AUTOMATIC CORE LOADING SYSTEM

Abstract

An automatic core loading system for loading a plurality of cores onto a rewind shaft includes a populating conveyor and a loading conveyor. The populating conveyor is configured to grab and move each core from a core source with the plurality of cores to a loading point for the loading conveyor one core at a time. The loading conveyor is configured to grab and move each of the cores from the populating conveyor at the loading point and move each core to a set position with a pre-determined or electronically measured gap between each core on the rewind shaft. Wherein, the automatic core loading system is configured to automatically load the plurality of cores onto the rewind shaft with the pre-determined or electronically measured gap between each core to match slit widths and spacing between a slit web of material.

Claims

1. An automatic core loading system for loading a plurality of cores onto a rewind shaft, the automatic core loading system comprising: a populating conveyor; a loading conveyor; the populating conveyor is configured to grab and move each core from a core source with the plurality of cores to a loading point for the loading conveyor one core at a time; and the loading conveyor is configured to grab and move each of the cores from the populating conveyor at the loading point and move each core to a set position with a pre-determined or electronically measured gap between each core on the rewind shaft.

2. The automatic core loading system according to claim 1 configured to automatically load the plurality of cores onto the rewind shaft with the pre-determined or electronically measured gap between each of the cores to match slit widths and spacing between a slit web of material.

3. The automatic core loading system according to claim 2 further comprising a gap sensor upstream of the rewind shaft, the gap sensor is configured to sense the slit widths and spacing of the slit web of material after being slit and communicate said slit widths and spacing to said automatic core loading system.

4. The automatic core loading system according to claim 3 further comprising bowed rolls and slitters upstream of the rewind shaft, where the gap sensor is configured to sense the slit widths and spacing of the slit web of material after being slit by the slitters and run through the bowed rolls.

5. The automatic core loading system according to claim 3, wherein the gap sensor is a single gap sensor driven by a web servo, where the gap sensor is configured to traverse across a machine width of the slit web of material after being slit for sensing the slit widths and spacing of the slit web of material.

6. The automatic core loading system according to claim 5, wherein the populating conveyor and the loading conveyor are servo controlled.

7. The automatic core loading system according to claim 6 further comprising a programmable logic controller in communication with the web servo and configured for controlling the populating conveyor and the loading conveyor to automatically load the plurality of cores onto the rewind shaft with the pre-determined or electronically measured gap between each of the cores to match the slit widths and spacing between the slit web of material, the programmable logic controller including a human machine interface panel configured for operator input to the automatic core loading system.

8. The automatic core loading system of claim 7, wherein: the populating conveyor including populating servos configured to control movements of the populating conveyor; the loading conveyor including loading servos configured to control movements of the loading conveyor; and the programmable logic controller is in communication with the populating servos and the loading servos to automatically load the plurality of cores onto the rewind shaft with the pre-determined or electronically measured gap between each core to match the slit widths and spacing between the web of material.

9. The automatic core loading system according to claim 1, wherein the populating conveyor and the loading conveyor are positioned in line with the rewind shaft.

10. The automatic core loading system according to claim 1 further comprising a frame configured to position the populating conveyor in line with the loading conveyor, the frame is also configured with an adjustable height for raising and lowering the populating conveyor and the loading conveyor.

11. The automatic core loading system according to claim 10 further comprising a staging conveyor in line with the populating conveyor and the loading conveyor, the staging conveyor is configured to move the plurality of the cores from the core source to the populating conveyor.

12. The automatic core loading system according to claim 11, wherein the staging conveyor including a flat belt staging conveyor configured to move each of the cores from a core hopper to the populating conveyor, whereby each of the cores are configured to move from the flat belt staging conveyor into the populating conveyor.

13. The automatic core loading system of claim 12, wherein the staging conveyor including a core sensor for scanning and checking the plurality of the cores from the core hopper, including scanning and checking an inside diameter of each of the cores, an outside diameter of each of the cores, and a length of each of the cores, whereby if any of the plurality of the cores are not to a core specification, the staging conveyor is configured to eject such a non-conforming core prior to being picked by the populating conveyor.

14. The automatic core loading system of claim 13, wherein the outside diameter of each of the cores is communicated to the populating conveyor and the loading conveyor, wherein the populating conveyor and the loading conveyor are configured to utilize the outside diameter of each of the cores for grabbing and moving each of the cores.

15. The automatic core loading system of claim 14, wherein: the populating conveyor including a left populating conveyor side and a right populating conveyor side, wherein a populating width between the left populating conveyor side and the right populating conveyor side is adjustable, whereby the populating conveyor is configured to grab and move one of the cores by decreasing the populating width between the left populating conveyor side and the right populating conveyor side to the outside diameter of each of the cores, and the populating conveyor is configured to release the core by increasing the populating width between the left populating conveyor side and the right populating conveyor side to greater than the outside diameter of each of the cores; and the loading conveyor including a left loading conveyor side and a right loading conveyor side, wherein a loading width between the left loading conveyor side and the right loading conveyor side is adjustable, whereby the loading conveyor is configured to grab and move one of the cores by decreasing the loading width between the left loading conveyor side and the right loading conveyor side to the outside diameter of each of the cores, and the loading conveyor is configured to release the core by increasing the loading width between the left loading conveyor side and the right loading conveyor side to greater than the outside diameter of each of the cores.

