Method and apparatus for preparing plastic material loads for supply to a molding press

Abstract: A load of plastic material is formed from two sheets (24, 24') cut successively from a roll (14) of strip material (16). The first sheet (24) is cut to a roughly constant length, weighed and loaded on to a conveyor (27). The second sheet (24') is cut to the length calculated according to the weight of the first sheet (24), and is loaded on to the conveyor (27) in a predetermined position in relation to the first sheet (24). Each sheet (24, 24') is positioned by transferring it from the cutting station (23) to a transfer structure (43) moved in relation to a stop structure (49) set each time to a given programmed position.

Description: The present invention relates to a method and apparatus for preparing plastic material loads for supply to a molding press. A common practice nowadays in the vehicle body component industry is to mold parts from plastic sheet material, such as heat-setting fiberglass-reinforced polyester resin known as SMC, which is usually supplied in rolls. For each production part, the press is loaded with a number of sheets cut off the roll, and the size of which must correspond accurately to the part being produced. For each production part, known systems provide for cutting off two sheets, the second of which varies in size so that the total size of the two sheets approximately equals that required for the part being produced. A major drawback of such systems is the poor or inconsistent quality of the parts produced, due to inevitable errors in cutting and positioning the sheets. Moreover, a good deal of time and effort is expended for calculating and measuring the size of the second sheet, and positioning it accurately in relation to the first sheet. It is known from the document JP-A-2121811 a system wherein a strip of SCM necessary for one product is successively unwound from a roll and is cut in segments of specific length. Each segment is weighed and the weights are added up, so that the final segment is increased or decreased to reach the total weight necessary for one product. It is also known from the document EP-A-394 845 an apparatus for cutting segments of a laminated strip-shaped material, continuously supplied to the apparatus. The segments are transferred to a conveyor where they are aligned by two parallel bars and are stacked in specific relative positions by moving the conveyor. It is an object of the present invention to provide a highly efficient method and apparatus for preparing plastic material loads for supply to a molding press. More particularly, the technical problem to be solved by the invention resides in preparing two sheets of the load for the molding press, with the requested weight of material and with an accurate relative positioning of the sheets. According to the present invention, this technical problem is solved by a method of preparing plastic material loads for supply to a molding press, wherein said material is initially in the form of a strip wound on a roll and thereafter is unwound from the roll, cut into preselected lengths and located on a conveyor for supplying the molding press; said method comprising a cut off stage, wherein a first sheet of approximately constant length of said strip is unwound from said roll and is cut in a cutting station; a weighing stage, wherein said first sheet is weighed; and a second cut off stage, wherein a second sheet is unwound from said roll and is cut in said cutting station; characterised by the following further stages: a first positioning stage, wherein a stop is set in a first position in respect to said conveyor, and wherein said first sheet after being so weighed is moved in a first direction as to be positioned on said conveyor against said stop; a calculating stage, wherein the length of said second sheet is calculated departing from the weight determined in said weighing stage; a moving stage, wherein said first conveyor moves said sheet a predetermined amount in a second direction perpendicular to said first direction; and a second positioning stage, wherein said stop is set in a second position in respect to said conveyor, and said second sheet so cut is moved in said first direction as to be positioned on said conveyor against said stop, whereby said second sheet is positioned in relation to said first sheet with a predetermined overlapping portion. According to the invention, the above technical problem is also solved by an apparatus for preparing plastic material loads for supply to a molding press, wherein said material is initially in the form of a strip wound on a roll and thereafter is unwound from the