Patent Description:
<CIT> discloses an apparatus for machining wooden beams with a drive means having a tool holding means for selectively accommodating different tools wherein the drive means is displaceable into a tool magazine for receiving or delivering a tool.

From <CIT> there is known a system as defined in the preamble of claim <NUM> and a method as defined in the preamble of claim <NUM>.

The exemplary system <NUM> described below and shown in the drawings includes an array <NUM> that interfaces with a saw <NUM> and provides blades <NUM> for a cutting arm <NUM> of the saw through a plurality of storage units <NUM> arranged in the array. Each storage unit <NUM> in the array <NUM> is configured to store a blade <NUM> for the saw <NUM>. The saw <NUM> may be configured to cut tissue logs <NUM> entering a saw house <NUM> on a conveyor <NUM>. In a general sense and as further modified as described below, the saw <NUM> and the cutting arm <NUM> may be of the type, for instance, as shown by way of example and not in any limiting sense, in <CIT>, <CIT>, and <CIT>. The array <NUM> of storage units <NUM> could thus contain many blades <NUM> for the saw <NUM> for a particular saw cutting operation or procedure as may be required by the application. As will be described below, each storage unit <NUM> is configured to store, receive, and transfer the blade <NUM>, whether a new blade, an expired blade, or partially-used blades for later use. The array may move in a direction generally parallel to the saw blade center axis. The movement may be independent of the saw or the array may move once coupled with the saw <NUM>. In addition or alternative, the storage units in the array may move in a direction generally parallel to the saw blade center axis relative to the saw once the array is coupled to the saw. In addition or alternative, the storage units may be stationary in the direction of travel of the saw blade center axis once the array is coupled with saw, and the saw may move as necessary. In each case, the array and/or storage unit may move, as needed to receive an expired blade, and load and mount a next-in-queue blade for use on the saw cutting arm. As used herein, the term "expired" means that the blade condition is used such that it is no longer suitable for the particular processing operation currently being conducted on the saw, and not necessarily that the blade is to be scrapped, and the term "new" means blades that have been readied for a particular saw processing operation, and not necessarily that the blades are new from a vendor or supplier or have never been used.

The array <NUM> may comprise a housing <NUM> configured to hold the plurality of storage units <NUM>. The array <NUM> may be portable and may be detachably mounted to the structure comprising the saw <NUM> and saw house <NUM>. An interface <NUM> may be built into a wall panel or other structural member of the saw house <NUM> to provide a detachable mount for the array <NUM> of storage units <NUM>. The interface <NUM> may allow the array <NUM> to be physically, mechanically, electrically, and/or electronically detachably mounted to a wall panel or other structural member of the saw house <NUM>. A system of cooperating connectors, for instance, pneumatic or hydraulic actuators <NUM> may engage with each and/or cooperate to secure the array <NUM> to the saw housing <NUM>. The interface <NUM> may provide a connection point <NUM> for the array <NUM> to mechanically connect with the saw. For instance, in one embodiment, the array may have a linkages or mechanical actuators that connect with cooperating linkages or mechanical actuators on the saw via the interface, thereby allowing the linkages on the array to be actuated via the saw. In other words, the linkages on the array may connect with linkages on the saw when the array is detachably mounted to the saw, so the linkages on the array are an extension of those on the saw. In this manner, movement of the storage unit between the retracted and extended position, and actuation of the storage unit blade tool holder receptacle, all of which will be described below, may be accomplished via mechanical linkages extending from the saw to the array. This would dispense with the need to provide electronic control systems on the array. In addition or alternative, the array <NUM> may be configured to draw electrical power and/or pneumatic or hydraulic fluid sources from the saw <NUM>. The array <NUM> may also have an on-board rechargeable battery to power electrical and electronic equipment on the array or draw electrical power from another external source (not shown). The array <NUM> may also be equipped with pneumatic or hydraulic actuators. The interface <NUM> and the connection point <NUM> may be configured to supply the array <NUM> with pneumatic or hydraulic fluid from the saw. The array <NUM> may also draw pneumatic or hydraulic fluid from the facility through external connections (not shown). The array may also have on board pumps to supply pneumatic or hydraulic fluid to respective components on the array. Accumulators, valves, and other conventional equipment needed for pneumatic or hydraulic actuation systems may be provided on the array, as applicable. As will be explained below in greater detail, the array <NUM> may also be electronically coupled to the saw <NUM> at the interface <NUM> and connection point <NUM> so control signals generated by the saw may be transmitted to the array for certain array based functions, and signals from the array may be transmitted to the saw for certain saw based functions. The transmission may be through a network <NUM> and may be wireless <NUM>. The array <NUM> of storage units <NUM> may be provided in the form of a cart with wheels (e.g., swivel casters) <NUM> that may be maneuvered to a position that allows the cart to mount directly with the saw house <NUM> via the interface <NUM>. The movement may be manual or automated via a track or other guidance system. The array of storage units in the form of a rolling cart allows the array to be maneuvered into the tight spaces on the converting floor that are usually found around the saw house and structure of the saw.

