Patent ID: 12214981

DETAILED DESCRIPTION OF AN EMBODIMENT OF THE INVENTION

With reference to the above-cited figures, a first scheme of a first plant according to the invention is indicated as a whole with number10. The plant is inside a production plant11, adapted to produce and store master rolls, also called herein primary logs B1, and to produce, from the master rolls B1, further rolls, herein called also secondary logs B2i.

The term “transverse” means a direction orthogonal to the feed direction f1of the thin product, i.e. a direction parallel to the axis of rotation of the master roll B1and to the axis of the secondary cores18iand therefore to the secondary logs B2i.

Firstly, the components of the known plant10will be described below. The plant10comprises a production line for producing a continuous thin product T, i.e. a web product, such as for example paper, tissue paper, non-woven fabric, or other similar products (films, multi-material products etcetera), whose end part is indicated with number12.

At the end of the production line12one or more winders13are arranged (in the figures only one winder is shown). The winder13comprises a mandrel on which a cylindrical tubular core is arranged supporting the thin product T and indicated below as primary support core14. The primary support core is driven into rotation in the direction of the forward movement f1(machine direction) of the thin product T on the line12, wherein the product is consequently wound on the primary core14to form the master roll or primary log B1.

Downstream of the winder13an unloading area15is arranged, where at least one first moving device16is arranged for moving the primary logs B1towards a packing area, or a storing area or even directly towards one (or more) rewinders17(in the scheme only one rewinder is shown), which, starting from the primary logs B1, realizes secondary logs B2i, as better described below.

At least one second moving device25is provided, adapted to move the produced secondary logs towards a packing station26.

In this example, the packing station26comprises a robot27, for example an anthropomorphous arm, that takes the secondary logs from the moving device25and put them on one (or more) conveyors28. A packing device39is provided at the end of the conveyor28, for example for packing by means of a film covering one or more secondary logs B2i.

Through a third moving device29the pack formed with one or more secondary logs is carried from the packing station26to the storing area.

The plant10provides for an electronic control apparatus30for controlling the various parts, providing for PLC systems for managing the operation of the various parts and interface PC that are operatively connected together via a network. The electronic control apparatus30also comprises a database system31comprising one or more sub-databases with the information uploaded before starting the production and those acquired during the various work steps. The database system31allows the various parts to inter-act in coordinated fashion.

According to the invention, a device32is provided for detecting parameters associated with the thin product T wound by the winder13to form the master roll B1, comprising defects in the surface and/or the thickness of the thin product. These parameters may also comprise one or more of the following: mechanical parameters, among which the e-modulus and/or the Poisson's ratio, winding parameters, among which the density profile of the log and/or tension and/or sliding, and/or NIP, position of joins for removing defects.

“Tension” is mechanical tension imparted to the product, which can be measured by means of load cells. “Sliding” is the over-speed imparted to the rollers involved in winding the product with respect to the unwinding speed of the product upstream or to the production speed. “NIP” is the force per width unit imparted between the reel being wound and the rollers involved in the winding process (called support rolls and rider rolls). The log density profile is calculated based on the weight and the diameter of the log under formation, whilst the e-modulus of the thin product is calculated by measuring or calculating the tension of the product and the elongation resulting from sliding. The Poisson's ratio is measured through the elongation derived from sliding and the shrinking of the product measure by means of an optical vision system.

As regards the joints for removing defects, reference is made to the position of these joints on the extension of the thin product that have been created by transversally cutting the product downstream and upstream of damaged areas and joining the resulting edges.

The parameters also include the weight of the respective log, measured for example through load cells or calculated by knowing the grammage of the product, the width and the number of meters wound, and the physical dimensions of the reels (wound meters, diameter, width etcetera).

The most important parameters are the defects in the surface and/or the thickness of the product (that may also include the thickness of the treatments done on the product, for example the coating thickness in the case of paper). Below specific reference will be made to the case of defects in the surface and/or the thickness, being understood that the inventive concept can be also extend to all the other product parameters indicated above, that can be associated with each respective log. In this case, other detection devices will be provided in the plant to perform the desired detection.

