Apparatus and Method for Automated Blade Change for Tissue Saw
A blade storage array is detachably mountable with a tissue log cutting saw. The saw has a cutting arm with a tool holder receptacle adapted and configured to hold a circular saw blade for the saw. The array has a plurality of storage units. Each storage unit is adapted and configured to store a circular saw blade for the saw. Each storage unit has a tool holder receptacle adapted and configured to hold a circular saw blade. Each storage unit is adapted and configured to move perpendicularly to the saw blade center axis.
This application is a divisional application of application Ser. No. 16/109,028, filed on Aug. 22, 2018, which claims the benefit of provisional application Ser. No. 62/553,244, which was filed on Sep. 1, 2017, the disclosures of which are incorporated by reference herein.
SUMMARYThis disclosure relates to a system for the automatic changing of a blade for a tissue log saw. The blades for the tissue log saw are stored in an array of storage units. Each storage unit in the array is configured to store a blade for the saw. Each storage unit is also extendable from the array to allow a stored blade to be loaded from the storage unit to the cutting head and to allow an expired blade to be received into the storage unit from the cutting head. When the array is interfaced with the saw, at least one storage unit in the array is empty to receive an expired or used blade from the saw, and the remainder of storage units in the array are preloaded with blades for the processing operation. The system facilitates tracking and inventory of blades, and allows the array of storage units to be moved to a location in a converting facility suited for inspection of the blades, removal of the blades from the storage units, and insertion of blades into storage units. The system minimizes the interaction of machine operators and maintenance personnel with the blades.
The exemplary system 20 described below and shown in the drawings includes an array 22 that interfaces with a saw 24 and provides blades 26 for a cutting arm 28 of the saw through a plurality of storage units 30 arranged in the array. Each storage unit 30 in the array 22 is configured to store a blade 26 for the saw 24. The saw 24 may be configured to cut tissue logs 32 entering a saw house 34 on a conveyor 36. In a general sense and as further modified as described below, the saw 24 and the cutting arm 28 may be of the type, for instance, as shown by way of example and not in any limiting sense, in U.S. RE30,598, U.S. Pat. Nos. 5,557,997, and 6,123,002 the disclosures of which are incorporated by reference herein. The array 22 of storage units 30 could thus contain many blades 26 for the saw 24 for a particular saw cutting operation or procedure as may be required by the application. As will be described below, each storage unit 30 is configured to store, receive, and transfer the blade 26, whether a new blade, an expired blade, or partially-used blades for later use. The array may move in a direction generally parallel to the saw blade center axis. The movement may be independent of the saw or the array may move once coupled with the saw 24. In addition or alternative, the storage units in the array may move in a direction generally parallel to the saw blade center axis relative to the saw once the array is coupled to the saw. In addition or alternative, the storage units may be stationary in the direction of travel of the saw blade center axis once the array is coupled with saw, and the saw may move as necessary. In each case, the array and/or storage unit may move, as needed to receive an expired blade, and load and mount a next-in-queue blade for use on the saw cutting arm. As used herein, the term “expired” means that the blade condition is used such that it is no longer suitable for the particular processing operation currently being conducted on the saw, and not necessarily that the blade is to be scrapped, and the term “new” means blades that have been readied for a particular saw processing operation, and not necessarily that the blades are new from a vendor or supplier or have never been used.
