ACCUMULATOR FOR PROCESSING LINE AND METHOD OF USE OF THIS

Abstract

A processing line processes logs from twisted web material and has upstream and downstream sections. A main accumulator has buckets that receive, hold, and release logs. An infeed feeder receives logs from the upstream section and conveys them to a bucket in the main accumulator. A loader has a loader accumulator and loader buckets that receive, hold, and release logs. A transfer conveyor between the main accumulator and the loader receives a log from the main accumulator bucket and conveys the log to a loader bucket independently of the infeed feeder. The loader receives a log from the transfer conveyor. The loader conveys the log in the loader bucket to a loader discharge. The loader discharge discharges the log from the loader bucket to the downstream section of the processing line.

Description

ACCUMULATOR FOR PROCESSING LINE AND METHOD OF USE OF THIS RELATED APPLICATION DATA This application claims the benefit of U.S. provisional application No. 62 / 887,723, filed on August 16, 2019, the disclosure of which is incorporated herein by reference. BACKGROUND AND FIELD OF THE INVENTION This disclosure pertains to an accumulator for a processing line. More specifically, the accumulator is configured to transfer twisted, web-wound logs between upstream and downstream sections of a processing line. The processing line may include a coiler for winding the web into logs upstream of the accumulator and a saw for cutting the logs into end-use rolls downstream of the accumulator. Accordingly, in one configuration, the accumulator receives logs from the coiler, stores them, and then transfers them at the desired time and sequence as required by the sawing operations. In another configuration, the accumulator can be used to receive, store, and deliver logs to other equipment in a timely manner. More specifically, the disclosure focuses on an accumulator with a loader and a transfer conveyor. The transfer conveyor is adapted and configured to transfer a log from the main accumulator to the loader, one log at a time, which helps maintain log quality. Additionally, the loader is adapted and configured to deliver the log to the downstream processing equipment in a more direct manner, which also helps maintain log quality. DESCRIPTION OF THE FIGURES Figure 1 is a process flow diagram showing an implementation of a log processing line transfer system; Figure 2 is a process flow diagram showing another embodiment of a log processing line transfer system; Figure 3 is a process flow diagram showing another embodiment of a log processing line transfer system; Figure 4 is a front elevation view of an illustrative accumulator of the transfer systems of the processing line in Figures 1-3; Figure 5 is a partial front elevation view of an illustrative transfer conveyor of the processing line transfer systems in Figures ly3; Figure 6A is a partial front elevation view of another illustrative transfer conveyor of the processing line transfer system in Figure 1; Figure 6B is a partial front elevation view of another illustrative transfer conveyor of the processing line transfer system in Figure 1; Figure 7 is a partial front elevation view of an illustrative transfer conveyor of the processing line transfer systems in Figure 2; Figure 8 is a front elevation view showing a portion of the processing line of Figure 1 with a first and second loader next to the accumulator of Figure 4, first and second transfer conveyors of the type shown in Figures 5-6 extending between the outlet side of the accumulator of Figure 1 and the first and second loaders, and four log saw conveyor lanes under each loader. Figure 9 is a front elevation view showing a portion of the processing line of Figure 2 with a first and second loader next to the accumulator of Figure 4, a single transfer conveyor of the type shown in Figure 6A and / or Figure 6B and / or Figure 7 extending between the outlet side of the accumulator of Figure 1 and the first and second loaders, and four log saw conveyor lanes under each loader. Figure 10 is a front elevation view showing a portion of the processing line in Figure 3 with a single loader next to the accumulator in Figure 4, a single transfer conveyor of the type shown in Figure 5 extending between the outlet side of the accumulator in Figure 1 and the loader, and four log saw conveyor rails at each of the two locations below the loader. Figure 11 is an illustrative perspective view of a main accumulator bucket or tray. Figure 12 is a front view of the main accumulator basin of Figure 11. Figure 13 is a perspective view of the transfer conveyor of Figure 5 with ramp portions fixed in place to extract logs from a bucket of the accumulator as the bucket moves along the transfer conveyor. Figure 14 is a perspective view of the transfer conveyor of Figure 6A and / or Figure 6B with ramp portions that are rotatably mounted on the transfer conveyor to remove logs from an accumulator bucket or to allow logs to remain in the accumulator bucket as the bucket moves along the transfer conveyor. DETAILED DESCRIPTION OF THE INVENTION Figures 1-3 provide an overview of the processing lines 10, 12, and 14 and the transfer systems 20, 22, and 24 described herein. The processing lines 10, 12, and 14 process logs 16 of twisted-wound web material, and the transfer systems 20, 22, and 24 transfer the logs from the upstream processing equipment 30 to the downstream processing equipment 32. For example, the processing line may include an unwinder that transfers the web material from a master roll to a rewinder that converts the web material into logs. The processing line may also include a sawing operation that converts the logs into rolls for end-use consumer packaging. The processing line may further include a packaging line for packaging the rolls for sale to consumers.The transfer system 20, 22, 24 can be arranged at any point along the line where it is necessary to queue logs for further processing. In this respect, the transfer system 20, 22, 24 receives logs from the upstream processing equipment 30, temporarily stores the logs, and then delivers them to the downstream processing equipment 32, as required. The transfer system 20, 22, 24 may include an inlet feeder 34 that receives logs from the upstream processing equipment 30 and loads them into a main accumulator 36, for example, as shown in Figure 4. The inlet feeder 34 is conventional. For example, and without limitation, the inlet feeder may be a table on which a log is moved. The inlet feeder may be a table with driven belts located above the table; the driven belts assist in moving a log along the table.The inlet feeder may be a paddle-type device similar to that shown in Figure 5. The main accumulator 36 is adapted and configured to store the logs. The main accumulator 36 is conventional and, by way of example and without limitation, the accumulator may be of the type shown in US documents 4142626, US 4168776 and / or US 6053304, disclosures of which are incorporated herein by reference. As described below, the transfer system 20, 22, 24 may include one or more transfer conveyors 40, 42. The