Abstract:
An automatic core joiner and cutter apparatus for use in the recycling of used cores and the manufacture of new conjoined cores is disclosed. The apparatus combines an infeed unit, a milling unit, and an outfeed unit, all controlled by a PC. The infeed unit includes at least two infeed rollers for supporting a used core member. An infeed pusher bar moves these core member into and out of contact with the milling unit. The outfeed unit includes at least two rollers for supporting a core remnant. An outfeed pusher bar moves the core remnant into and out of contact with the milling unit. The milling unit, positioned between the infeed and outfeed unit includes an infeed cutter and an infeed milling bit, an outfeed cutter and an outfeed milling bit. The infeed cutter removes the damaged end of the used core and the outfeed cutter removes the damaged end of a core remnant. The used core is milled by the infeed milling bit and the core remnant is milled by the outfeed milling bit. A glue applicator applies glue to at least one of the milled surfaces and the milled surfaces are mated together to produce a new conjoined core. The infeed cutting and milling operations and the outfeed cutting and milling operations are controlled by the controller and performed at the same time.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is based on and claims the benefit of U.S. provisional patent application 60/269,017 filed Oct. 14, 2009. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to the manufacture of paper roll cores designed for use in carrying continuous paper webbing rolled about the core member. More precisely, the invention provides an apparatus for use in the manufacture and recycling of paper roll cores cut to predetermined lengths to match the width of the paper web being wound about the core. 
     In the paper processing industries, raw material paper webbing is provided for use and is wound on paper roll cores. The wound paper roll core comes in all lengths and sizes and can weigh up to 8,000 lbs. The rolls are commonly transported by industrial crane such as overhead cranes. The cores receive chucks or plugs which are inserted into each end of the core to allow for the roll of raw material paper webbing to be engaged by a crane and transported, for instance, to an unwind machine for further processing. It is desirable to use paper roll cores many times to wind and unwind raw paper material. However, the plugging and transporting operation has a tendency to damage the ends of the paper roll cores, rendering the cores unusable. If the used core is not reusable the manufacturer incurs extensive problems with waste control and costs. If the damaged ends of the core are removed, the core becomes of a different length and is unusable. Thus a need exists for a reliable method to relengthen the core through the addition of a desired length of materials to the shortened core. 
     U.S. Pat. No. 6,706,133 provides an example of a proposed solution for joining the ends of cores such that the core ends are reworked to provide a straighter joined core with a cross-section of true roundness. The apparatus provides a clamp sleeve for receiving a first core section and a mandrel sleeve for receiving a second core section. The clamp sleeve is movable with regard to the center axis of the mandrel sleeve and guides are in place to force the movement of the clamp sleeve to occur coaxially with regard to the center axis of the mandrel sleeve. The ends of the core sections to be joined are worked with machining tools carried by the clamp sleeve. The machining tools rotate about the ends of the first and second core members providing machined female and male edges. After the ends of the first and second core members are machined, glue is applied to the mating surface and the clamp sleeve moves the first core member into a conjoined position with the second core member. The clamp sleeve then applies a radial pressure to the joint to secure the joining of the two core members. 
     The present invention provides an improvement over the apparatus shown in U.S. Pat. No. 6,706,133. The present invention provides an automatic core joining and cutting machine that will automatically rework and join the ends of used cores and further automatically cut the conjoined new core to a predetermined length desired by the operator for matching the width of the paper webbing raw material to be rolled onto the new conjoined core member. 
     BRIEF DESCRIPTION OF THE INVENTION 
     The core joiner and cutter apparatus of this invention is presented as three distinct units: an infeed unit, a milling unit, and an outfeed unit. The infeed and outfeed units each include pairs of rollers to support a used core member and a pusher bar for moving the used core into and out of contact with the milling unit. The milling unit includes a pair of rollers, at least one milling head, including an infeed cutter, an infeed milling bit, an outfeed cutter and an outfeed milling bit. 
