Abstract:
A cutting unit includes a stationary frame, a cutting drum, and an anvil drum. The cutting drum and the anvil drum are arranged one over the other for cutting web material fed therebetween. The upper drum is centred on a rotatable arbour and rotatably supported in the stationary frame. The lower drum is rotatable and movable towards and away from the upper drum. A rotatable carrier, movable towards and away from the upper drum, includes at least two contact rollers. The lower drum is shaftless and rests on the contact rollers. At least one contact roller is situated on either side of a central vertical plane of the lower drum for providing support of the lower drum by the contact rollers only. A pressing device moves the carrier and the lower drum towards and against the upper drum for providing cutting pressure between the upper drum and the lower drum.

Description:
TECHNICAL FIELD  
       [0001]    The present invention relates to a cutting unit comprising a cutting drum and an anvil drum arranged one over the other for cutting web materials fed between them. 
       BACKGROUND  
       [0002]    Prior art cutting units often comprise a cutting drum and an anvil drum. These are arranged on arbours, which are rotatable supported in a frame by bearing blocks. The cutting drum and the anvil drum are arranged one over the other with their arbours and axis of rotation extending horizontal and in parallel. In the prior art cutting units are known, where the cutting drum is arranged over the anvil drum, and cutting units, where the anvil drum is arranged over the cutting drum. Normally at least one of the drums is connected to a driving device for rotating the arbour with the drum. 
         [0003]    Cutting units are normally used for continuously cutting web material fed between the upper and the lower drum. The cut articles and the trim are evacuated by for example conveyors and vacuum nozzles. 
         [0004]    A known type of cutting unit has hydraulic, extendable cylinders that bear between the frame and the lower drum to press it against the upper drum for affecting the desired cutting pressure. To this end, the bearing blocks of the lower drum are movable arranged on linear guides, while the bearing blocks of the upper drum are fixed in the frame. 
         [0005]    After the cutting unit has been run a certain time, the cutting drum and the anvil drum have to be reground. A problem with regrinding is that in order to obtain desired cutting depth and cutting force during use, the cutting portions and anvil portions of the drums have to be strictly concentric in combination with an exact centring of the drum on the arbour and in the bearing blocks, which requires a very exact regrinding operation. In addition, the drums have to be removed from the cutting unit in order to carry out regrinding. This is a rather complex and time consuming operation, especially for the lower drum, which is more difficult to access below upper drum. 
       SUMMARY  
       [0006]    It is therefore an object of the present invention to provide a cutting unit, which alleviates at least one of the above-mentioned problems. 
         [0007]    According to the invention, this object is achieved by a cutting unit according to claim  1 . 
         [0008]    A cutting unit according to the invention comprises a stationary frame, a cutting drum having a cutting knife on an outer cylindrical surface thereof and a centre axis, and an anvil drum having an outer cylindrical surface and a centre axis. The cutting drum and the anvil drum are arranged one over the other with parallel centre axes for cutting web material fed between them. The upper of the cutting drum and the anvil drum is centred on an arbour, which is rotatable supported in the stationary frame and connectable to a driving device for rotating the arbour and the upper drum around the centre axis thereof. The lower of the cutting drum and the anvil drum is arranged rotatable around the centre axis thereof, and is arranged movable towards and away from the upper drum. The cutting unit further comprises a carrier, which is arranged movable towards and away from the upper drum. The carrier comprises at least two contact rollers, which have an outer cylindrical surface and which are arranged rotatable round a respective axis in the carrier, which axes are parallel to the centre axis of the cutting drum and the anvil drum. The lower drum is shaftless and is arranged with the outer cylindrical surface thereof resting on the outer cylindrical surface of the at least two contact rollers, wherein at least one contact roller is situated on either side of a central vertical plane of the lower drum for providing vertical and transversal support of the lower drum by the contact rollers only. The carrier is connectable to a pressing device for moving and pressing the carrier and the lower drum carried thereby towards and against the upper drum for providing cutting pressure between the upper drum and the lower drum. 
