CROSS-REFEENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63/352,126, which was filed on June 14, 2022 and entitled “System For Reducing Rolled Stock Waste,” the entire contents of which is hereby incorporated by reference in its entirety.

FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to a system for reducing waste of rolled stock. More specifically, the present disclosure relates to a system to reduce waste of rolled stock on a core by actively detecting a quantity of rolled stock on the core during unwinding and transitioning to a new roll in response to the detected quantity.

BACKGROUND

[0003] Rolled stock is generally known in the art. Rolled stock includes a medium wound onto a core in a roll format for shipping, storage, and/or use. Tn some use applications, the medium is unwound from the core. In some other applications, the medium is unwound from the core at high speed. In these high speed unwind applications, the unwind system can include at least two rolls of wound medium. One roll is actively being unwound. When the actively unwound roll reaches a predetermined roll diameter that indicates the medium is about to run out, the unwind system can splice in the other roll to facilitate a continuous unwinding of the medium. However, there are certain limitations in known systems that lead to significant amounts of medium waste on the roll core.

[0004] As one example, known systems can include an ultraviolet (UV) sensor that is configured to detect a marking that is physically placed on the medium by the rolled stock manufacturer. The marking is applied while the rolled stock is being wound onto the core. The physically placed marking is provided as an indicator of a “low” roll diameter. However, placement of the marking occurs at variable locations along the wound medium. The marking is not uniformly positioned at a standard position with a specific quantity of linear feet of stock on the core. Instead, the marking is positioned randomly with differing amounts of wound medium remaining on the roll (or with different lengths of linear feet of medium remaining on the core). Thus, the positioning of the marking is variable between rolls of wound medium, as the wound medium manufacturer has to place the marking. Different rolls can have the marking positioned at different positions along the length of the medium wound on the roll.

[0005] Further, manufacturers of rolled stock are not incentivized to minimize the amount of medium wound on the core. Manufacturers are instead incentivized to position the marker with a “safe” amount (or quantity) of medium wound on the core to avoid the roll running out of medium before spicing to the next roll. Stated another way, a manufacturer does not want a roll to “fail” by positioning the marking on the medium with a small amount (or length) of medium to the core (i.e., the marking is positioned in relatively close proximity to the core). If all of the medium on the core is used before the splice to the next roll, the next roll has to be manually spliced. Manual splicing of a roll is both labor and time intensive, and results in unwanted system downtime. This “safe” amount of medium wound on the core is unusable waste.

[0006] Accordingly, a substantial amount of rolled medium generally remains on the core after the splice to a new roll. This medium remaining on the core is not usable after the splice, and is waste. This waste on the core (or waste rolled medium) can be up to 3% of the total medium wound onto the core. Accordingly, what is needed is a system to reliably detect a quantity of medium on an unwinding roll to reduce medium waste on the core before initiating a splice to a new roll. In addition, a system is needed that eliminates variability from outside sources or third parties, such as manufacturers of rolled medium, that leads to medium waste.

SUMMARY

[0007] In one example of an embodiment, a sensor assembly configured to detect rolled stock on a core includes a sensor configured to detect a first roll of stock unwinding from a core, the stock unwinding from the core of the first roll is supplied as a web of stock, wherein in response to the sensor detecting a first detection configuration, the sensor takes no action and continues to detect the first roll, and wherein in response to the sensor detecting a second detection configuration, the sensor provides a command to a splice assembly to transition to a second roll of stock to replace the first roll of stock.

[0008] In another example of an embodiment of the sensor assembly, the sensor is configured to communicate with a manual splice actuation system.

[0009] In another example of an embodiment of the sensor assembly, the manual splice actuation system is configured to initiate a splice in response to the command from the sensor to transition from the first roll to the second roll to provide a continuous web of stock.

[0010] In another example of an embodiment of the sensor assembly, the sensor is configured to communicate with the manual splice actuation system to bypass an automatic splice actuation system.

[0011] In another example of an embodiment of the sensor assembly, the first detection configuration includes detecting the stock on the core.

[0012] In another example of an embodiment of the sensor assembly, the second detection configuration includes detecting the core.

[0013] In another example of an embodiment of the sensor assembly, the core defines an axis of rotation, the sensor is oriented relative to the first roll perpendicular to the axis of rotation.

[0014] In another example of an embodiment of the sensor assembly, the first detection configuration includes detecting a first quantity of stock on the core, the first quantity of stock is above a preprogrammed low level threshold.

[0015] In another example of an embodiment of the sensor assembly, the second detection configuration includes detecting a second quantity of stock on the core, the second quantity of stock does not exceed the preprogrammed low level threshold.

[0016] In another example of an embodiment of the sensor assembly, the core defines an axis of rotation, the sensor is oriented relative to the first roll parallel to the axis of rotation. [0017] In another example of an embodiment of the sensor assembly, the sensor is configured to detect a portion of the first roll of stock including the core.

[0018] In another example of an embodiment of the sensor assembly, the sensor utilizes machine vision to detect the first and second quantity of stock on the core.

[0019] In another example of an embodiment of the sensor assembly, the machine vision captures volumetric data of the stock on the core.

[0020] In another example of an embodiment of the sensor assembly, the machine vision captures geometric data of the stock on the core.

[0021] In another example of an embodiment of the sensor assembly, the preprogrammed low level threshold corresponds to no more than five impressions of rolled stock remain on the core.

[0022] In another example of an embodiment of the sensor assembly, the preprogrammed low level threshold corresponds to no more than three impressions of rolled stock remain on the core.

[0023] In another example of an embodiment of the sensor assembly, the sensor includes a light source configured to illuminate a portion of the first roll.

[0024] In another example of an embodiment of the sensor assembly, in response to the transition to the second roll of stock, no more than five impressions of rolled stock remain on the core.

[0025] In another example of an embodiment of the sensor assembly, in response to the transition to the second roll of stock, no more than three impressions of rolled stock remain on the core.

[0026] In another example of an embodiment of the sensor assembly, in response to the transition to the second roll of stock, between 1.5 and 2 impressions of rolled stock remain on the core. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. l is a schematic diagram of an example of a labeling assembly utilizing rolled stock from a plurality of rolls that integrates an embodiment of a detection assembly.

[0028] FIG. 2 is a perspective view of a sensor of the detection assembly of FIG. 1 in a first detection configuration detecting a first surface, shown as the rolled stock, and more specifically a label.

[0029] FIG. 3 is a perspective view of the sensor of the detection assembly of FIG. 1 in a second detection configuration detecting a second surface, shown as a core.

