System for Reducing Rolled Stock Waste

This application is a continuation of and claims priority to U.S. application Ser. No. 18/334,982, filed Jun. 14, 2023, which claims priority to U.S. Provisional Patent Application No. 63/352,126, which was filed on Jun. 14, 2022, and entitled “System For Reducing Rolled Stock Waste,” the entire contents of each of which are hereby incorporated by reference in their entirety.

The present disclosure relates to a system for reducing waste of rolled stock. More specifically, the present disclosure relates to a system to reduce waste of rolled stock on a core by actively detecting a quantity of rolled stock on the core during unwinding and transitioning to a new roll in response to the detected quantity.

Rolled stock is generally known in the art. Rolled stock includes a medium wound onto a core in a roll format for shipping, storage, and/or use. In some use applications, the medium is unwound from the core. In some other applications, the medium is unwound from the core at high speed. In these high speed unwind applications, the unwind system can include at least two rolls of wound medium. One roll is actively being unwound. When the actively unwound roll reaches a predetermined roll diameter that indicates the medium is about to run out, the unwind system can splice in the other roll to facilitate a continuous unwinding of the medium. However, there are certain limitations in known systems that lead to significant amounts of medium waste on the roll core.

As one example, known systems can include an ultraviolet (UV) sensor that is configured to detect a marking that is physically placed on the medium by the rolled stock manufacturer. The marking is applied while the rolled stock is being wound onto the core. The physically placed marking is provided as an indicator of a “low” roll diameter. However, placement of the marking occurs at variable locations along the wound medium. The marking is not uniformly positioned at a standard position with a specific quantity of linear feet of stock on the core. Instead, the marking is positioned randomly with differing amounts of wound medium remaining on the roll (or with different lengths of linear feet of medium remaining on the core). Thus, the positioning of the marking is variable between rolls of wound medium, as the wound medium manufacturer has to place the marking. Different rolls can have the marking positioned at different positions along the length of the medium wound on the roll.

Further, manufacturers of rolled stock are not incentivized to minimize the amount of medium wound on the core. Manufacturers are instead incentivized to position the marker with a “safe” amount (or quantity) of medium wound on the core to avoid the roll running out of medium before spicing to the next roll. Stated another way, a manufacturer does not want a roll to “fail” by positioning the marking on the medium with a small amount (or length) of medium to the core (i.e., the marking is positioned in relatively close proximity to the core). If all of the medium on the core is used before the splice to the next roll, the next roll has to be manually spliced. Manual splicing of a roll is both labor and time intensive, and results in unwanted system downtime. This “safe” amount of medium wound on the core is unusable waste.

Accordingly, a substantial amount of rolled medium generally remains on the core after the splice to a new roll. This medium remaining on the core is not usable after the splice, and is waste. This waste on the core (or waste rolled medium) can be up to 3% of the total medium wound onto the core. Accordingly, what is needed is a system to reliably detect a quantity of medium on an unwinding roll to reduce medium waste on the core before initiating a splice to a new roll. In addition, a system is needed that eliminates variability from outside sources or third parties, such as manufacturers of rolled medium, that leads to medium waste.

In one example of an embodiment, a sensor assembly configured to detect rolled stock on a core includes a sensor configured to detect a first roll of stock unwinding from a core, the stock unwinding from the core of the first roll is supplied as a web of stock, wherein in response to the sensor detecting a first detection configuration, the sensor takes no action and continues to detect the first roll, and wherein in response to the sensor detecting a second detection configuration, the sensor provides a command to a splice assembly to transition to a second roll of stock to replace the first roll of stock.

In another example of an embodiment of the sensor assembly, the sensor is configured to communicate with a manual splice actuation system.

In another example of an embodiment of the sensor assembly, the manual splice actuation system is configured to initiate a splice in response to the command from the sensor to transition from the first roll to the second roll to provide a continuous web of stock.

In another example of an embodiment of the sensor assembly, the sensor is configured to communicate with the manual splice actuation system to bypass an automatic splice actuation system.

In another example of an embodiment of the sensor assembly, the first detection configuration includes detecting the stock on the core.

In another example of an embodiment of the sensor assembly, the second detection configuration includes detecting the core.

In another example of an embodiment of the sensor assembly, the core defines an axis of rotation, the sensor is oriented relative to the first roll perpendicular to the axis of rotation.

In another example of an embodiment of the sensor assembly, the first detection configuration includes detecting a first quantity of stock on the core, the first quantity of stock is above a preprogrammed low level threshold.

In another example of an embodiment of the sensor assembly, the second detection configuration includes detecting a second quantity of stock on the core, the second quantity of stock does not exceed the preprogrammed low level threshold.