transfer conveyor may be a rotary pallet conveyor as shown in Figure 5 and Figure 12 ('40'), Figure 6A ('41'), 6B ('41''), Figure 13 ('41''), and Figure 7 ('42'). By way of example and without limitation, the transfer conveyor may be a belt-driven conveyor, a robotic arm conveyor, a pallet pusher-style conveyor, or another similar device configured to transport the log from the main accumulator to the loader. For illustrative purposes only, in the examples described herein, the transfer conveyor 40, 41, 4Γ, 42 is a pallet conveyor adapted and configured to transfer the log from the main accumulator to a loader 50, 52, 54.The loader 50, 52, 54 is adapted and configured to transfer the log to the downstream processing equipment 32. Figures 8-9 show two loaders 50, 52. Figure 10 shows one loader 54. One or more loaders may be provided. Figures 1-3 provide a non-limiting example of a process flow for processing lines 10, 12, 14. As shown in Figure 1, two transfer conveyors 40, 41, 41' and two loaders 50, 52 are provided. The transfer conveyors 40, 41, 41' work together with a dedicated loader 50, 52 to deliver logs to the downstream processing equipment 32. When logs are transferred from the main accumulator to both loaders 50, 52, the transfer conveyors 40, 41, 41' transfer logs from the main accumulator to the loaders one at a time, which can be simultaneous if the distance between the transfer conveyors is equal to an integer multiple of the distance between buckets in the main accumulator.When logs are transferred to a single loader—for example, when the log saw connected to that loader is operational but the log saw connected to another loader is not—one transfer conveyor operates independently of the other to transfer logs from the main accumulator to a loader. In Figure 2, a single transfer conveyor 42 is provided. The single transfer conveyor is configured to deliver logs to either the first loader 50 or the second loader 52, as required. The transfer conveyor 42 can selectively deliver logs to either the first or second loader 50, 52. Alternatively, the transfer conveyor 42 can alternately deliver logs to the first and second loaders 50, 52.In one configuration, the transfer conveyor 42 moves in a first direction (e.g., a first rotating direction) to transfer logs from the main accumulator 36 to the first loader 50, and in a second direction opposite to the first direction to transfer logs from the main accumulator 36 to the second loader 52. In Figure 3, a single transfer conveyor 40 transfers logs to a single loader 54. The loader 54 is adapted and configured to selectively transfer logs to the downstream processing equipment 32. Referring to Figure 4, the accumulator 36 has a frame 60, and has upper guide wheels 62 arranged adjacent to an upper frame member and lower guide wheels 64 arranged adjacent to a lower frame member. Intermediate guide wheels 66 are provided on a first and second trolley 68, 70 that can be moved vertically between the frame uprights 60 between the upper and lower frame members. Alternatively, a single trolley may be provided. An endless loop 72 extends around the guide wheels. The endless loop has a plurality of main accumulator buckets 74 with a generally V-shaped cross-section to support the logs 16 as they are received from the inlet feeder 34 and conveyed through the main accumulator 36 to the transfer conveyors 40, 41, 41', 42.The generally V-shaped cross-section of the bucket for supporting the logs may be shaped like fingers spaced intermittently along an axis of the bucket, as shown in Figures 11-12. In the drawing, only some of the buckets are shown for ease of illustration. The buckets of the main accumulator 74 may be evenly spaced along the endless loop 72. The buckets of the main accumulator 74 are pivotally connected to the endless loop 72 to allow logs 16 to be conveyed in the accumulator around the guide wheels 62, 64, 66 and to allow the buckets to pivot as required to receive a log from the inlet feeder 34 and to transfer a log to the transfer conveyors 40, 41, 4Γ, 42. In an inlet zone 80 of the main accumulator, inlet feeder 34 may be provided. Inlet feeder 34 is adapted and configured to receive a log 16 from the upstream processing equipment 30 and transfer the log to one of the basins of the main accumulator 74. For example, inlet feeder 34 may be configured to rotate and allow a log 16 to roll onto a conveyor blade of the inlet feeder, and by the continuous rotation of the conveyor blade, to allow the log to roll off the conveyor blade into a basin of the main accumulator 74. Inlet feeder 34 may pause its rotation, for example, at an angle of approximately 20–30 degrees, so that another log 16 stops against an edge of the inlet feeder's conveyor blade, thus preventing more than one log from rolling onto the conveyor blade.The inlet feeder, which pauses its rotation in this manner, helps compensate for a variable rate of logs arriving from the upstream processing equipment 30. The main accumulator bucket 74 can be stationary when receiving a log from the inlet feeder's conveyor blade; the main accumulator bucket 74 can be moving along the path of the auger loop while receiving a log from the inlet feeder's conveyor blade; or the main accumulator bucket 74 can be configured to rotate relative to the auger loop 72 when the bucket passes adjacent to the inlet feeder 34 to allow the bucket to receive the log from the inlet feeder's conveyor blade. The auger loop 72 can then convey the log 16 in the main accumulator bucket 74 upward and through the accumulator to the transfer conveyors 40, 41, 4Γ, 42.The inlet feeder 34 can be configured to detect the passage of the main accumulator bucket 74 and to initiate the transfer of the log ncQZQn / zznz / q / uili from the inlet feeder to the main accumulator bucket with a seamless transition. The rotation speed of the inlet feeder 34 and / or the speed of the endless loop 72 can be controlled as needed to allow the transfer of the log from the inlet feeder to the main accumulator bucket 74 with an uninterrupted transition. The logs 16 arranged in the buckets of the main accumulator 74 can be transported from the main accumulator's inlet zone 80 to its outlet zone 82. The transport rate can be controlled to maintain a sufficient number of logs queuing in the accumulator while delivering logs to the downstream processing equipment 32 at an acceptable rate. The first and second trolleys 68, 70 can be adjusted as needed to maintain the log storage and delivery rate to the downstream processing equipment. For example, when the rate of logs arriving at the main accumulator's inlet zone 80 is greater than the rate of logs leaving the main accumulator's outlet zone 82, one or both trolleys 68, 70 can be raised, thereby increasing the number of full buckets and reducing the number of empty buckets.The opposite occurs when the rate of logs leaving exit zone 82 increases relative to the rate of logs arriving at entry zone 80. A distance sensor, for example a laser, can be provided to detect an absolute height position of the cart, which can be used to calculate the percentage full of the accumulator. In