EP-4737367-A2 - SYSTEM FOR REDUCING ROLLED STOCK WASTE

EP4737367A2EP 4737367 A2EP4737367 A2EP 4737367A2EP-4737367-A2

Abstract

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.

Inventors

The designation of the inventor has not yet been filed

Assignees

Niagara Bottling, LLC

Dates

Publication Date: 20260506
Application Date: 20230614

Claims (15)

A sensor assembly configured to detect rolled stock on a core comprising: a sensor (104) configured to detect a first roll of stock (20) unwinding from a core (28), the stock unwinding from the core of the first roll is supplied as a web of stock (26), wherein in response to the sensor detecting a first detection configuration, the sensor takes no action and continues to detect the first roll, wherein in response to the sensor detecting a second detection configuration, the sensor provides a command to a splice assembly (16) to transition to a second roll of stock (24) to replace the first roll of stock, and wherein the sensor (104) is configured to communicate with a manual splice actuation system (34).
The sensor assembly of claim 1, wherein the manual splice actuation system is configured to initiate a splice in response to the command from the sensor (104) to transition from the first roll (20) to the second roll (24) to provide a continuous web of stock; and/or wherein the sensor is configured to communicate with the manual splice actuation system to bypass an automatic splice actuation system.
The sensor assembly of claim 1 or 2, wherein the first detection configuration includes detecting the stock on the core; and/or wherein the second detection configuration includes detecting the core (28); and/or wherein the core defines an axis of rotation, the sensor (104) is oriented relative to the first roll (20) perpendicular to the axis of rotation.
The sensor assembly of claim 1, 2 or 3, wherein 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 and/or wherein 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.
A labeling assembly for applying a label to a container, the assembly comprising: an unwind stand assembly configured to selectively unwind at least two rolls of stock, each roll of the at least two rolls of stock wound around a respective core; a splice assembly configured to receive a web of stock from each roll of the at least two rolls of stock, each web of stock in the form of a plurality of labels; a label application assembly configured to receive the plurality of labels and apply a label to a container; and a sensor assembly configured to detect an unwinding of a first roll of stock of the at least two rolls of stock, the sensor assembly further configured to, in response to detecting the core of the first roll of stock, send a signal to the splice assembly to transition from the web of stock of the first roll of stock to the web of stock of the second roll of stock of the at least two rolls of stock.
The labeling assembly of claim 5, wherein the sensor assembly being configured to detect the core of the first roll of stock includes the sensor assembly being configured to detect a quantity of stock on the core of the first roll of stock not exceeding a preprogrammed low level threshold; and optionally wherein the preprogrammed low level threshold corresponds to no more than five impressions of rolled stock remaining on the core of the first roll of stock, or wherein the preprogrammed low level threshold corresponds to no more than three impressions of rolled stock remaining on the core of the first roll of stock.
The labeling assembly of claim 5 or 6, wherein the core of the first roll of stock defines an axis of rotation and a sensor of the sensor assembly is oriented relative to the first roll of stock parallel to the axis of rotation.
The labeling assembly of claim 5, 6 or 7, wherein the sensor assembly utilizes machine vision to detect a quantity of stock on the core of the first roll of stock; and optionally wherein the machine vision captures volumetric data of the quantity of stock on the core of the first roll of stock; and/or wherein the machine vision captures geometric data of the quantity of stock on the core of the first roll of stock.
A sensor assembly configured to detect rolled stock on a core, the assembly comprising: a sensor configured to 1) detect a first roll of stock unwinding from a core and, 2) in response to detecting a quantity of stock on the core that does not exceed a predetermined threshold, send a signal to a splice assembly to transition to a second roll of stock to replace the first roll of stock.
The sensor assembly of claim 9, wherein the predetermined threshold corresponds to no more than five impressions of rolled stock remaining on the core or wherein the predetermined threshold corresponds to no more than three impressions of rolled stock remaining on the core or wherein the predetermined threshold corresponds to between 1.5 and 2 impressions of rolled stock remaining on the core.
A packaging assembly for applying packaging material to a plurality of containers, the assembly comprising: an unwind stand assembly configured to selectively unwind at least two rolls of stock, each roll of the at least two rolls of stock wound around a respective core; a splice assembly configured to receive a web of stock from each roll of the at least two rolls of stock, each web of stock in the form of packaging wrap; a packaging application assembly configured to receive the packaging wrap and apply the packaging wrap to the plurality of containers; and a sensor assembly configured to detect an unwinding of a first roll of stock of the at least two rolls of stock, the sensor assembly further configured to, in response to detecting the core of the first roll of stock, send a signal to the splice assembly to transition from the web of stock of the first roll of stock to the web of stock of the second roll of stock of the at least two rolls of stock.
The packaging assembly of claim 11, wherein the sensor assembly being configured to detect the core of the first roll of stock includes the sensor assembly being configured to detect a quantity of stock on the core of the first roll of stock not exceeding a preprogrammed low level threshold.
The packaging assembly of claim 12, wherein the preprogrammed low level threshold corresponds to no more than five impressions of rolled stock remaining on the core of the first roll of stock; or wherein the preprogrammed low level threshold corresponds to no more than three impressions of rolled stock remaining on the core of the first roll of stock.
The packaging assembly of claim 11, 12 or 13, wherein the sensor assembly utilizes machine vision to detect a quantity of stock on the core of the first roll of stock; and optionally wherein the machine vision captures volumetric data of the quantity of stock on the core of the first roll of stock; and/or wherein the machine vision captures geometric data of the quantity of stock on the core of the first roll of stock.
The packaging assembly of claim 11, 12, 13 or 14, wherein the packaging wrap is in the form of a film configured for shrink wrapping.

Description

CROSS-REFEENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63/352,126, which was filed on June 14, 2022 and entitled "System For Reducing Rolled Stock Waste," the entire contents of which is hereby incorporated by reference in its entirety. FIELD OF THE DISCLOSURE 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. BACKGROUND 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. SUMMARY 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