Method and apparatus for automatically splicing reels of web material

Abstract

The apparatus for automatically splicing reels of web material comprises a splicing assembly (5) adapted to take the trailing end of a first stub reel (21) of web material and apply it to the leading end of a second reel (22) of web material, said leading end being held adjacent to said second reel (22) of web material by a gripping means (3) rotated by the same second reel (22) at the same angular velocity, said leading end having a label (4) of adhesive material on its outwardly facing side.

Description

Detailed Description of the Invention

[0001] (explanation) (Technical field) The present invention relates to a method for automatically splicing reels of web material and to an apparatus for carrying out said method, and is particularly intended for use in an apparatus capable of automatically changing reels of web material.

[0002] (prior art) The use of automated machines that use reels of web material for the manufacture and packaging of products is currently known in various technical fields, and operation of these automated machines means replacing the reel that is being used when the web material is completely consumed.

[0003] As a result, devices have been developed that automatically change reels of web material without interrupting the machine's normal operating cycle. These devices essentially splice the trailing end of the exhausted reel with the leading end of a new reel. Therefore, a responsible operator must periodically feed one or more new reels of web material into the machine.

[0004] Devices for automatically changing reels of web material are known, for example, from patents EP 0 619 231 and EP 2 233 399.

[0005] Depending on the type of production, this operation is required relatively frequently, especially in certain production areas such as the production of electrical energy storage devices, where a reel of web material can be consumed within a few minutes, making reel changes necessary at high frequency.

[0006] A need therefore arises in certain production sectors to speed up the automated operation of joining the rear end of a used reel with the front end of a new reel, without damaging the web material, which may be very thin, during this operation.

[0007] Indeed, in production areas such as the manufacture of electrical energy storage devices, tapes of web material have a series of external edges or flags on at least one side that can easily bend or break on contact with a surface, which obviously causes an unacceptable amount of waste during the manufacturing phase.

[0008] Ultimately, the development of increasingly sophisticated automatic machines capable of reaching very high production speeds has created an urgent need for equally fast exchange of reels of web material, which in particular requires high-speed automatic splicing of the rear end of a used reel with the front end of a new reel.

[0009] (Disclosure) The object of the present invention is to solve the above-mentioned problems by devising a method that allows optimal automatic splicing of reels of web material in devices for changing reels of web material associated with machines that use the web material for the manufacture or packaging of products.

[0010] It is a further object of the present invention to provide a method for automatically splicing reels of web material which ensures that high production rates are achieved.

[0011] Another object of the present invention is to provide a method for automatically splicing reels of web material that maintains the integrity of the web material.

[0012] A further object of the present invention is to provide an apparatus capable of carrying out the subject method for automatically splicing reels of web material, which apparatus is of simple structural and functional design, has reliable operation, versatile use, and is relatively economical in cost.

[0013] The cited object is achieved according to the present invention by a method and an apparatus for automatically splicing reels of web material as set forth in claims 1 and 2.

[0014] An apparatus for automatically splicing reels of web material includes a splicing assembly adapted to take the trailing end of a first stub reel of web material and apply it to the leading end of a second reel of web material.

[0015] According to one aspect of the invention, the leading end of the second reel of web material is held adjacent to the second reel of web material by a gripping means rotated at the same angular velocity by the same second reel.

[0016] Preferably, said front end of the second reel of web material has a label of adhesive material on its outwardly facing side.

[0017] Preferably, the gripping means comprises a radial arm with a support member at its free end adapted to be connected to a drawing means for turning its surface outwards under vacuum, the radial arm being pivotally mounted on the reel and rotated therefrom at the same angular velocity.

[0018] Preferably, the support member comprises a vane extending in a plane tangent to the outer surface of the reel of web material.

[0019] Preferably, the gripping means is movable radially relative to the reel of web material to facilitate bringing the leading end of the second reel of web material into contact with the trailing end of the first out-of-material reel of web material.