16. The automatic core loading system of claim 15, wherein: the left populating conveyor side, the right populating conveyor side, or a combination thereof including populating grabbers with pointed ends configured for grabbing and holding one of the cores in the populating conveyor; the left loading conveyor side, the right loading conveyor side, or a combination thereof including loading grabbers with the pointed ends configured for grabbing and holding one of the cores in the loading conveyor; and wherein, the populating conveyor grips an individual core and indexes it forward a pre-determined or electronically measured length to the loading conveyor which is in line with and simultaneously loading the cores on the rewind shaft.

17. The automatic core loading system according to claim 13, wherein: the length of each of the cores is communicated to the populating conveyor and the loading conveyor for automatically loading the plurality of cores onto the rewind shaft with the pre-determined or electronically measured gap between each core to match slit widths and spacing between the slit web of material; as the populating conveyor indexes one of the cores onto the loading conveyor, each of the cores has the pre-determined or electronically measured gap between the adjacent core; once a series of gapped cores has been loaded on the loading conveyor, the series of gapped cores is then moved to predetermined locations that align with the slit widths and spacing between the slit web of material; once the series of gapped cores reach the predetermined locations, the rewind shaft includes an internal bladder configured to expand to hold the series of gapped cores in place on the rewind shaft at the predetermined locations; and once the series of gapped of cores are released from the loading conveyor, the frame of the automatic core loading system is configured to lower to a home position and allow a turret to index a populated rewind shaft in a cycle to a winding position.

18. The automatic core loading system according to claim 1, wherein: the automatic core loading system is configured to eliminate the need for cores to be manually loaded or spaced onto the shaft; the automatic core loading system is configured to allow an automated winder/rewinder machine to finish more rolls compared to an unautomated winder/rewinder machine with manual core loading, manual taping of the slit web of material to the cores, or manual finishing of the rolls; or a combination thereof.

19. An automatic core loading system for loading a plurality of cores onto a rewind shaft, the automatic core loading system comprising: a populating conveyor, the populating conveyor including populating servos configured to control movements of the populating conveyor; a loading conveyor, the loading conveyor including loading servos configured to control movements of the loading conveyor; the populating conveyor is configured to grab and move each core from a core source with the plurality of cores to a loading point for the loading conveyor one core at a time; the loading conveyor is configured to grab and move each of the cores from the populating conveyor at the loading point and move each core to a set position with a pre-determined or electronically measured gap between each core on the rewind shaft; the populating conveyor and the loading conveyor are positioned in line with the rewind shaft; a gap sensor upstream of the rewind shaft, the gap sensor is configured to sense slit widths and spacing of a slit web of material after being slit and communicate said slit widths and spacing to said automatic core loading system, wherein the gap sensor is a single gap sensor driven by a web servo, where the gap sensor is configured to traverse across a machine width of the slit web of material after being slit for sensing the slit widths and spacing of the slit web of material; the gap sensor is configured to sense the slit widths and spacing of the slit web of material after being slit by slitters and run through bowed rolls; a staging conveyor in line with the populating conveyor and the loading conveyor, the staging conveyor is configured to move the plurality of cores from the core source to the populating conveyor, wherein the staging conveyor is a flat belt staging conveyor configured to move the cores from a core hopper to the populating conveyor, wherein the cores move from the flat belt staging conveyor into the populating conveyor; the staging conveyor including a sensor for scanning and checking the plurality of cores from the core hopper, including scanning and checking an inside diameter of each core, an outside diameter of each core, and a length of each core, whereby if any of the plurality of cores are not to a core specification, the staging conveyor is configured to eject such a non-conforming core prior to being picked by the populating conveyor; the outside diameter of the cores is communicated to the populating conveyor and the loading conveyor, wherein the populating conveyor and the loading conveyor are configured to utilize the outside diameter of the cores for grabbing and moving each of the cores, wherein: the populating conveyor including a left populating conveyor side and a right populating conveyor side, wherein a populating width between the left populating conveyor side and the right populating conveyor side is adjustable, whereby the populating conveyor is configured to grab and move one of the cores by decreasing the populating width between the left populating conveyor side and the right populating conveyor side to the outside diameter of the cores, and the populating conveyor is configured to release the core by increasing the populating width between the left populating conveyor side and the right populating conveyor side to greater than the outside diameter of the core; and the loading conveyor including a left loading conveyor side and a right loading conveyor side, wherein a loading width between the left loading conveyor side and the right loading conveyor side is adjustable, whereby the loading conveyor is configured to grab and move one of the cores by decreasing the loading width between the left loading conveyor side and the right loading conveyor side to the outside diameter of the cores, and the loading conveyor is configured to release the core by increasing the loading width between the left loading conveyor side and the right loading conveyor side to greater than the outside diameter of the core; wherein: the left populating conveyor side, the right populating conveyor side, or a combination thereof including populating grabbers with pointed ends configured for grabbing and holding the core in the populating conveyor; the left loading conveyor side, the right loading conveyor side, or a combination thereof including loading grabbers with the pointed ends configured for grabbing and holding the core in the loading conveyor; wherein, the populating conveyor grips an individual core and indexes it forward a pre-determined or electronically measured length to the loading conveyor which is in line with and simultaneously loading the cores on the rewind shaft; wherein the length of the cores is communicated to the populating conveyor and the loading conveyor for automatically loading the plurality of cores onto the rewind shaft with the pre-determined or electronically measured gap between each core to match slit widths and spacing between the slit web of material; wherein as the populating conveyor indexes an individual core onto the loading conveyor, each core has a pre-determined or electronically measured gap between the adjacent core; a programmable logic controller in communication with the web servo and configured for controlling the populating conveyor and the loading conveyor to automatically load the plurality of cores onto the rewind shaft with the pre-determined or electronically measured gap between each core to match slit widths and spacing between the slit web of material, wherein the programmable logic controller is in communication with the populating servos and the loading servos to automatically load the plurality of cores onto the rewind shaft with the pre-determined or electronically measured gap between each core to match slit widths and spacing between webs of material; the programmable logic controller including a human machine interface panel configured for operator input to the automatic core loading system; wherein, the automatic core loading system is configured to automatically load the plurality of cores onto the rewind shaft with the pre-determined or electronically measured gap between each core to match slit widths and spacing between the slit web of material; wherein: once a series of gapped cores has been loaded on the loading conveyor, the series of gapped cores is then moved to predetermined locations that align with the slit widths and spacing between the slit web of material; once the cores reach the predetermined locations, the rewind shaft includes an internal bladder that is configured to expand to hold the series of cores in place on the rewind shaft at the predetermined locations; once the series of cores are released from the loading conveyor, the automatic core loading system including a frame that holds the populating conveyor and the loading conveyor that is configured to lower to a home position and allow a turret to index the populated rewind shaft in a cycle to a winding position; wherein: the automatic core loading system is configured to eliminate the need for cores to be manually loaded or spaced onto the shaft; and the automatic core loading system is configured to allow an automated winder/rewinder machine to finish more rolls compared to an unautomated winder/rewinder machine with manual core loading, manual taping of the web to the cores, or manual finishing of the roll.

