TECHNICAL FIELD
[0001] The present subject matter relates, in general, to rewinder shaft employed in systems and machinery for manufacturing or packaging of various articles.
BACKGROUND 5
[0002] Articles belonging to Fast Moving Consumer Goods (FMCG) industry, hereinafter referred to as FMCG articles are mass-manufactured with the use of various kinds of systems. For some articles, the manufacturing process may rely on use of paper or similar material. Such material may be used for manufacturing the article or for packaging other 10 types of articles. Examples of such articles include, but are not limited to, cigarettes. The material may be provided in the form of rolls. Such rolls may be mounted over a cylindrical drum, and onto the manufacturing machinery using bobbins. The material when required may be drawn from such bobbins which in turn may rotate over the cylindrical drum as the 15 material is dispensed.
BRIEF DESCRIPTION OF DRAWING
[0003] The features, aspects, and advantages of the subject matter will be better understood with regard to the following description, and accompanying figures. The use of the same reference number in different 20 figures indicates similar or identical features and components.
[0004] Fig. 1 illustrates a perspective view of the manufacturing system, as known in the prior art.
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[0005] Fig. 2 illustrates a perspective view of the manufacturing system, in accordance with an implementation of the present subject matter.
[0006] Fig. 3 illustrates another perspective view of the manufacturing system, in accordance with an implementation of the present subject 5 matter.
DETAILED DESCRIPTION
[0007] The present subject matter relates to systems for manufacturing and/or packaging of FMCG articles. As explained previously, material such as paper or cardboard may be provided as rolls 10 over bobbins provided over cylindrical cores. The bobbins in turn rotate and unwind over a cylindrical drum or a rewinder shaft as the material is dispensed. The cylindrical cores may be of cellulose material or any other compressible material. In such machinery, the cylindrical cores may be of a finite length which in turn measures less than the length of the rewinder 15 shaft. In order to increase the efficiency of the ensuing manufacturing process, multiple cores may be loaded onto the rewinder shaft along its length. As a result, the cores are so positioned such that each of the adjoining cores is stacked against each other, extending along the length of the rewinder shaft. The rewinder shaft loaded with the cores is then 20 mounted onto the machinery which is employed for manufacturing the desired article. During the manufacturing process, the rewinder shaft is rotated by various drive means or motors so as to affect the dispensing of the material for use in the manufacturing process. It should be noted that the mounting of the bobbins on the rewinder shaft is a manual process. 25 The bobbins are mounted concentrically with the rewinder shaft. It is
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desired that during the operation of the machine, the bobbins rotate along with the rewinder shaft without slipping while the paper is unrolled from bobbins. The slip-free contact is provided by way of the cylindrical cores. The cylindrical cores may be made of cellulose material or any other compressible material. 5
[0008] A plurality of cylindrical cores may be mounted over the shaft, such that each bobbin containing the sheet is mounted over an individual cylindrical core. The cylindrical cores are mounted and stacked adjacent to one another coaxially over the rewinder shaft over the entire length of the rewinder shaft beginning from the first end till the second end of the 10 rewinder shaft. The cylindrical cores are of equal width, therefore, the length of the shaft and the width of the cylindrical cores is such configured that the rewinder shaft may just accommodate an integer number of cylindrical cores over its length.
[0009] For proper operation of the system, the bobbins are to be 15 accurately mounted with respect to the cores on the rewinder shaft. The mounting should be such that distance between the edge of a bobbin and the edge of a core must not exceed a permissible limit, e.g., 0.5 mm. If the distance exceeds the permissible limit, the system output is adversely affected, and this defect is termed as core protrusion. When such cores 20 are used in manufacturing operations, the bobbins mounted over the cores wanders (shakes), thereby affecting the quality of the manufactured product.
[0010] In the conventional manufacturing systems, it is observed that during mounting of the cylindrical cores on the rewinder shaft, the last 25 cylindrical core near the engaging feature of rewinder shaft may cover the threads of the rewinder shaft by which they are secured onto the machine.
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Consequentially, while tightening the nut manually, due to variability in tightening force, the last cylindrical core near the engaging feature may get compressed. This may lead to variations in the width of the cylindrical core, and as a result disturb the distance between the edge of the bobbin and the edges of the core, thereby leading to defects referred to as core 5 protrusion defect. When bobbins are mounted over such cores and installed on machine for manufacturing and packaging purposes, the variation in the width of the cores cause the bobbin to shake while in operation and causing the material feed to wander, thereby affecting the quality of the final product and affecting the efficiency of the manufacturing 10 machine.
[0011] The present subject describes a manufacturing and packaging system that overcomes the defects of core protrusion. The last cylindrical core near the engaging feature of the rewinder shaft is prevented from being compressed during the tightening of nuts while the rewinder shaft is 15 manually mounted on the system.
