Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS AND METHODS FOR REEL HANDLING
Field
[0001] Apparatus and methods for reel handling are described herein and,
specifically, reel
handling using a tool, optionally attached to a robotic arm, configured for
removal of a spent reel
core and placement of a new reel on a spindle of packaging equipment.
Backormand
[0002] Packaging equipment often is used to form packages for items, such
as food items,
from flexible material, such as film. The flexible material can be provided on
a reel that is placed
on a spindle of the packaging equipment for unwinding and further processing.
Once a reel is
spent, a core of the reel is removed from the spindle of the packaging
equipment and a new reel of
material can be placed on the spindle. However, the film reels can weigh 15 to
50 or more pounds,
which can make them cumbersome to handle. The reel can have an outer diameter
of about 30
inches, for example, and the core can have a diameter of between about 1 and 4
inches, although
the reel and core can have a wide variety of dimensions.
[0003] One approach to automating handling of film reels is to manipulate
the reels by the
cores. For example, U.S. Patent Nos. 4,934,624; 5,265,999; and 6,276,629
disclose automated
handling equipment for placing reels of feel onto spindles of equipment by
attachment or grabbing
of the core.
[0004] A hybrid approach to manipulating a reel is disclosed in U.S.
Patent No. 9,120,636.
This patent discloses first clamping the periphery of the reel prior to
insertion of a spindle through
a central opening, but then movies the reel via the spindle to the packaging
machine. More
specifically, the patent discloses using a pair of clamping arms to clamp a
reel therebetween by
contacting the periphery of the reel. A spindle is inserted into a central
opening of the reel while
the reel is held by the clamping arms. The clamping arms move the reel, with
the spindle, into a
stand where the reel is supposed by the spindle. The clamping arms are then
released from
clamping the periphery of the reel, followed by being rotated so that seats of
the clamping arms
can then lift the reel by the spindle and move the reel, via the spindle, from
the stand to a packaging
machine.
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[0005] A different approach to manipulating a reel is disclosed in U.S.
Patent No.
8,353,662. Instead of lifting the reel by a core, this patent discloses the
use a suction head at the
end of an articulated, robotic arm to move the reel. A mechanical gripper is
provided in a central
portion of the suction head for use with removal of a core. Thus, the suction
head includes a portion
for manipulation of a reel by contacting the side face of the reel, and a
different portion for removal
of the core of a spent reel. However, there are moving parts associated with
the suction head. For
example, the mechanical gripper includes jaws and actuators. Also, the suction
head contacts the
side face of the reel.
[0006] Yet another approach is disclosed in U.S. Patent No. 5,249,757.
Like the '662
patent disclosed immediately above, this patent discloses the use of a
gripping device having
tubular appendages for contacting the periphery of a reel. The gripping device
also has a
mechanism for removal of a core of a spent reel. However, this patent
discloses that the appendages
and the mechanism for removal of the spent reel are movable via pressurized
actuation.
Su m mary
[0007] A multi-function reel change tool is provided for placing a reel of
material on a
spindle of packaging equipment and removing a core of a spent reel of material
from the spindle.
The tool includes a first set of one or more operative structures arranged for
lifting a reel of
material, supporting the reel of material during movement toward the packaging
equipment, and
placing the reel of material on the spindle by contacting the outer periphery
of the reel of material.
The tool also includes a second set of one or more operative structures,
different at least in part
from the first set of operative structures, arranged for pulling the core of a
spent reel of material
from the spindle and supporting the core during movement of the core away from
the packaging
equipment by contacting the outer periphery of the core.
[0008] Optionally, the tool has an axis of rotation about which the tool
can be rotated to
move between a first orientation, whereby the first set of operative
structures are arranged for
lifting a reel of material and placing the reel of material on the spindle,
and a second orientation,
different from the first orientation, whereby the second set of operative
structures are arranged for
removing the core of a spent reel of material from the spindle.
