Decoiler assembly

Abstract

The specification describes a Decoiler Assembly and its method of operation, together with systems, apparatus and methods of coil management. The Decoiler assembly includes a plurality of feed assemblies which can be selectively moved between a feeding position and a loading position.

Description

"Decoiler assembly"Technical Field

[0001] The present disclosure relates to an improved decoiler assembly for feeding sheet material to a production line. The present disclosure further relates to systems and methods of managing coils of sheet metal on-site.Background

[0002] The processing of sheet material finds application in many industries to manufacture a wide variety of products. Roll forming is one way to process sheet materials, and it uses a roll former to bend long strips of sheet material (typically metal) into a desired shape. The roll former has sets of shaped rollers, through which strips of sheet material pass to apply pressure to the sheet material to form the desired shape.

[0003] Typically, the sheet material to be processed in the roll former is manufactured and shipped in large diameter coils to minimise the volume taken up by the material and for easier handling. The coils of sheet material, which may include coils of sheet material having different properties (e.g. width, gauge, material, colour), can then be stored on-site in a coil farm until they are to be processed.

[0004] Decoilers are used in such processing facilities to deliver lengths of sheet material from the coils. In typical decoilers, coils of sheet material are mounted on a rotating mandrel, which can be driven to feed the sheet material to the roll forming line or allows for the sheet material to be pulled through the roll forming line. Once the coil is exhausted, or when a different sheet material is required for a production run, the production line is halted while a new coil is loaded onto the decoiler. The downtime experienced during this change of coil decreases production capacity, therefore, loss of profit. If multiple coil changes are required in a day, then the resulting downtime from coil changeover is significant.

[0005] To reduce the effects of coil change over, manufacturers often do longer production runs to produce inventory of all products made using a specific sheet metal, that is exhausting the entire coil. However, this can complicate production planning by requiring reasonable foresight of what products need to be produced on a given day. It also creates storage and handling difficulties for the produced products that take up a greater storage footprint and are more challenging to handle in comparison to the coiled starting material.

[0006] Yet a further challenge is to enable fast production of products using a specific coil at relatively short notice, without affecting production capacity or efficiency.

[0007] The present disclosure aims to provide an improved decoiler, and associated improved methods and systems for managing coils of sheet material onsite.

[0008] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims.Summary

[0009] Thus, according to one aspect of the present disclosure, there is provided a decoiler assembly for supplying sheet material to a production line, comprising: a frame; a first mandrel rotatably mounted to the frame, the first mandrel configured for receiving and selectively holding a coil of sheet material, the first mandrel having a feeding position for feeding sheet material to the production line and a loading position for loading and unloading coils of sheet material;a second mandrel rotatably mounted to the frame, the second mandrel configured for and selectively holding a coil of sheet material; at least one feed unit associated with the first and second mandrels for feeding sheet material to the production line; and at least one cutting unit associated with the first and second mandrels for selectively cutting sheet material being fed to the production line; and an actuator arrangement configured to move the first mandrel between the feeding position and the loading position.

[0010] According to another aspect of the present disclosure, there is provided a coil management system, comprising: a decoiler assembly according to the present disclosure; a coil farm for storing a coils of sheet material for loading onto the decoiler and receiving coils unloaded from the decoiler; and a coil transfer system for transporting coils of sheet material between the coil farm and the decoiler assembly for loading and unloading the mandrels in the loading position.

[0011] According to another aspect of the present disclosure, there is provided a decoiler assembly for supplying sheet material to a production line, comprising: a frame; a first feed assembly and a second feed assembly, wherein the first feed assembly comprises a first mandrel rotatably mounted to the frame, the first mandrel configured for receiving and selectively holding a coil of sheet material, andthe second feed assembly comprises a second mandrel rotatably mounted to the frame, the second mandrel configured for receiving and selectively holding a coil of sheet material, wherein the first feed assembly and the second feed assembly are each configured for feeding the sheet material to the production line; the decoiler assembly further comprising at least one cutting unit for selectively cutting sheet material being fed to the production line by the first feed assembly and the second feed assembly.

[0012] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, comprising an actuator arrangement configured to move the cutting arrangement with respect to the first mandrel and the second mandrel, at a speed relative to the speed of the sheet material being fed to the production line from a coil on the first mandrel or the second mandrel.

[0013] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the first feed assembly comprises a first cutting arrangement configured to cut the sheet material on a coil on the first mandrel as that is being fed to the production line, and the second feed assembly comprises a second cutting arrangement configured to cut the sheet material on a coil on the second mandrel as that is being fed to the production line.

[0014] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the first feed assembly further comprises a first mandrel drive configured move the first cutting unit with respect to the first mandrel at a speed relative to the speed of the sheet material being fed from a coil on the first mandrel to the production line.

