ROBOTIC CORE PLUG INSERTER

Abstract

The present invention relates to a new and useful method and apparatus for automatically inserting core plugs into wound paper cores that support rolls of paper, plastic film and other materials during manufacture.

Claims

1. An apparatus for the automatic locating and insertion of core plugs into cores of a roll comprising in combination: a conveyor member for moving a roll laterally; a clamping member for engaging a core plug; a sensor member for locating a center of a core contained within the roll; a rotating member engaged with the clamping member; a programable logic controller engaged with the rotating member and clamping member; a means for storing multiple core plugs and cueing up an individual core plug for clamping by the clamping member; and a means for programably controlling the position of the clamping member and the rotating member for positioning the core plug at a desired position withing the core.

2. The apparatus of claim 1 wherein the rotating member is capable of moving along the x, y and z-axis.

3. The apparatus of claim 1 wherein the means for storing and cueing up core plugs is a core plug magazine and shuttle.

4. An apparatus for locating and inserting core plugs into the wound cores of a roll comprising: a sensor in communication with a programable logic controller; a conveyor system capable of moving the rolls in a lateral direction; an expandable clamping device; the expandable clamping device having a clamp on a distal end and a clamping plate on a proximal end; a means for rotating the expandable clamping device along the x, y, and z axis; and wherein, when activated the expandable clamping device is capable of clamping a core plug between the clamping plate and the clamp, locating a center of a core, and inserting the core plug into the core such that the core plug is perpendicular to the core and at a predetermined depth.

5. A process for automatically locating and inserting core plugs into cores within a roll, such process including the steps of: positioning a roll, having a core, proximate to a core locating and insertion head; retrieving a core plug with a core locating and insertion head; clamping the core plug with the core locating and insertion head; locating the location of the core with the core locating and insertion head; moving the core locating and insertion head such that it is in proper alignment with the core to insert the core plug; tilting the core locating and insertion head such that the core plug is at a predetermined angle for insertion into the core: advancing the tilted core locating and insertion head into the core until the core plug reaches a predetermined depth: rotating the core locating and insertion head such that the core plug is perpendicular to the core; releasing the core plug from the core locating and insertion head; tilting the core locating and insertion head such that the core locating and insertion head can be retracted from the core plug without disturbing placement of the core plug, retracting the core locating and insertion head from the core, and advancing the roll laterally such that a second core plug can be inserted at an opposite end of the core.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. 1 is a perspective view of the robotic core plug inserter, supporting robot, core plug magazine and roll transfer conveyor.

[0023] FIG. 2 is a top view of the robotic core plug inserter, supporting robot, core plug magazine and roll transfer conveyor.

[0024] FIG. 3 is a rear view of the robotic core plug inserter, supporting robot, core plug magazine and roll transfer conveyor.

[0025] FIG. 4 is a side view of the robotic core plug inserter and supporting robot.

[0026] FIG. 5 is a perspective view of the robotic core plug inserter before it engages a roll on the transfer conveyor.

[0027] FIG. 6 is a perspective view of the robotic core plug inserter as it engages a roll on the transfer conveyor, before it seats the core plug insert.

[0028] FIG. 7 is a perspective view of the robotic core plug inserter seating the core plug insert in a roll.

[0029] FIG. 8 is front view of the robotic core plug inserter with captured core plug in its vertically aligned position.

[0030] FIG. 9 is a rear view of the robotic core plug inserter with captured core plug in its vertically aligned position.

[0031] FIG. 10 is a side view of the robotic core plug inserter with captured core plug in its vertically aligned position.

[0032] FIG. 11 is a side view of the robotic core plug inserter without a captured core plug.

[0033] FIG. 12 is a bottom view of the robotic core plug inserter without a captured core plug.

[0034] FIG. 13 is a cross-section view of the robotic core plug inserter fully extended.

[0035] FIG. 14 is a cross-section view of the robotic core plug inserter retracted.

[0036] FIG. 15 is a top view of the robotic core plug inserter.

[0037] FIG. 16 is an exploded view of the robotic core plug inserter.

[0038] FIG. 17 is a top view of the core plug magazine.

[0039] FIG. 18 is a perspective view of the core plug magazine.

[0040] FIG. 19 is a rear view of the core plug magazine.

[0041] FIG. 20 is a side view of the core plug magazine.

[0042] FIG. 21 is a cross-section view of the core plug magazine.

DETAILED DESCRIPTIONS OF THE INVENTION

[0043] All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.

[0044] Referring to FIGS. 1-7, there are shown two large rolls 20 of paper, plastic film or other material internally supported by spiral wound paper cores 2. A second large roll is waiting and shown in dotted lines. These large rolls typically vary in size by 30 to 96 inches in diameter and 26 to 80 inches in width. The rolls are shown resting upon a roll transfer conveyor 8, with the initial core plug insertion position shown by solid lines, and the second core plug insertion position shown by dashed lines. The core plug inserter 4 is shown attached to the end of a six-axis supporting robot 7 that is positioned adjacent the initial roll 20. Core plugs 9 are shown resting upon a core plug magazine 3 and within the grasp of a core plug inserter 4.

