Information
-
Patent Grant
-
6601291
-
Patent Number
6,601,291
-
Date Filed
Thursday, June 14, 200123 years ago
-
Date Issued
Tuesday, August 5, 200321 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Vidovich; Gregory
- Omgba; Essama
Agents
-
CPC
-
US Classifications
Field of Search
US
- 029 33 K
- 029 33 P
- 029 33 T
- 029 282
- 029 430
- 029 512
- 029 564
- 029 5641
- 029 711
- 029 712
- 029 721
- 029 722
- 029 798
- 425 392
- 425 394
-
International Classifications
-
Abstract
A core board forming apparatus includes a feeding apparatus for sensing and dispensing tubular cores at predetermined dispensing positions. A compression apparatus receives and detects the tubular cores and flattens and secure at least two flattened tubular cores together. A controller unit controls the operation of the feeding apparatus and the compression apparatus. The presence of first tubular core is detected after the step of dispensing. In response to detecting the first tubular core is substantially flattened. A core board product includes at least two substantially flattened paper cores fastened together by integral fastening members having two fastening portions extending directly through the flattened cores.
Description
FIELD OF THE INVENTION
The present invention generally relates to a board made from cores, and more particularly to cores used to accommodate a roll of paper in manufacturing paper products.
BACKGROUND OF THE INVENTION
In producing commercial paper products, large paper rolls are shipped in locomotive rails cars to paper processing plants. In general, the center of the paper rolls contain a 10-foot long “elongated tubular core” made of liner paper much like a tube found in a toilet tissue roll or a tube in wrapping paper. In the large paper rolls, the typical tubular core is five inches in diameter having about a one-half inch wall thickness. The paper processing plants use the paper rolls as input material for processing machines that produce a variety of paper products for the residential and commercial markets. In processing, the paper is unwound from the elongated tubular core of the respective paper roll and the core is typically discarded in a landfill after use.
In the past, a core board machine included a pneumatic press in which tubular cores were flattened between two compression plates. Core board was produced by manually placing a core between a stationary plate and a movable plate, which extended towards the stationary plate to flatten the core. The movable plate retracted and one or two cores were manually placed between the plates and flattened against the first core. While the moveable plate was extended, an operator manually positioned a screw gun to fasten several screws into the compressed cores to hold them together. The machine was labor intensive, had limited ability to produce a large quantity of core board product, and was expensive to manufacture.
Core board has been used as a packing material to protect large paper rolls from damage during transport in rail cars. However, there is a risk that the pointed end of the screws may protrude through the compressed cores and tear the paper rolls during shipment in the rail cars. Further, the screws can have a reduced fastening performance by loosening overtime. Accordingly, there was a need to prevent separation of the compressed cores so that the performance was consistent for the purpose of a packing material. Since the search is always on for improved products and lower costs, there is a particular need for an apparatus and a method of producing an improved core board product.
BRIEF SUMMARY OF THE INVENTION
Briefly, the present invention improves the art by providing an advanced core board forming apparatus, a method of making core board product and a core board product.
According to one aspect of the invention, a core board forming apparatus includes a feeding apparatus having a discharge portion for discharging a tubular core. A compression apparatus has a compression surface and a flattening surface movable together to flatten the tubular core. A conveying portion supports the tubular core at an interim location between the compression surface and the flattening surface in an uncompressed condition and releases the tubular core to the flattening surface when the compression surface and flattening surface move together to a closed position. A controller unit is configured to control the feeding apparatus and the compression apparatus. In this way, tubular cores are positioned by the conveying portion to substantially align and form a consistent core board product.
In a second aspect of the invention, a dispensing apparatus includes a device for detecting tubular cores at a predetermined dispensing position for sequentially dispensing each of the cores. A compression apparatus has a compression member for substantially flattening each of the dispensed tubular cores and a plurality of pivotable members configured to retain each of the dispensed cores below the compression member for conveyance to a flattening plate upon downward contact with the compression member. A processor unit is configured to execute computer readable code for controlling the dispensing apparatus and the compression apparatus.
In a third aspect of the invention, a method of making core board product is under the control of a processing unit. A first tubular core is dispensed to a conveying portion to support the first tubular core at an interim location. The first tubular core is conveyed to a flattening position under pressure of a compression member. The first tubular core is substantially compressed between the compression member and a flattening surface. The steps of dispensing, conveying, compressing is repeated for at least a second tubular core. The second tubular is substantially compressing core against the first tubular core. Then the substantially compressed first tubular core and second tubular core are fastened together in an abutting relationship with a plurality of fastening members so as to form the core board product.
