Patent Application
20180162669
The present invention concerns a winding machine to wind stretch films in bobbins. The invention is especially used in the production lines of plastic films to produce bobbins made by winding a continuous web of film.
Systems for producing plastic films, for example polyethylene films (the so-called “stretch film”), typically comprise a plurality of cascade steps for the direct in-line production by extrusion of film bobbins. In particular, the production lines of plastic films typically comprise a first step in which a continuous film web is produced by extrusion from a melted plastic mixture. The film output from the extruder passes through a plurality of intermediate cooling steps to finally come to a winding machine having the task of winding the film around tubular centers (typically made of cardboard and called “cores”) in order to form film bobbins.
As the web is wound around the core, the diameter of the bobbin gradually increases. Once the bobbin reaches a specific size, the film web is cut so that the portion of web downstream of the cut will wind around the bobbin being completed, while the portion of the web upstream of the cut will wind around a new core to form a new bobbin. In this way, a plurality of film bobbins can be uninterruptedly produced from a single continuous web formed by the upstream extruder. Since the film web is produced uninterruptedly, in order to prevent delays or errors that could block the entire production line, the above described steps have to be carried out rapidly and in reliable and repeatable ways.
Alternatively, systems in which large bobbins (the so-called “jumbo” bobbins) are initially formed to be subsequently fed to a winding machine able to produce film bobbins having smaller diameters and widths, are also known.
Winding machines for producing bobbins of stretch film, in which the cardboard core is fitted around a rotating shaft (called reel) rotated for winding the film around the core, are known. These winding machines are provided with a plurality of reels arranged on a holder rotatable around an axis. By rotating the holder, each reel is moved to take specific operative positions. Typically, at least three operative positions are provided: a position for loading a new core onto a free reel, a position for winding the film around the core, and a position for unloading the finished bobbin from the reel. By rotating around its own axis, the holder allows the reels to be simultaneously positioned in the above said operative positions.
Typically, the reel in the winding position is rotated by means of a motorized contact roll which facilitates the winding of the film around the core and allows to expel the air that could be trapped among the windings of the bobbin by applying a pressure on the film being wound around the core. As the diameter of the bobbin increases, the roll is moved radially outwards the bobbin.
Some winders are provided with further auxiliary rolls pressing the winding bobbin during the rotation of the reel holder in order to prevent air from becoming trapped, due to the cut, among the last windings of the bobbin being completed. Therefore, after the film has been cut, auxiliary rolls keep on pressing the film on the bobbin until the winding is completed. Also these rolls have to be moved in accurate and reliable ways, in order to prevent the formation of film wrinkles on the last layers of film.
The rolls are typically moved by means of swinging arms rotatable around a rotation axis parallel to the rotation axis of the reel holder. The rolls are placed at the end of the arms which are moved, for example, by means of pneumatic actuators. In particular, the arms are rotated by means of pistons and cylinders connected to a pneumatic circuit adapted to supply a pressure fluid inside the cylinders.
It is of fundamental importance to control the various pneumatic actuators, especially when the winding machine itself is used to sequentially produce different kind of bobbins (for example hand, machine and jumbo bobbins) during the film production. Basically, the various types of bobbins differ from each other on the basis of the diameter of the core (which varies, for example, depending on the thickness of the cardboard forming the core) and the final diameter to be reached by the bobbin.
Therefore, because the moving and positioning of various rolls are critical operations, if they are not carried out in an accurate, repeatable and reliable way, can cause offsets in positioning the rolls thereby causing air entrapment inside the bobbin. Proper operation of pneumatic systems in winding machines is quite critical and can be adversely affected even by minimal pressure changes that may inadvertently occur over time.
For these reasons, pneumatic systems of winding machines have to be periodically checked and cleaned in order to prevent clogging of ducts and valves or pressure drops in the pneumatic circuit which could adversely affect the proper winding and the quality of the final bobbins. Therefore, to carry out periodic maintenance of pneumatic circuits, the entire production line has to be stopped. This causes a slowdown of the production, a cost of manpower for servicing and an overall decrease in efficiency of the whole production line.
Object of the present invention is to overcome the known art problems briefly discussed above, and to provide a winding machine able to produce different kinds of bobbins in a more reliable way and requiring less maintenance with respect to the winders of the known art.
It is a further object of the present invention to provide a more effective method for winding bobbins with respect to those of the known art.
The present invention achieves these and others objects by means of a winding machine according to claim 1 and the respective dependent claims, and a method according to claim 10 and the respective dependent claims.