[0012] In an implementation of the present subject matter, the last cylindrical core near the drive side is replaced with a supplementary cylindrical core having a width smaller than the rest of the identical sized cylindrical cores such that the supplementary core no longer covers the 20 threaded portion of the rewinder shaft. Further, the length of region left uncovered on the rewinder shaft equal to the difference in width of the replaced core and the supplementary core is accommodated with a plurality of spacer rings. While manually mounting the rewinder shaft, the cylindrical core is, therefore, isolated from the tightening forces produced 25 during mounting of the rewinder shaft in the system, while the tightening forces are now borne by the spacer rings. The compression of the last
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cylindrical core near the engaging features of the rewinder shaft, and hence, the defect of core protrusion, is thereby prevented.
[0013] These and other advantages of the present subject matter would be described in greater detail in conjunction with the following figures. It should be noted that the description and figures merely illustrate 5 the principles of the present subject matter.
[0014] Fig. 1 illustrates a conventional manufacturing system 100, hereinafter referred to as the system 100. The system 100 comprises a tubular structured rewinder shaft 102, which extends between a first end (not shown in the figure) and a second end 104. A bobbin (not shown in 10 figure) comprising a wounded sheet, such as a plastic sheet or a paper sheet, is mounted on the rewinder shaft 102. In operation, the sheet may be unwound and dispensed from the bobbin as the rewinder shaft 102 rotates. The system 100 further comprises a first shaft mounting unit (not shown in the figure) and a second shaft mounting unit to mount the 15 rewinder shaft 102.
[0015] The following paragraphs explain the working of the rewinder shaft of conventional systems. During operation of the system, the bobbins are mounted over the rewinder shaft 102. To ensure a slip-free contact with the rewinder shaft 102, the bobbins are not directly mounted over the 20 rewinder shaft 102, but are mounted upon plurality cores, which are positioned between the rewinder shaft 102 and the bobbins. The cores are identical shaped cylindrical structures having equal width. For example in one implementation, the width of all the cores is selected to be 64 mm. The cores are made of a compressible material like cellulose or any other 25 compressible material. The plurality of cores is mounted by sliding and positioning each core along the length of the rewinder shaft 102, so that
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each core is positioned adjacent to at least one another core. The width of the core and the length of the rewinder shaft 102 are so selected that an integer number of cores cover the entire length of the rewinder shaft 102 from first end to the second end 104. After mounting the cores, the bobbins are mounted on the rewinder shaft 102 by sliding through the 5 drum portion of the bobbins over the length of the rewinder shaft 102, and positioned over the cores. The plurality of bobbins is arranged adjacent to one another, such that each bobbin is positioned over an individual core.
[0016] The second end of the rewinder shaft 102 includes an engaging feature 108, hereinafter referred to as threaded portion 108, 10 which includes helical threads formed integrally with the rewinder shaft 102, and extending along the length of the rewinder shaft 102. The threaded portion 108 engages with a rotational drive source (not shown in the figure) through which the rewinder shaft 102 rotates. The drive may be provided by an electric motor or any other suitable drive source. The 15 rewinder shaft 102 along with the bobbins mounted on it is fitted to the first mounting unit and the second mounting unit 112 of the system 100 along the first and the second end 104 of the rewinder shaft 102 respectively. The threaded portion 108 of the rewinder shaft is meshed with the corresponding threaded part of the drive source, and the rewinder shaft 20 102 is fitted to the system by tightening nuts. The second end 104 of the rewinder shaft 102 is, therefore, manually mounted and tightened on the system so as to ensure a proper fitment of the threaded portion 108 with the drive source.
[0017] In the prior art implementation, when the cores are mounted 25 over the rewinder shaft 102, the last core overlaps the threaded portion on the second end 104 of the rewinder shaft 102, as shown in Fig. 1. During
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mounting of the rewinder shaft 102 on the system 100, the second end of the rewinder shaft 102 is manually fitted and tightened with nuts. It is observed that during tightening of the nuts, the last core positioned near the second end of the rewinder shaft 102 gets compressed along its width. Due to variations in the tightening force during manual tightening, 5 variations are developed along the width of the last core near the second end of the rewinder shaft 102. As a result, when bobbins are mounted over the rewinder shaft 102, the distance between the edge of the last core and the corresponding bobbin mounted over the corresponding core may become more than 0.5 mm, thereby giving rise to the core protrusion 10 defect that may adversely affect the quality of the final product of the manufacturing process
[0018] Fig. 2 illustrates the system 100 for manufacturing and packaging of FMCG articles, as per the present implementation. As in the prior art implementation, the system 200 comprises a rewinder shaft 202, 15 and a plurality of cores of equal width mounted on the rewinder shaft 202. However, in the present implantation, the last core near the second end 204 of the rewinder shaft 202 is replaced with a supplementary core 206. The width of the supplementary core 206 is selected to be lesser than the width of the rest of the cores. Fig. 2 shows a blank region that would 20 otherwise be occupied with one of plurality of equal width cores. Fig. 2 also shows a threaded region 208 left uncovered due to absence of the core near the second end of the rewinder shaft. The supplementary core 206 will be mounted on the rewinder shaft 202 so as to cover the blank region. In one implementation, the width of the supplementary core is 25 selected to be 38 mm. The system 100 further comprises a first shaft
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mounting unit (not shown in the figure) and a second shaft mounting unit 212 to mount the rewinder shaft 202.
