Patent Publication Number: US-2015068379-A1

Title: Apparatus for punching moving material webs

Description:
The present application is a divisional application of U.S. application Ser. No. 13/337,720, filed Dec. 27, 2011, which claims priority to EP 11001073.3, filed Feb. 10, 2011. The disclosures of each are hereby incorporated by reference in their entireties. 
     The present invention relates to an apparatus for punching or perforating moving material webs. 
     DE 103 14 959 A1 discloses a punching unit which has a plurality of punching tools which are mounted on a shaft, the mutual spacing of which can be adjusted and which are intended to interact with a back-pressure cylinder. Each punching tool has a cylindrical disk, on the periphery of which a metal strip provided with punching profiles is detachably retained. 
     DE 298 05 004 U1 discloses another embodiment of a punching tool, which likewise has a cylindrical disk, on the periphery of which a metal punching sheet provided with a punching profile is detachably retained. This punching tool is provided with a device for attracting the punched-out parts (punch blanks) by suction and subsequently discharging them. 
     The present invention is now based on the object of devising an apparatus for punching moving material webs which permits alteration of the arrangement and/or shape (contour) of the parts to be punched out (punch blanks) in a simple and time-saving manner. 
     According to the invention, this object is achieved by an apparatus according to some features described herein. 
     Preferred further refinements of the inventive apparatus form the subject matter of some features described herein. 
    
    
     
       In the following text, the subject matter of the invention will be explained in more detail by using the figures, in which, purely schematically: 
         FIG. 1  shows a perspective view of a punching unit having a punching tool, 
         FIG. 2  shows a longitudinal section of a punching unit having two punching tools, 
         FIG. 3  shows the punching unit according to  FIG. 2  in a cross section, 
         FIG. 4  shows a perspective view of a punching tool, 
         FIG. 5  shows a perspective view of a first embodiment of a punching apparatus having two punching units, 
         FIG. 6  shows a perspective view of a first embodiment of a punching apparatus having three punching units, 
         FIG. 7  shows a perspective view of a second embodiment of a punching apparatus having two punching units, 
         FIG. 8  shows a perspective view of a second embodiment of a punching apparatus having three punching units, 
         FIG. 9  shows a perspective view in simplified form of the punching of holes in a material web, 
         FIG. 10  shows a side view in simplified form of a punching tool with the material web to be processed, 
         FIG. 11  shows a schematic illustration of the variation in the speed of rotation of the punching tool in different punching situations, 
         FIG. 12  shows a block diagram of the control system for a punching unit, 
         FIG. 13  shows a cross section of a punching unit having a first embodiment of a device for transporting the punched-out parts away, and 
         FIG. 14  shows a cross section of a punching unit having a second embodiment of a device for transporting the punched-out parts away. 
     
    
    
     If, in the following description of figures and in the claims, mention is made of “punching”, then this term is understood to mean both the actual punching (severing) and perforating, in which the perforated part remains temporarily connected to the material web via weakened points (perforations) and is separated out later. 
     By using  FIGS. 1 to 4 , the structure of two different embodiments of punching units  1  and  1 ′ will be described. The two embodiments differ only in the fact that the punching unit  1  ( FIG. 1 ) has one punching tool  2 , and the punching unit  1 ′ has two punching tools  2 ,  2 ′, which are of the same design. 
     The punching tools  2  or, respectively,  2 ,  2 ′ are rotationally firmly connected to a drive shaft  3  which, in the present exemplary embodiments, is a splined shaft. The drive shaft  3  is mounted such that it can rotate about its axis of rotation  3   a  and is connected to a drive device, not shown. Each punching tool  2  and  2 ′ is rotatably mounted in a tool holder  4  and, together with the latter, can be displaced along the drive shaft  3  in the direction of the axis of rotation  3   a  of the latter into various working positions. The punching tools  2 ,  2 ′ interact with a back-pressure cylinder  5 , which is mounted such that it can rotate about its axis of rotation  5   a  and is connected to a drive device, not shown. Each punching tool  2 ,  2 ′ is mounted, for example by using a radial coupling, in such a way that the distance between the punching tool  2 ,  2 ′ and the back-pressure cylinder  5  can be set individually ( FIGS. 2 and 3 ). The back-pressure cylinder  5  has a smooth surface, which is preferably hardened. The axis of rotation  3   a  of the drive shaft  3  and the axis of rotation  5   a  of the back-pressure cylinder  5  run parallel to each other. 