[0020] Preferably, the joining assembly includes a plurality of rollers rotatable in an appropriate phase relationship according to respective rotation axes parallel to the rotation axis of the reels, which sequentially grip the web material unwound from the first reel, cut the trailing end of the same first reel, transfer the trailing end of the first reel onto the leading end of the second reel, and join the trailing end to the leading end of the adhesive material using the label.

[0021] Preferably, the rollers counter-rotate relative to each other.

[0022] Preferably, the splicing assembly includes a first roller for winding and unwinding the web material, the first roller being connectable to drawing means for placing a circumferential surface thereof under vacuum to hold the web material as it is unwound from the first reel.

[0023] Preferably, the splicing assembly includes a second transfer roller at the rear end of the first reel downstream of the first roller, on the front end of the second reel, in accordance with the advance direction of the web material, and means for cutting the web material unwound from the first reel, carried on the second roller and adapted to define the rear end.

[0024] Preferably, the cutting means comprises a blade housed inside a seat formed radially on the body of the second roller, the blade protruding from the second roller to effect cutting of the web material and adapted to operate between an inactive retracted position and an advanced position.

[0025] Preferably, the splicing assembly comprises a third drive roller downstream of the second roller for driving the web material fed following splicing of the front end of the second reel and the rear end of the first reel, the third roller being connectable to drawing means for subjecting its circumferential surface to a vacuum.

[0026] Preferably, the first and second reels of web material are arranged in respective side-by-side working positions rotatably supported about parallel axes by respective powered coupling members and are coplanar.

[0027] Advantageously, said splicing assembly is carried by a movable assembly adapted to translate the same splicing assembly axially relative to said roller by a stroke the amplitude of which is greater than the thickness of the web material.

[0028] Preferably, the movable assembly is movable between a working position in which it is flush with the first and second reels of web material and a stored position in which the splicing assembly does not engage the web material being unwound from the reels.

[0029] Preferably, the movable assembly is capable of angularly rotating the joint assembly between first and second working positions which are mirror images of each other.

[0030] The present invention also relates to a method for automatically splicing reels of web material, the method comprising the steps of: (a) providing a reel of web material;

[0031] a. a first unwinding reel of web material is positioned in a working position alongside a second reel of web material supplying the same web material alongside, the first reel and the second reel being rotatable about parallel axes of rotation; b. Associating the leading end of said second reel of web material with a gripping means rotated by the same second reel (22) of web material, said leading end carrying an adhesive means (4) on its outwardly facing side; c. detecting a remaining diameter of said first unwind reel of said web material by sensor means; d. rotating the second reel of the web material upon detecting a predetermined remaining diameter of the first unwind reel of the web material; e. cutting the trailing end of said first unwind reel of web material; f. engaging the trailing end of the first reel of web material with a splice assembly located downstream of the first reel according to a feed direction of the web material; g. applying the trailing end of the first reel of web material onto the leading end of the second reel of web material that is rotated by the gripping means integrally with the second reel of web material; h. joining said trailing end and said leading end of said reel of web material by said adhesive means associated with the same leading end of said second reel.

[0032] The subject method provides for rotating a second reel of web material at a peripheral speed that substantially corresponds to the feed rate of said web material to the machine in which it is used.

[0033] According to one aspect of the invention, the method provides for engaging the trailing end of a first reel of web material with a plurality of rollers of the splicing assembly, the rollers being rotatable in an appropriate phase relationship according to their respective axes of rotation, the axes of rotation being parallel to the axes of rotation of the reels, to sequentially grip the web material unwound from the first reel, cut the trailing end of the first reel, transfer the trailing end of the first reel onto the leading end of the second reel, and splice the trailing end to the leading end with a label of the adhesive material.

[0034] According to a further aspect of the invention, the method includes, at the completion of the joining process of the trailing and leading ends of the reels, translating the splicing assembly from a working position coplanar with the first and second reels of web material to a retracted position in which the rollers of the splicing assembly do not engage the web material being unwound from the reels.

