Apparatus for managing a moving metal product in a plant for producing metal reels

Abstract

Apparatus (10) for managing a moving metal product (P, 120) driven in an automated manner, to separate and cut a portion (120a) of said metal product (P, 120).

Description

[0001] “APPARATUS FOR MANAGING A MOVING METAL PRODUCT IN A PLANT FOR PRODUCING METAL REELS”

[0002] FIELD OF THE INVENTION

[0003] The present invention concerns an apparatus for managing, that is, checking and sorting, a moving metal product, specifically a rod or wire, in an industrial process for the production of metal reels, in particular, but not limited to, starting from a hot rolling process. The apparatus is configured to identify, check, manipulate, and possibly remove portions of product that could cause problems or cobbles, or for simple samples.

[0004] The present invention also concerns a plant for producing metal reels that comprises such apparatus.

[0005] BACKGROUND OF THE INVENTION

[0006] Plants for producing metal reels in which a hot-rolled metal product, for example a smooth or ribbed rod, or a wire, is fed continuously or semi- continuously (for example with “billet to billet” feed) toward a winding unit in which a laying head, or coil-forming head, forms a continuous series of coils and places them, offset in length, on a continuous transport conveyor, generally a roller conveyor, on which the coils are subjected to cooling, are known.

[0007] An example of apparatus for managing a moving metal product, for example a hot-rolled bar or wire, is disclosed in US 3585887 A.

[0008] The product thus prepared ends its travel in a reel forming unit, usually being dropped into a well in the center of which there is a car on which the coils are stacked on top of each other to define the stack / spool.

[0009] It is known that the initial and / or final part of the product may not be formed correctly. Consequently, while the product advances on the roller conveyor it is necessary to check at least the condition of the last coil, or more generally of a last portion of product, to guarantee that the automatic reel forming unit operates without the risk of any entanglements along the continuous transport conveyor.

[0010] The cobble of the coils along the roller conveyor or in the forming unit is one of the most common problems and should be avoided, since it can cause malformation of the stacks, plant stoppages, damage to the structures, increased maintenance interventions and, in the presence of operators, even injury risks. In conventional rolling plants, checking the last portion of the advancing product is done manually by one or more operators who supervise the terminal zone of the roller conveyor where the product passes at a temperature of about 500 °C. Manual cutting of the tail portion of the moving product may present difficulties dictated by the high relative speed of the roller conveyor with respect to the operators, the temperatures in play, the weight of the portion of product to be removed from the roller conveyor, especially in the case of removals for sampling and quality control, the diameter of the product, and more.

[0011] Automated systems have also been proposed to carry out these operations of recognition, cutting and removal of the final portion of the product being worked. Some examples are disclosed in US 3756289 A, US 4498505 A.

[0012] However, these systems are not able to distinguish in a certain and clear way the final portion of the product from to the previous homogeneous part, or recognize whether this final portion presents any defects or a position / conformation such as to cause subsequent problems during winding. Therefore, the final part is often removed and often the removed part is larger than what is actually required, causing an undue increase in process waste. Or, the final part is not correctly recognized and removed, resulting in the possible generation of cobbles or production of nonconforming reels.

[0013] Furthermore, always due to the difficulty in precisely identifying the final portion with respect to the rest of the product being worked, the cutting and separating intervention, including automated, can comprise two overlapping wires, generating intermediate-sized off-cuts, which make it more difficult to manage them during evacuation, resulting in production problems.

[0014] There is therefore the need to perfect an apparatus for managing a moving metal product and a plant for producing metal reels which can overcome at least one of the disadvantages of the state of the art.

[0015] One purpose of the present invention is therefore to provide an apparatus capable of qualitatively managing the product being worked, in particular on at least one final portion thereof, thus reducing waste caused by incorrect defect identification and therefore excessive material removal.

[0016] Another purpose of the present invention is to provide a plant for producing metal reels having high productivity and less downtime compared to prior art plants.

[0017] The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.

[0018] SUMMARY OF THE INVENTION

[0019] The present invention is set forth and characterized in the independent claims. The dependent claims describe other characteristics of the present invention or variants to the main inventive idea.

[0020] In accordance with the above purposes, an apparatus for managing a moving metal product, preferably a hot-rolled rod or wire fed in a direction of feed in the form of coils in continuous succession, comprises at least one manipulation and cutting station, which is provided with at least one manipulation head configured to manipulate and cut a specific portion of the metal product.