20. A method of automatically loading a plurality of cores onto a rewind shaft of a winder/rewinder machine with predetermined gaps and locations of each core, the method including: providing an automatic core loading system comprising: a populating conveyor; a loading conveyor; the populating conveyor is configured to grab and move each core from a core source with the plurality of cores to a loading point for the loading conveyor one core at a time; and the loading conveyor is configured to grab and move each of the cores from the populating conveyor at the loading point and move each core to a set position with a pre-determined or electronically measured gap between each core on the rewind shaft; and using the provided automatic core loading system to automatically load the plurality of cores onto the rewind shaft of the winder/rewinder machine with the predetermined gaps and the locations of each core.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present disclosure will be better understood by reading the Detailed Description with reference to the accompanying drawings, which are not necessarily drawn to scale, and in which like reference numerals denote similar structure and refer to like elements throughout, and in which:

[0031] FIG. 1 is a perspective view of an automatic core loading system according to select embodiments of the instant disclosure;

[0032] FIG. 2 is a top view of the automatic core loading system of FIG. 1 showing a zoomed in view of the loading conveyors;

[0033] FIG. 3 is another top view of the automatic core loading system of FIG. 1 showing a zoomed in view of the adjustability of the conveyor width of the loading conveyors;

[0034] FIG. 4 is a cross-sectional side view of the automatic core loading system of FIG. 1 taken through the line 4-4 shown in FIG. 3;

[0035] FIG. 5 is a front view of the automatic core loading system of FIG. 1;

[0036] FIG. 6 is a rear view of the automatic core loading system of FIG. 1;

[0037] FIG. 7 is another top view of the automatic core loading system of FIG. 1;

[0038] FIG. 8 is a cross-sectional side view of the automatic core loading system of FIG. 1 taken through the line 8-8 shown in FIG. 7;

[0039] FIG. 9 is a partially disassembled perspective view of the frame and drive mechanisms for adjusting the height of the frame and the widths of the populating conveyor and the loading conveyor according to select embodiments of the automatic core loading system of FIG. 1;

[0040] FIG. 10 is a partially disassembled perspective view of the populating conveyor and the loading conveyor according to select embodiments of the automatic core loading system of FIG. 1 showing the left populating conveyor side and the left loading conveyor side with a zoomed in view of the populating grabbers or loading grabbers with pointed ends;

[0041] FIG. 11 is a top view of the automatic core loading system of FIG. 1 positioned in line with a core hopper and staging conveyor for automatically loading the cores into the disclosed automatic core loading system from a core source;

[0042] FIG. 12 is a schematic diagram showing the upstream components and the steps of slit rewinding on the disclosed automatic core loading system according to select embodiments of the instant disclosure;

[0043] FIG. 13A is a schematic view of the automatic core loading system according to select embodiments of the instant disclosure showing the plurality of cores being loaded onto the staging conveyor;