[0009] In one aspect, the tool includes one or more rear support members,
wherein the first
set of operative structures includes a first group of prongs projecting
relative to the one or more
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rear support members for cradling the reel of material, and wherein the second
set of operative
structures includes a second group of prongs projecting relative to the one or
more rear support
members for cradling the core.
1000101 In another aspect, the reel change tool includes one or more rear
support members,
wherein the first set of operative structures includes a first group of prongs
projecting relative to
the one or more rear support members for cradling the reel of material, and
wherein a pair of the
second set of operative structures are provided, with each of the pair
including a second group of
prongs projecting relative to the one or more rear support members for
cradling the core.
[00011] In yet another aspect, the reel change tool includes one or more rear
support
members, wherein the second set of operative structures includes a first pair
of prongs projecting
relative to the one or more rear support members and a second pair of prongs,
different from the
first pair of prongs, projecting relative to the one or more rear support
members, and wherein the
first set of operative structures includes the first and second pairs of
prongs.
[00012] In any of the foregoing aspects, the second group of prongs can
include a pair of
prongs spaced a distance apart that is smaller than a diameter of the core for
supporting the core
during movement of the core away from the packaging equipment.
[00013] Optionally, the first and second groups of prongs have at least one
prong in
common.
[00014] Optionally, at least two of the prongs of the second set of operative
structures can
be connected by a bridge spaced from the one or more rear support members.
Optionally, the at
least two of each of the pairs of the second group of prongs can be connected
by a bridge. The
bridge or bridges may each have an arcuate cut-out configured for pulling the
core from the
spindle.
[00015] In one aspect, the first set of operative structures includes a front
support and a rear
support spaced a distance apart by a plurality of spacers, the distance being
sufficient for the reel
of material to be supported between the front and rear supports by at least
the plurality of spacers.
[00016] Optionally, the second set of operative structures includes at least
the front support.
Also optionally, the front support may include an arcuate cut-out configured
for pulling the core
from the spindle.
[00017] Any of the tools described herein can include no independently
moveable
components.
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100018.1 Any of the tools described herein can be attached to a robotic arm.
1000191 Optionally, either the tool or the arm can include a flexible pusher
for closing an
access door to spindle of the packaging equipment
[00020] A method of using the tools described herein can include using the
first set of one
or more operative structures for lifting a reel of material, moving the reel
of material toward a
spindle of packaging equipment, and placing the reel of material on the
spindle; rotating the tool
from the first orientation to the second orientation; and using the second set
of one or more
operative structures for pulling a core of the reel of material off of the
spindle and moving the core
away from the packaging equipment.
[00021] The method may also include the steps of moving the tool away from the
spindle
of the packaging equipment after the step of using the first set of one or
more operative structures;
and moving the tool toward the spindle of the packaging equipment following
dispensing of at
least some material from the reel of material.
Brief Description of the Fieures
[0001] Figure 1 is a perspective view of a robotic arm having an attached
reel change tool,
and showing the robotic arm moving a reel of material, supported by the reel
change tool, toward
a spindle of an unwind station of packaging equipment;
[0002] Figure 2 is a perspective view of the robotic arm of Figure 1, but
showing the reel
of material having been inserted onto the spindle of the unwind station of the
packaging equipment
and the robotic arm moving the now-empty reel change tool away from the
equipment;
[0003] Figure 3 is a perspective view of the robotic arm of Figure 1, but
showing the reel
of material having been spent so that a core remains on the spindle of the
unwind station of the
packaging equipment, and the robotic arm moving the empty reel change tool
toward the
equipment;
[0004] Figure 4 is a perspective view of the robotic arm of Figure 1, but
showing the core
having been removed from the spindle of the unwind station of the packaging
equipment using the
reel change tool and the core, now supported by the reel change tool, moving
away from the
equipment;
[0005] Figure 5 is a perspective view of the reel change tool of Figure 1,
showing the reel
change tool supporting the reel of material;
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[0006] Figure 6 is a detailed view of the reel change tool of Figure 1,
showing the reel
change too supporting the core of a spent reel of material;
[0007] Figure 7 is a front elevation view of the reel change tool of
Figure 1, with the tool
supporting the core of a spent reel of material;
[0008] Figure 8 is a top plan view of the reel change tool of Figure 1,
showing the tool
empty;
100091 Figure 9 is a perspective view of an alternative reel change tool;
1000101 Figure 10 is a top plan view of the alternative reel change tool of
Figure 9;
1000111 Figure 11 is a front elevation view of the alternative reel change
tool of Figure 9,
showing the tool supporting a reel of material (shown in phantom); and
[00012] Figure 12 is a front elevation view of the alternative reel change
tool of Figure 9,
showing the tool support a core of a spent reel of material (shown in
phantom).