A first tubular core is dispensed to a conveying portion above a compression surface. The first tubular core is conveyed under downward pressure to the compression surface after detecting the presence of the first tubular core on the conveying portion. The first tubular core is substantially compressed on the compression surface. The steps of dispensing, conveying, compressing is preformed for at least a second tubular core in which during the step of compressing the compressed first tubular core and second tubular core are fastened with a plurality of fastening members so as to form the core board product.
In a fourth aspect of the invention, a core board product includes at least two substantially flattened tubular paper cores fastened together by a plurality of fastening members, the fastening members each has a first fastening portion contacting against only one of flattened cores and two second fastening portions extending through the flattened cores substantially perpendicular to the first fastening portion. In this way, the core board product prevents tearing abutting paper rolls during transportation.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary of the invention as well as the following detailed description of the invention considered in conjunction with the accompanying drawings provides a better understanding of the invention, in which like reference numbers refer to like elements, and wherein:
FIG. 1
is a schematic front elevational view of an apparatus for forming core board product according to the teachings of the present invention;
FIG. 2
is a schematic front elevational view of the apparatus of
FIG. 1
with a front portion removed to reveal components inside of the apparatus;
FIG. 3
is a schematic side elevational view of the apparatus of
FIG. 1
according to the teachings of the present invention;
FIG. 4
is an enlarged fragmentary side view of a discharging portion of the apparatus shown in
FIG. 1
;
FIG. 5
is a side sectional view of the apparatus of
FIG. 1
;
FIG. 6
is a schematic diagram of a controller unit of the apparatus of
FIG. 1
;
FIGS. 7-10
are side sectional views of the apparatus of
FIG. 1
illustrating a functional sequence according to the teachings of the present invention;
FIG. 11
is a schematic perspective view of an embodiment of a core board product according to the teachings of the present invention;
FIGS. 12A and 12B
are schematic sectional views of alternative fastening arrangements of the core board product shown in
FIG. 11
taken along line
12
—
12
.
FIG. 13
is a fragmentary schematic top plan view of a bottom portion of the apparatus of
FIG. 1
illustrating grooves and openings for control devices.
FIG. 14
is a schematic side elevational view of an embodiment of a core cutting apparatus; and
FIG. 15
is a fragmentary perspective view of a cutting device of the apparatus of FIG.
14
.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-12A
,
12
B, and
13
illustrate an embodiment of a core board forming apparatus
1
and a method of producing a core board product
7
according to the teachings of the present invention. Apparatus
1
comprises a dispensing section
3
for holding and discharging a plurality of tubular cores
13
. A core compression section
5
receives the tubular cores so as to flatten and secure the cores to form the core board product
7
shown in
FIG. 11. A
microprocessor controller unit
9
, shown in
FIG. 6
, controls the operation of dispensing section
3
and core compression section
5
. The details of apparatus
1
are described in detail below.
As illustrated in
FIGS. 3 and 5
, dispensing section
3
includes a holding portion
11
for temporarily storing cores
13
. A discharge chute
15
is mounted in front of holding portion
11
so that the cores are sequentially conveyed into compression section
5
under control of controller unit
9
. In a preferred embodiment, holding portion
11
of dispensing section
3
is constructed from parallel sidewall plates
17
mounted on opposing sides of a downwardly inclined floor plate
19
. Vertical supports
18
are mounted to sidewall plates
17
to support dispensing section
5
above a floor surface
10
. Referring to
FIG. 5
, inclined floor plate
19
is angled approximately 15 degrees from the horizontal so that cores
13
can roll forward by gravity from holding portion
11
into the discharge chute
15
. The angle of the inclined floor plate is preferably set in a range from 15 degrees to 25 degrees but other inclination angles are possible. As illustrated in
FIG. 5
, a rear wall plate
21
is fastened to the rear end of sidewall plates
17
and inclined floor plate
19
. A front wall plate
23
spans between the front portions of sidewall plates
17
such that a rearward opening
25
of discharge chute
15
is formed between a bottom edge of front wall plate
23
and inclined floor plate
19
. It should be recognized that there are a number of approaches and other constructions of the holding portion that enable storage and movement of cores to discharge chute
15
.
With reference to
FIGS. 3-5
, in a preferred embodiment, discharge chute
15
has a substantially enclosed shape having rearward opening
25
and a forward discharge opening
27
. An elongated portion of each sidewall plate
17
is vertically mounted to the opposite of sides of inclined floor plate
19
to form discharge chute
15
. As shown in
FIG. 5
, a top plate
29
is affixed to a top edge of the elongated portion of each sidewall plate
17
to enclose discharge chute
15
. The rear end of top plate
29
is affixed to front wall
23
at the bottom edge of front wall plate
23
. In one embodiment, as seen in
FIGS. 3 and 4
, aligned curved slots
31
are cut into the opposing sidewall plates
17
of the elongated portion. Top plate
29
includes corresponding horizontally aligned slot openings
33
extending between curved slots
31
.
