U.S. patent application number 13/635117 was filed with the patent office on 2013-01-10 for machine and method for winding reels of web material.
Invention is credited to Daniele Langella.
Application Number | 20130008995 13/635117 |
Document ID | / |
Family ID | 42979811 |
Filed Date | 2013-01-10 |
United States Patent
Application |
20130008995 |
Kind Code |
A1 |
Langella; Daniele |
January 10, 2013 |
MACHINE AND METHOD FOR WINDING REELS OF WEB MATERIAL
Abstract
The rewinding machine comprises: a first winding member (3) and
a second winding member (9) defining a winding cradle (19); a
winding rod inserter (25) for introducing a winding rod (A1; A2) in
the winding cradle (19) to wind a reel (B1) of web material (N) on
said winding rod. The inserter (25) is arranged and designed for
introducing the winding rod (A2) against the first winding member
(3) towards the winding cradle (19) and the second winding member
(5) is designed and arranged to allow a previously formed reel (B1)
to be unloaded from the winding cradle (19).
Inventors: |
Langella; Daniele; (Lucca,
IT) |
Family ID: |
42979811 |
Appl. No.: |
13/635117 |
Filed: |
March 10, 2011 |
PCT Filed: |
March 10, 2011 |
PCT NO: |
PCT/IT2011/000065 |
371 Date: |
September 14, 2012 |
Current U.S.
Class: |
242/533.2 |
Current CPC
Class: |
B65H 19/2246 20130101;
B65H 2301/414866 20130101; B65H 2301/41447 20130101 |
Class at
Publication: |
242/533.2 |
International
Class: |
B65H 19/22 20060101
B65H019/22 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 16, 2010 |
IT |
FI2010A000041 |
Claims
1. A rewinding machine comprising: at least a first winding member
and a second winding member defining a winding cradle; a winding
rod inserter for introducing a winding rod in said winding cradle
to wind a reel of web material on said winding rod, said winding
rod inserter being arranged and designed so as to introduce said
winding rod against the first winding member towards said winding
cradle, said second winding member having a variable configuration
and being designed and arranged to allow a reel, formed around a
first winding rod, to be unloaded from said winding cradle, through
a change in the configuration of said second winding member, said
winding rod inserter, said first winding member and said second
winding member being controlled so that said first reel of web
material wound around said first winding rod is unloaded from said
winding cradle through a change in the configuration of the second
winding member, while said winding rod inserter moves a second
winding rod towards the first winding member and said first winding
member brings said second winding rod into rotation, whereby
winding a second reel is started, said first winding member
comprising a first winding roller and said second winding member
comprising a plurality of further winding rollers controlled to be
in contact with the reel of web material, one or more of said
further winding rollers being movable such that said first reel
moves away from said first winding member towards an unloading area
maintaining said first reel in rotation and continuing to wind said
web material on said first reel while said first reel is
transferred toward said unloading area and said winding rod
inserter moves said second winding rod towards said first winding
member.
2. A rewinding machine as claimed in claim 1, wherein said winding
rod inserter is controlled to maintain said second winding rod
resting on said first winding member for a first phase of winding
of the web material around said second winding rod, before said
second winding rod is brought to rest on the second winding
member.
3-11. (canceled)
12. A rewinding machine as claimed in claim 1, wherein said second
winding member comprises a second winding roller, a third winding
roller and a fourth winding roller.
13. A rewinding machine as claimed in claim 12, wherein said first
winding roller and said second winding roller define a rest and
rotation nip for the reel in winding phase.
14. A rewinding machine as claimed in claim 12, wherein an
auxiliary winding roller is arranged between said first winding
roller of the first winding member and said second winding roller
of said second winding member.
15. A rewinding machine as claimed in claim 12, wherein said third
winding roller and said fourth winding roller are arranged and
controlled to move the first reel away from the first winding
member and to transfer the first reel towards said unloading
area.
16. A rewinding machine as claimed in claim 15, wherein said third
winding roller and said fourth winding roller are arranged and
controlled to transfer said first reel maintaining said first reel
in contact with the second winding roller.
17. A machine as claimed in claim 12, wherein said second winding
roller, said third winding roller and said fourth winding roller
are controlled to decelerate and subsequently to stop the rotation
of said first reel, said winding rod inserter bringing said second
winding rod against said first winding roller starting the winding
of a second reel around said second winding rod in contact with
said first winding roller.
18. A rewinding machine as claimed in claim 1, further comprising
guiding surfaces associated with said first winding member, against
which the winding rod inserter rests said winding rods.
19. A rewinding machine as claimed in claim 18, wherein said
guiding surfaces are arranged and designed to define a trajectory
for introducing the winding rods, extending around the first
winding member and moving gradually towards said first winding
member from a non-contact position to a contact position of the
winding rod with the web material driven around said first winding
member.
20. A rewinding machine as claimed in claim 19, wherein said
winding rod inserter comprises an engaging system for the winding
rods close to ends of said winding rods, said engaging system
maintaining the winding rods resting against said guiding
surfaces.
21. A rewinding machine as claimed in claim 18, wherein said
guiding surfaces are movable to impart an angular acceleration to
said winding rods.
22. A rewinding machine as claimed claim 1, wherein said winding
rod inserter, said first winding member and said second winding
member are arranged and controlled so that while said first reel is
unloaded from the winding cradle, the second winding rod is brought
to cooperate temporarily with only the first winding member,
through which the winding of the web material around said new
winding rod starts before said new winding rod starts to co-act
with the second winding member, while said second winding member
unloads said reel.
23. A rewinding machine as claimed in claim 1, wherein said first
winding member and said second winding member are controlled so as
to decelerate said first reel at the end of winding of the first
reel and before an introduction of the second winding rod.
24. A rewinding machine as claimed in claim 1, wherein said winding
rod inserter is associated with means for angular acceleration of
the second winding rod to drive said second winding rod into
rotation.
25. A method for producing reels of web material around winding
rods, the method comprising the steps of: winding a first reel of
web material around a first winding rod in a winding cradle
comprising a first winding member and a second winding member; at
an end of winding of said first reel of web material, unloading
said first reel of web material from said winding cradle, inserting
a second winding rod in said winding cradle, and winding a second
reel of web material around said second winding rod, said first
reel of web material being unloaded from said winding cradle
through a change in an arrangement of the second winding member,
while said second winding rod is driven into rotation by moving
said second winding rod towards the first winding member; arranging
a first winding roller and a second winding roller to define a seat
for supporting and rotating one of the first reel and the second
reel during winding; arranging a third winding roller and a fourth
winding roller with movable axes; winding said first reel in said
support and rotation seat in contact with at least said first
winding roller and said second winding roller; continuing winding
said first reel of web material between said first winding roller,
said second winding roller, said third winding roller, and said
fourth winding roller; moving said first reel of web material away
from said first winding roller and maintaining said first reel of
web material in rotation by means of at least said second winding
roller and said fourth winding roller and reducing the rotation
speed of the reel from a winding speed to a replacement speed, said
replacement speed being less than the winding speed; bringing said
second winding rod against said first winding roller and engaging
the web material between said first winding roller and said second
winding rod; severing the web material between the second winding
rod and the first reel; starting winding said second reel around
said second winding rod; moving the first reel of web material away
from the second winding roller; bringing the second reel in contact
with said second winding roller.
26-28. (canceled)
29. A method as claimed in claim 25, further comprising the step
of: moving said first reel of web material away from said first
winding roller maintaining said first reel of web material into
rotation by means of said second winding roller, said third winding
roller, and said fourth winding roller.
30. A method as claimed in claim 25, wherein, while the first reel
is moved away from the first winding roller, the third winding
roller is moved away from the first reel and said first reel is
transferred towards the unloading area through the fourth winding
roller.
31. A method as claimed in claim 25, further comprising the steps
of: reducing the rotation speed of the first reel by slowing down
the second winding roller, the third winding roller and the fourth
winding roller; moving the third winding roller and the fourth
winding roller away from the first reel; accelerating said third
winding roller and said fourth winding roller to the winding speed
and engaging said second winding rod and the second reel being
formed there around with said third winding roller and said fourth
winding roller.
32. A method as claimed in claim 25, further comprising the steps
of: forming a loop of web material between said first reel and said
second winding rod by slowing down the rotation speed of said first
reel; and holding said loop of web material between said second
winding rod and said first winding member and causing the severing
of the web material between said first reel and said second winding
rod.
33. (canceled)
34. A rewinding machine as claimed in claim 2, wherein said second
winding member comprises a second winding roller, a third winding
roller and a fourth winding roller.
35. A rewinding machine as claimed in claim 34, wherein said first
winding roller and said second winding roller define a rest and
rotation nip for one of the first reel and the second reel in
winding phase.
36. A rewinding machine as claimed in claim 34, wherein an
auxiliary winding roller is arranged between said first winding
roller of the first winding member and said second winding roller
of said second winding member.
37. A method as claimed in claim 29, wherein, while the first reel
is moved away from the first winding roller, the third winding
roller is moved away from the first reel and said first reel is
transferred towards the unloading area through the fourth winding
roller.
Description
TECHNICAL FIELD
[0001] The present invention relates to winding or rewinding
machines for producing rolls or reels of web material, such as
paper, tissue paper, non-woven fabric and the like. The invention
also relates to improvements to the winding methods for producing
rolls or reels of web material.
