Patent Grant
10695930
The present disclosure relates to a rotary cutting apparatus comprising a monitoring unit (28) being at least partially embedded in at least one of the first and the second drums (37 or 38) of the first and the second rotary devices (14 or 16), the monitoring unit (28) being configured for measuring at least one working parameter and for transmitting data representative of the at least one working parameter between the monitoring unit (28) and an interface transmission unit positioned outside either the first or second rotary device or both.
Furthermore, the present disclosure also relates to a method for transmitting data and energy.
Rotary cutting apparatus is for example known from EP-A-2 508 311.
However, when using rotary cutting apparatus, functional disorders may occur with the apparatus and/or also the apparatus may be exposed to wear. A usual reaction of the skilled person to solve this is to increase the cutting pressure of the rotary cutting apparatus in order to obtain a good cut once again until the maximum pressure is reached. When this happens, there will be no other solution than to stop the rotary cutting apparatus in order to change the broken and/or worn parts. Thus, this will mean severe consequences for both productivity and efficiency of the rotary cutting apparatus. Furthermore, the increase of cutting pressure will also shorten the lifetime of the equipment.
An aspect of the present disclosure is to provide an improved rotary cutting apparatus which will solve and/or reduce the problems mentioned above. The present disclosure therefore relates to a rotary cutting apparatus comprising a monitoring unit at least partially embedded in at least one of the first or the second drums of the first and the second rotary devices, the monitoring unit being configured for measuring at least one working parameter and for transmitting data representative of the at least one working parameter between the monitoring unit and an interface transmission unit positioned outside either the first or second rotary device or both. By measuring and following important working parameters, it will be possible to know when a maintenance operation is needed and also what maintenance is needed to be performed, such as for example preventive maintenance. A preventive maintenance operation is for example cleaning, checking and adjusting the equipment.
The monitoring unit, which is at least partially embedded in at least one of the first and the second drums will obtain, while machining is performed, accurate measurements relating to the cutting operation, such as the number of produced work-piece and/or a temperature of a cutting edge. Indeed, the position of the monitoring unit enables the disposition of sensing means very close to the external surface of the rotary device in which the monitoring unit is at least partially embedded thereby improving the accuracy of the measurements carried out in a remote position from the rotary devices and/or the cutting area.
According to one embodiment the monitoring unit may be at least partially embedded in both of the first and second drums of the first and the second rotary devices.
According to the present disclosure, the “cutting area” refers to a space closely surrounding the first and second rotary devices, particularly around a cutting edge provided onto the first or the second rotary device, when the rotary cutting apparatus is running.
The at least one working parameter refers to a physical property or a dynamic behavior or a state which is able to be measured or detected which relates to the cutting operation performed by the rotary cutting apparatus. The at least one working parameter may be a parameter related to the first and/or the second rotary device, the force means or any member of the rotary cutting apparatus participating to the cutting operation. Furthermore, the at least one working parameter may refer to any parameter which may be used to control the cutting operation.
Data representative of the at least one working parameter refers to data determined from the measured and/or detected working parameter. For example, a sensor measures a working parameter so as to output data representative of this working parameter. Furthermore, data representative of the working parameter also refers to data calculated according to the working parameter, for example calculating another parameter according to the working parameter or determining that a threshold value is reached. Examples, but not limiting, of what working parameters may be measured and/or detected are vibrations, dirtiness of the equipment and temperature.
Since the at least one working parameter is transmitted outside either the first or second rotary device or both while machining is performed, the monitoring unit allows a real-time control of the cutting operation. For example, it is possible to control the speed of rotation of the rotary devices and/or the feed speed of the work-piece.
This real-time control will provide for the possibility to directly reacting and solving deviation within the operation by e.g. varying the process, operation and/or machining conditions according to the measured working parameters, thereby improving the productivity of the rotary cutting apparatus. Furthermore, by measuring working parameters related to the first and/or second rotary device itself, it is possible to know in real-time the activity of said rotary device so as to know when maintenance is needed and, particularly, what kind of maintenance is needed. For example, when said rotary cutting device should be replaced, sharpened or ground. Hence, real-time transmission of working parameters will allow more efficient scheduling of the maintenance. Thus, by combining monitored working parameters and performance data, the monitoring unit will enable insights on maintenance and performance data for optimizing productivity of the rotary cutting apparatus.
According to one embodiment, the rotary cutting apparatus as defined hereinabove or hereinafter also comprises an interface transmission unit arranged onto the frame, wherein the monitoring unit is further configured for transmitting data through wireless transmission between the monitoring unit and the interface transmission unit.