In a preferred embodiment, as best seen in
FIG. 4
, curved slots
31
enable a first movable rod
35
and a second movable rod
37
to rotate upwardly so that the core can roll past each rod as requested by controller unit
9
. Likewise, movable rods
35
,
37
rotate downwardly to prevent the cores from rolling into compression section
5
. Each end of movable rods
35
,
37
extends through a hole in a lower end of a pivot member
39
. Likewise, the lower end of a pneumatic actuator
41
is pivotally mounted to the lower end of pivot member
39
via a pivot pin
43
. Pivot member
39
is constructed from a flat bar having holes that retain the pivot pin and the ends of movable rods
35
,
37
. The upper end of pivot member
39
is pivotally mounted to a bracket
45
that is affixed to top plate
29
of discharge chute
15
. An upper end of each pneumatic actuator
41
is pivotally fastened to a support bracket
47
is that affixed to cantilevered support plate
49
. Each cantilevered support plate
49
is substantially aligned with sidewall plates
19
and is affixed to front wall
23
to provide a structure for the supporting actuators
41
with support bracket
47
.
With reference to
FIG. 4
, in a preferred embodiment, core position sensors
51
,
52
are mounted underneath top plate
29
of discharge chute
15
so that a core abutted against each movable rod
35
,
37
can be detected. Each position sensor
51
,
52
is disposed such that a beam of light is directed just upstream of movable rods
35
,
37
to detect the presence of a core. In essence, position sensors
51
,
52
look upstream of the rods to see when a core is disposed against rods
35
,
37
so that a single core can be sequentially discharged into compression section
5
; however, sensors
51
,
52
also sense the absence of a core against the rods.
In an embodiment of the invention, core position sensors
51
,
52
are a photoelectric sensor that detects an object; however, other type of sensors may be used, including contact sensors or capacitive sensors. Core position sensors
51
,
52
are operatively coupled to microprocessor controller unit
9
by interface control hardware, such as wires or wireless connections. This enables controller unit
9
to receive and process a detection signal generated by position sensors
51
,
52
. Referring to
FIGS. 3
,
4
and
5
, in one arrangement, rod position sensors
54
,
56
may be mounted to top plate
29
to detect when rods
35
,
37
are in the up position. Sensors
54
,
56
are preferably proximity sensors that detect a magnetic field, but other types sensing devices that detect the presence of the rods in the up position are contemplated, such as photoelectric sensors, capacitive sensors, or limit switches. In an embodiment, the detection of the up position of rods
35
,
37
can be accomplished with encoders configured to sense the rotary motion of pivot member
39
. While discharge chute
15
is shown and described, other arrangements that sequentially dispense cores are possible, such as a rotating addle wheel type.
Referring to
FIGS. 1 and 2
, in an embodiment, compression section
5
preferably includes a rectangular frame formed by two spaced vertical channel members
53
and a horizontal channel member
55
affixed to the top end of each vertical channel member
53
. As seen in
FIGS. 2 and 5
, a back plate
57
is mounted between vertical channel members
53
. Back plate
57
includes an opening adapted to mate with the corresponding discharge opening
27
of discharge chute
15
. The lower end of back plate
57
includes a notch opening
59
enabling an unload ram
61
to discharge the core board product from compression section
5
.
Referring to
FIGS. 1
,
2
, and
5
, in a preferred embodiment, compression section
5
includes a press assembly
71
that compresses or flattens a dispensed core against a bottom plate
73
. Bottom plate
73
is mounted between vertical channel members
53
. Referring to
FIGS. 5 and 13
, bottom plate
73
includes two openings
128
for two optical sensors
75
to detect the presence or absence of a dispensed core on the plate, in which a beam of light is directed vertically into the openings from the sensors. Sensors
75
are operatively coupled to controller unit
9
. The use of the detection signal from optical sensors
75
will be described with the operation sequence of core board forming apparatus
1
. It is recognized that other types of sensing devices, such as contact or capacitive sensors may be used, instead of optical sensors
75
to detect a core on the bottom plate.
As best seen in
FIG. 2
, in a preferred embodiment, press assembly
71
is constructed from a top support member
69
, vertical plates
79
, and a compression plate
81
. Vertical plates
79
serve to physically connect top support member
69
and compression plate
81
into a single structure. Accordingly, vertical plates
79
are mounted on opposing sides of the top support member and the compression plate. A vertical stiffener plate
83
is mounted between the midpoint the opposing sides of top support member
69
and compression plate
81
to provide enhanced structural support.