     To begin operation, a used core member is positioned on the roller members on the infeed unit. The roller members may or may not be driven. The core member is pushed along the roller members toward the milling unit by a pusher bar, driven by a variable frequency drive motor. Torque control is utilized with the drive motor to monitor the force being exerted by the pusher bar. An absolute linear distance sensor is used to monitor the distance the pusher bar is driven. The linear distance sensor provides for linear measurements as to how far the core member is traveling to help determine the precise length of the core member. Positioned in parallel with the rollers is a hold down bar with a roller intended to engage the core member. The hold down bar keeps the core member in position on the rollers. The roller on the hold down bar may, in some embodiments be powered. Hold down clamps are positioned on each side of the milling unit to clamp the core member in position when the core member is being worked on by the at least one milling head. 
     After the infeed pusher bar pushes the core member into engagement with the milling unit, the infeed cutter engages the core member at a specified axial distance from the damaged end. The infeed cutter then commences the operation of cutting off the damaged end as the rollers rotate the core member. After the damaged end is removed the core member is moved into engagement with the infeed milling bit wherein an engagement surface is machined onto the clean end of the core member. 
     Simultaneously, a core remnant is positioned in the outfeed unit. An outfeed pusher bar pushes the core remnant toward the outfeed side of the milling unit. If the end of the core remnant is clean and not damaged, the end is engaged with the outfeed milling bit and an engagement surface is machined into the end. If the end of the core remnant is damaged the outfeed cutter blade engages with the core remnant to cut the damaged end off and provide a clean end surface for machining by the outfeed milling bit. 
     The infeed cutting blade, infeed milling bit and outfeed milling bit sequentially rework the ends of each core member and remnant into opposed mating configurations. Glue is applied to the infeed core member&#39;s reworked end and the outfeed side pusher bar pushes the outfeed core remnant to engage the infeed core member into a conjoined core member. 
     The outfeed cutting blade provides for the cutting of the newly joined core member at a precise distance from the core member&#39;s free end, thereby automatically providing a finished core member of specific length. Once the finished core member of specific length is complete, the finished core member is removed from the machine. The infeed side pusher bar engages the remaining new core remnant and pushes it toward the outfeed side of the machine. If the remaining core remnant is of sufficient length, it is again cut by the outfeed cutter to provide another core of specified length. If the remaining core remnant is too short to provide another core of specified length, the infeed pusher bar will push the remaining core remnant through the infeed unit. A new used core member is then placed in the infeed unit and the infeed pusher bar pushes it towards the infeed side of the milling unit. The new used core member is now positioned in the infeed unit and the new core remnant is positioned in the outfeed unit. The cutting and milling operations described above can then begin anew. 
     Preferably, the entire core joining and cutting apparatus is encased in a safety frame and the apparatus is completely controlled by electronic commands and signals through a PLC. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the core joiner and cutting apparatus of the present invention with the uppermost portion of the safety frame removed for clarity of viewing. 
         FIG. 2  is a top view of the infeed unit as used with the present invention. 
         FIG. 3  is an end view of the infeed unit of  FIG. 2 . 
         FIG. 4  is a top view of the outfeed unit of the present invention. 
         FIG. 5  is an end view of the outfeed unit of  FIG. 4 . 
         FIG. 6A  is a perspective view of the milling unit of the present invention. 
         FIG. 6B  is a front view of the milling unit of  FIG. 6A . 
         FIG. 7  is a perspective view of a pusher bar as used with the present invention. 
         FIG. 8  is a side view of the pusher bar of  FIG. 7 . 
         FIG. 9  is a perspective view of the automatic take up frame as used with the present invention. 
         FIG. 10  is a bottom view of the automatic take up frame of  FIG. 9 . 
         FIG. 11  is a perspective view of the hold down bar of the infeed unit as used with the present invention. 
         FIG. 12  is a side view of the hold down bar of  FIG. 11  showing the optional drive mechanism for the hold down roller. 
         FIG. 13  is a perspective view of a hold down clamp as used with the present invention. 
         FIG. 14  is a side view of the hold down clamp of  FIG. 13 . 
         FIG. 15  is a perspective view of the outfeed hold down and kicker bar as used with the present invention. 
         FIG. 16  is a side view of the hold down and kicker bar of  FIG. 15 . 