In another example of an embodiment of the sensor assembly, the core defines an axis of rotation, the sensor is oriented relative to the first roll parallel to the axis of rotation.

In another example of an embodiment of the sensor assembly, the sensor is configured to detect a portion of the first roll of stock including the core.

In another example of an embodiment of the sensor assembly, the sensor utilizes machine vision to detect the first and second quantity of stock on the core.

In another example of an embodiment of the sensor assembly, the machine vision captures volumetric data of the stock on the core.

In another example of an embodiment of the sensor assembly, the machine vision captures geometric data of the stock on the core.

In another example of an embodiment of the sensor assembly, the preprogrammed low level threshold corresponds to no more than five impressions of rolled stock remain on the core.

In another example of an embodiment of the sensor assembly, the preprogrammed low level threshold corresponds to no more than three impressions of rolled stock remain on the core.

In another example of an embodiment of the sensor assembly, the sensor includes a light source configured to illuminate a portion of the first roll.

In another example of an embodiment of the sensor assembly, in response to the transition to the second roll of stock, no more than five impressions of rolled stock remain on the core.

In another example of an embodiment of the sensor assembly, in response to the transition to the second roll of stock, no more than three impressions of rolled stock remain on the core.

In another example of an embodiment of the sensor assembly, in response to the transition to the second roll of stock, between 1.5 and 2 impressions of rolled stock remain on the core.

Before embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways.

The present disclosure is directed to a detection assembly,and associated detection and control system,. The assembly and system are configured to be retrofit to an assembly utilizing rolled stock, such as a labeling assemblyfor a container, or a packaging systemfor a plurality of containers(such as a stretch wrapping system, a shrink wrapping system, etc.). The assembly,and system,are configured to reduce waste of the rolled stock remaining on a core by initiating a splice in response to detection of a predetermined quantity of rolled stock remaining on the core. This maximizes use of the rolled stock by reducing the regularity of “early” splices between rolls of rolled stock during a continuous roll unwinding process.

It should be appreciated that a “roll of wound medium” or “rolled stock” or “reel-fed stock” can be a roll form of any suitable medium (or stock) wound onto a core. The roll can be any suitable or desired roll width, roll diameter, and/or core diameter. In addition, wound medium (or stock) can be any suitable medium. In one example of an embodiment disclosed herein, the wound medium includes labels for attachments to a container, such as a polyethylene terephthalate (PET) bottle. In another example of an embodiment disclosed herein, the wound medium includes a packaging material for wrapping a plurality of containers, such as a shrink wrap plastic material, a stretch wrap plastic material, or any other suitable packaging film. In yet other examples of embodiments, the wound medium can include any other material that is wound onto the core in roll form and that is unwound for use, and the unwinding of the wound medium is generally occurring in a continuous unwinding process where consecutive rolls of wound medium are spliced together.

With reference now to the figures,is a schematic diagram of an example of an embodiment of an assemblyutilizing rolled stock. The assemblyincorporates a detection systemconfigured to reduce rolled stock waste. The illustrated assembly is a labeling assembly. The labeling assemblyis configured to apply a label to a container. The container can be a bottle, such as a blow molded polyethylene terephthalate (PET) plastic bottle. However, in other embodiments, the container can be any suitable vessel, including, but not limited to, a plastic bottle, a metal can, a glass bottle, or any other vessel configured to contain a material. A nonlimiting example of the labeling assemblycan include a CONTIROLL system for reel-fed wrap-around labelling, manufactured by Krones AG, which has a corporate headquarters in Neutraubling, Germany. It should be appreciated that the labeling assemblycan be a module or step in a process, such as a bottling line. It should also be appreciated that the labeling assemblycan be any suitable assembly for applying labels to a container, and is not limited to a specific manufacturer, process application, or technology.

The labeling assemblycan includes an unwind stand assembly, a splice assembly, and a label application assembly. The unwind stand assemblyis configured to selectively unwind a plurality of rolls of rolled stock,. More specifically, the unwind stand assemblyunwinds at least a first roll of rolled stockand a second roll of rolled stock. The rolls of rolled stock,are separately unwound. Stated another way, each roll of rolled stock,can include its own unwind system to separately and independently unwind each roll of rolled stock,. The separate unwind systems further can concurrently unwind each roll of rolled stock,, for example during the splicing process, which is discussed further below.