roll, cut into sheets of preselected lengths and located on a conveyor for supplying the molding press; said apparatus comprising a cutting device for cutting said sheets off said strip, means for controlling a first unwinding of said roll to present to said cutting device an approximately constant length of said strip to cut a first sheet, means for weighing said first cut sheet, and means for locating said cut sheets on said conveyor; characterised by means for recording said weight of said first cut sheet and for calculating from said recorded weight a second length of said strip, said control means being conditioned by said second length so calculated for unwinding said roll as to present to said cutting device said second length of said strip to cut a second sheet; said locating means comprising adjustable stop means settable by said control means in respect to said conveyor in positions corresponding to said cut sheets, and transfer means for receiving said cut sheets and for individually transferring them along a first direction to said conveyor against said stop means; said control means being adapted to activate said conveyor to move said first sheet in a second direction perpendicular to said predetermined direction, whereby said second sheet is positioned in relation to said first sheet with a predetermined overlapping portion. A preferred, non-limiting embodiment of the present invention will be described by way of example with reference to the accompanying drawings, in which: Fig.1 shows a schematic plan view of a molding system comprising an apparatus in accordance with the present invention; Fig.2 shows a larger-scale part section along line II-II in Fig.1; Fig.3 shows a schematic part section along line III-III in Fig.1; Fig.4 shows a larger-scale plan view of a detail of the system according to the present invention; Fig.5 shows a front view along line V-V in Fig.4; Fig.6 shows a schematic section along line VI-VI in Fig.4; Fig.s 7 and 8 show the Fig.6 section in two different operating positions; Fig.9 shows a part view in perspective of the relative position of two sheets constituting the load; Fig.10 shows a block diagram of a control device for governing the system according to the present invention; Fig.11 shows a table of the various operating stages of the system according to the present invention. Number 12 in Fig.1 indicates an automatic vehicle body component manufacturing apparatus or system comprising a loading station 13 equipped with a roll 14 of plastic strip material 16 (Fig.2), e.g. fiberglass-reinforced polyester resin known as SMC. Strip 16 of SMC is supplied in two protective polyester films 17 and 18, which must be removed before use. For this purpose, system 12 also comprises a station 19 substantially consisting of two counter-rotating rollers 21 and 22 for respectively removing films 17 and 18. System 12 also comprises a cutting station 23 (Fig.3) where strip 16 is cut into sheets 24 and 24' (Fig.9) by a cutting device consisting substantially of two blades 25 controlled in known manner by a control unit 26 (Fig.10) described in detail later on. The Fig.10 blocks controlled by unit 26 represent the control circuits of the mechanical devices in Fig.s 1-6 and are indicated using the same numbering system. System 12 also comprises a first conveyor belt 27 (Fig.s 1 and 6-9) for receiving sheets 24, 24' required for a given production part. Controlled by unit 26, conveyor 27 feeds sheets 24, 24' on to a second conveyor belt 28 (Fig.1) by which they are fed through a preheat station 29 with an oven for heating sheets 24, 24' to a given temperature. A third conveyor 30, e.g. consisting of a number of belts, feeds sheets 24, 24' from station 29 to a loading station 31 featuring a loading device 32 controlled by unit 26 for loading sheets 24, 24' into the mold of a molding press 33. According to the present invention, system 12 comprises a weighing station 34 located between cutting station 23 and conveyor 27, and featuring a device 36 for weighing sheet 24, 24'. Weighing device 36 presents a display 37 (Fig.3), and is enabled by control unit 26 (Fig.10) for transmitting each weight to a computing unit 38 for storage in a memory 39. Computing unit 38 is also controlled by a routine stored, for example, in a ROM memory 40. As it is weighed, sheet 24, 24' is supported on a number of rollers 41 (Fig. 3) on a supporting structure 42 of weighing device 36. Rollers 41 are rotated in known manner by control unit 26 so as to feed sheet 24, 24' on to transfer means comprising a first structure 43 (Fig.s 4-6) movable perpendicularly to the axis of rollers 41 between two fixed positions. Structure 