Reel-forming machine and corresponding method for forming reels

Abstract

Reel-forming machine (10) comprising: a collection pit (12) configured to receive a continuous flow of preformed coils of metal wire (W), a centering rod (14) around which said coils of wire (W) are wound, a first platform (13) and a second platform (24) which are configured to move the coils of wire (W) vertically in order to form a reel (C). The reel-forming machine comprises a first cutting unit (27) and a second cutting unit (28) disposed downstream of the first cutting unit. The second cutting unit is configured to cut a coil of wire in the event that the first cutting unit fails to perform the cut. The invention also relates to a method for forming reels.

Description

[0001] “REEL-FORMING MACHINE AND CORRESPONDING METHOD FOR FORMING REELS”

[0002] FIELD OF THE INVENTION

[0003] The present invention concerns a reel-forming machine suitable to receive and accumulate a series of preformed coils of metal wire to form a reel with a preferably cylindrical configuration, but not only, starting from a hot rolling and finishing process of the continuous type.

[0004] BACKGROUND OF THE INVENTION

[0005] Plants for the production of metal reels are known in which a hot-rolled metal product, for example a smooth or ribbed rod or wire, is fed continuously or semi- continuously (for example with an “endless” or “billet-to-billef ’ feed) to a winding unit in which a laying head, or coil-forming head, forms a continuous series of coils of wire and places them, in a configuration staggered in length, on a continuous transport conveyor, generally a roller way, on which they are subjected to controlled cooling. One example of these plants is disclosed in EP 916 422.

[0006] The coils of metal wire terminate their travel in a reel-forming machine which comprises an essentially cylindrical collection pit, open upward and downward, a centering rod that extends through part of the collection pit, forming with it an annular passage for feeding the coils of wire, and a platform on which the coils are stacked, which is mounted mobile vertically with respect to the machine.

[0007] In some known solutions, the machine also comprises one or more interception members disposed on overlapping planes, at different heights, each provided with gripping arms, normally disposed outside the collection pit, and able to be oriented inside it to selectively block the fall of the coils in certain steps of the reel-forming method.

[0008] A single shear may be installed outside, or along the height of, the collection pit, and can be selectively inserted inside it to cut the coils of metal wire, normally to determine a portioning thereof once the desired weight of the reel has been reached, but also to separate the head and tail part of the wire which may have an undesired conformation. The shear can also be used to cut the coils of metal wire in the event of breakdowns in the plant, poor winding, presence of off-cuts or foreign elements in the collection pit. One disadvantage of traditional reel-forming machines is that the presence of a single shear does not guarantee sufficient safety in the event that the shear itself does not work correctly, or simply in the event that the shear is unable to intercept and cut the coil of wire at the desired moment. It must be considered that the wire to be cut can travel at high speed and have a very thin thickness, therefore it may happen that a shear driven to cut the wire and determine the formation of the reel is unable to intercept it.

[0009] In this case, in fact, the process has to be interrupted immediately and it is necessary to intervene manually with an increase in the costs caused by the interruption of the process and with a correlated increase in the risks for the operator’s safety. Furthermore, failure to cut could result in the formation of reels of the wrong weight.

[0010] Another disadvantage of known machines is that a single shear is not able to reach the coil of wire wherever it is located around the centering rod. Therefore, it happens, not infrequently, that the cut fails. This is due both to the position of the shear with respect to the collection pit or the centering rod, and also to the construction characteristics thereof, which allow limited movement trajectories which often are not able to intersect that of the coil of wire.

[0011] There is therefore a need to perfect a reel-forming machine, and a corresponding method for forming reels, which can overcome at least one of the disadvantages of the state of the art.

[0012] To do this it is necessary to solve the technical problem of increasing the reliability of the reel-forming machine, in particular as regards cutting the coils of metal wire in order to portion the reels continuously while they are being formed.

[0013] In particular, one purpose of the present invention is to provide a machine and to perfect a method for forming reels in which the cutting of the coils of metal wire occurs with precision.

[0014] Another purpose of the present invention is to provide a reel-forming machine which is operationally safe, efficient and allows to compensate for any possible malfunctions of the shear that is normally present.

[0015] Another purpose of the present invention is to provide a reel-forming machine which allows to obtain a high hourly productivity, understood as the number or weight of reels produced, with reduced machine stoppages. The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.