[0015] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the second feed assembly further comprises a second mandrel drive configured move the second cutting unit with respect to the second mandrel at a speed relative to the speed of sheet material on a coil on the second mandrel being fed to the production line.

[0016] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, further comprising a feed assembly actuator configured to move at least one of the first feed assembly and the second assembly from a respective feeding position and loading position.

[0017] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the feed assembly actuator is configured so that when one of the first feed assembly and the second feed assembly is in the feeding position, the other of the first feed assembly and second feed assembly is in the loading position.

[0018] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the feed assembly actuator is configured to move the first feed assembly to the feeding position and the second feed assembly to the loading position at substantially the same time.

[0019] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the feed assembly actuator comprises the frame, a base, and an actuator, and wherein the feed assembly actuator is configured to rotate the frame with respect to the base to thereby move the first feed assembly to the feeding position and the second feed assembly to the loading position.

[0020] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the frame is configured to rotate about a substantially vertical axis to move the first feed assembly betweenthe feeding position and the loading position, and to move the second feed assembly between the feeding position and the loading position.

[0021] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the first feed assembly comprises a first mandrel drive configured to rotate the first mandrel, and the second feed assembly comprises a second mandrel drive configured to rotate the second mandrel.

[0022] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein at least one of the first mandrel drive and the second mandrel drive is configured to rotate the first mandrel and the second mandrel in a first direction to facilitate feeding of sheet material to the production line and a second direction to facilitate retraction of sheet material back onto a coil.

[0023] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein at least one of the first mandrel drive and the second mandrel drive is configured to rotate its respective mandrel at variable speeds.

[0024] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the first mandrel drive is configured to rotate the first mandrel in a second direction to retract the sheet material onto the first coil after it has been cut by the first cutting unit.

[0025] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the second mandrel drive is configured to rotate the second mandrel in a second direction to retract the second sheet onto the second coil after it has been cut by the second cutting unit.

[0026] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the first mandrel holds the first coil of sheet material and the second mandrel holds a second coil of sheet material, and wherein the decoiler assembly is configured to:(a) move the first feed assembly into the feeding position;(b) engage a / the first mandrel actuator to rotate the first mandrel to feed sheet material from the first coil to the production line;(c) engage a / the cutting assembly or a / the first cutting unit to cut the sheet material from the first coil and form a rear edge in the sheet;(d) engage the actuator arrangement to move the second feed assembly to the feeding position;(e) engage a / the second mandrel actuator to rotate the second mandrel to feed sheet material from the second coil to the production line at a relatively fast speed to move a leading end of the sheet material on the second coil closer to the rear end.

[0027] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the first feed assembly further comprises a supplementary feed arrangement configured to, in use, orientate and tension sheet material on a coil on the first mandrel as it is fed to the production line.

[0028] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the second feed assembly further comprises a supplementary feed arrangement configured to, in use, orientate and tension sheet material on a coil on the second mandrel as it is fed to the production line.

[0029] According to another aspect of the present disclosure, there is provided a decoiler assembly as substantially described herein, wherein the first feed assembly further comprises a first feed unit and the second feed assembly further comprises a second feed unit.

[0030] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.Brief Description of Drawings

[0031] Specific embodiments of the invention will now be described by way of example only, with reference to the accompanying drawings in which:

[0032] Figure 1 is a side view of a decoiler assembly according to an embodiment of the present disclosure;

[0033] Figure 2A is a side view of a roll forming production line incorporating a decoiler assembly according to an embodiment of the present disclosure;

[0034] Figure 2B is a close-up view of Detail A noted in Figure 2A;

[0035] Figure 2C is a close-up view of Detail B noted in Figure 2A;

[0036] Figure 3 is a top view of a coil management system according to an embodiment of the present disclosure, showing a decoiler assembly, a coil transport assembly, and a coil farm;

[0037] Figure 4 is a top view of a decoiler assembly according to an embodiment of the present disclosure;

[0038] Figures 5 A to 5E are close-up cut through schematics showing operation of a decoiler assembly and method according to an embodiment of the present disclosure.Description of EmbodimentsDecoiler Assembly

[0039] Referring first to Figures 1 to 4, there is provided a decoiler assembly 100 for supplying sheet material 410 to a production line 500.

[0040] The decoder assembly 100 comprises at least first feed assembly indicated generally as 200, and optionally a second feed assembly indicated generally as 300. The feed assemblies 200, 300 are configured to selectively feed sheet material from coils provided to each of the feed assemblies 200, 300, into the production line 500.