According to one embodiment, the monitoring unit is being configured for measuring one working parameter. According to another embodiment, the monitoring unit is being configured for measuring more than one working parameter.
According to another embodiment, the monitoring unit as defined hereinabove or hereinafter is further configured for transmitting power energy through wireless transmission between the monitoring unit and the interface transmission unit. In the present disclosure, the term “power energy” refers to the energy needed to power the monitoring unit without the use of batteries. Thus, there will be no need to change batteries.
Suitably, the monitoring unit is configured for transmitting data together with power energy at a frequency between 1 and 25 kHz (between 1 and 25 thousand cycles per second) and it will enable wireless transmission of both data and power energy while avoiding unsatisfactory losses, which will happen when the wireless transmission is performed at high frequency, i.e. above 1 MHz (1 million cycles per second). When higher frequencies are used magnetic fields used for wireless transmission may be absorbed by the metals used in the equipment. If the magnetic fields are absorbed, they will heat the equipment which will cause problems. Therefore, the correct power energy frequency must be carefully selected.
According to yet another embodiment of the present rotary cutter device as defined hereinabove or hereinafter, each of the first and second pair of bearing housings comprises a stationary bearing housing coupled to the frame and a rotary bearing housing coupled to the first or the second shaft, wherein the monitoring unit comprises a rotary antenna coupled to a rotary bearing housing; and the interface transmission unit comprises a stationary antenna coupled to a stationary bearing housing of a same first or second pair of bearing housings, and wherein the interface transmission unit and the monitoring unit are configured for transmitting data and/or power energy between the stationary and the rotary antennas through wireless transmission.
Suitably, the monitoring unit comprises the at least one sensor for measuring at least one working parameter and outputting data representative of the at least one working parameter; a controller connected to the sensor for receiving data representative of the at least one working parameter, the controller being further configured for processing the data representative of the at least one working parameter and for transmitting the said data representative of the at least one working parameter to the interface transmission unit.
The monitoring unit may comprise at least one sensor selected from the group of a temperature sensor, a vibration sensor, a load sensor and a rotation sensor.
Suitably, the controller may comprise a memory for storing data which has been obtained from the sensor and/or data transmitted by the interface transmission unit and a calculator connected to the memory for calculating a new parameter. Since rotary tools can be assembled and disassembled in the rotary cutting apparatus several times, a memory which is able to store data obtained from the sensor or data transmitted by the interface transmission unit will allow the recovery and/also the surveillance of the operational history of the rotary cutting device at any time.
According to one embodiment, the at least one working parameter is selected from at least one of: a temperature at an external surface of the first and/or the second rotary devices, a temperature difference between the first and/or the second rotary devices, a vibration level of the first and/or the second rotary devices, a slippage between the first and the second rotary devices, the number of cuts performed by the first and/or the second rotary device(s) and the number of revolutions of the first and/or the second rotary device(s).
Suitably, the rotary cutting apparatus further comprises a display unit for displaying data transmitted by the monitoring unit.
Furthermore, the above-identified aspect of the present disclosure will also be achieved by a method for transmitting data comprising the following steps: providing a rotary cutting apparatus as defined hereinabove or hereinafter; measuring at least one working parameter with the monitoring unit; processing the data representative of the at least one working parameter; and transmitting the processed data representative of the at least one working parameter from the monitoring unit to an interface transmission unit through wireless transmission.
The method as defined hereinabove or hereinafter may further comprise the step of transmitting power energy from a power energy generator, positioned outside the first and/or the second rotary devices to the monitoring unit through wireless transmission.
Suitably, the steps of measuring at least one working parameter, processing the data representative of the at least one working parameter and transmitting data and/or power energy are performed while the first and/or the second rotary devices is rotated.
According to one embodiment of the method as defined hereinabove or hereinafter, one working parameter is measured. According to another embodiment of the method as defined hereinabove or hereinafter, more than one working parameter is measured.
Further features and advantages of the present disclosure will become apparent from the following detailed description of embodiments, given as non-limiting examples, with reference to the accompanying drawings listed hereunder.
When a piece of web is passed through the rotary anvil 16 and the rotary cutter 14, the cutting edge 20 deforms the web until it is cut. The web may be selected from, for example but not limited to, non-woven material, woven material, plastic films, cellulose, cardboard, paper or metallic sheet. The products and trim obtained from the cutting operation may be separated directly by the effect of pressure, but may also be separated as they are moved in different directions or on different belts after the cutting operation. For instance, the product goes straight and trim goes upwards or downwards.
