1. A system for inspecting the reel of a continuous web (100), comprising: ? a database management apparatus (200); ? at least one barcode reader (300) for scanning the barcodes; ? an electronic weighing scale (400) for measuring the weight of the reel; ? a reel rotating assembly (500); ? a sensor assembly (600); ? a programmable logic controller (PLC) (700) for controlling and managing the entire system; ? a status indicator (800); and ? a printer (900) for printing the status of the reel.

2. The system for inspecting the reel of a continuous web (100) as claimed in claim 1, wherein the database management apparatus (200) may be selected from computer, server, mobile or any similar device which organizes and stores details of each reel entering the system such as the reel number/code, weight, diameter, diametrical variation etc. in the form of a database.

3. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 2, wherein the barcode reader (300) reads the details of the reel from the barcode present on the reel.

4. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 3, wherein the electronic weighing scale (400) of a suitable measuring capacity may be used for measuring the weight of the reels entering the system (100).

5. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 4, wherein the output of the barcode reader (300) and the electronic weighing scale (400) is received by the programmable logic controller (PLC) (700) and transferred and stored in the database management apparatus (200).

6. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 5, wherein the reel rotating assembly (500) comprises: ? a housing (500a) comprising a plurality of lateral sides (501, 502, 503, 504) and a base (505), wherein said housing (500a) further comprises a plurality of radial holders (506, 507); (506’, 507’) on any two of the corresponding opposite lateral sides (502, 504) or (501, 503) spaced by a suitable distance; ? a plurality of rollers (508, 509), wherein the diametrically opposite ends (508a, 508b) and (509a, 509b) of each of the plurality of rollers (508, 509) are mounted into the corresponding plurality of radial holders (506, 506’) and (507, 507’) respectively; ? a motor (510) controlled by a drive, wherein at least one of the rollers is connected to the drive of the motor (510) for rotating the reel loaded onto the reel rotating assembly (500); ? a lifting means (511) movably attached to the housing (500a) to facilitate the loading and unloading of the reel on the reel rotating assembly (500).

7. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 6, wherein the lifting means (511) comprises: ? a cylindrical bar (511a) arranged acentrically along the length of the rollers (508, 509) in the space between the first roller (508) and the second roller (509); ? at least one pneumatic actuator (511b, 511b’) for pushing and pulling the cylindrical bar (511a); and ? a plurality of joining elements (511c, 511d) for connecting each of the diametrically opposite ends (511a’, 511a’’) of the cylindrical bar (511a) with each of the plurality of pneumatic actuators (511b, 511b’).

8. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 7, wherein the motor (510) of the reel rotating assembly (500) provides a variable speed drive.

9. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 8, wherein the reel rotating assembly (500) is configured to rotate the reel around a horizontal axis and may be located above or below the ground.

10. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 9, wherein both the electronic weighing scale (400) and reel rotating assembly (500) have been integrated together.

11. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 10, wherein the electronic weighing scale (400) comprises, a plurality of load cells (401, 402, 403, 404), wherein each of the load cells may be connected with the base (505) at each of the corners of the housing (500a) of the reel rotating assembly (500).

12. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the sensor assembly (600) comprises : ? a plurality of laser displacement sensors (601, 602, 603) configured to measure the vertical distance between the laser displacement sensors (601, 602, 603) and the circumference of the rotating reel using laser beams; and ? an adjustment means (604) for holding and adjusting the position of laser displacement sensors (601, 602, 603); wherein said adjustment means (604) can be arranged at any suitable distance vertically from the reel rotating assembly (500) such that the laser displacement sensors (601, 602, 603) are vertically above the reel.

13. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the adjustment means (604) comprises: ? a plurality of bars (604a, 604b) to position the laser displacement sensors (601, 602, 603) at any required distance above the reel depending on the range of the laser displacement sensors (601, 602, 603); and ? a sliding mechanism (604c) fastened to the edges of the plurality of bars (604a, 604b) above the reel rotating assembly (500), wherein said sliding mechanism (604c) facilitates the sliding of each of the plurality of laser displacement sensors (601, 602, 603) independently of one another laterally depending upon the length of the reel.

14. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the laser displacement sensors (601, 602, 603) may be preferably arranged at the periphery and more preferably at two diametrically opposite locations and the center of the reel with the help of the adjustment means (604).

15. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the plurality of laser displacement sensors (601, 602, 603) continuously measures the vertical distance between said laser displacement sensors (601, 602, 603) and the circumference of the reel.

16. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the data collected by the laser displacement sensors (601, 602, 603) is analyzed and processed by the programmable logic controller (PLC) (700) and transferred and stored in a desired format in the database management apparatus (200).

17. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the programmable logic controller (PLC) (700) is the central unit that controls the interworking of all the components, subcomponents of the system and processes commands and inputs from these components.

18. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the programmable logic controller (PLC) (700) comprises: ? an input means preferably a touch screen, for inputting various parameters such as permissible weight and dimensions of the reel, rotation cycle of the rotating assembly, etc.; ? a plurality of push buttons (702) with light indicator, for operating and controlling the system; and ? a display preferably integrated with the touch screen for displaying the input data and the output data collected from all the components of the system.

19. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the programmable logic controller (PLC) (700) takes inputs from the barcode reader (300), weighing scale (400), laser displacement sensor (601, 602, 603) and processes and converts the same input to provide outputs to status indicator (800) such as alarms. Said programmable logic controller (PLC) (700) also operates the pneumatic actuators of the lifting means (511) and the drive of the motor.

20. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the status indicator (800) can be a combination of audio and/or visual devices or can be a standalone audio or a standalone visual device.

21. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the printer (900) is connected to the programmable logic controller (PLC) (700) and prints the status of the reels.

22. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the system for inspecting the reel of a continuous web (100), optionally comprises a component for automated removal of the side cover provided at both side of the reel wherein, the cover is only removed once the barcode has been read by the barcode reader.

23. A method for inspecting reels of a continuous web (100), comprising the steps of: ? manually loading the reel (1000) onto the reel rotating assembly (500) with help of the lifting means (511) of the reel rotating assembly (500); ? rotating the reel (1000) partially using the variable drive of the motor (510) such that the barcode (301) is in the range of the barcode reader (300); ? reading the barcode (301) on the cover of a reel using the barcode reader (300) and storing its details in a database management apparatus (200) through programmable logic controller (PLC) (700); ? weighing the reel using an electronic weighing scale (400) and storing the detected value in the database management apparatus (200) through programmable logic controller (PLC) (700); ? validating the measured reel weight with the reel weight provided by the supplier on the reel cover. ? manually adjusting the placement of laser displacement sensor (601, 602, 603) according to width of reel using adjustment means comprising a plurality of bars (604a, 604b) with a sliding mechanism (604c) ? rotating the reel (1000) on the reel rotating assembly (500) for checking its roundness; ? checking the diametrical variations of rotating reel (1000) using a plurality of laser displacement sensors (601, 602, 603) and storing the same in the database management apparatus (200); ? processing the data collected by the laser displacement sensors (601, 602, 603) through programmable logic controller (PLC) (700) and comparing the diametrical variations with predefined limits ? indicating the status of the reels on the status indicator (800); ? rejecting the reels that are found to be oversized; and ? accepting the reels that are not oversized and storing them as non-defective in the database. ? Unloading the reel with the help of lifting means of the reel rotating assembly.