[0041] The decoiler assembly also includes a support structure having a frame 110 mounted on a base 120. In the illustrated embodiment, the first feed assembly 200 and the second feed assembly are each provided to the frame 110.

[0042] Each feed assembly 200, 300 includes a respective mandrel 210, 310. Each mandrel 210, 310 is configured for receiving a coil 400 of sheet material 410. The outer diameter of the mandrels 210, 310 may be adjustable such that it can be reduced to facilitate loading and unloading of coils 400, and expanded to clamp to a coil 400 or provide a strong friction fit for retaining the coil 400 on the mandrels 210, 310. This may be particularly important during decoding operation to ensure the coil 400 is securely held as the mandrel 210, 310 rotates while sheet material 410 is fed to the production line 500. In addition, the adjustable mandrel 210, 310 allows for the decoiler assembly 100 to be used with coils 400 having differing internal diameters.

[0043] The decoder assembly 100 further comprises at least one feed unit associated with the first and second mandrels for feeding sheet material to the production line. A single feed unit may be provided which is positioned to receive sheet material 410 from both the first and second mandrels 210, 310 when in a feeding position (as is discussed in more detail below). Alternatively, a first feed unit 220 may be provided to the first feed assembly 200 and thereby associated withthe first mandrel 210, and a second feed unit 320 may be provided with the second feed assembly 300 and thereby associated with the second mandrel 310. Where two feed units are provided, the first and second feed units 220, 320 each receive sheet material 410 from a coil 400 loaded on the associated first or second mandrel 210, 310 and facilitate decoiling of the sheet material 410 from the coil and feeding that to the production line 500.

[0044] The decoiler assembly further comprises at least one cutting unit associated with the first and second mandrels for selectively cutting sheet material being fed to the production line 500. A single cutting unit may be provided which is positioned to receive sheet material 410 from both the first and second mandrels 210, 310 when in their respective feeding positions. Alternatively, a first cutting unit 230 may be provided to the first feed assembly 200 and thereby associated with the first mandrel 210, and a second cutting unit 330 may be provided to the second feed assembly 300 and thereby associated with the second mandrel 310. Where two cutting units are provided, the first and second cutting units 230, 330 are each arranged such that sheet material 410 being fed to the production line 500 from the associated first or second mandrel 210, 310 interacts with the at least one cutting unit 230, 330 in a manner allowing for selective cutting of the sheet material 410 being fed to the production line 500.

[0045] Each of the first feed assembly 200 and the second feed assembly 300 have a feeding position and a loading position. In the feeding position, the mandrels 210, 310 are in position to allow for feeding sheet material 410 from a coil 400 loaded on the mandrel 210, 310 to the production line 500 via the respective feed units 220, 320, and cutting units 230, 330. In the loading position, the mandrels 210, 310 are in a position that facilitates loading and unloading of coils 400 onto or off from one mandrel 210, 310 while the other mandrel 210, 310 is in the feeding position supplying the sheet material 410 to the production line 500. That is, when one of the first and second mandrels 210, 310 is in the feeding position, the other of the first and second mandrels 210, 310 is in the loading position.

[0046] Providing an arrangement by which coils 400 can be loaded and unloaded on one mandrel 210, 310 while the other mandrel 210, 310 is in operationsupplying sheet material 410 to the production line 500 can reduce the time taken to change which coil 400 is supplying sheet material to the production line 500. The arrangement of the present disclosure further facilitates a dynamic operation of the production line 500 by allowing the quick change of coils 400 to produce products on demand without significant downtime, as well as removing the need to store excess products produced by completing a production run by running down a loaded coil 400.

[0047] In some embodiments, one of the first and second mandrels 210, 310 is moveable between the feeding position and the loading position. That is, one of the mandrels 210, 310 may be fixed such that the feeding position and the loading position are the same position. In this embodiment, the other of the mandrels 210, 310 may be moveable relative to the fixed mandrel 210, 310 between the loading and feeding positions. In one example of this embodiment, the mandrels may be vertically staggered.

[0048] In some embodiments, both the first and the second mandrels 210, 310 are moveable between their respective feeding and loading positions. For instance, the decoiler assembly 100 may further comprise a feed assembly actuator configured to move the first mandrel 210 between the feeding position and the loading position. The feed assembly actuator may further be configured to move the second mandrel 310 between the feeding position and the loading position.

[0049] In some embodiments, the feed assembly actuator comprises the frame 110 and a drive unit 110a which is configured to rotate of the frame 110 relative to the base 120. As the first feed assembly 200 and second feed assembly 300, and therefore also the mandrels 210, 310, are mounted to the frame 110 this rotation also moves the feed assemblies 200, 300. For example, the frame 110 may be rotatably mounted to the base 120 such that it is rotatable about a substantially vertical axis.