[0016] SUMMARY OF THE INVENTION

[0017] The present invention is set forth and characterized in the independent claims. The dependent claims describe other characteristics of the present invention or variants to the main inventive idea.

[0018] In accordance with the above purposes, and to resolve the technical problem disclosed above in a new and original way, also achieving considerable advantages compared to the state of the prior art, a reel-forming machine according to the present invention is configured to receive a flow, preferably but not necessarily continuous, of preformed coils of metal wire and to accumulate them in an overlapping maimer in order to define a vertical reel.

[0019] The reel-forming machine comprises a collection pit configured to receive a continuous flow of preformed coils of metal wire. The collection pit develops around an essentially vertical central axis between a first end and an opposite second end.

[0020] The reel-forming machine also comprises a centering rod which extends along the central axis. The centering rod advantageously comprises a first portion, disposed fixed inside the collection pit, and a second portion axially mobile with respect to the first portion between an approached position and a distanced position in order to define an interspace with it.

[0021] The reel-forming machine comprises both a first platform, disposed inside the collection pit and mobile parallel to the first portion in order to take a first accumulation of coils of wire up to the second end, and also a second platform, disposed outside the collection pit and mobile parallel to the second portion starting from the second end, in order to receive the first accumulation of coils of wire until a complete reel having a determinate weight is determined.

[0022] In accordance with one aspect of the present invention, the reel-forming machine comprises both a first cutting unit disposed in correspondence with the second end and configured to cut a coil of wire in order to separate the continuous flow of coils of wire from the complete reel, and also a distinct second cutting unit disposed downstream of the first cutting unit, with respect to a direction in which the coils of wire fall, and configured to cut, substantially in correspondence with the interspace, a coil of wire in the event the first cutting unit fails to perform the cut.

[0023] Doing so achieves at least the advantage of having a redundancy of cutting units disposed at different heights, so as to increase the certainty of intercepting and cutting a coil of wire. The second cutting unit is activated in case of “emergency”, that is, in the event that, for any reason whatsoever, the first cutting unit fails in its task.

[0024] Another advantage of this provision is that with this solution it is possible to continue the production even in case the first cutting unit fails. This is particularly important in case of use of the reel-forming machine in continuous rolling.

[0025] In accordance with another aspect of the present invention, the first cutting unit advantageously comprises two distinct opposite first cutting devices, installed at a same first working height and each provided with a first shear.

[0026] In accordance with another aspect of the present invention, each of the first cutting devices comprises a positioning member on which the first shear is installed, able to be moved in translation in the direction of the central axis in order to position the shear up to the proximity of the first portion. The positioning of the first shear can occur on an essentially vertical plane.

[0027] In accordance with another aspect of the present invention, the second cutting unit advantageously comprises a single second cutting device formed by an articulated arm installed at a second working height in correspondence with the interspace, able to be moved with an arcuate trajectory on a cutting plane which intersects the central axis in order to sweep the area subtended by the coils of wire, and by a second shear.

[0028] In accordance with another aspect of the present invention, the second shear is advantageously mounted on board the articulated arm and is configured to cut a coil of wire intercepted by the articulated arm.

[0029] According to a variant, the second shear can be disposed in a fixed position and the articulated arm can be configured to intercept a coil of wire and to take it in correspondence with the second shear.

[0030] In accordance with another aspect of the present invention, the articulated arm is rotatably pivoted to a frame of the reel-forming machine by means of a pin with vertical axis connected to a drive member. The articulated arm has an advantageously flat structure to offer a larger area for the interception of the coils of wire.

[0031] In accordance with another aspect of the present invention, the second shear comprises a fixed blade and a mobile blade both having at least partly mating shapes, wherein the mobile blade is pivoted to the fixed blade on a fulcrum connected to an actuator.

[0032] In accordance with another aspect of the present invention, the reel-forming machine comprises first interception members and distinct second interception members disposed in a fixed axial position with respect to the collection pit, normally outside the latter and selectively mobile inside it, the first interception members to cooperate with the first platform, the second interception members to cooperate with the first cutting unit.