DESC:FIELD OF THE INVENTION
The present invention relates to a system and a method for inspecting a reel, more particularly the weight and dimensions of a reel of a continuous web and preventing the defective reels which do not comply with specified tolerance limits to be utilized for production.
BACKGROUND OF THE INVENTION
The printing and packaging industries use several forms of continuous webs made of paper, film, plastic and the like. For instance, in case of newspaper printing, the long webs of paper are typically transported in the form of large reels from the paper mill to the printing press. Understandably, while transportation or during wounding of web over the reel, there can be differences in the dimensions of the reel which may further lead to differences in the product quality such as newspaper. Hence, these reels should only be used after it is determined that they possess the correct properties to function properly in the printing press. Some of the important properties that can be used to determine the quality of the paper are weight, moisture content, strength of paper, roundness of reel, etc. Careful inspection of the reel helps avoid problems during automatic reel change, web-breakage, poor printing quality of the final product, reduced printing speed, etc. All of these lead to an increase in the production costs and delays the distributionof the newspaper, which is unacceptable in the newspaper printing industry.
PCT publication number WO2000029809, discloses a laser based system for determining the shape and roundness of cylindrical bodies along with the computer program products. The system utilizes lasers which contact the surfaces of the cylindrical bodies such that laser beams reflect therefrom. The systems also include means for manipulating the laser beams to ultimately determine the shape and roundness of the cylindrical bodies.
Each of the printing and packaging industries maintains various racks for mounting various reels according to their weight, dimensions and the type. The system disclosed in the aforementioned prior art may be applied for inspecting the roundness of a reel, however it does not provide any provision to weigh and store data according to their types and the pattern in which it has been organized in its respective rack. Hence there is a need for a simple and economical system which can be applied for inspecting various parameters of a reel and provide details regarding the reel such as the barcode of the reel and its respective rack etc.
OBJECTS OF THE INVENTION
The principal object of the present invention is to overcome the drawbacks of the prior art. Another object of the present invention is to provide a system and a method for measuring the various critical parameters of a reel of a continuous web and compare it with the prescribed tolerance limits. Another object of the invention is to provide a system for inspecting a reel that can be used for various sizes of the reels. Yet another object of the present invention is to automatically identify the defective reels and reject them before being used for production.
SUMMARY OF THE INVENTION
The present invention is directed to a system and a method for inspecting the details and dimensions of a reel, more particularly reel of a continuous web and preventing the defective reels which do not comply with specified tolerance limits to be utilized for production.
In accordance with an embodiment of the invention there is provided a system for inspecting the reel of a continuous web, comprising:
? a database management apparatus;
? at least one barcode reader for scanning the barcodes;
? an electronic weighing scale for measuring the weight of the reel;
? a reel rotating assembly;
? a sensor assembly;
? a programmable logic controller (PLC) for controlling and managing the entire system;
? a status indicator; and
? a printer for printing the status of the reel.
In accordance with another embodiment of the invention the database management apparatus can be a computer, server, mobile or any similar device with a microprocessor, preferably a computer.
In accordance with another embodiment of the invention the database management apparatus organizes and stores details of each reel entering the system such as the reel number/code, weight, diameter, diametrical variation etc. in the form of a database.
In accordance with another embodiment of the invention the barcode reader reads the details of the reel from the barcode usually present at the cover of every reel.
In accordance with another embodiment of the invention the electronic weighing scale of a suitable measuring capacity may be used for measuring the weight of the reels entering the system.
In accordance with another embodiment of the invention the output of the barcode reader and the electronic weighing scale is received by the programmable logic controller (PLC) and transferred and stored in the database management apparatus for future reference.
In accordance with another embodiment of the invention the reel rotating assembly comprises:
? a housing comprising a plurality of lateral sides and a base, wherein said housing further comprises a plurality of radial holders on any two of the opposite lateral sides spaced by a suitable distance;
? a plurality of rollers, wherein the diametrically opposite ends of each of the plurality of rollers are mounted into the corresponding plurality of radial holders respectively;
? a motor controlled by a drive, arranged adjacent to any of the lateral side of the housing such that it can be connected to any of the diametrically opposite ends of the plurality of rollers, wherein at least one of the rollers is connected to the drive of the motor for rotating the reel loaded on the reel rotating assembly;
? a lifting means movably attached to the housing to facilitate the loading and unloading of the reel on the reel rotating assembly.
In accordance with another embodiment of the invention the lifting means comprises:
? a cylindrical bar arranged acentrically along the length of the rollers in the space between the first and the second rollers,
? at least one pneumatic actuator for pushing and pulling the cylindrical bar; and
? a plurality of joining elements for connecting each of the diametrically opposite ends of the cylindrical bar with each of the plurality of pneumatic actuators, wherein the cylindrical bar is inclined to the rollers when the pneumatic actuators are at rest, and the cylindrical bar declines when the pneumatic actuators are actuated and the piston of the actuators pushes the joining elements towards the corners of the base of the housing beneath the first roller.
In accordance with another embodiment of the invention the motor of the reel rotating assembly provides a variable speed drive, wherein the reel can be rotated partially around its axis of rotation so that the barcode of the reel is in the range of the barcode reader, or the reel may be rotated continuously for measuring the diametrical variations.
