Apparatus and methods for minimizing waste during web splicing

Abstract

An apparatus and methods are disclosed to reliably utilize material as close as possible to the end of the primary supply wheel so to minimize the roll waste. An indicator material, such as tape, is positioned on the primary and standby supply wheels at a distance from the end of the roll so that a reader, such as a machine vision system, can detect the presence or absence of the indicator material on the rolls. If the indicator material is present, the machine vision system will initiate a minimal waste splice logic. If the indicator material is absent, the machine vision system will initiate a standard splice logic.

1 . A method for minimizing waste during web splicing, the method comprising:
 providing an indicator material on a primary supply roll, said indicator material placed at a distance from the end of said primary supply roll;   providing a standby supply roll;   providing an indicator material reader;   detecting the presence or absence of the indicator material on said primary supply roll;   initiating a minimal waste splice logic in the presence of said indicator material on said primary supply roll, said minimal waste splice logic thereby employed to splice said primary and standby supply rolls;   initiating a standard waste splice logic in the absence of said indicator material on said primary supply roll, said standard waste splice logic thereby employed to splice said primary and standby supply rolls.   
     
     
         2 . The method according to  claim 1 , said minimal waste splice logic comprising:
 ascertaining a distance of said primary supply roll remaining between said indicator material and the end of said primary supply roll;   measuring the revolution speed of a spindle carrying said primary supply roll as said primary roll is expiring;   calculating time remaining until the expiration of said primary supply roll would be reached;   initiating a splice sequence through a web accumulator at a time immediately prior to said calculated time remaining until the expiration of said primary supply roll would be reached, thereby joining said expiring primary supply roll and said standby supply roll.   
     
     
         3 . The method according to  claim 1 , said standard waste splice logic comprising:
 measuring an initial diameter of said primary supply roll;   communicating said diameter to a splice controller;   measuring the revolution speed of a spindle carrying said primary supply roll as it expires;   calculating a remaining diameter on said expiring primary supply roll using a predetermined machine web speed and the measured revolution speed of a spindle;   initiating a splice sequence through a web accumulator when said expiring primary supply roll remaining diameter reaches a preset point, thereby joining said expiring primary supply roll and said standby supply roll.   
     
     
         4 . The method according to  claim 1 , said standby roll carrying an indicator material. 
     
     
         5 . The method according to  claim 1 , wherein the indicator material is placed at a known distance from the end of said primary supply roll. 
     
     
         6 . A method for minimizing waste during web splicing, the method comprising:
 providing an indicator material on a primary supply roll, said indicator material placed at a distance from the end of said primary supply roll;   providing a standby supply roll;   providing an indicator material reader;   detecting the presence or absence of the indicator material on said primary supply roll;   initiating a minimal waste splice logic in the presence of said indicator material on said primary supply roll, said minimal waste splice logic comprising:   ascertaining a distance of said primary supply roll remaining between said indicator material and the end of said primary supply roll;   measuring the revolution speed of a spindle carrying said primary supply roll as said primary roll is expiring;   calculating time remaining until the expiration of said primary supply roll would be reached;   initiating a splice sequence through a web accumulator at a time immediately prior to said calculated time remaining until the expiration of said primary supply roll would be reached, thereby joining said expiring primary supply roll and said standby supply roll;   initiating a standard waste splice logic in the absence of said indicator material on said primary supply roll, said standard waste splice logic comprising:   measuring an initial diameter of said primary supply roll;   communicating said diameter to a splice controller;   measuring the revolution speed of a spindle carrying said primary supply roll as it expires;   calculating a remaining diameter on said expiring primary supply roll using a predetermined machine web speed and the measured revolution speed of a spindle;   initiating a splice sequence through a web accumulator when said expiring primary supply roll remaining diameter reaches a preset point, thereby joining said expiring primary supply roll and said standby supply roll.