[0021] In a plant for producing and working metal reels, the metal product is fed by a roller conveyor in the direction of feed in the form of coils in continuous succession, which are produced, for example, by means of a winding unit having a laying head. The coils are then transported into an automatic reel forming unit. In this solution, the manipulation station is disposed in an intermediate position between the winding unit and the automatic reel forming unit.

[0022] In accordance with one aspect of the present invention, upstream of the manipulation station with respect to the coils’ direction of feed, advantageously in an intermediate position between the winding unit and the manipulation station, the apparatus according to the present invention comprises at least one separation station. The separation station is provided with at least one separation tool configured to cooperate with the specific portion of the metal product, in order to at least partly separate it from the rest of the metal product, defining at least one distinct segment on which the manipulation head can perform the cut.

[0023] For example, the separation tool can temporarily hold a desired number of final coils.

[0024] The separation tool is mounted on at least one movement member configured to move the separation tool both between a rest position, in which it is spaced apart from the coils, and at least one separation operating position, in which it intercepts a desired group of coils, and also in the direction of feed at a selective separation speed equal to or different from a nominal feeding speed of the coils, in order to induce an elastic deformation in the metal product between the coils and the separate group of coils, defining a distinct and partly unwound segment on which the manipulation head can perform a univocal and repeatable cut.

[0025] The separation station allows to perform a correct and univocal separation of the specific portion of the metal product without affecting normal production times, that is, without affecting the productivity of the plant in which the apparatus according to the present invention is installed.

[0026] The separation station comprises at least one video monitoring system configured to acquire a sequence of images of the metal product and of the defined segment, and at least one processing unit electronically connected both to the movement member and also to the video monitoring system, and configured to selectively command the movement member as a function of the images acquired by the video monitoring system in order to position the separation tool in a univocal condition of interception of the desired group of coils. This processing unit can be implemented with artificial intelligence configured to at least recognize the specific portion of the metal product and identify whether that specific portion of the metal product requires separation, according to predefined operating parameters, for example, as provided in international patent application WO-A- 2023100211, regarding the manipulation and cutting station.

[0027] Advantageously, the separation station and its tool are controlled precisely and univocally, based on the images acquired, in order to induce the elastic deformation and define the segment for the specific cut on the coils. In this way, the apparatus allows to qualitatively manage the product being worked, in particular on at least one final portion thereof, thus reducing any waste caused by incorrect identification of defects and, consequently, excessive material removal.

[0028] Moreover, the solution according to the present invention also offers the advantage that the entire metal reel production plant in which the apparatus is installed can achieve high productivity and a lower amount of plant downtime compared to prior art apparatuses.

[0029] In accordance with an advantageous embodiment, the movement member comprises at least one slider, which is configured to support the separation tool and is mounted sliding on a rail element disposed substantially parallel to the direction of feed. In this way, the movement of the slider along the rail determines the resulting advance of the tool in the direction of feed to perform the separation of the specific portion of metal product.

[0030] In accordance with other advantageous embodiments, the movement member comprises an articulated arm movable in at least two degrees of freedom, or even more, such as six degrees of freedom for example, in the event the latest generation of anthropomorphic arms are used. This allows to operate on the metal product, in particular on the terminal portion thereof, but not exclusively, regardless of its position, geometry or conformation.

[0031] In accordance with one aspect of the present invention, the processing unit is programmed so that the separation tool follows a sinusoidal trajectory correlated to the sizes and pitch of the rollers.

[0032] In accordance with one aspect of the present invention, the separation tool is a pin.

[0033] In accordance with another aspect of the present invention, the pin is moved by the movement member, accompanying the group of coils to the manipulation station.

[0034] In other embodiments, a second interception pin and a third interception pin are provided, each to carry out a compaction of the group of coils, the pins being disposed in sequence and upstream of the separation tool, or at least of its range of action, with respect to the direction of feed. These interception pins, which can, for example, take the form of pegs or obstacles, selectively positionable in the direction of feed, are configured to intercept the specific portion of the metal product, or the desired group of coils, before feeding them to the manipulation and cutting station.

[0035] In another embodiment, the apparatus comprises a deposit unit provided with arms on which the groups of coils are deposited.

[0036] DESCRIPTION OF THE DRAWINGS

[0037] These and other aspects, characteristics and advantages of the present invention will become apparent from the following description of an embodiment, given as a non-restrictive example with reference to the attached drawings wherein:

[0038] - figs. 1 and 2 are a top view and a lateral view, respectively, of a plant for producing metal reels, to which an apparatus for managing a moving metal product according to the present invention is applied;

[0039] - fig. 3 is a perspective view of an enlarged detail of the apparatus for checking a moving metal product, according to the present invention;

[0040] - fig. 4 is a lateral view of the detail of fig. 3; and

[0041] - fig. 5 is a schematic top view showing an operating sequence of a variant of the apparatus according to the present invention;

[0042] - fig. 6 is a variant of a detail of fig. 2.