     The punching tools  2 ,  2 ′ are guided by means of a guide (sliding guide), which is formed on the underside of a guide beam  7  and which extends over the entire working width of the punching unit  1 . This guide  6  runs parallel to the axis of rotation  5   a  of the back-pressure cylinder  5 . A correspondingly formed guide  8 , which is formed on the tool holder  4 , interacts with the guide  6  (see in particular  FIG. 3 ). The tool holder  4  and, with the latter, the punching tools  2 ,  2 ′ can be displaced in a translational manner along the guide  6  between different working positions. By means of a locking apparatus  9  illustrated only schematically ( FIG. 3 ), the punching tool  2 ,  2 ′ can be locked in any working position. Thus, it is also possible, in the punching unit  1 ′ shown in  FIG. 2 , to adjust, i.e. to change, the mutual spacing between the punching tools  2 ,  2 ′. 
     In  FIG. 4 , the structure of the punching tool  2  or  2 ′ is shown. The punching tool  2  or  2 ′ has a cylindrical base  10 , on the periphery of which a punching strip  11  is detachably retained. The punching strip  11  is preferably a metal strip, which is held on the base  10  by means of magnetic force. The punching strip  11  is provided with a number of punching shapes  12 , which are arranged distributed over the length of the punching strip  11 . Here, the distances between the punching shapes  12  can be the same or different. The punching shapes  12  can have the same shape or different shapes (contours). Provided on the periphery of the base  10  are positioning pins  13  which, when the punching strip is mounted, engage in positioning holes  14  on the punching strip  11 . In this way, the punching strip  11  is positioned correctly. It goes without saying that the punching strips  11  can also be fixed replaceably to the base  10  in another suitable way. In this connection, reference is made, for example, to DE 103 14 959 A1 and DE 298 05 004 U1, already mentioned. It is also conceivable to arrange a plurality of punching strips  11  on the periphery of the base  10 . 
     For each punching unit  1 ,  1 ′, more than two punching tools  2  can also be provided on the drive shaft  3 . 
     By using  FIGS. 5 to 8 , exemplary embodiments of punching apparatuses  15  and  16  will be described which have two punching units  1   a ,  1   b  and, respectively, three punching units  1   a ,  1   b ,  1   c , which are arranged one after another as seen in the direction of movement A of a material web  17  to be processed. In terms of structure, the punching units  1   a ,  1   b ,  1   c  correspond to the punching unit  1 ′ shown in  FIGS. 2 and 3  and each have two punching tools  4 . Therefore, in  FIGS. 5 to 8 , the same designations will be used as in  FIGS. 1 to 4  for mutually corresponding parts. 
     The exemplary embodiments shown in  FIGS. 5 and 6  differ from one another only in a different number of punching units  1   a ,  1   b  and  1   a ,  1   b ,  1   c . In both the exemplary embodiments, in each case the punching tools  2  of the one punching unit  1   a  are displaced with respect to the punching tools  2 ′,  2 ″ of the other punching unit  1   b  and  1   c , respectively, in the direction of the axis of rotation  3   a  of the drive shafts  3 , which therefore means in a direction which runs transversely, in particular at right angles, to the direction of movement A of the material web  17 . Likewise, the punching tools  2 ′ of the punching unit  1   b are offset with respect to the punching tools  2 ″ of the punching unit  1   c . This means that the punching tools  2  of the punching units  1   a ,  1   b ,  1   c  process different areas of the material web  17 . 
     In the embodiment according to  FIG. 5 , the punching tools  2  of the punching unit  1   a  are used to punch holes  18 ,  18 ′, which are used for example as storage holes, in the section  17   a  of the material web  17 , while, by using the tools  2 ′ of the second punching unit  1   b , holes  18 ,  18 ′ are punched in the material web section  17   b.  As  FIG. 5  shows, in both the material web sections  17   a,    17   b,  different punching can be carried out. For instance, in the material web section  17   a , the areas a and c are provided with holes  18 ,  18 ′, while the area b has no punching. By contrast, in the material web section  17   b,  the holes  18 ,  18 ′ are made in the areas e and f, while the area d has no punching. 
