Machine for cutting and bevelling cardboard reels for the recovery thereof

Abstract

The invention relates to a machine for cutting and bevelling cardboard reels for the recovery and subsequent reuse thereof to wind rolls of paper, wherein the machine (2) is mounted on a straight, level, open-topped metal table (1), the entirety of the table (1) of the machine (2), except the left and right sides, being protected by a metal structure covered by a grille in the form of a protective grating (10) for protecting the operator and the operation of cutting and recovering cores (N) of cardboard reels (5). The machine (2) is operated using three-phase voltage at 380 volts. The machine (2) comprises a main motor (11) having 3 hp and 1450 rpm, which is connected to a coaxial reducer (12) that drives core-holding rollers (13), the main motor (11) being commanded using control panel (14) with an on / off button. In accordance with the shape of the bevel-type cut of each core (N) of the cardboard reels (5), according to requirements, the direction of rotation of the main motor (11) is provided by a rotation inverter (15), wherein external and internal bevelling is produced to join the tubular portions of the core (N) by means of an adhesive. Also described as a method for recovering a core (N) of cardboard reels (5) having a size of 30.48 cm (12") or 40.64 cm (16").

Description

Invention Field

[0001] The invention relates to machines and devices designed for cutting cardboard cores or centers (hereinafter referred to as cardboard coils), and more specifically, to a machine for the recovery of cardboard coils which are typically discarded or deemed unfit for reuse due to damage at their ends. The process of the invention involves cutting, beveling, bonding, and smoothing of the cardboard coil, thereby enabling its recovery and reuse.Invention Background

[0002] The manufacture of paper for hygienic products involves the use of these cardboard coils as cores. Throughout the entire process of converting paper into a finished product (across various production lines), the cardboard coils become worn or damaged due to impacts or handling, rendering them unsuitable for further use.

[0003] During the paper manufacturing process, numerous physical and chemical variables are managed, which must first be measured in order to achieve adequate control-especially considering that a sheet of paper is delicate and requires careful, controlled handling to prevent irreversible damage to its presentation.

[0004] Typically, in the final stages of converting paper rolls into finished products, rewinding and cutting machines are employed. To obtain a paper product with acceptable presentation and quality, these types of machines require a high degree of automation.

[0005] In two-drum rewinding machines, the use of a "rider roll" is both important and beneficial. Firstly, it serves a safety function by preventing the paper rolls (approximately 2 meters in diameter and 2.73 meters in height) from shifting or falling off the drums while rotating. Secondly, it contributes to achieving proper winding of the product. The controlled force exerted by the rider roll on the paper rolls at all times ensures adequate compaction, while also maintaining proper tension control of the sheet during operation and regulating the differential speed between the front and rear drums-both of which are essential for roll hardness and optimal winding quality.

[0006] The system that controls the dynamics of the rider roll must be reliable and exhibit proper behavior in response to the various cutting patterns handled by this type of machine, thereby facilitating equipment operation. Accordingly, the cardboard coils on which the paper used in the aforementioned process is wound must be in optimal condition, ensuring proper smoothing at their joints so as to avoid tension issues during processing-issues that may arise from deformed or damaged coils and that could jeopardize operation, causing inefficiencies or process losses.

[0007] In the state of the art, there are patents concerning the handling and recycling of cardboard coils; however, these are mostly aimed at the removal of paper from the coil's surface, rather than at their recovery for reuse in the production process. One example is the machine protected by the U.S. patent "Corclean," which was designed to remove excess paper from cardboard coils through blades that move along their surface, merely cleaning the coil.

[0008] Another example pertains to winding and the control of tensions applied to cardboard coils, as disclosed in U.S. Patent No. 3,599,889, dated August 17, 1971, by John D. Pfeiffer.

[0009] An electronic control system for the rider roll, intended to regulate the nip force between the rewinding paper roll and the drums of the rewinder, determines the current nip using an analog electrical signal as a function of the diameter of the roll being wound, the geometry of the coil and the slitter drums, the paper density, the width of the roll being formed, and the relief pressure applied by the rider roll's counterweight system. A controller compares the actual nip with the desired nip, as determined by a nip setpoint. The initial nip and the nip slope can also be easily controlled (U.S. Patent No. 3,599,889, 1971).