         [0009]    Due to the provision of a carrier comprising contact rollers, the arbour/shaft for the lower drum can be refrained from, as well as corresponding bearing blocks in the frame. Thus, the lower drum is shaftless and supported vertically and transversally in the cutting unit by the carrier only. Since the carrier is movable arranged and connectable to a pressing device, the lower drum can be pressed against the upper drum in order to achieve a desired cutting pressure. The outer surface of the carrier rolls can be carefully manufactured to exact concentricity and they can during initial mounting be carefully positioned in the carrier. Then, the position of the lower drum in the carrier is well defined. During regrinding of the lower drum, the operator still has to ensure good cylindrical form of the lower drum. However, unlike when regrinding lower drums of prior art cutting units, the operator needs not observe good concentricity with respect to the centre axis, nor observing the position of the centre axis with respect to the arbour or the bearing blocks. The cylindrical form of the lower drum is during regrinding directly realized by rotating the lower drum with the outer peripheral surface thereof in contact with the grindstone. Consequently, the lower drum and support thereof by the carrier arrangement according to the present invention enable easier regrinding of the lower drum while the lower drum has the same movable function as prior art movable, lower drums. 
         [0010]    During use, the cutting unit is intended to rest on a horizontal plane. In this application expressions as “lower”, “upper”, “vertical” and “horizontal” relate to this horizontal plane. 
         [0011]    The drums of the cutting unit according to the present invention have a longitudinal extension round a centre axis. The expression “transverse” refers to a horizontal direction that is perpendicular to the longitudinal axis/centre axis. A “transverse plane” is to be understood as a vertical plane that is normal to the centre axis. 
         [0012]    The cutting unit according to the present invention is intended to continuously cut articles from a web material. Examples for articles that can be produced in this way are paper or card board blanks for packages, labels and hygienic products, such as diapers and sanitary towels. The web material can comprise a single layer or several layers, which can be laminated or held together in any other suitable way. When producing hygienic products, the web material can comprise layers of woven material, non-woven material, absorbent material and backing material. 
         [0013]    According to the invention, the cutting unit comprises a stationary frame. The frame is stationary with respect to movable parts of the cutting unit, but can be movable together with the cutting unit as a whole. The frame can comprise bars and plates forming a skeleton for supporting and holding together the parts of the cutting unit. 
         [0014]    The cutting unit according to the invention comprises a cutting drum and an anvil drum. The drums have a longitudinal extension round a longitudinal centre axis of revolution. The drums have an overall general cylindrical shape. The peripheral outer surface of the drums is rotational symmetrical round the centre axis of revolutions and has a constant diameter in zones that are active in cutting. The drums may also include zones that are inactive during cutting, which may have a smaller diameter or have non-circular cross sections. 
         [0015]    The cutting drum has a cutting knife on an outer cylindrical surface thereof. The cutting knife forms a cutting ridge on the surface, which forms a curve in the circumferential and/or axial directions of the cutting drum. The curve formed by the extension of the cutting knife over the cutting drum corresponds to the contour of the articles to be cut. 
         [0016]    The anvil drum and the cutting drum can comprise steel or be made from a harder material such as cemented carbide or the like. The drums can have an outer tube of the harder material applied to an inner tube or core of steel, for example by shrink fitting. 
         [0017]    According to the invention, the cutting drum and the anvil drum are mounted one over the other. Normally, their axes of revolutions are parallel and located in a common vertical plane. One of the cutting drum and the anvil drum is the upper drum and the other is the lower drum. 
         [0018]    The upper drum is centred on an arbour. The arbour may be in one piece extending through the upper drum from one axial end to the other or comprise a part of limited length at each end. The arbour has ends extending axially from the upper drum at each axial end. These ends are rotatable supported in the stationary frame, for example by bearing blocks. The arbour is at one end connectable to a driving device which is operable to rotate the arbour and the upper drum mounted thereon round the centre axis of revolution. 
         [0019]    The cutting unit according to the invention comprises a carrier, which supports at least two contact rollers. The carrier can comprise a framework of bars or a plate. The contact rollers are rotatable supported in the carrier. The axes of revolution of the contact rollers are parallel to the centre axis of revolution of the lower drum. 