In accordance with another embodiment of the invention the reel rotating assembly is configured to rotate the reel around a horizontal axis and may be located above or below the ground.
In accordance with a preferred embodiment, both the electronic weighing scale and reel rotating assembly have been integrated together as a single unit and located in a pit in the floor so that the reel can be easily rolled onto the system. This helps avoid the requirement for additional equipment for lifting the reel and moving it onto the next component of the system.
In accordance with the preferred embodiment the electronic weighing scale comprises, a plurality of load cells, wherein each of the load cells may be connected with the base at each of the corners of the housing of the reel rotating assembly.
In accordance with another embodiment of the invention thesensor assembly comprises:
? a plurality of laser displacement sensors configured to measure the vertical distance between the laser displacement sensors and the circumference of the rotating reel using laser beams; and
? an adjustment means for holding and adjusting the position of laser displacement sensors; wherein said adjustment means can be arranged at any suitable distance vertically from the reel rotating assembly such that the laser displacement sensors are vertically above the reel.
In accordance with yet another embodiment of the invention the adjustment means comprises:
? a plurality of bars to position the laser displacement sensors at any required distance above the reel depending on the range of the laser displacement sensors; and
? a sliding mechanism fastened to the edges of the plurality of bars above the reel rotating assembly, wherein said sliding mechanism facilitates the sliding of each of the plurality of laser displacement sensors independently of one another laterally depending upon the length of the reel.
In accordance with another embodiment of the invention the laser displacement sensors may be preferably arranged at the periphery and more preferably at two diametrically opposite locations and the center of the reel with the help of the adjustment means to check the roundness of the reel.
In accordance with another embodiment of the invention each of the plurality of laser displacement sensors continuously measures the vertical distance between said laser displacement sensors and the circumference of the reel while the reel rotates at least one round. This measured distance varies as per the variation in the reel diameter and is continuously transferred to the programmable logic controller (PLC), wherein the programmable logic controller (PLC) processes the data and determines the diametrical variation by calculating the difference between maximum and the minimum vertical distance between each of the plurality of laser displacement sensors and the reel after completing one rotation and compares the same with the predefined value and accordingly sets the output of the status indicator.
In accordance with another embodiment of the invention the data collected by the laser displacement sensors is analyzed and processed by the programmable logic controller (PLC) and transferred and stored in a desired format in the database management apparatus.
In accordance with another embodiment of the invention the programmable logic controller (PLC) is the central unit that controls the interworking of all the components, subcomponents of the system and processes commands and inputs from these components.
In accordance with another embodiment of the invention the programmable logic controller (PLC) comprises:
? an input means preferably a touch screen, for inputting various parameters such as permissible weight and dimensions of the reel, rotation cycle of the rotating assembly, etc.;
? a plurality of push buttons with light indicator, for operating and controlling the system; and
? a display preferably integrated with the touch screen for displaying the input data and the output data collected from all the components of the system.
In accordance with a preferred embodiment the programmable logic controller (PLC) takes inputs from the barcode reader, electronic weighing scale, laser displacement sensor and processes and converts the same input to provide outputs to status indicator such as alarms. Said programmable logic controller (PLC) also operates the pneumatic actuators of the lifting means and the drive of the motor.
In accordance with another embodiment of the invention the status indicator can be a combination of audio and visual devices such as light indicators with an alarm or can be a standalone audio or a standalone visual device wherein, said status indicator takes input from the programmable logic controller (PLC) and provides a visual and/or audio indication for the operators about the usability of the reel.
In accordance with another embodiment of the invention the printer for printing the status of the reels can be any sticker printer, wherein the printer is connected to the programmable logic controller (PLC) and prints the stickers for the rejected reels as per the commands received from the programmable logic controller (PLC).
In accordance with yet another embodiment of the invention there is provided a system for inspecting the reel of a continuous web, optionally comprising separate barcode readers for each reel rack to keep track of the reel consumption according to their respective racks.
In accordance with yet another embodiment of the invention there is provided a system for inspecting the reel of a continuous web, optionally comprising a component for automated removal of the side cover provided at both sides of the reel wherein, the cover is only removed once the barcode has been read by the barcode reader.
In accordance with yet another embodiment of the invention the component for automated removal of the cover can be provided at any location after the barcode reader.
In a further aspect of the invention there is provided a method for inspecting reels of a continuous web, comprising the steps of:
? manually loading the reel onto the reel rotating assembly with help of the lifting means of the reel rotating assembly;
? rotating the reel partially using the variable drive of the motor such that the barcode is in the range of the barcode reader.
? reading the barcode on the cover of a reel using the barcode reader and storing its details in a database management apparatus through programmable logic controller (PLC);
? weighing the reel using an electronic weighing scale and storing the detected value in the database management apparatus through programmable logic controller (PLC);
? validating the measured reel weight with reel weight provided by the supplier on the reel cover.