         FIG. 17  is a perspective view of the infeed cutter and milling head as used with the present invention. 
         FIG. 18  is a side view of the infeed cutter and milling head of  FIG. 17 . 
         FIG. 19  is a perspective view of the outfeed cutter and milling head as used with the present invention. 
         FIG. 20  is a side view of the outfeed cutter and milling head of  FIG. 19 . 
         FIG. 21  is a side view of the glue application apparatus as used with the present invention. 
         FIG. 22  is a perspective view of the glue application apparatus of  FIG. 21 . 
         FIG. 23  is a perspective view of the glue operation support roller as used with the present invention. 
         FIG. 24  is a side view of the glue support operation roller of  FIG. 23 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to  FIG. 1  the core joining and cutting apparatus of the present invention is shown. The apparatus includes a safety frame  10  which encapsulates the active machinery for safety reasons. The safety frame  10  preferably includes plexi-glass panels which completely enclose the machinery. For the purposes of clarity in  FIG. 1 , the top frame structure of the safety frame  10  has been removed to better enable viewing of the machinery components. 
     The apparatus of the invention, as shown in  FIG. 1 , includes an infeed unit A, milling unit B and outfeed unit C. 
     Referring now to  FIGS. 2 and 3 , the infeed side A of the apparatus includes a core singulator  16  which receives used cores from a storage or stacking area (not shown) and inserts the cores into the machine through a door (not shown) in the safety frame  10 . The used core rests upon motor driven infeed rollers  20 . A hold down mechanism  22  engages the core to ensure the core remains fixed in place between rollers  20  and hold down  22 . An infeed pusher bar  24  engages one end of the used core and is used to place the opposed end of the core in position proximate the milling unit B. The pusher bar  24  is positioned on rails  26  and is driven by a variable frequency drive motor  38  through a chain drive  28 . Torque control is utilized through the motor  38  and a distance sensor measures the linear movement imparted to the pusher bar  24 . The distance sensor sends signals to the electronic control or PLC (not shown) which then are used to calculate the length of the core member. Also included in the infeed unit A is a vacuum and filter unit  18  and a trash conveyor  19 . 
     Referring now to  FIGS. 4 and 5 , the outfeed side C of the apparatus carries the core remnant that has been previously machined by the milling unit B and joined and cut and is left over. The outfeed side C includes motor driven outfeed rollers  32  and outfeed hold down and kicker bar  34 . The outfeed side C further includes an outfeed pusher bar  36  driven by variable frequency drive motor  30 . Torque control is utilized through the motor  30  and an absolute linear distance sensor measures the linear movement imparted to the pusher bar  36 . The pusher bar  36  is positioned on rails  40  and will engage the distal end of the core remnant and push the core remnant to a position proximate the milling unit B. The length of the core remnant is calculated from measurements taken by the linear distance sensor of the distance traveled by the pusher bar. 
     Referring now to  FIGS. 6A and 6B  the milling unit B includes rollers  21  for supporting the used core and core remnant and core clamps  49  for maintaining the used core and core remnant in position as they are being machined. The milling unit B also includes an infeed cutter and milling head and an outfeed cutter and milling head. The infeed cutter and milling head includes a cutting blade  79  driven by drive motor  80  through belt  81 . The infeed cutting blade  79  is mounted on a vertical slide  78  that allows for the cutting blade  79  to be moved into and out of engagement with the end of the used core. The infeed milling bit  13  is attached to a servo cylinder  86  that automatically positions the depth of the infeed cutting blade  79 . The servo cylinder  86  then provides an automatic adjustment of the cutting blade  79  to accommodate cores of varying diameters and wall thicknesses based upon signals received from the PLC. The outfeed cutting blade  98  and milling bit  117  is driven by drive motor  100  through belt  101 . The drive motor  100  and belt  101 , cutting blade  98  and milling bit  117  are mounted on a vertical slide  90  for movement of the cutting blade  98  into and out of engagement with the surface of the core remnant. A horizontal slide  93  is provided to allow the milling bit  117  to move around the end of the core remnant and position itself inside the core remnant. A tracker assembly  95  senses the exterior surface of the core remnant and uses air cylinder  87  to extend the milling bit  117  clear of the end of the core remnant and return the milling bit  117  into engagement with the interior surface of the core remnant. 