[0045] Referring now to FIGS. 8-16, the core plug inserter 4 is shown. The major components of the core plug inserter 4 consist of; an air cylinder 5, machine vision camera 6, gripper finger 10, plug capture flange 11, gripper shaft 13, solenoid air valve 14 and magnetic piston sensors 15. Air cylinder 5 and placement of the magnetic piston sensors 15 have been selected to accommodate the stroke required for core plugs 9 having nominal thicknesses between 1¼″ and 1½″. It should be understood that the air cylinder 5 and the placement of the magnetic piston sensors 15 can be adjusted to accommodate other desired thicknesses outside the stated range. Solenoid air valve 14, operating in conjunction with a robot program, extends and retracts gripper shaft 13 to capture and release core plugs 9 secured between the gripper finger 10 and plug capture flange 11. Additional components that make up the complete core plug inserter 4 include the robot mounting plate 16, air cylinder gussets 17 and gripper shaft bushings 18. Robot mounting plate 16 attaches the assembled core plug inserter 4 to a robot 7. Air cylinder gussets 17 connect the robot mounting plate 16 to the core plug capture flange 11. The core plug capture flange 11 also serves as a mounting surface for the air cylinder 5. Gripper shaft bushings 18, installed within core plug capture flange 11, support gripper shaft 13 in its reciprocating movements.

[0046] Shown in FIGS. 4-7 the core plug inserter 4 is shown in various positions from preparation for insertion of a core plug 9 into a core 2 (FIGS. 4-5) to partial insertion (FIG. 6) and finally fully inserted (FIG. 7). In FIGS. 5-6 the core plug inserter 4 is shown at an angle to large roll 20 and core 2. In the preferred embodiment there is a 30 to 45 degree angular offset position of the core plug inserter 4 and captured core plug 9, which permits the core plug to be inserted into the internal diameter of core 2, with the least amount of force. However, the angular offset position can be adjusted to accommodate other cores or embodiments of the invention. The core plug inserter 4 rotates the core plug 9 30 to 45 degrees prior to inserting the core plug 9 into core 2. Once the core plug 2 is inside the core 2, the core plug inserter 4 rotates the core plug 9 so that it is perpendicular to the core 2, at a predetermined depth. The core plug inserter 4 then extends the gripper finger 10 to release the core plug 9. With core plug 9 released, the robot 7 can then extract the core plug inserter 4 from the core plug 9, the core 2, and roll 20.

[0047] The position of core 2 varies based on the size of the roll. Further, if roll 2 is comprised of softer material, core 2 could be located in a different elevational position. Therefore there is a need to automatically position the core plug inserter 4 relevant to core 2. The machine vision camera 6 is used to locate the position of the core 2 and properly align the core plug inserter 4 and thus the core plug 9.

[0048] Referring now to FIGS. 17-21 the core plug magazine 3 is shown. While the core plug inserter 4 is capable of functioning without the core plug magazine 3, it would require manual assistance in loading the core plugs 9. With the addition of the core plug magazine 3 the core plug inserter 4 can insert numerous core plugs 9, without operator interaction. Operation of the core plug magazine 3 begins with empty left core plug holder 21 and right core plug holder 22, core plugs 9 (not shown), cylinders 26 retracted and shuttle magazine in its left shifted position. An operator manually loads core plugs 9 into the left core plug holder 21 and right core plug holder 22. Core plugs 9 fall through the left core plug holder 21, and onto the recessed pocket of shuttle magazine 31, but they are stopped by the elevated surface of shuttle magazine 31 when loaded into and right core plug holder 22.

[0049] When the cycle begins, sensors 39 and 42 verify both the left and right core plug holders contain core plugs 9 and left cylinder 26 with attached clamp jaw 29 extends to apply pressure against core plug 9 within left core plug holder 21, securing the next lowest clamped core plug 9 and those immediately above it from further downward movement within the core plug holder 21.

[0050] Shuttle magazine 31 then shifts to the right allowing a core plug from right core plug holder 22 to drop into the right recessed magazine pocket of shuttle magazine 31. Following a brief time delay, right cylinder 26 with attached clamp jaw 29 extends to apply pressure against the core plug 9 within the right core plug holder 22, securing the next lowest clamped core plug 9 and those immediately above it from further downward movement.

[0051] At the same time the above movement takes place, shuttle magazine31 presents in the recessed pocket from left core plug holder 2 core plug 9 for transfer onto disc conveyor 32. Eject cylinder 34 with attached eject plate 36, mounted above recessed pocket of shuttle magazine 31 and previously extended, is commanded to retract and pull staged core plug 9 onto disc conveyor 32.

[0052] Upon confirmation that eject cylinder 34 has completed its retraction, disc conveyor 32 transports core plug 9 to a predetermined pick position at the conveyor end for capture by the core plug inserter 4. After a brief delay, eject cylinder 34 returns to its staged position for the next core plug 9 which will be delivered from the right core plug holder 22 using the same sequence of events as were applied to the left core plug holder 21.

[0053] The core plug inserter 4 engages the core plug 9 at the predetermined pick point by inserting gripper finger 10 into a hole in the center of core plug 9, then repositioning the gripper finger 10 at an edge of the center hole of core plug 9. The core plug inserter 4 then retracts air cylinder 5 which causes gripper finger 10 to clamp the core plug 9 between the gripper finger 10 and the core plug capture flange 11. Once the core plug 9 is placed inside the core 2, the core plug inserter 4 returns to the core plug magazine 3 to retrieve another core plug 9.

[0054] Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention.