Roll forming machine and corresponding method for forming roll

Abstract

A reel forming machine (10) comprising: a collection pit (12) configured to receive a continuous flow of pre-formed metal wire rolls (W); a centering rod (14) on which a wire roll (W) is wound; a first platform (13) and a second platform (24) configured to vertically move the wire roll (W) to form a reel (C). The roll forming machine comprises a first cutting unit (27) and a second cutting unit (28) arranged downstream of the first cutting unit. The second cutting unit is configured to cut the wire coil if the first cutting unit fails to perform cutting. The invention also relates to a method for forming a roll.

Description

Technical Field

[0001] The present invention relates to a roll forming machine suitable for receiving and stacking a series of pre-formed metal wire coils to form rolls having a preferred (but not limited to) cylindrical structure, starting from a continuous hot rolling and finishing process. Background Technology

[0002] Facilities for producing metal coils are known, in which hot-rolled metal products (e.g., smooth or ribbed bars or wires) are fed continuously or semi-continuously (e.g., using a "headless" or "bill-to-bill" feeding method) to a winding unit, in which a laying head or coil-forming head forms a series of continuous coils and places them along their length in an interleaved configuration on a continuous transport conveyor (typically a roller conveyor), on which the series of continuous coils undergoes controlled cooling. An example of such facilities is disclosed in EP916 422.

[0003] The metal wire coil terminates its journey in a spool forming machine, which includes: a generally cylindrical collection pit that opens upward and downward; a centering rod that extends through a portion of the collection pit to form an annular channel together with the collection pit for feeding the wire coil; and a platform on which the coil is stacked, the platform being mounted to be vertically movable relative to the machine.

[0004] In some known solutions, the machine also includes one or more intercepting members arranged at different heights on an overlapping plane, each intercepting member being provided with a clamping arm, which is typically arranged outside the collection pit and is capable of being oriented inside the collection pit in certain steps of the roll forming method to selectively block the roll from falling.

[0005] A single shear can be mounted outside the collection pit or along its height, and can be selectively inserted into the collection pit to cut metal wire coils. It is typically used to determine the segmentation of the coil once the desired weight is reached, and also to separate the head and tail portions of wire that may have undesirable configurations. The shear can also be used to cut metal wire coils in cases of facility malfunction, poor winding, or the presence of scrap or foreign objects in the collection pit.

[0006] One drawback of traditional spool forming machines is that the presence of a single shearing machine cannot guarantee sufficient safety if the shearing machine itself is not functioning correctly, or if the shearing machine is unable to intercept and cut the wire roll with the desired torque. It must be considered that the wire to be cut can travel at high speeds and is very thin; therefore, it is possible that the shearing machine, driven to cut the wire and determined to form the spool, may fail to intercept it.

[0007] In fact, in this case the process must be immediately interrupted and it is necessary to intervene manually, which leads to an increase in costs due to the interruption of the process and, relatedly, an increase in the safety risks for the operators. Moreover, the cutting failure can lead to the formation of a reel with an incorrect weight.

[0008] Another drawback of the known machines is that the single shearing machine cannot reach the wire reel, whatever its position around the centring rod. Therefore, cutting failure situations often occur. This is both due to the position of the shearing machine with respect to the collection pit or to the centring rod, and to the construction features of the shearing machine which allow a limited trajectory of movement that is not always able to intersect the trajectory of movement of the wire reel.

[0009] Therefore, there is a need to perfect a reel forming machine and a corresponding method for forming a reel which overcomes at least one of the drawbacks of the prior art.

[0010] To this end, it is necessary to solve the technical problem of increasing the reliability of the reel forming machine, in particular with regard to the cutting of the wire reels of metal in order to continuously segment the reel when forming the reel.

[0011] In particular, it is an object of the present application to provide a machine and to perfect a method for forming a reel in which the wire reels of metal are cut accurately.

[0012] Another object of the present application is to provide a reel forming machine which is safe, efficient to operate and which allows to compensate for any possible malfunction of the shearing machine which is usually present.

[0013] Another object of the present application is to provide a reel forming machine which allows to obtain a higher hourly productivity, understood as the number or weight of reels produced, while reducing the machine downtime.

[0014] The Applicant has designed, tested and implemented the present application to overcome the drawbacks of the prior art and to achieve these and other objects and advantages. SUMMARY

[0015] The present application is set forth and characterized in the independent claims. The dependent claims describe other characteristics or variants of the main application idea.