[0050] The first feed assembly 200 and the second feed assembly 300 may each be configured to rotate their respective mandrels 210, 310. This may be achieved by providing at least one mandrel actuator, and preferably a first mandrel actuator 210A provided to and configured to rotate the first mandrel 210, and a second mandrelactuator 310A provided to and configured to rotate the second mandrel 310. The mandrel actuator(s) 210A, 310A can rotate the mandrels 210, 310 to facilitate feeding sheet material from the coils 400 to the production line 500. In addition, the speed of rotation may be variable to assist in reducing the change overtime in swapping from coil 400 on the first feed assembly 200 to coil 400 on the second feed assembly. The mandrel actuators 210A, 310A may also be able to rotate the mandrels 210, 310 in two directions to facilitate both of feeding out of sheet material and retracting sheet material back onto a coil 400 e.g. provide a decoiling and coiling function.

[0051] Where a first feed unit 220 and first cutting unit 230 are provided, the first feed unit 220 and the first cutting unit 230 may be mounted on the frame 110 such that the sheet material 410 supplied by the first mandrel 210 is fed through the first feed unit 220 and first cutting unit 230 to the production line 500.

[0052] In the illustrated embodiment, the first feed assembly 200 includes a first platform 130 on which the first feed unit 220 and first cutting unit 230 are mounted.

[0053] The platform 120 is mounted on the frame 110, which helps to keep the first feed unit 220 and first cutting unit 230 in fixed alignment with the first mandrel 210 during rotation of the frame 110 to move the first mandrel 210 between the feeding and loading positions. In this embodiment, after loading of the first mandrel 210, the leading end of the loaded coil 400 may be fed to the first feed unit 220, thus priming the first feed unit 220 with sheet material 410 prior to or during movement into the feeding position. With the sheet material 410 already in position to be fed to the production line 500, the first feed unit 220 is primed to begin feeding sheet material 410 into the production line 500 as soon as the first mandrel 210 is in the feeding position or as otherwise required, thus minimising disruption to the production line 500 when changing to the coil 400 of sheet material on the first mandrel 210 as the feed source.

[0054] Similarly, the second feed assembly 300 includes a second platform 140 on which the second feed unit 320 and the second cutting unit 330 are mounted. The platform 140 is mounted on the frame 110 such that the sheet material 410 suppliedby the second mandrel 310 is fed through the second feed unit 320 and second cutting unit 330 to the production line 500.

[0055] By being mounted on the frame 110, the second feed unit 320 and second cutting unit 330 remain in fixed alignment with the second mandrel 310 during rotation of the frame 110 to move the second mandrel 310 between the feeding and loading positions. In this embodiment, after loading of the second mandrel 310, the leading end of the loaded coil 400 may be fed to the second feed unit 320, thus priming the second feed unit 320 with sheet material 410 prior or during to movement into the feeding position. With the sheet material 410 already in position to be fed to the production line 500, the second feed unit 320 is primed to begin feeding sheet material 410 into the production line 500 as soon as the second mandrel 310 is in the feeding position, thus minimising disruption to the production line 500 when changing to the coil 400 of sheet material on the second mandrel 310 as the feed source.

[0056] The first feed assembly 200 and the second feed assembly 300, are each provided with a feed assembly actuator which are configured to move the feed units 220, 320 and cutting units 230, 330 relative to their respective mandrel 210, 310. In the illustrated embodiment, the feed assembly actuators 212, 312 are provided by rams 212, 312, and sub-platforms 214, 314 which are movably mounted to a respective one of the platforms 130, 140. In use, extension and contraction of the rams 212, 312 causes the sub-platforms 130, 140 to move away from or towards the respective mandrels 210, 310. In addition, rails 212B 312B may be provided to facilitate or guide movement of the sub-platforms 130, 140.

[0057] Operation of the ram(s) 212, 312 is configured to move the sub-platforms 214, 314 synchronously with the sheet material 410 being feed into or through the feed units 220, 330 and cutting units 230, 330. That is, the feed units 220, 320 move at the same speed as the sheet material 410. This may facilitate cutting of sheet material 410 as it is continuing to be fed into the production line 500, thereby reducing or eliminating the need to completely stop feeding of sheet material when changing between the first feed assembly 200 and the second feed assembly 300.

[0058] Referring now to Figures 4 and 5a, which show more details of the first feed assembly 200. It should be understood that the configuration of the second feed assembly 300 is identical to the first feed assembly 200 and that it includes identical components and functions.

[0059] The first feed unit 220 includes a drive system, e.g. a pair of drive rollers 222A, 222B, that are configured to in use rotate and provide a force to assist or facilitate movement of the sheet material through the first feed unit 220.

