Patent Application
20230391572
The present invention relates to an unwinder for unwinding reels. The present invention also relates to a plant, at least partly automatic, comprising such an unwinder and a process for unwinding reels.
The present invention is usefully employed for unwinding reels in the field of converting strip-shaped material, such as paper, to feed the strip-shaped material to subsequent processing and converting stations for the production of the finished product.
In particular, the present invention is applied for unwinding reels of paper of the so-called “tissue” type in the production process of articles such as toilet paper, kitchen paper, napkins and the like.
It is currently known to produce the aforesaid articles from large diameter reels, generally varying between 1.5 metres and 3 metres, wherein one or more plies of paper are wound. At an early stage of the process, these reels are unwound in special unwinders in order to be submitted to processes for obtaining semi-finished products such as rolls of paper known as “logs”. Then, from these semi-finished products, through further processing and transformation steps, such as printing, embossing, laminating and still more, the finished products, such as the paper articles listed above, are obtained.
In particular, it is known that the unwinding process may be performed by unwinding the reel from the centre, rotating it axially, or by unwinding the reel from the outside.
Both axial and peripheral unwinders are known for these purposes.
Disadvantageously, in known unwinders, performing the reel exchange operation to replace an exhausted reel with a new one is a critical operation. Such a step in fact requires loading the new reel and then joining the ply of the exhausted reel with the ply of the new one, an operation which implies temporarily interrupting or slowing down the line. In fact, in the known unwinders, the unwinding of the new reel can be started after the unwinding of the first exhausted reel has been interrupted because it is necessary to place the new reel in the unwinder and to join the plies for the exchange of the two reels.
In the case of peripheral-type unwinders, which use belt systems to unwind the reel, the joining operation is even more critical due to the complexity resulting from the belt system.
Some unwinders of this type are for example disclosed in U.S. Ser. No. 11/254,534 B2, US 2006175457 A1 and WO 2013076011.
The task underlying the present invention is to make available an unwinder that allows to improve and optimise the quality of the unwinding process.
It is in particular the object of the present invention to speed up the exchange between an exhausted reel and a new reel and to ensure continuity of the process.
The above-mentioned task, as well as the objects mentioned and others which will better appear later, are achieved by an unwinder as recited in claim 1, by a plant, at least partly automatic, as recited in claim 9, and by a process for unwinding reels as recited in claim 13.
Other features are provided in the dependent claims.
Further characteristics and advantages will become clearer from the description of preferred but not exclusive embodiments of an unwinder shown only by way of a non-limiting example with the aid of the accompanying drawings, in which:
With reference to
The unwinder 1 is used to unwind reels 21, 22 of paper.
The unwinder 1 according to the present invention comprises a supporting structure 3 that is partially closed and defining an internal space suitable for unwinding at least one reel 21, 22.
The unwinder 1 described hereinafter has a substantially symmetrical structure, and is configured to also have two reels 21, 22 loaded at the same time, a first reel 21 of which being unwound, to be exhausted, and a new second reel 22 to be unwound, with a diameter for example of 1.5 metres or 3 metres.
In particular, the supporting structure 3 comprises a first lateral support 31 and a second lateral support 32 spaced from the first support 31.
The supporting structure 3 also comprises a crosspiece 4 interposed above between the first 31 and the second 32 support. In particular, the crosspiece 4 defines with the first support 31 and the second support 32 the partially closed structure.
Note that the unwinder 1 according to the present invention further comprises a first axial unwinding system 5 placed at the first support 31 and configured to axially unwind a first reel 21.
The unwinder 1 further comprises a second axial unwinding system 6 placed at the second support 32 and configured to unwind a second reel 22.
The unwinder 1 is then configured to unwind reels 21, 22 loaded thereon by unwinding them from the centre by means of the unwinding systems 5 and 6. More details on the unwinding systems 5, 6 are provided in the hereinafter description.
The unwinder 1 comprises a joining device 40 placed at the crosspiece 4 and configured to make a joint between a first ply 210 belonging to the first reel 21 and a second ply 220 belonging to the second reel 22 to perform a reel exchange.
In particular, note that the second unwinding system 6 is configured to load the second reel 22 from a loading zone L after the first reel 21 being unwound on the first unwinding system 5 reaches a first predetermined diameter.