[0035] Advantageously, with the joining assembly in the retracted position, the method provides for angularly rotating the joining assembly between first and second working positions which are mirror images of each other to prepare the roller for a subsequent joining operation.

[0036] DESCRIPTION OF THE DRAWINGS Details of the invention will become more apparent from the detailed description of a preferred embodiment of an apparatus for automatically splicing reels of web material, as shown by way of example in the accompanying drawings.

[0037] FIG. 1 is a side view of an apparatus for automatically splicing reels of web material in accordance with the present invention.

[0038] FIG. 2 is an enlarged portion of the apparatus shown in FIG.

[0039] 3 and 4 are side and front views, respectively, of a portion of the device.

[0040] 5 to 12 are schematic side views of the apparatus at subsequent stages of operation.

[0041] (Description of the embodiment of the present invention) With particular reference to these figures, an apparatus for automatically splicing reels of web material is generally designated by the reference numeral 1. In particular, in the figures, the numerals 21 and 22 respectively designate a first unwinding reel of web material 2 for feeding said web material 2 to an automatic machine that uses said web material 2 for production purposes, and a second unwinding reel of web material 2 for replacing the first unwinding reel when the first unwinding reel has expired. In the following, for simplicity, the reels 21, 22 will also be referred to as the running reel and the new reel.

[0042] Within the scope of the present invention, automatic splicing of reels of web material means splicing the rear end of an out-of-material reel to the front end of a new reel in order to make the supply of web material to the machine continuous.

[0043] The reels 21, 22 of web material are adapted to be supported in a substantially coplanar working position by a frame of the apparatus, not shown in the drawings, in a manner known in the art, with their respective axes of rotation parallel, preferably horizontal.

[0044] Of course, sets of reels of different types of web material can be placed on the apparatus frame and fed into the machine simultaneously.

[0045] The reels 21, 22 of web material are adapted to be inserted in known manner onto respective coupling members which are rotated by special drive members, said coupling members consisting essentially of a cylindrical hub 10, on which the tube or spindle 23 of the reel of web material is adapted to engage.

[0046] According to the invention, a gripping member 3 for the leading edge of the same web material is associated with each reel of web material. In a preferred embodiment, said gripping member 3 consists of a radius arm 30 provided at its free end with a vane 31 adapted to be connected to a drawing means for presenting its surface towards the outside of the reel under vacuum (see Figures 3 and 4). The radius arm 30 is pivotally attached to the reel and rotates at the same angular speed.

[0047] The vacuum vane 31 is adapted to hold said leading end of the web material having an adhesive label 4 applied to its outward facing side on the reel.

[0048] Advantageously, the gripping member 3 is adapted to be driven radially relative to the reel of web material, as defined below, to facilitate bringing the leading end of the second reel of web material into contact with the trailing end of the first out-of-material reel of web material.

[0049] The device 1 comprises a splicing assembly 5 suitable for joining the rear end of a first reel 21, which is about to run out of material, to the front end of a second reel 22, which is carried by the blades 31 of the gripping members 3 of the second reel 22, to which a label 4 of adhesive material is affixed (see FIG. 2). The splicing assembly 5 comprises a number of rollers rotatable in a suitable phase relationship according to respective axes of rotation parallel to the axes of rotation of the reels 21, 22. The rollers may have a rubberized outer surface for better grip on the web material.

[0050] Advantageously, the rollers of the splice assembly 5 are arranged coplanar and counter-rotating relative to one another.

[0051] In particular, the splicing assembly 5 includes a first roller 51 for unwinding the web material 2, which roller is connectable to a drawing means for placing its circumferential surface under vacuum during operation and holds the web material 2 unwound from the first reel 21.