Bearings
82
are mounted to the side of vertical plates
79
so that press assembly
71
travels freely against vertical bearing plates
84
inside of vertical channel members
53
. Bearing
82
are preferably cam follower types, but may also be roller bearing types. Vertical bearing plates
84
are spaced inward from channel members
53
. Referring to
FIGS. 1
,
2
and
5
, hydraulic actuators
63
vertically move press assembly
71
in compression section
5
. The upper ends of actuators
63
are pivotally mounted to the bottom surface of horizontal channel member
55
by attachment tangs
65
and pivot pins
67
. Likewise, the lower ends of hydraulic actuators
55
are pivotally mounted to top support member
69
of press assembly
71
by attachment tangs
65
and pivot pins
67
. In an alternative embodiment, the press assembly can be motor driven and configured with gears to move.
As best seen in
FIGS. 1
,
2
, and
5
, a press position sensor
85
is mounted on the inner surface of vertical channel member
53
to detect when press assembly
71
is in a full up position. Press position sensor
85
generates a detection signal when a magnetic field is created between a metal bar
87
that is mounted to the upper surface of top support member
69
; however, other types of sensors may be used for detection, such as limit switches. Similarly as other sensors of apparatus
1
, press position sensor
85
is operatively coupled to microprocessor controller unit
9
.
As best shown in
FIG. 2
, in a preferred embodiment, press assembly
71
also securely fastens at least two flattened cores together by fastening devices, such as pneumatic staple guns
77
. Staple guns
77
are commercially available and include a staple feeder cartridge
89
. Referring to
FIGS. 1
,
2
, and
4
, compression plate
81
includes the plurality of staples guns
77
for fastening the flattened cores together against bottom plate
73
. Staple guns
77
are mounted to the upper surface of the compression plate
81
via brackets
91
. Brackets
91
are mounted such that staple guns
77
are secured during vertical movement of press assembly
71
, but can slide out of bracket
91
for maintenance. Notch openings are included in compression plate
81
so that staple guns
77
can inject staple fasteners into the flattened cores.
As best seen in
FIG. 1
, in a preferred embodiment, compression section
5
includes a discharge gate
93
mounted inside of a maintenance gate
95
. More fully shown in
FIG. 10
, discharge gate
93
opens vertically to a predetermined height so that core board product
7
can be discharged from bottom plate
73
by unload ram
61
during the manufacturing operation. Maintenance gate
95
provides an arrangement for gaining access to press assembly
71
and staple guns
77
for maintenance or other purposes. Regarding discharge gate
93
, a pneumatic actuator
97
moves gate
93
up vertically.
As seen in
FIG. 1
, maintenance gate
95
comprises interconnected horizontal and vertical angle members
101
forming a rectangular frame that resides inside of the vertical channel members
53
. Maintenance gate
95
pivots about hinges
99
and discharge gate
93
rotates with gate
95
. Referring to
FIG. 3
, maintenance gate
95
is capable of being pivoted open by a pneumatic actuator
98
mounted to vertical channel member
53
. In use, a rod of actuator
98
pushes down on a wire
100
fed through pulleys
92
and lifts gate
95
to pivot about hinges
99
. As seen in
FIG. 1
, a handle
104
is provided to enable lifting of gate
95
. In addition, a gate proximity sensor
102
is mounted in the front of vertical channel member
53
to detect when gate
95
is closed. Again, other types of sensing devices can be used to detect when gate is closed, such as contact switches.
As shown in
FIG. 1
, discharge gate
93
is preferably slotted to enable vertical movement of staple guns
77
with press assembly
71
. A discharge gate proximity sensor
103
is mounted to the lower front of vertical channel member
53
to detect when discharge gate
93
is closed. A second discharge gate proximity sensor
106
detects when gate
93
is in the opened position. Sensor
106
is mounted near press position sensor
85
on vertical channel member
53
. Sensor
103
generates a detection signal when a magnetic field is created between a metal bar
105
that is mounted the lower front of discharge gate
93
. Likewise sensor
106
detects a magnetic field created by the upper part of discharge gate
93
. Controller unit
9
receives the detection signal preferably by control wires or, if desired, the detection signal may be transmitted by wireless communication connections. It should be recognized that alternative types of sensing devices that serve the same purposes as sensors
103
and
106
may be used.
Referring to
FIGS. 1
,
3
and
5
, in a preferred embodiment, compression section
5
further preferably includes a conveying portion formed by rotatable arms or fingers
107
. A front set of rotatable arms
107
is pivotally mounted to discharge gate
93
and a rear set of arms
107
is mounted to back plate
57
. As shown in
FIG. 5
, the front set of arms
107
and the rear set of arms
107
form a valley type structure such that both sets of arms are sloped towards each other. This enables a dispensed core to roll on the arms and to be centered above bottom plate
73
of compression section
5
.