43 presents a number of L-shaped bar elements 44 spaced parallel to the axis of rollers 41, and the horizontal arm of which is slightly below rollers 41. Structure 43 also presents a cross member 45 fitted with two braces 46, and two rods 47, each activated by a respective pneumatic linear actuator 48 controlled by unit 26 (Fig.10). Structure 43 cooperates with stop means comprising a second structure 49 (Fig.s 4-6) having a number of horizontal bars 51 interspersed with bars 44. Each bar 51 terminates in a stop element consisting of a vertical square 52 for arresting the cutting edge of sheet 24, 24'. Structure 49 is connected to two rods 53 of two pneumatic linear actuators 54 for moving structure 49, perpendicularly to the axis of rollers 41, into positions programmable in memory 40 of computing unit 38 according to the required position of sheets 24, 24'. Operation of the system according to the present invention will be described with the aid of the Fig.11 table. Firstly, control unit 26 rotates roll 14 (Fig.2) so as to unwind strip 16 preparatory to cutting off a first sheet 24, the length of which is programmed according to the part being produced, and which may, if necessary, be constant for a series of different parts. Normally, structure 49 is so positioned as to arrest first sheet 24 in the position required on conveyor 27, as shown by the dotted line in Fig.6. Control unit 26 then enables blades 25 (Fig.3) for performing a first operation or stage 56 (Fig.11) wherein first sheet 24 is cut off strip 16. The length of sheet 24 is usually only roughly equal to the programmed length, and, when cut, sheet 24 rests entirely on rollers 41 of structure 42. Control unit 26 then enables weighing device 36 for performing weighing stage 57, wherein first sheet 24 is weighed and the result shown on display 37. Control unit 26 then enables stage 58 for loading sheet 24 in a predetermined position on conveyor 27 (Fig.s 4-6). To do this, control unit 26 activates rollers 41 to transfer sheet 24 on to bars 44 of transfer structure 43, and then enables actuators 48 to move structure 43 rightwards in Fig.6. When positioned as required on conveyor 27, the edge of sheet 24 is arrested by squares 52, and, as structure 43 withdraws, sheet 24 is transferred in this position from bars 44 on to conveyor 27. At the same time, computing unit 38 performs control stage 59, which consists in storing the weight of sheet 24 in memory 39, and computing the length of strip 16 required for second sheet 24' to make up the total weight programmed for the production part. Computing unit 38 also governs control unit 26 so as to reel off strip 16 preparatory to cutting off second sheet 24' to the computed length. At this point, blades 25 are again enabled for performing a further cutting stage 60 wherein second sheet 24' is cut off strip 16. Finally, stage 61 is enabled for positioning second sheet 24'. To do this, control unit 26 first enables actuators 54 to move structure 49 rightwards into the position shown by the continuous line in Fig.6, which position corresponds with the required position of second sheet 24' on conveyor 27, perpendicular to the axis of rollers 41. At the same time, control unit 26 activates conveyor 27 to so position first sheet 24 as to receive second sheet 24' in the required mutual position parallel to the axis of rollers 41. Control unit 26 then activates rollers 41 to transfer second sheet 24' on to bars 44 of structure 43, and enables actuators 48 to arrest second sheet 24' against squares 52, as shown in Fig. 7. As structure 43 withdraws, second sheet 24' is transferred on to conveyor 27 as shown in Fig.8, with sheets 24 and 24' overlapping by a given portion 55, as shown in Fig.9. Finally, conveyor 27 is activated to feed sheets 24 and 24' on to second conveyor 28, while actuators 48 and 54 move structures 43 and 49 back to the start position. The advantages of the method and system according to the present invention will be clear from the foregoing description. In particular, automatic, accurate sizing of second sheet 24' provides for eliminating rejects due to material shortage, and, conversely, wastage and removal of excess material in the event of overloading. Moreover, accurate mutual positioning of sheets 24 and 24' with overlapping portion 55 ensures the production of good, consistent quality parts. To those skilled in the art it will be clear that changes may be made to the method and system as described and illustrated herein without, however, departing from the scope of the present invention. For example, changes may be made to the location of the various stations and the design of individual devices.