The array 22 may comprise a housing 40 configured to hold the plurality of storage units 30. The array 22 may be portable and may be detachably mounted to the structure comprising the saw 24 and saw house 34. An interface 42 may be built into a wall panel or other structural member of the saw house 34 to provide a detachable mount for the array 22 of storage units 30. The interface 42 may allow the array 22 to be physically, mechanically, electrically, and/or electronically detachably mounted to a wall panel or other structural member of the saw house 34. A system of cooperating connectors, for instance, pneumatic or hydraulic actuators 43 may engage with each and/or cooperate to secure the array 24 to the saw housing 34. The interface 42 may provide a connection point 44 for the array 22 to mechanically connect with the saw. For instance, in one embodiment, the array may have a linkages or mechanical actuators that connect with cooperating linkages or mechanical actuators on the saw via the interface, thereby allowing the linkages on the array to be actuated via the saw. In other words, the linkages on the array may connect with linkages on the saw when the array is detachably mounted to the saw, so the linkages on the array are an extension of those on the saw. In this manner, movement of the storage unit between the retracted and extended position, and actuation of the storage unit blade tool holder receptacle, all of which will be described below, may be accomplished via mechanical linkages extending from the saw to the array. This would dispense with the need to provide electronic control systems on the array. In addition or alternative, the array 22 may be configured to draw electrical power and/or pneumatic or hydraulic fluid sources from the saw 24. The array 22 may also have an on-board rechargeable battery to power electrical and electronic equipment on the array or draw electrical power from another external source (not shown). The array 22 may also be equipped with pneumatic or hydraulic actuators. The interface 42 and the connection point 44 may be configured to supply the array 22 with pneumatic or hydraulic fluid from the saw. The array 22 may also draw pneumatic or hydraulic fluid from the facility through external connections (not shown). The array may also have on board pumps to supply pneumatic or hydraulic fluid to respective components on the array. Accumulators, valves, and other conventional equipment needed for pneumatic or hydraulic actuation systems may be provided on the array, as applicable. As will be explained below in greater detail, the array 22 may also be electronically coupled to the saw 24 at the interface 42 and connection point 44 so control signals generated by the saw may be transmitted to the array for certain array based functions, and signals from the array may be transmitted to the saw for certain saw based functions. The transmission may be through a network 46 and may be wireless 48. The array 22 of storage units 30 may be provided in the form of a cart with wheels (e.g., swivel casters) 50 that may be maneuvered to a position that allows the cart to mount directly with the saw house 34 via the interface 42. The movement may be manual or automated via a track or other guidance system. The array of storage units in the form of a rolling cart allows the array to be maneuvered into the tight spaces on the converting floor that are usually found around the saw house and structure of the saw.
Once all the blades in the array of storage units are expired, the array of storage units can be unmounted from the saw house and transported to an area where blade disposition occurs. The blade disposition location is preferably not on the converting floor, but in a more remote area with plenty of space, lighting, and other support for safe handling and disposal of the expired blades.
For a saw or saw cutting process, two or more portable arrays of storage units may be provided. For example, once all the blades in the “in use” array of storage units are expired (e.g., of an unusable diameter for the particular processing operation currently being conducted), the second fully stocked array of storage units with new blades may be brought online, mounted to a wall panel or other structural member of the saw house via the interface, and quickly exchanged with the array of storage units with the expired blades. In this way, the restocking of the array of storage units reduces potential operational bottlenecks in the saw cutting operation.
In another aspect, the arrays may be part of a subscription system provided by a supplier. The supplier may have multiple arrays that may be provided to a customer for use. When the blades in a particular array are expired, the customer may return the array to the supplier for a new array of blades. The array may form a part of a shipping container to allow transport of the array between the supplier and the customer. Once an array is returned to the supplier, the array may be restocked with new or refurbished blades and calibrated for reuse. Functional aspects of the array may be checked and repaired as necessary. The supplier may collect and analyze blade operational data from returned arrays and provide recommendations and service bulletins in connection with the array or saw to customers. The data collection and analysis may be used for general product improvement.
