An apparatus for preparing parent reels of web material and production line comprising the apparatus

Abstract

The apparatus (11) comprises a first turntable (13) with a support for reels of web material and a second turntable (19) with a support for reels of web material or winding cores of said reels. A punch magazine (25) is further provided, adapted to contain a plurality of punches (P) insertable into winding cores for reels of web material. The apparatus also comprises a robot (27) with an effector (29) configured to insert punches (P) into winding cores and extract said punches (P) from the winding cores.

Description

AN APPARATUS FOR PREPARING PARENT REELS OF WEB MATERIAL AND PRODUCTION LINE COMPRISING THE APPARATUSDESCRIPTIONTECHNICAL FIELD

[0001] The present invention relates to improvements to apparatuses for converting web materials, especially paper, such as tissue paper in particular, wound in reels.B ACKROUND ART

[0002] In many industrial fields it is necessary to unwind reels of large diameter reels (known as parent reels or jumbo reels) of a web material to feed a converting line, in which the web material is converted into a finished product or a semi-finished product intended for further conversions.

[0003] Typically, in the field of what is called tissue paper, it is known to convert a web material, consisting of a cellulose fibre-based web, unwound from one or more parent reels, into logs or reels of dimensions intended for consumption, or into packs of napkins or tissues.

[0004] For this purpose, the parent reels are loaded onto unwinders which are located in the initial part of the converting line. The parent reels are wound around winding cores, for example made of cardboard. Once the parent reel is spent, the respective winding core is reused for winding a new parent reel. The winding core must therefore be removed from the unwinder.

[0005] In some cases, a partially unwound parent reel must be removed from the unwinder before the reel is completely spent. This happens, for example, in the event of breakage of the web material, especially when the reel has been mostly unwound, or if the web material is to be changed in order to move from one type of production to another.

[0006] Parent reels can have large dimensions. In modem plants for converting tissue paper, it is possible to process parent reels with diameters of up to 3 m and axial lengths of up to 3.6 m, which weigh up to 5 tons. The movement of the parent reels within a production or converting plant, in which one or more converting lines may be located,can occur by means of shuttles which are self-driving or driven by an operator and / or by means of one or more overhead cranes. To manoeuvre the parent reels it is advantageous that what are called punches are inserted inside two opposite ends of the respective winding core, typically made of material with high mechanical strength, for example metal. The punches are used, for example, to couple the parent reels by means of an overhead crane, or to support them inside the unwinder.

[0007] The punches are recyclable and must be removed from the winding cores once the relative reels are spent. The punches generally weigh a few tens of kilograms and must be inserted and removed into / from the winding cores of the parent reels at a height from the ground which can reach up to 1.5 m due to the large diameter of these reels. Therefore, for this activity, a great physical effort is required from an operator, which entails high risks of injury. The injury risk increases if the insertion or removal of the punches is difficult due to deformations and irregularities of the tubular winding core of the parent reel. In fact, the core of the parent reel, due to its repeated reuse, is subject to wear which can lead to deformations or crushing of the holes of the two ends of the winding core, or in some cases the breaking and disintegration of the edge of the cardboard forming the winding core of the parent reel. In these cases, in addition to having an injury risk for the operators, the operations of inserting and removing the punches are also slowed down, reducing the productivity of the converting line or of the production plant in general.

[0008] It would be advisable to arrange efficient and safe means for performing the operations of applying and removing the punches on and from the parent reels which solve and overcome the problems of the current state of the art.SUMMARY

[0009] According to one aspect, an apparatus is provided comprising a first turntable with a support for reels of web material and a second turntable with a support for reels of web material or winding cores of said reels. A punch magazine is further provided, adapted to contain a plurality of punches insertable into winding cores for reels of web material. The apparatus also comprises a robot with an effector configured to insert punches into winding cores and extract said punches from the winding cores.