[0044] FIG. 13B is a schematic view of the automatic core loading system of FIG. 13A showing the plurality of cores loaded onto the staging conveyor;

[0045] FIG. 13C is a schematic view of the automatic core loading system of FIG. 13A showing the plurality of cores loaded onto the staging conveyor with a first core being grabbed by the populating conveyor;

[0046] FIG. 13D is a schematic view of the automatic core loading system of FIG. 13A showing the plurality of cores loaded onto the staging conveyor with the first core being grabbed by the loading conveyor from the populating conveyor at the loading point;

[0047] FIG. 13E is a schematic view of the automatic core loading system of FIG. 13A showing the plurality of cores loaded onto the staging conveyor with the first core being positioned on the rewind shaft and the second core being grabbed by the populating conveyor from the staging conveyor;

[0048] FIG. 13F is a schematic view of the automatic core loading system of FIG. 13A showing the plurality of cores loaded onto the staging conveyor with the first core in position on the rewind shaft and the second core being grabbed by the loading conveyor from the populating conveyor at the loading point;

[0049] FIG. 13G is a schematic view of the automatic core loading system of FIG. 13A showing the plurality of cores loaded onto the staging conveyor with the first core positioned on the rewind shaft, the second core being positioned on the rewind shaft, and the third core being grabbed by the populating conveyor from the staging conveyor;

[0050] FIG. 13H is a schematic view of the automatic core loading system of FIG. 13A showing the plurality of cores loaded onto the staging conveyor with the first core and the second core in position on the rewind shaft with the predetermined gap therebetween, and the third core being grabbed by the loading conveyor from the populating conveyor at the loading point;

[0051] FIG. 13I is a schematic view of the automatic core loading system of FIG. 13A showing the plurality of cores loaded onto the staging conveyor with the first and second cores positioned on the rewind shaft with the predetermined gap therebetween, the third core being positioned on the rewind shaft, and the fourth core being grabbed by the populating conveyor from the staging conveyor;

[0052] FIG. 13J is a schematic view of the automatic core loading system of FIG. 13A showing the plurality of cores loaded onto the staging conveyor with the first core, the second core, and the third core in position on the rewind shaft with the predetermined gaps therebetween, and the fourth core being grabbed by the loading conveyor from the populating conveyor at the loading point;

[0053] FIG. 13K is a schematic view of the automatic core loading system of FIG. 13A showing the plurality of cores loaded onto the staging conveyor with the first, second and third cores positioned on the rewind shaft with the predetermined gaps therebetween, the fourth core being positioned on the rewind shaft, and the fifth core being grabbed by the populating conveyor from the staging conveyor;

[0054] FIG. 13L is a schematic view of the automatic core loading system of FIG. 13A showing the plurality of cores loaded onto the staging conveyor with the first core, the second core, the third core, and the fourth core in position on the rewind shaft with the predetermined gaps therebetween, and the fifth core being grabbed by the loading conveyor from the populating conveyor at the loading point; and

[0055] FIG. 13M is a schematic view of the automatic core loading system of FIG. 13A showing the plurality of cores all taken off of the staging conveyor with the first core, the second core, the third core, the fourth core and the fifth core in position on the rewind shaft with the predetermined gaps therebetween.

[0056] It is to be noted that the drawings presented are intended solely for the purpose of illustration and that they are, therefore, neither desired nor intended to limit the disclosure to any or all of the exact details of construction shown, except insofar as they may be deemed essential to the claimed disclosure.

DETAILED DESCRIPTION

[0057] Referring now to FIGS. 1-13, in describing the exemplary embodiments of the present disclosure, specific terminology is employed for the sake of clarity. The present disclosure, however, is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish similar functions. Embodiments of the claims may, however, be embodied in many different forms and should not be construed to be limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples.

[0058] The present disclosure may solve the aforementioned limitations of the currently available slitter rewinder core loading means and systems by providing automatic core loading system 10, as shown in FIGS. 1-13. Automatic core loading system 10 may be for automatically loading a plurality of cores 12 onto rewind shaft 14 (see FIG. 12). Automatic core loading system 10 may be for automatically loading the plurality of cores 12 onto rewind shaft 14 with pre-determined (or electronically measured) gap 26 therebetween and at set positions 24 to correspond to slit widths and spacing 28 of slit web of material 30. As such, automatic core loading system 10 may be designed and configured to first sense slit widths and spacing 28 of slit web of material 30, and then automatically load cores 12 onto rewind shaft 14 with pre-determined (or electronically measured) gaps 26 therebetween and set positions 24 to correspond to the sensed slit widths and spacing 28 of slit web of material 30. Automatic core loading system 10 may generally include populating conveyor 16 and loading conveyor 18. Populating conveyor 16 may be configured to grab and move each core from core source 20 with the plurality of cores 12 to loading point 22 for loading conveyor 18 one core 12 at a time. Loading conveyor 18 may be configured to grab and move each of the cores 12 one at a time from populating conveyor 16 at loading point 22 and move each core to set position 24 with pre-determined (or electronically measured) gap 26 between each core 12 on rewind shaft 14.