Detailed Description
[00013] A multi-function reel change tool is provided for use with a robotic
arm, such as a
collaborative robotic arm, for changing film rolls on packaging equipment. The
tool includes a
first part capable of acquiring, cradling, transporting and depositing a
partially full or full reel of
material by contacting an outer periphery of the reel and a second part
capable of acquiring,
cradling, transporting and depositing the core of a spent or partially spent
reel of material by
contacting the outer periphery of the core of the spent reel or material or
the outer periphery of the
material remaining on a partially spent reel. Preferably, but not necessarily,
the tool has no
independently moveable components.
[00014] A first embodiment of the reel change tool is depicted in Figures 1-8.
The reel
change tool 10 includes a first set of one or more operative structures
arranged for lifting a reel of
material 2, supporting the reel of material 2 during movement toward the
packaging equipment 6,
and placing the reel of material 2 on the spindle 8 by contacting the outer
periphery of the reel of
material 2. The reel change tool 10 also includes a second set of one or more
operative structures,
different at least in part from the first set of operative structures,
arranged for pulling the core 4 of
a spent reel of material from the spindle 8 and supporting the core 4 during
movement of the core
4 away from the packaging equipment 6 by contacting the outer periphery of the
core 4. The tool
has an axis of rotation about which the tool 10 can be rotated to move between
a first orientation,
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whereby the first set of operative structures are arranged for lifting a reel
of material 2 and placing
the reel of material 2 on the spindle 8, and a second orientation, different
from the first orientation,
whereby the second set of operative structures are arranged for removing the
core 4 of a spent reel
of material from the spindle 8.
[00015] Turning to details of the first embodiment of the reel change tool 10,
the first set of
operative structures includes a front support 12 and a rear support 14 spaced
a distance apart by a
plurality of spacers 16a-16e, as shown in Figures 5- 8. The distance being
sufficient for the reel
of material 2 to be supported between the front and rear supports 12 and 14 by
at least the plurality
of spacers 16 such that the reel 2 is cradled between the front and rear
supports 12 and 14 with the
weight of the reel 2 supported by some of the spacers 16a-16c to a large
extent, as shown in Figure
5. In other words, the spacers 16a-16c support the reel 2 in a vertical
direction, while the front and
rear supports 12 and 14 provide lateral support to the reel 2. The rear
support 14 can include an
attachment location for connecting the tool to the robotic arm 20.
[00016] The front and rear supports 12 and 14 are plate-like in appearance.
The rear support
can 14 be generally rectangular with rounded corners. The front support 12,
however, has a pair
of upward facing arcuate edges 18 and 22. A first, larger one of the arcuate
edges 18 spans nearly
from side to side of the front support 12. A second, smaller one of the
arcuate edges 22 is formed
as a deviation from the first arcuate edge 18. The second arcuate edge 22 is
dimensioned for
supporting the core 4 of a spent reel of material by the outer periphery
thereof, as shown in Figure
6. More specifically, there are a pair of spacers 16a and 16b positioned
adjacent the smaller
arcuate edge 22, as shown in Figures 6 and 7, for supporting the core 4 of a
spent reel of material.
That pair of spacers 16a and 16b cooperate with a third one of the spacers 16c
for supporting the
reel 2, as shown in Figure 5. The remaining pair of spacers 16d and 16e
provide additional support
to the front and rear supports 12 and 14.