[0010] Most patents and disclosures are directed toward cleaning the surface of the core or center of cardboard coils, rather than their recovery and reuse.Invention Object

[0011] An object of the invention is to provide a simple, yet effective and cost-efficient means to recover and reuse cardboard coils that have been damaged by impact or worn from use, and are therefore discarded. This is achieved through cutting, beveling, bonding, and smoothing around the coil's surface, ultimately enabling its reuse.Invention Summary

[0012] One or more of the foregoing objects may be achieved with a machine for the recovery of cardboard coils damaged by impact or worn from use, which are typically discarded, in accordance with Claim 1, and a method for the recovery of cardboard coils, in accordance with Claim 9. Variations of the invention are set forth in the dependent claims and the following description.

[0013] Disclosed herein is a machine for the recovery of discarded cardboard coils whose ends have been damaged by impact, cuts, or ordinary wear. The recovery machine for discarded cardboard coils consists of a metal structure in the form of a base table, on which the coil rests. Around its perimeter, a protective mesh is installed to ensure operator safety and proper machine operation.

[0014] The procedure begins by inserting into the interior of the cardboard coil a support adapted to its diameter-either 30.48 centimeters (12 inches) or 40.64 centimeters (16 inches)-to ensure axial centering of the cardboard coil along the longitudinal axis of the table. The tip of the cardboard coil is then manually inserted into the support. Subsequently, the "Tighten Coil" button is pressed, thereby securing the coil to the support.

[0015] The "Move Left" button is then pressed, causing the carriage along with the cardboard coil to move in that direction for as long as the button remains pressed. Once the cutting position is reached, the button is released, and the carriage comes to a stop.

[0016] The coil is then supported on rollers, which allow for centered and properly aligned rotation of the cardboard coil along its longitudinal axial axis.

[0017] Once the cardboard coil is precisely centered and aligned, the "Lower Roller" button is pressed, activating the descent of the pressure roller located to the left of the cutting knife. Next, the "Start" button is pressed to initiate rotation of the cardboard coil around its longitudinal axis. The "Right Cut" button must be kept pressed to lower the cutting knife until the cut is completed. Thereafter, the "Left Cut" button is pressed to activate the knife located on the cardboard coil holder head; this button must also be kept pressed until the cut is made, and then released. The "Stop" button is then pressed to halt the rotation of the cardboard coil, followed by the "Raise Roller" button to lift the pressure roller.

[0018] The internal or external beveling of the cardboard coil is then performed. To initiate this function, the "Start Milling" button is pressed, which activates the milling motor together with the dust extractor. The "Bevel" button is then pressed to advance the milling carriage toward the cardboard coil. Once the beveling operation has been completed, the carriage automatically returns to the standby position. The "Stop" button is then pressed, and the milling carriage is manually moved to the standby position.

[0019] After the above, the pressure roller must be raised to avoid interfering with the displacement of the cardboard coil. Then, the "Move Right" button is pressed until the carriage stops. The "Release Coil" button is then pressed to remove the coil from the machine. The leftover section of the cardboard coil remaining on the holder as a result of the cutting operation must also be removed.

[0020] The recovery of the cardboard coil consists of cutting and discarding the ends that are in poor condition, leaving the coil at a length that allows the addition of a segment measuring 250 millimeters or more in length, with the aim of restoring it to its original working length. After the beveling process, both recovered coil segments are joined by applying adhesive around the perimeter of the beveled cut, which has been precisely fitted. These two joined parts are then mounted in a press, which aligns them and applies pressure using a screw mechanism for approximately 30 minutes. Once removed from the press, the joint area is smoothed to eliminate any protrusions or imperfections that may interfere with the paper production process on the paper machine, particularly during the engagement of the first sheet of paper onto the surface of the recovered coil.Brief Description of the Figures

[0021] Figure 1 is a front perspective view of the machine for recovering cardboard coils, according to the present invention. Figure 2 is a rear perspective view of the machine for recovering cardboard coils, according to the present invention. Figure 3 is a left side perspective view of the machine for recovering cardboard coils, according to the present invention. Figure 4 is a detailed left side perspective view of the machine for recovering cardboard coils, according to the present invention. Figure 5 is a perspective view of a cardboard coil, according to the present invention. Figure 6 is a view of 16-inch cardboard coils already recovered and fitted with an extension, according to the present invention. Detailed Description of the Invention

[0022] The various aspects of the present description will be described more fully below with reference to the figures. The machine for recovering cardboard coils, as well as the system and method described herein, should not be construed as being limited to the aspects set forth in this description, but may vary within the scope of the appended claims. In particular, it should be understood that the exemplary embodiments of the machine for recovering cardboard coils shown in the figures may be freely modified within the scope of the claims.

[0023] The figures are schematic and not necessarily drawn to scale.

[0024] Operation begins by installing the support (S) for the core (N) of the cardboard coils (5), adjusted to the diameter of the cardboard coil to be recovered-either 30.48 centimeters (12 inches) or 40.64 centimeters (16 inches)-on the table (1) of the machine (2). The position of the knife holders (3) and the beveling head (4) must be adjusted using control commands that regulate each component respectively. For cardboard coil cores (N) measuring 30.48 centimeters (12"), the knife holders (3) and the beveling head (4) must be in the lower position; for cardboard coils with a core (N) of 40.64 centimeters (16"), the knife holders (3) and the beveling head (4) must be in the upper position.

[0025] To mount the core (N) of a cardboard coil (5), the support carriage (S) must be positioned as close as possible to the supporting rollers on the right lateral side.

[0026] Next, the tip of the core (N) of the cardboard coil (5) is manually inserted into the support carriage (S); that is, by pressing the "Tighten Coil" button, which secures the core (N) of the cardboard coil (5) to the support carriage (S).

[0027] Press the "Move Left" button located on the control panel (6), and the support carriage (S), with the core (N) of the cardboard coil (5) centered and secured, will move in the "Move Left" direction as long as the button remains pressed. Once the cutting position is reached, the button is released, and the support carriage (S) comes to a stop.

[0028] In this position, the "Lower Roller" button located on the control panel (6) is pressed, which activates the descent of the pressure roller (7) positioned to the left of the cutting blade or knife (8). Next, the "Start" button is pressed to activate the rotation of the core (center) of the cardboard coil (5). The "Right Cut" button on the control panel (6) is then held down, causing the knife (8) to descend until the cut is completed. Afterwards, the "Left Cut" button on the control panel (6) is pressed, activating the knife (8) located on the head (4) that holds the core (N) of the cardboard coil (5); this button is held down until the cut is made, and then released. The "Stop" button must be pressed to halt the rotation of the cardboard coil (5), followed by the "Raise Coil" button, which will raise the pressure roller (7).

[0029] The core (N) of the cardboard coil (5) is advanced to the right until it reaches the beveling position, and the pressure roller (7) is lowered by selecting either internal or external beveling. At this point, the milling carriage (F) will be in the standby position, which is the position closest to the operator. The milling carriage (F) is then manually moved transversely toward the machine (2) until it reaches the beveling position. The "Start" button is pressed to rotate the core (N) of the cardboard coil (5) in the direction corresponding to the selected bevel type: for external beveling, the core (N) rotates to the right, and for internal beveling, the core (N) rotates to the left as viewed from the beveling head (4).

[0030] The "Start Milling" button is pressed, which activates the milling motor (F) and the dust extractor (9). Then, the "Bevel" button located on the control panel (6) is pressed, causing the milling carriage (F) to advance toward the core (N). Once the beveling process is complete, the milling carriage (F) automatically returns to the standby position. Subsequently, the "Stop" button is pressed, and the milling carriage (F) is manually moved back to the standby position.

[0031] The pressure roller (7) is raised to ensure it does not interfere with the displacement of the core (N) of the cardboard coil (5).