STATE OF THE ART
[0002] In the paper converting industry and in other continuous web
material processing industries there is the need for producing
reels or rolls of wound web material constituting intermediate
products for subsequent converting operations. In the paper
converting field, in particular, it is provided for a single or
multiple ply of cellulosic material, for example tissue paper, to
be unwound and wound again on reels. For producing large diameter
reels, designed to be subsequently unwound and rewound in small
diameter logs that, cut orthogonally to their axis, producing
single rolls for final consumption, start-stop rewinding machines
are used, i.e. machines wherein the feed of the web material is
interrupted or substantially slowed down when a reel has been
completed to allow insertion of a new winding rod, around which the
subsequent reel is formed, in the machine.
[0003] These rewinding machines usually have a winding cradle
formed by two winding rollers with substantially parallel axes. A
winding rod or tubular winding core, around which the reel is
formed, is inserted in the nip formed between the two rollers. The
reel is formed above the nip between the rollers with a gradual
increase in diameter. In some cases a third movable winding-roller
is also provided, which is gradually raised as the reel diameter
increases. Once winding has been finished, the feed is interrupted,
the formed reel is unloaded from the winding cradle, the web
material is severed to form a tail of the finished reel and a head
for starting winding around a subsequent rod, the head is anchored
to a new winding rod and this latter is driven into rotation in the
winding cradle to start formation of the subsequent reel.
[0004] DE-A-3207461 schematically discloses a rewinding machine of
this type. WO-A-2007/048872 describes a rewinding machine of the
above mentioned type, wherein the first winding member comprises a
roller and the second winding member comprises a belt or a series
of belts, driven around two guide rollers. No means for unloading
the reels are described.
[0005] U.S. Pat. No. 4,456,190, IT-B-1130631, U.S. Pat. No.
4,635,867, U.S. Pat. No. 4,552,316 and DE-A-3151256 disclose
rewinding machines of the above mentioned type, wherein the reel is
unloaded by a side pusher that pushes the reel laterally to make it
roll outside the winding cradle. A separate insertion means inserts
a new rod or tubular winding core. In these machines the subsequent
winding rod or core is introduced in the winding cradle from the
top, i.e. it is put on the winding rollers.
[0006] U.S. Pat. No. 5,577,684, GB-A-2065081, U.S. Pat. No.
4,974,786, U.S. Pat. No. 4,516,735, U.S. Pat. No. 3,918,654 and
U.S. Pat. No. 5,911,384 describe rewinding machines of the above
mentioned type, wherein a single pivoting member, arranged on a
side of the winding cradle, not only unloads the formed reel to
move it away from the winding cradle, but also inserts a new
winding rod or core in said cradle from the top.
[0007] U.S. Pat. No. 3,841,578 discloses a rewinding machine with a
pair of winding rollers defining a winding cradle. The machine
further comprises a side roller, which pushes the reel, once it has
been completed, to move it away from the winding cradle. Once the
reel has been at least partially ejected from the winding cradle,
the winding rollers are moved away from each other. The reciprocal
movement away of the two winding rollers allows the insertion from
the bottom of a new winding rod. This winding rod passes across the
nip defined between the two rollers, which at are then moved
towards each other again to support the new winding rod or core and
to start winding of a new reel around the new core inserted from
the bottom upward.
[0008] U.S. Pat. No. 4,842,209 and US-A-2004/0159737 disclose
rewinding machines of the above mentioned type, wherein the new
winding core is inserted from the bottom after having moved the
winding rollers, defining the winding cradle, away from each other.
In these machines one of the two winding rollers also provides for
a series of belts driven around the same roller and around a third
guide roller. The reel is wound by maintaining it always in contact
with the first and the second winding roller. Once winding has been
finished, the reel is moved away from the winding cradle and
brought in contact with the belts entrained around the second
winding roller. The belts act as a transfer element for
transferring the reel from the winding cradle towards an unloading
area. When the formed reel is on the belts, the winding rollers can
be moved away from each other in order to insert, through the nip
defined between them, the new winding core, which is lifted from
the bottom upward. Once the end position of the winding rod or core
has been achieved, the winding rollers are moved towards each other
again to allow starting winding of the new reel.
[0009] One of the critical aspects of these machines is the
continuity of the winding process. The high dimension of the formed
reels and the operation complexity of unloading the reels and
inserting new winding rods often require for the web material feed
to be completely stopped once a reel has been completely wound, in
order to allow: the insertion of a new winding rod or core, the
severing of the web material, the anchoring of the head thereof on
a new winding rod or core, the start of the winding of the new
reel.
[0010] These start and stop cycles entail production losses as well
as stresses in the production line.
[0011] In winders for producing very large diameter reels, for
example winders arranged downstream of the continuous paper
machines, winding means are provided with a single winding roller
and a pair of guides. The reel is formed around a winding rod,
which is pressed against the winding roller and is supported on the
horizontal rectilinear guides extending from the winding roller
towards a reel unloading area. Usually a winding rod inserter is
provided in these winders, which brings the winding rod against a
single winding roller to wind a reel. The whole winding cycle is
performed through this single winding roller, against which the
reel is pushed by a pair of slides engaging the ends of the winding
rod and gradually moving away from the winding roller as the reel
diameter increases. Examples of this kind of machines are described
in WO-A-2009/049867; EP-A-0943569; DE-A-19944295; EP-A-1571109;
EP-A-1245515; U.S. Pat. No. 6,145,778; EP-A-1071627; GB-A-2188619;
U.S. Pat. No. 6,047,916.
[0012] U.S. Pat. No. 2,989,262 discloses a machine comprising a
first winding roller and a second winding roller, which define a
winding cradle. The machine also comprises a winding rod inserter
for introducing a winding rod in the winding cradle at the start of
each cycle. A reel of web material is wound around the winding rod.
The inserter is arranged and designed so as to introduce the
winding rods against the first winding roller towards the winding
cradle. Once a reel has been completely wound, the web material is
severed, the machine is stopped, the reel is unloaded from the
winding cradle and subsequently the new winding rod is inserted to
start a new winding cycle of a new reel.
SUMMARY OF THE INVENTION
[0013] The object of the present invention is to provide a new
rewinding machine and a new winding method that overcome, wholly or
partially, one or more drawbacks of the known machines.
[0014] According to one aspect, the invention relates to a
rewinding machine comprising: a first winding member and a second
winding member defining a winding cradle; a winding rod inserter
for introducing a winding rod in the winding cradle and for winding
a reel of web material on said winding rod, as well as a system of
roller(s) suitable to control the reel diameter increase. The
inserter is advantageously arranged and designed so as to introduce
the winding rod against the first winding member towards the
winding cradle; and the second winding member is designed and
arranged to allow a previously formed reel to be stopped and
unloaded from said winding cradle. In this way, while a formed reel
is unloaded from the winding cradle, a new winding rod is inserted
towards the winding cradle and starts to wind around itself a
second reel of web material as a result of the contact with only
one of the two winding members. The two winding members can be thus
controlled independently of each other, the first one to start
winding a new reel and the second one to stop and unload a reel
that has been completed during the previous winding cycle. The
cycle of unloading the reel and starting winding a new reel is
therefore faster and can be performed without stopping the machine.
The feed speed of the web material is preferably reduced during the
reel unloading, but it is not stopped. The speed reduction is
substantially lower than the reduction necessary in other known
rewinding machines, with consequent advantages from a productivity
viewpoint too.
[0015] In particular, the object of the present invention is a
rewinding machine comprising: [0016] at least a first winding
member and a second winding member defining a winding cradle;
[0017] a winding rod inserter for introducing a winding rod in the
winding cradle to wind a reel of web material on said winding rod,
said inserter being arranged and designed so as to introduce said
winding rod against the first winding member towards said winding
cradle; characterized in that: the second winding member has a
variable configuration and, if necessary, a variable speed
according to a law different from that of the speed of the first
winding member, and is designed and arranged to allow a reel,
formed around a first winding rod, to be unloaded from said winding
cradle, through a change in the configuration of said second
winding member; and that said inserter, said first winding member
and said second winding member are controlled such that said reel
of web material wound around said first winding rod is unloaded
from said winding cradle through a change in the configuration and,
if necessary, in the speed of the second winding member, whilst
said inserter moves a second winding rod, that can be previously
brought to the line speed, towards the first winding member and
said first winding member brings said second winding rod into
rotation.
[0018] In advantageous embodiments the first winding member
comprises a first winding roller. According to preferred
embodiments of the present invention, the second winding member can
comprise a flexible element, for example a belt or a series of
belts, entrained around a second winding roller and a guide
element, for instance a roller or a series of pulleys.
[0019] In some embodiments the first and the second winding roller
are arranged with parallel, preferably horizontal axes. In
preferred embodiments, the distance between the centers of the
rollers is fixed, i.e. not variable during the normal operating
cycle. The winding rods are preferably moved towards the winding
cradle, defined by the two winding rollers, from the same side on
which the reel is formed, i.e. without passing through the nip
between the two winding rollers. The web material is preferably fed
around one of the winding rollers, again without passing through
the nip between the two winding rollers.
[0020] In some preferred embodiments of the present invention the
first winding roller and the second winding roller are motorized
through distinct motors advantageously controlled by a control unit
to change the rotation speeds of the two winding rollers
differently one from the other during the winding cycle.
[0021] To unload the formed reel from the winding cradle, the
second winding member has preferably a variable arrangement in
shape and/or position and/or speed. In some preferred embodiments
of the invention, when the second winding member comprises a
winding roller and a flexible element or member entrained around
the winding roller and around another guide member, the arrangement
can be such that the flexible member or element tilts to unload the
reel. For example it can be lowered to transfer the formed reel
from the winding cradle towards an unloading station. Tilting can
be performed around the axis of rotation of the second winding
roller.