[0033] The present invention also concerns a method for forming reels comprising:

[0034] - a collection step, in which the continuous flow of preformed coils of metal wire is received in the collection pit around the centering rod which develop along the vertical central axis,

[0035] - a first transfer step, in which the coils of wire are accumulated on the first platform in correspondence with the first end of the collection pit and are transferred toward the second end of the collection pit,

[0036] - a second transfer step, in which the coils of wire accumulated on the first platform are released to the second platform, on which they continue to accumulate to form a complete reel; the second platform is moved from the second end toward a base of the centering rod.

[0037] In accordance with one aspect of the present invention, the method comprises a cutting step, in which the first cutting unit positioned downstream of the second end performs the cut of a coil of wire in order to separate the continuous flow of coils of wire from the complete reel, a control step in order to check if said first cutting unit fails to perform the cut and an additional cutting step, in which the second cutting unit, located downstream of the first cutting unit, performs the cut of a coil of wire in order to separate the continuous flow of coils of wire from the complete reel, in the event the first cutting unit fails to perform the cut.

[0038] In accordance with another aspect of the present invention, in the collection step the continuous flow of coils of wire, before being released to the first platform, is preliminarily accumulated on first interception members inserted in the collection pit, at a first end thereof. Moreover, before the cutting step or the possible additional cutting step is performed, the second interception members, positioned at the second end of the collection pit, are inserted inside the collection pit in order to prevent other coils of wire from falling and thus allow a facilitated cut by the cutting units located downstream.

[0039] DESCRIPTION OF THE DRAWINGS

[0040] These and other aspects, characteristics and advantages of the present invention will become apparent from the following description of one embodiment, given as a non-restrictive example with reference to the attached drawings wherein:

[0041] - fig. 1 is a schematic view of a reel-forming machine according to the present invention;

[0042] - figs. 2 and 3 show a detail of the second cutting unit which can only be seen schematically in fig. 1;

[0043] - figs. 4-11 show a possible operating sequence of the method for forming reels according to the present invention.

[0044] We must clarify that in the present description the phraseology and terminology used, as well as the figures in the attached drawings also as described, have the sole function of better illustrating and explaining the present invention, their function being to provide a non-limiting example of the invention itself, since the scope of protection is defined by the claims.

[0045] To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one embodiment can be conveniently combined or incorporated into other embodiments without further clarifications.

[0046] DESCRIPTION OF AN EMBODIMENT OF THE PRESENT INVENTION

[0047] With reference to fig. 1, a reel-forming machine 10 according to the present invention is configured to receive a flow, preferably but not necessarily continuous, of preformed coils of metal wire W and to accumulate them in an overlapping maimer in order to form a vertical reel C.

[0048] In order to better characterize the field of application of the reel-forming machine 10 of the present invention, and without any limits to generality, the metal wire, for example steel or an alloy thereof, can be a rod, smooth or ribbed, or a wire with a smaller thickness. The formed reels C can have an indicative weight which can vary from about 0.5 tons to about 10 tons, although the weight is normally around 2-6 tons.

[0049] The reel-forming machine 10 comprises a frame 11 configured to be mounted on a horizontal installation plane, such as a floor or a pit, or on another support structure.

[0050] The reel-forming machine 10 comprises a collection pit 12 fixed to the frame 11 and configured to receive the continuous flow of coils of wire W.

[0051] The collection pit 12 is mounted with an essentially vertical orientation, for example with respect to the installation plane of the reel-forming machine 10.

[0052] The collection pit 12 develops around a vertical central axis X between a first end 12a and an opposite second end 12b, both open. The distance between the two ends 12a, 12b defines the height of the collection pit 12.

[0053] The collection pit 12 can, by way of example, have a tubular shape with a circular or polygonal section. The section has a transverse size slightly larger than the diameter of the coils of wire W, in order to guide the coils of wire W as they fall downward due to gravity.

[0054] The reel-forming machine 10 comprises a centering rod 14 which extends along the central axis X.

[0055] The centering rod 14 comprises a first fixed portion 16, disposed for almost all of its length inside the collection pit 12, forming with it an annular passage 15 for the coils of wire W. The annular passage 15 extends for the entire height of the collection pit 12.

[0056] The centering rod 14 comprises a second mobile portion 17, disposed outside the collection pit 12 and able to be moved axially with respect to the first portion 16 between an approached position and a distanced position, determining, in the distanced position, an empty interspace I between the two portions 16, 17.