Once all the blades in the array of storage units are expired, the array of storage units can be unmounted from the saw house and transported to an area where blade disposition occurs. The blade disposition location is preferably not on the converting floor, but in a more remote area with plenty of space, lighting, and other support for safe handling and disposal of the expired blades.

For a saw or saw cutting process, two or more portable arrays of storage units may be provided. For example, once all the blades in the "in use" array of storage units are expired (e.g., of an unusable diameter for the particular processing operation currently being conducted), the second fully stocked array of storage units with new blades may be brought online, mounted to a wall panel or other structural member of the saw house via the interface, and quickly exchanged with the array of storage units with the expired blades. In this way, the restocking of the array of storage units reduces potential operational bottlenecks in the saw cutting operation.

In another aspect, the arrays may be part of a subscription system provided by a supplier. The supplier may have multiple arrays that may be provided to a customer for use. When the blades in a particular array are expired, the customer may return the array to the supplier for a new array of blades. The array may form a part of a shipping container to allow transport of the array between the supplier and the customer. Once an array is returned to the supplier, the array may be restocked with new or refurbished blades and calibrated for reuse. Functional aspects of the array may be checked and repaired as necessary. The supplier may collect and analyze blade operational data from returned arrays and provide recommendations and service bulletins in connection with the array or saw to customers. The data collection and analysis may be used for general product improvement.

The array <NUM> of storage units <NUM> may have a power supply, sensors, motion detectors, a computer processor, a memory storing data, and computer equipment that allows the array to connect to the network <NUM> with a like or another computer system or programmable logic control for the saw via the interface <NUM> and the connection point <NUM>. The array memory may store data structures of information <NUM> regarding the blades that are currently stored in the unit. Each storage unit <NUM> may also be equipped with like equipment so the blade information is maintained at the storage unit level. In one example, the array and/or the storage unit may be configured with a RFID device (e.g., a label or tag). The saw <NUM> may be configured to read and/or write to the RFID device on the array, storage unit or blade. The information <NUM> may include blade diameter, blade material, last saw cutting operational data, last inspection, last sharpening, last run-time, cumulative run-time, etc. The blade information <NUM> may also include information about a specific blade or storage unit that should be bypassed in the array and not used in the saw cutting operation because of a maintenance condition or expired inspection status. Information <NUM> regarding a blade may be transferred on the network <NUM> between the saw <NUM> and the array <NUM> so the array may correlate specific information about a blade and a storage unit <NUM>. Information <NUM> from the saw <NUM> may be downloaded to the array <NUM> so the array stores information about each blade and its respective storage unit <NUM>. The download of information may occur during operation with the array connected to the saw and/or prior to removing the array from the saw. The download of information <NUM> may occur via the network <NUM> or via the interface <NUM> and the connection point <NUM>. Information <NUM> including blade data from the array <NUM> may also be uploaded to the saw <NUM> once the array is mounted to the saw at the interface <NUM>. The upload of information <NUM> may occur via the network <NUM> or via the interface <NUM> and the connection point <NUM>. Storing information about each blade via the array allows for the reuse of blades. For instance, a blade that has been previously used in connection with processing large diameter rolls may still have a diameter sufficient to allow processing for smaller diameter rolls. If a blade became too small for a particular product or processing operation at the time it was in use, it could be retrieved and used again in connection with a subsequent product or processing operation. An array of storage units containing partially used blades could be used in a different saw cutting operation, and the array or storage unit RFID label information may be uploaded to the saw so that the saw and array may synchronize (and/or the storage units may sequence) in a manner necessary to mount the correct diameter blade for the desired process.