[0022] In some embodiments, with the first winding roller guiding
surfaces can be associated, against which the inserter rests said
winding rods.
[0023] In some embodiments the guides are advantageously arranged
and designed to define a winding rod-introduction trajectory,
extending around the first winding member and moving gradually
towards said winding member from a non-contact position to a
contact position of the winding rod with the web material driven
around said winding member. The guides can be driven to put the new
rod into rotation, so as to have a substantially synchronous speed
with the web material before the contact thereto. In other
embodiments the inserter can comprise one or two jaws or other
engaging members for engaging the winding rods, controlled so as to
impart to the winding rod a trajectory of gradual movement towards
the first winding member and to control the rod in the first
winding phase of the web material. The jaws or other engaging
members and/or the winding rods can be designed so as to allow the
winding rod to rotate around its own axis when the rod is still
engaged with the inserter but into contact with the first winding
member, which imparts a winding rotational movement to the winding
rod.
[0024] In preferred embodiments of the invention, the first winding
member, the second winding member and the inserter are controlled
such that, while a completed reel is unloaded from the winding
cradle by a movement of the second winding member, said inserter
brings a winding rod to co-act with the first winding member to
engage and start winding the web material around said winding rod.
The inserter is advantageously controlled to maintain said winding
rod resting on said first winding member for a first winding phase
of the web material around said winding rod, before said winding
rod starts to rest on the second winding member.
[0025] The invention also relates to a rewinding machine comprising
at least a first winding member comprising, or formed by, a first
winding roller and a second winding roller defining a winding
cradle; and, in addition, a winding rod inserter for introducing a
winding rod towards the winding cradle to wind a reel of web
material around the winding rod. The inserter is arranged and
designed so as to introduce the winding rod against the first
winding roller towards the winding cradle; and the second winding
member comprises a second winding roller, a guide element and a
flexible element entrained around the second winding roller and
around the guide element. The second winding member designed in
this way can change in configuration, i.e. in the reciprocal
position of the parts composing it, to unload a previously formed
reel from the winding cradle. The first and the second winding
roller advantageously form the winding cradle wherein the main part
of the winding cycle occurs.
[0026] In some embodiments the rewinding machine comprises a first
winding member, comprising a first winding roller, and a second
winding member, comprising a plurality of further winding rollers,
preferably with variable center-to-center distances. In some
embodiments the winding rollers forming the second winding member
define a cluster of winding rollers. The cluster of winding rollers
forming the second winding member can be advantageously controlled
and arranged so as to be in contact with a reel of web material. In
some embodiments, at least some of said winding rollers forming
said second winding member are movable so as to move a completed
reel away from the first winding member and towards an unloading
area, for instance towards an unloading station, which can comprise
a pivoting cradle receiving the reel and transferring it towards a
pick-up area. According to some embodiments, the winding rollers
forming the second winding member are advantageously controlled so
as to maintain in rotation the reel being completed and to continue
winding the web material around the reel, while said reel is
transferred towards the unloading area and the inserter moves a new
winding rod towards the first winding member. The first winding
member and the second winding member advantageously comprise
independent motors to rotate a first winding roller, being part of
or constituting the first winding member, and a second roller,
being part of the second winding member, at speeds independent of
each another.
[0027] The speed of the winding members can change from a
steady-state speed, or winding speed, to an exchange speed or
replacement speed, at which the reel being completed moves away
from the first winding member towards an exchange area. The second
winding member can be controlled so as further to slow down from
the exchange or replacement speed to a reduced speed, at which the
reel being completed is brought. This reduced speed is lower than
the exchange speed. When the reel rotates at a reduced peripheral
speed, lower than the exchange speed, at which the web material is
temporally fed, a loop can be formed, which facilitates the step of
severing the web material and starting winding a new reel on a new
winding rod.
[0028] In some embodiments the second winding member comprises a
cluster or set of winding rollers comprising a second winding
roller, a third winding roller and a fourth winding roller. In
advantageous embodiments the first winding roller and the second
winding roller are arranged with a preferably fixed
center-to-centre distance, and form therebetween a nip or seat for
resting and rotating the reel being wound. In some embodiments an
auxiliary winding roller is arranged between the first winding
roller of the first winding member and the second winding roller,
forming part of the second winding member. The auxiliary winding
roller can have a fixed axis or a movable axis to follow the
diameter increase of the reel being formed.
[0029] In some embodiments, when the second winding member
comprises a cluster of winding rollers comprising a second, a
third, and a fourth winding roller, said third winding roller and
said fourth winding roller are arranged and controlled such as to
move the first reel away from the first winding member and to
transfer it towards said unloading area. The transfer can occur by
maintaining the reel in contact with the second winding roller. In
other embodiments the third winding roller is controlled such as to
move away from the reel whilst the fourth winding roller is
displaced to transfer the reel from the winding area towards the
unloading area. In some embodiments at least some of the rollers
forming the second winding member are controlled such as to slow
down and then to stop the reel rotation.
[0030] If the second winding member comprises a cluster of winding
rollers, in some embodiments one of said winding rollers of the
cluster remains in a fixed position, whilst at least one other of
said winding rollers of the cluster is used to displace the reel,
making it roll on the winding roller, which remains in fixed
position. The rotation speed of at least some of the rollers of the
cluster of rollers forming the second winding member is controlled
to slow down and then to stop the reel rotation. Slowing down can
occur in two steps: in a first step, slowing down of the reel
rotation corresponds to a reduction in the feed speed of the web
material and therefore to it corresponds also a slowing down of the
first winding member. In a second step the first winding member
continues to move at the feed speed of the web material, whilst the
rollers of the second winding member further slow down and then
stop the rotation of the formed reel.
[0031] In some embodiments the second winding member comprises a
cluster of winding rollers comprising a second winding roller, a
third winding roller, and a fourth winding roller, which are
controlled to slow down and then to stop the rotation of said first
reel, whilst the inserter brings a second winding rod against the
first winding roller, starting winding a second reel around said
second winding rod in contact with said first winding roller, whose
rotation is not stopped during the replacement phase.
[0032] Preferably, the winding rod inserter is associated with
angular acceleration means for the winding rods to drive each
winding rod into rotation before it is brought in contact with the
web material. Each winding rod is advantageously accelerated by
said angular acceleration means, so as to have a peripheral speed
substantially equal to the feed speed of the web material when the
winding rod comes in contact with the web material.
[0033] In advantageous embodiments, winding starts by holding the
web material between the new winding rod and the first winding
member, whilst the peripheral speed of the first winding member and
of the winding rod are substantially equal and nearly corresponding
to the feed speed of the web material.
[0034] According to a different aspect, the invention relates to a
method for producing reels of web material around winding rods,
comprising the steps of: [0035] winding a first reel of web
material around a first winding rod in a winding cradle comprising
a first winding member and a second winding member, [0036] once
said first reel of web material has been wound, unloading said
first reel of web material from said winding cradle, inserting a
second winding rod in said winding cradle, and winding a second
reel of web material around said second winding rod; wherein the
first reel of web material is unloaded from the winding cradle
through a change in the arrangement of the second winding member,
while the second winding rod is driven into rotation by moving it
towards the first winding member.
[0037] According to some embodiments of the invention the first
reel of web material is unloaded from said winding cradle by making
the second winding member pivot from a winding position to an
unloading position.
[0038] In one embodiment, the method according to the present
invention comprises the steps of: [0039] slowing down the winding
speed; [0040] modifying the arrangement of the second winding
member from a winding position towards an unloading position thus
moving the first reel away from the first winding member and
towards an unloading area; [0041] bringing the second winding rod
against the first winding member, causing the second rod to start
rotation, and starting to wind the web material around the second
rod to form the second reel; [0042] bringing the second winding
member towards said winding position again and bringing the second
reel under formation around the second winding rod in contact with
said second winding member.
[0043] According to a further aspect of the present invention a
rewinding machine is provided, comprising: a first winding member
and a second winding member defining a winding cradle; and a
winding rod inserter for introducing a winding rod in said winding
cradle to wind a reel of web material on said winding rod.
Advantageously, the second winding member has a variable
configuration to unload a formed reel from said winding cradle; and
the inserter is arranged and controlled to transfer said winding
rod along a movement path towards said first winding member, along
said path the web material being engaged to said winding rod to
start winding around said winding rod driven into rotation by said
first winding member.
[0044] The invention also concerns a winding method comprising the
steps of: [0045] arranging a first winding roller and a second
winding roller to define a seat or cradle for supporting and
rotating the reel being wound; [0046] arranging a third winding
roller and a fourth winding roller with movable axes; [0047]
winding a first reel in said support and rotation seat in contact
with at least said first winding roller and said second winding
roller; [0048] continuing winding said first reel of web material
between said first winding roller, said second winding roller, said
third winding roller, and said fourth winding roller; [0049] moving
said first reel of web material away from said first winding roller
maintaining it into rotation through at least said second winding
roller and said fourth winding roller and reducing the rotation
speed of the reel from a winding speed to a replacement speed,
lower than the winding speed; [0050] bringing said second winding
rod against said first winding roller and engaging the web material
between said first winding roller and said second winding rod,
[0051] severing the web material between the second winding rod and
the first reel; [0052] starting winding a second reel around said
second winding rod; [0053] moving the first reel of web material
away from the second winding roller; [0054] bringing the second
reel in contact with said second winding roller.