[0032] The "Move Right" button is pressed until the milling carriage (F) comes to a stop. Then, the "Release" button for the core (N) of the cardboard coil (5) is pressed, and the coil is removed from the machine (2). Finally, the remaining section of the core (N) on the head (4), left over from the cutting operation, must also be removed. In Figure 1, a front perspective view of the machine (2) for recovering cores (centers) (N) of cardboard coils (5) discarded due to damage is shown. The machine (2) for recovering cores (N) of cardboard coils (5) is illustrated in a simplified manner and has the form of a straight table-like structure (1) with an open top end. The entire table (1), except for the entry and milling ends of the machine (2), is enclosed by a metal frame with a mesh-style protective grid (10). As described herein, the machine (2) of the invention may take any suitable form along the longitudinal axial direction of the core (N) and may be configured to accommodate cardboard coil cores (N) with diameters of 30.48 centimeters (12") or 40.64 centimeters (16"). Additionally, it should be understood that the cross-sectional shape of the machine for recovering cores (N) of cardboard coils (5) may differ from that shown in Figure 2.

[0033] The machine for recovering cores (N) of cardboard coils (5) consists of a metallic table-like structure (2), around the perimeter of which is located a metallic grid structure (3) that protects the operator (4) and the rotation of the core (center) of the cardboard coils (1).

[0034] The machine (2) for recovering cores (N) of cardboard coils (5) operates on three-phase voltage, specifically 380 volts.

[0035] The main motor (11), rated at 3 hp and 1,450 rpm, is connected to a coaxial reducer (12), which drives the core-carrying rollers (13). The main motor (11) is controlled from a control panel (14) via an ON / OFF button.

[0036] Depending on the bevel-type cut required for each core (N) of the cardboard coils (5), the rotation direction of the main motor (11) is managed through a rotation inverter (15). In Figure 2, a second motor (16) of ¼ hp and 1,450 rpm is shown, coupled to a worm gear reducer, located at the opposite end of the main motor (11), which drives a support carriage (S) on which the core holder head is mounted. This carriage moves longitudinally along the machine (2) for recovering cores (N) of cardboard coils (5) at a speed of 3 meters per minute to position the cores (N) for subsequent cutting and beveling the movement of this carriage (S) is limited at both ends by limit switches (not shown). The movement of the support carriage (S) is controlled from the control panel (6) via two buttons, one for rightward motion and one for leftward motion; the carriage (S) moves as long as the respective button remains pressed. The machine (2) for recovering cores (centers) of cardboard coils (5) comprises two cutting blade holders or knives (3) with their respective blades (8), which are mounted on metal frames (16) and pneumatically actuated-one located above the supporting rollers (13), and the other 2.53 meters toward the opposite end of the machine (2). These metal frames (16) contain an internal support that moves vertically, guided by linear bearings. The blade holders or knives (3) are mounted on this support (17). Additionally, on the support located above the supporting rollers (13), a pressure roller (7) is also mounted, which loads the cardboard coil and is pneumatically actuated. The aforementioned support (17) is equipped with a height adjustment system to adapt to the diameter of the core (N) of the cardboard coils (5). This movement is driven by a worm gear motor-reducer that actuates two screws to move the carriage (F) vertically over a 100-millimeter stroke. The motor operates on single-phase 220 volts and has a power rating of ¼ hp. Height regulation is controlled by an electric selector, and the stroke is limited by end-of-travel limit switches. The knife holders (3) are pneumatically operated from the control panel (6) via a button (18), which, when pressed, drives the knife holder (3) downward, and upon release of the button (18), the blade returns to its upward position.

[0037] The pressure roller (7), which is pneumatically actuated, is controlled by two separate buttons-one for lowering ("Lower") and one for raising ("Raise") the pressure roller (7).

[0038] The beveling head (4) is mounted at one end of the machine (2), following the supporting rollers (7), and includes two carriages (19). One of these carriages moves transversely to the machine and serves to position the beveling head for either internal or external beveling. This carriage (19) is moved manually by means of a hand crank connected to the carriage (19) via a toothed belt. Sobre este va Mounted atop this assembly is another carriage (19') that moves longitudinally, upon which the milling motor (F) is situated. This carriage (19') is actuated by a stepper motor (20), which is programmed to perform the beveling operation and subsequently return to the standby position. The height adjustment of the beveling head (4), depending on the diameter of the core (N) of the cardboard coils (5), is executed by a gear motor controlled via a diameter selector located on the control panel (6), which also governs the positioning of the cutting knives (8).