[0016] According to the above objects and in order to solve the technical problems disclosed above in a new and original way, while achieving quite remarkable advantages compared to the prior art, the reel forming machine according to the present application is configured to receive a preferably but not necessarily continuous flow of preformed wire reels of metal and to accumulate the wire reels of metal in an overlapping manner so as to define a vertical reel.

[0017] The reel forming machine comprises a collection pit configured to receive a continuous flow of preformed metal wire reels. The collection pit extends around a substantially vertical central axis between a first end and an opposite second end.

[0018] The reel forming machine also comprises a centring rod extending along the central axis. The centring rod advantageously comprises a first portion fixedly arranged inside the collection pit and a second portion axially movable with respect to the first portion between an approach position and a distancing position so as to define a gap with the first portion.

[0019] The reel forming machine comprises a first platform arranged inside the collection pit and movable parallel to the first portion so as to bring the first accumulated wire reels to the second end, and a second platform arranged outside the collection pit and movable parallel to the second portion starting from the second end so as to receive the first accumulated wire reels until a complete reel having a determined weight is formed.

[0020] According to an aspect of the present application, the reel forming machine comprises a first cutting unit arranged in correspondence of the second end and configured to cut the wire reels so as to separate the continuous flow of wire reels from the complete reel, and a second, distinct, cutting unit arranged downstream of the first cutting unit with respect to the direction of fall of the wire reels and configured to cut the wire reels substantially in correspondence of the gap in the event that the first cutting unit fails to perform the cut.

[0021] This achieves at least the advantage of having redundant cutting units arranged at different heights so as to increase the certainty of intercepting and cutting the wire reels. In the event of an "emergency", i.e. in the event that the first cutting unit fails to perform its task for any reason, the second cutting unit is activated.

[0022] Another advantage of this arrangement is that with this solution it is possible to continue production even in the event of failure of the first cutting unit. This is particularly important in the case of continuous rolling using the reel forming machine.

[0023] According to another aspect of the present application, the first cutting unit advantageously comprises two distinct and opposite first cutting devices mounted at the same first working height, and each provided with a first shearing machine.

[0024] According to another aspect of the present application, each of the first cutting devices comprises a positioning member on which the first shearing machine is mounted, the positioning member being movable in translation in the direction of the central axis so as to position the shearing machine in proximity to the first portion. The positioning of the first shearing machine can occur on a substantially vertical plane.

[0025] According to another aspect of the application, the second cutting unit advantageously comprises a single second cutting device formed by a hinged arm mounted with a corresponding gap at a second working height, movable in an arcuate trajectory on a cutting plane intersecting the central axis, so as to sweep the area subtended by the coil of wire.

[0026] According to another aspect of the application, the second cutting device advantageously comprises a second shearing machine mounted on the hinged arm and configured to cut the coil of wire intercepted by the hinged arm.

[0027] According to a variant, the second shearing machine can be arranged in a fixed position; and the hinged arm can be configured to intercept the coil of wire and to send it to the position corresponding to the second shearing machine.

[0028] According to another aspect of the application, the hinged arm is rotatably articulated to the frame of the coil former by a pin with a vertical axis connected to a drive member. The hinged arm has an advantageous flattened structure to provide a greater area to intercept the coil of wire.

[0029] According to another aspect of the application, the second shearing machine comprises a fixed blade and a movable blade, both having at least partially matching shapes, wherein the movable blade is articulated to the fixed blade by a fulcrum connected to an actuator.

[0030] According to another aspect of the application, the coil former comprises a first intercepting member and a different second intercepting member arranged in fixed axial positions with respect to the collection pit, generally arranged outside the collection pit and selectively movable inside the collection pit, the first intercepting member being intended to cooperate with the first platform and the second intercepting member being intended to cooperate with the first cutting unit.

[0031] The present application also relates to a method for forming a coil, the method comprising: - a collection step, in which a continuous flow of preformed coils of metal wire is received in a collection pit around a centring rod, the collection pit extending along a vertical central axis, - a first transfer step, in which the coils of wire are accumulated on a first platform corresponding to a first end of the collection pit and are transferred towards a second end of the collection pit, - a second transfer step, in which the coils of wire accumulated on the first platform are released onto a second platform on which they continue to accumulate to form a complete coil; the second platform moving from the second end towards a base of the centring rod.

[0032] According to one aspect of the present application, the method comprises a cutting step, in which a first cutting unit, located downstream of the second end, performs the cutting of the coils of wire in order to separate the continuous flow of coils of wire from the complete reel; a control step, which is performed in order to check whether the first cutting unit has failed to perform the cutting; and an additional cutting step, in which, in the event that the first cutting unit has failed to perform the cutting, a second cutting unit, located downstream of the first cutting unit, performs the cutting of the coils of wire in order to separate the continuous flow of coils of wire from the complete reel.

[0033] According to another aspect of the present application, in the collecting step, the continuous flow of coils of wire is initially accumulated on a first intercepting member, which is inserted inside the collecting pit at the first end of the collecting pit, before being released onto the first platform. Furthermore, before performing the cutting step or the possible additional cutting step, a second intercepting member, located at the second end of the collecting pit, is inserted inside the collecting pit in order to prevent other coils of wire from falling and thus to be able to facilitate the cutting performed by the cutting unit located downstream. BRIEF DESCRIPTION OF DRAWINGS

[0034] These and other aspects, features and advantages of the present application will become apparent from the following description of one embodiment thereof, given by way of non-limiting example only, with reference to the accompanying drawings, in which: - Figure 1 is a schematic view of a reel forming machine according to the present application; - Figure 2 and Figure 3 shows details of the second cutting unit, which can be seen only schematically in Figure 1 - Figures 4 to 11 shows a possible sequence of operations of a method for forming a reel according to the present application.

[0035] It must be specified that, in this description, the words and terms used, and also the figures as described in the drawings, have the sole function of better illustrating and explaining the present application, whose function is to provide a non-limiting example of the application itself, since the scope of protection is defined by the claims.

[0036] For ease of understanding, where possible, the same reference numerals have been used to identify common elements in the drawings. It should be understood that elements and features of one embodiment can be readily combined with those of another without further elaboration. DETAILED DESCRIPTION

[0037] With reference to Figure 1 , the reel forming machine 10 according to the present application is configured to receive a preferably, but not necessarily, continuous flow of preformed coils of wire W and to accumulate the coils of wire in an overlapping manner in order to form a vertical reel C. ​

[0038] To better characterize the application range of the coil forming machine 10 of the present application without any generality limitation, the metal wire rod (for example, steel or an alloy thereof) can be a smooth or ribbed bar, or a wire rod of smaller thickness. The indicated weight of the formed coil C can vary from about 0.5 tons to about 10 tons, although this weight is generally around 2 tons to 6 tons.

[0039] The coil forming machine 10 comprises a frame 11 configured to be mounted on a horizontal mounting plane, such as a floor or a pit, or on another support structure.

[0040] The coil forming machine 10 comprises a collection pit 12 fixed to the frame 11 and configured to receive a continuous flow of wire coils W.

[0041] The collection pit 12 is mounted in a substantially vertical direction, for example, with respect to the mounting plane of the coil forming machine 10.

[0042] The collection pit 12 extends around a vertical central axis X between a first open end 12a and an opposite second end 12b. The distance between the two ends 12a, 12b defines the height of the collection pit 12.

[0043] By way of example, the collection pit 12 can be of tubular shape with a circular or polygonal section. The transverse dimension of the section is slightly greater than the diameter of the wire coils W so as to guide the wire coils W when they fall due to gravity.

[0044] The coil forming machine 10 comprises a centering rod 14 extending along the central axis X.

[0045] The centering rod 14 comprises a first fixed portion 16, almost the entire length of which is arranged inside the collection pit 12, so as to form with the collection pit an annular channel 15 for the wire coils W. The annular channel 15 extends the entire height of the collection pit 12.

[0046] The centering rod 14 comprises a second movable portion 17 arranged outside the collection pit 12 and axially movable with respect to the first portion 16 between an approach position and a distancing position, so as to determine, in the distancing position, an empty gap I between the two portions 16, 17.

[0047] The first portion 16 can advantageously have a tapered upper end to facilitate the entry of the wire coils W.

[0048] The first portion 16 can be terminated at the lower part by a shaped extension 18 configured to be able to be temporarily connected with the second portion 17. The shaped extension 18 advantageously extends axially beyond the second end 12b of the collection pit 12 towards the second portion 17.