[0010] In advantageous embodiments, to make the system more efficient and reducethe overall footprint, in particular the overall dimensions of the apparatus associated with a production line, the robot is positioned between the first turntable and the second turntable.

[0011] Advantageously, in embodiments the apparatus further comprises a storage area for accumulating one or more reels provided with punches inserted in opposite ends of the respective winding core. It is thereby possible to store one or more reels arranged with the respective punches in the apparatus while the second turntable is made available to arrange a new reel.

[0012] In advantageous embodiments, the storage area can be aligned along the alignment direction of the first turntable, the second turntable and the robot positioned therebetween.

[0013] Further advantageous embodiments and features of the apparatus are defined in the dependent claims and described in detail below, with reference to the attached drawings.

[0014] According to a further aspect, a converting line comprising an apparatus of the type defined above, and a plant one or more converting lines with an apparatus of the type defined above, are described herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The invention will be better understood by following the description and the attached drawings, which illustrate an exemplary and non-limiting embodiment of the invention. More in particular, the drawings show in:Fig. 1 a plan view of a manufacturing plant with a converting line and an apparatus according to the present invention;Fig. 2 a plan view of a manufacturing plant with two production lines, which is served by an apparatus according to the invention;Fig. 3 a plan view of an apparatus according to the present invention;Fig. 4 and 5 enlargements of two portions of Fig. 3;Fig. 6 a side view of the apparatus of Fig. 2, 3, 4 and 5; andFig. 7 a section of an effector of the robot of the apparatus of Fig. 3 to 6, with a punch applied in side view.DETAILED DESCRIPTION

[0016] Fig. 1 shows a manufacturing plant 1, in which a tissue paper converting line is provided, indicated overall with 3. The converting line 3 comprises, in this exemplary embodiment, an unwinding section 5, comprising a plurality of unwinders 7, for example six unwinders. Downstream of the unwinding section 5, a further section 9 of the converting line is provided, which can be configured in various manners depending on the type of product which is made with the converting line 3. Typically, in the case of a converting line of parent reels (hereinafter briefly referred to as “reels”) for the production of rolls, the section 9 of the converting line comprises one or more of the following devices or stations: an embosser, a printing machine, a rewinder, a tail sealer, a log saw, a storage unit. Downstream of section 9, the converting line can continue towards a packaging area, where the products (rolls or other) are packaged. If the production concerns folded products, such as napkins, handkerchiefs or similar, the converting line can comprise a folding machine, or an interfolding machine, instead of a rewinder.

[0017] In Fig. 2, similarly to Fig. 1, a plant 1 is shown in which two converting lines 3 are arranged, which can be the same or different from one another, and which can comprise the elements mentioned above or part thereof.

[0018] In both cases, the converting line or lines 3 are served by an apparatus, indicated as a whole with 11, which has the function of allowing the application of punches in the opposite ends of the winding cores of full reels, and the removal of the punches from the spent winding cores. In Fig. 1 the apparatus is connected to the single converting line 3 and is advantageously placed next thereto and preferably next to the unwinding section 5. In Fig. 2 the apparatus 11 is connected to the two converting lines 3 and is placed at a distance therefrom. In other embodiments the number of converting lines served by the apparatus 11 can be greater than two.

[0019] An embodiment of the apparatus 11 for preparing reels of wound web material is shown in detail in Fig. 3, 4, 5 and 6.

[0020] In the illustrated embodiment, the apparatus 11 comprises a section 11A for preparing the reels, a storage area 1 IB for storing one or more reels prepared for being sent to the unwinder and a discharge area 11 C for unloading winding cores from whichthe punches previously inserted to move the reels wound thereon have been removed.

