Patent Application
20190185283
The present invention relates to machines and devices for processing continuous web materials, such for example, but not limited to, webs or strips for producing corrugated board.
Embodiments described herein also relate to machines or devices for unwinding reels of web material (so-called unwinders).
In many industrial fields, it is necessary to process continuously sheets or webs unwound from a reel. Typically, in the corrugated board field, unwinders are commonly used to produce sheets for board boxes or other products, that are provided with a plurality of means for supporting and unwinding the reek of web material, typically flat paperboard. A plurality of webs of corrugated board are fed from so-called corrugators (single facer) to hot surfaces (double facer) for producing multi-layer corrugated board.
The unwinder comprises a splicing device (below also called splicer) for splicing the trailing edge of a web material of a nearly empty roll or reel to the leading edge of a second web material of a new reel. By splicing the trailing edge and the leading edge of the two web materials in an automatic or semi-automatic way, it is possible to make the unwinder, and therefore the line comprising it, operate in a substantially continuous manner.
Modern unwinders and splicers of this type are disclosed for instance in EP 1609749 and in US 2004/0084133, the content whereof is incorporated in the present description.
If there is enough space at both sides of the processing line, the new reels of web material are inserted from a side of the processing line and the empty reels are extracted from the opposite side of the processing line. In some plant layout this is not possible, for example because there is not enough space at both sides of the processing line. This typically occurs when there is an obstacle, for example a wall, or another processing line, or any other obstacle, at a side of the processing line. Thus, 3-positions unwinders have been developed, allowing the reels to be inserted and extracted at the same side of the processing line. Exemplary embodiment of unwinders and processing lines of this type are disclosed in U.S. Pat. No. 7,441,579 and in U.S. Pat. No. 4,919,353, as well as in the two publications mentioned above (EP 1609749 and US 2004/0084133).
The use of 3-positions unwinders of this kind has some drawbacks. For example, they are very bulky, and this affects the overall length of the processing line. Moreover, unwinders of this kind are complex and expensive.
JP-S-4949 21211 discloses an unwinder for reels of web material comprising two pairs of arms rotating around a stationary support. The pairs of arms are used to pick-up a reel of web material, to bring it into an unwinding position, to supply material and to unload the reel onto a stationary unloading surface. The reel is brought towards the unwinder by making it roll on a surface until it is arranged on a vertically movable V-shaped cradle. The cradle is raised by means of a lift table arranged in a pit below the floor. The lift table shall have a very strong structure in order to raise the heavy reels, that can be some tons in weight, for example 3-5 tons. For this reason, the lift tables and the actuators thereof shall have large dimensions. The reels shall be brought onto the cradle by making them roll parallel to the machine direction, i.e. to the direction along which the web material will be fed. It is not possible to introduce the reels laterally, i.e. orthogonally to the machine direction. Therefore, it is difficult to lay out the processing line.
DE-A-4207199 discloses a plant where the reels can be inserted laterally, i.e. orthogonally to the machine direction. This known plant comprises an unwinder which comprises only one pair of pivoting arms to pick-up the reel from one or the other of two pick-up positions. The reel is inserted into one pick-up position or into the other by means of a respective shuttle. Each shuttle both transports the new reel into the loading position, and takes the empty reel away. Each shuttle has a V-shaped cradle to house the reel. The reels are brought towards the side of the processing line with the axis thereof oriented in machine direction, i.e. rotated by 90° with respect to the position that the reel shall take on the unwinder. The reel is arranged on a rotating table with a V-shaped cradle, arranged spaced from the unwinder and at the side of the processing line. The shuttles transfer each reel from the rotating table to the unwinder and vice versa. The rotating table is controlled so as to rotate by 90° in a horizontal plane and to orient the reel with the axis thereof in the suitable position for being transferred onto the shuttle and, therefrom, onto the unwinder. The shuttles and the rotating table are provided with pivoting movements in order to facilitate the transfer of the reels from the rotating table to the shuttles and vice versa. In order to transfer the reel from the shuttle to the unwinder, the shuttle shall be aligned with the arms of the unwinder and the arms shall be lowered towards the shuttle. The system is very complex and bulky. Moreover, it is not possible to take reels of variable diameter from the shuttle.
DE-A-19736491 discloses a shuttle for transporting paper reels, and a system to facilitate the loading of the reels onto the shuttle. The system for loading the reels onto the shuttle is provided with two series of rollers forming a cradle with variable arrangement. The shuttle is positioned between the two series of rollers. A series of rollers is fixed, while the other series of rollers pivots in order to allow the reel to roll beyond the rollers and to be positioned onto the shuttle. Then, the movable rollers are raised and form, together with the fixed rollers, a V-shaped cradle for centering the reel on the shuttle. This document does not provide any means for loading the reels onto, or unloading the reels from, an unwinder.