[0055] According to some embodiments of the method according to the
invention, it is provided for said first reel of web material to be
moved away from said first winding roller while maintaining it into
rotation by means of said second winding roller, said third winding
roller, and said fourth winding roller.
[0056] Whilst the first reel is moved away from the first winding
roller, the third winding roller is preferably moved away from the
first reel and the first reel is transferred towards the unloading
area by means of the fourth winding roller.
[0057] In some embodiments of the method according to the invention
it is provided that the rotation speed of the first reel is reduced
by slowing down the second winding roller, the third winding roller
and the fourth winding roller; that the third winding roller and
the fourth winding roller are moved away from the first reel; said
third winding roller and said fourth winding roller are accelerated
until the winding speed and said second winding rod and the reel
being formed around it are engaged with said third winding roller
and said fourth winding roller.
[0058] In some embodiments the winding method provides the steps
of: forming a loop of web material between said first reel and said
second winding rod slowing down the rotation speed of said first
reel; and of holding said loop of web material between said second
winding rod and said first winding member and causing the severing
of the web material between said first reel and said second winding
rod.
[0059] According to a further aspect of the present invention, a
rewinding machine is provided, comprising: a first winding member
and a second winding roller defining a winding cradle; a winding
rod inserter for introducing a winding rod in said winding cradle
to wind a reel of web material on said winding rod, said inserter
being arranged and designed so as to introduce said winding rod
against the first winding roller towards said winding cradle; a
plurality of further winding rollers with movable axes arranged and
controlled to unload a reel from said winding cradle whilst said
inserter brings a new winding rod against said first roller to
start winding a new reel of web material. The winding rollers can
be advantageously controlled to slow down the reel and subsequently
to stop it. Advantageously, the winding rollers hold the reel
between the second winding roller and said further winding rollers
during the phase of moving away from the cradle, slowdown and
stopping; preferably the second winding roller remains fixed, i.e.
it doesn't rotate, until winding starts around the new rod
maintaining the new rod in contact only with the first winding
member, for instance by using the inserter.
[0060] In some embodiments of the invention a rewinding machine for
producing reels of web material wound around winding rods is
provided, comprising a first winding roller, a second winding
roller defining with said first winding roller a winding cradle; an
inserter for introducing winding rods in said winding cradle; a
cluster of further winding rollers with movable axes, co-acting
with said first winding roller and said second winding roller to
maintain in rotation a first reel being formed and to move said
first reel away from said winding cradle, to slow down said first
reel and lastly to stop said first reel, whilst said inserter
introduces a new winding rod towards the first winding roller, said
first winding roller starting winding a new reel around said new
winding rod. The machine can advantageously provide for severing
means for severing the web material. In some embodiments the
severing means comprise air blows. The winding rollers can be
controlled to generate a loop of web material, which is engaged
around the new winding rod. The loop of web material can be formed
by changing the rotation speeds of the winding rollers, and in
particular by slowing down the second winding roller with respect
to the first winding roller.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] The invention will be better understood by following the
description below and the attached drawing, which shows a
non-limiting practical embodiment of the invention. More in
particular:
[0062] FIGS. 1 to 5 show a schematic side view of a rewinding
machine according to the invention in an operating sequence
comprising the formation of a complete reel, its unloading, and the
introduction of a new winding rod to start formation of a second
reel;
[0063] FIGS. 6 to 14 schematically show a machine according to the
invention in a different embodiment and a sequence of the
operations performed during a winding cycle;
[0064] FIGS. 15 to 23 show the machine of FIGS. 6 to 14 in a
different embodiment of the winding and replacing cycle of a formed
reel with a new winding rod;
[0065] FIGS. 24 to 32 show a further variant of the operation of
the machine of FIGS. 6 to 14; and
[0066] FIGS. 33 to 40 show a third embodiment of a machine
according to the invention and a related winding and replacing
cycle of a formed reel with a new winding rod.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0067] The rewinding machine, indicated in its entirety with number
1, comprises a first winding member 3 and a second winding member
5. In some embodiments the first winding member 3 is constituted
by, or comprised of, a winding roller rotating around a
substantially horizontal axis 3A. The rotation of the roller is
controlled by an electric motor, schematically indicated with
number 7.
[0068] In some embodiments, the second winding member 5 comprises a
second winding roller 9 rotating around a substantially horizontal
axis 9A substantially parallel to the axis 3A of the winding roller
3. The winding rollers 3 and 9 form a nip therebetween and define a
winding cradle.
[0069] In some embodiments the winding roller 9 is driven into
rotation by a second motor 8, distinct from the motor 7. The motors
7 and 8 are preferably connected to a central control unit 10, with
which also the other members of the machine are interfaced to
perform the winding cycle described below. The control unit 10 can
be a programmable microprocessor unit, preferably connected to a
panel, a display, a touch screen, a keyboard, or other user
interface means.
[0070] In some embodiments one or more belts 11 are advantageously
provided, entrained around the winding roller 9 and around a roller
13, connected to the roller 9, for instance through a pair of arms
15. In some preferred embodiments of the invention the arms 15 are
supported coaxially to the roller 9 and therefore pivot around the
axis of rotation 9A of the winding roller 9. Pivoting can be
controlled by a hydraulic or pneumatic cylinder-piston actuator, or
by a rotating actuator, for example by an electric motor. The
actuator controlling the pivoting movement of the arms 15 is not
shown for the sake of simplicity of representation. Also this
actuator can be controlled by the central control unit 10.
[0071] The winding cradle formed by the winding rollers 3 and 9 is
labeled as a whole with number 19. At every winding cycle a winding
rod is inserted in said cradle 19 to form a reel, with a procedure
described later on.
[0072] Around the winding roller 3 the web material N is fed,
coming from a downstream station and passing around a bow roller 21
to enlarge transversally the web material N. The winding roller 3
can be wholly or partially covered with a material having a high
friction coefficient to draw the web material and impart the
rotation movement to the reel being formed in the winding cradle
19. In a similar manner also the roller 9 can be wholly or
partially covered with a material with high friction coefficient.
In some embodiments the roller 9 has annular grooves, inside which
the belts 11 are guided. These latter can be in turn covered with,
or produced in, a material with high friction coefficient.
[0073] Adjacent to the rewinding machine 1, a station 2 is arranged
for receiving the single reels formed by the rewinding machine 1,
and from this station the reels are then unloaded towards a storage
area, a further processing line or other. As it will be clearly
apparent from the description below, the reels are unloaded from
the cradle formed by the rollers 3 and 9 on the station 2 through a
pivoting movement of the arms 15 and of the belts 11 around the
axis 9A of the winding roller 9.
[0074] A double guide 23 extends around the first winding roller 3.
More in particular, two guides 23 are provided at the two ends of
the winding roller 3, each of which has a curved guiding surface
with a profile gradually moving towards the cylindrical surface of
the winding roller 3 to allow the winding rods to move gradually
towards said roller. The winding rods, indicated with A1, A2, are
fed one after another by a winding rod inserter 25 for introducing
the rods in the winding cradle 19. The inserter 25 can be designed
in a known manner and has engagement members for engaging the ends
of the winding rods A and is provided with a rotation movement
around the axis 3A of the winding roller 3.
[0075] The machine described above operates as follows.
[0076] FIG. 1 shows an initial winding phase of a first reel B1
around a first winding rod A1. In this phase the web material N is
fed around an upper portion of the cylindrical surface of the
winding roller 3 and winds around the rod A1 to form a reel B1 in
contact with the winding rollers 3 and 9. The rotation speed of the
rollers 3 and 9 is substantially equal and it can achieve very high
values, in the order of 1500-2000 m/min. It should be understood
that these and other speed values in the present description are
indicated purely by way of non-limiting example.
[0077] As the diameter of the reel B1 increases, the reel centre
moves away from the pair of winding rollers 3 and 9 and the reel
periphery starts touching the upper branch of the belts 11
contributing to impart the rotation movement to the reel and thus
to increase the diameter thereof. The contact between belts 11 and
reel B1 being formed allows a more regular winding.
[0078] FIG. 2 shows the final winding phase of the reel B1. It is
in contact in a limited area of the winding roller 3 and in a
limited area of the winding roller 9, as well as along an arc of
the upper branch of the belts 11. Once the desired diameter, i.e.
the quantity of wound web material set by the operator, has been
achieved, the machine performs the replacement cycle for replacing
the formed reel B1 with a new winding rod A2. To this end, the
speed of the machine is reduced, without however stopping the
movement thereof. In some embodiments, starting from the
arrangement of FIG. 2, the web material speed is reduced from the
steady-state speed (1000-2000 m/min) to a speed of about 100 m/min
or, more in general, to a reduced replacement speed.
[0079] Subsequently (FIG. 3) the arms 15 are lowered rotating in
clockwise direction (in the figure), so as to bring the belts 11 in
such a position to allow the reel B1 to roll towards the unloading
station 2. In this phase auxiliary small planes 16 integral with
the arms 15 are advantageously aligned with an inclined unloading
plane 31, with which the unloading station 2 is provided. The reel
B1 rolls on the belts 11, on the small planes 16 and lastly
achieves the inclined unloading plane 31 to be definitely unloaded
in the station 2, taking the position indicated in FIG. 4. To move
the reel B1 away from the cradle 19 a pushing member can be used,
known and therefore not shown, for example of the type described in
the prior art documents cited in the introduction of the present
description. In this phase, the web material N is still intact and
extends therefore around a portion of winding roller 9, and around
a portion of the winding roller 3, crossing the cradle 19.