         [0020]    The lower drum rests with its outer peripheral surface on the outer peripheral surface of the contact rollers. The contact rollers are arranged below a central horizontal plane of the lower drum for such receiving the lower drum and providing vertical support. The contact rollers may, but needs not, have the same and constant diameter. It is sufficient if the outer peripheral surface of the contact rollers is tangent with the outer surface of the lower drum at least over a portion. One contact roller is arranged on either side of a vertical plane through the lower drum for providing support in both transverse directions of the lower drum. 
         [0021]    The lower drum is shaftless, i.e. it has no arbour for supporting it in the frame. The lower drum is sufficiently supported for rotation, and in both transversal directions and in the vertical direction by the carrier only. Thus, the support provided by the carrier is sufficient for ensuring adequate operation during cutting. Additional support is however not excluded. 
         [0022]    The carrier is connectable to a pressing device for pressing the lower drum against the upper drum for providing cutting pressure. The pressing device can be a mechanical device such as a screw, or hydraulic or pneumatic cylinders. The cutting pressure can be constant, set to a selectable value or continuously adjustable. 
         [0023]    The contact rollers can have the same or different longitudinal length. The carrier can comprises only two contact roller or many contact rollers on both sides of the vertical plane comprising the centre axis of the lower drum. The contact rollers can have an axial length or be disc-shaped. The contact rollers can be arranged on common axes of rotation (one at each side of the vertical plane). An advantage of having long or several contact rollers distributed over the length of the lower drum on each side of the vertical plane, is that the lower drum is prevented from twisting. Another advantage is that the lower drum is supported over its length and that the pressing force from the carrier is distributed over the length of the lower drum so that the lower drum is less prone to bending. Thereby, the cutting depth and/or force will be more even along the axial length of the drums. 
         [0024]    According to one embodiment of the cutting unit according to the invention, the contact rollers are arranged in the carrier in pairs. Two contact rollers are located opposite each other on either side of a vertical plane through the longitudinal centre axis of the lower drum. An advantage herewith is that the load of the lower drum is distributed evenly, which provides a more stable support. However, in other embodiments, the contact rollers can be arranged non-symmetrical. For example, the contact rollers can be located with their centre axis at different heights with respect to a central horizontal plane through the power drum, the contact roller can be arranged displaced relative each other in the longitudinal direction of the lower drum as seen on either side of a vertical plane through the longitudinal centre axis of the lower drum. 
         [0025]    According to one embodiment of the cutting unit, the cutting knife forms a curve in the circumferential and/or axial directions of the cutting drum in a cutting zone of the cutting drum. In an embodiment according to the invention comprising a pair of contact rollers, the contact rollers have a longitudinal length corresponding to the longitudinal length of the cutting zone and are arranged below the cutting zone. Consequently, the pressure transmitted by the contact rollers when the carrier moves the lower drum towards the upper drum extends over the area where the cutting is performed. An advantage with this arrangement is that the drums are subjected to less bending so that the cutting depth will be more equal along the axial, longitudinal direction. This is true for embodiments where the cutting drum is the lower drum as well as for embodiments where the anvil drum is the lower drum. 
         [0026]    According to one embodiment of the cutting unit according to the invention, the cutting drum comprises a bearer ring at each axial end thereof for being in rolling contact with the anvil during cutting. In an embodiment according to the invention comprising a pair of contact rollers, the contact rollers are arranged below the bearer rings. Consequently, the pressure transmitted by the contact rollers when the carrier moves the lower drum towards the upper drum is exerted at the area of the bearer rings. An advantage with this arrangement is that no bending is induced by the pressure from the carrier with the carrier rolls, because the pressure is applied to the lower drum at the same area as the counter pressure is applied by the upper drum bearer rings bearing against the lower drum. Thus, the cutting pressure and/or depth will advantageously be more equal along the axial length of the drums. This is true for embodiments where the cutting drum is the lower drum as well as for embodiments where the anvil drum is the lower drum. 
         [0027]    According to one embodiment of the present invention, the cutting unit comprises axial bearings for supporting the lower drum in the directions of the centre axis. The axial bearings can be of any suitable kind, for example a stop lug with a low friction surface for sliding against the rotating lower drum, a ball bearing, a roller bearing, a single wheel. The axial bearing can be mounted on the stationary frame. An advantage with axial bearings is that the lower drum is secured more reliable in the axial direction. 