     The same is true in a corresponding way in the embodiment according to  FIG. 6 , in which three sections  17   a,    17   b,    17   c  of the material web  17  can be processed differently. The tools  2  of the punching tool  1   a  process the material web section  17   a,  the punching tools  2 ′ of the punching tool  1   b  process the material web section  17   b,  and the punching tools  2 ″ of the punching tool  1   c  process the material web section  17   c.    
     As  FIG. 6  shows, regions a, d, g and, respectively, b, e, h and, respectively, c, f, e lying beside one another and belonging to the material web sections  17   a ,  17   b,    17   c  are processed differently. 
     The exemplary embodiments according to  FIGS. 7 and 8  also differ from one another only in a different number of punching units  1   a ,  1   b and  1   a ,  1   b ,  1   c . In both exemplary embodiments, in each case a punching tool  2 ,  2 ′,  2 ″ of a punching unit  1   a ,  1   b ,  1   c , as seen in the direction of movement A of the material web  17 , is aligned with a punching tool  2 ,  2 ′ and, respectively,  2 ″ of a different punching unit  1   a ,  1   b  and, respectively,  1   c . 
     In the embodiment shown in  FIG. 7 , in each case one of the punching tools  2  of the punching unit  1   a  is aligned with a punching tool  2 ′ of the other punching unit  1   b . Each pair of mutually aligned punching tools  2 ,  2 ′ makes holes  18 ,  18 ′ in one of the two material web sections  17   a,    17   b.  Here, in each case one of the two holes  18  and  18 ′ which are made in a material web area a, c, d and f, respectively, is punched by the punching tool  2  of the punching unit  1   a , and the other of the two holes  18 ,  18 ′ is punched by the punching tool  2 ′ of the other punching unit  1   b.    
     In the embodiment according to  FIG. 8 , the mutually aligned punching tools  2 ,  2 ″ of the punching units  1   a ,  1   c  are used to punch holes  18  in material web section  17   a,  while the mutually aligned punching tools  2 ,  2 ′ of the punching units  1   a ,  1   b are used to punch holes  18 ′ in material web section  17   b.  By means of the mutually aligned punching tools  2 ′,  2 ″ of the punching units  1   b ,  1   c , the holes  18 ″ are punched out in the material web section  17   c.  In this way, the individual areas a, d, g and, respectively, b, e, h and, respectively, c, f, i of the material web sections  17   a,    17   b,    17   c  can be processed differently from one another. 
     It goes without saying that, in the exemplary embodiment shown in  FIG. 8 , the punching tools  2 ,  2 ′,  2 ″ can also be aligned with one another in a different arrangement than as shown. 
     If, in the embodiments shown in  FIGS. 5 to 8 , punching strips  11  with differently formed punching shapes  12  are used in the punching tools  2 ,  2 ′,  2 ″, then punchings with different contours can be produced in the material web sections  17   a,    17   b,    17   c.    
     Furthermore, it is possible, in the same punching apparatus, to combine the mutual arrangement of the punching tools  2 ,  2 ′,  2 ″ which has been explained by using  FIGS. 5 and 6  and the mutual arrangement of the punching tools  2 ,  2 ′,  2 ″ which has been explained by using  FIGS. 7 and 8 . In such a solution, some of the punching tools  2 ,  2 ′,  2 ″ are aligned with one another as described, and some of the punching tools  2 ,  2 ′,  2 ″ are offset laterally relative to one another. 
     The arrangements of the punchings (holes)  18 ,  18 ′,  18 ″ illustrated by using  FIGS. 5 to 8 , i.e. the punching patterns in the areas a-i of the material web  17 , can be changed without any great expenditure of time. For example, the spacings between the punchings  18 ,  18 ′,  18 ″, as seen in the direction of movement A of the material web, and/or the number of punchings  18 ,  18 ′,  18 ″ per material web area a-i can be changed. 