     Further attached to the frame of the milling unit is the glue applicator  107  which includes a sensor for determining the surface of the milled end of the used core and a sensor for determining the complete application of glue to the milled surface of the used core. A glue applicator support roller  115  is located beneath the core and includes a piston and cylinder assembly  113  that extends to place the glue support roller  115  into contact with the outside surface of the used core and the core remnant as they are pushed into a mating and conjoined relationship. 
     Referring now to  FIGS. 7 and 8 , the pusher bar  24  as used on both the infeed unit A and outfeed unit C is shown in detail. The pusher bar  24  includes a pusher head  65  engaged to a frame  66 . The frame carries cam followers  67  for engagement with the rails  26 . Further engaged with the frame  66  are chain connectors  68  designed to engage the drive chain to provide movement for the pusher bar  24 . Wear bars  69  are provided to prevent undo wearing of the chain and pusher frame chain connector engagement. 
     Referring now to  FIGS. 9 and 10 , the automatic take up frame  39  for the pusher bar is shown in detail. There is an automatic take up frame positioned on both the infeed unit A and the outfeed unit C. The automatic take up frame  39  includes a variable frequency drive motor  30 ,  38  engaged to gear sprockets  59  by means of gear box  60  and drive shaft  61 . The gear sprockets  59  engage a chain drive (not shown) which in turn is engaged with the pusher bar  24 ,  36 . Preferably the motor  38  on the outfeed unit C controls pusher bar  24  on the infeed unit A and motor  30  on the infeed unit A controls pusher bar  36  on the outfeed unit C. Operation of the variable drive motor  30 ,  38  motivates the chain drive to move the pusher bar  36 ,  24  into and out of engagement with the core segments. A take up mechanism for removing slack from the chain drives includes a pair of idler rollers  62  engaged with an air stroke actuator  63 . The idler rollers are moved by the air stroke actuator  63  to engage the chain drive and remove slack therefrom. The automatic take up frame  39  is mounted on the core joiner frame through mounting brackets  64 . 
     Referring now to  FIGS. 11 and 12  the hold down mechanism  22  that is used on the infeed unit A is shown in detail. The hold down mechanism  22  includes a frame  41  mounted on the core joiner frame, carrying roller  42 . In some embodiments, roller  42  is not powered. In the embodiment shown in  FIGS. 11 and 12 , the roller  42  is powered and is engaged to a motor  43  through a drive belt  44  that in turn is carried by a series of idler sprockets  45  designed to maintain tension in the drive belt  44 . A pneumatic cylinder  46  is engaged with the frame  41  by means of a plunger rod  47  and pivot pin  48 . As shown in  FIG. 12 , operation of the pneumatic cylinder extends and retracts the drive roller  42  for engagement with the outside surface of the core. 
     Referring now to  FIGS. 13 and 14 , the core clamp  49  is shown in detail. There is a core clamp  49  positioned on both ends of the milling unit B. The core clamp  49  are designed to hold the used core and core remnant in an axially fixed position while they are being rotated and machined by the milling unit B. The core clamp  49  includes a slider bar  52  positioned and mounted on linear bearings  53 . A clamp plate  54  is positioned on the slider bar  52  and carries rollers  54  for engagement with the outer surface of the cores. Pneumatic cylinders  55  are positioned on cylinder mounting brackets  51  and are engaged with the slider bar  52  by means of pistons  57 . When energized by the pneumatic cylinders  55  the slider bar  52  moves the rollers  54  into and out of engagement with the cores by moving the slider bar  52  up and down the linear bearings  53 . 