[0080] In this phase the inserter 25 introduces a new winding rod
A2, which is driven along the guides 23 from the initial position
indicated with A2(X) in FIG. 3 to the final position indicated with
A2(Y) in the subsequent FIG. 4. During this movement towards the
winding cradle 19 the rod A2 is held at the ends of the inserter
25, which gradually rotates around the axis 3A of the winding
roller 3. The shape of the guides 23 is such that at a given point
the rod A2 presses against the winding roller 3 holding the web
material N between the winding rod A2 and said roller 3. In some
embodiments, on the winding rod A2 a winding core made of cardboard
is provided, advantageously provided for instance with a strip of
double-sided adhesive or with other adhesive means that, thanks to
the contact with the web material N and to the pressure on the web
material N comprised between the winding rod A2 and the winding
roller 3, cause the adhesion of the web material N and the
beginning of the material winding, with consequent severing,
breaking or interruption of the material in a position comprised
between the contact point with the new winding rod A2 and the
touching point with the winding roller 9.
[0081] Severing can be performed or facilitated through known
manual or automatic auxiliary means. Advantageously, in some
embodiments the rod can be previously accelerated so as to obtain a
peripheral speed nearly equal to the speed of contact with the
roller 3.
[0082] In this arrangement, whilst the reel B1 is transferred to
the station 2, a second reel of web material B2 begins winding
around the winding rod A2. In this phase the winding movement is
imparted only by the winding roller 3, as the rod A2 is maintained
in contact only with this roller due to the engagement with the
inserter 25. The winding speed is limited, due to the slowdown of
the machine in this replacement phase.
[0083] Subsequently (FIG. 4), when the reel B1 has been discharged
from the belts 11 and has taken the final position shown in FIG. 4,
the arms 15 can be raised again rotating around the axis 9A so as
to move to the position of FIG. 4 and the winding rod A2 can be
released in the winding cradle 19 contacting also the second
winding roller 9 and the belts 11. In this phase the inserter 25
can release the winding rod A2 and return in its starting position,
where it takes a new rod A3 for the subsequent replacement
cycle.
[0084] Winding continues around the winding rod A2 that in this
phase touches both the winding rollers 3 and 9 and receives
therefore the winding motion by both the winding members 3, 5.
These latter can be gradually accelerated until the steady-state
speed again. The winding cycle continues with increase in the
diameter of the second reel B2 as shown in FIG. 5.
[0085] In the meanwhile the inserter 25 is returned to the initial
position to receive a third winding rod A3, which will replace,
with a cycle similar to that described above, the reel B2 when this
latter will be completely wound.
[0086] During the unloading phase (FIG. 3), thanks to the fact that
the rollers 3 and 9 are actuated by two independent motors 7 and 8,
it is possible for the motion of the winding roller 9, and
therefore of the belts 11 driven around it, to be controlled
according to the unloading needs of the reel B1, if necessary
winding again the end part of the web material N, independently of
the rotation conditions of the roller 3, that will depend upon the
requirements of starting winding around the rod A2.
[0087] FIGS. 6 to 14 show a machine according to the invention in a
different embodiment and the corresponding sequence of winding and
replacing a formed reel with a new winding rod.
[0088] The machine, indicated as a whole with number 101, comprises
a first winding member comprising a first winding roller 103. The
machine furthermore comprises a second winding member, which in
turn comprises a second winding roller 105, a third winding roller
107 and a fourth winding roller 109. The set of rollers forming the
first winding member and the second winding member defines a
winding cradle. As will be more apparent below, the second winding
member has a variable conformation, i.e. the arrangement of the
rollers defining the second winding member is changed during the
winding cycle to allow unloading the formed reel and starting
winding the new reel with a substantially continuous operation of
the machine.
[0089] Adjacent to the first winding roller 103 a so-called bow
roller 111 is arranged to feed the web material N eliminating the
wrinkles thereof and/or enlarging the longitudinal cuts with which
the web material can be subdivided into a plurality of strips that
are simultaneously wound around a plurality of winding cores driven
on a same winding rod or spindle.
[0090] The winding rollers 103, 105, 107 and 109 advantageously
have substantially parallel axes of rotation. In some embodiments
the rollers 103 and 105 are provided with fixed axes and they have
therefore a centre-to-centre distance that doesn't change during
all the cycle of winding and replacing a wound reel with a new
winding rod. The rollers 103 and 105 advantageously define a nip or
seat for resting and rotating the reel being wound.
[0091] The winding rollers 107 and 109 forming, along with the
winding roller 105, the second winding member, advantageously have
movable axes of rotation to perform a series of operations on the
reel during the replacement steps, i.e. the steps of unloading the
finished reel and inserting the new winding rod, as well as during
the initial phase of winding a new reel, as it will be described in
greater detail hereunder with reference to the sequence of FIGS. 6
to 14.
[0092] In this embodiment the second winding member is therefore
substantially configured as a plurality or cluster of winding
rollers 105, 107, and 109. The arrangement or conformation of this
second winding member is variable, thanks to the fact that the axes
of rotation 105A, 107A, and 109A of the rollers 105, 107, and 109
respectively move relative one another thus changing the relative
position and the distance between the various rollers of the
rewinding machine 101.
[0093] The roller 105 and the axis of rotation 105A thereof are
preferably fixed with respect to a bearing structure of the
machine, whilst the rollers 107 and 109 with the respective axes
107A and 109A of rotation can move one with respect to the other
and both with respect to the winding roller 105. The translation
movement of the axes of rotation 107A, 109A of the rollers 107 and
109 can be obtained with an adequate system of guides and
actuators, not shown in detail in the drawing.
[0094] In some embodiments the rollers 103, 105, 107, and 109 can
be driven into rotation by two or more independent motors.
Independent motors means motors that can rotate with speeds
different from one another, advantageously under the control of a
programmable central processing unit. The speed of the rollers
changes in particular during the phase of replacing a wound reel
with a new winding rod. In particular, the rollers 103 and 105 can
be advantageously actuated by independent motors, so as to make
these rollers rotate with different speeds in at least some phases
of the winding cycle.
[0095] Instead of independent motors systems can be used to vary
the speed of rotation of one or the other of two or more rollers
actuated by a common motor. These rotation speed change systems can
comprise gear motors and auxiliary motors for adjusting the speed
of rotation of the outlet shaft of the gear motor relative to the
inlet speed of the gear motor.
[0096] Advantageously, to the first winding roller 103 an inserter
113 is associated, mounted so that it can rotate according to the
double arrow f.sub.113 in one direction and in the other around the
axis of rotation 103A of the first winding roller 103.
[0097] Adjacent to the set of rollers forming the first winding
member and the second winding member, a station 102 is arranged for
receiving the reels formed in the rewinding machine 101. The
receiving station 102 comprises a rest surface 102A fixed to a
frame 104. In some embodiments the frame 104 pivots according to
the double arrow f.sub.104 around an axis 104A for example by means
of an actuator, for instance a cylinder-piston actuator 106, for
the purposes described hereunder with reference to the operative
sequence shown in FIGS. 6 to 14. In other embodiments the frame 104
can be provided with a translation or roto-translation movement to
move the formed reel away from the rewinding machine 101.
[0098] In some embodiments, an auxiliary winding roller 115 is
arranged between the winding roller 103 and the winding roller 105
of the second winding member. In some embodiments the auxiliary
winding roller 115 has a diameter smaller than that of the first
winding roller 103 and of the second winding roller 105. In some
embodiments the axis 115A of the auxiliary winding roller 115 is
fixed. In other embodiments (described hereunder) the axis of the
auxiliary winding roller 115 is movable for instance in a
substantially vertical direction.
[0099] In some embodiments, one or more series of nozzles are
arranged in the space between the first winding roller 103 and the
second winding roller 105 to generate air jets. In FIGS. 6 to 14
two series of nozzles 117 and 119 are provided, interposed in the
nip between the rollers 103, 115 and between the rollers 115 and
105. The air jets generated by the nozzles 117, 119 facilitate the
start of winding a new reel around a new winding rod, as it will be
described in greater detail hereunder.
[0100] Advantageously, in some embodiments to the first winding
roller 103 guides 123 are associated that, analogously to what has
been illustrated with reference to the guides 23 of FIGS. 1 to 5,
form a support for the ends of a winding rod A, engaged by the
inserter 113, to allow a gradual movement of the rod towards the
first winding roller 103.
[0101] After having illustrated the main elements of the rewinding
machine in this second embodiment, a first winding method that can
be performed with this machine will now be described, illustrated
schematically in the sequence of FIGS. 6 to 14.
[0102] In FIG. 6 a first reel B1 is being wound around a first
winding rod A1. The reel B1 is rotating according to the arrow
f.sub.B (in counterclockwise direction in the figure) around its
own axis. The reel B1 is resting in the seat or cradle formed by
the first winding roller 103 and by the second winding roller 105.
The rollers 103 and 105 rotate (in clockwise direction in the
figure) with a peripheral speed substantially corresponding to the
peripheral speed of the reel B1, corresponding to the feed speed of
the web material N, according to the arrow f.sub.N. In this phase
of the winding cycle also the third winding roller 107 and the
fourth winding roller 109 rotate (in clockwise direction in the
figure) substantially at the same peripheral speed as the winding
rollers 103 and 105. A second winding rod A2 is arranged in the
inserter 113 and is temporarily still.