[0059] One feature of automatic core loading system 10 may be that it can be configured to automatically load the plurality of cores 12 onto rewind shaft 14 with pre-determined (or electronically measured) gap 26 between each core to match slit widths and spacing 28 between any slit web of material 30.

[0060] As best shown and described in FIG. 12, in select embodiments, automatic core loading system 10 may include gap sensor 32. Gap sensor 32 may be for sensing the slit widths and spacing 28 between slit web of material 30. Gap sensor 32 may be positioned upstream of rewind shaft 13. Gap sensor 32 may be configured to sense slit widths and spacing 28 of slit web of material 30 after being slit with slitters 48. The slit or gap sensor 32 may then communicate said slit widths and spacing 28 sensed to automatic core loading system 10, like to the computer or programmable logic controller 38 of automatic core loading system 10. In select embodiments, gap sensor 32 may be single gap sensor 34 driven by web servo 35. In this single gap sensor 34 embodiment, gap sensor 32 may be configured to traverse across machine width 36 of slit web of material 30 after being slit for sensing the slit widths and spacing 28 of the slit web of material 30. However, the disclosure is not so limited, and multiple gap sensors 32 may be used for sensing slit widths and spacing 28 of slit web of material 30. In select embodiments, automatic core loading system 10 or the automated winder/rewinder machine 104 that the system is used in, may include bowed rolls 46 and/or slitters 48. The bowed rolls 46 and slitters 48 may be positioned upstream of rewind shaft 14. In these embodiments, gap sensor 32 may be configured to sense slit widths and spacing 28 of slit web of material 30 after being slit by slitters 48 and run through the bowed rolls 46, as is commonly done in slitter rewinder processing, like simplex rewinding.

[0061] Another feature of automatic core loading system 10 may be that populating conveyor 16 and/or loading conveyor 18 may be servo controlled. This feature of having populating conveyor 16 and loading conveyor 18 servo controlled may allow for the movement of populating conveyor 16 and loading conveyor 18 to be automated with PLC program 38. However, the disclosure is not so limited and the movement of populating conveyor 16 and/or loading conveyor 18 may be controlled by any other automated means.

[0062] Referring again to FIG. 12, another feature of automatic core loading system 10 may be the inclusion of programmable logic controller 38, or PLC program 38. Programmable logic controller program 38 may be in communication with any servos (or the like) included in automatic core loading system 10, including, but not limited to, web servo 35, populating conveyor servos 42, loading conveyor servos 44, staging conveyor servos, servos for the raising and lower of frame 92, the like, etc. Programmable logic controller 38 may be configured for controlling populating conveyor 16 and loading conveyor 18 to automatically load the plurality of cores 12 onto rewind shaft 14 with pre-determined (or electronically measured) gap 26 between each core to match slit widths and spacing 28 between the slit web of material 30. In select embodiments, programmable logic controller 38 may include human machine interface panel 40, or HMI panel 40. Human machine interface panel 40 may be configured for operator input to automatic core loading system 10.

[0063] In select embodiments of automatic core loading system 10, populating conveyor 16 may include populating servos 42, or the like. Populating servos 42 may be configured to control movement of populating conveyor 16. Populating servos 42 may be configured to control the movement of populating conveyor 16, including, but not limited to, the grabbing motions (increasing and decreasing populating width 72 between opposing populating conveyors) and the longitudinal movement of the cores motion of the populating conveyors 16. Programmable logic controller 38 may be in communication with populating servos 42 to automatically load the plurality of cores 12 onto rewind shaft 14 with pre-determined (or electronically measured) gaps 26 between each core 12 to match slit widths and spacing 28 between web of material 30.

[0064] In select embodiments of automatic core loading system 10, loading conveyor 18 may include loading servos 44, or the like. Loading servos 44 may be configured to control the movement of loading conveyor 18, including, but not limited to, the grabbing motions (increasing and decreasing loading width 78 between opposing loading conveyors) and the longitudinal movement of the cores motion of the loading conveyors 18. Programmable logic controller 38 may be in communication with loading servos 44 to automatically load the plurality of cores 12 onto rewind shaft 14 with pre-determined (or electronically measured) gaps 26 between each core 12 to match slit widths and spacing 28 between web of material 30.

[0065] As shown in the Figures, in select embodiments of automatic core loading system 10, populating conveyor 16 and loading conveyor 18 may be positioned in line with rewind shaft 14 (sec FIGS. 13A-13M).

[0066] Referring now specifically to FIG. 11, in select embodiments, automatic core loading system 10 may further include staging conveyor 50. Staging conveyor 50 may be for moving plurality of cores 12 from core source 20 into populating conveyor 16. Staging conveyor 50 may be in line with populating conveyor 16 and loading conveyor 18. As such, staging conveyor 50 may be configured to move the plurality of cores 12 from core source 20 into populating conveyor 16. In select embodiments, as shown in FIG. 11, staging conveyor 50 may include flat belt staging conveyor 52. However, the disclosure is not so limited, and other various forms of staging conveyor 50 may be provided. As shown, flat belt staging conveyor 52 may be configured to move cores 12 from core hopper 54 to populating conveyor 16. Wherein, automatic core loading system 10 may be configured to move cores 12 from flat belt staging conveyor 52 into populating conveyor 16.