As illustrated in
FIG. 5
, each of rotatable arms
107
has an inclined elongated member
109
including a concave portion at the tip or receiving end to retain a core lengthwise between the front set and rear set of arm
107
. The members
109
contact the outer surface of the tubular core at discrete locations for conveyance to bottom plate
73
. The opposite end of rotatable arms
107
is counterweighted to enable each arm to pivot upwardly to a holding or position as shown. In sum, the conveying portion supports a dispensed tubular core at an interim location between compression plate
81
and bottom plate
73
in an open uncompressed condition so that the core can be place at a predetermined position on bottom plate
73
. The conveying portion also enables a core to be aligned on top a first compressed core for subsequent compression are fastening operations.
An optical sensor
111
is affixed underneath discharge chute
15
such that a substantially horizontal beam of light senses the presence or the absence of a dispensed core retained between the front and rear set of rotatable arms
107
. While an optical sensor is shown, a capacitive sensor may be also be used. Other constructions of the conveying portion are possible.
Referring to
FIG. 5
, core board forming apparatus
1
further includes an unload ram
61
for removing finished core board product
7
from compression section
5
. In a preferred embodiment, unload ram
61
includes a pneumatic cylinder with a rod having a pushing bar
64
configured to push the core board product. Unload ram
61
includes a proximity sensor that detects when it is retracted. The unload ram is horizontally mounted on beam supports
62
that are fastened to support members
18
and vertical channel members
53
.
Advantageously, microprocessor controller unit
9
may comprise a computing device for controlling operation core board forming apparatus
1
. In one embodiment of the invention, controller unit
9
comprises a central programmable logic control unit (PLC) or a series of independent central programmable logic control units configured for providing semi-automatic or automatic processing operation. Likewise, controller unit
9
may be a general purpose computer configured to operate with such programmable controllers. Nevertheless, the operational logic sequences for controlling core board apparatus
1
can be readily programmed by those having ordinary skill in the art.
As shown schematically in
FIG. 6
, in a preferred embodiment of the invention, controller unit
9
comprises a PLC-5 series programmable controller including 1771 series digital and analog input/output modules commercially available through the Allen-Bradley Company of Milwaukee, Wis.; however, other suitable equipment or devices may be used for the controller unit. Hardware components of microprocessor controller unit
9
may include a processing unit
113
, a system memory
115
, and a system backplane
117
that forms a data pathway for input/output modules
123
. Input/output modules
123
interface with various control devices, such as the sensing devices, comprising apparatus
1
. Processing unit
113
may be any suitable microprocessor used in industrial control systems. The system backplane
117
may be any of several types of conventional backplane structures. System memory
115
includes computer readable code in the form of read only memory (ROM) and random access memory (RAM). System memory
115
stores programmable instructions of the operational logic sequences
119
that are executed by processing unit
113
.
If desired, controller unit
9
can further include a computer readable storage device
121
that may comprise an Eraseable Programmable Read Only Memory (EPROM) to store data. Storage device
121
and associated computer-readable media provide nonvolatile storage of computer readable code and logic sequences. Controller unit
9
may operate in a networked environment (not shown) using a network connection in input/output modules
123
. The networked environment may include a local area network (LAN) any number of networking signaling used in industrial control systems, such as Ethernet, Controlnet, Devicenet, or Datahighway plus.
It should be recognized by one of ordinary skill in the art that a hydraulic system is used for moving the hydraulic actuators in compression section
5
. Such a hydraulic system includes a tank, a pump, pipes, hoses and control values. It should be apparent that pneumatic or air operated components described are interconnected to a pneumatic system in which the intended function of the component is controlled by microprocessor controller unit
9
via an air control valve (not shown). The control valve includes a solenoid that opens and closes according to an electrical signal transmitted by the controller unit. Such a pneumatic system includes an air compressor, filters, hoses, pipes, and regulators. In addition, the pump motor and air compressor motor may be interlocked with microprocessor controller unit
9
via contact relays (not shown) to provide electric power for operation. Other constructions of the hydraulic and pneumatic system are possible.
FIGS. 7-10
illustrate a functional overview of a method of making core board product in accordance with the present invention, as carried out by core board forming apparatus
1
. An operational cycle is herein defined as compression and securing of at least two cores together; however more cores may be used. For ease of explanation, use of the term “cores” denotes a generic tubular paper core without reference to the length. One arrangement, the elongated tubular cores can be cut into smaller core section. This enables the core board product have different lengths as a packing material or other purposes.
An embodiment of the dispensing or discharging sequence of dispensing section
3
is described below. Referring to
FIG. 7
, cores
13
have been placed in holding portion
11
of dispensing section
3
. At discharge chute
15
, first and second moveable rods
35
,
37
, respectively, are in a closed position to block the cores from freely rolling into the compression section. In use, the cores at the bottom of dispensing section
5
roll forward on incline floor plate
19
towards discharge chute
15
and a core abuts against the first moveable rod
35
. At this position, upstream core position sensor
51
detects the presence of a core in a first discharge position.