There is therefore the need for providing unwinders for unwinding reels of web material, for example paperboard, that are simpler and have more compact dimensions.
In order to overcome, partially or completely, one or more of the problems of the known unwinders, an unwinder is provided for unwinding reels of web material, comprising: a rotating support with a rotation axis and provided with engaging members for engaging the reels; a reel positioning system for loading the reels onto the rotating support; and an unloading system for unloading the reels from the rotating support.
Advantageously, the positioning system comprises a first conveyor for the reels and a pusher configured and arranged to push the reels from the first conveyor towards abutment members defining a pick-up position where the reel is taken by the rotating support. Moreover, the positioning system and the unloading system are arranged at opposite sides of the rotating support.
In the pick-up position, the reel axis is approximately arranged on the circular path of the engaging members, for example cones or tailstocks, with which the rotating support is provided. In this way it is possible, by means of the pusher, to arrange each reel in the suitable position for being taken by the engaging members, independently of the reel diameter. This allows handling reels of significantly different diameters.
The first conveyor may comprise a continuous flexible member, for example a chain or a belt. The first conveyor may comprise an active upper branch and a lower return branch. The active branch may be arranged level with the floor, in order that the first conveyor does not hinder operators and/or service vehicles, for example forklifts or the like.
In some embodiments, the positioning system is advantageously arranged below the floor.
In practical embodiments, the first conveyor has a reel feeding movement substantially parallel to the rotation axis of the rotating support, and the pusher has a movement substantially orthogonal to the rotation axis of the rotating support. The reels can be therefore inserted into the processing line, and extracted from the processing line, orthogonally to the longitudinal extension of the line.
In advantageous embodiments, the pusher comprises an arm pivoting around an articulation axis substantially parallel to the rotation axis of the rotating support. The articulation axis may be arranged at a height lower than the first conveyor, in order to reduce overall bulk.
In some embodiments, the abutment members comprise two abutment elements, spaced from each other along a direction substantially parallel to the rotation axis of the rotating support. Detectors may be associated with the two abutment elements, detecting when each abutment element has achieved, under the reel thrust, a given position. In this way, the correct positioning of the reel axis with respect to the rotation axis of the rotating support is ensured.
In advantageous embodiments, the unloading system comprises an unloading surface pivoting around a pivoting axis substantially parallel to the rotation axis of the rotating support.
The unloading system may also comprise a second conveyor. In some embodiments, the unloading surface and the second conveyor are advantageously arranged so as to make the reels roll from the rotating support along the unloading surface to the second conveyor.
The second conveyor may move parallel to the first conveyor.
The second conveyor may comprise a continuous flexible member, for example a chain or a belt. The second conveyor may comprise an active upper branch and a return lower branch. The active branch may be arranged level with the floor, in order that the second conveyor does not hinder the operators and/or the service vehicles, for example forklifts or the like.
In some embodiments, the unloading system is advantageously arranged below the floor.
In some embodiments, in order to control the rotating support very reliably during the reel unloading step, the unloading surface may be associated with detecting members, configured to detect the angular position of the unloading surface and to control the rotation of the rotating support accordingly.
The detectors interface, for example, a control unit configured to control the movement of the rotating support and the stop thereof in a position where the reel is released. The release position may be defined according to the angular position of the unloading surface.
In some embodiments, the unloading surface is functionally connected to at least one actuator arranged and configured to make the unloading surface pivot into a rejecting position for rejecting the reel towards the second conveyor.
Further advantageous features and embodiments of the unwinder are described below with reference to the attached drawing, and in the attached claims, forming an integral part of the present description.
The invention and the many advantages resulting therefrom will be better understood from the description below of some embodiments, set forth with reference to the accompanying drawing, where:
The following detailed description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Additionally, the drawings are not necessarily drawn to scale. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.
Reference throughout the specification to “one embodiment” or “an embodiment” or “some embodiments” means that the particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrase “in one embodiment” or “in an embodiment” or “in some embodiments” in various places throughout the specification is not necessarily referring to the same embodiment(s). Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
With initial reference to
In the illustrated embodiment, the unwinder 1 comprises a bearing structure 3, a rotating support 5 for supporting two reels of web material, one reel being processed and the other one waiting for being processed; and a splicing device, for example of a known type, not shown.
The two web materials may be spliced together, for example, when the first roll, i.e. the first reel from which the first web material is fed, is nearly empty and shall be replaced with a new one. However, also in other situations it could be necessary to splice a first web material coming from a first reel, i.e. roll of paper feeding into the corrugator, with the leading edge of a second web material coming from a new reel. This occurs, for example, when it is necessary to produce several types of corrugated board, for example if it is necessary to pass from a type of corrugated board to another requiring the use of a web material different from the first one in composition, thickness, width or other features.