exit zone 82, transfer conveyors 40, 41, 41', 42 may be provided. The transfer conveyor 40, 41, 41', 42 may be a rotary paddle conveyor as shown in Figures 5-7 and 13-14. The transfer conveyor may be motor-driven and include one or more transfer paddles 88, 90 that move with the main accumulator endless loop 72 and the main accumulator bucket 74 to transfer the log 16 from the main accumulator bucket to the loader 50, 52, 54. In an example as shown in Figures 5 and 13, the transfer conveyor 40 is coupled to a specific loader 52, 54 (e.g., as shown in the example in Figures 1, 3, 8, 10). The transfer conveyor 40 is configured to allow the log to roll out of the main accumulator hopper 74 along a first transfer vane 88 to a second transfer vane 90 that acts as a stop. By rotating the transfer conveyor vane (clockwise in Figure 5), the transfer conveyor is configured to allow the log to roll along the second portion of the transfer vane into the loader 52, 54. The transfer conveyor 40 may include a ramp portion 92 for transferring from the main accumulator to the transfer vane 88, 90 and a ramp portion 94 from the transfer vane to the loader.The main accumulator 36 may also have a ramp portion 98 that cooperates with the main accumulator bucket 74 to allow the log to be withdrawn from the bucket to the transfer paddle 40. As best shown in the. Figure 13 shows ramp portion 92 (and ramp portions 94 and 98, which are not shown in Figure 13) that can be interleaved with the fingers of the main accumulator bucket 74 to extract a log from the bucket as it advances past the ramp portions. Ramp portions 92, 94, and 98 can be fixed in place so that a log is extracted from each bucket as it advances past the ramp portions. Alternatively, the main accumulator bucket 74 can be rotated to release a log from the bucket onto the transfer conveyor 40. Alternatively or additionally, the ramp portions can be adapted and configured to allow some logs to remain in the accumulator buckets and to remove other logs from the accumulator buckets as the buckets advance past the ramp portions, for example, by pivoting or sliding the ramp portions to a first position where the logs remain in the main accumulator bucket 74 and to a second position where the logs are removed from the main accumulator bucket. In an example as shown in Figures 6A, 6B, and 14, the transfer conveyor 41, 41' has ramp portions 92a that are rotatable.In one configuration, ramp portions 92a can be rotated to a position generally transverse to the path of the main accumulator bucket 70 so that the ramp portions can remove the main accumulator bucket log to the transfer conveyor 41, 41' for delivery to the loader 50. In a second configuration, ramp portions 92a can be rotated to a position generally away from the path of the main accumulator bucket so that the ramp portions do not interfere with the main accumulator bucket log and allow it to pass to the transfer conveyor 40 for delivery to the second loader 52. Alternatively or additionally, the main accumulator bucket 74 can also be rotated to release a bucket log to the transfer conveyor 41, 4Γ.In Figure 6B, ramp portions 92 and 98 can also rotate into one position to help deliver the log to the first loader 50 and rotate into another position to allow the log to pass onto the transfer conveyor 40 for delivery to the second loader 52. In another example, as shown in Figures 2, 7, and 9, the transfer conveyor 42 is coupled to two loaders. The transfer paddle 42 can be configured to operate in two directions. The first direction can be as described above in relation to the transfer paddle 40 in Figure 5 (rotating clockwise), which directs the log to the first loader 50. The second direction can include allowing the log 16 to roll out of the main accumulator hopper 74 along a first transfer paddle 88 to a second transfer paddle 90 that acts as a stop. By rotating the transfer paddle (counterclockwise in Figure 7), the transfer paddle is configured to allow the log to roll back on the first transfer paddle 88 to a hopper 96 that directs the log to the second loader 52.The hopper may contain a conveyor to control the movement of the log along the hopper during delivery from transfer pallet 42 to the second loader 52. In the configurations described with one or two transfer conveyors 40, 41, 41', 42, when the main accumulator hopper 74 passes adjacent to the transfer paddle, the ramp portions 92, 94, 98 can release the log 16 (e.g., extract and / or rotate it face-to-face) from the main accumulator hopper to the first transfer paddle blade 88. The transfer conveyor 40, 42 can be configured to detect the presence of a log on the second transfer paddle blade 90 and to rotate and initiate the transfer of the log from the main accumulator hopper to the transfer conveyor with a seamless transition.The rotational speed of the transfer conveyor 40, 41, 41', 42 and / or the speed of the endless loop 72 can be controlled as needed to allow the log to be transferred from the main accumulator hopper 74 to the transfer conveyor with a continuous transition. The movement of the transfer conveyor 40, 41, 41', 42, the movement of the endless loop 72, and the movement of the inlet feeder 34 can be independent of each other. The rotational speed of the transfer conveyors 40, 41, 41', 42 can be controlled to meet the downstream processing requirements for log delivery, and the rotational speed of the inlet feeder 34 can be controlled based on the production rates of the upstream section of the processing line.The forward speed of the main accumulator's endless loop 72 can be a function of both the downstream processing requirements for log delivery and the production speeds of the upstream section of the processing line. As shown in the figures, the transfer conveyor 40, 41, 41', 42 is arranged between the outlet zone 82 of the main accumulator and the loader 50, 52, 54. Depending on the desired configuration, one or more transfer conveyors can be provided. In Figure 8, two transfer conveyors 40, 41, 41' are provided, and one loader 50, 52 is associated with each transfer pallet. Consequently, the first transfer conveyor 41, 41' can be adapted and configured to receive a log from one bucket of the main accumulator 74 as described above, and the second transfer conveyor 40 can be adapted and configured to receive another log from another bucket of the main accumulator 74 as described above.The first transfer conveyor 41, 41' may be provided with ramp portions 92a that can be moved between an open and a closed position, while the second transfer conveyor 40 may be provided with ramp portions 92 that are fixed in place. The system may be configured to allow the first and second transfer pallets 41, 41', 40 to receive logs one at a time from the buckets of the main accumulator 74 when both loaders are capable of receiving logs. When both loaders 50, 52 are capable of receiving logs, the actuators associated with the ramp portions 92a, 98 of the first transfer pallet 41, 41' may move the ramp portions 92a, 98 to an open position, allowing logs passing through them to remain in the buckets of the main accumulator 74 as the