[0030] FIG. 4 is a flow diagram of an embodiment of a detection and control system for use with the core detection assembly of FIG. 1.

[0031] FIG. 5 is a schematic diagram of an example of a portion of a packaging assembly utilizing rolled stock from a plurality of rolls that integrates another example of an embodiment of a detection assembly.

[0032] FIG. 6 is an example of an output detected by each sensor represented on a control monitor in a first detection configuration.

[0033] FIG. 7 is an example of an output detected by each sensor represented on a control monitor in a second detection configuration.

[0034] FIG. 8 is a flow diagram of an embodiment of a detection and control system for use with the core detection assembly of FIG. 5.

[0035] Before embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways. DETAILED DESCRIPTION

[0036] The present disclosure is directed to a detection assembly 100, 300 and associated detection and control system 200, 400. The assembly and system are configured to be retrofit to an assembly utilizing rolled stock, such as a labeling assembly 10 for a container 30, or a packaging system 50 for a plurality of containers 30 (such as a stretch wrapping system, a shrink wrapping system, etc.). The assembly 100, 300 and system 200, 400 are configured to reduce waste of the rolled stock remaining on a core by initiating a splice in response to detection of a predetermined quantity of rolled stock remaining on the core. This maximizes use of the rolled stock by reducing the regularity of “early” splices between rolls of rolled stock during a continuous roll unwinding process.

[0037] It should be appreciated that a “roll of wound medium” or “rolled stock” or “reel-fed stock” can be a roll form of any suitable medium (or stock) wound onto a core. The roll can be any suitable or desired roll width, roll diameter, and/or core diameter. In addition, wound medium (or stock) can be any suitable medium. In one example of an embodiment disclosed herein, the wound medium includes labels for attachments to a container, such as a polyethylene terephthalate (PET) bottle. In another example of an embodiment disclosed herein, the wound medium includes a packaging material for wrapping a plurality of containers, such as a shrink wrap plastic material, a stretch wrap plastic material, or any other suitable packaging film. In yet other examples of embodiments, the wound medium can include any other material that is wound onto the core in roll form and that is unwound for use, and the unwinding of the wound medium is generally occurring in a continuous unwinding process where consecutive rolls of wound medium are spliced together.

[0038] With reference now to the figures, FIG. 1 is a schematic diagram of an example of an embodiment of an assembly 10 utilizing rolled stock. The assembly 10 incorporates a detection system 100 configured to reduce rolled stock waste. The illustrated assembly is a labeling assembly 10. The labeling assembly 10 is configured to apply a label to a container. The container can be a bottle, such as a blow molded polyethylene terephthalate (PET) plastic bottle. However, in other embodiments, the container can be any suitable vessel, including, but not limited to, a plastic bottle, a metal can, a glass bottle, or any other vessel configured to contain a material. A nonlimiting example of the labeling assembly 10 can include a CONTIROLL system for reel-fed wrap-around labelling, manufactured by Krones AG, which has a corporate headquarters in Neutraubling, Germany. It should be appreciated that the labeling assembly 10 can be a module or step in a process, such as a bottling line. It should also be appreciated that the labeling assembly 10 can be any suitable assembly for applying labels to a container, and is not limited to a specific manufacturer, process application, or technology.

[0039] The labeling assembly 10 can includes an unwind stand assembly 14, a splice assembly 16, and a label application assembly 18. The unwind stand assembly 14 is configured to selectively unwind a plurality of rolls of rolled stock 20, 24. More specifically, the unwind stand assembly 14 unwinds at least a first roll of rolled stock 20 and a second roll of rolled stock 24. The rolls of rolled stock 20, 24 are separately unwound. Stated another way, each roll of rolled stock 20, 24 can include its own unwind system to separately and independently unwind each roll of rolled stock 20, 24. The separate unwind systems further can concurrently unwind each roll of rolled stock 20, 24, for example during the splicing process, which is discussed further below.

[0040] Each roll of rolled stock 20, 24 supplies a respective web 26, 27 of stock to the splice assembly 16. More specifically, the first roll of rolled stock 20 supplies a first web of stock 26 to the splice assembly 16, while the second roll of rolled stock 24 supplies a second web of stock 27 to the splice assembly 16. Stated another way, the splice assembly 16 receives a plurality of webs of stock 26, 27, each from one of the plurality of rolls of rolled stock 20, 24. It should be appreciated that each web of stock 26, 27 is wound around a core 28 (shown in FIGS. 2-3) to form the respective roll of rolled stock 20, 24. The splice assembly 16 then selects one of the plurality of webs of stock 26, 27 as an active web of stock 29. The active web of stock 29 is then supplied to the application assembly 18. It should be appreciated that the rolled stock unwound from each roll 20, 24, and which becomes the web of stock 26, 27, can be referred to as rolled stock 26, 27.

[0041] The application assembly 18 receives the active web of stock 29. Concurrently, the application assembly 18 receives a plurality of containers 30. More specifically, the plurality of containers 30 supplied to the application assembly 18 are unlabeled containers 30a. The application assembly 18 receives the unlabeled containers 30a, modifies the active web of stock 29, which are a plurality of labels in web form, and then applies one label to each container 30a. More specifically, the application assembly 18 applies an adhesive to each label, applies one label to each container 30a, and cuts each label from the plurality of labels in web form 29. It should be appreciated that the application assembly 18 can perform the label application in any order and with additional, fewer, or different steps. The labeled containers 30b exit the application assembly 18 for further processing and/or packaging.

[0042] As previously noted, the splice assembly 16 is configured to transition between the plurality of webs of stock 26, 27 as the active web of stock 29. The transition occurs in order to maintain a continuous web of the active web of stock 29. Stated another way, the splice assembly 16 is configured to change (or select) from the plurality of webs of stock 26, 27 as the active web of stock 29. Accordingly, the splice assembly 16 is configured to change (or select) from the plurality of rolls of rolled stock 20, 24, which respectively supply the webs of stock 26, 27, as the supply for the active web of stock 29. To facilitate this transition, or splice, between rolls of rolled stock 20, 24, the splice assembly 16 can include a splice system. The splice system can be any suitable known or future developed system configured to transition from one web of material to a another, separate web of material to continuously supply the active web of stock 29.