For example, the first predetermined diameter is ⅓ of the initial diameter of the reel 21, 22.
Preferably, the second new reel 22 is loaded when the first exhausted reel 21 reaches a further predetermined diameter below the first one.
The joining device 40 is thus configured to make the joint between the first reel 21 and the second reel 22 when the first reel 21 reaches a second predetermined diameter smaller than the first predetermined diameter.
The second predetermined diameter is also smaller than the further predetermined diameter.
For example, the second predetermined diameter is ⅙ of the initial diameter of the reel 21, 22.
The second unwinding system 6 is configured to unwind the second reel 22 after the joint has been made.
In particular, according to the present invention, the first unwinding system 5 is configured to interrupt unwinding the first reel 21 after the second unwinding system 6 has started unwinding the second reel 22.
What is stated in this description for the first reel 21 and for the second reel 22 also applies by reversing the terms, depending on which of the two unwinding systems 5, 6 is engaged in unwinding a reel 21, 22.
The unwinder 1 according to the present invention in fact ensures a continuous unwinding process, and the two unwinding systems 5 and 6 work alternately on respective reels 21, 22.
The unwinder 1 is automated, and comprises a control unit (not shown in the accompanying figures) configured to give certain commands to the various components of the unwinder 1, such as those mentioned above regarding unwinding systems 5, 6 and the joining device 40. More details on the operation of the unwinder 1 are hereinafter reported.
In greater detail, the first unwinding system 5 comprises two first arms 51, 52 coupled together and movably associated with the first lateral support 31.
Similarly, the second unwinding system 6 comprises two second arms 61, 62 coupled together and movably associated with the second lateral support 32.
The first arms 51, 52 are configured to move together, just as the second arms 61, 62 are configured to move together.
Each pair of arms 51, 52, 61, 62 is configured to lift a reel 21, 22 placed in the loading zone L.
Preferably, each pair of arms 51, 52, 61, 62 is configured to load the second new reel 22 when the first exhausted reel 21 reaches a further predetermined diameter below the first one.
In particular, the first arms 51, 52 and the second arms 61, 62 are configured to move either along a vertical direction Y, or along a horizontal direction X, either moving closer to or away from each other, to grasp and lift the reel 21, 22.
Each pair of arms 51, 52, 61, 62 is also configured to rotate a reel 21, 22 to unwind it axially. Each pair of arms 51, 52, 61, 62 is then configured to engage with a core 2 of a reel 21, 22 and to rotate it from the centre.
Preferably, the first support 31 comprises a first upright 50 for each first arm 51, 52. In other words, the first support 31 comprises two first uprights 50.
Each first upright 50 extends in the vertical direction Y.
Each first arm 51, 52 is, in particular, slidably constrained to the respective first upright 50.
The first support 31 further preferably comprises first sliding guides 53, 54 extending in a transverse direction X. Each first upright 50 is slidably constrained at respective ends to such first sliding guides 53, 54.
Similarly, the second support 32 preferably comprises a second upright 60 for each second arm 61, 62. In other words, the second support 32 comprises two second uprights 60.
Each second upright 60 extends in the vertical direction Y.
Each second arm 61, 62 is slidably constrained to the respective second upright 60.
Each first arm 51, 52 and each second arm 61, 62 is thus vertically movable by sliding on a respective upright 50, 60.
Still preferably, the second support 32 comprises second sliding guides 63, 64 extending in a transverse direction X. Each second upright 60 is slidably constrained at respective ends to such second sliding guides 63, 64. Each first arm 51, 52 and each second arm 61, 62 is therefore horizontally movable by sliding the respective upright 50, 60 to which it is constrained on the sliding guides 53, 54, 63, 64.
Preferably, moreover, each unwinding system 5, 6 comprises a torsion bar 55, 56, 65, 66 for each arm 51, 52, 61, 62.
Each torsion bar 55, 56, 65, 66 is slidably constrained to a respective upright 50, 60.
Accordingly, each first arm 51, 52 and each second arm 61, 62 is vertically movable by sliding the respective torsion bar 55, 56, 65, 66 on the respective upright 50, 60.