         [0028]    According to one embodiment of the present invention, the lower drum is hollow, or in other words, the lower drum has the shape of a hollow tube. An advantage herewith is that the lower drum is lighter than a solid lower drum. Thereby the lower drum requires less energy to rotate and to move up and down, and is easier to mount and dismount, and the whole cutting unit will weigh less. 
         [0029]    According to one embodiment of the present invention, the cutting unit comprises a safety device for preventing the lower drum from leaving the resting position thereof on the contact rollers. Since the lower drum lacks an arbour, it is freely supported on the carrier and is not locked to the frame by bearing blocks as are prior art drums. Thus, due to for example malfunction during cutting operations, the lower drum could possibly lift from the contact roller and damage other parts of the cutting unit. The safety device is intended to engage with the lower drum and restrain it to the contact rollers or at least force it back on to them, in case the lower drum should be subjected to forces striving to push the lower drum away from its resting position. The safety device can be of any suitable kind, for example a bar extending through a hollow lower drum, or plates extending to the sides of the lower drum. 
         [0030]    According to one embodiment of the present invention, the stationary frame comprises an opening facing the axial end of the lower drum. Preferably, the opening is located in line with the lower drum when the lower drum is in a lower position, distanced from the upper drum. However, in other embodiments, the opening can be in line with the lower drum when it is in other, raised positions. This opening is larger than the largest cross section of the lower drum. Due to the lower drum resting freely on the carrier and not being attached to the frame by bearings, the lower drum can be easily removed from the cutting unit through this opening. In embodiments having safety devices and axial support devices for the lower drum, these may have to be removed first. However, removal of the lower drum is still considerably easier according to this embodiment than in many prior art cutting units, because in many prior art cutting units first upper parts of the frame have to removed, then the upper drum with its shaft and bearings and finally the lower drum with its shaft and bearings. 
         [0031]    According to one embodiment of the present invention, the lower drum is the anvil drum. This construction is advantageous with respect to handling of the web and cut articles during operation. To have the anvil drum below is especially advantageous in embodiments where the lower drum is axially removable. One frequent reason for removing a drum is for regrinding. Normally the anvil drum wears faster than the cutting drum. If the cutting drum is made of cemented carbide, the anvil drum is reground about three times as often as the cutting drum. 
         [0032]    According to one embodiment of the present invention, the cutting unit comprises a linear guide for guiding the carrier during pressing thereof towards and against the upper drum. An advantage with the linear guide is that the axis of rotation of the upper drum and the lower drum are held more in parallel, which enables better cutting quality. The linear guide can constitute a part of the frame. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0033]    The invention may be performed in many different ways, and by way of example only, embodiments thereof will be described in detail with reference being made to accompanying drawings, in which: 
           [0034]      FIG. 1  is a front perspective view of a cutting unit according to a first embodiment of the invention; 
           [0035]      FIG. 2  is a rear perspective view of a cutting unit according to the first embodiment of the invention, wherein the bearings of the carrier has been removed; 
           [0036]      FIG. 3  is a side view of a cutting unit according to the first embodiment of the invention; 
           [0037]      FIG. 4  is a front view of a cutting unit according to the first embodiment of the invention; 
           [0038]      FIG. 5  is a cross section along a transverse, vertical plane through the first embodiment of the invention; 
           [0039]      FIG. 6  is an enlarged view of the lower drum and the support arrangement thereof according to the first embodiment of the invention; 
           [0040]      FIG. 7  is a front perspective view of a cutting unit according to a second embodiment of the invention; 
           [0041]      FIG. 8-10  show how the lower drum can be removed in the first embodiment of the invention; 
       
    
    
     DETAILED DESCRIPTION 
       [0042]    With reference to  FIGS. 1-6 , a first embodiment of the cutting unit according to the present invention is shown. The cutting unit comprises a stationary frame  1 , which includes four corner columns in the form of tubes with circular cross section  2 , a base plate  3  and a top plate  4 . During use, the base plate  3  is intended to be supported horizontally such that the base plate  3  has its extension in a horizontal plane. The cutting unit further comprises an upper drum  5  in the form of a cutting drum and a lower drum  6  in the form of an anvil drum, wherein “upper” and “lower” is relative the horizontal plane of the base plate  3 . The drums  5 ,  6  have an overall cylindrical shape and longitudinal centre axis of rotation,  8 ,  9 . The axes of rotation  8 ,  9  of the cutting and anvil drums  5 ,  6  are parallel and located in the same vertical plane C, c.f.  FIG. 3 . 