[0043] To initiate the splice, the splice assembly 16 includes a manual splice actuation system 34. The manual splice actuation system 34 can include a user actuatable member (not shown), such as a switch, button, or other control that can be actuated by the user (or an operator) to initiate operation of the splice assembly 16. For example, actuating the control on the manual splice actuation system 34 can manually initiate operation of the splice assembly 16, triggering a splice from one of the webs 26, 27 to the other of the webs 27, 26. This in turn transitions one of the webs 26, 27 as the active web of stock 29 to the other of the webs 27, 26 as the active web of stock 29. Stated another way, the triggering the splice transitions one of rolls of rolled stock 20, 24 as the supply for the active web of stock 29 to the other of the rolls of rolled stock 24, 20 as the supply for the active web of stock 29. To facilitate communication, the manual splice actuation system 34 is in operable communication with the splice assembly 16 by a data connection 36 (also referred to as a first data connection 36 or a first communication connection 36). [0044] It should be appreciated that the example of the embodiment of the labeling assembly 14 discussed herein illustrates two rolls of rolled stock 20, 24, and more specifically two rolls 20, 24 of labels. The two rolls are provided for purposes of illustration, and are not intended to be limiting. The labeling assembly 14 includes at least two rolls of rolled stock 20, 24. In other examples of embodiments the plurality of rolls of rolled stock 20, 24 include more than two rolls. Systems can include three, four, five, or six or more rolls of rolled stock 20, 24 to supply the application assembly 18. Utilizing additional rolls of rolled stock reduces the frequency of changing unwound rolls with new, fully wound rolls of rolled stock. As such, the first roll of rolled stock 20 can be any of the plurality of rolls of rolled stock, and the second roll of rolled stock 24 can be any other of the plurality of rolls of rolled stock. The splice assembly 16 simply changes between the rolls of rolled stock 20, 24 in order to provide a continuous web of as the active web of stock 29. It should be appreciated that while the assembly 10 illustrates two rolls of rolled stock 20, 24, the assembly 10 should be considered to include at least two rolls of rolled stock 20, 24. Tn other examples of embodiments, the assembly 10 can include any suitable number of rolls of rolled stock 20, 24 to facilitate operation. It should also be appreciated that the roll of rolled stock 20, 24 that is supplying the active web of stock 29 can be referred to as an active roll of rolled stock 20, 24.

[0045] With continued reference to FIG. 1, a detection assembly 100 (also referred to as a core detection assembly 100 or a stock on core detection assembly 100 or a sensor assembly 100) is operably connected to the assembly 10. The detection assembly 100 is configured to be retrofit to any suitable labeling assembly 10. In one or more examples of embodiments, a manufacturer can restrict access to certain control logic associated with the labeling assembly 10. As such, once the labeling assembly 10 is installed and operational, the party that purchased (and/or operates) the labeling assembly 10 is unable to access or otherwise change or modify the control logic. In these examples, the assembly 10 can include both an automatic splice actuation system and a manual splice actuation system that allows an operator to manually bypass the automatic splice actuation system. The detection assembly 100 advantageously can operate without requiring modification of the existing control logic on a labeling assembly 10, as the detection assembly is configured to communicate with the manual splice actuation system, which does not require access or modification of the inaccessible control logic of the automatic splice actuation system. Accordingly, the core detection assembly 100 can be installed on any known labeling assembly 10 as an aftermarket retrofit addition. In other examples of embodiments, the detection assembly 100 can advantageously operate with or without requiring modification of the existing control logic on the assembly 10. Accordingly, the detection assembly 100 can be installed on any known assembly 10 (or 50, discussed further below), as an aftermarket retrofit addition. It should be appreciated that in other examples of embodiments, the manufacturer can allow for communication of aftermarket components to communicate with certain components of the assembly 10, including but not limited to the splice actuation system 34.

[0046] The core detection assembly 100 includes a plurality of sensors 104. In the illustrated embodiment, there is one sensor 104 associated with each roll of rolled stock 20, 24. In the illustrated embodiment, the sensors 104 include a first sensor 104a and a second sensor 104b. The first sensor 104a is associated with the first roll of rolled stock 20, while the second sensor 104b is associated with the second roll of rolled stock 24. Each sensor 104a, b is configured to monitor the associated roll of rolled stock 20, 24, and detect a low level of stock remaining on the core. In the illustrated example of an embodiment, each sensor 104a, b is configured to detect the core when the core is exposed. Exposure of the core indicates that the stock on the associated roll has been fully used, and a splice to another roll is necessary.

[0047] Each sensor 104a, b can be mounted to the labeling assembly 10 in any suitable manner to orient the sensor 104a, b relative to the associated roll of rolled stock 20, 24 to facilitate detection of the core. For example, each sensor 104a, b can be mounted to the labeling assembly 10 using metal tubing, brackets, fasteners, or any other suitable mounting structure. In other examples of embodiments, each sensor 104a, b can be free standing. Each sensor 104a, b simply needs to be positioned to maintain the necessary orientation relative to the associated roll of rolled stock 20, 24 to detect the rolled stock 26, 27 and/or the core 28 during unwinding of each roll of rolled stock 20, 24 to support operation of the labeling assembly 10. In the illustrated embodiment, each sensor 104a, b is oriented perpendicular to an axis of rotation 38 of the associated rolled stock 20, 24 (shown in FIGS. 2-3). Stated another way, each sensor 104a, b includes an emitter 105a, b and a receiver 106a, b (shown in FIG. 1). The emitter 105a, b is oriented to emit a detection signal 112a, 112b that is aligned with a radius of the rolled stock 20, 24. Stated another way, the emitter 105a, b is oriented to emit a detection signal 112a, 112b that is perpendicular to the axis of rotation of the associated rolled stock 20, 24. The receiver 106a, b is oriented to receive the emitted signal 112a, b. In the illustrated embodiment each sensor 104a, b is a Q4X Series Laser Sensor sold by Banner Engineering Corp, headquartered in Minneapolis, Minnesota, USA. However, in other embodiments, any suitable sensor that can be configured to detect a rolled stock, a core of the rolled stock, and differentiate between the rolled stock and the core can be utilized in the core detection assembly 100. Thus, suitable sensors 104a, b can include, but are not limited to, laser, infrared, optical, or other photoelectric sensor. In addition, while the illustrated sensor 104 can be a diffuse-reflective type sensor, in other embodiments, the sensor 104 can be a through-beam sensor, retro-reflective sensor, or any other sensor configured to detect a change in surface conditions of an object. It should be appreciated that the axis of rotation 38 of the roll of rolled stock 20, 24 can be defined by the core 28 (or the axis of rotation of the core 28).