Each arm 51, 52, 61, 62 is also hinged to the respective torsion bar 55, 56, 65, 66. Accordingly, each arm 51, 52, 61, 62 is configured to rotate relative to the torsion bar 55, 56, 65, 66.
The arms 51, 52, 61, 62, torsion bars 55, 56, 65, 66 and uprights 50, 60 are in signal communication with the control unit, which controls movements thereof.
In greater detail, the first arms 51, 52 and the second arms 61, 62 are configured to switch from a first configuration in which they are transverse to the respective upright 50, 60 to a second configuration in which they are close to the respective upright 50, 60.
In particular, when in the first configuration, the first arms 51, 52 and the second arms 61, 62 are arranged so as to form an angle of between 80° and 100°, preferably of about 90° with the respective upright 50, Such a configuration can be seen in
The first arms 51, 52 and second arms 61, 62 are configured to switch between the first and second configuration by rotating with respect to the respective torsion bar 55, 56, 65, 66.
In
The arms 51, 52, 61, 62 are in the first configuration when the respective reel 21, 22 being held has a diameter greater than the first diameter.
The arms 51, 52, 61, 62 are configured to switch to the second configuration when the reel 21, 22 reaches the first diameter.
Preferably, each arm 51, 52, 61, 62 comprises a spindle 8 configured to engage with a core 2 of a reel 21, 22.
Each spindle 8 is configured to rotate to unwind the reel 21, 22. In particular, the spindles 8 of first arms 51, 52, and second arms 61, 62 are configured to rotate with respect to a horizontal direction X.
The spindles 8 of the first pair of arms 51, 52 are configured to rotate jointly and, similarly, the spindles 8 of the second pair of arms 61, 62 are configured to rotate jointly.
Still preferably, each arm 51, 52, 61, 62 comprises a first motor 511, 521, 611, 621 configured to set the respective spindle 8 in motion.
Accordingly, the first motors 511 and 521 of the first arms 51, 52 and the first motors 611 and 621 of the second arms 61, 62 are preferably coupled together so that the control unit operates them jointly in order to rotate the spindles 8 and consequently the reel 21, 22.
In particular, as the unwinding is of the axial type, the control unit is configured to progressively increase the speed of rotation of the spindles 8 of the pair of arms 51, 52, 61, 62 that are unwinding a reel 21, 22 as the diameter of the reel 21, 22 decreases.
Preferably, the spindles 8 are of the expandable type. In the case of expandable-type spindles 8, preferably each first arm 51, 52 and each second arm 61, 62 further comprises a second motor 851, 852, 861, 862 configured to open and close the spindle 8. Accordingly, each first arm 51, 52 and each second arm 61, 62 comprises a jack 853, 854, 863, 864 associated with the spindle 8 of the respective arm 51, 52, 61, 62, and configured to make the spindle 8 expandable and closable. Each second motor 851, 852, 861, 862 is then configured to work with the respective jack 853, 854, 863, 864 to open and close the spindle 8. Preferably, the spindle 8 has an opening/closing range between 150 and 450 mm, to interact with cores 2 of reels 21, 22 having different dimensions.
The spindles 8 are configured to be fitted inside the core 2 of a reel 21, 22 of at least a predetermined minimum length to ensure sealing. Such a minimum length is, for example, between 200 and 800 mm. For example, each spindle 8 of a pair of arms 51, 52, 61, 62 is fitted by a length of 500 mm into the core 2 of a reel 21, 22 having a diameter of 3 metres and a length of 2850 mm.
According to a preferred embodiment, shown in
According to this embodiment, the supporting structure 3 also comprises a second support base 34 that extends away from the second support 32 towards the first support 31.
The first base 33 and the second base 34 are spaced apart from each other, thus defining the above-mentioned loading zone L of a reel 21, 22 to be unwound, to be loaded into the unwinder 1 by means of the first arms 51, 52 or by means of the second arms 61, 62.
The first base 33 and second base 34 are in particular configured to accommodate a respective exhausted reel 21, 22.
Preferably, the first base 33 and the second base 34 comprise respective conveyor belts 330, 340. In particular, the conveyor belts 330, 340 are configured to move an exhausted reel 21, 22 placed on the respective base 33, 34 to an unloading zone S. For example, the conveyor belts 330, 340 are configured to move, and then let the reel 21, 22 drop in the unloading zone S.