Each blade <NUM> may define a plane <NUM> (<FIG>) with one side facing the cutting arm <NUM> of the saw <NUM> and the opposite side of the plane facing the storage unit <NUM>. Each blade <NUM> may be configured with a tool holder <NUM> on the saw cutting arm <NUM> facing side of the plane <NUM> and a tool holder <NUM> on the storage unit <NUM> facing side of the plane. The saw <NUM> may be configured such that the saw cutting arm <NUM> has a tool holder receptacle <NUM> adapted and configured to engage the blade tool holder <NUM> on the saw facing side of the blade. Each storage unit <NUM> may have a tool holder receptacle <NUM> adapted and configured to engage the tool holder <NUM> on the storage unit <NUM> facing side of the blade. Each storage unit <NUM> may be configured to store the blade in a generally vertical configuration such that the axis of rotation <NUM> (<FIG>) of the stored blade is generally horizontal and parallel to the direction of the log travel <NUM> (<FIG>). The array <NUM> may also include one or more empty storage units <NUM>' (<FIG>, <FIG>) to the extent the saw already has one or more blades already mounted in the saw. Each storage unit <NUM> may have a hollow interior sufficient to accommodate the geometry of a blade <NUM> and an opening into the hollow interior sufficient to expose the storage unit tool holder receptacle <NUM> and allow the blade to be received in the hollow interior of the storage unit. The tool holder receptacle <NUM> of the storage unit <NUM> secures the blade in the hollow interior to prevent unwanted movement of the blade in the storage unit. The tool holder receptacle <NUM> in the storage unit may be similar or cooperate with the tool holder receptacle <NUM> used on the saw cutting arm to make exchange between the saw cutting arm and the storage unit simple and universal. In one example, the blade <NUM> may be secured on the saw arm <NUM> and inside the storage unit <NUM> with a collet mechanism. In this example, the blade tool holder <NUM>,<NUM> may comprise a male end of a collet that is mounted on both sides of the center of the blade <NUM> at the blade cutting axis <NUM> (<FIG>), and both the saw arm and the storage unit tool holder receptacles <NUM>,<NUM> may comprise the cooperating female portion of the collet mechanism. The collet mechanism on the saw arm <NUM> and the storage unit <NUM> may oppose each other when the storage unit is brought into register with the saw cutting arm. In other words, the male collet on one side of the blade may interface into the saw arm and the male collet on the opposite side of the blade may be for interface into the storage unit. In the alternative to a collet mechanism, the tool holder receptacle on the storage unit or saw cutting arm may be a chuck mechanism, a jaw-chuck mechanism, or other cooperating system of tapered sleeves configured to receive an arbor, tapered sleeve or fixture mounted to the saw blade.