[0048] Each sensor 104a, b is in operable communication with the manual splice actuation system 34 by an associated data connection 108. More specifically, the first sensor 104a is in operable communication with the manual splice actuation system 34 by a data connection 108a (also referred to as a second data connection 108a or a second communication connection 108a). The second sensor 104b is in operable communication with the manual splice actuation system 34 by a data connection 108b (also referred to as a third data connection 108b or a third communication connection 108b). Each of the data connections 108 can be wired, wireless, or any suitable system for communication (e.g., radio, cellular, BLUETOOTH, 802.11 Wireless Networking protocol, etc.).

[0049] Each sensor 104a, b emits a signal 112a, b, and the receiver 106a, b (also referred to as a detector 106a, b) detects the emitted signal 112a, b. In the illustrated embodiment, the first sensor 104a emits a first signal 112a. The first signal 112a is emitted to the first roll of rolled stock 20. The receiver 106a of the first sensor 104a then detects the emitted first signal 112a. Similarly, the second sensor 104b emits a second signal 112b. The second signal 112b is emitted to the second roll of rolled stock 24. The receiver 106b of the second sensor 104b detects the emitted second signal 112b. [0050] Each sensor 104a, 104b is programmed to detect a first surface and a second surface, the second surface being different from the first surface. Stated another way, each sensor 104a, 104b is programmed to detect a first detection configuration and a second detection configuration. With reference to FIG. 2, each sensor 104a, b is configured to detect the first detection configuration and detect the first surface, which is the rolled stock 26, 27 (or stock rolled on the core 28). In the illustrated embodiment, the rolled stock 26, 27 is the roll of labels. With reference to FIG. 3, each sensor 104a, b is also configured to detect the second detection configuration and detect the second surface, which is the core 28 of the roll of rolled stock 20, 24. In programming each sensor 104a, 104b, the sensor is configured to detect the first surface 26, 27 and the second surface 28. To detect the change in surface conditions, each sensor 104a, 104b can be programmed to detect changes in reflectivity, opacity, whiteness / brightness, color, refractivity, or any other property suitable for differentiating the first surface from the second surface. A detected change between the first surface 26, 27 and the second surface 28 results in detection of a responsive change in surface conditions of the roll of rolled stock 20, 24. Stated another way, the programmed detected change in surface conditions between the first surface 26, 27 and second surface 28 results in an indication that all of the rolled stock 26, 27 is empty. The first surface 26, 27 (i.e., the rolled stock or rolled labels) are completely unwound (or used) exposing the second surface 28 (i.e., the core 28 of the roll).

[0051] FIG. 4 illustrates an example of an embodiment of a detection and control system 200 that utilizes information detected by the sensors 104a, 104b to initiate a splice between rolls of rolled stock 20, 24. The system 200 operates in association with the detection assembly 100 to advantageously reduces waste by initiating the splice in response to the core of the active roll of stock 20 or 24 being exposed and subsequently detected by the associated sensor 104a or 104b. This maximizes use of the rolled stock 26 or 27 that is stored on the respective roll 20 or 24. The system 200 is in communication with the manual splice actuation system 34 to initiate actuation of the manual splice actuation system 34. This advantageously facilitates a retrofit addition of the detection assembly 100 and associated system 200 to any suitable labeling assembly 10.

[0052] The detection and control system 200 can be integrated into the detection assembly 100. For example, the system 200 can be a separate controller (not shown) configured to receive information detected by the sensors 104a, 104b, and further selectively communicate commands to actuate the manual splice actuation system 34 of any suitable labeling assembly 10. In other examples of embodiments, the system 200 can be operably connected to the manual splice actuation system 34 to initiate selective operation of the manual splice actuation system 34 in response to the information detected and communicated by the sensors 104 of the core detection assembly 100. The core detection and control system 200 includes a series of processing instructions or steps that are depicted in flow diagram form.

[0053] Referring to FIG. 4, the process of the core detection and control system 200 begins at step 204. At step 204, the labeling assembly 10 is operating to apply labels to containers 30. One of the plurality of rolls of rolled stock 20, 24 is the active roll of rolled stock 20 or 24. The sensor 104a or 104b that is associated with the active roll 20 or 24 is the active sensor 104a or 104b. The active roll of rolled stock 20 or 24 is being unwound, with the associated unwound web of stock 26 or 27 being the active web of stock 29. It should be appreciated that the roll of rolled stock 20, 24 can be any two rolls of a plurality of rolls of stock. Stated another way, there can be two or more rolls of rolled stock in the plurality of rolls of stock.

[0054] At step 208, the system 200 detects whether the manual splice actuation system 34 has been actuated. More specifically, the system 200 detects whether an operator or other user has manually actuated the manual splice actuation system 34, such as by actuating the user actuatable member. If the process does not detect that the manual splice actuation system 34 has been actuated, or “no,” the process proceeds to step 212. If the process does detect that the manual splice actuation system 34 has been actuated, or “yes,” the process proceeds to step 216.

[0055] At step 212, the system 200 receives detection data from the active sensor 104a or 104b. The process then determines whether the active sensor 104a or 104b detects the second surface (i.e., the core of the active roll). If the active sensor 104a or 104b detects the first surface of the active roll 20 or 24, or “no,” the active sensor 104a or 104b is detecting the unwinding stock 26 or 27. The process then returns to step 208 and repeats. If the active sensor 104a or 104b detects the second surface of the active roll 20 or 24, or “yes,” the active sensor 104a or 104b is detecting the core of the active roll 20 or 24. This indicates that the active roll 20 or 24 is completely unwound by exposing the core. The process proceeds to step 214, where a command is initiated (and sent) to actuate the manual splice actuation system 34. The manual splice actuation system 34 receives this command, and proceeds to step 216.

[0056] At step 216, the manual splice actuation system 34 initiates a splice from the active roll to a secondary roll. It should be appreciated that in response to detecting actuation of the manual splice at step 208, an operator has manually initiated actuation of the manual splice. For example, the operator has actuated the user actuatable member to initiate a splice through the manual splice actuation system 34. It should be appreciated that in response to the active sensor 104a or 104b detecting the second surface of the active roll (or detecting the core) at step 212, the process initiates the command to operate the manual splice actuation system 34 at step 214.