As mentioned, in this example, the device32detects the defects in the surface or the thickness (or, more in general, the parameters) associated with the thin product T being wound in the winder13to form the master roll B1. For example, the detection device32comprises a vision system with a camera, and/or a QCS system and/or a metal detection system, all these systems being known.

The vision systems are systems that, through image acquisition, are able to detect defects such as holes, tears, folds, foreign parts etcetera. For example, the QCS systems are based on the reflection and/or the refraction of infrared sources or on the absorption of beta particles and allow for example to detect the thickness profile of the product, the grammage profile, the relative humidity profile, the thickness profile of special finishings (coating); these parameters are associated to the quality of the product. Excessive differences of these measurements with respect from the reference values mean defects of the product. The metal detection systems are systems adapted to detect the presence of metal foreign bodies in the product, even smaller than one millimeter.

The detection device32(including one or more of the above mentioned systems) is arranged for example between the exit of the production line12and the winder13, or preferably on this latter or near this latter. The detection system32associates the defects with the position they have on the master roll B1according to a reference system associated with the master roll, comprising for example the position coordinates of the defects in the master roll in terms of meters of product unwound from the center of the master roll and of distance from an edge of the master roll.

The information on the defects are stored in a first database DB1of the database system31; in addition to the number and the position of the defects (or, more in general, parameters) on the master roll, the information also comprise, for example, also the type of defects detected.

Before winding the product T on the primary core14at the winder13, to form the master roll B1, the primary support core14is electronically marked by applying a first label or RFID support33, for example on an outer edge of the primary core14.

Once the primary log B1has been realized, through a first electronic device for reading and/or writing on electronic supports, for example an RFID antenna34operatively connected with the electronic control apparatus30and arranged at the exit of the winder13, a primary code X is assigned to the RFID label33, having a match in a second database DB2of the database system31.

The electronic apparatus30makes an association, in said second database DB2, between the information on the defects (or, more in general, parameters) detected on the product T (number, position and type) of the primary log present in the first database DB1and the primary ID code X of the primary log, so that in this second database DB2, to a given primary ID code information are associated on the defects in the surface and/or the thickness of the respective primary log, that can be identified based on their position on the log.

Obviously, the primary ID code X can be assigned to the RFID label33also before the beginning of the step of winding the product T on the winder13(the assigning may occur for example before applying the RFID label to the primary core, or immediately after this), whilst the association of the detected defects (or, more in general, parameters) occurs when the winding step is finished. Moreover, the RFID label33may be applied to the primary support core14even after the step of winding on the winder13(and the code can be assigned before applying the RFID label to the primary log, or immediately after that).

From the unloading area15of the winder13, the primary log B1, through the first moving device16(for example a carriage or a shuttle), is carried and loaded on the rewinder17. Here, a second electronic device for reading and/or writing on electronic supports, for example a second RFID antenna35, reads the primary ID code X of the primary log B1programmed in the electronic RFID label33. Therefore, the electronic apparatus30identifies the primary log being processing, and, through the primary code X, acquires the information on the defects (or, more in general, parameters) stored in the first database DB1.

The rewinder17comprises a station22where the tubular cylindrical secondary support cores18iare produced for the secondary logs B2ito be formed, and a winding station19providing for an unwinding area20for unwinding the master roll, an arranging area21for arranging the secondary support cores18icoaxial and adjacent to one another, in front of the unwinding area20, and a cutting device23, with a plurality of blades24, arranged between the unwinding area and the arranging area21. Position translators (not shown) are associated with the blades24to move the blades according to the direction f2, i.e. transversally to the unwinding direction, and to adjust the cut position so as to cut the thin product into continuous webs of transverse width equal to the transverse width of the secondary support cores18i.

As mentioned, the electronic apparatus30identifies the primary log B1being processing at the rewinder17, and, through the primary code X, acquires the information on the desired parameters (defects or other mechanical or winding parameters) stored in the first database DB1.