[0057] The first portion 16 can advantageously have a tapered upper end to facilitate the entry of the coils of wire W.

[0058] The first portion 16 can terminate at the lower part with a shaped prolongation 18, configured to allow the temporary connection with the second portion 17. The shaped prolongation 18 advantageously extends axially beyond the second end 12b of the collection pit 12 toward the second portion 17.

[0059] The reel-forming machine 10 also comprises a first platform 13, disposed inside the collection pit 12 and able to be moved parallel to the first portion 16 of the centering rod 14 in order to take a first accumulation of coils of wire W up to the second end 12b of the collection pit 12.

[0060] The reel-forming machine 10 also comprises a second platform 24, disposed outside the collection pit 12 and able to be moved parallel to the second portion 17, downward starting from the second end 12b, in order to receive the first accumulation of coils of wire W, which can continue to form, until a complete reel C having a determinate weight is determined.

[0061] The first and second platform 13, 24 are able to be moved, as well as parallel to the central axis X, as previously described, also so as to be taken away from and closer to each other with respect to the central axis X; both movements are by means of their own movement members 25, 26, of a known type and therefore not described in detail. By way of example only, the movement members 25, 26 can comprise guides, sliders, sliding blocks, actuators, motors, and other similar or comparable components.

[0062] The first and second platform 13, 24 are preferably disposed along different directrices, for example oriented at 90°, with respect to the central axis X so as not to interfere with each other during movement.

[0063] According to the present invention, the reel-forming machine 10 comprises, fixed to the frame 11, both a first cutting unit 27 disposed in correspondence with the second end 12b and configured to cut a coil of wire W in order to separate the continuous flow of coils of wire W from the complete reel C, and also a distinct second cutting unit 28 disposed downstream of the first cutting unit 27, with respect to a direction in which the coils of wire W fall, and configured to cut a coil of wire W in the event the first cutting unit 27 fails to perform the cut.

[0064] Both the first cutting unit 27 as well as the second cutting unit 28 are advantageously disposed downstream of the second end 12b of the collection pit 12.

[0065] According to one variant, at least the first cutting unit 27 can be installed in a position comprised between the ends 12a, 12b of the collection pit 12. The lateral wall of the collection pit 12 can be provided with suitable apertures to allow the first cutting unit 27 to enter in order to cut the coils of wire W.

[0066] The first cutting unit 27 is preferably disposed in a fixed position with respect to the frame 11.

[0067] According to a possible implementation, the first cutting unit 27 can be provided with positioning means to be oriented, on the fly or with the machine stationary, around the collection pit 12, that is, around the central axis X.

[0068] The first cutting unit 27 is preferably located facing the shaped prolongation 18 provided at the lower end of the first portion 16 of the centering rod 14.

[0069] The first cutting unit 27 can therefore perform the cut of the coil of wire W only on one side, because it is disposed in front of the shaped prolongation 18 which defines a sort of “end of travel”.

[0070] The first cutting unit 27 comprises at least one first cutting device 29.

[0071] In general terms, 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 coil of wire W when necessary (redundancy).

[0072] According to some embodiments, the first cutting unit 27 advantageously comprises two distinct first cutting devices 29, preferably installed opposite each other with respect to the central axis X at a same first working height Hl, and each provided with a first shear 32 for intercepting and cutting a coil of wire W, on one side or the other.

[0073] According to one possible embodiment of the reel-forming machine 10, the shears 32 are able to be both driven simultaneously on the basis of a weight value of the reel C which is accumulating on the second platform 24, measured by means of a weight meter 38 operatively connected to means for managing and controlling the reel-forming machine 10, which are not shown in the drawings.

[0074] According to the invention, the first shear 32 is configured to perform the cut on an essentially vertical cutting plane SI. A person of skill in the art will understand that the cutting plane SI, alternatively, can be horizontal or inclined with respect to the central axis X.

[0075] Each first cutting device 29 also comprises a positioning member 30 at the end of which the first shear 32 is installed, facing toward the collection pit 12.

[0076] The first shear 32 can comprise a first blade 32a and a second blade, or counter blade, 32b reciprocally mobile with respect to each other to determine the cut of the coil of wire W possibly intercepted between them.