[0049] The reel forming machine 10 also comprises a first platform 13 arranged inside the collection pit 12 and movable parallel to the first portion 16 of the centring rod 14 so as to bring the first accumulated coil of wire W to the second end portion 12b of the collection pit 12.

[0050] The reel forming machine 10 also comprises a second platform 24 arranged outside the collection pit 12 and movable parallel to the second portion 17 from the second end portion 12b downwards so as to receive the first accumulated coil of wire W which can continue to be formed until the complete reel C having a determined weight is determined.

[0051] As previously described, the first platform 13 and the second platform 24 are also movable parallel to the central axis X so as to move away and closer to each other also with respect to the central axis X; both movements are carried out by moving means 25, 26 of their own known type, therefore not described in detail. By way of example only, the moving means 25, 26 can comprise guides, sliders, sliding blocks, actuators, motors and other similar or equivalent components.

[0052] The first platform 13 and the second platform 24 are preferably arranged along different reference lines, for example, oriented at 90° with respect to the central axis X so as not to interfere with each other during the movements.

[0053] According to the present application, the reel forming machine 10 comprises both a first cutting unit 27, fixed to the frame 11, arranged in correspondence of the second end portion 12b and configured to cut the coil of wire W so as to separate the continuous flow of coils of wire W from the complete reel C; and a second cutting unit 28, arranged downstream of the first cutting unit 27 with respect to the direction of fall of the coil of wire W and configured to cut the coil of wire W in the event that the first cutting unit 27 fails to perform the cut.

[0054] Both the first cutting unit 27 and the second cutting unit 28 are advantageously arranged downstream of the second end portion 12b of the collection pit 12.

[0055] According to a variant, at least the first cutting unit 27 can be installed at a position comprised between the end portions 12a, 12b of the collection pit 12. The side wall of the collection pit 12 can be provided with suitable holes to enable the first cutting unit 27 to enter so as to cut the coil of wire W.

[0056] The first cutting unit 27 is preferably arranged in a fixed position with respect to the frame 11.

[0057] According to a possible embodiment, the first cutting unit 27 can be provided with positioning means to be oriented around the collection pit 12, i.e. around the central axis X, in operation or with the machine stationary.

[0058] The first cutting unit 27 is preferably positioned facing the shaped extension 18 provided at the lower end of the first portion 16 of the centring rod 14.

[0059] Therefore, the first cutting unit 27 can perform the cutting of the wire coil W only on one side, since it is arranged in front of the shaped extension 18 which defines a sort of "end of travel".

[0060] The first cutting unit 27 comprises at least one first cutting device 29.

[0061] In general, the number of first cutting devices 29 can be one, two, three or more. It is clear that the greater the number of first cutting devices 29, the greater the probability of intercepting and cutting the wire coil W, if necessary (redundancy).

[0062] According to some embodiments, the first cutting unit 27 advantageously comprises two distinct first cutting devices 29, preferably mounted opposite each other at the same first working height H1 with respect to the central axis X, and each provided on one side or the other with a first shearing machine 32 for intercepting and cutting the wire coil W.

[0063] According to one possible embodiment of the coil former 10, it is possible to simultaneously drive the shearing machines 32 on the basis of the weight value of the coil C being accumulated on the second platform 24, measured by means of a weight meter 38 operatively connected to the means for managing and controlling the coil former 10, not shown in the drawings.

[0064] According to the present application, the first shearing machine 32 is configured to perform the cutting on a substantially vertical cutting plane S1. The skilled person will understand that, as an alternative, the cutting plane S1 can be horizontal or inclined with respect to the central axis X.

[0065] Each first cutting device 29 also comprises a positioning member 30, at the end of which the first shearing machine 32 is mounted facing the collection pit 12.

[0066] The first shearing machine 32 can comprise a first blade 32a and a second blade or counterblade 32b, reciprocally movable with respect to each other to determine the cutting of the wire coil W possibly intercepted between them.

[0067] The first blade 32a advantageously has a curved shape so as to more easily intercept the wire coil W, cooperating with the second blade 32b to block it.

[0068] The first shearing machine 32 can be a hydraulic shearing machine.

[0069] The first shearing machines 32 are normally located in a position not interfering with the coil W and can be brought into an interfering position, for example following a trajectory described below.