In particular, according to the present invention, the winding machine comprises a supporting frame and at least one reel holder mounted on the supporting frame. Each holder is rotatable around its own axis and is provided with a plurality of reels integrally rotatable therewith so that at least one first reel is in at least one operative winding position of a bobbin.
The winding machine comprises a contact roll adapted to cooperate with the first reel in an operative winding position. The contact roll is movable between at least one proximal contacting position, where it contacts the bobbin being wound for facilitating the peripheral winding of the stretch film onto the bobbin, and at least one distal position from the bobbin.
The winding machine comprises an accompanying roll movable between at least one distal position from the winding bobbin and at least one proximal contacting position wherein it contacts the bobbin. The accompanying roll is adapted to facilitate the peripheral winding of the stretch film during the rotation of the reel holder, for switching the first reel from the operative position for winding the bobbin to an operative position for unloading the bobbin.
The contact roll and the accompanying roll are respectively coupled with a first operating arm and a second operating arm both rotatable around respective rotation axes parallel to the rotation axis of the bobbin.
According to an aspect of the present invention, the rotation of the operating arms is caused by electric actuators.
The electric actuators are supplied by at least one electric power circuit connected to a logic control unit which controls the electric current output to each actuator.
With this solution, the system for moving the rolls is made much easier with respect to actuators of the known art in which a pneumatic circuit is required in order to feed a pressure fluid to the actuators. In fact, for the electric power circuit no particular maintenance is required in order to assure a reliable production of different kind of bobbins. Furthermore it was found that, by means of electric actuators, the positioning of rolls is more accurate and more rapid with respect to winders in which the movement of rolls is caused by pneumatic actuators. Moreover, the positioning of rolls is more reliable and can be repeated over time, further facilitating the change of operation settings for processing bobbins of different sizes and different types of films to be wound.
In this way, it is possible to reduce maintenance costs and keep the production line operating for a long time without interruptions, with a generally greater efficiency and reliability with respect to solutions of the known art.
According to a particular aspect of the present invention, the electric actuators are of the linear type. For example, electric actuators comprise an electric motor, preferably of the brushless type, and a linear element coupled with the electric motor by means of a transmission converting the rotary motion of the electric motor into linear motion, for example by means of a screw/nut thread coupling. The operating arms are preferably pivoted to the frame and rotated around respective pins by means of the displacement (for example the linear displacement) caused by the electric actuators.
According to a particular aspect of the present invention, the winding machine comprises means for detecting the current absorbed by the electric actuators. In particular, the logic control unit adjusts the current output from the electric power circuit depending on the current absorbed by the electric actuators. For example, the logical unit can adjust the current output from the electric power circuit so that the electric actuators generate a specific torque whereby at least the contact roll applies a given pressure on the film being wound, for example a constant pressure independent of the bobbin diameter which changes during winding.
The winding machine according to the present invention further comprises means for determining the position of the rolls with respect to the bobbin being wound. In an embodiment, the means for determining the position comprise at least one encoder, preferably of the absolute type. Advantageously, in case of linear electric actuators, the absolute encoder can be housed inside the electric actuator for detecting the number of revolutions made by the electric motor. The logic control unit can determine the position of the rolls depending on the number of revolutions made by the electric motor, for example by means of a map previously obtained by experimental tests.
According to a particular aspect of the present invention, the winding machine further comprises a threading-up electric motor, i.e. a motor allowing a reel having a new core loaded thereon to be rotated at a speed suitable for starting to wind a new bobbin. In particular, before cutting the film, a second reel having a new core loaded thereon is advantageously rotated so that, as a result of a rotation of the reel holder, it reaches a winding position at a rotating speed close to that of the contact roll (threading-up).
Preferably, the threading-up electric motor can be coupled with the second reel having a new core loaded thereon by means of a magnetic coupling. The magnetic coupling between the reel and the electric motor allows to carry out the thread-up during the holder rotation without having to motorize each single reel with a respective threading-up motor. Advantageously, this solution allows the reels to be mounted in the neutral position in the holder thereby simplifying the structure of the reel holder.
According to a further aspect of the present invention, the winding machine comprises an electromagnetic brake for braking the rotation of a reel having a finished bobbin loaded thereon in unloading position. In particular, once the bobbin has been finished it still rotates by inertia. The rotation of the finished bobbin can be stopped by the electromagnetic brake thereby speeding up unloading operations. The magnetic coupling between the electromagnetic brake and the reel having a finished bobbin in unloading position allows to simplify the holder structure without having to mount a brake on each reel.
