• a drive motor for rotating the reel spool and winding a paper web thereon to create a parent roll of increasing diameter;
• an air permeable endless flexible belt having an inside surface and an outside surface supported for rotation around a plurality of support rolls defining a predetermined path of travel, the predetermined path of travel having a winding region including a free span and a pair of support rolls, and a web transport region preceding the winding region, the paper web residing on the outside surface and positioned adjacent the reel spool engaging the reel spool during winding such that the free span is deflected from the predetermined path of travel by the paper web wound on the reel spool;
• a deflection sensor mounted within the belt measuring a deflection of the inside surface from the predetermined path of travel;
• an actuator for positioning the reel spool and the belt relative to each other to vary the deflection of the inside surface;
• a controller connected to the deflection sensor and the actuator for controlling the deflection of the inside surface as the parent roll diameter increases;
• and
• a means for pressure reduction located along at least a portion of the inside surface in the winding region.

A method of winding a web to form a roll comprising the steps of:

• engaging an air permeable endless flexible member against a reel spool creating a nip such that the flexible member is deflected from a predetermined path of travel, the endless flexible member having a winding region, a web transport region, and an inside surface;
• rotating the reel spool;
• rotating the endless flexible member;
• advancing the web into the nip and directing the web around the reel spool to form a roll of increasing diameter;
• sensing the amount of deflection of the flexible member by the roll as the diameter of the roll increases;
• moving at least one of the reel spool and the flexible member in response to the sensing step to vary the amount of deflection of the flexible member;
• and
• reducing the pressure along at least a portion of the inside surface within the winding region.