Still referring to
FIG. 7
, upon detection of the core in the first position, a detection signal is processed by microprocessor unit
9
to actuate a control valve (not shown) that operates pneumatic actuators
41
connected to first moveable rod
35
. The lowered end of actuator
41
lifts upward to impart an upward rotation of pivot member
39
and first movable rod
35
. The first movable rod follows the curvature of the curved slots
31
in discharge chute
15
. Eventually, first movable rod
35
rotates upward just enough to enable the core to roll under the rod. In this point, the presence of the core is detected by downstream core position sensor
52
. In one arrangement, an alert condition indicates that the core might be misaligned in discharge chute
15
. The alert condition is programmed to activate when rod
35
is detected in the up position by rod position sensor
54
and the absence of a core is detected by core position sensor
52
.
In a preferred embodiment, a second discharge position is defined when a core in disposed between the first and second moveable rods. In the second discharge position and after a short time delay, such as 1.5 seconds, the first movable rod is rotated back down into the closed position. Second movable rod
37
is rotated upward by its pneumatic actuators
41
to allow the core to roll under the rod when it receives a core request signal from microprocessor controller unit
9
. Advantageously, sensors
51
,
52
detect the tubular core at predetermined first and second dispensing positions to ensure sequentially discharging the cores.
An embodiment of the operation of the compression section is described below. In a preferred embodiment, a first core request signal is generated at the start of the operational cycle in which the microprocessor unit scans the sensors
75
,
85
,
102
,
103
,
111
so that compression section
5
is ready to accept a core. For example, optical sensors
75
at bottom plate
73
detects that there is the absence of a core in compression section
5
. Press assembly
71
is detected in the full up position. Maintenance gate
93
and discharge gate
95
are detected as closed. Optical sensors
111
detect absence of a core on arms
107
.
As shown in
FIG. 8
, the first core request signal has been generated and a dispensed core
125
has been conveyed from dispensing section
3
on to the conveying portion formed by rotatable arms
107
. In this point in the operational sequence, optical sensor
111
detects the presence of the dispensed core on arms
107
. In one arrangement, an alert condition is programmed to activate when rod
37
is detected in the up position by rod position sensor
56
and the absence of a core is detected by optical sensor
111
.
As shown in
FIG. 9
, upon detection of the dispensed core
125
, a detection signal is processed by microprocessor unit
9
to actuate a control valve (not shown) for operating hydraulic actuators
63
connected to press assembly
71
. Accordingly, press assembly
71
moves in a downward stroke towards dispensed core
125
. Press assembly
71
comes in contact with dispensed core
125
. As a downward motion of compression plate
81
pushes on dispensed core
125
, arms
107
rotate downwardly so that core
125
is guided and centered on bottom plate
73
of the compression section. At the end of the downward stroke, arms
107
release the dispensed core
125
and the core is compressed against bottom plate
73
by compression plate
81
.
Press assembly
71
then returns to the full up position in an upward stroke, in which rotatable arms
107
rotate back to the holding position ready to accept a second core for flattening. Press position sensor
85
detects the presence of press assembly
71
in the full up position, in which controller unit
9
counts the number of downward strokes in the operational cycle. If desired, by counting the number of downward strokes more cores can be dispensed and flattened by compression section
5
to form a single core board product. In the illustrated arrangement, two downward strokes are used in the operational cycle.
Similarly as shown in
FIG. 8
, after detection of press assembly
71
by sensor
85
, a second core request signal is generated so that second movable rod
37
opens to permit a second core to rest on rotatable arms
107
similarly as dispensed core
125
. As shown in
FIG. 10
, the second core is then compressed against the flattened first dispensed core
125
. Microprocessor controller unit
9
determines that a second downward stroke has occurred so that in the extended position of the second downward stroke, the compressed cores are stapled together by staple guns
77
against bottom plate
73
. Following fastening of the compressed cores, discharge gate
93
is opened vertically by pneumatic actuator
97
in which gate sensor
106
detects the predetermined opening to stop movement of the gate
93
. Core board product
7
is then ejected by unload ram
61
by pushing bar
64
into a retaining bin
127
.
After the method, as illustrated in
FIGS. 11
,
12
A and
12
B, a core board product
7
comprises at least two substantially flattened tubular paper cores
12
fastened together in an abutting relationship by a plurality of integral fastening members
130
. Fastening members
130
are preferably located at discrete predetermined locations on the flattened cores
12
. Fastening members
130
can have any number of orientations and directions on the tubular cores.
As shown in
FIGS. 12A and 12B
, in alternative embodiments, integral fastening members
130
have a first fastening portion
131
abutting one of the flattened cores, two substantially perpendicular fastening portions
133
extending through each of the flattened cores. Winged portions
135
abut the flattened tubular core opposite of the tubular core abutted by first fastening portion.