buckets advance past the first transfer conveyor 41, 41'.When all the buckets between transfer conveyors 41, 40, and 41' contain logs, the actuators associated with ramp portions 92a and 98 of the first transfer conveyor 41 and 41' move those portions to a closed position, and the buckets in accumulator 74 continue to advance until a quantity of logs equal to the quantity of logs between the transfer conveyors has been transferred to each loader 50 and 52. The system can be configured to allow only the first transfer pallet 41 and 41' to receive logs when only the first loader 50 is capable of receiving logs, and to allow only the second transfer pallet 40 to receive logs when only the second loader 52 is capable of receiving logs. The first loader 50 can receive logs until the loader car 110 reaches a full position.A distance sensor, such as a laser, can be provided to detect the absolute height position of loader trolley 110, which can be used to calculate the percentage full of the loader's accumulator. The second loader 52 can receive logs until the addition of logs in the buckets between transfer conveyors 41, 40, and 41' causes loader trolley 110 to reach its full position. This prevents the system from stopping the flow of logs to both loaders, which is undesirable, and prevents logs from returning to the accumulator feed zone, which is also undesirable as it creates the risk of the accumulator attempting to load a log into a bucket that already contains one. In the configuration shown in Figure 9, a transfer conveyor 42 is provided with the first and second loaders 50, 52. The transfer conveyor 42 can be adapted and configured to receive a log from a hopper of the main accumulator and to transport logs alternately to the first and second loaders 50, 52 as described above. The system can be configured to remove a log from a hopper of the main accumulator by advancing the hopper past the stationary ramp portions as described above in relation to Figure 5. Alternatively, the system can be configured to remove a log from a hopper of the main accumulator by rotating the hopper.For example, the system can be configured to rotate a front main accumulator bucket towards the transfer conveyor so that the transfer conveyor can transport the main log to the first loader, and to rotate a next main accumulator bucket (for example, the next one in line after the front main accumulator bucket) towards the transfer conveyor so that the transfer conveyor can transfer the next log to the second loader.Alternatively, the system can be configured to rotate a sequence of buckets from the main accumulator (one or more in a line) towards the transfer conveyor, so that the transfer conveyor can transport that sequence of logs to one of the two loaders, and then rotate another sequence of buckets from the main accumulator (one or more in a line) towards the transfer conveyor so that the transfer conveyor can transport that sequence of logs to the other of the two loaders. In the configuration of Figure 10, a transfer conveyor 40 is provided with a loader 54. The transfer conveyor 40 can be configured to receive a log from a main accumulator bucket 74 as described above in relation to Figure 5 and transfer the log to the loader 54. The system can be configured to rotate a front main accumulator bucket toward the transfer conveyor to transfer a log to the loader, and to rotate a next main accumulator bucket (e.g., the one next in line after the front main accumulator bucket) toward the transfer pallet to transfer the next log to the loader. With reference to the embodiment of the loaders 50, 52 shown in Figures 8-9, each loader may have a plurality of guide wheels 102 around which an endless loop 104 is driven. The endless loop of the loader 104 may have a plurality of loader buckets 106, which may be evenly spaced along the endless loop of the loader. The loader buckets 106 may have a generally V-shaped cross-section to support the logs as they are received from the transfer pallet 40, 42 and conveyed through the loader. The generally V-shaped cross-section of the bucket for supporting the logs may be in the form of fingers spaced intermittently along an axis of the bucket, as shown in Figure 11.In the embodiment of the loaders shown in Figures 8-9, the loader 50, 52 also has intermediate guide wheels 108 provided on a loader carriage 110 that can be moved within the loader frame. In the figures, only some of the loader buckets are shown for ease of illustration, and in the loader on the left in the figures, the position of the loader carriage is shown ghosted at various locations within the loader frame. The loader buckets 106 can be pivotally connected to the endless loop of the loader 104 to allow the logs 16 to be conveyed from the transfer conveyor 40, 41, 41' around the loader's guide wheels 102, 108 and to rotate the loader buckets as required to transfer the logs from the loader to the downstream processing equipment 32. In Figures 8-9, each loader 50, 52 has an inlet zone 114 adjacent to the transfer conveyor 40, 42 and a discharge point 116. In the examples provided, the discharge point 116 is aligned with the rails of a log saw conveyor 118. Specifically, the discharge point 116 is suspended above the rails of the log saw conveyor 118. Alternatively, the loader 116 discharge point may be aligned with other downstream processing equipment. A bucket from loader 106 may pass through the discharge point 118 and align with a rail of the log saw conveyor 118. The control system may be configured to allow the loader 106 bucket to rotate sufficiently to permit a log in a loader bucket to fall from the bucket onto the rail of the log saw conveyor 118 when the bucket is in position above the log saw rail.As shown in Figures 8-9, four conveyor lanes are provided for the log saw conveyor 118. Four actuators can be positioned laterally across the discharge 116, one for each lane. Each actuator can be configured to rotate the bucket and release the log onto a lane of the log saw conveyor 118 when the bucket passes through the discharge and aligns with the desired lane of the log saw. In one example, a bucket can pass through the discharge to position 1, which is aligned with lane 1 of the log saw conveyor. Actuator 1 can be activated to rotate the bucket in position 1 to allow the log to be released from the bucket and received onto lane 1 of the log saw conveyor. A similar scheme can be used for the remaining lanes.Consequently, the system can be configured to allow the selective placement of logs into a desired lane of the log saw conveyor. For example, if a log is required for lane 3, the loader's endless loop can transport a log in a loader bucket through the loader discharge to position 3, at which point actuator 3 would engage the bucket and release the log from the bucket into lane 3. Depending on downstream log delivery requirements, the 110 loader car can be moved as needed to allow a certain number of logs to be queued within loaders 50 and 52. This provides greater operational flexibility to meet downstream requirements and also allows the accumulator to be decoupled from the loader, enabling