         [0043]    The cutting drum comprises two cutting knives  7 , which form an axially and circumferentially curving ridge over a mantle surface of the cutting drum  5 . There is arranged a curving cutting knife  7  at each axial end of the cutting drum  5  in a cutting zone  10 , c.f.  FIG. 1 . Between the cutting zones  10 , there is a central zone  14  that is not involved in the actual cutting. The cutting drum  5  comprises a bearer ring  11  at each axial end. 
         [0044]    An arbour comprises two parts extending from the cutting drum, one at each axial end. The arbour parts are received in a bearing block  12 , respectively. The bearing blocks  12  are attached to the vertical columns  2  of the frame by means of a yoke  13 , respectively. The bearing block  12  allow the arbour with the cutting drum  5  to rotate round the centre axis  8  relative the stationary frame  1 . To this end, one of the arbour parts can be connected to a driving device for rotating the cutting drum  5 . The driving device can include an electric motor, gearing components and transmission components (not shown) 
         [0045]    The cutting drum comprises internal air channels, which are connectable to an air source and a vacuum source (not shown). In selected positions at the peripheral surface of the cutting drum the air channels end in orifices  15 . By during use selectively supplying air pressure or vacuum pressure to the orifices, cut articles and rim pieces can be retained or pushed away from the cutting drum  5 . The central zone  14  of the cutting drum  5  is involved in this handling of the cut article. With reference to  FIG. 2 , the cutting unit comprises steering rolls  22  for during use guiding the rim pieces away from the cutting unit. 
         [0046]    The cutting unit further comprises a carrier  16 . The carrier  16  comprises a plate  17 , which is arranged sliding on the four corner columns  2  by bearings  18 . Four contact rollers  19  are supported for rotation in the plate  17 . The contact rollers  19  are arranged in symmetrical pairs, wherein in each pair of contact rollers  19  is located on either side of the vertical plane C comprising the axis of rotation  8 ,  9  of the cutting and anvil drums  5 ,  6 . The axes of rotation  20  of the contact rollers  19  that are located on the same side of the plane C are located on a common geometrical axis. The axis of rotation  8 ,  9 ,  20  of all contact rollers  19 , the cutting drum  5  and the anvil drum  6  are parallel. All four contact rollers have the same dimensions, such as the same diameter and the same longitudinal length. The outer peripheral surfaces of the contact rollers  19  are tangent to an imaginary cylinder corresponding to the anvil drum  6 . 
         [0047]    The anvil drum  6  is shaftless, or in other words, has no arbour connecting it to the frame  1 . The anvil drum  5  is placed resting on the contact rollers  19  in the carrier  16 . The contact rollers  19  are located below a central horizontal plane D, which comprises the centre axis of rotation  9  of the anvil drum  6 , for providing vertical support, c.f.  FIG. 4 . With reference to  FIG. 5 , a central angle a with the centre axis  9  of the anvil drum  6  as vertex and with the sides passing through the centre axis  20  of one contact roller  19  in a pair of contact rollers  19  respectively is 50° Thereby, the contact rollers  19  provide transversal support to the anvil drum  5 . 
         [0048]    In other embodiments of the present invention the angle a can be  45  -  120 ° . Within this range, the contact rollers  19  are advantageously able to provide both vertical and transversal support to the anvil drum  6 . 
         [0049]    At each axial end, the lower drum  6  has anvil zones  21  for cooperation with the cutting zones  10  of the cutting drum  5 . The anvil zones  21  have a larger diameter than a central zone between them. The anvil zones  21  of the anvil drum  6  have about the same axial length as the cutting zones  10  together with the bearer ring  11  of the cutting drum  5  and are arranged for, in use, being in rolling engagement. The contact rollers  19  have about the same axial length as the anvil zones  21 . Consequently, during use, the pressure transmitted by the contact rollers  19  is vertically aligned with the bearer rings  11  and distributed over the cutting zones  21 . A transversal, vertical plane E passes through a contact roller  19 , an anvil zone  21  and a bearer ring  11 , c.f.  FIG. 4 . 