[0021] In the illustrated embodiment, the section 11 A comprises a first turntable 13 with a support 15 for receiving spent reels B or empty winding cores, from which the previously inserted punches must be extracted. The support 15 can be configured in the form of a conveyor, or can comprise a conveyor, for moving the spent reels or winding cores in a horizontal direction, orthogonal to the vertical rotation axis A-A of the first turntable. In Figs. 3, 4 and 6, A indicates a spent winding core or a spent reel containing a winding core, from which punches P must be extracted, previously inserted by means of the apparatus 11 in the manner described below.

[0022] In some embodiments, the first turntable 13 can be provided with a lifting and lowering movement parallel to the vertical rotation axis A-A. The lifting and lowering movement is indicated with fA in Fig. 6. The rotation movement of the turntable 13 is indicated with fl3 and can be controlled by an actuator 17, for example an electric motor with an output pinion meshing with a toothed wheel integral with the turntable 13.

[0023] In some embodiments, it is possible to associate the first turntable 13 with mechanical retaining members for the spent reels A during the extraction step of the punches P, as will be described later in greater detail. The mechanical retaining members can engage the spent reels a on their outer cylindrical side surface. For example, the mechanical retaining members can be formed by a gripper, a jaw, or in general by one or more arms, by a shaped surface, or other suitable element which presses the spent reel A against the support 15 of the turntable 13.

[0024] The apparatus 11 further comprises a second turntable 19 with a support 21 for full reels of web material. In the drawing, Bl indicates a new reel, supported on the second turntable 19.

[0025] The support 21 can be configured in the form of a conveyor, or can comprise a conveyor, for moving the full reels in a horizontal direction, orthogonal to the vertical rotation axis B-B of the second turntable. In Figs. 3, 4 and 6, Bl indicates a new reel supported on the second turntable 19.

[0026] In some embodiments, the second turntable 19 can be provided with a liftingand lowering movement parallel to the vertical rotation axis B-B. The lifting and lowering movement is indicated with fB in Fig. 6. The rotation movement of the second turntable 19 is indicated with fl 9 and can be controlled by an actuator 23, for example an electric motor with an output pinion meshing with a toothed wheel integral with the second turntable 19. To rotate the first turntable 13 and the second turntable 19 it is possible to use any other suitable actuator, such as a pneumatic or hydraulic piston. In fact, it is not necessary for the rotation to always be in the same direction. It is also possible to impose rotations in alternating directions-

[0027] The first turntable 13 and the second turntable 19 are aligned in a direction F.

[0028] The apparatus 11 further comprises a magazine 25 of punches P adapted to contain a plurality of punches insertable into winding cores for reels of web material. In the illustrated embodiment the magazine 25 comprises four seats for as many punches P, but it must be understood that in other embodiments the magazine 25 can comprise a different number of seats, for example greater than four, to contain more punches P. The punches can be the same or different, depending on the need to use, for example, reels with winding cores different in shape, size and / or material.

[0029] In the illustrated embodiment, the magazine 25 is placed in the section 11 A, between the first turntable 13 and the second turntable 19.

[0030] The apparatus 11 further comprises a robot 27 with an effector 29 (see Fig. 7) configured to insert punches P into winding cores of new reel and extract punches P from empty winding cores and / or from winding cores of partially or totally spent reels. The robot is located in the section 11 A of the apparatus 11.

[0031] In the illustrated embodiment, the robot 27 is an anthropomorphic robot, i.e., comprising an articulated arm. In embodiments, the robot 27 can comprise six numerically controlled axes to allow a high operating flexibility.

[0032] In advantageous embodiments, the robot 27 is aligned with the first turntable 13 and the second turntable 19 in the direction F. For example, in advantageous embodiments, the base of the robot 27 can be centered on the conjunction line of the rotation axes A-A of the first turntable 13 and B-B of the second turntable 19. In other embodiments, the base of the robot 27 may not be centered on the conjunction line of the rotation axes A-A of the first turntable 13 and B-B of the second turntable 19,remaining however preferably comprised between the first turntable 13 and the second turntable 19.