The rotary cutter 14 is provided with an elongated cutter shaft 15 and a cutter drum 38, the cutter drum 38 being coaxially arranged on the cutter shaft 15 about a rotation axis A. The shaft has an axial extension on each side of the cutter drum 38, where a pair of cutter bearing housings 31 is provided, respectively. The pair of cutter bearing housings 31 is each connected to the frame 12 by means of a fastening element, such as a screw. The cutter shaft 15 is preferably made of steel and is adapted to be connected to a not shown rotatable power source.
The cutter drum 38 is provided with a pair of annular support rings 18 and the cutting edge 20 for cutting articles from a web. The cutter drum 38 may be provided with more than one cutting edge 20, for example the cutter drum 38 may comprise a pair of annular cutter sleeves, each provided with cutting members or cutting edges. The support rings 18 may be separate parts. Alternatively, one of the support rings may be an integrated part of a cutter sleeve and the other support ring may be an integrated part of the other cutter sleeve. The cutting drum 38 may also comprise an intermediate annular sleeve without cutting edges between the annular cutter sleeves, the intermediate sleeve and the cutter sleeve being coaxially arranged in relation to the axis A. Alternatively, the cutter drum 38 may be made of one single piece, forming an integrated annular sleeve, the axial extension of which corresponding to that of the cutter drum 38.
The support rings 18, the annular cutter sleeves and/or the intermediate annular sleeve may be made of steel and/or a cemented carbide and/or a cermet. The rings may be press-fitted, shrink-fitted, screwed or glued onto a portion of the cutter shaft 15 having an enlarged diameter, altogether constituting said cutter drum 38.
The rotary anvil 16 is provided with an elongated anvil shaft 17 and an anvil drum 37, the anvil drum 37 being coaxially arranged on the anvil shaft 17 about a rotation axis B.
The anvil drum 37 comprises a pair of support rings 18 and an annular anvil sleeve coaxial to the axis B. The annular anvil sleeve and the support rings 18 may be made as a single piece, forming an integrated annular sleeve, the axial extension of which corresponding to that of the anvil drum 37 (see also
The support rings may be press-fitted or shrink-fitted or glued onto a portion of the anvil shaft 17 having an enlarged diameter, altogether constituting said anvil drum 37 (see also
The support rings 18 of the anvil drum 37 are adapted to bear against the support rings 18 of the cutter drum 38 for positioning the rotary cutter 14 and the rotary anvil 16 in a cutting relationship during the cutting operation.
The anvil shaft 17 is arranged vertically above the cutter shaft 15 in such a way that the axis B is parallel to and is in the same plane as the axis A. Particularly, when the frame 12 is attached to a basement in a horizontal position, the axis B is parallel to and is in the same vertical plane as the axis A. Alternatively, the basement may be tilted relative to a horizontal or intermediate direction.
A pair of anvil bearing housings 29 is arranged on either sides of the anvil drum 37 and connected to a pair of craddles 23 of a force means 22.
A pair of cylinders 25 is used for pressing the craddles 23 including the pair of anvil bearing housings 29 and thus also the anvil support ring 18 as well as the external surface of the annular anvil sleeve towards and against the support rings 18 and the cutting edge 20 of the cutter drum 38, respectively. The cylinders 25 may be pneumaticly or hydraulicly moved. The cylinders may also be replaced by loading systems actuated by a screw-nut couple.
As shown in
For the sake of clarity, even if both of the rotary cutter 14 and the rotary anvil 16 comprise a monitoring unit 28, only the monitoring unit 28 of the rotary anvil 16 is described below. The monitoring unit 28 of the rotary cutter 14 is structurally and functionally similar to the monitoring unit 28 of the rotary anvil 16 described below. Alternatively, the monitoring unit 28 of the rotary cutter 14 and the rotary anvil 16 may be different. For example, the monitoring unit 28 of the rotary cutter 14 and of the rotary anvil 16 may comprise different types of sensors or the monitoring unit 28 may be differently embedded in the cutter 37 and anvil 38 drums. Alternatively, the rotary cutting apparatus 10 may have only one of the rotary cutter 14 and of the rotary anvil 16 comprising a monitoring unit 28.
As shown in
Furthermore, the controller comprises a memory 34 and a calculator 35. The calculator 35 will enable the controller 32 to calculate a calculated parameter with respect to the working parameter measured by the sensors, such as the temperature difference within the rotary cutter 14 or the rotary anvil 16, or such as a temperature level by comparing a measured temperature to a predetermined temperature threshold.