[0067] Still referring to FIG. 11, one feature of automatic core loading system 10 may be the inclusion of core sensor 56. Core sensor 56 may be included with staging conveyor 50, as shown in FIG. 11, or it may be included in other parts of automatic core loading system 10, like with populating conveyor 16. Core sensor 56 may be for scanning and checking the plurality of cores 12 from core source 20, like core hopper 54. Core sensor 56 may scan parameters of each core 12, including but not limited to, scanning and checking inside diameter 58 of each core 12, outside diameter 60 of each core 12, and length 62 of each core 12. Whereby, if any of the plurality of cores 12 are not to core specification 64, staging conveyor 50 (or populating conveyor 16, or another apparatus of system 10) may be configured to eject such a non-conforming core 66 prior to being picked by populating conveyor 16. In addition, in select embodiments, as a core 12 leaves staging conveyor 50 and is picked by populating conveyor 16, where populating conveyor 16 may advance core 12 for a second length check (also for tolerance) and may then be loaded via loading conveyor 18 onto winding shaft 14 in required location 88 to match the registered slit web of material 30. The following cores 12 may also be checked and then loaded onto winding shaft 14 with the required predetermined gap 26 between each to align with the slit widths and spacing 28 of slit web of material 30.

[0068] Another feature of automatic core loading system 10 may be that outside diameter 60 of cores 12 may be communicated to populating conveyor 16 and/or loading conveyor 18. Wherein, populating conveyor 16 and loading conveyor 18 may be configured to utilize outside diameter 60 of cores 12 for grabbing and moving each core 12.

[0069] As best shown in FIGS. 1-5, in select embodiments of automatic core loading system 10, populating conveyor 16 may include left populating conveyor side 68 and right populating conveyor side 70, with adjustable populating width 72 therebetween. Wherein, populating width 72 between left populating conveyor side 68 and right populating conveyor side 70 may be adjustable, whereby populating conveyor 16 may be configured to grab and move one of the cores 12 by decreasing populating width 72 between left populating conveyor side 68 and right populating conveyor side 70 to outside diameter 60 of cores 12. Conversely, populating conveyor 16 may be configured to release core 12 by increasing populating width 72 between left populating conveyor side 68 and right populating conveyor side 70 to greater than outside diameter 60 of core 12 being moved. In select embodiments, left populating conveyor side 68, and/or right populating conveyor side 70, may include populating grabbers 80, as best shown in FIG. 10. Populating grabbers 80 may include any means or mechanisms for gripping or grabbing cores 12 with populating conveyor 16. In select embodiments, as shown in the Figures, populating grabbers 80 may include pointed ends 82 configured for grabbing and holding one of the core 12 in populating conveyor 16.

[0070] As best shown in FIGS. 1-4 and 6, in select embodiments of automatic core loading system 10, loading conveyor 18 may include left loading conveyor side 74 and right loading conveyor side 76, with adjustable loading width 78 therebetween. Wherein, loading width 78 between left loading conveyor side 74 and right loading conveyor side 76 may be adjustable, whereby loading conveyor 18 may be configured to grab and move one of the cores 12 by decreasing loading width 78 between left loading conveyor side 74 and right loading conveyor side 76 to outside diameter 60 of the core 12. Conversely, loading conveyor 18 may be configured to release the core 12 by increasing loading width 78 between left loading conveyor side 74 and right loading conveyor side 76 to greater than outside diameter 60 of core 12. In select embodiments, left loading conveyor side 74, and/or right loading conveyor side 76, may include loading grabbers 84. Loading grabbers 84 may include any means or mechanisms for gripping or grabbing cores 12 with loading conveyor 18. In select embodiments, as shown in the Figures, similar to populating grabbers 80, loading grabbers 84 may include pointed ends 82 configured for grabbing and holding one of the cores 12 in loading conveyor 18.

[0071] Another feature of automatic core loading system 10 may be that length 62 of cores 12 can be communicated to populating conveyor 16 and/or loading conveyor 18 for automatically loading the plurality of cores 12 onto rewind shaft 14 with the pre-determined (or electronically measured) gaps 26 between each core 12 to match slit widths and spacing 28 between the slit web of material 30. In select embodiments, populating conveyor 16 may grip an individual core 12 and index it forward a pre-determined (or electronically measured) length to loading conveyor 18 which is in line with and simultaneously loading cores 12 on rewind shaft 14 (see FIGS. 13A-13M). Wherein, as the populating conveyor 16 indexes an individual core 12 onto loading conveyor 18, each core 12 may have pre-determined (or electronically measured) gap 26 between each adjacent core 12.

[0072] Another feature of automatic core loading system 10 may be that once a series of gapped cores 86 has been loaded on loading conveyor 18, the series of gapped cores 86 may then be moved to predetermined locations 88 that align with the slit widths and spacing 28 between the slit web of material 30 (see FIG. 12).

[0073] Another feature of automatic core loading system 10 may be that once the cores 12 reach the predetermined locations 88, rewind shaft 14 may include internal bladder 90 that is configured to expand to hold the series of cores 12 in place on rewind shaft 14 at predetermined locations 88. The use of rewind shaft 14 with internal bladder 90 may be commonly done in slitter rewinder processing, like simplex rewinding. Rewind shaft 14 may be capable of accommodating either fiber or plastic cores of various diameters.