better sequencing of log delivery to downstream processing equipment. For example, when the rate of logs arriving at loader 50 and 52 is higher than the rate of logs leaving the loader, car 110 can be raised, thus increasing the number of full buckets and reducing the number of empty buckets. The opposite occurs when the rate of logs leaving loader 50 and 52 increases relative to the rate of logs arriving at the loader. In the embodiment of Figure 10, the loader 54 has a plurality of guide wheels 122 around which an endless loop 124 is driven. The endless loop of the loader 124 may have a plurality of loader buckets 126, which may be evenly spaced along the loader's endless loop. The loader buckets 126 may have a generally V-shaped cross-section to support the logs as they are received from the transfer pallet 40 and conveyed through the loader. The generally V-shaped cross-section of the bucket for supporting the logs may be in the form of fingers spaced intermittently along an axis of the bucket, as shown in Figure 11. In Figure 10, only some of the loader buckets are shown for ease of illustration.The loader buckets 126 can be pivotally connected to the endless loop of the loader 124 to allow logs to be conveyed from the transfer conveyor 41, 41' around the loader's guide wheels 122, and to rotate the buckets as required to transfer logs from the loader bucket to a stockpile area 130 arranged between a loader discharge 132 and a saw. In the embodiment of Figure 10, the loader has multiple accumulation zones 130 that align with the conveyors 118 of the downstream processing equipment. Specifically, in Figure 10, the loader 54 is provided with a first and a second accumulation zone 130 that correspond to the conveyors 118 of the first and second log saws. The loader's discharge 132 includes actuators for each accumulation zone 130. The actuators are configured to sufficiently rotate a bucket 126 that passes through the accumulation zone to allow the log in the loader's bucket to fall from the bucket into a designated accumulation zone lane. The logs can then be released from the accumulation zone lane onto a lane of the log saw conveyor.The release of a log from a lane in the accumulation zone to a lane on the log saw conveyor can be independent of the release of a log from another lane in the accumulation zone to a lane on a different conveyor. As shown in the figures, four accumulation zone lanes are provided for each accumulation zone 130. Each accumulation zone lane corresponds to a conveyor lane for a log saw. Consequently, four actuators can be positioned laterally across each accumulation zone 130. Each actuator can be configured to rotate a bucket sufficiently to release the log onto a desired accumulation zone lane. The accumulation zone lane can then be opened to drop the log from the accumulation zone lane onto a corresponding lane on the log saw.In one example, a bucket can pass through the unloading chute to accumulation zone 1 in position 1, which is aligned with accumulation lane 1. Actuator 1 can be activated to rotate the bucket, allowing the log to be released and received in lane 1 of the accumulation zone. From there, lane 1 of the accumulation zone can open to drop the log from lane 1 of the accumulation zone into lane 1 of the log saw. A similar scheme can be used to fill the remaining lanes in the accumulation zone for each accumulation zone in the unloading chute. The system can be configured to allow the selective placement of a log into a desired lane of a specific accumulation zone and then into a desired lane of a log saw.As an example, if a log is required for lane 3 of accumulation zone 1, the loader's endless loop can transport a log in a bucket through the loader's discharge to position 3 in accumulation zone 1. At this point, actuator 3 is engaged, causing the bucket to rotate and release the log into lane 3 of accumulation zone 1. Subsequently, lane 3 of accumulation zone 1 can open to drop the log from lane 3 into lane 3 of the log saw conveyor. As accumulation zone lane fills, a bucket from loader 126 can pass through accumulation zone 130 and be recirculated through the loader as needed.In this respect, the loader in Figure 10 does not need to include a mobile cart to accommodate any difference between filling and emptying the loader's buckets, unlike the loaders in Figures 8 and 9. Using the transfer system 20, 22, 24 described herein, a log 16 can be moved directly from a hopper 74 of the main accumulator to a hopper of the loader 106, 126 and to a corresponding conveyor rail 118 of a log saw. This improves quality control during processing, as the process prevents logs from coming into contact with each other. For example, a common defect encountered when logs come into contact during processing involves the transfer of adhesive from the adhesive tail of one log to the surface of an adjacent log in contact. Because the logs do not touch each other during transfer, problems with adhesive tail transfer are avoided. Another common defect encountered when logs come into contact during processing is surface scratching of the logs.Another common defect encountered when logs come into contact with each other during processing is deformed logs. Another common defect when logs come into contact with each other during processing is that the sealed end of the twisted netting wrapped around the outside of a log opens. In view of the foregoing, it will be seen that the various advantages of the invention are achieved. The embodiments were chosen and described to better explain the principles of disclosure and their practical application, thereby enabling other people skilled in the art to make better use of the various embodiments and with various modifications as they suit the particular use contemplated. Since various modifications can be made to the constructions and methods described and illustrated herein without departing from the scope of the invention, it is intended that everything contained in the foregoing description or shown in the accompanying drawings be interpreted as illustrative and not limiting. Therefore, the extent and scope of the present invention should not be limited by any of the illustrative embodiments described above, but should be defined solely in accordance with the following appended claims and their equivalents. It should also be understood that when elements of the present invention are introduced in the claims or in the preceding description of illustrative embodiments of the invention, the terms "comprising," "including," and "having" are intended to be open-ended and mean that there may be additional elements beyond those listed. Furthermore, the term "portion" should be interpreted to mean part or the whole of the qualifying article or element. Additionally, the use of identifiers such as "first," "second," and "third" should not be construed to impose a relative position or temporal sequence between limitations. Moreover, the order in which the steps of any method claim that follows are presented should not be construed to limit the order in which those steps must be performed, unless such order is inherent or explicit.