[0052] Downstream of the first unwinding roller 51 is arranged a second roller 52 which transfers the rear end of the first reel 21 onto the front end of the second reel 22 in the forward direction of the web material 2. Means 6 for cutting the web material 2 unwound from the first reel 21 are suitable for defining said rear end and are mounted on the second transfer roller 52. In a preferred embodiment, the cutting means 6 consists of a blade 60 housed in a seat 61 formed radially on the body of the second roller 52. The blade 60 protrudes from the second roller 52 to cut the web material 2 and is movable between an inactive retracted position and an advanced position.

[0053] Downstream of the second transport roller 52 is arranged a third roller 53 which drives the web material 2 fed into the machine after joining the front end of the second reel 22 with the rear end of the first reel 21. The third drive roller 53 can be connected to drawing means for subjecting its periphery to a vacuum.

[0054] As will be better defined below, the splicing assembly 5 is carried by a movable assembly, not shown in the drawings, adapted to position the rollers 51, 52, 53 according to the arrangement of the reel of web material to be unwound. In particular, this movable assembly is adapted to translate the splicing assembly 5 in the axial direction of the rollers 51, 52, 53 by a stroke having a width greater than the thickness of the web material 2, and to rotate the same splicing assembly 5 according to a horizontal axis parallel to the axes of the same rollers 51, 52, 53 between a first polishing position and a second polishing position.

[0055] The operation of the apparatus for automatically splicing reels of web material can be readily understood from the following description.

[0056] When a special sensor means known in the art detects that the diameter of the running reel 21 has reached a predetermined value, i.e., that the same running reel 21 has reached the end of its life within a predetermined time, the rotation of a new reel 22, which has been set in a working position in advance, is operated.

[0057] It should be noted that at this stage, the counter-rotating rollers 51, 52, 53 of the splicing assembly 5 are arranged in a coplanar working position relative to the reels 21, 22 of web material. Preferably, the rollers 51, 52, 53 have the same peripheral speed. The web material 2 unwound from the first reel 21 sequentially engages these rollers 51, 52, 53 of the splicing assembly 5 and runs freely between them, as can be seen in FIG.

[0058] The second reel 22 is rotated at a peripheral speed substantially equal to the unwinding speed of the web material 2 from the first reel 21. During this process, the leading end of the web material from the second reel 22 is wound around the outer circumferential surface of the same second reel 22 and held in close contact therewith by the vacuum blades 31 of the gripping member 3 which rotates integrally with the second reel 22.

[0059] When it is detected that the first reel 21 is nearing the end of its life, the drawing means is activated to apply a vacuum to the outer circumferential surface of the first roller 51. In this way, the web material 2 is held on the evacuated outer circumferential surface of the first roller 51.

[0060] In the correct phase relationship, the cutting means 6, transported by the second transport roller 52, is in a radial position relative to the first unwinding roller 51 (Figure 5). At this moment, a blade 60 is activated which cuts the web material 2. The cut web material defines the rear end of the reel 21 downstream of the cutting line, which then continues to advance over the second roller 52 and is joined to the front end of a new reel 22, thus ensuring a continuous supply of web material to the machine. The web material remaining upstream of the cutting line is instead held by the first vacuum roller 51 and wound onto the same first roller.

[0061] The rollers 51, 52, 53 of the splicing assembly 5 rotate synchronously with the rotation of the new reel 22, thereby bringing the rear end of the first reel 21 in the correct phase relationship ahead of the front end of the new reel 22 carried by the vacuum blades 31 of the gripping member 3 (FIG. 6). In this way, the joining of the two ends of the reels 21, 22 is achieved thanks to the adhesive label 4.

[0062] Advantageously, to facilitate this joining operation, the vacuum blades 31 of the gripping member 3 can be moved radially outward with a very limited amplitude so as to press the front end of the new reel 22 carrying the label 4 of adhesive material against the opposite rear end of the first reel 21 carried by the second roller 52.