     In all the exemplary embodiments described, the material web  17  is moved forward with a constant or changing speed v in a manner that is not illustrated in more detail but known per se. The back-pressure cylinder  5  of each punching unit  1  is driven at a peripheral speed which corresponds to the speed of movement v of the material web  17 . In each punching unit  1 , the drive shaft  3  is driven independently of the back-pressure cylinder  5 . This means that the drive shaft  3  can be driven at a rotational speed which differs from the peripheral speed of the back-pressure cylinder  5  and therefore from the speed of movement v of the material web  17 . This enables adaptation of the punchings to be made in the material web  17  during operation, as will be explained in more detail below by using  FIGS. 9 to 11 . 
     The material web  17  provided with punchings  18  is then processed further and cut or folded in the longitudinal and/or transverse direction in a manner known per se. 
     With reference to  FIGS. 9 to 11 , an important aspect of the subject matter of the invention will now be described, namely the possibility of punching holes  18  in the material web  17 , the mutual spacing of which does not correspond to the spacing of the punching shapes  12  of the punching strip  11 . 
     In  FIG. 9 , a punching tool  2  having a punching strip  11  wound on is shown in an illustration corresponding to the illustration of  FIG. 4 . The spacing, uniform in this case, between the punching shapes  12  of the metal punching sheet  12  is designated by x.  FIG. 9  also shows a material web  17  in which holes  18 ,  18 ′,  18 ″ are to be punched out, the mutual spacings y and y′ of which differ from the spacings x between the punching shapes  12 . 
     In the side view of  FIG. 10 , in which the punching tool is illustrated only wholly schematically, as is the material web  17  having the holes  18 ,  18 ′,  18 ″ made or to be made, the spacings x and y between the punching shapes  12  and between the holes  18 ,  18 ′,  18 ″ are shown. In this  FIG. 10 , the direction of rotation (reference direction of rotation) of the punching tool  2  is designated by B, and its working diameter, which is determined by the cutters of the punching shapes  12 , is designated by d. A working circumference U of the punching tool  2  is defined by these cutters of the punching tools  2  and, respectively, by the working diameter d. In  FIG. 10 , s designates an angle which defines a synchronizing region. Each punching tool  12  is assigned such a synchronizing region s. The angle designated by r is designated a dynamic region. Such a dynamic region is located between each punching shape  12 . 
     In order to punch the holes  18 ,  18 ′,  18 ″ with unequal mutual spacings y, y′, the punching tool  2  is in each case driven in the synchronizing region s with a peripheral speed at the working circumference U which is equal to the speed of movement v of the material web  17 . In this synchronizing region s, the punching of the holes  18 ,  18 ′ and  18 ″ is then carried out. In the dynamic regions r, the peripheral speed of the punching tool  2  can be varied and the spacing y, y′ between the holes  18  and  18 ′ just punched and the next hole  18 ′ or  18 ″ to be punched can be adapted appropriately. This is now to be explained by using  FIG. 11 . 
     In  FIGS. 11   a  to  11   d , graphs relating to various punching operations are shown, in which in each case the angular velocity co of the punching tool  2  is shown as a function of the time t. In these graphs, the variations in speed are shown in two synchronizing regions s, in which in each case punching is carried out, and in a dynamic region r lying in between. Above the graphs, the punching tool  2  is illustrated schematically in its various respective rotational positions. ω 1  designates that angular velocity of the punching tool  2  which corresponds to a peripheral speed of the punching tool  2  which coincides with the speed of movement v of the material web  17 . This means that, in the synchronizing regions s, the punching tools  12  run synchronously with the material web  17 . Appearances are different in the dynamic region r, in which the angular velocity  6 ) of the punching tool  2  can be chosen independently of the speed of movement v of the material web  17 , specifically in a manner matched to the ratio of the spacings y, y′ between the holes  18 ,  18 ′,  18 ″ to the spacing x between the punching shapes  12 . 
     In the graph of  FIG. 11   a , the variation over time of the angular velocity co of the punching tool  2  is shown in the situation in which the spacing y, y′ between two holes  18 ,  18 ′,  18 ″ is smaller than the spacing x between the punching shapes  12 . In this case, the angular velocity co in the dynamic region r must be increased briefly, which means the punching tool  2  must be accelerated and then retarded again to the angular velocity cal. 