[0077] The first blade 32a advantageously has a curved shape so as to more easily intercept the coil of wire W in order to take it in cooperation with the second blade 32b.

[0078] The first shear 32 can be a hydraulic shear.

[0079] The first shear 32 is normally located in a position which does not interfere with the coils of wire W and can be taken into an interfering position, for example according to the trajectory described below.

[0080] The positioning member 30 is able to be moved in the direction of the central axis X by means of guide members (not shown), configured in such a way that the first shear 32 performs a trajectory which comprises a first movement slightly inclined with respect to the axis X so as to be disposed below the coil of wire W, a second essentially vertical movement to acquire the coil of wire W and finally a movement which cuts the coil of wire W. The trajectory is performed on a substantially vertical plane.

[0081] The trajectory performed by the first shear 32 is programmed to always be the same, regardless of the position of the coil of wire W. Therefore, the shears 32 are “blind” and may or may not acquire and cut a coil of wire W substantially in probabilistic terms.

[0082] 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 primary cut has been successful or not. The pressure sensors 39 can be applied on each of the shears 32 and detect if a cutting force having a sufficient value has been applied or not on the moving wire W.

[0083] In the event that both shears 32 fail to perform the cut, which can occur for any reason whatsoever, for example lack of engagement or malfunction, the second cutting unit 28 located downstream is activated, on the basis of the weight of the reel C, measured by means of the weight meter 38, or by means of a contactless system, for example video or laser.

[0084] According to the present invention, the second cutting unit 28 comprises at least one second cutting device 31 provided with a second shear 34.

[0085] According to one possible embodiment, the second cutting device 31 can have the same characteristics as the first cutting device 29 and will not be described again, for the sake of brevity.

[0086] According to an advantageous embodiment, shown in figs. 2-3, the second cutting unit 28 comprises a single second cutting device 31 which comprises both an articulated arm 33 installed at a second working height H2, in correspondence with the interspace I which is formed when the second portion 17 of the centering rod 14 is moved away from the first portion 16, and also a second shear 34.

[0087] The working heights Hl, H2 are measured with respect to the first end 12a of the collection pit 12.

[0088] The articulated arm 33 is able to be moved with an arcuate, in particular circular, trajectory on a substantially horizontal cutting plane S2 to sweep the area subtended by the coils of wire W, in order to intercept at least one of them, from any side. The swept area also comprises the area of the interspace I. The cutting plane S2 intersects the central axis X.

[0089] The second shear 34 is advantageously mounted on board the articulated arm 33, at a terminal end thereof, with the purpose of cutting the coil of wire W intercepted by the articulated arm 33.

[0090] The articulated arm 33 is rotatably pivoted to the frame 11 by means of a pin 35 with a vertical axis. The pin 35 is connected to a drive member 36 which causes its rotation in order to rotate the articulated arm 33.

[0091] The articulated arm 33 has an extension such that the second shear 34 can reach the coils of wire W in any position whatsoever, that is, at any distance from the central axis X.

[0092] The second shear 34 comprises, in an integral manner, a fixed blade 34a and a mobile blade 34b, whose shapes are at least partly mating.

[0093] The mobile blade 34b is pivoted to the fixed blade 34a on a fulcrum 34c connected to an actuator 37 by means of a suitable mechanical kinematic motion. 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 distinct portion of the articulated arm 33.

[0094] The actuator 37 is also advantageously mounted on board the articulated arm 33.

[0095] The second shear 34 can be a hydraulic shear. The drive of the actuator 37 determines the rotation of the mobile blade 34b against the fixed blade 34a, causing the cut of the coil of wire W intercepted between them.

[0096] According to one variant, the second shear 34 can be disposed in a fixed position, for example on the frame 11 or other suitable position, and the articulated arm 33 can be configured to intercept the coil of wire W and to take it in correspondence with the second shear 34.

[0097] According to one embodiment, in the space between the first cutting unit 27 and the second cutting unit 28 there are disposed optical devices 40, such for example laser scanners, configured for visually detecting the remaining wire W between the first cutting unit 27 and the second cutting unit 28.

[0098] According to some embodiments, again with reference to fig. 1, the second portion 17 is mounted on a base 19. The base 19 is placed on a support structure 20 with which a lifting member 21 is associated, which can be of a known type and therefore not described in detail, configured to determine the vertical movement of the support structure 20.