A further object of the present invention is a method for the in-line winding of bobbins of stretch film in a winding machine comprising at least one reel holder mounted on a supporting frame and rotatable around its own axis, and a plurality of reels mounted on the holder and integrally rotatable therewith so that at least one first reel is in an operative winding position of a bobbin. The method comprises a step of rotating a core on a reel in an operative winding position and a step of positioning a contact roll in at least one proximal contacting position where it contacts the winding bobbin for facilitating the peripheral winding of the stretch film on the core.
When the bobbin reaches a specific diameter close to the one provided for completing it, the holder is rotated in order to bring the reel from the operative winding position to an unloading position to unload the bobbin.
Preferably, a first rotation is made by the holder in order to bring the reel being wound to a second operative winding position. During the holder rotation, the contact roll is kept in contact with the bobbin being wound and an accompanying roll is moved to a determined distance from the bobbin being wound.
According to an aspect of the present invention, as previously described referring to the winding machine according to the present invention, the contact roll and the accompanying roll are moved by means of electric actuators.
According to an aspect of the present invention, the method further comprises a step of detecting the position of the rolls with respect to the bobbin being wound. Advantageously, the rolls are moved depending on the position detected by encoders, for example by moving the rolls by a feedback control of the supply current provided to the electric actuators depending on the detected position of the rolls.
For example, an embodiment can provide that the movement of the accompanying roll is based on the position of the rolls with respect to one another. Preferably, once the first reel has reached the above said second winding position, the accompanying roll is positioned at a certain distance from the bobbin (preferably at a distance of less than one millimeter). Then, the accompanying roll is brought into contact with the bobbin and, at the same time, the contact roll is brought to a distal position from the bobbin. The contact roll and the accompanying roll contact the bobbin being wound for a split second (typically of the order of a millisecond). The holder is then rotated so that the first reel (carrying the bobbin being wound) reaches the cutting position and the following unloading position to unload the bobbin. The accompanying roll is simultaneously moved so as to be kept in contact with the bobbin being wound during the holder rotation.
As previously described for the winding machine according to the invention, the method further comprises a step of detecting the current absorbed by the electric actuators, so that during the film winding, the rolls are moved between a first proximal contacting position and a second proximal contacting position depending on the detected current absorption.
In this way, both the contact roll and the accompanying roll are moved in order to apply a certain pressure on the bobbin while the film is wound and accompanied to the final winding step.
When the bobbin being wound reaches the unloading operative position, a second reel having a new core previously loaded thereon reaches the operative winding position. During this step, preferably the second reel carrying a new core is rotated at a speed close to that of the contact roll. This operation (threading-up) is preferably carried out by means of an electric motor magnetically coupled with the reel having a new core loaded thereon. In this way, the threading-up can be carried out during the rotation of the reel holder without any contact among the parts. This solution allows the threading-up to be carried out by means of a single motor, thereby without coupling a threading-up motor with each reel that would result in the reel holder excessively weighted down. As the second reel with the new core reaches the operative winding position, the contact roll is moved so as to press the film on the new core and subsequently the film is transversely cut. The portion of the film upstream of the cut begins to wind onto the new core, while the portion downstream of the cut is wound around the bobbin loaded on the first reel and brought to the unloading position. Once the bobbin is finished, the accompanying roll is brought to a distal position from the bobbin ant the reel with the finished bobbin is preferably braked by an electromagnetic brake in order to allow the bobbin to be unloaded from the reel.
Further aspects and advantages of the present invention will become more evident from the following description, made for illustration purposes and without limitation, with reference to the accompanying schematic drawings, in which:
Each reel holder 12 is provided with four reels 1-4 preferably arranged 90° from each other. Reels 1-4 are integrally rotatable with the holder 12 so that at least one first reel 1 is in at least one operative winding position of a bobbin 5. In particular, the holder 12 comprises two flanges 14 (each figure showing only one of the two flanges) and each reel 1-4 is supported between the two flanges 14 of the holder 12. By rotating the holder 12, the reels 1-4 move among different operative positions described in more detail hereinafter in the present description.
The winding machine 10 further comprises a contact roll 15a adapted to cooperate with a first reel 1 at an operative winding position, and an accompanying roll 15b adapted to cooperate with the above said reel, during rotation of the reel holder in order to bring the reel 1 from the operative winding position to an unloading operative position (position taken by the reel 1 shown in
The contact roll 15a and the accompanying roll 15b are respectively coupled with a first operating arm 16a and a second operating arm 16b both rotatable around respective rotation axes 17a, 17b parallel to the rotation axis of the bobbin. Preferably, the rotation axes 17a, 17b of the operating arms 16a, 16b and the rotation axis of the bobbin 5 are parallel to the rotation axis 13 of the reel holder 12. The operating arm 16a, 16b are rotated by means of electric actuators 18a, 18b.