Claims

1. A processing line for processing a plurality of logs of twisted, web-wound material, wherein the processing line has an upstream section and a downstream section and the processing line comprises: a main accumulator having an endless loop with a plurality of main accumulator buckets, wherein each bucket in the plurality of main accumulator buckets is adapted and configured to receive, hold, and release a log; an inlet feeder adapted and configured to receive a log from the upstream section of the processing line and convey the log to a bucket in the plurality of main accumulator buckets;a loader adapted and configured with a loader accumulator, wherein the loader has an endless loop with a plurality of loader buckets, each bucket of the plurality of loader buckets being adapted and configured to receive, hold, and release a log; and a transfer conveyor disposed between the main accumulator and the loader, wherein the transfer conveyor is adapted and configured to receive a log from a bucket of the main accumulator into the plurality of main accumulator buckets, wherein the transfer conveyor is adapted and configured to convey a log from a bucket in the plurality of main accumulator buckets to a bucket in the plurality of loader buckets independently of the inlet feeder; wherein the loader is adapted and configured to receive a log in a bucket in the plurality of loader buckets from the transfer conveyor;and where the loader is adapted and configured to transport a log in a bucket in the plurality of loader buckets to a loader discharge, the loader discharge is adapted and configured to discharge a log from a bucket of the plurality of loader buckets to the downstream section of the processing line.

2. The processing line of claim 1, wherein the downstream section of the processing line comprises a log saw.

3. The processing line of claim 2, wherein the loader discharge is aligned with a log saw conveyor rail.

4. The processing line of claim 1, wherein the downstream section of the processing line comprises a first and a second log saw.

5. The processing line of claim 1 further comprising an additional loader, the additional loader having an additional loader accumulator, the additional loader having an endless loop with a plurality of additional loader buckets, each bucket in the plurality of additional loader buckets being adapted and configured to receive, hold and release a log;and where the transfer conveyor is arranged between the main accumulator and the auxiliary loader, the transfer conveyor is adapted and configured to receive a log from a bucket in the main accumulator in the plurality of buckets of the main accumulator, the transfer conveyor is adapted and configured to transport a log from a bucket in the plurality of buckets of the main accumulator to a bucket in the plurality of buckets of the auxiliary loader independently of the inlet feeder and independently of transporting a log from a bucket in the plurality of buckets of the main accumulator to a bucket in the plurality of buckets of the loader; and where the auxiliary loader is adapted and configured to receive a log in a bucket in the plurality of buckets of the auxiliary loader from the transfer conveyor;where the additional loader is adapted and configured to carry a log in a bucket in the plurality of buckets of the additional loader to a discharge of the additional loader, the discharge of the additional loader being adapted and configured to discharge a log from a bucket of the plurality of buckets of the additional loader to the downstream section of the processing line; and where the discharge of the additional loader is adapted and configured to discharge a log from a bucket in the plurality of buckets of the additional loader to the downstream section of the processing line independently of the loader discharge that discharges a log from a bucket of the plurality of buckets of the loader to the downstream section of the processing line.