The array 22 of storage units 30 may have a power supply, sensors, motion detectors, a computer processor, a memory storing data, and computer equipment that allows the array to connect to the network 46 with a like or another computer system or programmable logic control for the saw via the interface 42 and the connection point 44. The array memory may store data structures of information 52 regarding the blades that are currently stored in the unit. Each storage unit 30 may also be equipped with like equipment so the blade information is maintained at the storage unit level. In one example, the array and/or the storage unit may be configured with a RFID device (e.g., a label or tag). The saw 24 may be configured to read and/or write to the RFID device on the array, storage unit or blade. The information 52 may include blade diameter, blade material, last saw cutting operational data, last inspection, last sharpening, last run-time, cumulative run-time, etc. The blade information 52 may also include information about a specific blade or storage unit that should be bypassed in the array and not used in the saw cutting operation because of a maintenance condition or expired inspection status. Information 52 regarding a blade may be transferred on the network 46 between the saw 24 and the array 22 so the array may correlate specific information about a blade and a storage unit 30. Information 52 from the saw 24 may be downloaded to the array 22 so the array stores information about each blade and its respective storage unit 30. The download of information may occur during operation with the array connected to the saw and/or prior to removing the array from the saw. The download of information 52 may occur via the network 46 or via the interface 42 and the connection point 44. Information 52 including blade data from the array 22 may also be uploaded to the saw 24 once the array is mounted to the saw at the interface 42. The upload of information 52 may occur via the network 46 or via the interface 42 and the connection point 44. Storing information about each blade via the array allows for the reuse of blades. For instance, a blade that has been previously used in connection with processing large diameter rolls may still have a diameter sufficient to allow processing for smaller diameter rolls. If a blade became too small for a particular product or processing operation at the time it was in use, it could be retrieved and used again in connection with a subsequent product or processing operation. An array of storage units containing partially used blades could be used in a different saw cutting operation, and the array or storage unit RFID label information may be uploaded to the saw so that the saw and array may synchronize (and/or the storage units may sequence) in a manner necessary to mount the correct diameter blade for the desired process.
Each blade 26 may define a plane 60 (
To load the new, next in queue blade 26′, the selected storage unit 30″ will move from the retracted position within the array 22 to the extended position away from the array into the saw house 34, as shown in
The array 22, the storage unit 30, or the saw 24 may be configured with a blade cleaner 90 to allow for cleaning of the blade 26.
In view of the foregoing, it will be seen that the several advantages are achieved and attained. The embodiments were chosen and described in order to best explain the principles of the disclosure and their practical application to thereby enable others skilled in the art to best utilize the various embodiments and with various modifications as are suited to the particular use contemplated. As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.
Claims
1. A blade storage array for a tissue log cutting saw, the array having a plurality of storage units, each of the storage units being adapted and configured to store a circular saw blade for the tissue log cutting saw, the array having a memory configured to store a data structure, the data structure comprising a plurality of data items associated together as a storage unit profile, the data items of the storage unit profile comprising data representative of at least one of a blade diameter, a blade material, last saw cutting operational data, a last blade inspection, a last blade sharpening, a last blade run-time, a cumulative number of cuts, and a cumulative blade run-time, the data items of the storage unit profile being associated with at least one circular saw blade stored in the storage unit of the array, the array being configured to transmit the storage unit profile to the tissue log cutting saw.
2. The array of claim 1 wherein the array comprises a processor, the processor is configured to store the data structure in the memory, the processor is adapted and configured to be in communication with the saw via a network and exchange data relating to the storage unit profile with the tissue log cutting saw.
3. The array of claim 2 wherein in response to detection of the array being detachably mounted to a structure of the saw and in communication on the network with the tissue log cutting saw, the processor is further configured to automatically update the storage unit profile based on operational data generated by the tissue log cutting saw.
4. The array of claim 2 wherein, in response to detection of the array being detachably mounted to a structure of the saw and in communication on the network with the saw, the processor is further configured to automatically upload the storage unit profile to a processor associated with the tissue log cutting saw.
5. The array of claim 1 wherein each storage unit has a tool holder receptacle that is adapted and configured to releasably secure the circular saw blade in the storage unit in manner such that the circular saw blade defines a plane in the storage unit with the circular saw blades stored in the storage units within the array being aligned coaxially and in parallel planes that are axially spaced within the blade storage array, each storage unit being adapted and configured to reciprocate in a linear direction parallel to the plane of the circular saw blade in the storage unit, each storage unit being adapted and configured to reciprocate in the linear direction independently of another storage unit, each storage unit being adapted and configured to exchange the saw blade between the tissue log cutting saw and the storage unit when the blade storage array is detachably mounted to the tissue log cutting saw.
6. The array of claim 1 wherein the data structure comprising the plurality of data items associated together as the storage unit profile includes a storage unit profile for each circular saw blade stored in a respective storage unit.
7. The array of claim 1 wherein the array is adapted and configured to move in a direction generally parallel to the saw blade center axis.
8. The array of claim 1 wherein the array is adapted and configured to move without connection to the tissue log cutting saw.