Each roll of rolled stock,supplies a respective web,of stock to the splice assembly. More specifically, the first roll of rolled stocksupplies a first web of stockto the splice assembly, while the second roll of rolled stocksupplies a second web of stockto the splice assembly. Stated another way, the splice assemblyreceives a plurality of webs of stock,, each from one of the plurality of rolls of rolled stock,. It should be appreciated that each web of stock,is wound around a core(shown in) to form the respective roll of rolled stock,. The splice assemblythen selects one of the plurality of webs of stock,as an active web of stock. The active web of stockis then supplied to the application assembly. It should be appreciated that the rolled stock unwound from each roll,, and which becomes the web of stock,, can be referred to as rolled stock,.

The application assemblyreceives the active web of stock. Concurrently, the application assemblyreceives a plurality of containers. More specifically, the plurality of containerssupplied to the application assemblyare unlabeled containersThe application assemblyreceives the unlabeled containersmodifies the active web of stock, which are a plurality of labels in web form, and then applies one label to each container. More specifically, the application assemblyapplies an adhesive to each label, applies one label to each containerand cuts each label from the plurality of labels in web form. It should be appreciated that the application assemblycan perform the label application in any order and with additional, fewer, or different steps. The labeled containersexit the application assemblyfor further processing and/or packaging.

As previously noted, the splice assemblyis configured to transition between the plurality of webs of stock,as the active web of stock. The transition occurs in order to maintain a continuous web of the active web of stock. Stated another way, the splice assemblyis configured to change (or select) from the plurality of webs of stock,as the active web of stock. Accordingly, the splice assemblyis configured to change (or select) from the plurality of rolls of rolled stock,, which respectively supply the webs of stock,, as the supply for the active web of stock. To facilitate this transition, or splice, between rolls of rolled stock,, the splice assemblycan include a splice system. The splice system can be any suitable known or future developed system configured to transition from one web of material to a another, separate web of material to continuously supply the active web of stock.

To initiate the splice, the splice assemblyincludes a manual splice actuation system. The manual splice actuation systemcan include a user actuatable member (not shown), such as a switch, button, or other control that can be actuated by the user (or an operator) to initiate operation of the splice assembly. For example, actuating the control on the manual splice actuation systemcan manually initiate operation of the splice assembly, triggering a splice from one of the webs,to the other of the webs,. This in turn transitions one of the webs,as the active web of stockto the other of the webs,as the active web of stock. Stated another way, the triggering the splice transitions one of rolls of rolled stock,as the supply for the active web of stockto the other of the rolls of rolled stock,as the supply for the active web of stock. To facilitate communication, the manual splice actuation systemis in operable communication with the splice assemblyby a data connection(also referred to as a first data connectionor a first communication connection).

It should be appreciated that the example of the embodiment of the labeling assemblydiscussed herein illustrates two rolls of rolled stock,, and more specifically two rolls,of labels. The two rolls are provided for purposes of illustration, and are not intended to be limiting. The labeling assemblyincludes at least two rolls of rolled stock,. In other examples of embodiments the plurality of rolls of rolled stock,include more than two rolls. Systems can include three, four, five, or six or more rolls of rolled stock,to supply the application assembly. Utilizing additional rolls of rolled stock reduces the frequency of changing unwound rolls with new, fully wound rolls of rolled stock. As such, the first roll of rolled stockcan be any of the plurality of rolls of rolled stock, and the second roll of rolled stockcan be any other of the plurality of rolls of rolled stock. The splice assemblysimply changes between the rolls of rolled stock,in order to provide a continuous web of as the active web of stock. It should be appreciated that while the assemblyillustrates two rolls of rolled stock,, the assemblyshould be considered to include at least two rolls of rolled stock,. In other examples of embodiments, the assemblycan include any suitable number of rolls of rolled stock,to facilitate operation. It should also be appreciated that the roll of rolled stock,that is supplying the active web of stockcan be referred to as an active roll of rolled stock,.

With continued reference to, a detection assembly(also referred to as a core detection assemblyor a stock on core detection assemblyor a sensor assembly) is operably connected to the assembly. The detection assemblyis configured to be retrofit to any suitable labeling assembly. In one or more examples of embodiments, a manufacturer can restrict access to certain control logic associated with the labeling assembly. As such, once the labeling assemblyis installed and operational, the party that purchased (and/or operates) the labeling assemblyis unable to access or otherwise change or modify the control logic. In these examples, the assemblycan include both an automatic splice actuation system and a manual splice actuation system that allows an operator to manually bypass the automatic splice actuation system. The detection assemblyadvantageously can operate without requiring modification of the existing control logic on a labeling assembly, as the detection assembly is configured to communicate with the manual splice actuation system, which does not require access or modification of the inaccessible control logic of the automatic splice actuation system. Accordingly, the core detection assemblycan be installed on any known labeling assemblyas an aftermarket retrofit addition. In other examples of embodiments, the detection assemblycan advantageously operate with or without requiring modification of the existing control logic on the assembly. Accordingly, the detection assemblycan be installed on any known assembly(or, discussed further below), as an aftermarket retrofit addition. It should be appreciated that in other examples of embodiments, the manufacturer can allow for communication of aftermarket components to communicate with certain components of the assembly, including but not limited to the splice actuation system.