The rotating support 5 may comprise two pairs of arms 6A and 6B. Each arm 6A, 6B carries a tailstock 9, configured to engage the ends of a respective reel B of wound web material, for example paperboard. The arms of each pair are parallel to each other and arranged side-by-side, so that in the side views shown in the drawing only one arm per each pair 6A, 6B is visible, as the two arms of each pair are arranged over each other.
The tailstocks 9, coaxial with each other, are provided with an extraction and retraction movement parallel to the axis thereof and are provided with brakes controlling the unwinding of the respective reel of web material, usually unwound through traction. The brakes allow keeping the web material suitably tensioned during unwinding. The rotating support 5 is provided with a rotation movement according to th arrow f5 around a substantially horizontal rotation axis A-A. The rotation around the axis A-A according to arrow f5 may be controlled by one or more motors, not shown. The rotating support 5 may also comprise a pair of guide rollers or return rollers 15 in order to guide the web material during the various steps of the operation cycle.
The bearing structure 3 may have uprights 3A and crossbars 3B. Guide rollers, not shown, for guiding the web material, and the splicer, that is not part of the present invention, are supported on the crossbars 3B.
The rotating support 5 is associated with a positioning system 21 for loading the reels B onto the rotating support 5, and an unloading system 22 for unloading the reels from the rotating support 5.
In the illustrated embodiment, the positioning system 21 is housed below a floor P, in a volume 23 that is surrounded by a casing 25 and is partially covered by a cover or plate 24. The cover 24 is shown only in
In some embodiments, the positioning system 21 comprises a conveyor 27, for example a chain or a belt, movable according to a feeding direction of the reels B, indicated with f27 in
The positioning system 21 also comprises a pusher 29 to push the reels 13 from the first conveyor 27 towards a position where they are engaged by the tailstocks 9 of the arms 6A, 6B of the rotating support 5. In the illustrated embodiment, the pusher 29 comprises an arm 29A carrying a roller 29B. The roller 29B is mounted idle on the arm 29A and has an axis preferably parallel to the rotation axis A-A of the rotating support 5. The pivoting movement of the pusher 29 is approximately orthogonal to the rotation axis A-A of the rotating support 5.
In the illustrated embodiment, the arm 29 is hinged around an articulation or rotation axis B-B, preferably arranged below the floor P, for example below the conveyor 27. By means of an actuator 31, for instance a hydraulic cylinder-piston actuator, the arm 29A is made pivot according to the double arrow f29 (
The positioning system 21 also comprises abutment members defining a pick-up position where the reel B is taken by the rotating support 5. In the illustrated embodiment, the abutment members, indicated as a whole with number 33, comprise two abutment elements 35A, 35B for the reel B. The abutment elements 35A, 35B may comprise, for example, idle rollers mounted around rotation axes preferably parallel to the axes A-A and B-B. The rollers 35A, 35B are preferably coaxial with, and spaced from, each other along the common rotation axis. In the illustrated embodiment, as visible in particular in
In some embodiments, each abutment element 35A, 35B is resiliently biased towards a rest position, shown in
In the illustrated embodiment, each oscillating member 37A, 37B is resiliently biased upwards, towards a rest position, by means of a respective compression spring 41 or other suitable member.
A respective rest surface 43A, 43B for the reels B may be associated with each abutment element 35A, 35B.
The angular position of each oscillating member 37A, 37B may be detected by means of position detectors, for example micro-switches 45. Advantageously, one position detector is provided for each oscillating member. In particular, the detectors 45 may be configured to detect when the respective oscillating member 37A, 37B (and therefore the corresponding abutment element 35A, 35B) achieves a position of maximum lowering under the thrust of a reel B, as it will be better described below with reference to
Details on the operation of the positioning system will be described below with reference to
The unloading system 21 is illustrated in greater detail in
In the illustrated embodiment, the unloading system 22 comprises an inclined pivoting unloading surface 51, shown in
The pivoting unloading surface 51 is articulated around an axis C-C preferably substantially parallel to the rotation axis A-A of the rotating support 5.
One or more actuators 53 are associated with the pivoting unloading surface 51, for purposes that will be explained below.
The unloading system 22 may also comprise a second conveyor 61, for example a chain or a belt. The second conveyor 61 may be movable in a direction f61, approximately parallel to the axis A-A and to the axis C-C. The active branch, i.e. the upper branch of the second conveyor 61, defining the transport height of the second conveyor 61, may be arranged at a height greater than the pivoting axis C-C.