The memory 34 will enables the storage of data representative of the working parameter outputted by the sensors and data coming from the interface transmission unit 26, such as a predetermined threshold. The data transmission from the sensors or from the interface transmission unit 26 to the memory 34 may be carried out continuously or at regular time intervals, even when a cutting operation is operated.
In order for the at least partially embedded measuring unit of the rotary anvil 16 to measure, process and store data representative of working parameter, the temperature sensors 30, the calculator 35 and the memory 34 may be embedded in the rotary anvil 16. As shown on
Furthermore, for enabling recovery of the data representative of the working parameters processed by the controller 32 and/or stored in the memory 34, the monitoring unit 28 comprises a connector 40 reachable from outside the rotary anvil 16. The connector 40 is configured to be connected in an assembled position of the rotary anvil 16, i.e. a position in which the rotary anvil 16 may be operated for a cutting process. Therefore, data may be recovered while the rotary cutting apparatus is operated so that the interface transmission unit 26 is able to use data representative of the working parameters for controlling the cutting operation and/or to inform a user. Alternatively, data may also be recovered with the connector 40 in a disassembled position of the rotary anvil 16. The connector 40 may also be connected to an interface transmission unit, for example connected to a movable interface transmission unit or a computer, for recovering data representative of the working parameters in order to display or to document the history of the rotary anvil 16 independently from the rotary cutting apparatus 10.
For transmitting data representative of the working parameters on the exterior of the rotary anvil 16, when the rotary anvil 16 is assembled to the rotary cutting apparatus 10, the monitoring unit 28 is configured for transmitting these data through wireless transmission. In this embodiment, the monitoring unit 28 further comprises a rotary antenna 42 connected to the connector 40. The rotary antenna 42 is coupled to the rotary anvil 16 so that when the rotary anvil 16 is rotated, the rotary antenna 42 rotates in the same direction. For transmitting data representative of the working parameters to the interface transmission unit 26, a stationary antenna 44 is provided within the interface transmission unit 26. Both the stationary 44 and rotary 42 antennas consist in wound coils magnetically coupled together to form an induction system, thus ensuring that wireless data are transmitted. For improving the efficiency and quality of the wireless transmission between the stationary 44 and rotary 42 antennas, the stationary 44 and rotary 42 antennas are positioned close to each other, Particularly, the pair anvil bearing housings 29 comprises a rotary bearing housing coupled to the end shaft 36 and a stationary bearing housing coupled to the frame 12. The rotary antenna 42 is coiled and coupled to the rotary bearing housing and the stationary antenna 44 is coiled and coupled to the stationary bearing housing. In this way, when the rotary cutting apparatus is being operated, the rotary antenna 42 rotates together with the rotary anvil 16, whereas the stationary antenna is static with respect to the frame 12.
For ensuring a constant operability of the monitoring unit 28, the stationary 44 and rotary 42 antennas are further configured to transfer power energy though wireless transmission. In this way, the rotary anvil 16 does not need any battery. For transferring both data and power energy, data signal and energy waves are superimposed at a same frequency. For an efficient wireless transmission of both data and power energy, the data signal and the energy waves are transmitted at a frequency between 1 and 25 kHz (between 1 and 25 thousand cycles per second).
For transferring data and energy power from the interface transmission unit 26 to the controller 32, energy and data signals are superimposed and transmitted from the stationary antenna 44 to the rotary antenna 42. The energy and data signals are then separated by a demodulation electronic circuit disposed within the controller 32 to store the energy signal in power capacities and the data signal in the memory 34.
For transferring measured temperatures from the controller 32 to the interface transmission unit 26, load modulation principle is performed. Particularly, the current in the primary circuit of the induction system consisting of the stationary 44 and rotary 42 antennas is varied and then demodulated by an analogic electronic circuit. The data signal is then stored in a memory installed within the interface transmission unit 26.
The rotary anvil 16 may have one or more stationary 44 and rotary 42 antennas. Furthermore, the number of stationary 44 and rotary 42 antennas will depend on whether to dissociate or associate data and energy in same stationary 44 and rotary 42 antennas or to create a possible backup.
The monitoring unit 28 further comprises vibration sensors 46, rotation sensors 48 and load sensors 50.