[0019] In the implementation as depicted in Fig. 3, rewinder shaft 202 further includes supplementary core 206, and a plurality of metallic spacer rings 210. The spacer rings 210 are hollow cylindrical ring structures made 5 of metal, and the width of the rings is selected depending upon the width of the supplementary core. The spacer rings 210, therefore, cover the length of rewinder shaft 202 that is left uncovered upon mounting of the supplementary core. For example, in one implementation, wherein the width of each of plurality of the cores is 64 mm and the width of 10 supplementary core is 38 mm, spacer rings of width 16 mm are used, while in another implementation, employing a supplementary core of width 42mm, width of spacer rings used is 12 mm.
[0020] The rewinder shaft 202 includes a first end and a second end 204. The first end of the rewinder shaft 202 is rotatably mounted onto the 15 manufacturing system. In one example, the second end 204 of the rewinder shaft 202 may include an engaging feature 208 for rotatably fitting and mounting the rewinder shaft 202 to the system. Continuing with system, the rewinder shaft 202 may be provided with a plurality of cylindrical cores of a same finite width. The width of the cylindrical cores is 20 such that it is less than length of the rewinder shaft 202. The cylindrical cores are mounted and stacked coaxially over the rewinder shaft 202 beginning from the first end. When stacked, each of the adjacent cores remain in contact with the next adjoining cores. Once stacked, the cylindrical cores are so arranged such that they extend along a length 25 equivalent to difference between longitudinal measure of the rewinder shaft 202.
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[0021] When stacked, a certain space greater than the width of the cylindrical core is left uncovered as indicated in FIG. 2. Onto such space a plurality of metallic spacer rings 210 may be stacked with each other and accommodated at the second end of the rewinder shaft 202, such that the spacer rings 210 occupy a remaining portion of rewinder shaft 202. In 5 another example of the present subject matter, as shown in FIG. 3, a supplementary core 206 is coaxially accommodated between the plurality of the cylindrical cores and the spacer rings 210, wherein the supplementary core 206 is of a width less than the width of each of the cylindrical cores. 10
[0022] During the mounting of the rewinder shaft 202 on the system, the second end 204 of the rewinder shaft is fastened to the mounting unit 212 by manually tightening the nuts. In the present implementation, due to the presence of spacer rings, the cores are isolated from the tightening forces, while the tightening forces are now borne by the metallic spacer 15 rings 210. The compression of the last cylindrical core on the drive side of the rewinder shaft, and thus, the defect of core protrusion, is thereby prevented.
[0023] Although the present subject matter has been described with reference to specific embodiments, this description is not meant to be 20 construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the subject matter, will become apparent to persons skilled in the art upon reference to the description of the subject matter.

I/We Claim:
1. A system for manufacturing articles, the system comprising:
a winder shaft (202) having a first end and a second end (204), the first end of the winder shaft (202) is rotatably mounted onto the system, and the second end (204) of the winder shaft (202) 5 comprises an engaging feature (208) for rotatably fitting and mounting the winder shaft (202) to the system;
a plurality of cylindrical cores of a same width, each of a width less than length of the winder shaft (202), with the cores mounted and stacked coaxially over the winder shaft (202) 10 beginning from the first end and in contact with at least one adjacent cylindrical core, such that the plurality of cylindrical cores extend along a length equivalent to difference between longitudinal measure of the winder shaft (202);
a plurality of metallic spacer rings (210) stacked with each 15 other and accommodated at the second end of the winder shaft (202), such that the spacer rings (210) occupy a remaining portion of winder shaft (202); and
a plurality of bobbins comprising sheet wound over a cylindrical drum, the bobbins being mounted on the plurality of 20 cylinder cores, such that each bobbin is mounted on an individual cylindrical core.
2. The system as claimed in claim 1, further comprising a supplementary core (206) coaxially accommodated between the plurality 25 of the cylindrical cores and the spacer rings (210), wherein the
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supplementary core (206) is of a width less than the width of each of the cylindrical cores.
3. The winder shaft (202) as claimed in claim 1, wherein the length of winder shaft (202) is configured to accommodate an integer number of the 5 plurality of cores.
4. The system as claimed in claim1 , wherein the cores could be made of material one of a paper, polyvinyl chloride (PVC), and metallic material.
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5. The system as claimed in claim 1, wherein width of each cylindrical core is 64 mm.
6. The system as claimed in claim 1, wherein width of the supplementary core (206) is 38 mm. 15
7. The system as claimed in claim 1, wherein the winder shaft (202) is fitted along the second end (204) to the system by tightening nuts.
8. The system as claimed in claim 1, wherein the distance between 20 edge of each bobbin and edge of the each core is less than 0.5mm.