Preferably, the electric actuators 18a, 18b are of the linear type and comprise preferably brushless electric motors 19a, 19b and each comprises a linear element, for example operating bars 20a, 20b coupled with the respective electric motors 19a, 19b by a coupling that converts the rotary motion of the electric motor into a linear motion, for example by a screw/nut thread coupling. The rotation of the electric motors 19a, 19b in one way or the other causes the operating bars 20a, 20b to be moved forward or backward. The first operating arm 16a and the second operating arm 16b are coupled with a first electric actuator 18a and a second electric actuator 18b, respectively. In particular, each operating bar 20a, 20b of the respective electric actuator 18a, 18b is constrained to a respective operating arm 16a, 16b.
By means of the electric actuators it is therefore possible to move the rolls 15a, 15b between at least one proximal contacting position wherein it contacts the bobbin being wound and at least one distal position from the bobbin.
In particular, the winding machine 10 comprises a circuit providing the power supply 21 to the electric actuators 18a, 18b and a logic control unit 22 adapted to adjust the current output from the electric power circuit 21 to the electric actuators 18a, 18b. The logic control unit 22 selectively drives the electric actuators 18a, 18b by adjusting the supply power provided by the power circuit 22 to each electric actuator 18a, 18b. The current can be adjusted in several ways known per se in the art, for example by means of PWM regulators or similar.
The winding machine 10 further comprises means 23 for detecting the current absorbed by the electric actuators 18a, 18b. The means 23 for detecting the absorbed current can comprise for example two amperometers 23a, 23b (for example connected to the electric power circuit 21) used by the logic control unit 22 to determine the current absorbed by the respective electric actuators 18a, 18b.
In this way, the logic control unit 22 can adjust the current output from the electric power circuit 21 depending on the current absorbed by the electric actuators. In particular, the logic control unit 22 adjusts the supply current provided to the electric actuators 18a, 18b in order to generate a specific torque adapted to move the operating arms 16a, 16b and, therefore, the rolls 15a, 15b depending on the detected current absorption. In this way the logic control unit 22 adjusts the supply current provided to the electric actuators 18a 18b so that at least the contact roll 15a applies a predetermined pressure to the bobbin 5 being wound. The current absorption detected by means of the amperometers 23a, 23b is a measure indicating the pressure applied by the corresponding contact roll 15a to the bobbin 5 being wound. Therefore, the present solution allows the supply current provided to the electric actuators 18a, 18b to be feedback controlled so that the rolls 15a, 15b apply to the bobbin 5 a predetermined pressure, for example a constant pressure, during the film winding through the whole winding step, thereby preventing the formation of air bubbles among the layers of wound film.
The winding machine 10 further comprises means 24 for detecting the position of the rolls 15a, 15b with respect to the bobbin 5 being wound. In the embodiment shown in
However, in additional embodiments position sensors can also be provided, for example optic sensors allowing the logic control unit 22 to determine the position of the rolls 15a, 15b with respect to the bobbin 5.
The logic control unit 22 adjusts the current output from the power circuit 21 to the electric actuators 18a, 18b based on the position detected by means of the absolute encoders 24a, 24b (or generally by the means 24 for detecting the position of the rolls) in order to bring the rolls 15a, 15b to specific predetermined positions depending on the kind of bobbin to be produced.
The contact roll 15a is moved between a first proximal contacting position and at least one second proximal contacting position; as the diameter of the bobbin 5 increases, the roll 15a is moved away from the bobbin 5 always keeping it in contact with the latter. The logic control unit 22 determines the position of the contact roll 15a with respect to the bobbin 5 being wound by means of the absolute encoder 24a of the first electric actuator 18a. For example, the position of the contact roll 15a can be evaluated in order to determine the diameter reached by the bobbin 5 being wound.
Once the bobbin 5 reaches a predetermined diameter (for example depending on the kind of bobbin to be produced), the reel holder 12 is rotated counterclockwise, for example by about 30°, so as to bring the first reel 1 from the first operative winding position shown in
In both cases, the distance D between the bobbin 5 being wound and the accompanying roll 15b is the same. In other words, the second electric actuator 18b allows to set the distance D independently from the kind of bobbin to be produced. In this way, the positioning of the accompanying roll 15b in contact with the bobbin is carried out in the same way independently from the diameter achieved by the bobbin 5.
The logic control unit 22 determines the position of the second roll 15b by means of the second absolute encoder 24b and adjusts the supply current to the second electric actuator 18b by means of a feedback control so that the accompanying roll 15b reaches a given position detected by means of the encoder 24b, at a specific distance D from the bobbin 5.