[0060] In addition, the drive rollers 222A, 222B may help to align the sheet material 410 with respect to the cutting unit 230.

[0061] The cutting unit 230 includes a cutting arrangement configured to cut sheet material 410 as required. In the illustrated embodiment, the cutting arrangement is provided by at least one guillotine blade 234 which can be selectively actuated to move towards and cut the sheet material 410.

[0062] The first feed assembly 200 includes additional components to facilitate feeding of sheet material 410 into the first feed unit 220 and first cutting unit 230. For instance, a supplementary feed arrangement may be provided to facilitate feeding of the sheet material 410 into the first feed unit 220 at a desired orientation and / or tension. In the illustrated embodiment, the supplementary feed arrangement is provided by one or more of a first guide roller 213, a guide 215, and a second guide roller 217.

[0063] The first guide roller 213 is movably mounted to the first feed assembly 200, and configured to move between an engaged position and a retracted position e.g. by rotating about pivot point 216. In the engaged position, the first guide roller 213, whereas in the retracted position the first guide roller 213 does not hinder loading of a coil 400 onto the mandrel 200. In addition, in-use, the first guide roller 213 tensions the sheet material 410 to facilitate it being fed into the feed unit 220 at a desired orientation, to facilitate it being cut or fed into the production line 500.

[0064] The feed unit guide 215 and the second guide roller 217 facilitate feeding of the sheet 410 into the feed unit 220 at a required orientation.

[0065] The supplementary feed arrangement may also include at least one side roller e.g. a pair of side rollers 218a, 218b which are located between the first feed unit 220 and the first cutting unit 230. Thes side rollers 218a, 218b may further assist with alignment and positioning of the sheet material as it is fed into the first cutting unit 230.

[0066] The supplementary feed arrangement may also facilitate automatic feeding of the sheet 410 into the feed unit 220 irrespective of the width of the sheet or thickness of coil 400. Therefore, manual labour to feed the sheet 410 into the feed unit 220 is not required. This may provide a significant safety improvement by ensuring than workers are not required to be close to moving components of the decoder assembly 100.

[0067] Operation and Method of Manufacture

[0068] Referring now to Figures 5A to 5D which are schematics showing operation of the decoder assembly 100.

[0069] In Figure 5A, the first feed assembly 200 is loaded with a coil 400A of sheet material 410a. The first mandrel drive 210A is engaged to rotate the mandrel 210, which causes the sheet material 410A to be fed through first feed unit 220, first cutting unit 230, and into production line 500.

[0070] As can be seen in Figure 5A, the actuator 212 has positioned the subplatform 214 relatively close to the first mandrel 210.

[0071] When it is desired to change from a coil 400A to a second coil 400B, a change signal is sent by a control system (not illustrated) to the decoiler assembly 100. The first feed assembly actuator 212 is engaged to move the sub-platform 214 away from the first mandrel 210 in the direction of travel of the sheet material 410A e.g. in the direction indicated by arrow A in Figure 5A.

[0072] The first cutting unit 230 is engaged, and guillotine blade 234 moves towards, and applies sufficient force to cut, the sheet material 410A. As the subplatform 214 is moving at the same speed as the sheet material 410A it can be cut without having to stop feeding of the sheet material 410A into the production line 500. This position is shown in Figure 5B.

[0073] The guillotine blade 234 is retracted. The first mandrel 210 is stopped rotating and engaged to rotate in a reverse direction. This retracts the potion of the sheet material 410A between the guillotine blade 234 and the first mandrel 210 to be retracted back onto the coil 400 A. When the sheet material 410A has been fully retracted onto the coil 400A the mandrel drive actuator 210A is disengaged.

[0074] The feed assembly actuator can be engaged to move the first feed assembly 200 from the feeding position into the loading position. This can occur as soon as the trailing end 410C of the sheet material 410A is clear of the first feed assembly 200 e.g. out of the cutting unit 230. This is beneficial to reducing the change over time between coils. However, it can also occur after the uncut portion of the sheet material 410A has been retracted back onto the coil 410.

[0075] Due to the configuration of the feed assembly actuator 110A, the second feed assembly 300 is moved into the feeding position at the same time as the first feed assembly 200 is moved into the loading position. This is achieved by rotating the frame 110 with respect to the base 120. This position is shown in Figure 5C.

[0076] The second mandrel drive 310B is engaged to rotate the second mandrel 310 and to thereby feed out the sheet material 410B on the coil 400B. The supplementary feed arrangement facilitates automatically feeding the sheet material 410B into the feed unit 320 at the correct angle and tension. This may occur before the second feed assembly is moved into the feeding position e.g. the feed unit is primed with sheet material. This may further reduce the change over time between the coils 400A, 400B.

