The present disclosure is generally related to devices for cutting material off bulk roll cores and more particularly is related to a bulk roll cutting device with safety linkage.
In the process of manufacturing paper products from bulk paper materials, e.g., with the manufacture of magazines, newspapers, paper-based consumer goods, cardboard, or other paper goods, large rolls of paper are utilized. These rolls are often referred to as bulk rolls and they often consist of the rolled paper material formed over a cardboard core, or a core made from another material. These bulk rolls can weigh a ton or more and can commonly have a length dimension of between 18 inches to 66 inches, although specific weights and dimensions can vary.
During manufacture of the paper product, the paper on the bulk roll is unwound off the core in a continuously operating machine. When the paper on bulk roll is nearing the end of its run, the leading end of a new bulk roll is spliced to the trailing end of the spent roll. This splicing normally occurs quickly and prior to all of the paper on the spent bulk roll actually being consumed. As such, there can often be several layers of remaining paper left on the core of the spent bulk roll. It is desirable to remove these residual layers and reuse the core of the bulk roll, since the core is an expensive structure and it is designed and intended to be reused.
Various devices have been developed to remove the residual layers of the paper from the core, including devices which use a hydraulic piston to move a blade which cuts through the residual layers with a swinging guillotine movement. While these devices are effective, if they're not properly configured for the specific size of the bulk roll—specifically, the size of the core of that bulk roll—the blade of the device can become loose and possibly create a hazardous situation for the machine's operator. In particular, if the blade is not configured properly relative to the core of the bulk roll, when the blade is moved using a hydraulic piston, the arm on the hydraulic piston can become dislodged from a bracket on which it is mounted, which can allow the blade and hydraulic piston assembly to free fall towards the arbor.
Thus, a heretofore unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies.
Embodiments of the present disclosure provide an apparatus, system, and related methods for a bulk roll cutting apparatus with safety linkage. Briefly described, in architecture, one embodiment of the system, among others, can be implemented as follows. The bulk roll cutting apparatus with safety linkage has a frame holding a blade. The blade is movable between a cutting position and a retracted position, wherein in the cutting position, the blade is positioned proximate to an arbor. At least one link arm is movably connected to the frame. An actuator is connected between the at least one link arm and the blade. An adjustment device is connected between the at least one link arm and the frame, the adjustment device controlling a cutting depth of the blade relative to the arbor. A safety linkage is connected between the at least one link arm and the frame, the safety linkage preventing an inadvertent gravitational fall of the blade.
The present disclosure can also be viewed as providing an apparatus for removing bulk rolled material from a core. Briefly described, in architecture, one embodiment of the apparatus, among others, can be implemented as follows. The apparatus has a frame having two frame walls, the frame supporting a swing blade movable between a cutting position and a retracted position, wherein in the cutting position, the blade is positioned proximate to an arbor capable of holding a bulk roll. At least one link arm is movably connected to the frame through a first shaft extending between the two frame walls, whereby the at least one link arm is positioned at least partially in a space formed between the two frame walls. An actuator is connected between the at least one link arm and the blade, the actuator positioned at least partially in the space formed between the two frame walls. An adjustment device is connected between the at least one link arm and the frame through a second shaft, the adjustment device being adjustable to control a cutting depth of the blade relative to the arbor. A safety linkage is connected between the at least one link arm and the frame through the second shaft, the safety linkage preventing an inadvertent gravitational fall of the blade.
The present disclosure can also be viewed as providing a method of preventing inadvertent gravitational falls of a blade of an apparatus for removing bulk rolled material from a core. In this regard, one embodiment of such a method, among others, can be broadly summarized by the following steps: providing an apparatus having a frame holding an arbor and a blade, the blade movable between a cutting position and a retracted position, wherein in the cutting position, the blade is positioned proximate to the arbor holding a bulk roll of material with core; controlling movement of the blade between the cutting and retracted positions with an actuator connected between the frame, through at least one link arm, and the blade; controlling an adjustment of a cutting depth of the blade relative to the bulk roll of material with core using an adjustment device connected between the at least one link arm and the frame; and preventing an inadvertent gravitational fall of the blade with a safety linkage connected between the at least one link arm and the frame.
Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.
Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
Within the industry, various devices have been produced to cut the residual layers off a core of a bulk roll. In general, these machines allow for fast and efficient removal of the residual layers as compared to unrolling the residual layers off the core. In operation, these machines typically hold the bulk roll in a stationary position on an arbor or mandrel and move a cutting blade or knife through the residual layers of the paper.
One particular type of machine for removing these residual layers of paper from the core of a bulk roll is a bulk roll cutting machine which uses a hydraulic-actuated swing arm blade.
The cutting action of the blade 12 may be achieved through actuation of the actuator 16, which causes the actuator 16 to extend, thereby rotating the swing arms 14 about the pivot points attached to the frame of the bulk roll cutting device 10. This movement causes the blade 12 to lower towards the bulk roll 24 with a lateral swing or guillotine cutting action, e.g., where the blade 12 is moved in both vertical and horizontal directions simultaneously. Movement of the blade 12 in this fashion may provide the desired cutting effect on the residual layers of paper 28 on the bulk roll 24, in that, the combination of horizontal and vertical movement may create a shear slicing effect on the residual layers of paper 28 which may prove to be more desirable than only a vertical movement (chopping effect). However, various devices may be configured to perform different cutting actions, all of which are considered within the scope of the present disclosure.
To ensure successful operation of the bulk roll cutting device 10, the blade 12 must achieve the precise cutting position required for the residual layers of paper 28 on the bulk roll 24 to be fully removed from the core 26, but for the core 26 itself to be left intact so it can be reused. In other words, the blade 12 must descend far enough into the bulk roll 24 to fully cut through the residual layers of paper 28, or substantially all of the residual layers of paper 28, yet not descend so far that the cutting edge of the blade 12 cuts into the core 26 substantially enough to cause damage to it. To ensure the blade 12 achieves this position during the cutting action, the bulk roll cutting device 10 must be configured or adjusted for each bulk roll 24 having a differently sized core 26 needing to be processed.
In practice, prior to processing a bulk roll 24 or a plurality of bulk rolls 24 having the same core 26 size, the operator of the bulk roll cutting device 10 must go through the blade adjustment procedure to adjust the cutting depth of the blade 12. A common blade adjustment procedure includes the operator first moving the blade 12 to a down position, e.g., the bottom stroke or cutting position, when the arbor 22 of the bulk roll cutting device 10 is free from a bulk roll 24. The down position of the blade 12 is illustrated in
In particular, adjusting the adjustment device 30 will either raise or lower the distal end 42 of the link arm 40, causing the link arm 40 to rotate about a pivot point 46 at its proximate end 44, in turn, raising or lowering the piston attachment point 48. Raising or lowering the piston attachment point 48 on the link arm 40 adjusts the reach of the actuator 16 relative to the arbor 22 and therefore can be used to adjust the relative position or distance of the blade 12 attached to the actuator 16 to the arbor 22 to configure the cutting depth. Accordingly, with the blade 12 in the down position, the operator can adjust the adjustment device 30 until the desired cutting depth is achieved, which may include the cutting edge of the blade 12 being positioned in contact with the blank core 26 or substantially in contact with the blank core 26 (such that the cutting edge of the blade 12 is positioned within a minimal predetermined distance to the outer surface of the core 26). The exact cutting depth selected may vary depending on the type of core 26, the size of the core 26, the type of residual material to be cut off the core 26, or other factors, such as the preciseness of cut desired by the operator.