The accompanying roll 15b is moved by the electric actuator 18b depending on the position the contact roll 15a has taken, detected by the encoder 24a. The logic control unit 22 can use the position of the contact roll 15a (indicating the size of the diameter of the bobbin 5, for example when the reel 1 is in the second winding position) for obtaining the position to be reached by the accompanying roll 15b so that the latter is positioned at a given distance D from the bobbin 5.
Then, the accompanying roll 15b is brought into contact with the bobbin 5 and at the same time the contact roll 15a is brought to a distal position from the bobbin 5. The rolls 15a, 15b simultaneously contact the bobbin 5 being wound for a split second (typically of the order of a millisecond).
The logic control unit 22 adjusts the supply current to be provided to the second electric actuator 18b based on the current absorption detected by the ammeter 23b so that the accompanying roll 15b keeps applying a predetermined pressure on the bobbin (for example the same pressure previously applied by the contact roll 15a). Also the accompanying roll 15b is rotated by a similar electric motor 25b coupled to the roll 15b by means of a drive belt. In this way the first reel 1 keeps winding at the same rotation speed of the contact roll 15a.
Subsequently, the reel holder 12 rotates more 60° counterclockwise to bring the first reel 1 to an operative unloading position (as shown in
At the same time, a second reel 2 having a new core 7 previously loaded thereon is rotated by a threading-up electric motor (not shown in figures) arranged behind the flange 14 and coupled with the second reel 2 by means of a magnetic coupling.
Preferably, the threading-up operation is carried out during the rotation of the holder 12 to bring the second reel 2 to the operative winding position (while the first reel 1 is brought to the unloading position). In particular, the threading-up electric motor is provided with an electromagnet for coaxially coupling with the second reel 2. During rotation of the holder 12 the threading-up electric motor is integrally moved with the holder 12 so that the electromagnet is still coaxial to the second reel 2. The electromagnet transmits the rotary motion of the threading-up electric motor to the second reel 2, without any contact among the parts, so as to cause the second reel 2 to have a rotation speed close to that of the contact roll 15a.
Once the second reel 2 reaches the operative winding position (as shown in
The portion of the film downstream of the cut, with respect to the sliding direction of the film 6, keeps on winding around the bobbin 5 loaded on the first reel 1 in an operative unloading position with the accompanying roll 15b being kept in a contact position wherein it contacts the bobbin until the latter is finished.
Once the film portion downstream of the cut is completely wound around the bobbin 5, the accompanying roll 15b is brought by means of the second electric actuator 18b to a distal position from the bobbin 5 to allow the finished bobbin 5 to be unloaded from the first reel 1 in an unloading position.
After detaching the accompanying roll 15b from the finished bobbin 5, the bobbin 5 keeps on rotating by inertia. In order to speed up the unloading of the bobbin 5, the winding machine 10 further comprises a brake, for example of the electromagnetic type, to brake the rotation of the first reel 1 in the unloading position. Preferably, the magnetic brake (not shown in figures) is positioned behind the flange 14 at the unloading position of the bobbin. The electromagnetic brake comprises an electromagnet which, when activated, brakes until stopping the first reel 1 having the finished bobbin loaded thereon, thereby generating parasitic currents by electromagnetic induction, as known per se in the art.
Once the reel 1 carrying the finished bobbin has been stopped, then the unloading step of the bobbin follows (shown in
At the same time of the unloading step of the finished bobbin, a new core 7 is loaded onto a third reel 3 positioned 90° from the unloading position (in a position diametrically opposite to the operative winding position). By means of an additional mechanical arm 32, the new core 7 is fitted around the third reel 3 in a way similar to the unloading step of the finished bobbin 5 from the first reel 1. In particular, the new core 7 is fitted on the third reel 3 by passing it through a further hollow (not shown) in one of the two flanges 14.
The fourth reel 4, arranged in the position diametrically opposite to the unloading position, carries a core 7 which was loaded during the step of unloading the finished bobbin and loading a new core of the previous cycle.
At the end of the step of unloading the finished bobbin and loading a new core, the arrangement shown in
Although not specifically shown in figures, the reels 1-4 can be of the expandable type, for example mechanically driven, so as to be able to accommodate cores having different diameters. Moreover, although a single core 7 has been referred to for the sake of simplicity, it is also possible that two or more cores are loaded at the same time on the same reel depending on the size of the bobbins to be simultaneously wound.
| Number | Date | Country | Kind |
|---|---|---|---|
| 15166350.7 | May 2015 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2016/060129 | 5/5/2016 | WO | 00 |