[0043] We must clarify that the phraseology and terminology used in the present description, as well as the figures in the attached drawings also in relation as to how described, have the sole function of better illustrating and explaining the present invention, their purpose being to provide a non-limiting example of the invention itself, since the scope of protection is defined by the claims.

[0044] To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one embodiment can be conveniently combined or incorporated into other embodiments without further clarifications.

[0045] DESCRIPTION OF AN EMBODIMENT OF THE PRESENT INVENTION

[0046] With reference to figs. 1 and 2, an apparatus 10 according to the present invention is shown, for managing a metal product P, which can be a smooth or ribbed rod or a metal wire, moving in a direction of feed X.

[0047] The metal product P is disposed according to a series of coils 120 disposed offset in the direction of feed X by means of machines of a known type, such as a coilforming head for example.

[0048] The metal product P is moved on a substantially horizontal movement plane Z, which can also be inclined upward or downward, for example, in the direction of feed X, and with a certain nominal speed VI, chosen as a function of desired productivity parameters.

[0049] Once its movement on the movement plane Z has ended, the metal product P can be packaged into reels or stacks 200.

[0050] In the embodiment shown with reference to figs. 1-2, a plant 100 for producing metal reels 200 is schematized, for example starting from a hot-rolled metal product P, in which the apparatus 10 is applied.

[0051] The plant 100 comprises a winding unit 110 having a laying head 111 and configured to receive the metal product P in linear form and to conform it into coils 120, and an automatic reel forming unit 113 able to receive the metal product P conformed into coils 120 and group it into reels 200.

[0052] The plant 100 comprises a roller conveyor 112, or cooling belt, on which the coils 120 of metal product P are laid. The roller conveyor 112 has an initial end 112a, in correspondence with which the winding unit 110 is disposed, and a terminal end 112b in correspondence with which the automatic reel forming unit 113 is disposed.

[0053] The roller conveyor 112 defines the movement plane Z of the metal product P and can integrate cooling systems so as to bring the temperature of the metal product P from about 1000 °C at exit from the winding unit 110, to about 500 °C at the end of the roller conveyor 112.

[0054] As stated, the plant 100 comprises the apparatus 10 which is disposed in a position comprised between the initial end 112a and the terminal end 112b of the roller conveyor 112.

[0055] The apparatus 10 is disposed on the side of the roller conveyor 112 and substantially comprises a separation station 20 and a manipulation and cutting station 11, which are operatively disposed in sequence with each other in the direction of feed X, in cooperation with the roller conveyor 112.

[0056] The separation station 20 comprises a movement member 21 on which a separation tool is mounted, in this specific case in the form of a pin 22, and configured to move the latter between a rest position (not shown), in which it is spaced apart from the coils 120, and at least one separation position, in which it intercepts a desired group 120a of coils 120. Furthermore, the same movement member 21 is configured to selectively move the pin 22 also in the direction of feed X, but at a selective separation speed V2 that can have both direction and also absolute value which differ from the nominal feeding speed VI of the coils 120. The group of coils 120a can be a terminal, or tail, portion, or a sampling portion disposed, for example, in a position comprised between the tail and the head of the metal product P.

[0057] This at least temporary difference in speed allows for an elastic deformation of the metal product P, between the coils 120 and the desired group 120a separated by the pin 22, defining at least one distinct segment 120b. Also part of the separation station 20 is a video monitoring system 18 for the acquisition of a video sequence and / or a sequence of digital images of the metal product P being worked, specifically of the coils 120 advancing on the roller conveyor 112, and of the segment 120b defined by the action of the pin 22 on the group of coils 120a.

[0058] This sequence of images can be continuous or acquired at regular or non-regular intervals.

[0059] The video monitoring system 18 can comprise at least one video camera 18a preferably positioned aboard the movement member 21 (fig. 2 and fig. 6), and oriented in a direction substantially perpendicular to the direction of feed X.

[0060] In this case, the sequence of images can be acquired “in pursuit”, by intrinsic mobility of the movement member 21.

[0061] Alternatively, the video camera 18a can also be disposed in a fixed position with respect to the metal product P being worked, along or above the movement plane Z, so as to guide the movement member 21.

[0062] The separation station 20 also comprises a processing unit 19 electronically connected both to the movement member 21 and also to the video monitoring system 18, and configured to selectively command the movement member 21 as a function of the images acquired by the video monitoring system 18, so as to position the pin 22 in a univocal condition of interception of the desired group 120a of coils 120.