9. The array of claim 1 wherein the array comprises a radio frequency identification device, the radio frequency identification device is adapted and configured to transmit the storage unit profile to the tissue log cutting saw.
10. The array of claim 9 wherein the radio frequency identification device is adapted and configured to receive data from the tissue log cutting saw to update the storage unit profile.
11. The array of claim 1 wherein the memory comprises a memory associated with each of the circular saw blades stored in the storage units.
12. The array of claim 11 wherein the memory associated with each of the circular saw blades comprises a radio frequency identification device.
13. A method comprising:
- providing an array with a plurality of storage units, at least one of the storage units storing a circular saw blade for a tissue log cutting saw, the at least one storage unit being adapted and configured to exchange the circular saw blade with the tissue log cutting saw when the blade storage array is detachably mounted to the tissue log cutting saw, the array having a memory configured to store a data structure;
- storing a data structure in the memory of the array, the data structure comprising a plurality of data items associated together as a storage unit profile, the data items of the storage unit profile comprising data representative of at least one of a blade diameter, a blade material, last saw cutting operational data, a last blade inspection, a last blade sharpening, a last blade run-time, a cumulative number of cuts, a cumulative blade run-time, the data items of the storage unit profile being associated with the circular saw blade stored in the at least one storage unit;
- releasably mounting the array to a structure of the tissue log cutting saw; and
- transmitting the storage unit profile to the tissue log cutting saw.
14. The method of claim 12 wherein the array comprises a processor, the processor is configured to store the data structure in the memory; and wherein the step of transmitting the storage unit profile to the tissue log cutting saw includes placing the array in communication with the saw via a network and exchanging data relating to the storage unit profile with the tissue log cutting saw.
15. The method of claim 14, wherein in response to detection of the array being releasably mounted to the structure of the tissue log cutting saw and the array being on the network in communication with the tissue log cutting saw, automatically uploading data associated with the storage unit profile to a processor associated with the saw.
16. The method of claim 13, wherein the step of storing the data structure in the memory of the array includes associating the data structure with a particular saw blade stored in a particular storage unit of the array.
17. The method of claim 13, further comprising updating the storage unit profile based on operational data generated by the tissue log cutting saw.
18. The method of claim 13, wherein the step of transmitting the storage unit profile to the saw includes configuring a radio frequency identification device to transmit the storage unit profile to the tissue log cutting saw.
19. The method of claim 18 further comprising configuring the radio frequency identification device to receive operational data from the saw to update the storage unit profile.
20. The method of claim 13, further comprising:
- removing the array from the structure of the tissue log cutting saw;
- providing a further array, the further array having a plurality of storage units, at least one of the storage units in the further array storing a circular saw blade for the tissue log cutting saw, the at least one storage unit being adapted and configured to exchange the circular saw blade with the tissue log cutting saw when the further blade storage array is detachably mounted to the tissue log cutting saw, the further array having memory configured to store a data structure;
- storing a data structure in the memory of the further array, the data structure comprising a plurality of data items associated together as a storage unit profile, the storage unit profile data items comprising data representative of at least one of a blade diameter, a blade material, last saw cutting operational data, a last blade inspection, a last blade sharpening, a last blade run-time, a cumulate number of cuts, a cumulative blade run-time, the storage unit profile data being associated with at least one circular saw blade stored in the storage unit in the further array; and
- releasably mounting the further array to the structure of the tissue log cutting saw; and
- transmitting the storage unit profile of the further array to the tissue log cutting saw.
21. The method of claim 20, wherein the step of transmitting the storage unit profile to the tissue log cutting saw includes automatically uploading data associated with the storage unit profile of the further array in response to detection of the further array being mounted to the structure of the saw.
22. The method of claim 20 further comprising updating the storage unit profile of the further array based on operational data generated by the tissue log cutting saw.
Type: Application
Filed: Feb 4, 2021
Publication Date: Jun 17, 2021
Inventors: Matthew J. Chike (Luxemburg, WI), Stefano Spinelli (Green Bay, WI), Cory P. Gussert (Pulaski, WI), Jonathon T. Zahn (Green Bay, WI)
Application Number: 17/167,142