<FIG> illustrate an exemplary sequence of operations to remove an expired blade from the saw arm <NUM> and to install the new, next in queue stored blade <NUM>' onto the saw arm. The array <NUM> may be configured such that motion of one storage unit in the array may be independent of the motion of another storage unit. For instance, each storage unit <NUM> of the array may be configured to move linearly from the array into the saw house <NUM> independently of another storage unit. In addition, the array of storage units <NUM> may also be configured to move in the direction of log travel <NUM>. When a blade exchange needs to be performed, the saw cutting arm <NUM> may go to a pre-determined position, for instance, left of the cutting gap <NUM> (<FIG>) in the conveyor <NUM>. The empty storage unit <NUM>' in the array of storage units may move from the retracted position in the array (<FIG>) to the extended position away from the array and into the saw house such that the empty storage unit is placed in alignment with the saw cutting arm as shown in <FIG>. Then, as shown in <FIG>, the entire array <NUM> of storage units <NUM> may move the appropriate distance in a direction <NUM> parallel to the direction <NUM> of the travel of the log <NUM> to bring the empty storage unit <NUM>' to a position immediately adjacent to the saw cutting arm <NUM>. As shown in <FIG>, the tool holder receptacle <NUM> on the empty storage unit <NUM>' may then secure the blade tool holder <NUM> on the storage unit side of the blade <NUM>. At this point, the storage unit <NUM> may be physically connected to the saw <NUM>. As shown in <FIG>, the saw cutting arm tool holder receptacle <NUM> may then release the blade tool holder <NUM> on the saw cutting arm <NUM> side of the blade <NUM>. At this point, the transfer of the blade from the saw cutting arm to the storage unit is complete. As shown in <FIG>, the array <NUM> of storage units <NUM> may then move away from the saw arm <NUM> in a direction <NUM> parallel to the log travel direction <NUM> a distance sufficient to enable the tool holder <NUM> extending from the saw cutting arm side of the blade <NUM> to clear from the saw cutting arm <NUM>. As shown in <FIG>, once clear, the storage unit <NUM> may move from the extended position in the saw house <NUM> to the retracted position back into the array <NUM>.

To load the new, next in queue blade <NUM>', the selected storage unit <NUM>" will move from the retracted position within the array <NUM> to the extended position away from the array into the saw house <NUM>, as shown in <FIG>. Then, as shown in <FIG>, the array <NUM> of storage units will move the appropriate distance in the direction <NUM> to interface and engage the tool holder <NUM> on the saw side of the blade <NUM> to the tool holder receptacle <NUM> on the saw cutting arm <NUM>. As shown in <FIG>, the saw cutting arm tool holder receptacle <NUM> will secure the blade tool holder <NUM> on the saw cutting arm side of the blade. At this point, the storage unit <NUM> and saw <NUM> are connected. As shown in <FIG>, once secured on the saw arm <NUM>, the storage unit tool holder receptacle <NUM> will release the blade tool holder <NUM> on the storage unit <NUM> side of the blade <NUM>'. As shown in <FIG>, the entire array <NUM> of storage units <NUM> may move in the direction <NUM> a distance sufficient to allow the tool holder <NUM> of the storage unit <NUM> side of the blade <NUM>' to clear the storage unit. As shown in <FIG>, once clear, the storage unit <NUM> may retract back into the array <NUM> of storage units. The retracted storage unit <NUM> is now considered the empty storage unit in the array of storage units and will be the next storage unit to receive an expired blade as shown in <FIG>. Equipped with the next in queue blade <NUM>', the saw <NUM> can resume cutting operations. The sequence of exchange may reoccur until all the blades in the array of storage units are expired. At this point, a new array of storage units with a complement of new blades may be swapped out with the array of expired blades. Although the description and drawings show the saw cutting arm and storage unit with a tool holder receptacle comprising a female collet portion and the blade tool holder comprising a male collet portion extending from the saw side of the blade and storage side of the blade, the features may be reversed.