     Referring now to  FIGS. 15 and 16 , the hold down and kicker bar  34  of the outfeed unit C includes a support frame  50  mounted on the core joiner frame and positioned proximate the outfeed rollers  32 . The support frame  50  carries hold down roller  51 . A pneumatic cylinder  83  is engaged with the support frame  50  by means of a plunger rod  84  and pivot pin  85 . As shown in  FIG. 16 , when the piston  84  is extended the frame  50  rotates to disengage the hold down roller  51  from the surface of the core remnant. Retraction of plunger rod  84  by cylinder  83  pulls the hold down roller  51  into engagement with the surface of the core remnant. The support frame  50  further carries kicker bars  74 , pivotally engaged thereto. Pneumatic cylinders  75  are engaged with the kicker bars  74  via pistons  76  and pivot pins  77 . When the pistons  76  are extended from the cylinders  75  the kicker bars  74  rotate about pivot pins  77  to push the new core member from the outfeed unit C for transfer to a core stacking bin (not shown). 
     Referring now to  FIGS. 17 and 18 , the infeed cutter and milling head  12  is shown in detail. The cutter portion of the infeed cutter and milling head is mounted for movement on a vertical slide  78 . The cutter portion includes cutting blade  79  engaged with a drive motor  80  through belt  81 . The used core is rotated by the infeed rollers  20  and the cutting blade  79  is automatically positioned by the servo cylinder  89  to come into engagement with the outer surface of the used core, thereby enabling the cutting blade  79  to cut off the damaged end which drops onto the trash conveyor  19  ( FIG. 2 ). The infeed milling bit  13  is engaged with a pneumatic cylinder  89  by means of a pivot arm  88 . After the cutting blade  79  has removed the damaged end of the used core the servo cylinder  89  extends to place the milling bit  13  into engagement with the newly cut end of the used core. The servo cylinder  89  provides depth control for the milling bit  13 , enabling it to mill a smooth mating surface on the end of the used core. 
     Referring now to  FIGS. 19 and 20 , the outfeed cutting tool and milling head  14  is shown in detail. The outfeed cutting tool and milling head is designed for movement in both the vertical and horizontal direction with respect to the core remnant. The outfeed cutting tool and milling head performs operations on the core remnant that is positioned in the outfeed unit C. The outfeed cutting tool and milling head moves vertically on slide  90  by means of cylinder  91  and piston  92  combination. The outfeed cutting tool and milling head  14  moves horizontally with respect to the core remnant on slide  93  through motion imparted by cylinder  94 . Tracking assembly  95 , designed to sense and engage the outer surface of the core remnant uses an air cylinder  94  to extend the milling bit  117  past the end of the core remnant. The milling bit  117  is then moved vertically and moves into the interior of the core remnant. The cutting and milling head  14  includes cutting blade  98  and mill bit  117  driven by drive motor  100  through belt  101 . The core remnant is rotated by the outfeed rollers  32  and the cutting blade  98  cuts off the damaged end which drops onto the trash conveyor  19  ( FIG. 3 ). After the cutting blade  98  has removed the damaged end of the core remnant, the cutting and milling head  14  is moved horizontally by air cylinder  94  with respect to the end of the core remnant to a position wherein the milling bit  117  can safely clear the core remnant&#39;s clean end for placement into the interior of the core remnant. The milling and cutting head  14  is lowered vertically on slide  90  to place the milling bit  117  into the interior of the core remnant and then is moved horizontally to place the milling bit  117  into engagement with the interior surface of the clean end of the core remnant. A mating surface is then milled into the inside surface of the new clean end of the core remnant, using wheel  99  as a guide to determine the depth of the cut. 
     Referring now to  FIGS. 21 and 22 , the automatic glue applicator is shown in detail. The applicator is mounted on the core joiner frame by bracket  102  and slide  103 . A cylinder  104  and piston  105  combination is engaged between the bracket  102  and the applicator mounting plate  106 . The applicator  107  is fixed on the applicator mounting plate  106  by piston  105 . The glue applicator  107  includes a valve  108  intended for engagement with a hose (not shown) which feeds glue to the applicator  107 . The applicator ( 107 ) further includes an application nozzle  109  and sensor  110  for sensing the surface of the milled end of the used core. A second sensor  112  monitors the application of glue to the milled end of the used core as the used core is turned by the infeed rollers  20  and discontinues the flow of glue when the entire circumference of the milled end of the used core has received glue. 