[0063] In the embodiment schematized in figs. 1 and 2, the movement member 21 comprises a slider 23, configured to support the pin 22 and mounted sliding on a rail element, or more simply rail 24, provided on the side of the roller conveyor 112 in an operating condition substantially parallel to the direction of feed X.

[0064] By way of example, the slider 23 is moved selectively along the rail 24 by means of a translation kinematics 25, which can provide a kinematic system with rotary motor and transmission belt or chain, as schematized in the attached drawings; however, any other known kinematic system is not excluded, for example with linear actuators, with worm screw, motorized wheels or other.

[0065] In this solution, the movement of the pin 22 between the rest position and the separation position is realized by means of a dedicated actuator 26 mounted on board the slider 23. In the solution shown in fig. 6, and in part in fig. 4, the movement member 21 comprises an articulating arm 27 configured to support the pin 22 and moveable in at least six degrees of freedom. In turn, the articulated arm 27 is mounted on a slider 28, by means of which it can be selectively moved in the direction of feed X at the selective separation speed V2.

[0066] In both of the aforementioned solutions, the pin 22 is moved individually along the roller conveyor 112 being inserted from above or below, so as to intercept the desired group 120a of coils 120, by means of the signals coming from the video monitoring system 18 and the processing unit 19 that identify the terminal coils 120 of a wire that falls from the laying head 111, destined to become a reel 200.

[0067] It is not excluded that the movement member 21 can be implemented so as to able to define right to left transverse movements of the pin 22. In the same way, as schematized in fig. 4, in addition to an initial step for separating the group of coils 120a from the coils 120, so as to define the segment 120b, it can stabilize the shape of the group of coils 120a and cancel the spring back effect of the metal product P. The inserted pin 22, once it has defined the segment 120b, continues to follow the normal feed of the coils 120 in the direction of feed X, so as not to stretch too much, preventing a new tail defect from being created, as a consequence, which could generate tangling problems during the formation of the reel 200.

[0068] As schematized in fig. 4, to prevent any problems of interference between the roller conveyor 112 and the pin 22, the processing unit 19 can be programmed so that the pin 22 follows a sinusoidal trajectory T correlated to the sizes and pitch of the rollers. This movement along the trajectory T is equally executable both in the embodiment with arm 27 (as shown in fig. 4) and also in the embodiment with slider 23. Alternatively, a simplified solution can provide a suitable median shaping of the rollers of the roller conveyor 112, aimed at allowing the passage of the pin in the direction of feed X, without any interference with the rollers.

[0069] The manipulation and cutting station 11 can comprise an articulated arm 17 having a manipulation head 12 provided with a gripping tool 13 and a cutting tool 14 configured to, respectively, manipulate the coils 120 and cut the metal product P in correspondence with the segment 120b defined by the action of the pin 22, that is, to separate the desired group of coils 120a.

[0070] The articulated arm 17 can preferably be moved in a minimum of two, up to even six degrees of freedom, depending on the technology used, and can be moved in an additional seventh degree of freedom. For this purpose, the articulated arm 17 can be mounted on a slider 15 movable on rail, for example shared by the separation station 20 in the solution with articulated arm 27, so that the arm 17 itself can follow the product P being worked.

[0071] The same pin 22 performs a function of accompanying the group of coils 120a until the manipulation and cutting station 11 is reached, at least as regards the segment 120b. In other words, the pin 22 accompanies the group of coils 120a at least until the cutting tool 14 cuts the metal product P.

[0072] In the variant shown in fig. 5, the separation tool consists of a pin 122, generally vertically movable as described heretofore, namely, between a rest position in which it is below the movement plane Z and does not interfere with the coils 120, and an interception operating position in which it is incident to the movement plane Z so as to hold the group of coils 120a that are to be manipulated / cut by means of the articulated arm 17. In the latter solution, the pin 122 can be configured to be inserted between the rollers of the roller conveyor 112 in order to clamp the one or more coils 120a, while the other coils 120 advance in the direction of feed X, defining the segment 120b.

[0073] In this solution, once the metal product P has been cut, the pin 122 returns to the rest position so as to allow the coils 120a to slide on the roller conveyor 112. In this solution, a second interception pin 123 can be advantageously provided, which is shaped and operatively configured to temporarily stop the group of separate coils 120a, so as to compact the latter, in a collected stack.