[0077] The speed of rotation of the second mandrel 310 can be relatively fast compared to the speed at which the cut portion of the sheet material 410A is beingfed into the production line 500. Therefore, a leading end 410D of the sheet material 410B approaches, and ideally substantially catches up to, a trailing end of the sheet material 410A. This minimises the change over time between the sheet material 410A, 410B being fed into a production line 500. This position is shown in Figure 5D.

[0078] When the first feed assembly is in the loading position, the coil 400A can be changed e.g. using the coil management system as described herein.

[0079] The process described herein may be repeated to facilitate any required changing between coils to optimise operation of the production line 500. In the repeated process, the operation of the second feed assembly 300 is identical to that of the first feed assembly 200 described herein. For instance, to change from coil 400B, the actuators 312 are engaged to move the sub-platform 140 away from the second mandrel 310 in the direction of travel of the sheet material 410B. The guillotine blade 334 is engaged to cut the sheet material 410B, and the second mandrel drive 310B is disengaged to stop feed of the sheet material 410B to the second feed unit 320. The second mandrel drive 310A is then rotated in a second direction to retract the uncut portion of the sheet material 410B back onto the coil 400B.

[0080] The feed assembly actuator 110A can then be engaged to move the second feed assembly 300 into the loading position and the first feed assembly 200 into the feeding position.

[0081] As can be seen, the process described herein does not require workers to interact with the mechanical components of the decoiler assembly 100 to facilitate changing between coils 410A, 410B. This may be a significant improvement in health and safety by removing injury risks. In addition, the foregoing operation may be a faster method of changing between coils 410A, 410B than provided in the prior art.

[0082] It should also be understood that the present technology may provide an improved method of managing coils of sheet material used in production lines, including one or more steps required to implement the functions described herein.

[0083] Coil Management System

[0084] Referring now to the Figure 3, there is further provided a coil management system for managing coils 400 on-site and supplying sheet material 410 to a production line 500.

[0085] The coil management system comprises a decoder assembly 100 according to the present disclosure, a coil farm 800, and a coil transfer system.

[0086] The coil farm 800 stores a plurality of coils 400 of sheet material for loading onto the decoiler assembly 100, and receives unspent coils 400 unloaded from the decoiler assembly 100 after a production run for that coil 400 is complete. The coils 400 may be stored and inventoried in any appropriate manner.

[0087] The coil transfer system allows for transporting of the coils 400 of sheet material between the coil farm 800 and the decoiler assembly 100 for loading and unloading the mandrels 210, 310 in their loading positions. The coil transfer system may be configured to transfer coils 400 directly from the coil farm 800 to a mandrel 210, 310 in its loading position. Alternatively, the coil transfer system may further comprise an intermediate storage device, such as a coil turnstile 700, for holding coils in transit between the coil farm 800 and the decoiler assembly 100. In this way, a small number of coils 400 to be used in subsequent production runs are available nearby the decoiler assembly 100 for loading as required.

[0088] To facilitate movement of the coils 400 to various positions in the decoiler system, at least one coil car 600 may be provided for transporting the coils 400 between the coil farm 800, the coil turnstile 700, and the decoiler assembly 100.

[0089] The decoiler system may further comprise a coil inventory system for tracking coil 400 location, managing inventory of coils 400 and product, and / or the quantity of sheet material 410 used and / or remaining for each coil 400 in the coil farm 800. The quantity of sheet material 410 on a coil 400 may be determined by a scale for measuring the weight of coils 400 prior to loading and / or after unloading from the decoiler assembly 100.

[0090] To supply sheet material 410 to a production line, a coil 400 of sheet material held by the first mandrel 210 is fed by the first feed unit 220 through the first cutting unit 230 to the production line 500. As the production run proceeds, sheet material 410 is continuously drawn from the coil 400, with the first mandrel 210 rotating to facilitate feeding of the sheet material 410.

[0091] While production continues from the coil 400 on the first mandrel 210, the first mandrel 210 is in the feeding position and the second mandrel 220 is in the loading position. With reference to Figure 3, a coil car 600 receives a coil 400 of sheet material required for the next production run from the coil turnstile 700, with the coil 400 having been previously retrieved from the coil farm 800 and loaded onto the turnstile 700 in anticipation of the upcoming production run. The coil car 600 then transports the coil 400 to the second mandrel 310, onto which the coil 410 is mounted and secured. The second feed unit 320 is then primed with the leading end of the sheet of material 410 from the coil 400.