[0070] The positioning member 30 is movable by means of guide members (not shown) along the direction of the central axis X and is configured so that the first shearing machines 32 perform a trajectory comprising the following movements: a first movement, slightly inclined with respect to the axis X so as to be arranged underneath the coil W; a second substantially vertical movement to access the coil W; and a final movement which cuts the coil W. This trajectory is performed on a substantially vertical plane.

[0071] The trajectory performed by the first shearing machines 32 is programmed to be always the same, regardless of the position of the coil W. The shearing machines 32 are therefore "blind" and can or can not access and cut the coil W, with a high degree of probability.

[0072] According to one possible embodiment, the first cutting unit 27 is provided with one or more pressure sensors 39, preferably of the hydraulic type, configured to detect whether the first cut has been successful or not. The pressure sensors 39 can be applied on each of the shearing machines 32 and detect whether a cutting force of sufficient value has been applied on the moving wire W. In the event that both shearing machines 32 fail to perform the cut, which can happen for any reason, for example lack of engagement or malfunction, the second cutting unit 28 located downstream is activated on the basis of the weight of the coil C, measured by means of a weight gauge 38 or by means of a non-contact system, for example video or laser.

[0073] According to the present application, the second cutting unit 28 comprises at least one second cutting device 31 provided with a second shearing machine 34.

[0074] According to one possible embodiment, the second cutting device 31 can be characterized by the same features as the first cutting device 29 and will not be described again for the sake of brevity.

[0075] According to Figures 2 to 3 According to the advantageous embodiment shown in the accompanying drawings, the second cutting unit 28 comprises a single second cutting device 31 which comprises both a second shearing machine 34 and an articulated arm 33 mounted at a second working height H2 corresponding to the gap I formed when the second portion 17 of the centring rod 14 moves away from the first portion 16.

[0076] The working heights H1, H2 are measured with respect to the first end 12a of the collection pit 12.

[0077] The articulated arm 33 is capable of moving in an arcuate, particularly circular, trajectory on the generally horizontal cutting plane S2 to sweep across the area opposite the wire roll W, so as to intercept at least one wire roll from either side. The swept area also includes the area of ​​gap I. The cutting plane S2 intersects the central axis X.

[0078] The second shearing machine 34 is advantageously mounted on the end of the articulated arm 33 for the purpose of cutting the wire roll W intercepted by the articulated arm 33.

[0079] The hinge arm 33 is rotatably pivotally connected to the frame 11 by a pin 35 having a vertical axis. The pin 35 is connected to a drive member 36, which drives the pin to rotate so as to rotate the hinge arm 33.

[0080] The articulated arm 33 has an extension that allows the second shearing machine 34 to reach the wire coil W at any position (i.e., at any distance from the central axis X).

[0081] The second shearing machine 34 includes a fixed blade 34a and a movable blade 34b integrally, the shapes of which at least partially match.

[0082] The movable blade 34b is pivotally connected to the fixed blade 34a via a fulcrum 34c connected to the actuator 37 by means of suitable mechanical kinematic movement. The fixed blade 34a is advantageously mounted on a first portion of the articulated arm 33, while the movable blade 34b is advantageously mounted on a second, different portion of the articulated arm 33.

[0083] The actuator 37 is also advantageously mounted on the articulated arm 33.

[0084] The second shearing machine 34 can be a hydraulic shearing machine.

[0085] The actuator 37 is driven to rotate the movable blade 34b relative to the fixed blade 34a, thereby cutting the wire roll W intercepted between them.

[0086] According to one variation, the second shear 34 may be arranged in a fixed position, for example, on the frame 11 or other suitable location, and the articulated arm 33 may be configured to intercept the wire roll W and bring it to a position corresponding to the second shear 34.

[0087] According to one embodiment, an optical device 40, such as a laser scanner, is arranged in the space between the first cutting unit 27 and the second cutting unit 28, and is configured to visually detect the remaining wire W between the first cutting unit 27 and the second cutting unit 28. According to some embodiments, refer again Figure 1The second portion 17 is mounted on a base 19. The base 19 is placed on a support structure 20 associated with a lifting member 21, which can be of known type and therefore not described in detail, configured to determine a vertical movement of the support structure 20.

[0088] By activating the lifting member 21, the support structure 20 can be lowered, bringing the second portion 17 to the far position, and raised, bringing the second portion 17 to the near position, and vice versa.