[0099] By activating the lifting member 21, the support structure 20 can be lowered, thus taking the second portion 17 to the distanced position, and raised, thus taking the second portion 17 to the approached position, and vice versa.

[0100] According to one embodiment, the base 19 is associated with a slider 22 sliding on horizontal guides 23 which are provided on the support structure 20. When the reel C has been completed and the second portion 17 has been taken to the distanced position, by moving the slider 22, the reel C, which is still wound around the second portion 17, can be taken to an unloading zone distanced from the central axis X, where it can subsequently be tied and extracted.

[0101] According to other embodiments, the base 19 can be associated with an overturning mechanism which allows it to be rotated, for example by about 90°, so that the second portion 17 is disposed horizontally and the reel C can be tied and extracted.

[0102] According to one embodiment, the reel-forming machine 10 comprises first interception members 41 and second interception members 42 disposed in cooperation with the collection pit 12.

[0103] The first interception members 41 and the second interception members 42 are associated with their own movement means configured to allow their insertion into, and extraction from, the collection pit 12.

[0104] The first interception members 41 and the second interception members 42 are disposed on distinct horizontal planes, that is, at different heights along the height of the collection pit 12.

[0105] The first interception members 41 are disposed in proximity to the first end 12a of the collection pit 12. The second interception members 42 are disposed in proximity to the second end 12b of the collection pit 12, above the first cutting unit 27.

[0106] The first interception members 41 are disposed in functional cooperation with the first platform 13, being disposed above it, being able to block the fall of the coils of wire W, allowing, in some cases, a preliminary accumulation thereof. In other words, the first interception members 41 have the function of temporarily obstructing the annular passage 15, preventing the coils of wire W from falling and possibly allowing a temporary accumulation of coils of wire W on them.

[0107] The second interception members 42 are disposed in functional cooperation with the first cutting unit 27 to guide the coils of wire W in order to subsequently allow the first cutting unit 27 to intercept and cut a coil of wire W.

[0108] The second interception members 42 have also the function of supporting the first portion 16 of the centering rod 14 when the second portion 17 is in the distanced position.

[0109] The operation of the reel-forming machine 10 described heretofore, which corresponds to the method according to the present invention, comprises the following steps, schematically shown in figs. 4-11.

[0110] A collection step, shown in fig. 4, in which a continuous flow of preformed coils of metal wire W is received in the collection pit 12 around the centering rod 14, the collection pit 12 and the centering rod 14 developing along a vertical central axis X, and is advantageously accumulated on the first interception members 41 which are inserted in the collection pit 12 at its first end 12a, or slightly below.

[0111] A first transfer step, shown in fig. 5, in which the coils of wire W accumulated on the first interception members 41 are released to the first platform 13, located downstream of the first interception members 41, which is moved toward the second end 12b of the collection pit 12. A second transfer step, shown in fig. 6, in which the coils of wire W accumulated on the first platform 13 are released to the second platform 24, on which they continue to accumulate until they form a complete reel C, that is, one of the desired weight. The second platform 24 is moved from the second end 12b toward the base 19 of the centering rod 14.

[0112] With reference to figs. 7 and 8, the method also comprises a cutting step, in which the second interception members 42, positioned at the second end 12b, are inserted inside the collection pit 12 to guide the coils of wire W (fig. 7) to the first cutting unit 27, positioned downstream, which performs the cut of a coil of wire W in order to separate the continuous flow of coils of wire W from the complete reel C (fig. 8).

[0113] As shown in fig. 9, in the event the first cutting unit 27 fails to perform the cut, the method provides an additional cutting step in which the second cutting unit 28, located downstream of the first cutting unit 27, performs the cut of a coil of wire W in order to separate the continuous flow of coils of wire W from the complete reel C.

[0114] After one of the two cutting steps, or just before they occur, the complete reel C is released from the second platform 24 to the base 19, on which it remains temporarily resting, see for example figs. 7-9. The second platform 24 can then rise so as to reposition itself in correspondence with the second end 12b, so that the second transfer step can be repeated for a new reel C, fig. 11.