[00017] The purpose of the first, larger arcuate edge 18, which is
discontinuous due to the
second, smaller arcuate edge 22, is twofold. The first, larger arcuate edge 18
provides access to
the second, smaller arcuate edge 22 while keeping the latter relative close to
the axis of rotation.
The raised ends of the first, larger arcuate edge 18 also provide stability to
the reel 2 when cradled
in the tool 10, as shown in Figure 5, by contacting the reel 2 at a sufficient
span and elevation,
relative to the core 4 thereof. In addition to the upward facing arcuate edges
18 and 22, the front
support 12 also includes a downward facing arcuate edge for weight reduction
purposes.
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[00018] The spacers 16 can be bolts or the like, either with or without a
sleeve disposed
thereabout. Other constructions of the spacers 16 can be used, such as an
element having internal
threads disposed at each end. A pair of spacers 16 can be provided, with one
adjacent each end of
the front and rear supports 12 and 14, as shown in Figures 7 and 8. The
spacers 16 join the front
and rear supports 12 and 14 together at a distance sufficient for a reel of
material 2 to be positioned
between the supports 12 and 14. Thus, for a wider roll of material than that
illustrated, spacers of
increased length than illustrated can be utilized. The spacers 16 are
preferably closer to the lower
edges as compared to the top edges of the supports 12 and 14 such that more of
the height of the
supports 12 and 14 are available for supporting the reel of material 2.
[00019] As mentioned above, the reel change tool 10 is preferably attached to
a robotic arm
20, as shown in Figures 1-6. Preferably, though not necessarily, the robotic
arm 20 is part of a
cobot or cooperative robot. An example of a robotic arm is available from
Universal Robots
(Odense, Denmark).
[00020] The robotic arm 20 can be of many different forms suitable for
carrying out the
steps described herein with respect to manipulation of reels of materials 2
and their cores 4. In the
example illustrated in Figures 1-6, the robotic arm 20 has multiple axes of
rotation. The arm 20
can be attached to a base station 24, as shown in Figure 1. A support post 26
of the robotic arm
20 can be attached to the base station 24, as shown in Figure 1. A proximate
arm 28 can be attached
relative to the support post 26 at a proximate joint 29 and configured for
rotation relative to the
support post 26 in both a horizontal direction and a vertical direction. A
distal arm 30 can in turn
be attached relative to the proximate arm 28 at a distal joint 32 and also
configured for rotation
relative to the proximate arm 28 in both a horizontal direction and a vertical
direction. A multi-
direction joint 34 can be attached relative to the distal arm 30, at an
opposite end portion thereof
from the proximate arm 28. The multi-direction joint 34 can have an attachment
for connecting
relative to the tool 10, such as the rear support 14 of the tool 10. The multi-
direction joint 34 can
have multiple directions of rotation, as shown in Figure 6.
[00021] A mentioned above, the robotic arm 20 can optionally be attached to a
base station
24. An exemplary embodiment of the base station 24 is shown in Figure 1. The
base station 24
includes a controller 36 for the robotic arm 20, a platform 38, and can
include one or more locations
40 for holding reels of material 2. A cart 42 configured to support a row of
reels can also be
provided.
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[00022] To add a reel of material 2 to the spindle 8 of the packaging
equipment 6, the robotic
arm 20 is used to position the reel change tool 10 to lift the reel 2 from the
base station 24. More
specifically, the front and rear supports 12 and 14 of the tool 10 are aligned
generally parallel to
but below the faces of the reel of material 2. The tool 10 is then moved
upward in a generally
vertical direction so that the reel 2 is disposed between the front and rear
supports 12 and 14. As
the tool 10 continues to move upward in a generally vertical direction, the
spacers 16 of the tool
contact the periphery edges of the reel 2 and lift the reel 2 from the base
station 24. With the
reel 2 now cradled by the tool 10, the tool 10 and reel 2 are moved toward the
spindle 8 by the
robotic arm 2, as shown in Figure 1. If the unwind station 7 of the packaging
equipment 6 has one
or more doors 9 for selectively blocking access to the spindle 8, the door or
doors 9 can be manually
or automatically opened. The robotic arm 20 them moves the tool 10 and the
reel 2 to position the
reel 2 on the spindle 8. The tool 10 is then moved generally vertically
downward such that it no
longer is supporting the reel 2 and then away from the spindle 8. If present,
the one or more doors
9 can be closed. The doors 9 can optionally be closed using a finger 44, such
as a flexible finger,
attached relative to the robotic arm 20 or on the tool 10. The robotic arm 20
then moves the now-
empty tool 10 away from the spindle 8 of the packaging equipment 6, as shown
in Figure 2.