[0103] Once the required web material has been wound around the
reel B1, the replacing phase starts, involving removal of the reel
B1, severing of the web material N, introduction of the second
winding rod A2 and start winding of a new reel B2 around the second
winding rod A2.
[0104] To this end, in an advantageous embodiment, in the
arrangement of FIG. 6 a phase already starts of slowdown of the
machine, reducing the feed speed of the web material N. At the same
time the peripheral speed of the winding rollers 103, 105, 107, and
109 is reduced. Typically, in some embodiments the steady-state
winding speed, i.e. the speed outside the replacing phase, can be
around 1000-2000 m/min. The machine is slowed down from this
winding speed for instance to about 100-200 m/min, preferably
50/150 m/min, for instance about 100 m/min. The speed values must
be intended just as non-limiting examples.
[0105] FIG. 7 shows the subsequent phase of the replacing cycle.
During this phase the reel B1 is moved towards an unloading area
through a translation movement of the third winding roller 107 and
of the fourth winding roller 109, that move according to the arrows
f.sub.107 and f.sub.109 respectively. In this phase all the winding
rollers are still in rotation and the reel B1 continues winding at
a low speed. It is in contact with the second winding roller 105,
the third winding roller 107 and the fourth winding roller 109.
[0106] To obtain a more gradual and uniform start of the winding of
a new reel B2 around the second winding rod A2, this latter is
driven into rotation by a member, not shown, preferably until it
achieves a peripheral speed equal to the speed of the winding
roller 103 and to the feed speed of the web material N during the
replacement phase.
[0107] In the subsequent phase, shown in FIG. 8, the inserter 113,
rotating around the axis 103A of the first winding roller 103,
brings the second winding rod 102 gradually towards the winding
cradle, and more in particular towards the rest and rotation seat
defined by the first winding roller 103 and by the second winding
roller 105. In this rotation movement around the axis 103A of the
first winding roller 103, the rod rests with its ends on the guides
123 that are suitably shaped to move the axis of the second winding
rod A2 gradually towards the cylindrical surface of the first
winding roller 103. In this phase the first reel B1 continues
rotating at the replacement speed, maintained into rotation by the
winding rollers 103, 107, and 109.
[0108] According to a preferred embodiment of the invention, at
this point a step is performed of forming a loop of web material N
to obtain severing of the web material N and to form a tail end
that remains wound around the reel B1 and a head end that winds
around the second winding rod A2.
[0109] FIG. 9 shows the phase of forming the loop and severing the
web material. In this embodiment the winding rollers 105, 107, and
109 further slow down, whilst the winding roller 103 continues
rotating at the reduced speed to which the machine has been brought
during the previous operating phase. Following this slowdown, the
quantity of web material between the second winding rod A2 and the
contact point of the reel B1 on the second winding roller 105
increases, with consequent formation of a loop of web material,
indicated with A.sub.N. In some embodiments the nozzles 117 and 119
are actuated by generating air flows pushing the loop of web
material AN upwards, causing tensioning and severing of the web
material N in an intermediate position between the second winding
rod A2 and the rest point of the reel B1 on the winding roller 105.
In combination with, or alternatively to, the air flows, severing
of the web material can be obtained by providing an adhesive means
on the winding rod A2, for example a strip of double-sided
adhesive, a glue, a suction system inside the rod or any other
means causing the adhesion of the web material to the outer surface
of the winding rod A2. When, due to the gradual rotation of the
inserter 113 around the axis 103A, it is brought in contact with
the web material N driven around the first winding roller 103, the
adhesion occurs of the web material N on the second rod A2, which,
rotating in the winding direction, causes the start of the winding
of the web material N around the second winding rod A2. With or
without the aid of the air flows generated by the nozzles 117 and
119, this causes severing of the web material in an adequate
position along the loop A.sub.N formed in the manner described
above.
[0110] Preferably, as shown in FIG. 10, the subsequent phase of the
replacement cycle entails stopping the rotation of the second
winding roller 105, of the third winding roller 107 and of the
fourth winding roller 109, i.e. of the cluster of winding rollers
forming the second winding member. In this phase the web material N
continues winding around the second winding rod A2 which remains
engaged by the inserter 113 and pressed against the cylindrical
surface of the first winding roller 103. This latter gradually
accelerates so as to bring the winding speed to the steady-state
value (for instance 1000-2000 m/min).
[0111] In the illustrated embodiment, in the subsequent phase shown
in FIG. 11 the inserter 113 continues rotating around the axis 103A
of the first winding roller 103, bringing the second winding rod A2
with the new reel B2 being formed around it in the space defined
between the first winding roller 103 and the second winding roller
105. In this embodiment, due to this movement and to the increase
in its diameter, the second reel B2 contacts also with the
auxiliary winding roller 115 rotating at a peripheral speed
corresponding to the feed speed of the web material N and to the
speed of rotation of the first winding roller 103.
[0112] The third winding roller 107 translates upwards and the
fourth winding roller 109 translates horizontally pushing the reel
B1 towards the unloading area defined by the station 102. An
intermediate plane 130 arranged between the second winding roller
105 and the surface 102A allows the first reel B1, pushed by the
fourth winding roller 109, to roll until to be completely in the
unloading station 102 (FIG. 12). This movement frees the area above
the rest and rotation seat defined by the first winding roller 103
and by the second winding roller 105. In this way the third winding
roller 107 and the fourth winding roller 109 can be arranged above
the second winding roller 105 and the rest and rotation seat
defined by the first winding roller 103 and by the second winding
roller 105. The fourth winding roller 109 and preferably also the
third winding roller 107 return to the steady-state speed of
rotation, with a peripheral speed corresponding to the feed speed
of the web material. The second winding roller 105 is also driven
into rotation again and gradually accelerated until to achieve the
peripheral speed corresponding to the feed speed of the web
material.
[0113] As shown in FIG. 12, the fourth winding roller 109 moves
towards the second reel B2 being formed. Therefore in this phase,
whilst the first reel B1 is in the unloading station 102, the
second reel B2 winding around the second winding rod A2 is in
contact with three winding rollers and more precisely: the first
winding roller 103, and the second and fourth winding roller 105,
109 of the second winding member.
[0114] In the subsequent FIG. 13 the phase is shown wherein also
the third winding roller 107, that has been brought again to a
peripheral speed equal to the feed speed of the web material N,
contacts the second reel B2 winding around the second winding rod
A2. In this phase the reel B2 is in contact with five winding
rollers.
[0115] The second winding rod A2 has been released by the inserter
113 that can gradually return in the initial position to receive a
new winding rod, as shown in the subsequent FIG. 14. This new
winding rod can be the rod A1 that has been removed from the reel
B1 that, with a pivoting of the frame 104, is unloaded towards a
storage area, a transferring system or other.
[0116] In the meanwhile the second reel B2 continues winding and
the increase in its diameter is allowed by a gradual displacement
of the third winding roller 107 and of the fourth winding roller
109, whilst the contact with the auxiliary winding roller 115 is
lost. Therefore in this phase the second reel B2 being wound is in
contact with the first winding member constituted by the first
winding roller 103 and with the second winding member constituted
by the cluster of winding rollers 105, 107, and 109. When the reel
B2 has achieved the desired diameter, i.e. the required quantity of
web material N, the replacement cycle starts again starting from
the arrangement of FIG. 6.
[0117] In the sequence of FIGS. 15 to 23 a different method is
illustrated to perform the replacement cycle of the finished reel
B1 with a new winding rod A2 and start winding a new reel B2 on the
new winding rod A2 using the same machine illustrated in FIGS. 6 to
14.
[0118] FIG. 15 shows the final phase of winding the first reel B1,
similarly to FIG. 6. FIG. 16 illustrates the start of the ejection
of the formed reel B1. This phase corresponds substantially to the
phase of FIG. 7. By comparing FIGS. 7 and 16 it is clear that in
this operating mode the third winding roller 107 is moved away from
the reel B1 and is not used to perform the phase of slowdown and
ejection of the first reel B1. In this embodiment, in order to
eject the first reel B1 from the rest and rotation seat only the
fourth winding roller 109 is used whilst the third winding roller
107 is raised towards a position from which it will be then brought
again near the second winding roller 103.
[0119] In FIG. 17, corresponding to FIG. 8, the start is shown of
the contact between the second winding rod A2 and the web material
N. In FIG. 18 the phase is illustrated of severing the web material
to form the head end and the tail end. In FIG. 19 the second reel
B2 starts winding around the second winding rod A2, whilst the
first reel B1 is in contact with the second winding roller 103 and
with the fourth winding roller 109 that can stop rotating.
[0120] In FIG. 20 the second reel B2 being formed around the second
winding rod A2 (still engaged by the inserter 113) is brought in
contact not only with the first winding roller 103, but also with
the auxiliary winding roller 115. The fourth winding roller 109,
moving from left to the right (in the figure) makes the first reel
B1 to roll towards the unloading station 102. In FIG. 21 the first
reel B1 is housed in the unloading station 102, the fourth winding
roller 109 has been brought in contact with the second reel B2 and
the third winding roller 107 is near the second winding roller 105
and has passed above and around the completed reel B1.
[0121] In FIG. 22 the second reel B2 is winding in contact with the
five winding rollers 103, 105, 107, 109 and 115 that are brought
again to the steady-state or winding speed (typically 1000-2000
m/min). The inserter 113 has been brought again in the position of
receiving a new winding rod, whilst the previously formed reel B1
is moved towards the outlet by pivoting of the structure 104.