One concern with adjusting the bulk roll cutting device 10 to have the desired cutting depth is with operator error, or more particularly, with operators failing to follow the proper adjustment procedures. The cutting depth may need to be adjusted for each differently sized core 26, such that it may be common for the bulk roll cutting device 10 to be adjusted frequently. Instead of adjusting the blade cutting depth with a blank core when the blade 12 is in the down position, noted above as the proper procedure, some operators may cut corners and choose to adjust the adjustment device 30 while the blade 12 is raised. This creates a situation where the adjustment device 30 can be adjusted beyond optimal and safe positions. For example, the operator may lengthen the adjustment device 30 too far which may allow one or both of the threaded inserts to become removed or separated from the central rotatable body, which can allow the link arm 40 to swing downwards about the pivot point 46, thereby effectively allowing the blade 12 to drop down to the arbor 22. In another example, the operator may shorten the adjustment device 30 too much such that the link arm 40 can swing downwards about the pivot point 46 and drop the blade 12 on to the arbor 22. These situations can create hazardous conditions for the operator or any other personnel in the vicinity.
To prevent these hazards, a bulk roll cutting device 110 with the hydraulic-actuated swing arm blade can include a safety linkage.
On the lower end of the device 110, an arbor 122 or mandrel is positioned substantially parallel to the blade 112. A bulk roll can be placed on the arbor 122 such that the core 126 of the bulk roll and the residual layers of paper are positioned substantially parallel to the blade 112. The device 110 further includes an adjustment device 130 which can either raise or lower the distal end 142 of the link arm 140. The adjustment device 130 includes opposing threaded inserts 132 which threadedly connect to a central rotatable body 134, whereby rotation of the body 134 relative to the inserts 132 causes the inserts 132 to move closer together or further apart from one another along an axial direction. Adjustment of the adjustment device 130 causes the link arm 140 to rotate about a pivot point 146 at its proximate end 144, in turn, raising or lowering the piston attachment point 148. Raising or lowering the piston attachment point 148 on the link arm 140 adjusts the reach of the hydraulic piston 116 relative to the arbor 122 and therefore can be used to adjust the relative position or distance of the blade 112 attached to the hydraulic piston 116 to the arbor 122 to configure the cutting depth.
A safety linkage 150 is positioned on the device 110 in a location connecting the distal end 142 of the link arm 140 to the frame 111 of the device 110, and in particular, the frame 111 of the device 110 at the location where the adjustment device 130 connects to the frame 111, or at another location on the frame 111. Accordingly, in one example, the safety linkage 150 may be connected to the point on the frame 111 and the link arm 140 where the adjustment device 130 is connected. These connection points are shown in detail in
At least one of the first and second linkage members 152, 154 may include a mechanical stop 158 which is positioned to make contact between the first and second linkage members 152, 154 and prevent relative movement beyond a predetermined distance. For example, in
In
As is shown by block 202, an apparatus having a frame holding an arbor and a blade is provided, wherein the blade is movable between a cutting position and a retracted position, wherein in the cutting position, the blade is positioned proximate to the arbor holding a bulk roll of material with core. Movement of the blade between the cutting and retracted positions is controlled with an actuator connected between the frame, through at least one link arm, and the blade (block 204). An adjustment of a cutting depth of the blade relative to the bulk roll of material with core is controlled using an adjustment device connected between the at least one link arm and the frame (block 206). An inadvertent gravitational fall of the blade is prevented with a safety linkage connected between the at least one link arm and the frame (block 208). Any number of additional steps, functions, processes, or variants thereof may be included in the method, including any disclosed relative to any other figure of this disclosure.
It should be emphasized that the above-described embodiments of the present disclosure, particularly, any “preferred” embodiments, are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present disclosure and protected by the following claim.
This application is a divisional application of U.S. application Ser. No. 16/696,367 entitled “Bulk Roll Cutting Apparatus with Safety Linkage and Related Methods” filed Nov. 26, 2019, which claims benefit of U.S. Provisional Application Ser. No. 62/795,400 entitled, “Bulk Roll Cutting Device with Safety Linkage” filed Jan. 22, 2019, the entire disclosures of which are incorporated herein by reference.
Number | Date | Country | |
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62795400 | Jan 2019 | US |
Number | Date | Country | |
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Parent | 16696367 | Nov 2019 | US |
Child | 17519386 | US |