Patent Description:
It is known that the automatic machines for forming filter bags are provided with a plurality of reels for feeding various types of material necessary for forming filter bags. Each reel is supported by a corresponding motor-driven shaft protruding from a wall of the machine frame.

In particular, each automatic machine is basically provided with at least one reel of filter paper (in some cases also two reels, of which one is for direct feeding and the other as reserve in the case of emptying the first reel) and a reel with strips of labels on which is added, in the case of packages with this option, also a reel of strips of material for wrapping the filter bags formed.

Currently, the changing of reels can be performed manually or automatically.

In the first case, an operator operating the machine proceeds as follows:.

However, this replacement process has several drawbacks:.

In the second reel changing system, a central unit connected to the automatic machines is used and with units movable along fixed rails or with wheels provided with an arm for picking up and releasing the reels.

In this case, the movable unit is programmed to pick up the replacement reels from a series of storage units positioned around the packaging machines and bring them to the packaging machines where the unit, using the pick-up and release arm (usually robotic), replaces the empty reel under the control of the central unit.

This second solution makes it possible to reduce the presence of personnel but forces the manufacturer to increase the volume occupied around the production lines (machines) so as to be able to locate the reel storage units necessary for the replacements in the machine as well as the spaces and structures necessary for moving the movable reel replacement units.

These factors lead to increases in the overall costs of the lines without, however, justified increases in the productivity of the production lines.

The aim of the invention is to provide an automatic machine for forming filter bags containing infusion products which overcomes the above-mentioned drawbacks.

In particular, the aim of this invention is to provide an automatic machine for forming filter bags containing infusion products which is able to automate and speed up the reel changing process.

A further aim of the invention is to provide an automatic machine for forming filter bags containing infusion products which is able to always guarantee the correct reel changing as a function of the needs of the machine with limited reaction times and with reduced overall dimensions. Said aims are fully achieved by the automatic machine for forming filter bags containing infusion products according to the invention, as characterised in the appended claims.

The features of the invention will become more apparent from the following detailed description of a preferred, non-limiting embodiment of it, illustrated by way of example in the accompanying drawings, in which:.

With reference to the accompanying drawings and with particular reference to <FIG>, the automatic machine according to the invention, denoted in its entirety by the numeral <NUM>, is used, in particular, for forming filter bags containing infusion products (such as tea, coffee, camomile and the like).

The automatic machine <NUM> comprises a load-bearing frame <NUM> having a base <NUM>, a vertical wall <NUM>, a horizontal wall <NUM> facing the base <NUM> and a vertical front wall <NUM>, defining a machine front, from which protrudes at least one motor-driven supporting shaft <NUM> which supports a respective reel <NUM> of wound material (in this case filter paper).

As illustrated, the automatic machine <NUM> comprises a plurality of operating stations <NUM> positioned along the front wall <NUM> through which a processing path extends along which the material present on the reel <NUM> is unwound from the reel <NUM>.

The operating stations <NUM> are schematically illustrated by way of example only and represent all devices which are able to form, along an operating path, the filter bags containing infusion products.

It should be noted that the automatic machine <NUM> preferably comprises a second shaft <NUM> supporting a further reel <NUM> with wound material defining, for example, pickup tags to be applied to the filter bags to be formed.

This second shaft <NUM> protrudes from the front wall <NUM> and parallel to the first supporting shaft <NUM>.

As illustrated, (see also <FIG>) the automatic machine <NUM> comprises a first storage unit <NUM> configured to house replacement reels 7a and positioned directly associated with the load-bearing frame <NUM> of the machine <NUM> and located close to the shaft <NUM> supporting the reel <NUM> (nearly empty and to be replaced).

In the drawings, by way of example, the first storage unit <NUM> may be associated with one of the vertical <NUM> or horizontal <NUM> walls of the load-bearing frame <NUM> of the machine again close to the shaft <NUM> supporting the reel <NUM>.

The automatic machine <NUM> also comprises a device <NUM> for picking and releasing replacement reels 7a (having, preferably, a motor-driven axis X10) configured for picking up a replacement reel 7a from the first storage unit <NUM> and positioning it on the supporting shaft <NUM>.

The pick-up and release device <NUM> is positioned directly associated with the load-bearing frame <NUM> close to the first storage unit <NUM>.

By way of a construction example, the picking up device may be associated with one of the vertical <NUM> or horizontal <NUM> walls of the load-bearing frame <NUM> of the automatic machine <NUM>.