[0074] In this embodiment, in cases where it is necessary, a third interception pin 124 can be provided in sequence, substantially in correspondence with the manipulation and cutting station 11 , to carry out a further compaction before the manipulation by the gripping tool 13.

[0075] Alternatively, the pin 22 can be moved by the movement member 21, substantially accompanying the group of coils 120a directly to the manipulation and cutting station 11.

[0076] The apparatus 10 can also comprise a deposit unit, not shown in the attached drawings, provided with arms on which there are deposited groups of coils 120a which are removed. It is clear that modifications and / or additions of parts may be made to the apparatus 10 for managing a moving metal product P in a plant 100 for producing metal reels 200 as described heretofore, without thereby departing from the field and scope of the present invention, as defined by the claims. It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art will be able to achieve other equivalent forms of an apparatus for managing a moving metal product in a plant for producing metal reels, having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby. In the following claims, the sole purpose of the references in brackets is to facilitate their reading and they must not be considered as restrictive factors with regard to the field of protection defined by the claims.

Claims

CLAIMS1. Apparatus (10) for managing a moving metal product (P), preferably a hot- rolled rod or wire fed in a direction of feed (X) in the form of coils (120) in continuous succession, comprising at least one manipulation and cutting station (11) having at least one manipulation head (12) configured to manipulate and cut a specific portion of said metal product (P), characterized in that it comprises:- at least one separation station (20) disposed upstream of said manipulation and cutting station (11), with respect to said direction of feed (X), and provided with at least one separation tool (22, 122);- wherein said separation tool (22, 122) is mounted on at least one movement member (21) configured to move said separation tool (22, 122) both between a rest position, in which it is spaced apart from said coils (120), and at least one separation operating position, in which it intercepts a desired group of coils (120a), and also in said direction of feed (X) at a selective separation speed (V2) equal to or different from a nominal feeding speed (VI) of said coils (120), in order to induce an elastic deformation in the metal product (P) between said coils (120) and said separate group of coils (120a), defining a distinct and partly unwound segment (120b) on which said manipulation head (12) can perform a univocal and repeatable cut;- said separation station (20) comprising at least one video monitoring system (18) configured to acquire a sequence of images of said metal product (P) and of said distinct and partly unwound segment (120b), and at least one processing unit (19) electronically connected both to said movement member (21) and also to said video monitoring system (18), and configured to selectively command said movement member (21) as a function of the images acquired by said video monitoring system (18) in order to position said separation tool (22, 122) in a univocal condition of interception of said group of coils (120a).

2. Apparatus (10) as in claim 1, characterized in that said movement member(21) comprises at least one slider (23) configured to support said separation tool(22) and mounted sliding on a rail element (24) disposed substantially parallel to said direction of feed (X).

3. Apparatus (10) as in one or the other of the previous claims, characterized in that said movement member (21) comprises an articulated arm (27) configured tosupport said separation tool (22) and movable in at least two degrees of freedom.

4. Apparatus (10) as in one or the other of the previous claims, characterized in that said processing unit (19) is programmed so that said separation tool (22) follows a sinusoidal trajectory (T) correlated to the sizes and pitch of the rollers.

5. Apparatus (10) as in claim 4, characterized in that said separation tool is a pin (22, 122).

6. Apparatus (10) as in claim 5, characterized in that said pin (22, 122) is moved by said movement member (21), accompanying said group of coils (120a) to said manipulation and cutting station (11).

7. Apparatus (10) as in claim 5, characterized in that it comprises a second interception pin (123) and a third interception pin (124) which are disposed in sequence with respect to said pin (122) in said direction of feed (X) so as to each carry out a compaction of said group of coils (120a).

8. Apparatus (10) as in one or the other of the previous claims, characterized in that it comprises a deposit unit provided with arms on which said groups of coils (120a) are deposited.

9. Plant (100) for producing and working metal reels (200), equipped with an apparatus (10) as in claims from 1 to 8, comprising:- a winding unit (110) having a laying head (111) and configured to receive a metal product (P) in linear form and to conform it into coils (120);- an automatic reel forming unit (113) able to receive said metal product (P) conformed into coils (120) and form a reel (200);- a roller conveyor (112) configured to move said metal product (P) conformed into coils (120) in a direction of feed (X) from an initial end (112a), in correspondence with which said winding unit (110) is disposed, to a terminal end (112b), in correspondence with which said automatic reel forming unit (113) is disposed, and- at least one manipulation and cutting station (11) disposed in a position comprised between said initial end (112a) and said terminal end (112b) of said roller conveyor (112) and having at least one manipulation head (12) configured to manipulate and cut a specific portion of said metal product (P) conformed into coils (120).

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