[0033] In general, it is advantageous for the robot to be aligned along an alignment direction defined by the rotation axis A-A of the first turntable 13 and the rotation axis B-B of the second turntable, in the sense that, in a plan view, the base of the robot is comprised in a volume interposed, i.e., at least partially or totally comprised, between the volume in which the first turntable moves and the volume in which the second turntable moves.

[0034] In fact, the aligned arrangement along F of the robot 27 and the two turntables 13, 19 is particularly advantageous in terms of overall dimensions and efficiency of the system. Furthermore, it allows the volume within which it is necessary to move the effector 29 of the robot 27 to be reduced, thus allowing greater manoeuvring speed and the use of a robot of limited dimensions.

[0035] The storage area 1 IB can be configured to accommodate one or more full reels B arranged to be transferred to a respective unwinder of a converting line 3.

[0036] In the illustrated embodiment the storage area 1 IB is configured to accommodate two reels indicated by B2 and B3, respectively. In other embodiments the storage area 1 IB can be configured to accommodate a single reel, or more than two reels.

[0037] As will be clear from the subsequent description of the operating mode of the apparatus 11, the reels B2, B3 housed in the storage area 11B are already provided with punches P inserted in the two opposite axial ends of the respective winding cores.

[0038] Advantageously, the storage area 11B is aligned with the first turntable 13, the robot 27 and the second turntable 19 in the direction F.

[0039] In the illustrated embodiment, the storage area 1 IB comprises a plurality of conveyors indicated with 31, 33 and 35. In this case, the conveyors are aligned along the direction F. In the diagram depicted in Figs. 3 to 6, the conveyors 31, 33 and 35 are configured as belt conveyors, on which the reels B2, B3 rest by means of their cylindrical surface. However, it is not excluded to configure the conveyors in a different manner, for example in passive form, i.e., creating them as simple supports on which the reels are placed, by means of the cylindrical side surface or by means of thepunches P, and moved by rolling or sliding. In other embodiments it is possible, to make these supports as tracks on which the punches protruding from the two ends of the reel winding cores can slide or roll, for example.

[0040] Furthermore, while in the drawing the reels are arranged with their axes oriented parallel to the direction F, in other embodiments, depending for example on the type of conveyors, the reels can be oriented with their axis in a direction orthogonal to the direction F.

[0041] In the embodiment illustrated in Fig. 3 to 6, the conveyors 31, 33 and 35 comprise respective actuators 31 A, 33 A and 35A, for example electric motors, for their movement.

[0042] In Fig. 3 to 6, the conveyors 33 and 35 constitute supports for the same number of reels B2, B3 waiting to be transferred to a converting line 3. The conveyors 33 and 35 are configured to keep the reels B2, B3 oriented with their winding axis parallel to the direction F, which also represents the direction of movement of the conveyors themselves. In other embodiments, the conveyors can be configured and arranged to support the reels B2, B3 with their axes orthogonal to the direction F. For example, the conveyors 33 and 35 can be rotatable around a vertical axis in a manner similar to the turntables 13 and 19.

[0043] In some embodiments, the conveyor 31 constitutes a member for transferring the reels arranged with the respective punches P from the second turntable 19 towards the subsequent conveyors 33, 35, which form seats for receiving the reels B2, B3 waiting to be transferred to the unwinder of a converting line 3.

[0044] To carry out its transfer member function, the conveyor 31 can have a shape and / or size different from the other conveyors of the storage area 11B. In some embodiments, the conveyor 31 can be provided with a vertical movement according to f 1. The vertical movement of the conveyor 31 is particularly advantageous if it is necessary to handle reels of very variable diametric dimensions.

[0045] If necessary or useful, the other conveyors 33, 35 of the storage area 1 IB can also be provided with a lifting and lowering movement (not shown).