The unloading zone S, in this sense, is defined as adjacent to the unwinder 1, both at the first support 31 and at the second support 32. In case a lateral support 31, 32, is present, i.e. a pair of arms 51, 52, 61, 62 suitable for unwinding a reel 21, 22, also an unloading zone S of an exhausted reel 21, 22 is present.
In the above-mentioned unwinder 1, as two bases 33, 34 are present, there are two separate unloading zones S.
The operation of the unwinder 1 is described hereinafter.
The first reel 21 is unwound axially by means of the first unwinding system 5, as shown in
During the unwinding step, when the first reel 21 reaches a diameter smaller than a predetermined first diameter, the first arms 51, 52, switch to the second configuration, rotating of about 90 degrees clockwise.
In
Still during the step of unwinding the first reel 21, a second reel 22 is brought, either manually or automatically, into the loading zone L. This step is shown in
The second arms 61, 62, opposite those used for unwinding the first reel 21, rotate switching from the second configuration to the first configuration in order to pick up the second reel 22, as shown in
At that step, the second arms 61, 62 have a maximum opening dimension, which is greater than the length of the core 2 of the second reel 22, in order to be able to grip the reel 22, as shown in
The second arms 61, 62 move vertically from above downwards and then upwards again to centre the spindle 8 on the hole of the core 2 of the reel 22.
Once the hole of the core 2 is centred, the arms 61, 62 move towards each other to have each spindle 8 enter the core 2 of the reel 22, as shown in
Subsequently, the spindles 8 expand to grip the core 2 internally and allow unwinding the reel 22 by means of the first motors 611, 621 of the second pair of arms 61, 62.
When the exchange and joint have been made, the step of unwinding the second new reel 22 begins, as shown in
The spindles 8 of the first arms 51, 52 close and only then do the first arms 51, 52 open, causing the spindles 8 to exit the core 2 of the first reel 21 to let the exhausted reel 21 drop onto the respective conveyor belt 330.
Referring to
A plant 100, at least partly automatic, also forms a part of the present invention. Such a plant 100 is suitable for the semi-automatic unwinding of reels 21, 22 of paper by means of the unwinder 1 described above.
Referring to
Such a reel 21, 22 may be brought to the preparation station P by an automatic reel-conveying machine 9, schematically shown in
The preparation station P also includes a stand 91 on which the reel 21, 22 is placed once it has been prepared for unwinding.
The plant 100 also comprises an unwinding station W, comprising at least an unwinder 1 as described above and a loading zone L.
The system 100 may comprise, in the unwinding station W, multiple unwinders 1, wherein the unwinders 1 are placed adjacent to each other, with the lateral supports 31, 32 facing each other and/or with the lateral supports 31, 32 aligned with each other.
The unwinding station W further comprises at least one unloading zone S.
The system 100 depicted comprises, for example, an unloading zone S for each support base 33, 34 of each unwinder 1.
It should be noted that, according to the present invention, the plant 100 comprises a transport element 10 configured to accommodate the reel 21, 22 and to transport the reel 21, 22.
Preferably, the transport element 10 is an automatic shuttle.
In this case, the plant 100 comprises a central control unit (not shown) in signal communication with the control unit of the unwinder 1 and the automatic shuttle, in order to drive transport thereof.
According to one embodiment, the shuttle, shown in
Preferably the shuttle comprises two support fins 131 extending away from the tray 13 in an oblique direction and configured to embrace the reel 21, 22 in order to prevent it from rolling.
The transport element 10 has such dimensions to accommodate a new reel 21, 22. The carriage 11, for example, has dimensions of 2000 mm×2000 mm for 1.5 metre or 3 metre reels. The length of the tray 13 is preferably similar or equal to the length of the core 2 of the reel 21, 22.
Still preferably, the transport element 100 is configured to move on a pre-tracked path G. This pre-tracked path G connects the various stations mentioned above and others described hereinafter.
In particular, the transport element 10 is configured to transport the reel 21, 22 from the preparation station P to the unwinding station W. Specifically, the transport element 10 is configured to pick up the reel 22 from the stand 91 when the first reel 21 being unwound reaches the first predetermined diameter, to bring it to the loading zone L.