6. The processing line of claim 5, wherein the downstream section of the processing line comprises a first and a second log saw.

7. The processing line of claim 6, wherein the loader discharge is aligned with a conveyor rail of the first log saw, and the additional loader discharge is aligned with a conveyor rail of the second log saw.

8. The processing line of claim 1 further comprising: an additional loader, the additional loader having an additional loader accumulator, the additional loader having an endless loop with a plurality of additional loader buckets, each bucket in the plurality of buckets of the additional loader being adapted and configured to receive, hold, and release a log; and an additional transfer conveyor disposed between the main accumulator and the additional loader, wherein the additional transfer conveyor is adapted and configured to receive a log from a bucket of the main accumulator in the plurality of buckets of the main accumulator, wherein the additional transfer conveyor is adapted and configured to transport a log from a bucket in the plurality of buckets of the main accumulator to a bucket in the plurality of buckets of the additional loader independently of the inlet feeder;where the additional loader is adapted and configured to receive a log in a bucket in the plurality of buckets of the additional loader from the additional transfer conveyor; where the additional loader is adapted and configured to convey a log in a bucket in the plurality of buckets of the additional loader to a discharge of the additional loader, the discharge of the additional loader being adapted and configured to discharge a log from a bucket of the plurality of buckets of the additional loader to the downstream section of the processing line; and where the discharge of the additional loader is adapted and configured to discharge a log from a bucket in the plurality of buckets of the additional loader to the downstream section of the processing line independently of the discharge of the loader that discharges a log from a bucket of the plurality of buckets of the loader to the downstream section of the processing line.

9. The processing line of claim 8, wherein the downstream section of the processing line comprises a first and a second log saw.

10. The processing line of claim 9, wherein the loader discharge is aligned with a conveyor rail of the first log saw, and the additional loader discharge is aligned with a conveyor rail of the second log saw.

11. A processing line transfer system for transferring a plurality of twisted-wound web material logs in the processing line between a main accumulator and a first downstream section and between the main accumulator and a second downstream section, wherein the main accumulator has an endless loop with a plurality of main accumulator buckets, and each bucket of the plurality of main accumulator buckets is adapted and configured to receive, hold, and release a log, wherein the processing line transfer system comprises: a first loader having an endless loop with a plurality of first loader buckets, wherein each bucket in the plurality of first loader buckets is adapted and configured to receive, hold, and release a log;a second loader having an endless loop with a plurality of second loader buckets, wherein each bucket in the plurality of second loader buckets is adapted and configured to receive, hold, and release a log; and a transfer conveyor adapted and configured to couple to the main accumulator, wherein the transfer conveyor is adapted and configured to couple to at least one of the first and second loaders, wherein the transfer conveyor is adapted and configured to transport a log from a bucket in the plurality of buckets of the main accumulator to a bucket of at least one of the plurality of first loader buckets and the plurality of second loader buckets;wherein each bucket in at least one of the plurality of first buckets of the loader and second buckets of the loader can be placed in the corresponding endless loop of the first loader and the endless loop of the second loader to receive a log from the transfer conveyor; wherein the first loader is adapted and configured to convey a log in a bucket in the plurality of buckets of the first loader to a discharge of the first loader, the discharge of the first loader is adapted and configured to discharge a log from a bucket of the plurality of buckets of the first loader to the first downstream section;where the second loader is adapted and configured to carry a log in a bucket in the plurality of buckets of the second loader to a discharge of the second loader, the discharge of the second loader being adapted and configured to discharge a log from a bucket of the plurality of buckets of the second loader to the second downstream section; and where the discharge of the first loader is adapted and configured to discharge a log from a bucket of the plurality of buckets of the first loader to the first downstream section regardless of whether the discharge of the second loader discharges a log from a bucket of the plurality of buckets of the second loader to the second downstream section.

12. The processing line of claim 11, wherein the first and second downstream sections of the processing line comprise a first and a second log saw.

13. The processing line of claim 11, wherein the transfer conveyor is adapted and configured to transport a log from a bin in the plurality of bins of the main accumulator to a bin in the plurality of bins of the first loader and to transport a log from a bin in the plurality of bins of the main accumulator to a bin in the plurality of bins of the second loader.

14. The processing line of claim 12, wherein the transfer conveyor is adapted and configured to selectively transport a log from a bin in the plurality of bins of the main accumulator to a bin in the plurality of bins of the first loader and to selectively transport a log from a bin in the plurality of bins of the main accumulator to a bin in the plurality of bins of the second loader.

15. The processing line of claim 12, wherein the transfer conveyor is adapted and configured to move in a first direction to transport a log from a bucket in the plurality of buckets of the main accumulator to a bucket in the plurality of buckets of the first loader and in a second direction opposite to the first direction to transport a log from a bucket in the plurality of buckets of the main accumulator to a bucket in the plurality of buckets of the second loader.