[0046] The discharge area 11C for unloading empty winding cores can comprise aconveyor 37, which can be advantageously oriented according to the direction F and which can be suitably aligned along the vertical plane containing the vertical rotation axes A-A and B-B of the turntables 13, 19, or in any case generally aligned along the direction F. The number 37A indicates an actuator for moving the conveyor 37.

[0047] The apparatus 11 can be provided with one or more detection devices such as laser scanners or radar, in order to identify the presence of operators therein. In particular, it is possible to provide each zone 11 A, 1 IB, 11C with a detection device. If an operator enters a zone, it is possible to stop the movement of the robot 27 or alternatively reduce the speed thereof. Furthermore, it is possible to decrease the operating speed of the robot 27 when an operator enters a zone different from that associated with the robot 27, i.e., when an operator enters the storage zone 1 IB, or enters the zone 11C for example to clean the winding cores A from residual material, if the robot 27 does not carry out this operation. In a further variant it is possible to decrease or stop the operating speed only of the zone 11A or 11B or 11C in which the entry of an operator is detected.

[0048] The apparatus 11 described so far has the purpose of automating and simplifying the operations of inserting punches into the axial ends of each winding core A of the reels Bl, B2, B3 and of extracting the punches from spent cores and / or from partially unwound reels.

[0049] For this purpose, the apparatus 11 operates as follows. A reels Bl can be positioned on the second turntable 19 by means of a suitable mover arranged for this purpose. The mover can comprise a shuttle 41 provided with gripping members 43, as schematically indicated in Fig. 3. The gripping members can comprise a rod which inserts into the winding core or a pair of jaws which grasp the reel on its cylindrical surface.

[0050] In other embodiments, it can be envisaged that the individual reels Bl are transferred onto the second turntable 19 by means of an overhead crane, schematically indicated with 45.

[0051] In the illustrated embodiment it is envisaged that the reel Bl is transferred onto the turntable 19 oriented with the winding axis thereof orthogonal to the direction F, but this is not essential. The orientation of the reel when it is transferred onto thesecond turntable 19 can also depend on the type of transfer member used. For example, if the reel is engaged on a rod which is inserted into the winding core (Fig.3), the orientation will necessarily be orthogonal to the direction F, but if the core B 1 is placed on the second turntable 19 by means of an overhead crane 45, or with the shuttle 41 by means of a transfer member other than the rod, for example a gripper or jaw, the orientation can be rotated by 90° and thus parallel to the direction F.

[0052] Each reel Bl which is placed on the second turntable 19 has no punches P and must be equipped with a pair of such punches. For this purpose, the second turntable 19 is positioned so that first one and then the other axial end of the respective winding core faces the robot 27. The robot 27 takes a respective punch P from the magazine 25, and inserts it into the axial end of the winding core facing the centre of the section 11 A. Once the first punch has been inserted, the turntable 19 performs a 180° rotation and presents to the robot 27the other end of the winding core, into which the robot 27 inserts a second punch.

[0053] The reel Bl provided with two punches P can be taken from the turntable 19 to be directly transferred to an unwinder. For this purpose, an overhead crane 45 and / or a shuttle 41 can be used. The overhead crane 45 can be automatic or manual.

[0054] If, when the reel Bl is ready with its punches P inserted it is not possible to transfer it to a converting line 3, it can be transferred to the storage area 1 IB. For this purpose, the conveyors 31, 33 and 35 are used. From the storage area 11B the reels B2, B3 can be taken (by means of overhead crane 45 or shuttle 41) when it is necessary to transfer them to a respective converting line 3.