[0057] The manual splice actuation system 34 transitions the active roll. For example, in one embodiment, where the first roll 20 is the active roll, the actuation of the manual splice actuation system 34 transitions from the first roll 20 to the second roll 24 as the active roll. After completion of the splice, the second roll 24 becomes the active roll, with the unwound web of stock 27 being the active web of stock 29. In another example of an embodiment, where the second roll 24 is the active roll, actuation of the manual splice actuation system 34 transitions from the second roll 24 to the first roll 20 as the active roll. After completion of the splice, the first roll 20 becomes the active roll, with the unwound web of stock 26 being the active web of stock 29. Again, it should be appreciated that in examples of embodiments of the unwind stand assembly 14 having three or more rolls, the first roll 20 and the second roll 24 can be any two rolls of the three or more rolls. After the successful splice and transition of the active roll, the completed roll (or roll that was spliced out) can be removed and replaced with a new roll. The new roll can later be spliced in for use when one (or more) other rolls used.

[0058] After the successful splice, the process proceeds to step 220 where the active sensor is transitioned. More specifically, the active sensor is transitioned from the completed roll (or the roll spliced out) to the new active roll (or the roll spliced in). In the embodiments where the splice transitions from the first roll 20 to the second roll 24, the active sensor transitions from the first sensor 104a to the second sensor 104b. Similarly, in the embodiment where the splice transitions from the second roll 24 to the first roll 20, the active sensor transitions from the second sensor 104b to the first sensor 104a. Following reassignment of the active sensor 104a or 104b for monitoring the change in active roll 20 or 24, the process then returns to step 208, where the detection of either a manual splice (at step 208) or the second surface (at step 212) repeats for the new active roll.

[0059] With reference now to FIG. 5, a schematic diagram of an example of an embodiment of a portion of an assembly 50 utilizing rolled stock is provided. The illustrated assembly 50 is a packaging assembly 50. The packaging assembly 50 is configured to apply packaging material that is supplied as rolled stock. The packaging assembly 50 incorporates another example of an embodiment of a detection system 300 configured to reduce rolled stock waste. It should be appreciated that the illustrated portion of the packaging assembly 50 can be a module or step in a process, such as a packaging line. It should also be appreciated that the packaging assembly 50 can be any suitable assembly for applying packaging material to a package, and is not limited to a specific manufacturer, process application, or technology. In the illustrated embodiment, the packaging material is a film configured for shrink wrapping. In other examples of embodiments, the packaging material can be any suitable packaging material provided in roll form that is unwound for use by the packaging assembly and that incorporates the detection system 300.

[0060] The packaging assembly 50 can includes an unwind stand assembly 54, a splice assembly 56, and a packaging application assembly 58. The unwind stand assembly 54 is configured to selectively unwind a plurality of rolls of rolled stock 20a, 24a. More specifically, the unwind stand assembly 54 unwinds at least a first roll of rolled stock 20a and a second roll of rolled stock 24a. The rolls of rolled stock 20a, 24a are separately unwound. Stated another way, each roll of rolled stock 20a, 24a can include its own unwind system to separately and independently unwind each roll of rolled stock 20a, 24a. The separate unwind systems further can concurrently unwind each roll of rolled stock 20a, 24a, such as during the splicing process, which is discussed further below.

[0061] Each roll of rolled stock 20a, 24a supplies a respective web 26a, 27a of stock to the splice assembly 56. More specifically, the first roll of rolled stock 20a supplies a first web of stock 26a to the splice assembly 56, while the second roll of rolled stock 24a supplies a second web of stock 27a to the splice assembly 56. Stated another way, the splice assembly 56 receives a plurality of webs of stock 26a, 27a, each from one of the plurality of rolls of rolled stock 20a, 24a. It should be appreciated that each web of stock 26a, 27a is wound around a core 28a (shown in FIGS. 6-7) to form the respective roll of rolled stock 20a, 24a. The splice assembly 56 then selects one of the plurality of webs of stock 26a, 27a as an active web of stock 29a. The active web of stock 29a is then supplied to the packaging application assembly 58. It should be appreciated that the rolled stock unwound from each roll 20a, 24a, and which becomes the web of stock 26a, 27a, can be referred to as rolled stock 26a, 27a.

[0062] The application assembly 58 receives the active web of stock 29a. Concurrently, the application assembly 58 receives a package 60a requiring application of the rolled stock (e.g., packaging shrink wrap, packaging wrap, etc.). More specifically, a plurality of containers supplied to the application assembly 58 can be arranged in a package orientation, such as a case or a plurality of containers that is not wrapped. The application assembly 58 receives the package 60a, modifies the active web of stock 29a, which is packaging, and then applies the packaging to the package 60a. More specifically, the application assembly 58 applies the packaging wrap 29a around the package 60a, and cuts the packaging wrap 29a from the wrap 29a in web form 29a. It should be appreciated that the application assembly 58 can perform the packaging application in any order and with additional, fewer, or different steps. The wrapped package 60b then exit the application assembly 58 for further processing and/or packaging. For example, the wrapped package 60b can be finally packaged and transferred for shipping, or the wrapped package 60b can proceed to an additional step, such as a heat tunnel of a shrink wrap process (or any other suitable additional step to complete packaging.

[0063] The splice assembly 66 is configured to transition between the plurality of webs of stock 26a, 27a as the active web of stock 29a. The transition occurs in order to maintain a continuous web of the active web of stock 29a. Stated another way, the splice assembly 56 is configured to change (or select) from the plurality of webs of stock 26a, 27a as the active web of stock 29a. Accordingly, the splice assembly 56 is configured to change (or select) from the plurality of rolls of rolled stock 20a, 24a, which respectively supply the webs of stock 26a, 27a, as the supply for the active web of stock 29a. To facilitate this transition (or splice) between rolls of rolled stock 20a, 24a, the splice assembly 56 can include a splice system. The splice system can be any suitable known or future developed system configured to transition from one web of material to a another, separate web of material to continuously supply the active web of stock 29a.

[0064] To initiate the splice, the splice assembly 56 includes a splice actuation system 64. The splice actuation system 64 can be an automatic system that is integrated into the packaging assembly 50, or it can be a manual system that includes a user actuatable member (not shown), such as a switch, button, or other control that can be actuated by the user (or an operator) to initiate operation of the splice assembly 56. The splice actuation system 64 can initiate operation of the splice assembly 56 in response to operator interaction (manual splice) or in response to a command from a control system (automatic splice), triggering a splice from one of the webs 26a, 27a to the other of the webs 27a, 26a. This in turn transitions one of the webs 26a, 27a as the active web of stock 29a to the other of the webs 27a, 26a as the active web of stock 29a. Stated another way, the triggering the splice transitions one of rolls of rolled stock 20a, 24a as the supply for the active web of stock 29a to the other of the rolls of rolled stock 24a, 20a as the supply for the active web of stock 29a. To facilitate communication, the splice actuation system 64 is in operable communication with the splice assembly 56 by a data connection 66 (also referred to as a first data connection 66 or a first communication connection 66).