Therefore, the electronic apparatus30takes into account the information on the desired series of parameters of the thin product in the primary log B1being processed at the rewinder17. The electronic apparatus30manages the rewinding step based on the production needs, determining the number and/or the transverse width of the plurality of secondary support cores18i, and therefore the corresponding cut of the thin product coming from the primary log or master roll B1. Therefore, a desired second series of parameters is associated with each secondary log B2iproduced from the primary log B1.

In the simplest case, the cut of the thin product of the log B1occurs according to pre-set production needs. The production needs require, for example, starting from the primary log B1, six secondary logs B2iof given width, for example all equal to one another, or some equal to one another and other of different width.FIG.2shows the case of production needs for six secondary logs B2iof different width, starting from a primary log or master roll B1′.

The electronic apparatus30manages the rewinding step by using the production information related to the dimensions of the logs to be produced, adequately positioning the blades of the cutting device23.

Moreover, the electronic apparatus30controls the station22where the secondary support cores18iare produced so that these secondary cores18iare produced so as to realize the secondary logs according to the production specifications (the secondary cores18′ have the same transverse width as the webs of the respective secondary logs). Once the cores have been produced and positioned on the area21, the thin product is unwound from the log B1′, cut and wound in the corresponding cores.

For example, on the primary log B1′ ofFIG.2two areas h and y have been detected with surface defects (or, more in general, desired mechanical, unwinding parameters, defects etc. have been detected) arranged, for instance, near the centerline of the primary log and near an edge, repeated along the whole winding extension in a substantially constant manner. These defects are stored in the first database DB1and associated with the code X1identifying the log B1′. Once the primary log B1′ is on the rewinder17, the electronic apparatus30reads the code X1from the respective first RFID label33and identifies the maps of defects h and y associated with the log. Then, the electronic control apparatus30transforms the information on the position of the defects on the primary log B1′ into information on the position of the defects on each secondary log B2ito be produced.

Adequately, once realized, the secondary support cores18iare electronically marked by applying respective second electronic RFID labels or supports35.

By means of a third electronic device for reading and/or writing on electronic supports, for example a third RFID antenna36provided in the rewinder17, the electronic control apparatus30assigns to the second RFID labels35of the secondary cores18irespective secondary ID codes Ki, having a match in the second database DB2of the database system31.

The electronic control apparatus30, as already mentioned, has transformed the information on the position of the defects on the primary log B1′ into information on the position of the defects on each secondary log B2i, for example the coordinates of the position of the defects on the secondary logs in terms of meters unwound from the center of the secondary log and of distance from an edge of the secondary log (i.e. with respect to a reference system integral with the secondary log). The apparatus30therefore associated, in the second database DB2, the secondary codes Kiand the respective information on the position of the defects on the respective secondary logs B2i, so that to each secondary log B2ia set of desired parameters (defects, mechanical parameters, unwinding parameters etc.) is associated and this set is stored, in association with the code of the secondary log, in the database system31. In the example ofFIG.2, six secondary logs B21, B22, B23, B24, B2yand B2hhave been produced (with cores18h-181-182-18y-183-184).

Consequently, for each secondary log B2ia map of desired parameters (defects, mechanical parameters, unwinding parameters, etc.) is known, that can be used in order to optimize the subsequent steps of production of products coming from these secondary logs, if necessary even in a second plant, other than the plant where they have been produced, as the database system31with the information can be shared between the electronic management systems of the second plant. For example, the logs B2yand B2hcan be rejected, or marked as of lower quality, or used in downstream production processes, communicating to the respective production system when to intervene for overcoming the detected defects.

Practically, in this example, the cut of said plurality of secondary support cores, and therefore the corresponding cut of the thin product coming from the primary log or master roll, provides for cut positions transverse to the unwinding direction of the primary log that are independent of the information on the series of parameters of the thin product in the primary log.

According to some embodiments, the electronic apparatus30can organize the rewinding step by using the information on the defects of the primary log B1stored in the database system31, so as to optimize this step.