[0063] After joining the two ends of the reels 21, 22, the web material 2 continues to run over the third drive roller 53 and is unwound from the second reel 22 (Figure 7). In practice, the web material 2 is clamped between the second and third drive rollers 52, 53 with a pressure that is appropriately adjusted so that it does not run against the rollers 52, 53. The passage of the web material 2 between the second and third rollers 52, 53 also has the function of compressing the labels 4 in the adhesive material and ensuring their grip.

[0064] When the splicing of the reels of web material is completed, the movement of the movable assembly is operated to move the splicing assembly 5 to a retracted position so as to disengage the web material 2, and to rotate itself about a horizontal axis in a working position mirroring that of the splicing assembly 5 before rotation (see Figures 8 to 11).

[0065] At the same time, the out-of-material reel is automatically removed from the hub 10 in a known manner and a new subsequent reel 24 is inserted in its place (FIG. 12). It should be noted that in the new configuration, the rollers of the splicing assembly 5 are rotated towards the second reel 22 in their previous mirror position, i.e. rotated 180°. In this way, the apparatus is prepared for the subsequent operation of splicing reels and a continuous supply of web material to the apparatus is ensured.

[0066] The method and apparatus for automatically splicing reels of web material according to the present invention achieves the objective of optimally performing automatic splicing of reels of web material in machines that use such web material for the manufacture or packaging of products.

[0067] In particular, it has been found that the method and apparatus for automatically splicing reels of web material according to the present invention allows for high operating speeds and allows for continuous supply of web material even when the machine is configured to operate at very high speeds.

[0068] This has become possible thanks to the inventive idea of ​​equipping a reel of web material with a gripping member capable of holding the front end of said web material close to the outer surface of the reel, which is equipped with adhesive means suitable for splicing the rear end of a run-out reel, and of providing a splicing assembly capable, on a specific command, of separating the rear end of the web material from the run-out reel and applying this rear end to the end of a new reel to perform automatic splicing.

[0069] Another feature of the present invention is the fact that the splicing assembly can be prepared for subsequent reel changes while the running reel is feeding the web material, thereby avoiding downtime or slowdowns in splicing the ends of the reels and allowing for continuous feeding of the web material to the machine.

[0070] In practice, the joining of the reel ends, and therefore the replacement of the reel itself, is carried out on a web material that is unwound at a feed rate set by the machine, so that the device adapts to the operating speed of the machine.

[0071] The devices described as examples are susceptible to numerous modifications and variations to suit different needs.

[0072] In practical embodiments of the present invention, the materials used, as well as the shapes and dimensions, can be varied as required.

[0073] Where reference signs are used to refer to technical features described in the claims, the reference signs are used strictly for the purpose of enhancing the understanding of the claims and are therefore not to be considered limiting in any way on the elements identified by the reference signs for illustrative purposes. [Brief explanation of the drawings]

[0074] [Figure 1] 1 is a side view of an apparatus for automatically splicing reels of web material in accordance with the present invention; [Figure 2] 2 is an enlarged portion of the device shown in FIG. 1. [Figure 3] 1A and 1B are side and front views, respectively, of a portion of the device. [Figure 4] 1A and 1B are side and front views, respectively, of a portion of the device. [Figure 5] 5A and 5B are schematic side views of the device in subsequent operating steps. [Figure 6] 5A and 5B are schematic side views of the device in subsequent operating steps. [Figure 7] 5A and 5B are schematic side views of the device in subsequent operating steps. [Figure 8] 5A and 5B are schematic side views of the device in subsequent operating steps. [Figure 9] 5A and 5B are schematic side views of the device in subsequent operating steps. [Figure 10] 5A and 5B are schematic side views of the device in subsequent operating steps. [Figure 11] 5A and 5B are schematic side views of the device in subsequent operating steps. [Figure 12] 5A and 5B are schematic side views of the device in subsequent operating steps.