[0065] It should be appreciated that the example of the embodiment of the packaging assembly 50 discussed herein illustrates two rolls of rolled stock 20a, 24a, and more specifically two rolls 20a, 24a of packaging material. The two rolls are provided for purposes of illustration, and are not intended to be limiting. The packaging assembly 54 includes at least two rolls of rolled stock 20a, 24a. In other examples of embodiments the plurality of rolls of rolled stock 20a, 24a include more than two rolls. Systems can include three, four, five, or six or more rolls of rolled stock 20a, 24a to supply the application assembly 58. Utilizing additional rolls of rolled stock reduces the frequency of changing unwound rolls with new, fully wound rolls of rolled stock. As such, the first roll of rolled stock 20a can be any of the plurality of rolls of rolled stock, and the second roll of rolled stock 24a can be any other of the plurality of rolls of rolled stock. The splice assembly 56 simply changes between the rolls of rolled stock 20a, 24a to provide a continuous web of as the active web of stock 29a. It should be appreciated that while the assembly 50 illustrates two rolls of rolled stock 20a, 24a, the assembly 50 should be considered to include at least two rolls of rolled stock 20a, 24a. In other examples of embodiments, the assembly 50 can include any suitable number of rolls of rolled stock 20a, 24a to facilitate operation. It should also be appreciated that the roll of rolled stock 20a, 24a that is supplying the active web of stock 29a can be referred to as an active roll of rolled stock 20a, 24a.

[0066] With continued reference to FIG. 5, a detection assembly 300 (also referred to as a core detection assembly 300 or a stock on core detection assembly 300 or a sensor assembly 300) is operably connected to the assembly 50. The detection assembly 300 is configured to be retrofit to any suitable packaging assembly 50. In one or more examples of embodiments, a manufacturer can allow for communication of aftermarket components to communicate with certain components of the assembly 50. In the illustrated embodiment, the detection assembly 300 is configured to communicate with the splice actuation system 64. In other examples of embodiments, the manufacturer of the assembly 50 can restrict access to certain control logic associated with the assembly 50. As such, once the assembly 50 is installed and operational, the party that purchased (and/or operates) the assembly 50 is unable to access or otherwise change or modify the control logic. The detection assembly 300 can advantageously operate with or without requiring modification of the existing control logic on the assembly 50. Accordingly, the detection assembly 300 can be installed on any known assembly 10, 50 as an aftermarket retrofit addition.

[0067] It should also be appreciated that the assembly 10, 50 discussed above, though different operationally, have common components for utilizing rolled stock. As such, it should be appreciated that each detection assembly 100, 300 can be utilized on either assembly 10, 50. As such, the embodiments of the detection assembly 100, 300 are not limited for use in association with a certain or specific assembly (e.g., the label assembly 10, the packaging assembly 50, etc ). Instead, the detection assemblies 100, 300 can be implemented in association with any suitable assembly 10, 50 that utilizes a plurality of rolled stock in a continuous web process, and that includes at least two rolls of stock 20, 24, 20a, 24a, and a splice assembly 36, 56 to form a continuous active web of stock 29, 29a.

[0068] With continued reference to FIG. 5, The detection assembly 300 includes a plurality of sensors 304. In the illustrated embodiment, a sensor 304 is associated with each roll of rolled stock 20a, 24a. In the illustrated embodiment, the sensors 304 include a first sensor 304a and a second sensor 304b. The first sensor 304a is associated with the first roll of rolled stock 20a, while the second sensor 304b is associated with the second roll of rolled stock 24a. Each sensor 304a, b is configured to monitor the associated roll of rolled stock 20a, 24a, and detect a low level of stock remaining on the core. In the illustrated example of an embodiment, each sensor 304a, b is configured to detect a low level of rolled stock on the core that indicates that the stock on the associated roll has been fully used, and a splice to another roll is necessary.

[0069] Each sensor 304a, b can be mounted to the assembly 50 in any suitable manner to orient the sensor 304a, b relative to the associated roll of rolled stock 20a, 24a to facilitate detection of the core. For example, each sensor 304a, b can be mounted to the packaging assembly 50 using metal tubing, brackets, fasteners, or any other suitable mounting structure. In other examples of embodiments, each sensor 304a, b can be free standing. Each sensor 304a, b simply needs to be positioned to maintain the necessary orientation relative to the associated roll of rolled stock 20a, 24a to detect the rolled stock 26a, 27a and/or the core 28 during unwinding of each roll of rolled stock 20a, 24a to support operation of the assembly 50. In the illustrated embodiment, each sensor 304a, b is oriented parallel to an axis of rotation 38a of the associated rolled stock 20a, 24a (shown in FIGS. 6-7). Stated another way, each sensor 304a, b includes an emitter 305a, b and a receiver 306a, b (shown in FIG. 5). The emitter 305a, b is oriented to emit a detection signal 312a, 312b that is aligned (or parallel) with an axis of rotation of the core (or parallel to the core) of the rolled stock 20a, 24a. Stated another way, the emitter 305a, b is oriented to emit a detection signal 312a, 312b that is parallel to the axis of rotation of the associated rolled stock 20a, 24a. The receiver 306a, b is oriented to receive the emitted signal 312a, b. Each sensor 304a, b also includes a light source 307a, 307b (also referred to as an illumination source 307a, 307b). The light source 307a, 307b is configured to emit light to illuminate a portion of the roll of rolled stock 20a, 24a including the core and the rolled stock remaining on the core. In other examples of embodiments, the light source 307a, 307b can be external to the sensor 304a, b.

[0070] In the illustrated embodiment each sensor 304a, b is a IV3 Series Vision Sensor with Built-in Al sold by Keyence Corporation of America headquartered in Itasca, Illinois, USA. However, in other embodiments, any suitable sensor that can be configured to detect a rolled stock, a core of the rolled stock, and differentiate between the rolled stock and the core can be utilized in the core detection assembly 300. Thus, suitable sensors 304a, b can include, but are not limited to, laser, infrared, optical, or other photoelectric sensor. In addition, while the illustrated sensor 304 can be a machine-vision type sensor, in other embodiments, the sensor 304 can be a through-beam sensor, retro-reflective sensor, diffuse-reflective, or any other sensor configured to detect an object, a feature of an object, a geometry of an object, a volume of an object, a change in geometry of an object, or a change in volume of an object, or portions of the object.