[0089] According to one embodiment, the base 19 is associated with a slider 22 sliding on a horizontal guide 23 provided on the support structure 20. When the winding drum C has been completed and the second portion 17 has been brought to the far position, by moving the slider 22 it is possible to bring the winding drum C, still wound on the second portion 17, to an unloading area far from the central axis X, in which the winding drum C can be subsequently tied and removed.

[0090] According to other embodiments, the base 19 can be associated with a turnover mechanism which enables the base to be rotated, for example by about 90°, so as to arrange the second portion 17 horizontally and to tie and remove the winding drum C.

[0091] According to one embodiment, the winding drum forming machine 10 comprises a first intercepting member 41 and a second intercepting member 42 arranged in cooperation with the collection pit 12.

[0092] The first intercepting member 41 and the second intercepting member 42 are associated with their own movement means configured to enable the intercepting members to be inserted into the collection pit 12 and removed therefrom.

[0093] The first intercepting member 41 and the second intercepting member 42 are arranged on different horizontal planes, i.e. at different heights along the height direction of the collection pit 12.

[0094] The first intercepting member 41 is arranged close to the first end 12a of the collection pit 12. The second intercepting member 42 is arranged close to the second end 12b of the collection pit 12, above the first cutting unit 27.

[0095] The first intercepting member 41 is arranged in functional cooperation with the first platform 13 and above the first platform 13, able to block the fall of the winding of wire W, in some cases able to preliminarily accumulate the winding of wire. In other words, the first intercepting member 41 has the function of temporarily obstructing the annular passage 15, preventing the fall of the winding of wire W and able to temporarily accumulate the winding of wire W thereon.

[0096] The second intercepting member 42 is arranged to functionally cooperate with the first cutting unit 27 to guide the wire roll W, thereby enabling the first cutting unit 27 to subsequently intercept and cut the wire roll W.

[0097] When the second part 17 is in the away position, the second intercepting member 42 also functions to support the first part 16 of the centering rod 14.

[0098] The previously described operation of the roll forming machine 10 corresponding to the method according to the invention includes: Figures 4 to 11 The following steps are illustrated schematically.

[0099] Figure 4 The diagram illustrates a collection step in which a continuous flow of pre-formed metal wire coils W is received in a collection pit 12 surrounding a centering rod 14 (the collection pit 12 and the centering rod 14 extend along a vertical central axis X) and advantageously stacked on a first intercepting member 41, which is inserted into the collection pit at or slightly below a first end 12a of the collection pit 12.

[0100] Figure 5 The diagram illustrates a first transfer step in which the wire roll W stacked on the first interceptor 41 is released to a first platform 13 located downstream of the first interceptor 41, which moves toward the second end 12b of the collection pit 12.

[0101] Figure 6 The diagram illustrates a second transfer step, in which the wire rolls W stacked on the first platform 13 are released to the second platform 24, where they continue to stack until they form a complete roll C, i.e., a roll with the desired weight. The second platform 24 moves from the second end 12b toward the base 19 of the centering rod 14.

[0102] refer to Figure 7 and Figure 8 The method further includes a cutting step, wherein a second intercepting member 42, positioned at the second end 12b, is inserted into the collecting pit 12 to cut the wire coil W ( Figure 7 The wire coil W is guided to a first cutting unit 27 located downstream, which performs cutting on the wire coil W to separate the continuous flow of the wire coil W from the complete spool C. Figure 8 ).

[0103] like Figure 9 As shown, in the event that the first cutting unit 27 fails to perform a cut, the method provides an additional cutting step, wherein a second cutting unit 28 located downstream of the first cutting unit 27 performs a cut on the wire roll W in order to separate the continuous flow of the wire roll W from the complete roll C.

[0104] After one of the two cutting steps, or just before they take place, the complete reel C is released from the second platform 24 to the base 19, on which it is still temporarily resting, for example, see Figures 7 to 9 . Then, the second platform 24 can be raised in order to reposition itself in correspondence with the second end 12b, so that the second transfer step can be repeated for the new reel C ( Figure 11 ).

[0105] The cutting step is preferably carried out with the first portion 16 of the centring rod 14 in the approach position ( Figure 8 ).