The core detection assemblyincludes a plurality of sensors. In the illustrated embodiment, there is one sensorassociated with each roll of rolled stock,. In the illustrated embodiment, the sensorsinclude a first sensorand a second sensor. The first sensoris associated with the first roll of rolled stock, while the second sensoris associated with the second roll of rolled stock. Each sensoris configured to monitor the associated roll of rolled stock,, and detect a low level of stock remaining on the core. In the illustrated example of an embodiment, each sensoris configured to detect the core when the core is exposed. Exposure of the core indicates that the stock on the associated roll has been fully used, and a splice to another roll is necessary.

Each sensorcan be mounted to the labeling assemblyin any suitable manner to orient the sensorrelative to the associated roll of rolled stock,to facilitate detection of the core. For example, each sensorcan be mounted to the labeling assemblyusing metal tubing, brackets, fasteners, or any other suitable mounting structure. In other examples of embodiments, each sensorcan be free standing. Each sensorsimply needs to be positioned to maintain the necessary orientation relative to the associated roll of rolled stock,to detect the rolled stock,and/or the coreduring unwinding of each roll of rolled stock,to support operation of the labeling assembly. In the illustrated embodiment, each sensoris oriented perpendicular to an axis of rotationof the associated rolled stock,(shown in). Stated another way, each sensorincludes an emitterand a receiver(shown in). The emitteris oriented to emit a detection signalthat is aligned with a radius of the rolled stock,. Stated another way, the emitteris oriented to emit a detection signalthat is perpendicular to the axis of rotation of the associated rolled stock,. The receiveris oriented to receive the emitted signal. In the illustrated embodiment each sensoris a Q4X Series Laser Sensor sold by Banner Engineering Corp. headquartered in Minneapolis, Minnesota, USA. However, in other embodiments, any suitable sensor that can be configured to detect a rolled stock, a core of the rolled stock, and differentiate between the rolled stock and the core can be utilized in the core detection assembly. Thus, suitable sensorscan include, but are not limited to, laser, infrared, optical, or other photoelectric sensor. In addition, while the illustrated sensorcan be a diffuse-reflective type sensor, in other embodiments, the sensorcan be a through-beam sensor, retro-reflective sensor, or any other sensor configured to detect a change in surface conditions of an object. It should be appreciated that the axis of rotationof the roll of rolled stock,can be defined by the core(or the axis of rotation of the core).

Each sensoris in operable communication with the manual splice actuation systemby an associated data connection. More specifically, the first sensoris in operable communication with the manual splice actuation systemby a data connection(also referred to as a second data connectionor a second communication connection). The second sensoris in operable communication with the manual splice actuation systemby a data connection(also referred to as a third data connectionor a third communication connection). Each of the data connectionscan be wired, wireless, or any suitable system for communication (e.g., radio, cellular, BLUETOOTH, 802.11 Wireless Networking protocol, etc.).

Each sensoremits a signal, and the receiver(also referred to as a detector) detects the emitted signal. In the illustrated embodiment, the first sensoremits a first signalThe first signalis emitted to the first roll of rolled stock. The receiverof the first sensorthen detects the emitted first signal. Similarly, the second sensoremits a second signalThe second signalis emitted to the second roll of rolled stock. The receiverof the second sensordetects the emitted second signal

Each sensoris programmed to detect a first surface and a second surface, the second surface being different from the first surface. Stated another way, each sensor,is programmed to detect a first detection configuration and a second detection configuration. With reference to, each sensoris configured to detect the first detection configuration and detect the first surface, which is the rolled stock,(or stock rolled on the core). In the illustrated embodiment, the rolled stock,is the roll of labels. With reference to, each sensoris also configured to detect the second detection configuration and detect the second surface, which is the coreof the roll of rolled stock,. In programming each sensorthe sensor is configured to detect the first surface,and the second surface. To detect the change in surface conditions, each sensor,can be programmed to detect changes in reflectivity, opacity, whiteness/brightness, color, refractivity, or any other property suitable for differentiating the first surface from the second surface. A detected change between the first surface,and the second surfaceresults in detection of a responsive change in surface conditions of the roll of rolled stock,. Stated another way, the programmed detected change in surface conditions between the first surface,and second surfaceresults in an indication that all of the rolled stock,is empty. The first surface,(i.e., the rolled stock or rolled labels) are completely unwound (or used) exposing the second surface(i.e., the coreof the roll).