? manually adjusting the placement of laser displacement sensor according to width of reel using adjustment means comprising a plurality of bars with a sliding mechanism;
? rotating the reel on the reel rotating assembly for checking its roundness;
? checking the diametrical variations of rotating reel using a plurality of laser displacement sensors and storing the same in the database management apparatus;
? processing the data collected by the laser displacement sensors through programmable logic controller (PLC) and comparing the diametrical variations with predefined limits
? indicating the status of the reels on the status indicator;
? rejecting the reels that are found to be out of roundness;
? accepting the reels that are not within the prescribed roundness and storing them as non-defective in the database; and
? unloading the reel with the help of lifting means of the reel rotating assembly.
In accordance with another embodiment of the invention there is provided a method, wherein the barcode reader will not read the bar code until the reel is placed onto the reel rotating assembly.
In accordance with another embodiment of the invention there is provided a method, wherein the system for inspecting the reel will not operate until a certain predefined weight is detected by the system.
Other aspects, advantages, and salient features of the present invention will become apparent to those skilled in the art from the following detailed description read in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings are illustrative of the preferred embodiment for enabling the present invention, are descriptive of some of the methods, and are not intended to limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description.
Figure 1: shows the perspective view of the system for inspecting the reel of a continuous web.
Figure 2: shows the top view of reel rotating assembly integrated with the electronic weighing scale.
Figure 3: shows top view of the lifting means of the reel rotating assembly.
Figure 4: shows the isometric view of the sensor assembly.
Figure 5: shows the front view of the programmable logic controller (PLC).
Figure 6: shows the enlarged view of the touch screen display of programmable logic controller (PLC).
Figure 7: shows the side view of loading/unloading the reel onto the reel rotating assembly and the side view of the reel loaded onto the reel rotating assembly.
Figure 8: shows the isometric view of the reel of a continuous web with the barcode.
Figure 9: shows the perspective view of the system for inspecting the reel of a continuous web with the reel loaded onto the reel rotating assembly of the system.
Figure 10: shows the flow chart of the operation of the system for inspecting the reel.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of the present invention will be described hereinafter in reference to the accompanying drawings.
It is to be noted that, as used in the specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or”, unless the content clearly dictates otherwise. It should also be noted that by the term “substantially” it is meant that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.
Hereinafter, a system for inspecting the reels of the present invention will be explained in more details. The same reference numerals are given to the same parts as those of the aforementioned embodiments and their minute explanation has been omitted.
The term “inspecting” refers to the measurement of various parameters of a reel of a continuous web such as, weight, diametrical variations etc. The term “database management apparatus” refers to a device that can be used to store data in an organized form. The term “reel rotating assembly” refers to a system capable of rotating the reel over its surface. The term “sensor assembly” refers to a combination of plurality of laser displacement sensors arranged together to measure the roundness of the reel. The term “system for inspecting a reel” and “system” have been used interchangeably.
Figure 1: shows the perspective view of the system for inspecting the reel (100) of a continuous web, wherein the system for inspecting the reel (100) comprises:
? a database management apparatus (200);
? a barcode reader for scanning the barcodes (300);
? an electronic weighing scale for measuring the weight of the reel (400);
? a reel rotating assembly (500);
? a sensor assembly (600);
? a programmable logic controller (PLC) for controlling and managing the entire system (700);
? a status indicator (800); and
? a printer for printing the status of the reels (900).
The database management apparatus (200) is a computer for organizing and storing details of each reel entering the system such as the reel number/code, weight, diameter, diametrical variation etc. in the form of a database.
The barcode reader (300) reads the details of the reel from the barcode usually present at the cover of every reel.
The electronic weighing scale (400) of a suitable measuring capacity preferably upto 3 ton capacity is used for measuring the weight of the reels entering the system (100).
The reel rotating assembly (500) is configured to rotate the reel around a horizontal axis and is located in a pit the floor.
The sensor assembly (600) can be arranged at any suitable distance vertically from the reel rotating assembly (500) to check the roundness of the reel.
The bar code reader (300); the electronic weighing scale (400); the reel rotating assembly (500); the sensor assembly (600); the status indicator (800); and the printer (900) are connected to the programmable logic controller (PLC) (700) through cable lines. The programmable logic controller (PLC) (700) is further connected to the database management apparatus (200). The programmable logic controller (PLC) (700) is the central unit and controls the interworking of all the components, subcomponents of the system and processes commands and inputs from these components.
An alarm is provided as a status indicator (800) such that the alarm goes on when the diametrical variations in the reel are outside the predefined limits.
The printer (900) is a sticker printer, wherein the printer (900) is connected to the programmable logic controller (PLC) (700) and prints the stickers for the rejected reels as per the commands received from the programmable logic controller (PLC) (700).
Figure 2: shows the top view of reel rotating assembly (500) integrated with the electronic weighing scale (400); wherein the electronic weighing scale (400) and reel rotating assembly (500) forms a single unit and is located in a pit in the floor (not shown) so that the reel can be easily loaded onto the reel rotating assembly (500). This helps avoid the requirement for additional equipment for lifting the reel and moving it onto the next component of the system (100).
The reel rotating assembly (500) is configured to rotate the reel around a horizontal axis and comprises:
? a cubical housing (500 a), comprising lateral sides (501, 502 ,503, 504,) and a base (505) not shown wherein the sides lateral sides (502, 504) are shorter than lateral sides (501, 503) and further comprises a plurality of radial holders (506, 507) on the lateral side (502) and the corresponding radial holders (506’, 507’) (not shown) on the corresponding opposite lateral side (504) spaced by suitable distance;
? a plurality of rollers (508, 509), wherein the diametrically opposite ends (508a, 508b) and (509 a, 509 b) of each of the plurality of rollers (508, 509) are mounted into the corresponding plurality of radial holders (506, 506’(not shown)) and (507, 507’(not shown)) respectively;
? a motor (510) controlled by a drive arranged adjacent to the lateral side (504) of the cubical housing (500a), wherein the diametrically opposite end (508 b) of the roller (508) is connected to the motor (510) for rotating the reel loaded on the reel rotating assembly (500); and
? a lifting means (511) movably attached to the cubical housing (500a) to facilitate the loading and unloading of the reel.
The electronic weighing scale (400) comprises:
? a plurality of load cells (401, 402, 403, 404) with an average capacity of 3 ton, wherein each of the plurality of load cells (401, 402, 403, 404) are connected with the base (505) at each of the corners (501’, 502’, 503’, 504’) of the cubical housing (500a) of the reel rotating assembly.
The motor (510) of the reel rotating assembly (500) is attached to the cubical housing (500 a) of the reel rotating assembly (500) through a metal sheet (not shown).
The motor (510) of the reel rotating assembly (500) provides a variable speed drive, wherein the reel can be rotated partially around its axis of rotation so that the barcode of the reel is in range of the barcode reader (300), or the reel may be rotated continuously for measuring the diametrical variations.
Figure 3: shows top view of the lifting means (511) of the reel rotating assembly (500), wherein the lifting means (511) comprises:
? a cylindrical bar (511a) arranged acentrically along the length of the plurality of rollers (508, 509) in the space between the roller (508) and roller (509);
? pneumatic actuators (511b, 511b’(not shown)) for pushing and pulling the cylindrical bar (511a); and
? a plurality of joining elements (511c, (511 d not shown)) for connecting each of the diametrically opposite ends (511 a’, 511a‘’) of the cylindrical bar (511 a) with the corresponding pneumatic actuator (511b, 511b’(not shown)) respectively, wherein the cylindrical bar (511 a) is inclined to the roller (508) when the pneumatic actuators (511b, 511b’(not shown)) are at rest, and the cylindrical bar (511a) declines when the pneumatic actuators (511b, 511b’(not shown)) are actuated and the piston of the actuators (511b, 511b’(not shown)) pushes the joining elements (511c, (511d not shown)) towards the corners (504’, 503’(not shown))of the base (505) of the cubical housing (500a) beneath the roller (508).
Figure 4: shows the isometric view of the sensor assembly (600), wherein the sensor assembly (600) comprises:
? a plurality of laser displacement sensors (601, 602, 603) configured to measure the vertical distance between the laser displacement sensors (601, 602, 603) and the circumference of the rotating reel (not shown) using laser beams; and
? an adjustment means (604) for holding and adjusting the position of laser displacement sensors (601, 602, 603), wherein said adjustment means (604) can be arranged at any suitable distance vertically from the reel rotating assembly (500) such that the laser displacement sensors (601, 602, 603) are vertically above the reel (not shown).
In accordance with yet another embodiment of the invention the adjustment means (604) comprises:
? a plurality of bars (604a, 604b) to position the laser displacement sensors (601, 602, 603) at any required distance above the reel (not shown) depending on the range of the laser displacement sensors (601, 602, 603); and
? a sliding mechanism (604c) fastened to the edges of the plurality of bars (604a, 604b) above the reel rotating assembly (500), wherein said sliding mechanism (604c) facilitates the sliding of each of the plurality of laser displacement sensors (601, 602, 603) independently of one another laterally depending upon the length of the reel.
The laser displacement sensors (601, 602, 603) are preferably arranged at the periphery and more preferably at two diametrically opposite locations and the center of the reel with the help of the adjustment means (604) to check the roundness of the reel by measuring the variation in diameter at different locations on its periphery.
Figure 5: shows the front view of the programmable logic controller (PLC) (700), wherein the programmable logic controller (PLC) (700) comprises:
? a touch screen display (701), for inputting and displaying various parameters such as permissible weight and dimensions of the reel, rotation cycle of the rotating assembly (500)(not shown), the output data collected from all the components of the system for inspecting a reel (100) etc.; and
? a plurality of push buttons (702) with light indicators, for switching ON/OFF the PLC, operating the reel rotating assembly (500)(not shown), loading and unloading the reel, resetting the cycle etc.
The PLC (700) is the central unit that controls the interworking of all the components (200, 300, 400, 500, 600, 800, 900 shown in Fig 1) of the system (100) and processes commands and inputs from these components. The programmable logic controller (PLC)(700) takes inputs from the barcode reader (300), the electronic weighing scale (400 of fig 1), Laser displacement sensor (500 of fig 1) and processes and converts the same input to provide outputs to the status indicator (800 of fig 1). Said PLC (700) also operates the pneumatic actuators (511b, 511b’ of fig 3) of the lifting means (511 of fig 1) and the drive of the motor (510 of fig 2).
Figure 6: shows the enlarged view of the touch screen display (701) of the programmable logic controller (PLC) (700), wherein the operator can input parameters, such as reel rotation time, time for the fault alarm, time, date, minimum value of weight for the system to be activated and see the output of the barcode reader such as SAP, MFG, weight of the reel etc.
Figure 7: shows the side view (7a) of loading/unloading the reel (1000) onto the reel rotating assembly (500) and the side view (7b) of the reel (1000) loaded on to the reel rotating assembly (500).