[0055] The apparatus 11 also allows punches P to be extracted from spent reels and / or empty cores. These are transferred, by means of overhead crane 45 or shuttle 41, onto the first turntable 13. Also in this case, the orientation taken by the winding core A placed on the first turntable 13 can depend on the means by which it is transferred or on other dimensional considerations. The spent winding cores which are placed on the first turntable 13 are provided with punches P which have previously been inserted into the reel from which the winding core comes, and which in turn has been unwound by an unwinder in a converting line 3. The robot 27 extracts each punch P from the respective axial end of the winding core A. For this purpose, the first turntable 13 sequentially takes two angular positions offset by 180° to present first one andthen the other end of the winding core A to the robot 27. The punches P extracted from the winding core are transferred by the robot 27 to the magazine 25 and can be used to equip a new reel Bl. In some cases, if a new reel Bl is present on the second turntable 19 and a spent reel or empty core A is simultaneously present on the first turntable 13, the robot 27 can extract a punch P from the spent reel, or empty winding core, and insert it directly into the new reel B 1.

[0056] During the extraction step of the punches P, the core A can be retained on the turntable 13 to prevent it from moving due to the friction which tends to retain the punch P in the winding core. For this purpose, mechanical retaining members, not shown, can be provided.

[0057] Once the punches P have been removed from the winding core A, this can be transferred to the discharge area 11C on the conveyor 37. For this purpose, the conveyor 15 with which the first turntable 13 is provided can be activated.

[0058] Any residues of web material wound on the winding core A can be removed from the winding core when it is on the first turntable 13 and / or when it is on the conveyor 37 of the discharge area 11C. The removal of residues of web material can be performed manually or automatically by means of specific tools applied to the robot 27 or to an auxiliary robot, not shown.

[0059] The winding cores A cleaned of any residues of web material and from which the punches P have been removed can be taken from a carriage 47 and transferred to a winder, for example.

[0060] Fig. 7 shows a diagram of an effector 29, with which the robot 27 can be provided. The effector 29 is shown in a section along a median plane containing the axis of the punch when grasped by the effector 29. Fig. 7 also shows (in a side view and partial section) a punch P engaged by the effector 29. In the illustrated embodiment, the punch P is expandable, i.e., provided with extractable and retractable elements indicated with Pl and arranged according to two annular crowns in the portion of the punch P intended to be inserted in the winding core A of the reel. The punch P also has a flange P2, from which the portion of the punch (bearing the extractable and retractable elements Pl) intended to be inserted into the winding core A extends on one side. A shank P3 extends from the opposite side of the flange P2.

[0061] The effector 29 comprises a punch gripping system. The gripping system can comprise a pair of jaws 29A. In the illustrated embodiment a jaw is fixed with respect to a bracket 29B of the effector 29, through which the effector 29 is engaged to the robot 27. The other jaw is movable and is driven by an actuator 29C, for example , which can comprise an electric motor acting on a reducer which controls the movement according to f29 of a rod or bar, for example a threaded bar 29D connected to the movable jaw 29 A. The latter can be guided by guides 29E. The movable jaw can be guided with any other suitable means, such as one or more slides integral with the jaw 29 A and sliding along one or more guides 29E integral with the bracket 29B. The actuator for moving the movable jaw is preferably an electric motor, but in simplified solutions, which for example do not require reducers, it is possible to use pneumatic or hydraulic actuators, for example cylinder-piston actuators.

[0062] When the effector 29 is intended to manipulate expandable punches such as the one illustrated in Fig. 7, the effector 29 can be provided with an actuator which, by means of a stem or other mechanical member, acts on an internal mechanism of the punch P to control the extraction and / or retraction of the elements Pl.

[0063] Thereby the effector can insert the punch P into the winding core with the elements Pl retracted and command their extraction to lock the punch P in the winding core when the robot 27 carries out the operations of setting up a new reel with the relative punches P. Conversely, when the robot 27 must remove a punch P from a winding core of a spent reel, after the effector 29 has engaged the shank P3 of the punch still inserted in the winding core A, the actuator will control the retraction of the elements Pl to ensure that the punch can be extracted from the empty or spent winding core.