     If the spacing y, y′ between two holes  18 ,  18 ′,  18 ″ is the same as the spacing x between the punching shapes  12 , then the punching tool  2  in the dynamic region r continues to be driven with the angular velocity ω1, as illustrated in graph  11   b.  In this case, the punching tool  2  neither has to be accelerated briefly nor retarded briefly. 
     In the graph of  FIG. 11   c , the variation over time of the angular velocity co of the punching tool  2  is shown for the situation in which the spacing y, y′ between two holes  18 ,  18 ′,  18 ″ is greater than the spacing x between the punching shapes  12 . In this case, the angular velocity co in the dynamic region r must be reduced briefly, which means that the punching tool  2  must be retarded and then accelerated to the angular velocity ω 1  again. 
     If no hole (punching) has to be made in an area of the material web  17  (see, for example, the material web areas b and d in  FIG. 5 ), then after a punching, the punching tool  2  is stopped briefly within the following dynamic region r and, before reaching the following synchronizing region s, is accelerated to the angular velocity ω1 again, as illustrated in the graph according to  FIG. 11   d.    
     In certain cases, the direction of rotation of the punching tool  2  is reversed in the dynamic region r, i.e. the punching tool  2  is rotated briefly in the reverse direction. 
     As described, by means of controlled acceleration and retardation of the punching tool  2  in the dynamic region r, the spacing y between two punchings  18 ,  18 ′,  18 ″ can be influenced. In this way, it is possible to obtain spacings y between the punchings  18 ,  18 ′,  18 ″ which do not correspond to the spacings x between the punching shapes  12  of the punching strip  11 . Merely by changing the peripheral speed of the punching tool  2  in the dynamic region r, it is possible to produce different punching patterns without mechanical transpositions being necessary. 
     In order that the angular velocity w of the punching tool  2  can be changed as required, as by using  FIG. 11 , in such a way that the punchings  18  in the material web  17  are made at the desired locations, the drive for the punching tool  2  must be controlled appropriately. In  FIG. 12 , a block diagram of a corresponding control device is illustrated. In this  FIG. 12 , in an illustration corresponding to that of  FIG. 3 , a punching unit  1  is shown, of which only the components important in connection with the control system are provided with the corresponding designations. 
     In this  FIG. 12 , the machine control system is designated by  19  and the drive control system for the drive of the drive shaft  3  of the punching tool  2  is designated by  20 . The machine control system  19  is connected to a sensor  21 , a contrast sensor in the present case, which scans markings applied to the material web  17  and feeds corresponding scanning signals to the machine control system  19 . The machine control system  19  is further connected to a control valve  22  of an output transport device for leading the punched-out parts (punch blanks) away, which will be explained in more detail by using  FIG. 13 , and is also connected to the drive control system  20 . 
     In the machine control system  19 , the information relating to the position of the punchings  18  to be made in the material web  17  and the speed of movement v of the material web  17  is stored. From these variables, the angular velocity ω1 is derived. 
     On the basis of the scanning signals obtained from the sensor  21  and the data stored in the machine control system  19  or determined in the latter, the machine control system  19  then determines the angular velocity ω at which the punching tool  2  must be driven in the dynamic region r in order that the punching/s is/are carried out in the correct position. In addition, the machine control system  19  activates the control valve  22  of the output transport device at the correct time. 
     In  FIGS. 13 and 14 , sectional illustrations corresponding to  FIG. 3  of two different embodiments of output transport devices for the punched-out parts, which means the punch blanks, are shown. 
     In the embodiment according to  FIG. 13 , the punch blanks are separated out of the material web  17  and transported away by means of a time-coordinated compressed air surge. The punch blanks separated out can be attracted by suction or fed to a collecting container arranged underneath the material web. The output transport device  23  used to separate out the punch blanks is illustrated only wholly schematically and has the control valve  22  already mentioned in connection with  FIG. 12 . The inlet of the control valve  22  is connected to a compressed air connection  26 , which is connected to a compressed air source, not illustrated. On the outlet side, the control valve  22  is connected to a blower nozzle  25 . 