[0115] The cutting step preferably occurs when the first portion 16 of the centering rod 14 is in the approached position (fig. 8).

[0116] During the cutting step, the positioning member 30 of the first cutting device 29 is moved in the direction of the central axis X following a trajectory, on a preferably vertical plane, so as to dispose the first shear 32 under a coil of wire W and in the immediacy perform the cut.

[0117] The first shear 32 can only perform the cut from the side where the first cutting device 29 is located, since it is able to act only in the zone that reaches the first portion of the centering rod 14.

[0118] During the cutting step, both first cutting devices 29 can be activated simultaneously, advantageously on the basis of the weight of the reel C being completed. This is to increase the probability of intercepting and cutting a coil of wire W.

[0119] The possible additional cuting step occurs advantageously when the first portion 16 of the centering rod 14 is in the distanced position (fig. 9). In this case, the second interception members 42 are inserted inside the collection pit 12 also in order to allow the first portion 16 of the centering rod 14 to be temporarily supported.

[0120] Moreover, during the additional cuting step, the second cuting unit 28 can intercept and cut the coil of wire W by moving in the interspace I which forms between the first portion 16 and the second portion 17, since it is able to range over a much larger area that can intersect the central axis X.

[0121] During the possible additional cuting step, the articulated arm 33 of the second cuting device 31 is moved in rotation, following an essentially circular arcuate trajectory, on the substantially horizontal cuting plane S2, to sweep the area subtended by the coils of wire W, in order to intercept at least one of them, from any side. Subsequently, the second shear 34 of the second cuting device 31 performs the cut of the intercepted coil of wire W.

[0122] The movement of the articulated arm 33 can advantageously comprise passing through the central axis X.

[0123] The possible additional cuting step is performed in the event that the first cuting devices 29 have failed. The failure of the first cuting devices 29 can be identified on the basis of the weight of the reel C, which could continue to increase, or by means of a suitable video or laser system.

[0124] Once the cut is performed, fig. 10, the completed reel C is separated from the continuous flow of coils of wire W which continues to be processed upstream in order to form another reel C.

[0125] The method then provides an evacuation step, in which the second portion 17 of the centering rod 14 which is associated with the base 19 is axially moved away, if it is not already, from the first portion 16 of the centering rod 14 (distanced position) in order to allow the just completed reel C to be extracted, fig. 11.

[0126] When the reel C is complete, that is, when it has reached a determinate weight, and favorably before the later is evacuated, the method again carries out both the collection step, to accumulate the coils of wire W in order to form a new reel C, and also the transfer step, which can restart thanks to the fact that after the second transfer step the first platform 13 has risen as far as below the first interception members 41, from the outside of the collection pit 12, and subsequently the second transfer, cutting and evacuation step.

[0127] The repetition of the collection step can start after the transfer step, for example while the first platform 13 is rising.

[0128] It is clear that modifications and / or additions of parts may be made to the reelforming machine 10 and to the method as described heretofore, without departing from the field and scope of the present invention, as defined by the claims.

[0129] 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 will be able to achieve other equivalent forms of a reel-forming machine and corresponding method for forming reels, having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby.

[0130] In the following claims, the sole purpose of the references in brackets is to facilitate their reading and they must not be considered as restrictive factors with regard to the field of protection defined by the claims.

Claims

CLAIMS1. Reel-forming machine (10) comprising:- a collection pit (12) configured to receive coils of metal wire (W), which develops around a central axis (X) vertical between a first end (12a) and an opposite second end (12b),- a centering rod (14) comprising a first portion (16) fixed inside said collection pit (12) and a second portion (17) mobile with respect to said first portion (16) between an approached position and a distanced position in order to define an interspace (I) between them,- a first platform (13), disposed inside said collection pit (12) and mobile parallel to said first portion (16) in order to take a first accumulation of coils of wire (W) up to said second end (12b),- a second platform (24), disposed outside said collection pit (12) and mobile parallel to said second portion (17) starting from said second end (12b) in order to receive said first accumulation of coils of wire (W) until a complete reel (C) having a determinate weight is determined, characterized in that it comprises both a first cutting unit (27) disposed in correspondence with said second end (12b) to separate a flow of coils of wire (W) from the complete reel (C), and also a distinct second cutting unit (28) disposed downstream of said first cutting unit (27), with respect to a direction in which said coils of wire (W) fall, and configured to act in correspondence with said interspace (I) in order to cut a coil of wire (W) in the event said first cutting unit (27) fails to perform the cut.