For example, the electronic apparatus30, based on the information on desired parameters (defects, mechanical parameters, unwinding parameters, etc.), can calculate the number of secondary logs B2ito be produced, avoiding the area of the thin product T wound in the primary log B1where there is the greater number of defects, i.e. realizing a given number of secondary logs of acceptable quality (i.e. with a number of defects minimum or null) and a given number of secondary logs with a high number of defects, that will be rejected (or qualified as “low quality”). This is done by positioning the blades of the cutting device23in the transverse direction of the product in the most adequate manner in order to isolate the defects in the secondary logs to reject. Practically, in this second example, the cut of said plurality of secondary support cores, and therefore the corresponding cut of the thin product coming from the primary log or master roll, provides for cut positions transverse to the unwinding direction of the primary log that are a function of the information on the desired series of parameters of the thin product in the primary log.

Before positioning the blades of the cutting device23, the electronic apparatus30controls the station22where the secondary support cores18iare produced so that these secondary cores18iare produced in an optimized manner as described above (the secondary cores18ihave the same transverse width as the webs of the respective secondary logs). Practically, the number and/or the transverse width of the plurality of secondary support cores18i, and therefore the corresponding cut of the thin product coming from the primary log B1, are determined taking into account the information related to the position of the defects of the thin product in the primary log, so that in each secondary log B2ia desired second set of defects is provided.

In the database system31are therefore stored the secondary logs to be rejected and the secondary logs to be forwarded to the following production steps.

For example, again with reference toFIG.2, two areas h and y with surface defects have been detected on the primary log B1′. These defects are stored in the first database DB1and associated with the code X1identifying the log B1′. Once the primary log B1′ is on the rewinder17, the electronic apparatus30reads the code X1from the respective first RFID label33and identifies the maps of defects h and y associated with the log. Then, the electronic control apparatus30transforms the information on the position of the defects on the primary log B1′ into information on the position of the defects on each secondary log B2ito be produced. Based on this, the electronic control apparatus30controls the station22so that the secondary support cores18iare produced so as to create a first series of secondary logs B2iaccording to the production needs (in the example four secondary logs B21. . . B24), and two secondary logs B2yand B2hcontaining the two areas h and y with the defects. Therefore, four secondary support cores18iare produced of the desired transverse width (accordingly to the production orders regarding the logs dimensions) and two secondary support cores18y18h(containing a high number of defects and, therefore, to be rejected), according to the following order (from an outer edge to the following one):18h-181-182-18y-183-184.

In the station22, the secondary support cores are produced by cutting a common tubular cylindrical support core into six parts, into the plurality of secondary support cores (with the above specified dimensions) on which the product T being rewound will be wound (in some embodiments, the station where the cores are realized can be omitted).

The secondary support cores, coaxial and adjacent to one another in the order18h-181-182-18y-183-184, are arranged in the area21of the rewinder13. Analogously, the electronic apparatus30arrange the five blades24of the cutting device23so as to cut the product T exiting from the primary log B1′, according to the machine direction, into webs corresponding to the interfaces between the secondary support cores18h-181-182-18y-183-184.

Then, the rewinding step starts, i.e. the unwinding of the thin product T from the primary log B1′ and the following winding of the product T, adequately cut by the device23in the positions described above, on the secondary cores18i, so as to realize the secondary logs B2i.

Adequately, once realized, the secondary support cores18h-181-182-18y-183-184are electronically marked by applying respective second electronic RFID labels or supports35.

By means of a third electronic device for reading and/or writing on electronic supports, for example a third RFID antenna36provided in the rewinder17, the electronic control apparatus30assigns to the second RFID labels35of the secondary cores18irespective secondary ID codes Ki, having a match in the second database DB2of the database system31.

The electronic control apparatus30, as already mentioned, has transformed the information on the position of the defects on the primary log B1′ into information on the position of the defects on each secondary log B2i, for example the coordinates of the position of the defects on the secondary logs in terms of meters unwound from the center of the secondary log and of distance from an edge of the secondary log (i.e. with respect to a reference system integral with the secondary log). The apparatus30therefore associated, in the second database DB2, the secondary codes Kiand the respective information on the position of the defects on the respective secondary logs B2i, so that to each secondary log B2ia set of defects is associated and this set is stored, in association with the code of the secondary log, in the database system31.