Claims

1. 1. A method for automatically splicing reels of web material, comprising: a) placing a second reel (22) of web material (2) in a working position, the second reel (22) being arranged side by side with a first unwinding reel (21) of web material (2) and supplying the same web material (2) side by side, said first and second reels (21, 22) being rotatable on parallel axes of rotation; b) associating the leading end of said second reel (22) of web material with a gripping means (3) rotated by the same second reel (22) of web material, said leading end carrying an adhesive means (4) on its outwardly facing side; c. detecting the remaining diameter of said first unwind reel (21) of web material by sensor means; d. rotating the second reel (22) of web material upon detecting a predetermined remaining diameter of the first unwind reel (21) of web material; e. Cutting the trailing end of said first unwind reel (21) of web material; f) engaging the trailing end of the first reel (21) of web material with a splice assembly (5) located downstream of the first reel (21) according to the feed direction of the web material (2); g. applying the trailing end of the first reel (21) of web material to the leading end of the second reel (22) of web material which is rotated by the gripping means (3) together with the same second reel (22) of web material; h) joining said rear end and said front end of the reels (21, 22) of web material together by said adhesive means (4) associated with the same front end of said second reel (22).

2. 1. An apparatus for automatically splicing reels of web material, comprising: a splicing assembly (5) adapted to take the trailing end of a first reel (21) of web material (2) that is about to run out of material and apply it to the leading end of a second reel (22) of web material; The said front end is rotated by the same second reel (22) at the same angular velocity and is held adjacent to said second reel (22) of web material by gripping means (3) carrying a label (4) of adhesive material on its outwardly facing side.

3. said gripping means (3) comprising a radius arm (30) provided at its free end with a vane (31) connectable to a suction means for placing its outwardly facing surface under vacuum; 3. The apparatus of claim 2, wherein the radius arm (30) is pivotally mounted to the reel (22) and rotates therewith at the same angular velocity.

4. the splicing assembly (5) includes a plurality of rollers (51, 52, 53) rotatable in a suitable phase relationship according to respective rotation axes parallel to the rotation axes of the reels (21, 22); 4. The apparatus according to claim 2 or 3, wherein the rollers sequentially grip the web material (2) unwound from the first reel (21), cut the rear end of the same first reel (21), transfer the rear end of the first reel (21) onto the front end of the second reel (22), and join the rear end and the front end via the label (4) of the adhesive material.

5. the splicing assembly (5) comprising a first roller (51) for gripping and unwinding the web material (2); 5. Apparatus according to any one of claims 2 to 4, wherein the first roller (51) is connectable to drawing means for placing a vacuum on its periphery so as to hold the web material (2) unwound from the first reel (21).

6. 6. The apparatus according to claim 5, wherein the splicing assembly (5) comprises, downstream of the first roller (51), a second roller (52) for transferring the trailing end of the first reel (21) onto the leading end of the second reel in accordance with the direction of travel of the web material (2), and means (6) carried on the second roller (52) for cutting the web material (2) unwound from the first reel (21), suitable for separating the trailing end.

7. 7. The device according to claim 6, wherein the cutting means (6) comprises a blade (60) housed in a seat (61) formed radially in the body of the second roller (52), the blade (60) protruding from the second roller (52) to cut the web material (2) and operable between an inoperative retracted position and an advanced position.

8. 8. Apparatus according to claim 7, wherein the splicing assembly (5) comprises a third roller (53) downstream of the second roller (52) for driving the supplied web material (2) once the front end of the second reel (22) has been spliced ​​to the rear end of the first reel (21), the third roller (53) being connectable to drawing means for placing its circumferential surface under vacuum.

9. 9. Apparatus according to any one of claims 4 to 8, wherein the joining assembly (5) is held by a movable assembly adapted to translate axially relative to the rollers (51, 52, 53) with a stroke width greater than the thickness of the web material (2).

10. 10. Apparatus according to any one of claims 4 to 9, wherein said joining assembly (5) is carried by a movable assembly adapted to rotate the same joining assembly (5) about a vertical axis between a first working position and a second working position.

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