16. The processing line of claim 11, wherein the transfer conveyor is adapted and configured to transport a log from a bin in the plurality of bins of the main accumulator to a bin in the plurality of bins of the first loader; and the transfer system of the processing line further comprises an additional transfer conveyor adapted and configured to couple between the main accumulator and the second loader, wherein the additional transfer conveyor is adapted and configured to transport a log from a bin in the plurality of bins of the main accumulator to a bin in the plurality of bins of the second loader independently of the transfer conveyor;where each bucket of the plurality of buckets of the main accumulator can be placed in the endless loop of the main accumulator to release a log to the additional transfer conveyor, and each bucket of the plurality of buckets of the second loader can be placed in the endless loop of the second loader to receive a log from the additional transfer conveyor.; 17. A method for transferring a plurality of twisted web-wound logs between an upstream section and a downstream section of a processing line, wherein the method comprises: feeding a log from the upstream section of the processing line to a main accumulator, wherein the main accumulator has an endless loop with a plurality of main accumulator buckets and each bucket in the plurality of main accumulator buckets is adapted and configured to receive, hold, and release a log, and the feeding step includes conveying the log to a bucket in the plurality of main accumulator buckets; conveying the log in a bucket in the plurality of main accumulator buckets;transferring the log from the main accumulator to a loader, where the loader has a loader accumulator, the loader has an endless loop with a plurality of loader buckets and each bucket in the plurality of loader buckets is adapted and configured to receive, hold and release a log, the transfer step includes transporting the log from a bucket in the plurality of the main accumulator buckets to a bucket in the plurality of loader buckets, where the transport step occurs independently of the step of feeding the log from the upstream section of the processing line to the main accumulator; and transporting the log in a bucket in the plurality of loader buckets to a loader discharge; and at the discharge, discharging the log from a bucket in the plurality of loader buckets to the downstream section of the processing line.

18. The method of claim 17, wherein the step of unloading the log from a bucket of the loader's bucket plurality to the downstream section of the processing line includes unloading the log onto a conveyor rail of a log saw.

19. A method for transferring a plurality of twisted web material logs between an upstream section of a processing line and a downstream section of the processing line, wherein the method comprises: feeding a log from the upstream section of the processing line to a main accumulator, wherein the main accumulator has an endless loop with a plurality of main accumulator buckets and each bucket in the plurality of main accumulator buckets is adapted and configured to receive, hold, and release a log, and the feeding step includes conveying the log to a bucket in the plurality of main accumulator buckets; conveying the log in a bucket in the plurality of main accumulator buckets;transferring the log from the main accumulator to one of the first and second loaders where each of the first and second loaders has an endless loop with a plurality of loader buckets and each bucket in the plurality of buckets of the corresponding first and second loaders is adapted and configured to receive, hold and release a log, the transfer step includes transporting the log from a bucket in the plurality of buckets of the main accumulator to a bucket of the plurality of buckets of the first and second loaders, where the transport step occurs independently of the step of feeding the log from the upstream section of the processing line to the main accumulator; and transporting the log in a bucket of one of the plurality of buckets of the corresponding first and second loaders to a discharge of the corresponding first and second loaders;and at the discharge of the first and second corresponding loaders, unload the log from a bucket of one of the plurality of buckets of the first and second loaders to the downstream section of the processing line.; 20. The method of claim 19, wherein the step of transporting the log from a bucket in the plurality of buckets of the main accumulator to a bucket of one of the plurality of buckets of the first and second loaders includes operating a first transfer conveyor to transport the log from a bucket in the plurality of buckets of the main accumulator to a bucket of the plurality of buckets of the first loader and operating a second transfer conveyor to transport the log from a bucket in the plurality of buckets of the main accumulator to a bucket of the plurality of buckets of the second loader.

21. The method of claim 19, wherein the step of transporting the log from a bucket in the plurality of buckets of the main accumulator to one of the plurality of buckets of the first and second loaders includes operating a first transfer conveyor to perform one of the steps of transporting the log from a bucket in the plurality of buckets of the main accumulator to a bucket of the plurality of buckets of the first loader and transporting the log from a bucket in the plurality of buckets of the main accumulator to a bucket of the plurality of buckets of the second loader.

22. The method of claim 21, wherein the step of transporting the log from a bucket in the plurality of buckets of the main accumulator to a bucket of one of the plurality of buckets of the first and second loaders includes operating the transfer conveyor to selectively transport the log from a bucket in the plurality of buckets of the main accumulator to a bucket of the plurality of buckets of the first loader and selectively transport the log from a bucket in the plurality of buckets of the main accumulator to a bucket of the plurality of buckets of the second loader.

23. The method of claim 19, wherein the step of transporting the log from a bucket in the plurality of buckets of the main accumulator to a bucket of one of the plurality of buckets of the first and second loaders includes operating the transfer conveyor in a first direction to transport the log from a bucket in the plurality of buckets of the main accumulator to a bucket of the plurality of buckets of the first loader and in a second direction opposite to the first direction to transport the log from a bucket in the plurality of buckets of the main accumulator to a bucket of the plurality of buckets of the second loader.

24. The method of claim 19 further comprising aligning the discharge of the first loader with a conveyor rail of a first log saw, and aligning the discharge of the second loader with a conveyor rail of a second log saw.

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