[0092] To change coils 400, the first cutting unit 230 selectively cuts the sheet material 410 being fed by the first feed unit 220. In the embodiment shown in the Figures, the frame 110 is then rotated 180° to bring the second mandrel 310 into the feeding position while simultaneously moving the first mandrel 210 into the loading position. Once in position, the second feed unit 320 feeds the leading end of the sheet material 410 to the production line 500 behind the trailing end of the sheet material 410 from the first mandrel 210.

[0093] Although the decoiler assembly has been described with respect to having two mandrels 210, 310, it will be appreciated that the decoiler assembly may comprise more than two mandrels without departing from the spirit of the present disclosure. For example, a plurality of mandrels may be provided that could be moved in series into respective feeding positions, and having at least one loading position corresponding to a feeding position of another mandrel.

[0094] It will be appreciated by persons skilled in the art that numerous variations and / or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. Thepresent embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

CLAIMS:

1. A decoiler assembly for supplying sheet material to a production line, comprising: a frame; a first mandrel rotatably mounted to the frame, the first mandrel configured for receiving and selectively holding a coil of sheet material, the first mandrel having a feeding position for feeding sheet material to the production line and a loading position for loading and unloading coils of sheet material; a second mandrel rotatably mounted to the frame, the second mandrel configured for receiving and selectively holding a coil of sheet material; at least one feed unit associated with the first and second mandrels for feeding sheet material to the production line; at least one cutting unit for selectively cutting sheet material being fed to the production line; and an actuator arrangement configured to move the first mandrel between the feeding position and the loading position.

2. The decoiler assembly according to claim 1, wherein the actuator arrangement is further configured to move the second mandrel between a feeding position and a loading position.

3. The decoiler assembly according to any one of the preceding claims, wherein when one of the first and second mandrels is in the feeding position, the other of the first and second mandrels is in the loading position.

4. The decoiler assembly according to any one of the preceding claims, wherein the actuator arrangement comprises the frame and the frame is rotatable on a base about a substantially vertical axis to move the first and second mandrels between the respective feeding and loading positions.

5. The decoiler assembly according to any one of the preceding claims, wherein: the at least one feed unit comprises a first feed unit associated with the first mandrel and a second feed unit associated with the second mandrel; and / or the at least one cutting unit comprises a first cutting unit associated with the first mandrel and a second cutting unit associated with the second mandrel.

6. The decoiler assembly according to claim 5, wherein the first feed unit and the first cutting unit are mounted on the frame.

7. The decoiler assembly according to claim 5 or claim 6, wherein the second feed unit and the second cutting unit are mounted on the frame.

8. The decoiler assembly according to any one of claims 5 to 7, wherein: the frame comprises a first platform extending in a feed direction of the first mandrel and a second platform extending in a feed direction of the second mandrel; the first feed unit and the first cutting unit are mounted on the first platform; the second feed unit and the second cutting unit are mounted on the second platform; and the frame is rotatable about a substantially vertical axis to move the first and second mandrels between the respective feeding position and loading positions.

9. The decoiler assembly according to any one of the preceding claims, wherein the at least one feed unit is configured to be primed with sheet metal from a coil on an associated mandrel.

10. A decoiler assembly for supplying sheet material to a production line, comprising: a frame; a first feed assembly and a second feed assembly, wherein the first feed assembly comprises a first mandrel rotatably mounted to the frame, the first mandrel configured for receiving and selectively holding a coil of sheet material, and the second feed assembly comprises a second mandrel rotatably mounted to the frame, the second mandrel configured for receiving and selectively holding a coil of sheet material, wherein the first feed assembly and the second feed assembly are each configured for feeding the sheet material to the production line; the decoiler assembly further comprising at least one cutting unit for selectively cutting sheet material being fed to the production line by the first feed assembly and the second feed assembly.

11. A decoiler assembly according to claim 10, comprising an actuator arrangement configured to move the cutting arrangement with respect to the first mandrel and the second mandrel, at a speed relative to the speed of the sheet material being fed to the production line from a coil on the first mandrel or the second mandrel.

12. A decoiler assembly according to claim 10, whereinthe first feed assembly comprises a first cutting arrangement configured to cut the sheet material on a coil on the first mandrel as that is being fed to the production line, and the second feed assembly comprises a second cutting arrangement configured to cut the sheet material on a coil on the second mandrel as that is being fed to the production line.

13. A decoiler assembly according to claim 12, wherein the first feed assembly further comprises a first mandrel drive configured move the first cutting unit with respect to the first mandrel at a speed relative to the speed of the sheet material being fed from a coil on the first mandrel to the production line.

14. A decoiler assembly according to either one of claims 12 or 13, wherein the second feed assembly further comprises a second mandrel drive configured move the second cutting unit with respect to the second mandrel at a speed relative to the speed of sheet material on a coil on the second mandrel being fed to the production line.