Moreover, in the database system31, associated with the secondary ID code Kiof a secondary log B2i, there are, in addition to the information on the position of the defects in the surface and/or the thickness, also general information on the log, such as the dimensions of the secondary log, the weight, the type of produced material, and sales data.

Consequently, for each secondary log B2ia map of defects is known, that can be used in order to optimize the subsequent steps of production of products coming from these secondary logs, if necessary even in a second plant, other than the plant where they have been produced, as the database system31with the information can be shared between the electronic management systems of the second plant.

Preferably, the secondary logs B2iare marked on the respective secondary support cores18ibefore the step of winding the thin product on the secondary cores. In other embodiments, the marking can be performed after the winding, i.e. when the secondary logs B2ihave been finished and/or unloaded from the rewinder13.

The programming step for assigning the secondary ID code Kito the respective second RFID label35can be performed before applying the second RFID label t the corresponding secondary log, or once the second RFID label has been applied to the secondary log, as described above (and secondary ID code Kican be also assigned after the step of winding the product on the respective second core18i, but in any case preferably before the secondary log B2iexit the rewinder13.

Once the primary log B1′ has been rewound into secondary logs B2i, the primary log no longer exists and therefore the electronic control apparatus30deletes the data stored in the first RFID label and the first support core can be used again for a new primary log. Therefore, the information associated with the primary ID code X can be deleted from the database system31.

Once the secondary logs B2iwith the respective second labels have been realized, they are moved from the rewinder13, through the second moving devices25, for example carriages or shuttles, to the packing station26.

In other embodiments, in the plant the winder can be not provided, and the continuous thin product is fed from the production line directly to a winder like a rewinder, so that from the production line the product is cut into webs of width equal to the support cores present in the rewinder, so as to create a plurality of logs that then will be moved to the packing area or to other processing areas.

It should be noted that the cut in a rewinder may provide only for the cut of the side trimmings of the thin product being wound on the cores, so that from the rewinding a single log can exit with the wound finished product and one or two logs with the trimmings, that shall be rejected; alternatively, only one log may be present and the trimmings are continuously discharged through suction openings.

It should be noted that, in other embodiments, one or more detection device can be provided in the rewinder for detecting product parameters analogously to the detection device32(the parameters can comprise all the parameters indicated above or only some of them), for example defects in the thickness or the surface (it can also comprise, for example, a device for detecting metal particles as described above). The parameters detected according to the position on the respective log are associated with the code of the respective log produced in the rewinder and stored in the database system.

In the packing station26a fourth electronic device is provided for reading and/or writing on electronic supports, for example a fourth RFID antenna40that is operatively connected with the electronic control apparatus30, reading the second RFID labels35of the second logs B2iarriving to the station26, reading the secondary ID codes Kithereof. Based on this reading, the electronic control apparatus30interacts with the second database DB2, accesses the information on the defects of the respective secondary logs B2iand verifies the logs to be packed and the logs to be rejected. Or, simply, the electronic control apparatus30already knows that the secondary logs B2iassociated to a given secondary code Kiare to be rejected (in the previous example, the logs B2hand B2ywith the codes Khand Ky) and operates accordingly.

The robot27takes the secondary logs B2ito be rejected and put them in a discharged area, whilst the secondary logs B2ito be packed are arranged in a pile on the conveyor28, at the end of which a pile of secondary logs B2iis wound with a covering film so as to form a pack P of secondary logs B2i.

The electronic control apparatus30creates, in the database system31, an association between the secondary codes Kiof the logs forming each pack P. If necessary, in the database system a tertiary ID code F of the pack P is generated, with which the secondary codes of the logs of that pack are associated.

A check station45, comprising a fifth electronic device for reading and/or writing on electronic supports, such as a fifth RFID antenna45A, reads the secondary codes Kifrom the second RFID labels of the logs forming the pack P, in order to verify whether they are all those programmed or an error occurred during the packing step, i.e. whether there are more secondary logs, or less secondary logs than those programmed.