     Referring now to  FIGS. 23 and 24  the glue application support roll is shown in detail. The glue application support roll includes a frame  112  engaged with the core joiner frame by cylinder and piston combination  113  and bracket  114 . The frame carries a coated roller  115 . The roller is preferably coated in neoprene or some other coating impervious to the glue being applied to the used core. When the milled used core has received glue and is positioned to be joined with the milled core remnant the cylinder  13  extends its piston and places the roller  115  in contact with the joined core remnants as the core remnants are rotated and pressed together. The roller  115  removes excess glue from the seam of the joined remnants. 
     The sequence of operation for the core joining and cutting apparatus is as follows. The infeed side A of the apparatus receives a used core from the core singulator  16 . The used core is engaged by the pusher bar  24  and pushed toward the infeed cutting and milling head  12 . An electronic photo eye (not shown) positioned proximate the infeed cutting and milling head  12  sees the front edge of the used core and signals the PLC to stop movement of the pusher bar  24 . The infeed cutting and milling head  12  is moved over the used core end, wherein the infeed cutting blade  79  is moved into engagement with the outer surface of the used core and cuts through the core surface as the used core is rotated by the infeed rollers  20 , allowing the damaged end of the used core to be removed. The cutting blade  79  is moved out of engagement with the used core and the infeed milling bit  13  is moved into engagement with the freshly cut end of the used core. The infeed milling bit  13  engages the outer surface of the freshly cut end of the used core and mills the end to a given depth based upon the wall thickness of the core and other variables such as bit wear, etc. The infeed milling bit  13  then disengages from the core and the glue applicator  107  applies glue to the surface of the milled outer surface of the used core. The thermal scanner ensures that the glue has been properly applied to the milled outer surface of the core. 
     Preferably, at the same time the used core is being worked on at the infeed unit, a core remnant positioned on the outfeed unit of the apparatus is being prepared to receive a milled end. The outfeed cutting blade  98  is moved into engagement with the core remnant outer surface and cuts through the core remnant surface as the core is rotated by the outfeed rollers  32  thus allowing the damaged end of the core remnant to be removed. The outfeed cutting blade  98  is moved out of engagement with the core remnant and the outfeed milling bit  117  is moved into position in the interior of the core remnant. The outfeed milling bit  117  clears the cut edge of the core remnant through movement on slides  90  and  93 . The outfeed milling bit then mills the interior surface of the freshly cut end of the core remnant to a given depth based upon the wall thickness of the core and the diameter of the wheel  99 . The milled end of the core remnant is then pushed by pusher bar  36  into engagement with the glued surface of the newly milled used core positioned in the infeed side of the milling unit. The force with which the core remnant is pushed to engage the glued milled surface of the used core is dependant upon the wall thickness and size of the core. The PLC sets the force by monitoring the torque measured by motor  30 . 
     The conjoined core is then pushed a specified distance as defined by the linear distance sensor to a position proximate the outfeed cutting blade  98 . A new conjoined core of specified length is then cut and removed from the outfeed side of the apparatus. The pusher bar  24  is then driven to push the remaining conjoined core further toward the outfeed side. If the linear distance sensor detects that the remaining conjoined core is long enough to cut and produce a new core of specified length, the pusher bar  24  further to the outfeed side stops and the outfeed cutting blade  98  again cuts the conjoined core. If the remaining conjoined core is of insufficient length to produce a new core of specified length, the pusher bar  24  is driven to push the now new core remnant to a position wherein the opposed uncut end of the new core remnant is adjacent the outfeed cutting blade  98 . The infeed side of the apparatus receives a new used core and the simultaneous infeed and outfeed cutting and milling operations start anew. While the preferred sequence of operation is explained herein as simultaneous infeed and outfeed operations, it is acknowledged that the infeed and outfeed operations may also be sequential. 
     The above detailed description of the present invention is given for explanatory purposes. It will be apparent to those skilled in the art that numerous changes and modifications can be made without departing from the scope of the invention. Accordingly, the whole of the foregoing description is to be construed in an illustrative and not a imitative sense, the scope of the invention being defined solely by the appended claims.