[0074] As best shown in FIGS. 1, 4-6, 8 and 9, another feature of automatic core loading system 10 may be the inclusion of frame 92. Frame 92 may be configured for holding and positioning populating conveyor 16 in line with loading conveyor 18. Frame 92 may include many various components for holding populating conveyor 16 in line with loading conveyor 18, as best shown in FIG. 9. As shown, frame 92 may include various gears and moving components for allowing the motions of populating conveyor 16, loading conveyor 18, and for adjusting the height of automatic core loading system 10. By using this adjustable height of frame 92, once the series of cores 12 are released from loading conveyor 18, automatic core loading system 10 with populating conveyor 16 and loading conveyor 18 may be configured to lower to home position 94 and allow turret 96 (see FIGS. 13A-13M) to index a populated rewind shaft (see FIG. 13M) in a cycle to a winding position, as commonly done in slitter rewinder processing, like simplex rewinding. As such, in select embodiments, automatic core loading system 10 may include frame 92 configured to adjust the height of populating conveyor 16 and loading conveyor 18.

[0075] Another feature of automatic core loading system 10 may be that it can be configured to eliminate the need for cores 12 to be manually loaded or spaced onto rewind shaft 14.

[0076] Another feature of automatic core loading system 10 may that it can be configured to allow automated winder/rewinder machine 104 to finish more rolls compared to an unautomated winder/rewinder machine with manual core loading, manual taping of the web to the cores, and/or manual finishing of the roll, as is commonly used in current slitter rewinder processing, like simplex rewinding.

[0077] In yet another aspect, the present disclosure embraces method 200 of automatically loading cores 12 onto rewind shaft 14 of a winder/rewinder machine 104 with predetermined gaps 26 and locations 88 of each core 12. The disclosed method of automatically loading cores 12 may include utilizing the disclosed automatic core loading system 10 in any of the embodiments and/or combinations of embodiments shown and/or described herein. As best shown in FIG. 12, the upstream components prior to automatic core loader system 10 are shown. Step 1 represents the web slitting process, where a full web width is slit with slitters 48. In select embodiments, as an example, slitter holders may be mounted on a dove tail or linear bearings and manually positioned to the rings or fully automated slitter holder and ring. If fully automated, the first step may be slitter position feedback to the main PLC program 38 to identify the anticipated slit locations or widths and spacing 28. Female slitter rings may be mounted on a driven shaft (in an automated system the ring position may also b located in conjunction to the holders). Step 2 shows web slit width established. As an example, a servo traversing sensor for identifying the slitter ring positions for the required slit width for the operator to manually move the rings starting positions center (for remaining edge trim or end for predetermined edge trim). This is not required if the slitter positioning is an automated stand alone system. Step 3 shows the manual and automated servo controlled bowed rolls 46 for selecting the angle for slit separation. The two bowed rolls 46 may be to separate the web 30 for winding/rewinding on a single shaft 14 (which may or may not be servo controlled). Step 4 shows the use of gap sensor 32 to measure the slit locations, including the slit width and spacing 28. Gap sensor(s) 32 for measuring/communicating the slit width and spacing 28, where locations giving feedback to PLC 38 to set pre-determined (or electronically measured) gaps 26 and location 88 to be placed on winding shaft 14 required to align with the edges of slit web 30. Gap sensor 32 may also verify slit width dimensions and web stability to maintain the slit gap required. Step 4 confirms the slit separation/gap between slits. Finally, step 5 represents the core location on the winding/rewind shaft 14 with pre-determined (or electronically measured) gaps 26 between adjacent cores 12. Cores 12 loaded on rewind shaft 14 with the required spacing to match slit width edges/gap. This portion includes core hopper 54 for volume loading and servo driven control of core feed and placement on winding shaft 14. Automatic core loading system 10 also checks core ID 58, OD 60 and length 62.