131
. As shown in
FIG. 13
, in an embodiment, grooves
129
located on bottom plate
73
are generally aligned with staple guns
77
to bend over the fastening member to form the winged portions
135
. The grooves have a configuration like conventional stapler backing plates to bend over the ends of staples. A strong board product is formed by resisting a springing effect of the substantially flatten cores. The springing effect occurs when a compressed core tends to open. As shown in
FIGS. 12A and 12B
, when several compressed cores are layered together, first fastening portion
131
and wing portion
135
of fastening member
130
resists the springing effect of the compressed cores to form a relatively strong compressive bond between the flatten cores. Advantageously, core board product
7
is formed with an improved fastening arrangement that prevents tears in large paper rolls during rail transport operations by not separating apart.
Referring to
FIGS. 14-15
, if desired, the tubular cores may be cut into smaller sections by a semi-automated core cutting apparatus
200
. Control devices described in connection with core cutting apparatus
200
can be operatively coupled to microprocessor controller
9
or a separate controller unit. Referring to
FIG. 14
, in an embodiment, the core cutting apparatus may comprises an elongated tubular core guide
201
attached to a pivotal circular saw
203
for cutting a core into a smaller core section. Core guide
201
is constructed from a horizontally aligned forward tube
205
, and a rear tube
207
with both having an inside diameter sized to accommodate one core. Tubes
205
,
207
are horizontally supported by support members
209
mounted on top of vertically disposed beam members
211
. Tubes
205
,
207
can be constructed from steel pipes. Tubes
205
,
207
are fastened to support member
209
and beam members
211
by welding or other methods. The wall of forward tube
205
includes a slot opening
213
along its length so that an operator can slide an elongated core inside of the tube. Rear tube
207
has a predetermined length so that elongated cores are cut into a corresponding length.
Referring to
FIG. 14
, a gap
215
is formed between forward tube
205
and rear tube
207
so that saw
203
is enabled to cut and separate of the core. A saw blade cover
217
is welded to both tubes
205
,
207
on opposite sides of gap
215
. Referring to
FIG. 15
, saw
203
is pivotally mounted to a support
219
by a pivot pin
221
. Saw
203
is also mounted a pneumatic actuator that is mounted so that upward and downward movement of a rod
223
of the actuator pivots saw
203
about pin
221
. A saw proximity sensor
225
detects when saw
203
has pivoted into a downward position. Saw proximity sensor
225
is mounted in a vertical position to detect when a magnetic field is formed in a short distance at its sensing end. If desired, sensor
225
may be a mechanical switch, or optical sensor to detect position of the saw.
Referring to
FIG. 14
, the top portion of discharge end
226
of rear tube
207
preferably includes an opening for an optical sensor
227
to detect the presence of the leading end of the core in tube
207
. Near optical sensor
227
at discharge end
226
, an air cylinder
229
is mounted in which its rod extends downward to block the movement of the core upon detection of the core leading end by sensor
227
. Referring to
FIG. 15
, in use, upon detection of core leading end, the rod
223
moves downward to the blade of saw
203
activates. During downward rotation of saw
203
, the saw blade separates the core. Saw proximity sensor
225
detects the end of the rotation and saw
203
is pivot back by rod
223
. While not shown, another proximity sensor detects when the saw in the up position.
A core clamping arrangement is provided at front end of tube
205
prior to gap
215
. The clamping arrangement includes an air cylinder (not shown) attached to a curved clamp (not shown) and return springs (not shown). In use, upon detection of the core leading end by sensor
227
, the rod on air cylinder extends downward and forces the curved clamp on the core against the inner surface of tube
205
. As a result, the core is prevented from rotating while being cut by saw
203
. The return springs moved the clamp back up with the rod of the air cylinder after the core is cut by the saw.
Thus, a core board forming apparatus
1
has been described for producing core board product. Apparatus
1
is capable of producing a core board product about every 15 seconds while in operation. The substantially precision operation of apparatus
1
reduces errors and enables a consistent board product without significant variations in product quality.
While the present invention has been described with reference to exemplary embodiments, it will be understood by those of ordinary skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims
- 1. A system for producing a paper core board, comprising:a feeding apparatus having a discharge portion for discharging a tubular core; a compression apparatus having a compression surface and a flattening surface movable together to flatten the tubular core, and a conveying portion for supporting the tubular core at an interim location between the compression surface and the flattening surface in an uncompressed condition and for releasing the tubular core to the flattening surface when the compression surface and flattening surface move together to a closed position; and a controller unit configured to control the feeding apparatus and the compression apparatus.
- 2. The system of claim 1, wherein the discharge portion of the feeding apparatus, further comprises a sensing device for detecting the presence of the tubular core at a predetermined dispensing position above the conveying portion of the compression apparatus.