The vibration sensors 46, such as accelerometers, are placed at different positions, for example on the rotary anvil 16, on the rotary cutter 14 or on the frame. Alternatively, the vibration sensors 46 may be also embedded in the rotary cutter 14 and the rotary anvil 16 and their data may be transmitted in the same way as described for the temperature data from the temperature sensors 30.
The rotation sensors 48 are associated with toothed wheels, one coupled to an end shaft 36 of the rotary anvil 16 and another one coupled to an end shaft 39 of the rotary cutter 14, to be able to determine the rotation speed of the rotary cutter 14 and the rotary anvil 16 and to detect the slippage between the rotary cutter 14 and the rotary anvil 16. The rotation sensors 48 may be of inductive, capacitive, Hall effect or encoder types. Alternatively, the rotation sensors 48 may be also embedded in the rotary cutter 14 and the rotary anvil 16 and their data may be transmitted in the same way as described for the temperature data from the temperature sensors 30.
The load sensor 50 is physically placed within the interface transmission unit 26 and measures the pressure applied on the rotary anvil 16 by the cylinders 22. The load sensors 50 may be load cells or pressure sensors in case of pneumatic or hydraulic loading systems. Alternatively, the load sensors 50 may also be embedded in the rotary cutter 14 and/or the rotary anvil 16 and their data may be transmitted in the same way as described for the temperature data from the temperature sensors 30.
Furthermore, the monitoring unit 28 is also configured to measure time through stationary and embedded clocks in order to track changes in a synchronized way.
The data representative of the working parameters are for example the temperature difference in the rotary cutter 14, the temperature difference, typically the difference between the maximum and minimum temperatures in the rotary anvil 16, the vibration level of the rotary cutter 14, the vibration level of the rotary anvil 16, the slippage between rotary anvil 16 and rotary cutter 14, the rotation speed of the rotary cutter 14, the rotation speed of the rotary anvil 16, the pressure in the cylinders 22, the number of cuts performed by the rotary cutter 14 and/or the number of cuts performed by the rotary anvil 16.
The rotary cutting apparatus 10 further comprises a display unit 52 for displaying the data representative of the measured working parameters or performance records. The display unit 52 comprises a Human Machine Interface (HMI), directly connected to the interface transmission unit 26 for displaying by means of a screen with a High-Definition Multimedia Interface (HDMI) or Video Graphics Array (VGA) port.
An example of the interface displayed by the display unit 52 is shown in
The rotary cutting apparatus 10 may be operated for transmitting data and/or energy power using the following steps: a) measuring a working parameter with one of the sensors installed within the rotary cutting apparatus 10, b) determining data representative of the working parameter according to the measured working parameter, c) transmitting the processed data representative of the working parameter from the monitoring unit 28 to an interface transmission unit through wireless transmission, e.g. at frequency between 1 and 25 kHz. The rotary cutting apparatus 10 may also transmit power energy from a power energy generator fixed with respect to the frame 12 to the monitoring unit 28. The wireless transmission of data and power energy may be performed during the cutting operation.
For enabling maintenance of the rotary cutter 14 and/or the rotary anvil 16, such as re-grinding and re-sharpening, the rotary anvil 16 and the rotary cutter 14 may be provided with tight seals and protections so the maintenance may be carried out in the same way as for ordinary cutting apparatus.
Even though the present disclosure has been described with precise embodiments above, many variations are possible within the scope of the disclosure.
For instance, the monitoring unit 28 may comprise deformation gauges for measuring the deformation of the rotary cutter 14 and/or the rotary anvil 16, for example the deformation of the cutting edge 20.
Alternatively to the HMI, the interface may use standard or developed communications such as CANopen, Process Field Bus (Profibus) or a specific software.
Furthermore, the interface transmission unit 26 may also comprise alarms to signal abnormal data evolution and a possible need for maintenance and download ports, such as a Universal Serial Bus (USB) port, for directly downloading the data representative of the working parameters stored either in the memory 34 of the monitoring unit 28 and/or in a stationary memory of the interface transmission unit 26.
In one of the embodiment described above, both the rotary cutter 14 and the rotary anvil 16 comprise a monitoring unit 28 so as to transmit data and/or power energy from and to the interface transmission unit 26. Alternatively, the rotary cutting apparatus 10 may have only one of the rotary cutter 14 and the rotary anvil 16 comprising a monitoring unit 28.
| Number | Date | Country | Kind |
|---|---|---|---|
| 15306573 | Oct 2015 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2016/073562 | 10/3/2016 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2017/060196 | 4/13/2017 | WO | A |
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| 20180354149 A1 | Dec 2018 | US |