The cylindrical bar (511a) of the lifting means (511) is inclined towards the roller (508) when the pneumatic actuators (511b, 511b’(not shown)) are at rest, such that the reel (1000) does not come in contact with the rollers (508, 509) and prevents any harm due to direct impact of the reel weight. When the operator presses the loading button on the PLC (700 of fig 5) the pneumatic actuator (511b, 511b’ (not shown)) is actuated and the piston of the actuators (511b, 511b’(not shown)) pushes the joining elements (511c, 511d (not shown)) towards the corners (504’, 503’ (not shown)) of the base (505) of the cubical housing (500a) beneath the roller (508) and the cylindrical bar (511a) declines such that the reel (1000) is properly placed on the rollers (508, 509).
Figure 8: shows the isometric view of the reel of a continuous web (1000) with the barcode (301). The reel is wounded with a continuous web of paper and is covered by a covering sheet. The barcode of the manufacturer and the internal barcode of the printing press have been incorporated in barcode (301).
Figure 9: shows the perspective view of the system for inspecting the reel (100) with the reel (1000) loaded onto the reel rotating assembly (500) of the said system (100).
The programmable logic controller (PLC) (700) is the central unit. The bar code reader (300); the electronic weighing scale (400 (not shown)); the reel rotating assembly (500); the sensor assembly (600); the status indicator (800); and the printer (900) are connected to the programmable logic controller (PLC) through cable lines. The programmable logic controller (PLC) (700) is further connected to the database management apparatus (200).
The programmable logic controller (PLC) controls the interworking of all these aforementioned components of the system (100) and processes commands and inputs from these components.
The programmable logic controller (PLC)(700) takes inputs from the barcode reader (300), the electronic weighing scale (400 (not shown)), laser displacement sensor (500) and processes and converts the same input to provide outputs to the status indicator (800). Said programmable logic controller (PLC) also operates the pneumatic actuators (511b, 511b’) (not shown) of the lifting means (511) and the drive of the reel rotating assembly (500).
The above description constitutes a description of major components of the system for inspecting the reel (100) that embody the invention. The method of inspecting the reel of a continuous web contemplated by the invention and the steps involved in the method can be best ascertained by the reference to the Figures 7, 9 and 10 which diagrammatically display various operations performed by the system (100).
The reel is manually loaded onto the reel rotating assembly (500) with help of the lifting means (511) of the reel rotating assembly (500). When the reel is rolled on to the lifting means (511) the cylindrical bar (511a) of the lifting means (511) is inclined to the roller (508) and the pneumatic actuators (511b, 511b’ (not shown)) are at rest, such that the reel (1000) does not come in contact with the rollers (508, 509) and prevents any harm due to direct impact of the reel weight.
When the operator presses the loading button, the pneumatic actuators (511b, 511b’(not shown)) are actuated and the piston of the pneumatic actuators (511b, 511b’(not shown)) pushes the joining elements (511c, 511d(not shown)) towards the corners (504’, 503’(not shown)) of the base (505) of the cubical housing (500a) beneath the roller (508) and the cylindrical bar (511a) declines such that the reel (1000) is properly placed on the rollers (508, 509).
The reel (1000) may be rotated partially by using the variable drive of the motor (510) such that the barcode (301) is in the range of the barcode reader (300). The barcode reader (300) will not operate until certain amount of weight is sensed by the electronic weighing scale (400).
As soon as the minimum weight is detected, the barcode reader (300) reads the barcode (301) on the cover of the reel (1000). The weight of the reel (1000) is also calculated simultaneously by the electronic weighing scale (400) and displayed on the touch screen display (701) of the PLC (700). The output of the barcode reader (300) and the electronic weighing scale (400) is received by the PLC (700) and transferred and stored in the database management apparatus (200) for future reference. The PLC (700) then validates the measured reel weight with reel weight provided by the supplier on the reel cover. Before checking the roundness of the reel (1000) the width of the reel (1000) is set using the adjustment means (604) of the sensor assembly (600) comprising a plurality of bars (604a, 604 b) with a sliding mechanism (604c); the laser displacement sensors (601, 602, 603) are arranged at the two diametrically opposite locations and the center of the reel with the help of the adjustment means (604).
The reel is then rotated on the reel rotating assembly (500) to check the roundness of the reel (1000) by measuring the variation in diameter at different locations on its periphery. The laser displacement sensors (601, 602, 603) continuously measures the vertical distance between said laser displacement sensors (601, 602, 603) and the circumference of the reel (1000) while the reel (1000) rotates at least one round. This measured distance varies as per the variation in the reel diameter and is continuously transferred to the PLC (700). The PLC (700) processes the data and determines the diametrical variation by calculating the difference between maximum and the minimum vertical distance between each of the laser displacement sensors (601, 602, 603) and the reel (1000) after completing one rotation and compares the same with the predefined value. The data collected by the laser displacement sensors (601, 602, 603) is analyzed and processed by the PLC (700) and transferred and stored in a desired format in the database management apparatus (200). If the diametrical variation is within the predefined limit the reel (1000) is accepted else the reel is rejected. When the diametrical variation is above the predefined limit, a red light is displayed on the touch screen display (701) of the PLC (700) and the status indicator (800) is turned ON indicating that the reel should be rejected. The operator can then print the data of the rejected reel through the printer (900) and paste it onto the reel to differentiate between accepted and rejected reels. The reel is then unloaded from the reel rotating assembly (500) with the help of the lifting means (511) of the reel rotating assembly (500). When the operator presses the unloading button, the pneumatic actuators (511b, 511b’ (not shown)) gets back to its original position and pulls the piston of the pneumatic actuators (511b, 511b’(not shown)) towards its rest state. The cylindrical bar (511a) of the lifting means (511) gets inclined to the roller (508) such that the reel (1000) is lifted and is no longer in contact with the rollers (508, 509).
Although the invention has been described in detail in the foregoing embodiments for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be described by the following claims.