- 3. The system of claim 2, wherein the discharge portion further comprises a movable member for discharging the tubular core.
- 4. The system of claim 3, wherein the movable member comprises a rod extending across the discharge portion.
- 5. The system of claim 1, wherein the conveying portion comprises a plurality of holding members configured to contact the tubular core at discrete locations.
- 6. The system of claim 1, wherein the conveying portion supports the tubular core at an interim location spaced away from the flattening surface and then releases the tubular core toward the flattening surface upon relative movement of the compression surface and flattening surface to flatten the tubular core.
- 7. The system of claim 6, wherein the conveying portion controls the movement of the tubular core to a predetermined position on the flattening surface.
- 8. The system claim 7, wherein the conveying portion includes a plurality of rotatable members.
- 9. The system of claim 5, further comprising a sensing device for detecting the presence of the tubular core on the plurality of members so that the compression surface travels to apply pressure to the tubular core.
- 10. The system of claim 1, wherein the compression apparatus further comprises an ejection device for discharging the tubular core flattened by the compression surface.
- 11. The system of claim 1, wherein the compression apparatus further comprises a plurality of fastening devices for inserting fastening members into a plurality of tubular cores substantially flattened between the compression surface and flattening surface.
- 12. The system of claim 1, wherein the conveying portion comprises a plurality of rotatable members configured to release the tubular core on the flattening surface under pressure applied by the compression surface.
- 13. An apparatus for making a core board product, comprising:a dispensing apparatus having a device for detecting tubular cores at a predetermined dispensing position and sequentially dispensing cores; a compression apparatus having a compression member for substantially flattening each of the dispensed tubular cores and a plurality of pivotable members configured to retain each of the dispensed cores below the compression member for conveyance to a flattening plate upon downward contact with the compression member; and a processor unit configured to execute computer readable code for controlling the dispensing apparatus and the compression apparatus.
- 14. The apparatus of claim 13, wherein the dispensing apparatus further comprises a movable dispensing member at the predetermined dispensing position.
- 15. The apparatus of claim 13, further comprising a sensing device for detecting the presence of each of the dispensed tubular cores on the pivotable members.
- 16. The apparatus of claim 13, wherein each of the pivotable members includes an elongated portion having a distal tip with a concave surface for holding the dispensed cores at a plurality of discrete locations.
- 17. The apparatus of claim 13, wherein the compression apparatus further comprises a plurality of fastening devices for inserting fastening members into a plurality of tubular cores substantially flattened by the compression member.
- 18. The apparatus of claim 17, wherein the plurality of fastening devices are mounted to the compression member.
- 19. The apparatus of claim 17, wherein the flattening plate contains at least one groove for bending a portion of each of the fastening members against one of the tubular cores abutting the flattening plate.
- 20. The apparatus of claim 19, wherein the compression apparatus further comprises an unloading device for discharging the tubular cores flattened by the compression member.
- 21. An apparatus for making a core board product comprising:a dispensing component having a device for sequentially dispensing tubular cores; a compression component configured for substantially flattening each of the dispensed tubular cores; a plurality of movable members collectively defining a holding location for each of the dispensed cores relative to the Compression Component for conveyance to a flattening member responsive to movement of the compression component towards the holding location; a controller for controlling the dispensing component and the Compression component, said controller including: a processing unit configured to execute computer readable instructions, and; a memory for storing computer readable instructions that, when executed by said processor unit, cause the apparatus to: a) dispense a first tubular core to the holding location; b) convey the first tubular core to a flattening member responsive to movement of the compression component; c) compress the first tubular core between the compression component and a flattening component; d) repeat steps a) through b) for at least a second tubular core; and e) substantially compress the second tubular core against the first tubular core; and f) fasten the substantially compressed first tubular core and second tubular core together in an abutting relationship with a plurality of fastening members so as to form the core board product.
- 22. The apparatus of claim 21, in which the computer executable instructions cause the apparatus to fasten said fastening members so that a first fastening portion of said fastening members abuts against at least one of the flattened tubular cores, and a second fastening portion of said fastening members is substantially perpendicular to the first fastening portion for extending through the flattened first tubular core and the flattened second tubular core.
- 23. The apparatus of claim 22, in which the computer executable instructions cause the apparatus to fasten the fastening members so that a third fastening portion abuts the flattened tubular core opposite of the at least one tubular core abutted by the first fastening portion.
- 24. The apparatus of claim 23, in which the computer executable instructions cause the apparatus to eject said core board product from the flattening component.
- 25. The apparatus of claim 21, in which the computer executable instructions cause the apparatus to detect the first tubular core at a predetermined dispensing position with respect to the dispensing component before dispensing to said holding location.
US Referenced Citations (25)