[0106] During the cutting step, the positioning member 30 of the first cutting device 29 moves on a preferably vertical plane following a trajectory in the direction of the central axis X in order to arrange the first shearing machine 32 under the wire reel W and immediately perform the cut.

[0107] The first shearing machine 32 can perform the cut only from the side on which the first cutting device 29 is located, since it can only act in the area reaching the first portion of the centring rod 14.

[0108] During the cutting step, the two first cutting devices 29 can advantageously be activated simultaneously on the basis of the weight of the completed reel C. This is in order to increase the probability of intercepting and cutting the wire reels W.

[0109] When the first portion 16 of the centring rod 14 is in the distancing position ( Figure 9 ), the possible additional cutting step is advantageously performed. In this case, the second intercepting member 42 is inserted inside the collection pit 12 also in order to allow the temporary support of the first portion 16 of the centring rod 14.

[0110] Moreover, during the additional cutting step, the second cutting unit 28 can move in the gap I formed between the first portion 16 and the second portion 17 in order to intercept and cut the wire reels W, since it is able to cover a much greater area that can intersect the central axis X.

[0111] During the possible additional cutting step, the articulated arm 33 of the second cutting device 31 moves in rotation on a substantially horizontal cutting plane S2 along a substantially circular arc trajectory in order to sweep the area facing the wire reels W, intercepting at least one of them from any side. Subsequently, the second shearing machine 34 of the second cutting device 31 performs the cut of the intercepted wire reel W.

[0112] The movement of the articulated arm 33 can advantageously comprise a crossing of the central axis X.

[0113] In the event of malfunction of the first cutting device 29, a possible additional cutting step is performed. The malfunction of the first cutting device 29 can be identified on the basis of the weight of the reel C, which can continue to increase, or by means of suitable video or laser systems.

[0114] Once the cutting has been performed ( Figure 10 ), the finished reel C is separated from the continuous flow of wire coils W, which continues to be processed upstream in order to form another reel C.

[0115] The method then provides a removal step, in which the second portion 17 of the centring rod 14 associated with the base 19, if it has not already moved axially away from the first portion 16 of the centring rod 14 (away position), moves axially away from this first portion, so as to be able to take out the reel C just finished ( Figure 11 ).

[0116] When the reel C is finished, i.e. when it has reached the determined weight, and advantageously before the reel is removed, the method performs both the collection step, to accumulate the wire coils W to form a new reel C, and the transfer step, which can restart thanks to the fact that, after the second transfer step, the first platform 13 has been raised from outside the collection pit 12, as far as below the first intercepting member 41, and subsequently proceeds with the second transfer, cutting and removal steps.

[0117] The collection step can be repeated after the transfer step, for example when the first platform 13 is raised.

[0118] It is clear that parts modifications and / or additions can be made to the reel forming machine 10 and to the method as described hitherto, without departing from the field and scope of the present invention, as defined by the claims.

[0119] It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art shall be able to achieve other equivalent forms of reel forming machines and corresponding methods for forming a reel, which have the characteristics as set forth in the claims and hence fall within the scope of protection defined by the following claims.

[0120] In the following claims the sole purpose of the reference signs placed in brackets is to facilitate their reading and they should not be considered as limiting factors with respect to the scope of protection defined by the claims.

Claims

1. A roll forming machine (10), comprising: - A collection pit (12) is configured to receive a coil of metal wire (W), the collection pit extending about a vertical central axis (X) between a first end (12a) and an opposite second end (12b); - Centering rod (14) includes a first part (16) and a second part (17), the first part (16) being fixed inside the collection pit (12), and the second part (17) being movable relative to the first part (16) between an approach position and a distance position to define a gap (I) between them; - A first platform (13) is arranged inside the collection pit (12) and is movable parallel to the first part (16) to bring the first stacked wire roll (W) to the second end (12b). - A second platform (24), arranged outside the collection pit (12) and movable parallel to the second part (17) from the second end (12b), to receive the first stacked wire rolls (W) until a complete roll (C) with a defined weight is formed. The roll forming machine is characterized by comprising both a first cutting unit (27) and different second cutting units (28), wherein the first cutting unit is arranged corresponding to the second end (12b) to separate the flow of the wire roll (W) from the complete roll (C); the different second cutting units are arranged downstream of the first cutting unit (27) relative to the direction in which the wire roll (W) falls, and are configured to function in accordance with the gap (I) so as to cut the wire roll (W) if the first cutting unit (27) fails to perform cutting.