Moreover, the automatic machine <NUM> comprises a control unit <NUM> positioned on the automatic machine <NUM> and configured to activate the device <NUM> for picking up and releasing replacement reels 7a in the presence of a run out signal of the reel <NUM> present on the supporting shaft <NUM>.

In other words, the automatic machine <NUM> has a storage unit integrated for replacement reels and a device which is able to replace the reels which are gradually used up without the need for external intervention.

The first storage unit <NUM> may be filled at the start of the operating activity of the automatic machine in such a way as to make the machine independent for a long operating period without the need for checks at predetermined times.

The machine in its entirety does not have a considerable increase in the overall size compared with prior art solutions and allows lines to be created alongside each other in automatic machines in reduced spaces.

As illustrated, the first storage unit <NUM> is associated with the at least one vertical side wall <NUM> of the machine <NUM> positioned close to the reel supporting shaft <NUM>.

It should be noted that the first storage unit <NUM> projects outwards from the frame <NUM> of the machine <NUM>.

Again as illustrated, the device <NUM> for picking up and releasing the replacement reels 7a is associated with the vertical front wall <NUM> of the machine and positioned close to the reel supporting shaft <NUM> and the first storage unit <NUM>.

In light of this, the pick-up and release device <NUM> projects outwards from the frame <NUM> of the machine <NUM>.

The unit comprising the first storage unit <NUM> and the pick-up and release device <NUM> are close together in a compact structure projecting laterally and frontally from the machine frame.

It should be noted that the pick-up and release device <NUM> comprises a robotic arm <NUM> (with two or more axes of movement) having, at a relative free end, a gripper <NUM> for picking up and releasing the replacement reel 7a configured to engage/disengage in/from a central hole <NUM> or core of the replacement reel 7a.

The robotic arm <NUM> comprises the first motor-driven axis X10 protruding relative to the machine front and parallel to the axis of extension of the first shaft <NUM> supporting the reel and can therefore, with the remaining axes, have a <NUM>° operation in such a way as to easily reach the first storage unit <NUM> and the shaft <NUM> in a fast and precise fashion.

The arm <NUM> has, for example, a gripper <NUM> with three claws configured to enter into the core of the reel, for a certain depth (see also <FIG>) and, by means of a movement of the claws radially away from each other, locking the reel for its handling and movement from the storage unit to the supporting shaft.

The machine <NUM> also comprises a reel pressing element <NUM> configured to stabilise the replacement reel 7a on the supporting shaft <NUM>.

In light of this, the reel pressing element <NUM> is carried by a tubular element <NUM> (shaft) associated outside the frame <NUM> of the machine and close to the first storage unit <NUM> and the device <NUM> for picking up and releasing the replacement reel 7a.

It should be noted that the tubular element or shaft <NUM> is provided with means <NUM> for quick coupling and detachment of the reel pressing element <NUM> in such a way as to allow the picking up and repositioning by the pick-up and release device <NUM>.

According to an embodiment, the quick coupling and detachment means <NUM> comprise an annular plate having magnetic properties for retaining, in suspension, the reel pressing element <NUM>.

It should be noted that the tubular supporting shaft <NUM> is associated with the horizontal wall <NUM> of the frame <NUM> of the machine, in such a way as to position the reel pressing element <NUM> close to and above the pick-up and release device <NUM>.

As illustrated and in an example embodiment, the reel pressing element <NUM> comprises a tubular cylinder body 15a (open at the two ends) with a diameter greater than a diameter of the shaft <NUM> supporting the reel and configured, in use, for being coupled with (the gripper <NUM>) the robotic arm <NUM> and carried to the supporting shaft <NUM> (see <FIG>).

The reel pressing element <NUM> (at one end of the tubular cylinder 15a) comprises a rigid ring 15b having a diameter greater than the diameter of the reel supporting shaft <NUM> and configured, in use, to be placed in contact with a flat surface 7a of the replacement reel in such a way as to allow, under the action of the robotic arm <NUM> of the pick-up and release device <NUM>, a stable positioning, by axial sliding, of the replacement reel 7a on the supporting shaft <NUM> (see <FIG>).

In other words, the replacement reel 7a is picked up from the gripper <NUM> in the first storage unit <NUM> (see <FIG>) and the robotic arm positions it at the shaft <NUM> where it is partly inserted (<FIG> and <FIG>).