[0039] The tool that performs the beveling is a conical milling cutter (F) specifically manufactured for this operation, with a maximum diameter of 80 millimeters and a length of 70 millimeters. It features four longitudinal slots into which tungsten carbide cutting inserts are mounted. These inserts gradually trim the edge of the cardboard coil as it rotates around its longitudinal axial axis, producing either an internal or external bevel with a length of 60 millimeters. The recovery of the core (N) of the cardboard coils (5) consists of cutting and discarding the ends found to be in poor condition (21), and leaving the core (N) of the cardboard coils (5) at a length that allows the addition of a segment measuring 250 millimeters or more, in order to restore its original working length. During this process, a dust extractor (9) is also used to remove particles and dust resulting from the wear of the core (N). An internal bevel is applied to the core (N) of the cardboard coils (5) from which the damaged ends (21) have been removed, and an external bevel is applied to the segment that will be used to restore the length. Adhesive is then applied to the entire surface of the bevel, after which both parts are mounted in a press (not shown), which aligns them and applies pressure by means of a screw (not shown) for approximately 30 minutes. Once the core (N) of the cardboard coils (5) is removed from the press, the joint area is abraded until it is smoothly polished, in order to prevent any protrusion that may cause difficulties when engaging the coil with the paper in the paper machine. In Figure 5, a perspective view is shown of a core (N) of the cardboard coils (5), with the perimeter of its end (21) damaged or in poor condition. In Figure 6, a view is shown of cores (N) of the cardboard coils (5), measuring 40.64 centimeters (16"), already recovered and fitted with a cardboard coil extension (22), in accordance with the present invention.Industrial Application

[0040] The present invention, relating to a machine for the recovery of cardboard coils that are discarded or fail to meet the quality standards for reuse due to damage at their ends, is applicable in the industrial sector-particularly in the manufacture of cardboard coils, papermaking, and metal-mechanical industries.List of Reference Numerals

[0041] 1Structural table of the machine 2Machine 3Cutting blade holder 4Beveling head 5Cardboard coil 6Control panel 7Pressure or loading roller 8Cutting blade or knife 9Dust extractor 10Machine safety grid 11Main motor 12Coaxial reducer 13Core-supporting rollers 14Control board 15Rotation inverter 16Metal frames 17Support 18Push button 19Carriages 20Stepper motor 21Damaged ends of the core 22Cardboard core extension segment 23Second motor FMilling carriage SCore support carriage NCore of the cardboard coil

Claims

1. A cutting, beveling, and recovering machine (2) for cores (N) or centers of cardboard coils (5) measuring 30.48 cm (12") or 40.64 cm (16"), for their recovery and subsequent reuse in the winding of paper rolls, CHARACTERIZED in that the machine (2) is mounted on a straight, leveled metal table (1) with its top end open, wherein the entire table (1) of the machine (2), except for the left and right lateral ends, is enclosed by a metal structure covered with a mesh-like protective grid (10), serving as a safety guard for the operator and for the cutting and recovery operations of the cores (N); the operation of the machine (2) is performed using three-phase voltage of 380 volts; the machine (2) comprises a main motor (11) rated at 3 hp and 1,450 rpm, which is connected to a coaxial reducer (12) that drives the core-supporting rollers (13), with the main motor (11) being controlled via a control board (14) equipped with an ON / OFF button; according to the bevel-type cut required for each core (N) of the cardboard coils (5), the rotational direction of the main motor (11) is governed by a rotation inverter (15).

2. The cutting, beveling, and recovering machine (2) for cores (N) of cardboard coils (5), according to claim 1, CHARACTERIZED in that a second motor (23), rated at ¼ hp and 1,450 rpm, is coupled to a worm gear reducer located at the opposite end of the main motor (11), and displaces a support carriage (S) on which the core holder head is mounted; said carriage moves longitudinally along the machine (2) to allow recovery of the cores (N) of the cardboard coils (5), at a speed of 3 meters per minute, in order to position the cores (N) for subsequent cutting and beveling; the movement of this support carriage (S) is limited at both ends by limit switches (not shown), and its displacement is controlled from the control panel (6) via two buttons, one for rightward movement and one for leftward movement; the support carriage (S) moves while the respective button remains pressed.