The array <NUM>, the storage unit <NUM>, or the saw <NUM> may be configured with a blade cleaner <NUM> to allow for cleaning of the blade <NUM>. <FIG> shown one embodiment where the storage unit <NUM> of the array is provided with the blade cleaner <NUM>. In this configuration, the blade cleaner <NUM> may be provided with a cleaning member <NUM> for engaging one or both sides of the blade <NUM> and removing adhesive or other residue from the saw cutting operation. The cleaning member <NUM> may comprise a brush, a moistened pad, or sponge. Cleaning fluid may be provided to the cleaning member to assist in the cleaning. As shown in <FIG>, the cleaning member <NUM> may be mounted on a slide <NUM> having a fixed portion operatively mounted to a side wall or structural member of the array <NUM> or storage unit <NUM> and an extension portion slidably connected to the fixed portion to move between a retracted position (<FIG>) in which the cleaning member <NUM> is spaced from the blade <NUM>, and an extended position (<FIG>) in which the cleaning member engages the blade for cleaning the blade. The slide <NUM> may be driven with an actuator <NUM> (e.g., electric, pneumatic, hydraulic) or electric motor and screw (e.g., ball screw, lead screw). The storage unit <NUM> may be configured to rotate the blade via the blade tool holder <NUM> while the slide <NUM> is in the extended position and the cleaning member <NUM> is engaging the blade <NUM> so as to allow the edge of the blade and a radial distance inward from the edge of the blade to be cleaned. The cleaning may occur on both sides when a cleaning member is positioned on each side of the blade. A fiber optic sensor (not shown) or feedback position (e.g. encoder) may be used to sense the blade edge and provide signals to the actuator for controlling motion of the slide <NUM> and the positioning the cleaning members <NUM> relative to the blade edge, thereby allowing the blade cleaner <NUM> to extend the slide <NUM> and the cleaning member <NUM> at varying distances to clean various diameter blades and to prevent cleaning member from extending too far and the blade <NUM> from adversely impacting the cleaning member and/or slide. In the alternative to that shown in <FIG>, the cleaning member <NUM> may be fixed in position within the array or storage unit. As the storage unit is cycled between the extended and retracted positions, the cleaning member may engage and clean the blade as the blade is moved within the storage unit between the extended and retracted positions. The cleaning operation may occur prior to moving a blade from the storage unit to the saw, for instance, as the storage unit moves from the retracted position within the array to extended position, the cleaning member may engage the blade. The cleaning operation may also occur after the blade is transferred from the saw to the storage unit, for instance, as the storage unit moves from the extended position after receiving the blade from the saw to the retracted position within the array, the cleaning member may engage the blade. The saw may also transfer the blade to the storage unit during the saw cutting operation for purposes of cleaning. For instance, the saw may transfer the blade to the storage unit and allow the storage unit to cycle between the extended and retracted positions repeatedly as needed until the blade is cleaned at which point the blade may be returned to the saw via the storage unit and back into service in the cutting operation. The blade may also be rotated in the storage unit (whether in the extended position or retracted position) so as to allow the cleaning member to engage the blade. The cleaning member may also move with rotational or translational motion relative to the blade when engaging the blade for cleaning operations.

Claim 1:
A system (<NUM>) comprising a tissue log cutting saw (<NUM>) and a blade storage array (<NUM>, wherein the saw (<NUM>) has:
a cutting arm (<NUM>) with a tool holder receptacle (<NUM>) for holding a circular saw blade (<NUM>) for the saw (<NUM>) and a saw house (<NUM>);
the circular saw blade (<NUM>) being rotatable about a center axis on the saw cutting arm (<NUM>);
the blade center axis being generally parallel to a direction of travel of the tissue log (<NUM>) through the saw;
the array (<NUM>) comprising a housing (<NUM>) holding a plurality of storage units (<NUM>);
each storage unit (<NUM>) for storing a circular saw blade (<NUM>) for the saw (<NUM>);
each storage unit having a tool holder receptacle (<NUM>) for holding a circular saw blade (<NUM>);
characterized in that:
the array (<NUM>) is detachably mountable to a structure of the saw; and
each storage unit (<NUM>) is moveable perpendicularly to the saw blade center axis in a linear movement from the array (<NUM>) into the saw house (<NUM>).