Subsequently, the gripper <NUM> releases the replacement reel 7a and the robotic arm <NUM> moves to the reel pressing element <NUM>, where the gripper <NUM> couples with the central tubular element 15a (<FIG>).

At this point, the robotic arm <NUM> detaches the reel pressing element <NUM> and transports it to the replacement reel 7a just inserted, partly, in the supporting shaft <NUM> (see <FIG>).

In this position, the robotic arm <NUM> presses on the reel pressing element <NUM> having the rigid ring 15b in contact with the flat outer surface of the reel 7a in such a way as to make it slide axially along the supporting shaft <NUM> until it is completely housed (<FIG>).

The automatic machine <NUM> comprises a second storage unit <NUM> for housing replacement reels (in this case, for example, reels <NUM> having strips of wound tags) associated with the at least one vertical side wall <NUM> of the frame <NUM> of the machine and positioned close to the first storage unit <NUM>. In short, the second storage unit <NUM> is located under the first storage unit <NUM> using the vertical surface of the wall <NUM>.

In light of this, the device <NUM> for picking up and releasing the replacement reel is associated with the frame <NUM> at an intermediate position between the first storage unit <NUM> and the second storage unit <NUM>.

In this way, the robotic arm <NUM> can operate without distinction quickly and rapidly on both the storage units present on the automatic machine.

By way of a construction example, the first storage unit <NUM> comprises a rigid structure having a cradle portion <NUM> for supporting a plurality of replacement reels 7a, a side portion <NUM> for associating with the vertical side wall <NUM> of the frame <NUM> of the machine and a rigid disc-shaped base <NUM>, supported by the cradle portion <NUM>, for supporting the replacement reels 7a.

The second storage unit <NUM> also has a substantially similar structure.

The device <NUM> for picking up and releasing the replacement reel also comprises a box-shaped body <NUM> associated with the vertical side wall <NUM> of the frame <NUM> of the machine <NUM> configured to support the robotic arm <NUM> (which protrudes from one side or surface of the box-shaped body <NUM> coplanar with the vertical front wall <NUM>) and house the mechanical and electronic structures of the pick-up and release device <NUM>.

The preset aims are achieved with an automatic machine structured in this way thanks to the synergic combination between the traditional machine combined with a group of storage units with robotic arms integrated in the machine.

This architecture makes it possible to obtain a compact system wherein the machine is substantially "self-sufficient" for many operating hours without the intervention of external robotic systems for reel changing, keeping the complex machine compact.

This type of structure creates a compact machine which only needs a single loading of a plurality of reels at the start of operation in such a way as to allow a long operating duration without the need for further constant checks or supplies.

Claim 1:
An automatic machine comprising:
- a load-bearing frame (<NUM>) comprising a base (<NUM>), at least one vertical side wall (<NUM>), a horizontal wall (<NUM>) facing the base (<NUM>), a vertical front wall (<NUM>), defining a machine front, from which protrudes at least one motor-driven supporting shaft (<NUM>) which supports a respective reel (<NUM>) of wound material;
- a plurality of operating stations (<NUM>) positioned on the front wall (<NUM>) through which a processing path extends along which said material proceeds while it is unwound from the reel (<NUM>);
- a first storage unit (<NUM>) configured to house replacement reels (7a) and positioned directly associated with the load-bearing frame (<NUM>) of the machine and located close to the shaft (<NUM>) supporting the reel (<NUM>);
- a device (<NUM>) for picking up and releasing replacement reels configured for picking up one of the replacement reels (7a) from the first storage unit (<NUM>) and positioning it on the supporting shaft (<NUM>), said pick-up and release device (<NUM>) being positioned directly associated with the load-bearing frame (<NUM>) and located close to the first storage unit (<NUM>); and
- a control unit (<NUM>) configured for activating the device (<NUM>) for picking up and releasing reels in response to a run out signal of the reel (<NUM>) present on the supporting shaft (<NUM>), the automatic machine being characterized in that it further comprises
- a reel pressing element (<NUM>) configured to stabilise the replacement reel (7a) on the supporting shaft (<NUM>); the reel pressing element (<NUM>) being carried by a supporting element (<NUM>) associated outside the frame (<NUM>) of the machine, close to the first storage unit (<NUM>) and the pick-up and release device (<NUM>); the supporting element (<NUM>) being equipped with means (<NUM>) for quick coupling and detachment of the reel pressing element (<NUM>) in such a way as to allow it to be picked up and repositioned by the pick-up and release device (<NUM>).