3. The cutting, beveling, and recovering machine (2) for cores (N) or centers of cardboard coils (5), according to claim 2, CHARACTERIZED in that it comprises two cutting blade holders or knives (3) with their respective cutting blades (8), which are mounted on metallic frames (16) and are pneumatically actuated one located above the core-supporting rollers (13) and the other positioned 2.53 meters toward the opposite end of the machine (2); these metallic frames (16) contain an internal support that moves vertically, guided by linear bearings, on which the cutting blade holders (3) are mounted; on the support located above the core supporting rollers (13), a pressure roller (7) is also mounted, which loads the coil and is pneumatically actuated.

4. The cutting, beveling, and recovering machine (2) for cores (N) or centers of cardboard coils (5), according to claim 3, CHARACTERIZED in that it comprises a support (17) that holds the cutting blade holders (3) and includes a height adjustment system configured to adapt to the diameter of the core (N) of the cardboard coils (5); this vertical displacement is performed by a worm gear motor-reducer that actuates two screws to move the carriage (F) vertically over a stroke of 100 mm; the motor used for this displacement operates at 220 volts, single-phase, and has a power rating of ¼ hp.

5. The cutting, beveling, and recovering machine (2) for cores (N) or centers of cardboard coils (5), according to claim 4, CHARACTERIZED in that the knife holders (3) are pneumatically operated from the control panel (6) by means of a button (18), which, while pressed, drives the knife holder (3) downward, and upon release of said button (18), the knife returns to its upper position.

6. The cutting, beveling, and recovering machine (2) for cores (N) or centers of cardboard coils (5), according to claim 5, CHARACTERIZED in that a pressure roller (7), pneumatically actuated, is controlled by means of one button to lower and another button to raise the pressure roller (7).

7. The cutting, beveling, and recovering machine (2) for cores (N) or centers of cardboard coils (5), according to claim 6, CHARACTERIZED in that a beveling head (4) is mounted at one end of the machine (2), following the core-supporting rollers (7), and comprises two carriages (19); one of them moves transversely to the machine and is intended to position the beveling head for internal or external beveling; this carriage (19) is moved by a hand crank connected to the carriage (19) through a toothed belt. Mounted on this carriage is a second carriage (19') that moves longitudinally and carries a milling motor (F); this second carriage (19') is driven by a stepper motor (20).

8. The cutting, beveling, and recovering machine (2) for cores (N) or centers of cardboard coils (5), according to claim 7, CHARACTERIZED in that the tool performing the beveling is a conical milling cutter (F) specifically designed for this operation, with a maximum diameter of 80 mm and a length of 70 mm, comprising four longitudinal slots into which tungsten carbide cutting inserts are mounted, which progressively trim the edge of the cardboard coil as it rotates around its longitudinal axis, forming an internal or external bevel with a length of 60 mm.

9. A method for recovering cores (N) or centers of cardboard coils (5), CHARACTERIZED in that it comprises cutting and discarding the ends that are in poor condition (21) and leaving the core (N) of the cardboard coils (5) at a length that allows the addition of a segment of 250 mm or more, so as to restore the original working length of each core (N), whether 30.48 cm (12") or 40.64 cm (16"); during this process, a dust extractor (9) is also used to remove particles and dust generated by the wear of the core (N).

10. The method for recovering cores (N) or centers of cardboard coils (5), according to claim 9, CHARACTERIZED in that once the damaged ends (21) of the core (N) of the cardboard coils (5) have been trimmed, an internal bevel is applied to the core (N) and an external bevel to the segment intended to restore the original length; an adhesive is then applied to the entire surface of the bevel, and both parts are mounted in a press (not shown), which aligns them, and pressure is subsequently applied by means of a screw (not shown) for approximately 30 minutes.

11. The method for recovering cores (N) or centers of cardboard coils (5), according to claim 10, CHARACTERIZED in that once the core (N) of the cardboard coils (5) is removed from the press (not shown), the bonded joint area is abraded until smoothly finished, in order to eliminate any protrusions that may interfere with the engagement of the paper coil in the paper machine.

12. The method for recovering cores (N) or centers of cardboard coils (5), according to claim 11, CHARACTERIZED in that an extension segment (22) is added to the already recovered cores (N)

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