[0122] In FIG. 23, corresponding to FIG. 14, the second reel B2
being formed around the second winding rod A2 is in contact with
the winding rollers 103, 105, 107 and 109, whilst it has lost the
contact with the auxiliary winding roller 115 due to the increase
in its diameter.
[0123] Once the reel B2 has achieved the desired dimension, the
replacement cycle starts again starting from the condition of FIG.
15.
[0124] In the sequence of FIGS. 24 to 32, a modified embodiment is
shown, wherein the auxiliary winding roller 115 is provided with an
upwards and downwards translation movement according to the double
arrow f.sub.115, so as to remain in contact with the reel being
formed until the final diameter is achieved, as shown in FIG. 24.
To this end the auxiliary winding roller 115 is gradually raised
from the initial position (FIG. 29) until the final position (FIG.
24). Otherwise, the replacement cycle can be substantially equal to
that described with reference to the two sequences of FIGS. 6 to 14
or to that illustrated in FIGS. 15 to 23.
[0125] In the sequence shown in FIGS. 24 to 32, the third winding
roller 107 accompanies the deceleration and the unload of the first
reel B1, similarly to what has been described with reference to the
sequence of FIGS. 6 to 14, but it must be understood that in this
embodiment again the replacement cycle can be modified so that the
third winding roller 107 doesn't participate in the translation and
unloading phase of the reel B1, but moves away from the reel B1
before the latter starts the slowdown phase.
[0126] In summary, and with reference to the sequence illustrated
in FIGS. 6 to 14, the cycle shown in the sequence of FIGS. 24 to 32
is as follows.
[0127] FIG. 24 shows the completion of winding the reel B1, in
contact with the five winding rollers 103, 105, 107, 109 and 115.
The feed speed of the web material is equal to the steady-state
speed (for example 1000-2000 m/min) corresponding to the peripheral
rotation speed of all the winding rollers. Once the desired
quantity of web material around the reel B1 has been achieved, the
machine is slowed down, bringing the feed speed of the web material
as well as the peripheral speeds of the various rollers to the
replacement speed. A second winding rod A2 is arranged in the
inserter 113.
[0128] In FIG. 25 the third winding roller 107 and the fourth
winding roller 109 forming part of the cluster of the rollers
defining the second winding member start to translate towards the
right in the figure, displacing the formed reel B1 towards the
unloading section 102, and therefore moving it away from the first
winding roller 103 and removing it from the rest and rotation seat
defined by the first winding roller 103 and by the second winding
roller 105. Preferably in this phase the winding rod A2 engaged by
the inserter 113 starts rotating and is brought to a peripheral
speed approximately equal to the reduced feed speed of the web
material N.
[0129] In FIG. 26 the inserter 113, pivoting around the axis 103A
of the winding roller 103, brings the second winding rod A2 in
contact with the web material N that is held between the winding
rod A2 and the cylindrical surface of the first winding roller
103.
[0130] In FIG. 27 severing of the web material is shown, if
necessary with the aid of the air jets generated by the nozzles 117
and 119. The speed of rotation of the reel B1 is furthermore slowed
down by reducing the peripheral speed of the winding rollers 105,
107, and 109 to form the loop A.sub.N of web material between the
point of contact of the reel B1 and the winding roller 105 and the
new winding rod A2.
[0131] In FIG. 28 the second winding roller 105, the third winding
roller 107 and the fourth winding roller 109, i.e. the cluster of
winding rollers forming the second winding member, stop, whilst the
first winding roller 103 starts accelerating, until achieving the
winding steady-state speed. The second reel B2 continues winding in
contact only with the first winding roller 103, the second winding
rod A2 still remaining engaged by the inserter 113 that provides to
maintain the second reel B2 pressed against the first winding
roller 103.
[0132] In FIG. 29 the third winding roller 107 moves away from the
reel B1 and starts its movement of passing over the reel B1 to
achieve the winding position again. The fourth winding roller 109
pushes the formed reel B1 in the unloading station 102, so that the
reel B1 loses the contact with the second winding roller 105. The
inserter 113 is furthermore lowered bringing the second reel B2 in
contact with the auxiliary winding roller 115.
[0133] In FIG. 30 the fourth winding roller 109, which has been
accelerated to the winding speed, contats the second reel B2. The
reel B2 is therefore in contact with three winding rollers 103, 115
and 109. The inserter 113 can be unreleased from the second winding
rod A2 and returns in the loading position, as shown in FIG. 31. In
this arrangement also the third winding roller 107, which has
returned to the peripheral speed corresponding to the winding
speed, is in contact with the second reel B2. Winding of the reel
B2 continues in contact with the five winding rollers 103, 115,
105, 107 and 109, until the final diameter is achieved (FIG. 32 and
subsequently FIG. 24) to start a new replacement cycle.
[0134] FIGS. 33 to 40 show a further embodiment of the machine
according to the invention. The same numbers indicate parts
identical or equivalent to those in FIGS. 6 to 32.
[0135] In this embodiment the rewinding machine comprises a first
winding member comprising a first winding roller 103 and a second
winding member comprising a cluster of three winding rollers 105,
107 and 109, indicated hereunder as second winding roller 105,
third winding roller 107 and fourth winding roller 109. The winding
rod inserter is again labeled 113. This embodiment lacks the
auxiliary winding roller 115 and a single series of compressed air
nozzles 117 can be provided, arranged in the space or nip between
the first winding roller 103 and the second winding roller 104
below the plane on which the axis of rotation 103A of the first
winding roller 103 and the axis of rotation 105A of the second
winding roller 105 are placed.
[0136] With reference to the sequence of FIGS. 33 to 40, in a
possible embodiment the machine illustrated herein performs a cycle
of replacing the formed reel B1 with a new winding rod or core A2
as follows.
[0137] In FIG. 33 the reel B1 is in the final winding phase. The
rewinding machine starts to slow down from the steady-state speed
to the replacement speed. In FIG. 34 the second winding rod A2 is
engaged by the inserter 113. In FIG. 35 the third winding roller
107 and the fourth winding roller 109 of the second winding member
start to move the reel B1 towards the unloading area in the
unloading station 102. The reel B1 is still in contact with the
three rollers 105, 107, and 109 rotating at reduced speed. The new
winding rod A2 is moved towards the rest and winding seat defined
between the first winding roller 103 and the second winding roller
105.
[0138] In FIG. 36 the loop A.sub.N of web material is formed with
or without the aid of the air flows generated by the nozzles 117.
The winding rollers 105, 107 and 109 have furthermore decelerated
with respect to the feed speed of the web material N, to allow the
formation of the loop as described above.
[0139] In FIG. 37 the completed reel B1 is unloaded in the
unloading station 102 whilst the third winding roller passes over
the reel B1 and the fourth winding roller 109 moves towards the
cradle or rest and winding seat formed by the rollers 103 and 105.
The second winding rod A2 is brought towards the nip between the
rollers 103 and 105 so as to bring the second reel B2 in contact
with the first winding roller 103 and with the second winding
roller 105.
[0140] In FIG. 38 the fourth winding roller is put in contact with
the reel B2 that is therefore engaged between the rollers 103, 105
and 109. The inserter 113 can be released and returns in the
initial position (FIG. 39), whilst the winding rollers started
rotating again at the steady-state speed. The third winding roller
107 is still in raised position.
[0141] In the subsequent FIG. 39 also the third winding roller 107
is again in contact with and engaged with the second reel B2 that,
in this phase, is wound in contact with the four rollers 103, 105,
107 and 109 rotating at the winding speed.
[0142] In FIG. 40 a subsequent phase is shown, wherein the reel B2
is increased in diameter whilst a new winding rod has been engaged
by the inserter 113. From this arrangement the completion of the
reel B2 is achieved, i.e. the condition of FIG. 33, to start a new
cycle of replacing the completed reel with a new winding rod.
[0143] FIGS. 41 to 48 show a further embodiment of a rewinding
machine according to the invention. The same numbers indicate parts
identical or equivalent to those of the previously illustrated
embodiment.
[0144] In the example of FIGS. 41 to 48 the members are also shown
that are intended to rotate and translate the axes 109A and 107A of
the rollers 109 and 107. In the illustrated embodiment the winding
roller 107 is carried by a slide 107B able to slide along a guide
107C. The guide 107C is pivoted around an axis indicated with 107D,
substantially parallel to the axes of the winding rollers. The
slide 107B can slide according to the double arrow f.sub.107B along
the guide 107C. A similar arrangement is provided for the support
of the winding roller 109. The latter is carried by a slide 109B,
able to slide in a guide 109C, pivoted around an axis 109D. The
slide 109B can slide according to the double arrow f.sub.109B along
the guide 109C and this latter can pivot or rotate according to the
double arrow f.sub.109C around the axis 109D. The rotation around
the axes 107D and 109D can be controlled by an electronically
controlled electric motor or other adequate actuator. The
translation movement of the slides 107B and 109B along the guides
107C and 109C can be controlled by a screw and nut screw system,
with an electrically controlled electric motor that controls for
instance the rotation of the nut screw and that can be carried by
the guide.
[0145] The machine of FIGS. 41 to 48 furthermore comprises, on both
the sides of the machine, a system for the axial engagement of the
winding rods. In some embodiments the engagement systems comprise,
on each of the two sides of the machine, a pair of jaws 201 carried
by a cursor 203 which, by means of a threaded bar 205 controlled by
an actuator 207 (for instance an electric motor), allows movement
in vertical direction according to the double arrow f.sub.203 of
the cursor 203 carrying the jaws 201. As will be explained
hereunder with reference to the operating cycle illustrated in the
sequence of FIGS. 42, 43, 44, 47 and 48, the jaws 201 follow the
increase of the reel B that is in the winding cradle and are opened
and closed to receive, hold and unload the winding rods on which
the reels of web material N are formed.