We Claim:
1. A system for inspecting the reel of a continuous web (100), comprising:
? a database management apparatus (200);
? at least one barcode reader (300) for scanning the barcodes;
? an electronic weighing scale (400) for measuring the weight of the reel;
? a reel rotating assembly (500);
? a sensor assembly (600);
? a programmable logic controller (PLC) (700) for controlling and managing the entire system;
? a status indicator (800); and
? a printer (900) for printing the status of the reel.
2. The system for inspecting the reel of a continuous web (100) as claimed in claim 1, wherein the database management apparatus (200) may be selected from computer, server, mobile or any similar device which organizes and stores details of each reel entering the system such as the reel number/code, weight, diameter, diametrical variation etc. in the form of a database.
3. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 2, wherein the barcode reader (300) reads the details of the reel from the barcode present on the reel.
4. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 3, wherein the electronic weighing scale (400) of a suitable measuring capacity may be used for measuring the weight of the reels entering the system (100).
5. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 4, wherein the output of the barcode reader (300) and the electronic weighing scale (400) is received by the programmable logic controller (PLC) (700) and transferred and stored in the database management apparatus (200).
6. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 5, wherein the reel rotating assembly (500) comprises:
? a housing (500a) comprising a plurality of lateral sides (501, 502, 503, 504) and a base (505), wherein said housing (500a) further comprises a plurality of radial holders (506, 507); (506’, 507’) on any two of the corresponding opposite lateral sides (502, 504) or (501, 503) spaced by a suitable distance;
? a plurality of rollers (508, 509), wherein the diametrically opposite ends (508a, 508b) and (509a, 509b) of each of the plurality of rollers (508, 509) are mounted into the corresponding plurality of radial holders (506, 506’) and (507, 507’) respectively;
? a motor (510) controlled by a drive, wherein at least one of the rollers is connected to the drive of the motor (510) for rotating the reel loaded onto the reel rotating assembly (500);
? a lifting means (511) movably attached to the housing (500a) to facilitate the loading and unloading of the reel on the reel rotating assembly (500).
7. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 6, wherein the lifting means (511) comprises:
? a cylindrical bar (511a) arranged acentrically along the length of the rollers (508, 509) in the space between the first roller (508) and the second roller (509);
? at least one pneumatic actuator (511b, 511b’) for pushing and pulling the cylindrical bar (511a); and
? a plurality of joining elements (511c, 511d) for connecting each of the diametrically opposite ends (511a’, 511a’’) of the cylindrical bar (511a) with each of the plurality of pneumatic actuators (511b, 511b’).
8. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 7, wherein the motor (510) of the reel rotating assembly (500) provides a variable speed drive.
9. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 8, wherein the reel rotating assembly (500) is configured to rotate the reel around a horizontal axis and may be located above or below the ground.
10. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 9, wherein both the electronic weighing scale (400) and reel rotating assembly (500) have been integrated together.
11. The system for inspecting the reel of a continuous web (100) as claimed in claims 1 to 10, wherein the electronic weighing scale (400) comprises, a plurality of load cells (401, 402, 403, 404), wherein each of the load cells may be connected with the base (505) at each of the corners of the housing (500a) of the reel rotating assembly (500).
12. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the sensor assembly (600) comprises :
? a plurality of laser displacement sensors (601, 602, 603) configured to measure the vertical distance between the laser displacement sensors (601, 602, 603) and the circumference of the rotating reel using laser beams; and
? an adjustment means (604) for holding and adjusting the position of laser displacement sensors (601, 602, 603); wherein said adjustment means (604) can be arranged at any suitable distance vertically from the reel rotating assembly (500) such that the laser displacement sensors (601, 602, 603) are vertically above the reel.
13. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the adjustment means (604) comprises:
? a plurality of bars (604a, 604b) to position the laser displacement sensors (601, 602, 603) at any required distance above the reel depending on the range of the laser displacement sensors (601, 602, 603); and
? a sliding mechanism (604c) fastened to the edges of the plurality of bars (604a, 604b) above the reel rotating assembly (500), wherein said sliding mechanism (604c) facilitates the sliding of each of the plurality of laser displacement sensors (601, 602, 603) independently of one another laterally depending upon the length of the reel.
14. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the laser displacement sensors (601, 602, 603) may be preferably arranged at the periphery and more preferably at two diametrically opposite locations and the center of the reel with the help of the adjustment means (604).
15. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the plurality of laser displacement sensors (601, 602, 603) continuously measures the vertical distance between said laser displacement sensors (601, 602, 603) and the circumference of the reel.
16. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the data collected by the laser displacement sensors (601, 602, 603) is analyzed and processed by the programmable logic controller (PLC) (700) and transferred and stored in a desired format in the database management apparatus (200).
17. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the programmable logic controller (PLC) (700) is the central unit that controls the interworking of all the components, subcomponents of the system and processes commands and inputs from these components.
18. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the programmable logic controller (PLC) (700) comprises:
? an input means preferably a touch screen, for inputting various parameters such as permissible weight and dimensions of the reel, rotation cycle of the rotating assembly, etc.;
? a plurality of push buttons (702) with light indicator, for operating and controlling the system; and
? a display preferably integrated with the touch screen for displaying the input data and the output data collected from all the components of the system.
19. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the programmable logic controller (PLC) (700) takes inputs from the barcode reader (300), weighing scale (400), laser displacement sensor (601, 602, 603) and processes and converts the same input to provide outputs to status indicator (800) such as alarms. Said programmable logic controller (PLC) (700) also operates the pneumatic actuators of the lifting means (511) and the drive of the motor.
20. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the status indicator (800) can be a combination of audio and/or visual devices or can be a standalone audio or a standalone visual device.
21. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the printer (900) is connected to the programmable logic controller (PLC) (700) and prints the status of the reels.
22. The system for inspecting the reel of a continuous web (100) as claimed in preceding claims, wherein the system for inspecting the reel of a continuous web (100), optionally comprises a component for automated removal of the side cover provided at both side of the reel wherein, the cover is only removed once the barcode has been read by the barcode reader.
23. A method for inspecting reels of a continuous web (100), comprising the steps of:
? manually loading the reel (1000) onto the reel rotating assembly (500) with help of the lifting means (511) of the reel rotating assembly (500);
? rotating the reel (1000) partially using the variable drive of the motor (510) such that the barcode (301) is in the range of the barcode reader (300);
? reading the barcode (301) on the cover of a reel using the barcode reader (300) and storing its details in a database management apparatus (200) through programmable logic controller (PLC) (700);
? weighing the reel using an electronic weighing scale (400) and storing the detected value in the database management apparatus (200) through programmable logic controller (PLC) (700);
? validating the measured reel weight with the reel weight provided by the supplier on the reel cover.
? manually adjusting the placement of laser displacement sensor (601, 602, 603) according to width of reel using adjustment means comprising a plurality of bars (604a, 604b) with a sliding mechanism (604c)
? rotating the reel (1000) on the reel rotating assembly (500) for checking its roundness;
? checking the diametrical variations of rotating reel (1000) using a plurality of laser displacement sensors (601, 602, 603) and storing the same in the database management apparatus (200);
? processing the data collected by the laser displacement sensors (601, 602, 603) through programmable logic controller (PLC) (700) and comparing the diametrical variations with predefined limits
? indicating the status of the reels on the status indicator (800);
? rejecting the reels that are found to be oversized; and
? accepting the reels that are not oversized and storing them as non-defective in the database.
? Unloading the reel with the help of lifting means of the reel rotating assembly.