[0071] Each sensor 304a, b is in operable communication with the splice actuation system 64 by an associated data connection 308. More specifically, the first sensor 304a is in operable communication with the splice actuation system 64 by a data connection 308a (also referred to as a second data connection 308a or a second communication connection 308a). The second sensor 304b is in operable communication with the splice actuation system 34 by a data connection 308b (also referred to as a third data connection 308b or a third communication connection 308b). Each of the data connections 308 can be wired, wireless, or any suitable system for communication (e.g., radio, cellular, BLUETOOTH, 802.11 Wireless Networking protocol, etc.).

[0072] Each sensor 304a, b emits a signal 312a, b, and the receiver 306a, b (also referred to as a detector 306a, b) detects the emitted signal 312a, b. In the illustrated embodiment, the first sensor 304a emits a first signal 312a. The first signal 312a is emitted to the first roll of rolled stock 20a. The receiver 306a of the first sensor 304a then detects the emitted first signal 312a. Similarly, the second sensor 304b emits a second signal 312b. The second signal 312b is emitted to the second roll of rolled stock 24a. The receiver 306b of the second sensor 304b detects the emitted second signal 312b. To assist with detection of the emitted signals 312a, 312b, the light source 307a, 307b of each sensor 304a, b illuminates at least a portion of the associated roll of rolled stock 20a, 24b. A background 310 can be positioned on a side of the rolls 20a, 24a opposite the sensors 304a, b. The background 310 has a color that is a first color (or a first reference color) that is generally black (or very dark) to provide contrast between the background and the detected core and rolled stock on the core.

[0073] Each sensor 304a, 304b is programmed to detect a value of rolled stock remaining on the core. The value is a predetermined (or programmed) value representative of a low level threshold of rolled stock on the core and requiring actuation of the splice assembly 56. With reference now to FIG. 6, which is an example of an output detected by each sensor 304a, b represented on a control monitor in a first detection configuration. Each sensor 304a, b detects an amount of rolled stock 26a, 27a remaining on the core 28. The detected quantity of rolled stock 26a, 27a and the core 28 are illustrated relative to the darker background 310. Each sensor 304a, 304b is configured to use color to differentiate between the rolled stock 26a, 27a on the core 28 and the core 28. Each sensor 304a, 304b utilizes machine vision to detect an amount of rolled stock 26a, 27a remaining on the core 28. In one example, each sensor 304a, 304b can detect a portion of the rolled stock 26a, 27a, and utilize geometric based machine vision to detect a dimension 314 of rolled stock 26a, 27a remaining on the core 38. Each sensor 304a, 304b can include a preprogrammed dimension that is associated with a low level threshold 318 (or a low level quantity 318) of rolled stock 26a, 27a remaining on the core 28. The dimension data detected by each sensor 304a, 304b can be analyzed relative to the preprogrammed low level threshold 318. In another example, each sensor 304a, 304b is configured to detect a portion of the rolled stock 26a, 27a, and utilize volumetric based machine vision to detect a volume 314 of rolled stock 26a, 27a remaining on the core 28. to capture volumetric data associated with a portion of the rolled stock 26a, 27a remaining on the core 28. The sensors 304a, 304b are programmed to associate the detected volumetric data with the detected portion 314 of the rolled stock 26a, 27a. The volumetric data is programmed to be associated with a quantity of rolled stock 26a, 27a remaining on the core 28. Accordingly, each sensor 304a, 304b actively detects and monitors the quantity of rolled stock 26a, 27a remaining on the core 28, updating the detected geometric data as an associated value 316 relative to a preprogrammed low level limit value 318 (also referred to as a low level threshold 318).

[0074] In the first detection configuration, the value (or quantity) of rolled stock 26a, 27a remaining on the core 28 is above (or greater than) the low level threshold 318. Accordingly, each sensor 304a, 304b actively detects and monitors the quantity of rolled stock 26a, 27a remaining on the core 28, updating the detected dimension data as an associated value 316 relative to a preprogrammed low level limit value 318 (also referred to as the low level threshold 318). In the first detection configuration, the value (or quantity) of rolled stock 26a, 27a remaining on the core 28 is above (or greater than) the low level threshold 318. It should be appreciated that the sensors 304a, 304b can utilize any appropriate machine vision system to detect a portion 314 of the rolled stock 26a, 27a remaining on the core 38. As a nonlimiting example, the sensors 304a, 304b can utilize geometric, volumetric, laser triangulation, coded light, structured light, active stereo vision, or any other suitable or known machine vision technology.

[0075] With reference now to FIG. 7, which is an example of an output detected by each sensor 304a, b represented on a control monitor in a second detection configuration. In the second detection configuration, the amount of rolled stock 26a, 27a remaining on the core 28, specifically the associated value 316, is at or less than the low level threshold 318. Stated another way, the detected amount of rolled stock 26a, 27a remaining on the core 28, as detected by each sensor 304a, 304b, is below (or at or below) the low level threshold 318. In one example, the detected geometric value 316 of rolled stock 26a, 27a remaining on the core 28 is below (or at or below) the low level threshold 318 In another example, the detected volumetric value 316 of rolled stock 26a, 27a remaining on the core 28 is below (or at or below) the low level threshold 318. In response to the detected amount of rolled stock 26a, 27a remaining on the core 28 being detected below (or at or below) the low level threshold 318, the associated sensor 304a, 304b communicates with the splice actuation system 64 to initiate a splice from one roll of rolled stock 20a, 24a to another roll of rolled stock 24a, 20a. It should be appreciated that the detected low level threshold 318 correlates to less than five impressions remaining on the core after the splice, and more specifically less than four impressions remaining on the core after the splice, and more specifically less than three impressions remaining on the core after the splice, and more specifically less than two impressions remaining on the core after the splice, and more specifically between approximately 1.5 and two impressions remaining on the core after the splice. It should be appreciated that the term “impressions” is intended to be interpreted as one full use of the rolled stock for the associated task. For example, one impression corresponds to a quantity of rolled stock to fully complete one task, such as wrapping one unit packaging, or labeling one bottle, etc.