[0146] The functioning sequence illustrated in FIGS. 42, 43, 44,
47, and 48 is similar to the sequence illustrated in FIGS. 34 to 40
and therefore hereunder the sequence will be described in summary,
highlighting only the differences with respect to the previously
illustrated functioning cycle.
[0147] In FIG. 42 a reel B1 is nearly completed. The rod A1, on
which it has been wound, has been already released from the jaws
201 that have been opened. The reel B1 is in contact with the first
winding member formed by the winding roller 103 and with the second
winding member, formed by the group or cluster of winding rollers
105, 107 and 109 that rotate in the directions indicated by the
arrows in the figure. A second winding rod A2 is ready at the
inserter 113.
[0148] With the already described movement of the winding rollers
107 and 109, the reel B1 is moved from the cradle formed by the
winding rollers 103 and 105 to the position of FIG. 47, wherein it
is on the surface 102A in the unloading station 102. The winding
rollers 107 and 109 make a movement similar to that described above
to move the formed reel B1 in the unloading station 102 and to
return, firstly the roller 109 and then the roller 107, in contact
with a second reel B2 that in FIG. 48 is in the initial winding
phase, in contact with the four winding rollers 103, 105, 107 and
109.
[0149] The figures clearly show the way to obtain the rotation and
translation movement of the rollers 107 and 109 according to the
trajectories necessary to unload the reel and start winding a
subsequent reel, by means using the slides and the guides 107B,
107C and 109B, 109C.
[0150] Differently than in the embodiment disclosed above, in this
case the winding rod ends projecting from the reel being formed are
engaged by the jaws 201. As already noted, in the phase shown in
FIG. 42 the jaws 201 are opened to allow the rod A1 to exit when
the reel B1 begins to be translated towards the unloading station
102. In FIG. 43, while the reel B1 is rolling, under the thrust and
the control of the rollers 107 and 109, towards the unloading
station 102, the two pairs of jaws 201 are made translate downwards
near the nip or cradle formed between the winding rollers 103 and
105, to receive the second rod A2, which is engaged in this phase
by the inserter 113 and begins to be angularly accelerated until it
achieves a peripheral speed approximately equal to the feed speed
of the web material N. In this phase the winding rollers can be
slowed down from the steady-state winding speed to a lower
speed.
[0151] FIG. 44 shows the phase of approaching movement of the
second rod A2 inside the nip or cradle formed between the winding
rollers 103 and 105. FIGS. 45 and 46 show an enlargement of the
process for severing the web material N in this phase, with the
formation of a tail end LC, that ends to wind on the reel B1, and
of a head end LT, that begins to wind around the new winding rod
A2, adequately brought to the necessary speed of rotation. The head
end LT can be anchored to the second winding rod A2 by using a
strip of double-adhesive or in any other manner, for example
through suction, electrostatic charges, by applying a liquid glue
or simple water, if necessary with starch or other slightly or
temporarily adhesive substance, or in any other adequate
manner.
[0152] A series of compressed air nozzles 117 arranged between the
rollers 105 and 107 generate air jets that facilitate the formation
of the loop of web material. The peripheral speed of rotation of
the reel B1 is slowed down so as to loose the web material N and
form the loop and facilitate severing and beginning of winding the
new reel.
[0153] In FIG. 47 the reel B1 is resting in the unloading station
102, whilst the new reel B2 (not shown in FIG. 47) is in the phase
of initial winding, in contact with the winding rollers 103, 105
and 109. The jaws 201 on both the sides of the machine are closed
and engage the ends of the winding rod A2. Adequate supports on the
rod or on the jaws allow the rod to rotate with respect to the jaws
around the axis of the rod.
[0154] The winding roller 107 is passing over the already formed
reel B1 to move towards the new reel B2 being formed. FIG. 48 shows
the position achieved by the winding rollers 103, 105, 107 and 109
in contact with the new reel B2, whose rod A2 is engaged at both
the ends by the jaws 201. The inserter 113 has returned to the
position in which it receives a second winding rod indicated with
A3, which will be inserted in the machine at the subsequent
replacement cycle. The reel B1 begins the unloading movement by
means of a pivoting motion around the axis 104A due to the effect
of the actuator 106. The pairs of jaws 201 begin to be gradually
raised due to the effect of the threaded bar 205 following the
diameter increase of the new reel B2.
[0155] FIGS. 49 to 52 show an operating sequence illustrating a way
for obtaining the angular acceleration of a new winding rod,
indicated with A2, which is engaged by the inserter 113 and
inserted in the winding cradle. The specific embodiment illustrated
in FIGS. 49 to 52 corresponds to that shown in the FIGS. 41 to 48.
It should be noted that a similar system for angular acceleration
of the winding rod can be adopted also in the other embodiments. In
the illustrated example the inserter 113 comprises a pair of jaws
113A, 113B suitable to open and close to receive, engage and
release the winding rods. The jaws 113A and 113B are connected to
actuators 113C and 113D respectively, which control the opening and
closing movement of the jaws and the movement of the winding rod
towards the guiding surfaces that control the movement thereof
towards the winding roller 103. The jaws and the actuators 113C,
113D (in the illustrated example two linear actuators in the form
of hydraulic or pneumatic cylinder-pistons, for example) are
carried by a rotating equipment 113E, rotating in alternate
directions around the axis 103A of the winding roller 103. The
rotation movement according to the double arrow f.sub.113 is
imparted through a toothed wheel 250 engaging with toothed sector
113F integral with the rotating equipment 113E. M205 schematically
indicates a motor, imparting the rotation to the toothed wheel 250.
The motor M250 is suitably controlled by a programmable control
unit, to which the other motors and actuators of the machine are
interfaced.
[0156] The described arrangement is on both sides of the machine,
which is therefore provided with a double inserter 113, with two
pairs of jaws 113A, 113B on both the sides to engage the opposite
ends of the winding rods A1, A2, A3.
[0157] In the illustrated embodiment, on each side of the machine a
respective wheel 260 is arranged, whose axis is indicated with 260A
and is parallel but not coinciding with the rotation axis 103A of
the winding roller 103. The wheels 260 are outside the winding
roller 103, i.e. flanking it.
[0158] With each wheel 260, which advantageously has a
substantially smooth circular edge, treated, if necessary, so as to
have a high friction coefficient, a toothed wheel 262 is integral,
coaxial with each wheel and engaging with a toothed wheel 264,
whose rotation is controlled by a motor schematically indicated
with M264. Through the motor M264, that can be single for the two
toothed wheels 264 on the two sides of the machine, the two wheel
260 are driven into rotation at a controlled speed. Alternatively
the wheels 260 can be constituted by smooth or V-shaped pulleys
with a plurality of grooves, mounted outside the end of the rollers
and between sides of the roller and jaws 113A and 113B driven into
rotation by belts drawn by a single axis moved by a single
motor.
[0159] As it is clear from the sequence illustrated in FIGS. 49 to
52, a winding rod A2 previously inserted in the machine on guiding
profiles 266 (FIG. 49) is engaged by the jaws 113A and 113B on the
two sides of the machine and is moved, through rotation of the
inserter 113 according to f.sub.113, towards the cradle or nip
formed between the winding rollers 103 and 105. In this movement,
as the centre of rotation of the inserter 113 doesn't match with
the centre of rotation of the wheels 260, the winding rod A2 is
moved gradually from a position distanced from the edge of the
wheels 260 to a position of contact with the wheels (FIG. 50).
[0160] Continuing the rotation of the inserter 113 from the
position of FIG. 50 towards the position of FIG. 52, by means of
the actuator 113C, provided on both the sides of the machine, the
ends of the rod A2 are maintained in contact with the circular
edges of the two wheels 260. These form therefore the surfaces for
guiding the rod and moving it towards the winding roller 103 and
towards the cradle between the winding rollers 103 and 105. At the
same time the rotation f the wheels 260, controlled by the motor
M264, drives in rotation the rod A2, which can be therefore brought
to the desired peripheral speed, advantageously equal to or
substantially equal to the feed speed of the web material N in the
replacement phase.
[0161] In this embodiment the wheels 260 form therefore the guiding
surfaces for the rod A1, A2, A3 and at the same time the means for
angular acceleration of the rod.
[0162] It is also possible to obtain these two functions through
separate members, for instance the guide through static surfaces
and the acceleration through at least one belt or preferably two
belts that engage tangentially respectively with the one or the
other of the two ends of the winding rod while the rod is moved
from the initial position to the final position in the insertion
cycle.
[0163] As it is clearly apparent from FIGS. 49 to 52, the eccentric
arrangement of the wheels 260 on one side and of the winding roller
103 on the other side allows a gradual passage, without particular
stresses, of the winding rod A2 from the contact with the wheels
260 (FIGS. 49 and 50) to the position of contact with the winding
roller 103 (FIGS. 51 and 52).
[0164] It is understood that the drawing only shows an example
provided by way of a practical arrangement of the invention, which
can vary in forms and arrangements without however departing from
the scope of the concept underlying the invention. Any reference
numbers in the appended claims are provided for the sole purpose of
facilitating reading of the claims in the light of the description
and the drawing, and do not in any manner limit the scope of
protection represented by the claims.
* * * * *