2. The roll forming machine (10) according to claim 1, characterized in that, The first cutting unit (27) includes two different and opposite first cutting devices (29) which are installed at the same first working height (H1) and each first cutting device is provided with a first shearing machine (32).

3. The roll forming machine (10) according to claim 2, characterized in that, Each of the first cutting devices (29) includes a positioning member (30) on which the first shear (32) is mounted. The positioning member is capable of translating along the direction of the central axis (X) to position the first shear (32) near the first part (16).

4. The roll forming machine (10) according to any one of the preceding claims, characterized in that, The second cutting unit (28) includes a single second cutting device (31) formed by a hinged arm (33) and a second shear (34), the hinged arm being mounted at a second working height (H2) corresponding to the gap (I), the hinged arm being able to move in an arcuate trajectory on a cutting plane (S2) intersecting the central axis (X) in order to sweep across the area opposite to the wire roll (W).

5. The roll forming machine (10) according to claim 4, characterized in that, The second shearing machine (34) is mounted on the articulated arm (33) and configured to cut the wire roll (W) intercepted by the articulated arm (33).

6. The roll forming machine (10) according to claim 4 or 5, characterized in that, The articulated arm (33) has a flat structure and is rotatably pivotally connected to the frame (11) of the roll forming machine (10) by means of a pin (35) with a vertical axis connected to the drive member (36).

7. The roll forming machine (10) according to claim 4, 5 or 6, characterized in that, The second shearing machine (34) includes a fixed blade (34a) and a movable blade (34b), both having at least partially matched shapes, wherein the movable blade (34b) is pivotally connected to the fixed blade (34a) via a fulcrum (34c) connected to the actuator (37).

8. The roll forming machine (10) according to any one of the preceding claims, characterized in that, The roll forming machine (10) includes a first intercepting member (41) and different second intercepting members (42), the first intercepting member and the different second intercepting members being arranged in a fixed axial position relative to the collection pit (12), typically arranged outside the collection pit, and selectively movable inside the collection pit, the first intercepting member (41) being used to cooperate with the first platform (13), and the second intercepting member (42) being used to cooperate with the first cutting unit (27).

9. The roll forming unit according to any one of the preceding claims, characterized in that, The roll forming unit includes an optical device (40) arranged in the space between the first cutting unit (27) and the second cutting unit (28), the optical device being configured to visually detect the remaining wire (W) between the first cutting unit (27) and the second cutting unit (28).

10. The roll forming unit according to any one of the preceding claims, characterized in that, The first cutting unit (27) is provided with one or more pressure sensors (39) configured to detect whether the initial cut is successful.

11. A method for forming a roll, comprising: - Collection step, wherein a continuous flow of pre-formed metal wire coils (W) is received in a collection pit (12) surrounding a centering rod (14), the collection pit (12) and the centering rod (14) extending along a vertical central axis (X), - First transfer step, wherein the wire roll (W) is stacked on a first platform (13) corresponding to a first end (12a) of the collection pit (12) and transferred toward a second end (12b) of the collection pit (12). - A second transfer step, wherein the wire rolls (W) stacked on the first platform (13) are released to the second platform (24), where they continue to be stacked on the second platform to form a complete roll (C), and the second platform is moved from the second end (12b) toward the base (19) of the centering rod (14). The method is characterized by comprising: - A cutting step, wherein a first cutting unit (27) located downstream of the second end (12b) performs cutting on the wire roll (W) to separate the continuous flow of the wire roll (W) from the complete spool (C). - Control step, the control step is executed to check whether the first cutting unit (27) has failed to perform the cutting. - An additional cutting step, wherein, if the first cutting unit (27) fails to perform the cutting, a second cutting unit (28) located downstream of the first cutting unit (27) performs the cutting on the wire roll (W) to separate the continuous flow of the wire roll (W) from the complete roll (C).

12. The method according to claim 11, characterized in that, In the collection step, before being released to the first platform (13), the continuous flow of the wire roll (W) is initially deposited on the first intercepting member (41), which is inserted into the collection pit at the first end (12a) of the collection pit (12), and is characterized in that, before performing the cutting step or the possible additional cutting step, a second intercepting member (42) located at the second end (12b) is inserted into the collection pit (12) to guide the wire roll (W) to the first cutting unit (27).

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