[0076] FIG. 8 illustrates an example of an embodiment of a detection and control system 400 that utilizes information detected by the sensors 304a, 304b to initiate a splice between rolls of rolled stock 20a, 24a. The system 400 operates in association with the detection assembly 300 to advantageously reduces waste by initiating the splice in response to the core of the active roll of stock 20a or 24a being exposed and subsequently detected by the associated sensor 304a or 304b. This maximizes use of the rolled stock 26a or 27a that is stored on the respective roll 20a or 24a. The system 400 is in communication with the splice actuation system 64 to initiate actuation of the splice assembly 56. This advantageously facilitates a retrofit addition of the detection assembly 300 and associated system 400 to any suitable assembly 10, 50.

[0077] The detection and control system 400 can be integrated into the detection assembly 300. For example, the system 400 can be a separate controller (not shown) configured to receive information detected by the sensors 304a, 304b, and further selectively communicate commands to actuate the splice actuation system 64 of any suitable assembly 50. In other examples of embodiments, the system 400 can be programmed (or integrated) into the sensors 304a, 304b and configured to communicate with the splice actuation system 64. In the illustrated embodiment, the system 400 is advantageously configured to communicate with the splice actuation system 64 without additional programming of a programmable logic controller (PLC). The detection and control system 400 includes a series of processing instructions or steps that are depicted in flow diagram form.

[0078] Referring now to FIG. 8, the process of the detection and control system 400 begins at step 404. At step 404, the packaging assembly 50 is operating to package containers 30. One of the plurality of rolls of rolled stock 20a, 24a is the active roll of rolled stock 20a or 24a. The sensor 304a or 304b that is associated with the active roll 20a or 24a is the active sensor 304a or 304b. The active roll of rolled stock 20a or 24a is being unwound, with the associated unwound web of stock 26a or 27a being the active web of stock 29a. It should be appreciated that the roll of rolled stock 20a, 24a can be any two rolls of a plurality of rolls of stock. Stated another way, there can be two or more rolls of rolled stock in the plurality of rolls of stock.

[0079] At step 404, the system 400 detects whether the splice actuation system 64 has been manually actuated. More specifically, the system 400 detects whether an operator or other user has manually actuated the splice actuation system 64, such as by actuating the user actuatable member. If the process does not detect that the splice actuation system 64 has been manually actuated, or “no,” the process proceeds to step 412. If the process does detect that the splice actuation system 64 has been manually actuated, or “yes,” the process proceeds to step 416.

[0080] At step 412, the system 400 receives detection data from the active sensor 304a or 304b. The process then determines where the detected value 316 by the active sensor 304a or 304b is relative to the low level threshold 318. If the active sensor 304a or 304b detects that the detected value 316, which can be a volumetric value representative of a quantity of rolled stock 26a, 27a remaining on the core 28, is greater than the low level threshold 318, or “no,” the active sensor 304a or 304b is detecting a sufficient amount of rolled stock 26a, 27a unwinding from the core 28. The process then returns to step 208 and repeats. If the active sensor 304a or 304b detects that the detected value 316 is equal to or less than the low level threshold 318, or “yes,” the active sensor 304a or 304b is detecting a low level of rolled stock on the core 28 of the active roll 20a or 24a. This indicates that the active roll 20a or 24a is nearing (or closing in on) completely being unwound and exposing the core. The process proceeds to step 414, where a command is initiated (and sent) to actuate the splice actuation system 64. The splice actuation system 64 receives this command, and instructs the splice assembly 56 to initiate a splice from the active roll of rolled stock 20a, 24a to the other roll of rolled stock 24a, 20a. The process then proceeds to step 420.

[0081] At step 416, the splice actuation system 64 manually initiates a splice from the active roll to a secondary roll. It should be appreciated that in response to detecting actuation of the manual splice at step 408, an operator has manually initiated actuation of the manual splice. For example, the operator has actuated the user actuatable member to initiate a splice through the manual splice actuation system 64. It should be appreciated that in response to the active sensor 304a or 304b detecting the second surface of the active roll (or detecting the core) at step 412, the process initiates the command to operate the splice actuation system 64 at step 414.

[0082] When the splice was actuated manually or automatically by a signal from the active sensor 304a or 304b, the splice actuation system 64 transitions the active roll. For example, in one embodiment, where the first roll 20a is the active roll, the actuation of the splice actuation system 64 transitions from the first roll 20a to the second roll 24a as the active roll. After completion of the splice by the splice assembly 56, the second roll 24a becomes the active roll, with the unwound web of stock 27a being the active web of stock 29a. In another example of an embodiment, where the second roll 24a is the active roll, actuation of the splice actuation system 54 transitions from the second roll 24a to the first roll 20a as the active roll. After completion of the splice by the splice assembly 56, the first roll 20a becomes the active roll, with the unwound web of stock 26a being the active web of stock 29a. Again, it should be appreciated that in examples of embodiments of the unwind stand assembly 54 having three or more rolls, the first roll 20a and the second roll 24a can be any two rolls of the three or more rolls. After the successful splice and transition of the active roll, the completed roll (or roll that was spliced out) can be removed and replaced with a new roll. The new roll can later be spliced in for use when one (or more) other rolls used.

[0083] After the successful splice, the process proceeds to step 420 where the active sensor is transitioned. More specifically, the active sensor is transitioned from the completed roll (or the roll spliced out) to the new active roll (or the roll spliced in). In the embodiments where the splice transitions from the first roll 20a to the second roll 24a, the active sensor transitions from the first sensor 304a to the second sensor 304b. Similarly, in the embodiment where the splice transitions from the second roll 24a to the first roll 20a, the active sensor transitions from the second sensor 304b to the first sensor 304a. Following reassignment of the active sensor 304a or 304b for monitoring the change in active roll 20a or 24a, the process then returns to step 408, where the detection of either a manual splice (at step 408) or a detection of a value that is below (or at or below) the low level threshold 318 (at step 412) repeats for the new active roll.

[0084] One or more aspects of the detection assembly 100, 300 and associated detection and control system 200, 400 provides certain advantages. As previously noted, the system 200, 400 and assembly 100, 300 reduces rolled stock (label or packaging) waste by initiating the splice in response to detection of the core. Thus, the rolled stock is almost entirely used, with only a few impressions (of labels or packaging) remaining after a successful splice. In addition, the assembly 100, 300 and associated system 200, 400 is configured to be a retrofit addition to any suitable labeling assembly 10, packaging assembly 50, or other assembly utilizing rolled stock in a continuous web process. The assembly 100, 300 and system 200, 400 can operate with a splice actuation system or a manual splice actuation system, and does not require access to restricted control logic associated with the assembly 10, 50. These and other advantages are realized by the disclosure provided herein.