At the same time, the respective first arms 51, 52 in which the first reel 21 is being unwound switch to the second configuration to leave room for positioning the new reel 22 in the loading zone L.
Once the reel 21, 22 has been brought into the loading zone L, the transport element 10 is configured to stay in the loading zone L until one of the pairs of arms 51, 52, 61, 62 lifts the reel 21, 22.
In particular, one of the pairs of arms 51, 52, 61, 62 lifts the new reel 22, already positioned in the loading zone after the first reel 21 has reached a first predetermined diameter, at the moment when the first exhausted reel 21 reaches a further predetermined diameter below the first predetermined diameter.
Subsequently, when the first exhausted reel 21 reaches a second predetermined diameter that is smaller than the further predetermined diameter, a joint is made between the first reel 21 and the second reel 22 in order to carry out the reel exchange before the first reel 21 is totally exhausted.
In the plant 100, the transport element 10 is also configured to move from the loading zone L to an unloading zone S close to the first base 33 and/or the second base 34 after one of the pairs of arms 51, 52, 61, 62 has lifted the reel 21, 22 from the transport element 10.
The unwinder 1 is preferably configured to let the exhausted reel 21, 22 drop onto the transport element 10 when the transport element 10 is in the unloading zone S. Thereby, the exhausted reel 21, 22 is dropped onto the transport element 10, which can then move it away from the unwinder 1.
Preferably, the plant 100 also comprises a deposit station Z suitable for accommodating exhausted reels 21, 22.
Therefore, the transport element 10 is also configured to transport an exhausted reel 21, 22 from the unloading zone S to the deposit station Z.
At the deposit station Z, the exhausted reels 21, 22 are cleaned from residual paper, e.g. by an operator, so that the core 2 can be reused.
Optionally, such a step is automated.
Optionally, the plant 100 also includes an exchange station K for incomplete reels.
In this case, the transport element 10 is configured to move also to the exchange station K.
A process for unwinding reels 21, 22 by means of an unwinder 1 as described above also forms a part of the present invention.
In particular, the process comprises an initial step of preparing a first reel 21 for unwinding.
Such a step is preferably performed manually by an operator who removes the protective film surrounding the reel 21, 22.
The process comprises a step of transporting the first reel 21 to the loading zone L.
The process comprises a further step of loading a first reel 21 into the unwinder 1 by means of the first arms 51, 52.
Once the first reel 21 has been loaded, the process then comprises a subsequent step of starting the unwinding of the first reel 21.
According to the process according to the present invention, when the first reel 21 reaches a first predetermined diameter, a step of transporting a second reel 22 to the loading zone L is comprised.
The process comprises a step of loading the second reel 22 into the unwinder 1 by means of the second arms 61, 62 after the second reel 22 has been transported to the loading zone L. In particular, such a step is carried out when the first reel 21 reaches a further predetermined diameter below the first predetermined diameter.
When the first reel 21 reaches a second predetermined diameter smaller than said first predetermined diameter, the process provides joining a first ply 210 belonging to the first reel 21 and a second ply 220 belonging to the second reel 22 to perform a reel exchange between the first reel 21 and the second reel 22. The second predetermined diameter is also smaller than the further predetermined diameter.
Such a joining step is performed automatically.
The process then comprises successive steps of starting the unwinding of the second reel 22 and interrupting the unwinding of the first reel 21.
In particular, the step of interrupting the unwinding of the first reel 21 is carried out after the step of starting the unwinding of the second reel 22.
It is thereby possible to avoid downtime and optimise the process of unwinding reels by speeding up the reel exhange passage, placing a new second reel 22 near the unwinder 1, and loading it, even making the joint, before a first reel 21 is exhausted. Thereby, the unwinder 1, being automated, ensures a continuous unwinding process of the reels.
The unwinder, plant and process for unwinding reels thus conceived are susceptible to numerous modifications and variations, all falling within the scope of the inventive concept; moreover, all the details may be replaced by technically equivalent elements. In practice, the materials used, as long as they are compatible with the specific use, as well as the dimensions and the contingent shapes, may be any according to the technical requirements.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102022000011762 | Jun 2022 | IT | national |