Claims: A method of preparing plastic material loads for supply to a molding press (33), wherein said material is initially in the form of a strip (16) wound on a roll (14) and thereafter is unwound from the roll (14), cut into preselected lengths and located on a conveyor (27) for supplying the molding press (33); said method comprising a cut off stage (56), wherein a first sheet (24) of approximately constant length of said strip (16) is unwound from said roll (14) and is cut in a cutting station (23); a weighing stage (57), wherein said first sheet (24) is weighed; and a second cut off stage (60), wherein a second sheet (24') is unwound from said roll (14) and is cut in said cutting station (23); characterised by the following further stages: a first positioning stage (58), wherein a stop (52) is set in a first position in respect to said conveyor (27), and wherein said first sheet (24) after being so weighed is moved in a first direction as to be positioned on said conveyor (27) against said stop (52); a calculating stage, wherein the length of said second sheet (24') is calculated departing from the weight determined in said weighing stage (57); a moving stage, wherein said conveyor (27) moves said first sheet (24) a predetermined amount in a second direction perpendicular to said first direction; and a second positioning stage (61), wherein said stop (52) is set a in second position in respect to said conveyor (27), and said second sheet (24') so cut is moved in said first direction as to be positioned on said conveyor (27) against said stop (52), whereby said second sheet (24') is positioned in relation to said first sheet (24) with a predetermined overlapping portion (55). A method as claimed in Claim 1, characterised in that said calculating stage is comprised in a control stage (59) for governing said second cutting stage (60); said control stage (59) consisting in recording in a memory (39) the weight of said first sheet (24), computing from said weight so recorded in said memory (39) the length of said second sheet (24'), and controlling the unwinding of said strip (16) in relation to said station (23) according to the length so computed. A method as claimed in Claim 1 or 2, characterised in that said stop (52) is arranged to arrest the cutting edge of said sheets (24, 24'); said conveyor (27) being moved in said moving stage (61) parallel to said cutting edge. An apparatus for preparing plastic material loads for supply to a molding press (33), wherein said material is initially in the form of a strip (16) wound on a roll (14) and thereafter is unwound from the roll (14), cut into sheets (24, 24') of preselected lengths and located on a conveyor (27) for supplying the molding press (33); said apparatus comprising a cutting device (25) for cutting said sheets (24, 24') off said strip (16), means (26) for controlling a first unwinding of said roll (14) to present to said cutting device (25) an approximately constant length of said strip (16) to cut a first sheet (24), means (36) for weighing said first cut sheet (24), and means (43, 44, 49, 51, 52) for locating said cut sheets (24, 24') on said conveyor (27); characterised by means (38, 39) for recording said weight of said first cut sheet (24) and for calculating from said recorded weight a second length of said strip (16), said control means (26) being conditioned by said second length so calculated for unwinding said roll (14) as to present to said cutting device (25) said second length of said strip (16) to cut a second sheet (24'); said locating means (43, 44, 49, 51, 52) comprising adjustable stop means (49, 51, 52) settable by said control means (26) in respect to said conveyor (27) in positions corresponding to said cut sheets (24, 24'), and transfer means (43, 44) for receiving said cut sheets (24, 24') and for individually transferring them along a first direction to said conveyor (27) against said stop means (49, 51, 52); said control means (26) being adapted to activate said conveyor (27) to move said first sheet (24) in a second direction perpendicular to said predetermined direction, whereby said second sheet (24') is positioned in relation to said first sheet (24) with a predetermined overlapping portion (55). An apparatus as claimed in Claim 4, characterised in that said means (38, 39) for recording said weight and for calculating said second length include a memory (39) for storing said weight, and programmable means (40) for computing said second length on the basis of said stored weight, said programmable means (40) governing said control means (26) also for selectively enabling said cutting device (25). An apparatus as claimed in Claim 4 or 5, characterised in that said cutting device (25) operates in conjunction with a moving means (41) for moving the sheets (24, 24') so cut toward said transfer means (43, 44), said control means (26) further coordinating the cutting of said sheets (24, 24') and the operation of said moving means (41). An apparatus as claimed in Claim 5, characterised in that said transfer means (43, 44) comprise a first structure (43) movable between two fixed positions by a first linear actuator (48), said stop means (49, 51, 52) being adapted to arrest the cut edge of said sheets (24, 24') and comprising a second structure (49) moved each time by a second linear actuator (54) into stop positions programmed on said programmable means (40). An apparatus as claimed in Claim 7, characterised in that said first and second structures (43, 49) are moved in a predetermined common direction, each said structure (43, 49) comprising a number of elements (44, 51) spaced perpendicularly to said predetermined direction and interspersed with each other.

Inventors: BELLETTATO BRUNO, BELLETTATO, BRUNO
Applicants: IVECO FIAT, IVECO FIAT S.P.A.
Application year: 1993
Main classification: B29C70
IPC codes: B29C31, B29C70