The pivoting unloading surface 51 may take a plurality of positions, which can be detected by means of suitable detectors. In some embodiments, three angular positions of the pivoting unloading surface 51 are detected. For example, two micro-switches may be provided, schematically indicated with 55 and 57, cooperating with followers 59, 61 integral with the inclined unloading surface 51. The detectors 55, 57 may interface the programmable central control unit 47 and may be arranged so as to detect three angular positions of the pivoting unloading surface 51, for example a first angular position, where the inclined surface 51S of the pivoting unloading surface 51 forms an angle α1 with the horizontal, a second position, where this angle is equal to α2, and a third position, where this angle is equal to α3. The angles α1, α2 and α3 are, for example, 4°, 2° and 1° with respect to the horizontal.
The system for detecting three angular positions allows the operation of the unloading system for the reels B described below.
The pivoting unloading surface 51 is carried by arms 52 hinged at C-C, shaped so as to allow the second conveyor 61 to pass above the same arms, in order that the upper branch of the second conveyor 61 is approximately aligned with the surface 51S of the pivoting unloading surface 51.
A concave metal sheet 63 may be arranged at the side of the second conveyor 61 opposite with respect to the side where the pivoting unloading surface 51 is arranged, in order to stop the reel B that is unloaded from the rotating support 5 onto the second conveyor 61 as described below.
When the reel B1 rests on the first conveyor 27, the axis X-X of the reel B1 lies approximately on a vertical plane passing through the centerline of the first conveyor 27. The position of the axis X-X varies according to the diameter of the reel B1 and is not necessarily arranged on the circular path (indicated with C in
As it is shown in
Now, the reel B1 may be handled by means of the rotating support 5 according to the unwinding cycle provided for the unwinder 1 and not described.
As it is particularly clear from
When a reel B1 shall be replaced with a new reel B2, the reel B1 is unloaded from the rotating support with a cycle represented in the sequence of
The reel B2 has been previously engaged by the tailstocks 9 of the pair of arms 6B with a sequence substantially equal to that described above with reference to
In order to control the lowering movement of the reel B1 up to the suitable position for unloading it, it is possible to use the detectors 55, 57 instead of controlling the angular position of the rotating support 5. Namely, to control the angular movement of the rotating support 5 through the motor thereof may be particularly difficult due to the presence of two reels B1, B2 supported by the rotating support 5, the weights of which can significantly vary and are not known. In fact, the reel B1 may be unloaded when it is completely empty or when it is only partially empty, and shall be replaced, during the working process, with a reel 92 of different type in order to process a different production batch. The reel B2 may be, in turn, a new reel or a partially used reel, for example a reel partially used for a previous production cycle. The reels may also have different axial lengths and/or may be constituted by web material of different grammage. Due to all these factors, the weight distribution on the arms 6A, 6B of the rotating support 5 is not known, and therefore it is difficult to control the rotation of the support only by means of the rotation motor.
The detectors 55, 57 allow to modulate the rotation speed of the rotating support 5 according to the angular position taken by the pivoting unloading surface 51 under the thrust of the reel B1 that is gradually lowered, without the need for using the rotation motor. When the pivoting surface 51 has achieved the second angular position α2 (for example, approximately 2° with respect to the horizontal), the programmable central control unit 47 may send the rotation control motor a command for slowing down the rotating support 5. Finally, the rotation of the rotating support 5 is stopped upon the command of the programmable central control unit 47 when the detectors 55, 57 have detected that the unloading surface 51 has achieved an angular position α3 (for example 1° inclined with respect to the horizontal). This condition is illustrated in
In the subsequent step, indicated in
At this point, the rotating support 5 may further rotate so as to bring the arms 6A towards the area where the positioning system 21 is arranged, where a new reel is taken. Simultaneously, the reel B2 engaged by the arms 6B is brought towards the unloading position 22.
In the floor P a pair of cavities 67 is provided, indicated in broken line in the sequence of
In some embodiments, in order to optimize the operation of the device when reels 1-3 of particularly small diameter are loaded, the positioning system may comprise a curved metal sheet 26 (
Moreover, in order to optimize the operation of the unloading system when the diameter of the winding cores to be unloaded is particularly small, or when the reel is completely empty and the only winding core shall be unloaded, an angular position detector may be associated to the rotating support 5, configured to stop the rotation of the support in a position of minimum lowering. If the reel or the winding core engaged by the tailstocks 9 has such a small diameter that it does not touch the pivoting unloading surface 51 before the rotating support has achieved the position of minimum lowering, the rotation is anyway stopped, independently of the signal sent by the detectors 55, 57, and the tailstocks 9 are released from the winding core, which rolls along the pivoting unloading surface 51. In this way the risk of a collision between the tailstocks and the pivoting unloading surface is avoided.
| Number | Date | Country | Kind |
|---|---|---|---|
| UA2016A004142 | Jun 2016 | IT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CN2017/087322 | 6/6/2017 | WO | 00 |