[0078] Referring now to FIGS. 13A-13M, schematic drawings are shown according to select embodiments of the instant disclosure, representing the process that populating conveyor 16 and loading conveyor 18 may take for loading cores 12 onto rewind shaft 14 with pre-determined (or electronically measured) gaps 26. FIG. 13A shows the plurality of cores 12 being loaded onto staging conveyor 50, like from core hopper 54. FIG. 13B shows the plurality of cores 12 loaded onto the staging conveyor and moving toward populating conveyor 16. FIG. 13C shows the plurality of cores 12 loaded onto staging conveyor 50 with a first core 12 being grabbed by populating conveyor 16. FIG. 13D shows the plurality of cores 12 loaded onto staging conveyor 50 with the first core 12 being grabbed by loading conveyor 18 from populating conveyor 16 at loading point 22. FIG. 13E shows the plurality of cores 12 loaded onto staging conveyor 50 with the first core 12 being positioned on rewind shaft 14 and the second core 12 being grabbed by populating conveyor 16 from staging conveyor 50. FIG. 13F shows the plurality of cores 12 loaded onto the staging conveyor 50 with the first core 12 in position on rewind shaft 14 and the second core 12 being grabbed by loading conveyor 18 from populating conveyor 16 at loading point 22. FIG. 13G shows the plurality of cores 12 loaded onto staging conveyor 50 with the first core 12 positioned on rewind shaft 14, the second core 12 being positioned on rewind shaft 14, and the third core 12 being grabbed by the populating conveyor 16 from staging conveyor 50. FIG. 13H shows the plurality of cores 12 loaded onto staging conveyor 50 with the first core 12 and the second core 12 in position on rewind shaft 14 with predetermined gap 26 therebetween, and the third core 12 being grabbed by loading conveyor 18 from populating conveyor 16 at loading point 22. FIG. 131 shows the plurality of cores 12 loaded onto staging conveyor 50 with the first and second cores 12 positioned on rewind shaft 14 with predetermined gap 26 therebetween, the third core 12 being positioned on rewind shaft 14, and the fourth core 12 being grabbed by populating conveyor 16 from staging conveyor 50. FIG. 13J shows the plurality of cores 12 loaded onto staging conveyor 50 with the first, second, and third cores 12 in position on rewind shaft 14 with the predetermined gaps 26 therebetween, and the fourth core 12 being grabbed by loading conveyor 18 from populating conveyor 16 at loading point 22. FIG. 13K shows the plurality of cores 12 loaded onto staging conveyor 50 with the first, second and third cores 12 positioned on rewind shaft 14 with the predetermined gaps 26 therebetween, the fourth core 12 being positioned on rewind shaft 14, and the fifth core 12 being grabbed by the populating conveyor 16 from the staging conveyor 50. FIG. 13L shows the plurality of cores 12 loaded onto staging conveyor 50 with the first, second, third, and fourth cores 12 in position on rewind shaft 14 with the predetermined gaps 26 therebetween, and the fifth core 12 being grabbed by loading conveyor 18 from populating conveyor 16 at loading point 22. Finally, FIG. 13M shows the plurality of cores 12 all taken off of staging conveyor 50 with the first, second, third, fourth, and fifth core 12 in position on rewind shaft 14 with predetermined gaps 26 therebetween. At this point, the process of automatically loading the cores 12 onto rewind shaft 14 is complete and expandable bladder 90 will enlarge to lock the cores 12 in position on rewind shaft 14. Frame 92 may then lower to home position 94, where turret 96 may rotate or index rewind shaft 14 a cycle to a winding position. The process may then start over for loading additional cores onto another rewind shaft 14.

[0079] In sum, automatic corer loading system 10 may be designed to automatically load cores 12 onto single rewind shaft 14 with pre-determined (or electronically measured) gaps 26 between each core 12 aligning with the slit web of material 30 for simplex winding. Automatic core loading system 10 includes a number of inline conveyors, staging conveyor 50, populating conveyor 16, and loading conveyor 18, to position the cores 12 on rewind shaft 14 with the required spacing (predetermined gaps 26) between each core 12 to match the web slit widths and spacing 28. The cores 12 move from flat belt staging conveyor 52 into the servo controlled populating conveyor 16. Populating conveyor 16 grips an individual core 12 and indexes it forward a pre-determined (or electronically measured) length to the longer loading conveyor 18, which is in line with and simultaneously loading the cores 12 on rewind shaft 14. Loading conveyor 18 may also be simultaneously loading rewind shaft 14 (note the final core location to the slit web may not be set yet). As populating conveyor 16 indexes an individual core 12 onto loading conveyor 18, each core 12 has pre-determined (or electronically measured) gap 26 between the adjacent core 12.

[0080] Once the series of gapped cores 86 has been loaded on loading conveyor 18 the series of gapped cores 86 may then be moved to predetermined location 88 that aligns with the existing slit widths and spacing 28 of slit web of material 30. Once the series of gapped cores 86 reach the set location 88, rewind shaft 14 may have internal bladder 90 that expands to hold the series of gapped cores 86 in place. The cores 12 are released from the loading conveyor 18 gripper belt, frame 92 then lowers to home position 94, which may allow the turret 96 to index the populated rewind shaft 14 in the cycle to the winding position.

[0081] Pre-determined (or electronically measured) gap 26 may be the difference between automatic core loading system 10 and previous, core loaders. Previous core loaders also load cores onto a simplex rewind shaft, but they do not have pre-determined (or electronically measured) gap 26 between the cores. They are instead stacked against one another and or repositioned individually by other means. However, some other methods do utilize a clam shell which hold cores with full slit width gaps and applied to Duplex winding or narrow separations using a single clam shell for Simplex winding. Unlike the disclosed automatic core loading system 10, these previous methods require changeout of clam shells for each and every slit width.

[0082] In the specification and/or figures, typical embodiments of the disclosure have been disclosed. The present disclosure is not limited to such exemplary embodiments. The use of the term and/or includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.

[0083] The foregoing description and drawings comprise illustrative embodiments. Having thus described exemplary embodiments, it should be noted by those skilled in the art that the within disclosures are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present disclosure. Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Accordingly, the present disclosure is not limited to the specific embodiments illustrated herein but is limited only by the following claims.