Adequately, a labeling device46electronically marks the pack P, for example by applying a third RFID label47to the pack P, and performs the programming thereof through an RFID antenna for assigning a tertiary ID code F to this third RFID label (not shown in the figures).

Alternatively, the third label can be made of paper and indicate the secondary codes Kiof the secondary logs B2iforming it or the tertiary code F identifying the pack as a whole.

The pack P, formed and verified, is sent in an adequate manner (for example by means of a pallet moved by a forklift) to the warehouse or to the delivering area for being sent to a second plant50where the subsequent processing steps will be performed.

With reference again to the primary log B1, once it has been formed in the winder12, instead of being sent to the rewinder13, it can be directly sent to the packing station26through the moving devices16. Here, it is packed and sent to the warehouse or directly to the delivering area for being sent to the plant50where the subsequent processing steps will be performed.

Adequately, the database system31, or at least a section thereof, is associated with a server51that can be accessed telematically, also remotely, so that from a reading of the primary ID code X associated with the first RFID label33during a processing in the second plant it is possible to have information associated with the code X, i.e. with the primary log B1being processed, and therefore information on the position of the defects on the primary log. It is therefore possible to optimize the production in this second plant based on this information shared through the database system31remotely accessible. It will be therefore possible, for example, to perform a rewinding step in the second plant according to methods analogous to those described above.

Adequately, as the database system31is associated with a server that can be telematically accessed remotely, also the information on the secondary logs B2ican be accessed during the subsequent processing of these logs in a second plant50. Therefore, from the reading of the secondary codes Kistored on the second RFID labels35provided on the secondary logs B2iit will be possible to known the information on the position of the defects on these secondary logs and therefore to optimize the production of products from these secondary logs (for example rewinding into logs of smaller dimension, even accordingly to methods different than that described above), this ideally resulting in producing a finished product knowing the defects distribution thereon (or, more in general, the distribution of the desired parameters detected and associated).

In the example described above specific reference has been made to electronic RFID labels and to corresponding RFID antennas for reading/writing the labels. In other embodiments, instead of electronic labels graphic supports may be also used, such as for example paper labels with alphanumeric codes, or bar codes, or QR codes or other codes. In this case, instead of antennas writing and reading the supports remotely, printers are necessary to print the graphic labels and devices for optically reading the graphic symbols. Moreover, labels with magnetic band can be used together with respective devices for writing and reading data stored in the magnetic band.

In general, the supports to which the ID codes are associated can be fixed to the support cores on which the product is wound to create the log, or on the outer surface of the log.

Thanks to the method and the plant according to the invention, it is therefore possible to track the movement of the primary and secondary logs inside the production plant, optimizing in particular the step of rewinding and/or packing, rejecting the portions of primary log containing unacceptable defects detected and historicized during the step of forming the log.

With the method and the plant according to the invention is it possible to historicize in the logs, in addition to the defects, also all the product and process parameters allowing optimization of the subsequent processing of the product wound the respective log.

Moreover, thanks to the use of graphic of RFID labels, all the steps of moving and storing the logs in the plant are facilitated.

Moreover, thanks to the use of graphic or RFID labels in the secondary or primary logs it is possible to track the various parameters indicated above (and in particular the defects) contained therein after the processing in the first production plant. The information of the labels will be useful to access a remote database containing the features of the logs, including the defects thereof. The information will be useful to optimize the whole converting process. The database can be therefore accessed by all the people involved in the processing chain up to the end product.

Last but not least, the use of an RFID label instead of graphical labels allows maintaining the information associated to the labels for a longer time with respect to the paper label. The use of an electronic system for reading the labels also reduces the risk of reading codes by the operators and accelerates the reading steps.

It is understood that what is illustrated purely represents possible non-limiting embodiments of the invention, which may vary in forms and arrangements without departing from the scope of the concept on which the invention is based. Any reference numerals in the appended claims are provided for the sole purpose of facilitating the reading thereof in the light of the description herein before and the accompanying drawings and do not in any way limit the scope of protection.