2. Reel-forming machine (10) as in claim 1, characterized in that said first cutting unit (27) comprises two distinct opposite first cutting devices (29), installed at a same first working height (Hl) and each provided with a first shear (32).

3. Reel-forming machine (10) as in claim 2, characterized in that each of said first cutting devices (29) comprises a positioning member (30) on which said first shear (32) is installed, which can be moved in translation in the direction of said central axis (X) in order to position said first shear (32) up to the proximity of said first portion (16).

4. Reel-forming machine (10) as in any claim hereinbefore, characterized in that said second cutting unit (28) comprises a single second cutting device (31) formedby an articulated arm (33) installed at a second working height (H2) in correspondence with said interspace (I), which can be moved with an arcuate trajectory on a cutting plane (S2) which intersects said central axis (X) in order to sweep the area subtended by said coils of wire (W), and by a second shear (34).

5. Reel-forming machine (10) as in claim 4, characterized in that said second shear (34) is mounted on board said articulated arm (33) and is configured to cut a coil of wire (W) intercepted by said articulated arm (33).

6. Reel-forming machine (10) as in claim 4 or 5, characterized in that said articulated arm (33) has a flat structure and is rotatably pivoted to a frame (11) of said reel-forming machine (10) by means of a pin (35) with vertical axis connected to a drive member (36).

7. Reel-forming machine (10) as in claim 4, 5 or 6, characterized in that said second shear (34) comprises a fixed blade (34a) and a mobile blade (34b) both having at least partly mating shapes, wherein said mobile blade (34b) is pivoted to said fixed blade (34a) on a fulcrum (34c) connected to an actuator (37).

8. Reel-forming machine (10) as in any claim hereinbefore, characterized in that it comprises first interception members (41) and distinct second interception members (42) disposed in a fixed axial position with respect to the collection pit (12), normally outside the latter and selectively mobile inside it, said first interception members (41) to cooperate with said first platform (13), said second interception members (42) to cooperate with said first cutting unit (27).

9. Reel-forming unit as in any claim hereinbefore, characterized in that it comprises optical devices (40) disposed in the space between said first cutting unit (27) and said second cutting unit (28) configured for visually detecting the remaining wire (W) between said first cutting unit (27) and said second cutting unit (28).

10. Reel-forming unit as in any claim hereinbefore, characterized in that said first cutting unit (27) is provided with one or more pressure sensors (39) configured to detect whether the primary cut has been successful or not.

11. Method for forming reels comprising:- a collection step, in which a continuous flow of preformed coils of metal wire (W) is received in a collection pit (12) around a centering rod (14), the collection pit (12) and the centering rod (14) developing along a vertical central axis (X),- a first transfer step, in which the coils of wire (W) are accumulated on a first platform (13) in correspondence with a first end (12a) of said collection pit (12) and are transferred toward a second end (12b) of said collection pit (12),- a second transfer step, in which the coils of wire (W) accumulated on said first platform (13) are released to a second platform (24), on which they continue to accumulate in order to form a complete reel (C), and which is moved from said second end (12b) toward a base (19) of said centering rod (14), characterized in that it comprises:- a cutting step, in which a first cutting unit (27) positioned downstream of said second end (12b) performs the cut of a coil of wire (W) in order to separate the continuous flow of coils of wire (W) from the complete reel (C),- a control step in order to check if said first cutting unit (27) fails to perform the cut;- an additional cutting step, in which a second cutting unit (28), located downstream of said first cutting unit (27), performs the cut of a coil of wire (W) in order to separate the continuous flow of coils of wire (W) from the complete reel (C), in the event said first cutting unit (27) fails to perform the cut.

12. Method as in claim 11, characterized in that in said collection step said continuous flow of coils of wire (W), before being released to said first platform (13), is preliminarily accumulated on first interception members (41) inserted in said collection pit (12) at a first end (12a) thereof, and in that before said cutting step or said possible additional cutting step is performed, second interception members (42), positioned at the second end (12b), are inserted inside said collection pit (12) to guide the coils of wire (W) to said first cutting unit (27).

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