15. A decoder assembly according to any one of claims 10 to 14, further comprising a feed assembly actuator configured to move at least one of the first feed assembly and the second assembly from a respective feeding position and loading position.

16. A decoiler assembly according to claim 15, wherein the feed assembly actuator is configured so that when one of the first feed assembly and the second feed assembly is in the feeding position, the other of the first feed assembly and second feed assembly is in the loading position.

17. A decoiler assembly according to either one of claims 15 or 16, wherein the feed assembly actuator is configured to move the first feed assembly to the feeding position and the second feed assembly to the loading position at substantially the same time.

18. A decoiler assembly according to any one of claims 15 to 18, wherein the feed assembly actuator comprises the frame, a base, and an actuator, and wherein the feed assembly actuator is configured to rotate the frame with respect to the base to thereby move the first feed assembly to the feeding position and the second feed assembly to the loading position.

19. A decoiler assembly according to claim 18, wherein the frame is configured to rotate about a substantially vertical axis to move the first feed assembly between the feeding position and the loading position, and to move the second feed assembly between the feeding position and the loading position.

20. The decoiler assembly according to any one of claims 10 to 19, wherein the first feed assembly comprises a first mandrel drive configured to rotate the first mandrel, and the second feed assembly comprises a second mandrel drive configured to rotate the second mandrel.

21. The decoiler assembly according to claim 20, wherein at least one of the first mandrel drive and the second mandrel drive is configured to rotate the first mandrel and the second mandrel in a first direction to facilitate feeding of sheet material to the production line and a second direction to facilitate retraction of sheet material back onto a coil.

22. A decoiler assembly according to either one of claims 20 or 21, wherein at least one of the first mandrel drive and the second mandrel drive is configured to rotate its respective mandrel at variable speeds.

23. A decoiler assembly according to any one of claims 20 to 22, wherein the first mandrel drive is configured to rotate the first mandrel in a second direction to retract the sheet material onto the first coil after it has been cut by the first cutting unit.

24. A decoiler assembly according to any one of claims 20 to 23, wherein the second mandrel drive is configured to rotate the second mandrel in a second direction to retract the second sheet onto the second coil after it has been cut by the second cutting unit.

25. A decoiler assembly according to any one of claims 10 to 24, wherein the first mandrel holds the first coil of sheet material and the second mandrel holds a second coil of sheet material, and wherein the decoiler assembly is configured to:(a) move the first feed assembly into the feeding position;(b) engage a / the first mandrel actuator to rotate the first mandrel to feed sheet material from the first coil to the production line;(c) engage a / the cutting assembly or a / the first cutting unit to cut the sheet material from the first coil and form a rear edge in the sheet;(d) engage the actuator arrangement to move the second feed assembly to the feeding position;(e) engage a / the second mandrel actuator to rotate the second mandrel to feed sheet material from the second coil to the production line at a relatively fast speed to move a leading end of the sheet material on the second coil closer to the rear end.

26. A decoiler assembly according to one of claims 10 to 25 wherein the first feed assembly further comprises a supplementary feed arrangement configured to, in use, orientate and tension sheet material on a coil on the first mandrel as it is fed to the production line.

27. A decoiler assembly according to any one of claims 10 to 26, wherein the second feed assembly further comprises a supplementary feed arrangement configured to, in use, orientate and tension sheet material on a coil on the second mandrel as it is fed to the production line.

28. A decoiler assembly according to claim 27, wherein the first feed assembly further comprises a first feed unit and the second feed assembly further comprises a second feed unit.

29. A coil management system, comprising: a decoiler assembly according to any one of the preceding claims; a coil farm for storing a plurality of coils of sheet material for loading onto the decoiler and receiving coils unloaded from the decoiler; and a coil transfer system for transporting coils of sheet material between the coil farm and the decoiler assembly for loading and unloading the mandrels in the loading position.

30. A coil management system according to claim 29, wherein the coil transfer system comprises at least one coil car for transporting coils to and from the coil farm, and / or to and from a loading position for loading and unloading the decoiler assembly.

31. A coil management system according to claim 029 or claim 30, wherein the coil transfer system comprises a coil turnstile for holding coils in transit between the coil farm and the decoiler assembly.

32. A coil management system according to any one of claims 29 to 31, further comprising a coil inventory system for tracking coil location, managing inventory of coils and product, and / or quantity of sheet material used and / or remaining from each coil in the coil farm.

33. A coil management system according to claim 32, wherein the coil inventory system comprises a scale for measuring the weight of coils prior to loading and / or after unloading from the decoiler assembly.

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