Robotic core plug inserter

Abstract

The present invention relates to a new and useful method and apparatus for automatically inserting core plugs into wound paper cores that support rolls of paper, plastic film and other materials during manufacture.

We claim: 
     
         1 . An apparatus for the automatic locating and insertion of core plugs into cores of a roll comprising in combination:
 a conveyor member for moving a roll laterally;   a clamping member for engaging a core plug;   a sensor member for locating a center of a core contained within the roll;   a rotating member engaged with the clamping member;   a programable logic controller engaged with the rotating member and clamping member;   a means for storing multiple core plugs and cueing up an individual core plug for clamping by the clamping member; and   a means for programably controlling the position of the clamping member and the rotating member for positioning the core plug at a desired position withing the core.   
     
     
         2 . The apparatus of  claim 1  wherein the rotating member is capable of moving along the x, y and z-axis. 
     
     
         3 . The apparatus of  claim 1  wherein the means for storing and cueing up core plugs is a core plug magazine and shuttle. 
     
     
         4 . An apparatus for locating and inserting core plugs into the wound cores of a roll comprising:
 a sensor in communication with a programable logic controller;   a conveyor system capable of moving the rolls in a lateral direction;   an expandable clamping device;   the expandable clamping device having a clamp on a distal end and a clamping plate on a proximal end;   a means for rotating the expandable clamping device along the x, y, and z axis; and   wherein, when activated the expandable clamping device is capable of clamping a core plug between the clamping plate and the clamp, locating a center of a core, and inserting the core plug into the core such that the core plug is perpendicular to the core and at a predetermined depth.   
     
     
         5 . A process for automatically locating and inserting core plugs into cores within a roll, such process including the steps of:
 positioning a roll, having a core, proximate to a core locating and insertion head;   retrieving a core plug with a core locating and insertion head;   clamping the core plug with the core locating and insertion head;   locating the location of the core with the core locating and insertion head;   moving the core locating and insertion head such that it is in proper alignment with the core to insert the core plug;   tilting the core locating and insertion head such that the core plug is at a predetermined angle for insertion into the core:   advancing the tilted core locating and insertion head into the core until the core plug reaches a predetermined depth:   rotating the core locating and insertion head such that the core plug is perpendicular to the core;   releasing the core plug from the core locating and insertion head;   tilting the core locating and insertion head such that the core locating and insertion head can be retracted from the core plug without disturbing placement of the core plug,   retracting the core locating and insertion head from the core, and   advancing the roll laterally such that a second core plug can be inserted at an opposite end of the core.