[00023] To remove the core 4 of a spent or otherwise at least partially
depleted reel of
material, the empty tool 10 of the robotic arm is moved toward the spindle 8
of the packaging
equipment 6, as shown in Figure 3. If present, the one or more doors 9 can be
manually or
automatically opened to provide access to the spindle 8. The tool 10 is
rotated about its axis of
rotation relative to the robotic arm 20 to position the second arcuate edge 22
for pulling the core 4
from the spindle 8. Once the core 4 is supported by the tool 10, as shown in
Figure 6, the robotic
arm 20 moves the tool 10 and core 4 away from the spindle 8 and the packaging
equipment 6, as
shown in Figure 4. The core 4 can then be removed from the tool 10, such as
manually or upon
movement of the tool 10 into a position that allows the core 4 to fall out The
tool 10 and robotic
arm 20 can then be used to place a new reel of film material 2 on the spindle
8 using the
aforementioned process.
[00024] A second embodiment of the reel change tool 50 is depicted in Figures
9-12. The
reel change tool 50 includes a first set of one or more operative structures
arranged for lifting a
reel of material 2, supporting the reel of material 2 during movement toward
the packaging
equipment 6, and placing the reel of material 2 on the spindle 8 by contacting
the outer periphery
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of the reel of material 2. The reel change tool 50 also includes a second set
of one or more operative
structures, different at least in part from the first set of operative
structures, arranged for pulling
the core 4 of a spent reel of material from the spindle 8 and supporting the
core 4 during movement
of the core 4 away from the packaging equipment 6 by contacting the outer
periphery of the core
4. The tool 50 has an axis of rotation about which the tool 50 can be rotated
to move between a
first orientation, whereby the first set of operative structures are arranged
for lifting a reel of
material 2 and placing the reel of material 2 on the spindle 8, and a second
orientation, different
from the first orientation, whereby the second set of operative structures are
arranged for removing
the core 4 of a spent reel of material from the spindle 8.
1000251 Turning to details of the second embodiment of the reel change tool
50, the tool
includes a rear support 52 with a plurality of prongs 54, 56, 58 and 60 that
project outwardly from
the rear support 52, as shown in Figures 9 and 10. The reel change tool 50 of
the second
embodiment can be attached to a robotic or cobotic arm 20 of the type
described herein.
[00026] The rear support 52 can have a central hub 62 with arms 64, 66, 68 and
70 extending
diagonally outwardly therefrom in a generally X-shaped configuration. The rear
support 52 can
include an attachment location, such as at the central hub 62, for connecting
the tool 50 to the
robotic arm 20. The arms 64, 66, 68 and 70 include an upper pair of arms 64
and 66 and a lower
pair of arms 68 and 70. The lateral sides of rear support 52 can be connected
as well by lateral
supports 72,74. The rear support 52 is preferably of a generally planar
construction so that a face
of the reel of material 2 can be supported thereagainst. The rear support 52
can be unitary, or it
can be made of multiple parts joined together. Projecting outwardly and,
preferably, generally
perpendicularly to the rear support are the plurality of prongs 54, 56, 58 and
60.
[00027] The prongs 54, 56, 58 and 60 are disposed along the bottom portions of
the lower
pair of arms 68 and 70, as shown in Figure 9. A first pair of prongs 54 and 56
are attached to one
of the bottom pair of arms 70 of the rear support 52, and a second pair of
prongs 58 and 60 are
attached to the other one of the bottom pair of arms 68. The first pair of
prongs 58 and 60 are
connected at their end portions, opposite the rear support 52, by a bridge 76.