         [0050]    With reference to  FIG. 6 , the lower drum  6  is hollow and has the shape of a tube. A safety device in the form of a bar  23  extends through the hollow anvil drum  6 . The bar is releasable lockable in a clamp  24  at each axial end. When in use, and in the position with the anvil drum  6  resting on the contact rollers  19 , the bar  23  extends through the hollow drum  6  without contacting the interior walls thereof. The clamp  24  is attached to the carrier  16 , so that the position of the bar  23  relative the anvil drum  6  is unaffected when the anvil drum  6  is moved by the carrier  16 . 
         [0051]    For supporting the anvil drum  6  in the longitudinal axial direction, axial bearings in the form of a wheel  25  are mounted on the frame and in line with the axial end of the anvil drum  6 , c.f.  FIG. 6 . 
         [0052]    Between two columns  2  at the axial end of the anvil drum  5 , an open space is left. This space forms an opening, which is large enough to allow axial removal of the anvil drum  6  there through. 
         [0053]    Finally, the cutting unit comprises two pneumatic cylinders  26 , which are connected to the carrier for lifting and pressing the carrier with anvil drum towards and against the cutting drum  5 . 
         [0054]    During use, when a web material is fed between the cutting drum  5  and the anvil drum  6  for cutting article therefore by the cutting unit according to the first embodiment of the invention, the anvil drum  6  is pressed against the cutting drum by a selected force corresponding to a desired cutting pressure. This is achieved by the air cylinders  26  pressing the carrier  16  with the anvil drum  6  against the cutting drum. Due to the carrier being slidingly arranged on the four columns, the carrier is linearly guided by the columns  2 . Thereby, the axis of rotation  9  of the anvil drum  6  is held in parallel with the axis of rotation of the cutting drum, so that good cutting quality is achieved. 
         [0055]    The pressure transmitted by the contact rollers  19  extends over the area where the cutting is performed, i.e. along the axial position of the cutting zones  19  and anvil zones  21 . In addition, the contact rollers  19  apply pressure at the area of the bearer rings  11 . No bending is induced by the pressure from the carrier with the carrier rolls, because the pressure is applied to the lower drum at the same area as the counter pressure is applied by the cutting drum bearer rings  11  being in rolling contact with the anvil drum. Thus, the cutting pressure and/or depth will advantageously be more equal along the axial length of the drums. Consequently, the cutting pressure and depth will be more equal along the axial, longitudinal direction. 
         [0056]    When the cutting unit has been in use for a certain time, it may be necessary to regrind the anvil drum  6 . With reference to  FIGS. 8-10 , an operator can remove the anvil drum  6  by operating the pneumatic cylinders  26  to lower the anvil  6  into a lower position where the anvil drum clears off the cutting drum  5 . Then, the clamps  25  are opened so that the bar  23  can be removed. At one axial end, the clamp  24  and the axial bearing wheel  25  are removed. Thereafter, the operator can lift the anvil drum  6  from the contact rollers  19 , and pass the anvil drum  6  through the opening provided by the space between the columns  2  at the axial end. 
         [0057]    During regrinding of the lower drum, the operator has to ensure good cylindrical form, which is directly realized by rotating the lower drum with the outer peripheral surface thereof being in contact with the grindstone. Thanks to the anvil drum  6  being shaft less and being supported on carrier rolls  19  in a carrier  16  instead of having an arbour that is supported by bearing blocks in the frame, the operator need not observe good concentricity with respect to the centre axis, nor observing the position of the centre axis with respect to the arbour or the bearing blocks. Thus, removal of the anvil drum  6  and regrinding thereof is a considerably less complex and time consuming operation 
         [0058]    In  FIG. 7 , an alternative embodiment of the present invention is shown, which differ from the first embodiment described above mainly in that the upper drum is the anvil drum  6  and the lower drum is the cutting drum  5 .