[0064] Alternatively, as shown in greater detail in Fig. 7, it is possible to use pneumatically expandable punches P. In this case, to control the extraction and / or retraction of the elements Pl, the effector 29 can be provided with a compressed air dispenser 29F, which can be connected by means of a nozzle to an inlet port for the compressed air of the expandable punch. In preferred embodiments, the compressed air inlet port of the punch can be positioned at the axis of the expandable punch. To insert the expandable punch P into the winding core A, the robot 27 takes an expandable punch Pby means of the effector 29, also pneumatically connecting the compressed air dispenser of the effector 29 to the compressed air inlet port of the expandable punch. Subsequently, after the punch has been firmly grasped by the effector 29, compressed air is delivered into the expandable punch P causing the retraction of the elements Pl. Once the elements Pl have been retracted, the robot 27 inserts the expandable punch P into the winding core A. Finally, the delivery of compressed air into the punch P is interrupted, causing the extraction of the elements Pl which press against the internal cylindrical surface of the winding core A, constraining the expandable punch to the winding core itself.

[0065] This operation is performed for the two ends of the winding core A for two respective punches.

[0066] Conversely, when it is necessary to extract an expandable punch P from a winding core A, the robot 27, by means of the effector 29, couples an expandable punch P inserted into the winding core A, engaging the shank P3 thereof. The pneumatic connection is then made between the compressed air dispenser 29F of the effector 29 and the inlet port for the compressed air of the expandable punch P. Compressed air is then delivered to retract the elements Pl, releasing the punch P from the winding core A. The robot 27 can then extract the punch from the winding core A. Once the punch P has been completely extracted from the winding core A it is possible to interrupt the delivery of compressed air to the punch P, which can be deposited by means of the robot 27 in the magazine 25. If the robot must insert the punch P just extracted into a new reel Bl, the delivery of compressed air may not be interrupted.

[0067] In some embodiments, to facilitate the operations of inserting and extracting the punches into and from the winding cores, the effector 29 can be provided with a video camera or a sensor system of another type, for example laser sensors, to identify the exact position of the hole in which to insert the punch and / or of the shank of a punch to be extracted. In Fig. 7 a generic sensor of this type is indicated with 29H. The sensor can be interfaced with a central unit 50 (Figs. 3-4), which is in turn connected to the robot 27 and to other parts of the apparatus 11 to control the movements of the various members described above and carry out the punch insertion and extraction cycles.

[0068] If the sensor 29H is a camera, or in general a vision system, exploiting forexample artificial intelligence algorithms, it is possible to frame the end holes of the winding core A to identify shape defects, edge irregularities, deformations due to wear or other types of defects. These defects may be such as to prevent the insertion or correct insertion of the punch P in the hole of the winding core A.

[0069] If, due to defects in the hole of the winding core A, the robot 27 fails to insert the punch P into the winding core A or if the sensor 29H directly detects such defects, it is possible to change an effector by uncoupling the effector 29 and loading an auxiliary tool onto the robot 27 to reform the winding core hole and / or a tool to remove any deformed and / or excess material of the winding core A distributed around the inner edge of the core itself. Once the shape of the damaged hole has been restored, it is possible to uncouple the auxiliary tool and load the effector 29 onto the robot 27 again and restore the insertion cycle of the punches P into the winding core A.

[0070] The auxiliary tools can be arranged in the magazine 25 or in a dedicated tool holder.

[0071] Often the tolerance between the external diameter of the punch P and the internal edge of the winding core A can be even less than 20mm. Therefore, advantageously the punches P, whether they are expandable or not, can have the end which is inserted into the winding core A with a conical or wedge shape so as to facilitate the insertion of the punch itself into the end hole of the core. Thereby both the centring of the punch P with the end hole of the winding core is facilitated and the forces required to push the punch inside the core in the event of friction between the punch itself and the internal surface of the winding core are at least partially reduced.