     When the control valve  22  is activated by the machine control system  19  ( FIG. 12 ), the connection between the compressed air connection  24  and the blower nozzle  25  is opened briefly. A compressed air surge  26  is produced, which blows the punch blank out of the material web  17 . It is important that the activation of the control valve  22  is carried out at the correct time, in order that the compressed air surge  26  is generated when the punch blank is located underneath the blower nozzle  25 . 
     In the output transport device  27  shown in  FIG. 14 , which is also illustrated only wholly schematically, the punch blanks are attracted to the punching tool  2  by suction by means of negative pressure in a suction region  28 , which corresponds to the synchronizing region s shown in  FIG. 10 . During the onward rotation of the punching tool  2 , the punch blank is separated from the punching tool  2  again in a blow-off region  29 , which lies in a dynamic region r ( FIG. 10 ), specifically either blown away by means of a positive pressure and/or sucked away by means of negative pressure. The punch blanks separated from the punching tool  2  are carried away by a suction line  30 . 
     It goes without saying that the output transport devices  23  and  27  described can be provided both in a punching unit  1  according to  FIG. 1  and in a punching unit  1 ′ according to  FIG. 2 . It is also possible, in order to transport the punch blanks away, to provide both an output transport device  23  according to  FIG. 13  and an output transport device  27  according to FIG. 
       14 . This means that, in one and the same punching tool  2 , the punch blanks are transported away in two different ways. 
     A further important aspect of the present invention is the following: 
     A punching unit  1 , as shown in  FIG. 1 ,  FIG. 2  or in  FIGS. 5 to 8 , has at least one punching tool  2  which interacts with a rotatably mounted back-pressure cylinder  5  that can be driven and which is arranged on a rotatably mounted drive shaft  3  that can be driven. This punching unit  1  also has a guide  6  extending in the direction of the axis of rotation  3   a  of the drive shaft  3  and separate from this drive shaft  3 , along which guide the punching tool  2  is guided during adjustment and which extends parallel to the longitudinal axis  5   a  of the back-pressure cylinder  5 . 
     This specific refinement of the punching unit  1 , as defined in claim  15 , has the advantage that the drive shaft  3  does not have to fulfill any guide tasks and only has to be designed to transmit the drive power. This makes it possible to use lighter drive shafts  3  and in this way to keep the masses which have to be accelerated and retarded during a change in the drive speed of the punching tools  2  in the dynamic region r ( FIG. 10 ) as small as possible. 
     As described, a punching unit  1 ,  1 ′ or a plurality of punching units  1   a ,  1   b ,  1   c  arranged one after another are used, of which each punching unit has one or more punching tools  2 , which can be adjusted along their drive shaft  3  and can be locked in their respective working positions. This arrangement makes it possible, in a simple way and with relatively little expenditure of time, to transpose the punching units  1  in such a way that the arrangements of the parts to be punched out, which means the punching patterns, are different. By replacing the punching strips  11 , which is very easily possible, both the punching patterns but also the shape (contour) of the parts to be punched out can be changed. 
     Driving the punching tools  2  independently of the back-pressure cylinder  5  widens the area of use of the punching unit  1 , as has been explained by using  FIGS. 9 to 11 . 
     In a further embodiment, the punching tool  2  or the punching tools  2 ,  2 ′ are mounted in such a way that these can be moved briefly in the direction away from the back-pressure cylinder  5 . This makes it possible also to drive the punching tools  2 ,  2 ′ in the synchronizing region s at a peripheral speed which differs from the peripheral speed of the back-pressure cylinder  5  and from the speed of movement v of the material web  17 . Briefly lifting a punching tool  2 ,  2 ′ off the back-pressure cylinder  5  and the material web makes it possible to deactivate certain punching shapes  12  during the rotation of the punching tool  2 ,  2 ′, which means not bringing them into contact with the material web  17 , and in this way skipping a punching  18 . This means that the sequence of the punchings  18 ,  18 ′,  18 ″ made in the material web  17  in the direction of movement A of the material web  17  differs from the sequence of punching shapes  12  of the punching tool  2 ,  2 ′ in the peripheral direction of the latter.