Likewise, the second
pair of prongs 58 and 60 are connected that their end portions, opposite the
rear support 52, by a
bridge 80. The bridges 76 and 80 are preferably, though not necessarily,
identical. The bridges
76 and 80 each include an arcuate cut out 78 and 82 configured for
facilitating removal of the hub
4 of a spent or partially spent reel of material. Each of the pairs of prongs
54, 56 and 58, 60 are
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spaced closer together than the pairs of prongs are spaced, although these
dimensions can be altered
to accommodate reels of material 2 of different sizes. A pair of short,
protruding guides 84 can
optionally be provided at end portions of the upper pair of arms 64 and 66, as
shown in Figure 9,
for supporting upper peripheral portions of the reel of material 2.
[00028] Each of the pairs of prongs 54, 56 and 58, 60 individually constitute
a second group
of prongs and, optionally, together with the rear support 52, constitute the
second set of operative
structures. Each of the pairs of prongs 54, 56 and 58, 60 are configured to
support the core 4 or a
partially spent reel of material therebetween, as shown in Figure 12. With two
such pairs of prongs
54, 56 and 58, 60 provided on the tool 50, either pair can be used for removal
of the core 4 or
partially spent reel of material. Together, all four prongs 54, 56, 58, 60
constitute at least part of
the first group of operative structures and are positioned to support the reel
of material 2 by the
periphery thereof, as shown in Figure 11, with the rear support 52 optionally
being part of the first
group of operative structures for supporting the reel 2.
[00029] To add a reel 2 of material to the spindle 8 of the packaging
equipment 6, the robotic
arm 20 is used to position the second embodiment of the reel change tool 50 to
lift the reel 2 from
the base station 24. More specifically, the first and second pair of prongs
54, 56 and 58, 60 are
pointed toward the reel of material 2 and positioned therebelow. The tool 50
is then moved upward
in a generally vertical direction so that the reel 2 is lifted upward by some
or all of the prongs 54,
56, 58, 60, contacting peripheral surfaces of the reel 2, and can lean
rearward toward the rear
support 52, as shown in Figure 11. With the reel 2 now cradled by the tool 50,
the tool 50 and reel
2are moved toward the spindle 8 by the robotic arm 20. If the unwind station 7
of the packaging
equipment 6 has one or more doors 9 for selectively blocking access to the
spindle 8, the door or
doors 7 can be manually or automatically opened. The robotic arm 20 them moves
the tool 50 and
the reel 2 to position the reel 2 on the spindle 8. The tool 50 is then moved
generally vertically
downward such that it no longer is supporting the reel 2 and then away from
the spindle 8. If
present, the one or more doors 9 can be closed. The doors 9 can optionally be
closed using a finger
44, such as a flexible finger, attached relative to the robotic arm 20 or the
tool 50. The robotic arm
20 then moves the now-empty tool 50 away from the spindle 8 of the packaging
equipment 6.
[00030] To remove the core 4 of a spent or otherwise at least partially
depleted reel of
material, the empty tool 50 of the robotic arm 20 is moved toward the spindle
8 of the packaging
equipment 6. If present, the one or more doors 9 can be manually or
automatically opened to
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provide access to the spindle 8. The tool 50 is rotated about its axis of
rotation relative to the
robotic arm 20 to position the arcuate edge 78 or 82 of one of the bridges 76
or 80 for pulling the
core 4 from the spindle 8. Once the core 4 is supported by the tool 50, as
shown in Figure 12, the
robotic arm 20 moves the tool 50 and core 4 away from the spindle 8 and the
packaging equipment
6. The core 4 can then be removed from the tool 50, either manually or upon
movement of the
tool 50 into a position that allows the core 4 to fall out. The tool 50 and
robotic arm 20 can then
be used to place a new reel of material 2 on the spindle 8 using the
aforementioned process.
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