illustrates an example of an embodiment of a detection and control systemthat utilizes information detected by the sensorsto initiate a splice between rolls of rolled stock,. The systemoperates in association with the detection assemblyto advantageously reduces waste by initiating the splice in response to the core of the active roll of stockorbeing exposed and subsequently detected by the associated sensoror. This maximizes use of the rolled stockorthat is stored on the respective rollor. The systemis in communication with the manual splice actuation systemto initiate actuation of the manual splice actuation system. This advantageously facilitates a retrofit addition of the detection assemblyand associated systemto any suitable labeling assembly.

The detection and control systemcan be integrated into the detection assembly. For example, the systemcan be a separate controller (not shown) configured to receive information detected by the sensorsand further selectively communicate commands to actuate the manual splice actuation systemof any suitable labeling assembly. In other examples of embodiments, the systemcan be operably connected to the manual splice actuation systemto initiate selective operation of the manual splice actuation systemin response to the information detected and communicated by the sensorsof the core detection assembly. The core detection and control systemincludes a series of processing instructions or steps that are depicted in flow diagram form.

Referring to, the process of the core detection and control systembegins at step. At step, the labeling assemblyis operating to apply labels to containers. One of the plurality of rolls of rolled stock,is the active roll of rolled stockor. The sensororthat is associated with the active rolloris the active sensororThe active roll of rolled stockoris being unwound, with the associated unwound web of stockorbeing the active web of stock. It should be appreciated that the roll of rolled stock,can be any two rolls of a plurality of rolls of stock. Stated another way, there can be two or more rolls of rolled stock in the plurality of rolls of stock.

At step, the systemdetects whether the manual splice actuation systemhas been actuated. More specifically, the systemdetects whether an operator or other user has manually actuated the manual splice actuation system, such as by actuating the user actuatable member. If the process does not detect that the manual splice actuation systemhas been actuated, or “no,” the process proceeds to step. If the process does detect that the manual splice actuation systemhas been actuated, or “yes,” the process proceeds to step.

At step, the systemreceives detection data from the active sensororThe process then determines whether the active sensorordetects the second surface (i.e., the core of the active roll). If the active sensorordetects the first surface of the active rollor, or “no,” the active sensororis detecting the unwinding stockor. The process then returns to stepand repeats. If the active sensorordetects the second surface of the active rollor, or “yes,” the active sensororis detecting the core of the active rollor. This indicates that the active rolloris completely unwound by exposing the core. The process proceeds to step, where a command is initiated (and sent) to actuate the manual splice actuation system. The manual splice actuation systemreceives this command, and proceeds to step.

At step, the manual splice actuation systeminitiates a splice from the active roll to a secondary roll. It should be appreciated that in response to detecting actuation of the manual splice at step, an operator has manually initiated actuation of the manual splice. For example, the operator has actuated the user actuatable member to initiate a splice through the manual splice actuation system. It should be appreciated that in response to the active sensorordetecting the second surface of the active roll (or detecting the core) at step, the process initiates the command to operate the manual splice actuation systemat step.

The manual splice actuation systemtransitions the active roll. For example, in one embodiment, where the first rollis the active roll, the actuation of the manual splice actuation systemtransitions from the first rollto the second rollas the active roll. After completion of the splice, the second rollbecomes the active roll, with the unwound web of stockbeing the active web of stock. In another example of an embodiment, where the second rollis the active roll, actuation of the manual splice actuation systemtransitions from the second rollto the first rollas the active roll. After completion of the splice, the first rollbecomes the active roll, with the unwound web of stockbeing the active web of stock. Again, it should be appreciated that in examples of embodiments of the unwind stand assemblyhaving three or more rolls, the first rolland the second rollcan be any two rolls of the three or more rolls. After the successful splice and transition of the active roll, the completed roll (or roll that was spliced out) can be removed and replaced with a new roll. The new roll can later be spliced in for use when one (or more) other rolls used.

After the successful splice, the process proceeds to stepwhere the active sensor is transitioned. More specifically, the active sensor is transitioned from the completed roll (or the roll spliced out) to the new active roll (or the roll spliced in). In the embodiments where the splice transitions from the first rollto the second roll, the active sensor transitions from the first sensorto the second sensorSimilarly, in the embodiment where the splice transitions from the second rollto the first roll, the active sensor transitions from the second sensorto the first sensorFollowing reassignment of the active sensororfor monitoring the change in active rollor, the process then returns to step, where the detection of either a manual splice (at step) or the second surface (at step) repeats for the new active roll.