[0072] If the apparatus 11 is associated with more than one converting line 3, or in general when the apparatus 11 is not arranged laterally to a converting line 3, it is possible to have to transport the reel Bl with the punches P inserted into the two ends of the winding core A by means of vehicles from the apparatus 11 towards the converting line or lines 3. During the transport, jolts, vibrations or accidental impacts can cause the punches P to slide out of the winding core. In this case it is preferable to use expandable punches which, as previously described, are fixed to the winding core by means of the expansion of the elements Pl. If non-expandable punches P are used, it is possible to provide the punches P with friction elements between the punch and theinternal surface of the winding core. For example, it is possible to use brushes protruding from the external surface of the punch, to counteract any forces which could cause the punches to slide out during the transport by means of shuttles.

Claims

Claims1. An apparatus for preparing reels of wound web material, comprising: a first turntable with a support for reels of web material; a second turntable with a support for reels of web material or winding cores of said reels; a punch magazine adapted to contain a plurality of punches insertable into winding cores for reels of web material; a robot with an effector configured to insert punches into winding cores and extract said punches from winding cores.

2. The apparatus of claim 1, wherein the robot is positioned between the first turntable and the second turntable.

3. The apparatus of claim 1 or 2, further comprising a storage area to accumulate one or more reels having punches inserted in opposite ends of the respective winding core.

4. The apparatus of claim 3, wherein the first turntable, the second turntable, and the storage area are aligned with each other along an alignment direction.

5. The apparatus of claim 4, wherein the storage area is configured to accommodate oriented reels with their respective winding axis oriented according to the alignment direction.

6. The apparatus of any one of claims 3 to 5, wherein the storage area includes at least one conveyor to handle the reels.

7. The apparatus of any one of claims 3 to 6, wherein the storage area comprises a plurality of conveyors aligned with each other to receive a plurality of reels.

8. The apparatus of any one of the preceding claims, including a discharge area for spent reels.

9. The apparatus of claim 8, wherein the first turntable, the second turntable, and the spent reels discharge area are aligned with each other.

10. The apparatus of any one of the preceding claims, wherein at least one, and preferably each, of said first turntable and second turntable is provided with a lifting and lowering motion.

11. The apparatus of any one of the preceding claims, wherein one, and preferably each, of the first turntable and second turntable is provided with a conveyor to move the reels or winding cores in a horizontal direction.

12. The apparatus of claim 11, wherein the conveyor is adapted to move the reels parallel to the respective axis of the winding core.

13. The apparatus of any one of the preceding claims, wherein the robot is a six-axis, preferably anthropomorphic robot provided with an effector configured to engage punches.

14. The apparatus of claim 13, wherein the effector is removable and interchangeable with one or more of the following: a device for removing material from winding cores; a device for shaping the winding core hole; a device for removing web material from spent winding cores.

15. The apparatus of any one of the preceding claims, wherein the robot comprises a sensor adapted to provide information for positioning the robot effector.

16. The apparatus of any one of the preceding claims, wherein at least some of the punches are expandable and wherein the robot effector is preferably provided with a member for expanding and / or retracting the expandable punch engaged by the effector.

17. The apparatus of one or more of the preceding claims, wherein the punch is provided with an identification device, preferably an RFID tag.

18. A paper converting line, particularly a tissue paper converting line, comprising at least one reel unwinder and an apparatus of claims 1 to 17, said apparatus being arranged alongside one side of the paper converting line, preferably said apparatus being arranged parallel to said side of the paper converting line.

19. The line of claim 18, comprising an automated overhead crane to pick up and load reels fitted with punches onto said at least one unwinder and unloadspent reels fitted with punches, or winding cores of said reels, from said at least one unwinder.

20. The line of claim 19, wherein said reels provided with punches are taken from the second turntable or, when present, from the storage area; and wherein the spent reels or winding cores, provided with punches, unloaded from said at least one unwinder, are deposited on the first turntable.

21. Manufacturing plant comprising one or more paper converting lines and one or more apparatuses of claims 1 to 16 and / or one or more lines of claims 18

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