PLANT AND METHOD FOR LABELING REELS OF WEB MATERIAL

Abstract

The plant includes at least one support (3) for the reels (B1, B2 . . . . Bn) to be labeled, a label dispenser, a first labeling robot (11) adapted to take labels from the label dispenser and to insert them into the central openings of the reels arranged on the support, and a second handling robot (31) adapted to take the reels and to move them away from the support (3).

Claims

1. A plant for labeling and handling reels of web material, the reels having a central opening, around which the web material is wound, the plant comprising: at least a support for the reels to be labeled; a label dispenser; a first labeling robot adapted to take labels from the label dispenser and to insert the labels into the central openings of the reels arranged on the support; and a second handling robot adapted to take the reels and to move the reels away from the support.

2. The plant of claim 1, wherein the support for the reels to be labeled is configured to support the reels resting with respective side surfaces of the reels on the support.

3. The plant of claim 1, wherein the label dispenser comprises a label printing device.

4. The plant of claim 1, wherein the first robot comprises a first anthropomorphic arm.

5. The plant of claim 1, wherein the second robot is configured to modify the orientation of the reels and to arrange the reels with a respective axis of the reels in an approximately vertical position.

6. The plant of claim 1, wherein the second robot comprises a second anthropomorphic arm.

7. The plant of claim 1, wherein the first robot includes a label pickup device comprising at least one rod-like element provided with a plurality of label pickup members configured to engage the labels and to release the labels on an inner surface of the central opening of the reels.

8. The plant of claim 7, wherein the rod-like element is connected to the robot at an intermediate point and comprises two linear portions extending from the intermediate point, each linear portion having at least one label pickup member.

9. The plant of claim 1, wherein at least one system for searching the reel center is associated with the first robot and the second robot.

10. The plant of claim 1, wherein the second robot comprises a first reel gripping and handling member, configured to engage the reels from the inside of the central opening.

11. The plant of claim 10, wherein the first gripping and handling member is an expandable member.

12. The plant of claim 1, wherein the second robot comprises a second reel gripping and handling member for gripping and handling the reels, configured to engage the reels on an outer surface of the reels.

13. The plant of claim 12, wherein the second gripping and handling member comprises a pair of jaws provided with a reciprocal movement towards, and away, from each other to radially grip the reels from the outside.

14. The plant of claim 1, wherein the second robot comprises a handler for gripping and handling separating sheets intended to be interposed between stacked reels and/or to cover end faces of a stack of reels.

15. The plant of claim 1, comprising an outer labeler adapted to label the reels on the outer surface.

16. The plant of claim 1, wherein the support comprises a V-shaped rest surface for a series of aligned reels.

17. The plant of claim 1, wherein the support comprises a conveyor to move the reels towards the first robot and the second robot.

18. The plant of claim 1, wherein the support is configured to arrange the reels with a reel axis inclined with respect to the horizontal, so that the reel closest to the first robot and to the second robot is arranged at greater height than the reel farthest from the first robot and the second robot.

19. The plant of claim 1, comprising a further support for the reels, the first robot and the second robot being configured to act on reels resting on both supports.

20. A method for labeling and handling reels of wound web material having a central opening and a side outer surface, the method comprising the following steps: arranging a plurality of reels on a reel support; through a first robot, applying a label inside each reel in the reel central opening; and through a second robot, taking each labeled reel from the support and moving the labeled reel therefrom.

21. The method of claim 20, wherein the step of taking and moving each reel comprises the step of overturning the reel and arranging the reel with the respective axis in a vertical position, and the step of stacking a plurality of reels coaxially with one another.

22. The method of claim 20, wherein during the step of taking and moving the reel, the first robot carries out a step of picking up one or more labels to be applied to subsequent reels arranged on the support.

23. The method of claim 20, further comprising the step of applying a label to the outer surfaces of the reels, while the reels are arranged on the support.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0043] The invention will be better understood by following the description below and the attached drawing, showing a non-limiting embodiment of the invention. More specifically, in the drawing:

[0044] FIG. 1 shows a front view of a reel with a tubular winding core defining a central opening;

[0045] FIG. 2 is a cross-section according to II-II of FIG. 1;

[0046] FIG. 3 is a front view of a reel with a central opening without the winding core;

[0047] FIG. 4 shows a cross-section according to IV-IV of FIG. 3;

[0048] FIG. 5 is an axonometric view of a plant according to a first embodiment;

[0049] FIG. 6 is a plan view of the plant of FIG. 5;

[0050] FIG. 7 shows an axonometric view of a first robot, or labeling robot, of the plant of FIGS. 5 and 6;

[0051] FIG. 8 is a plan view of a second robot, or handling robot, of the plant of FIGS. 5 and 6;

[0052] FIG. 9 is an axonometric view of the second robot of FIG. 8;

[0053] FIGS. 10, 11 and 12 are simplified views of the plant, with some parts omitted, and more precisely a side view, a plan view and an axonometric view, in a step where the first robot picks the labels up from a labeling machine;

[0054] FIGS. 13 and 14 are simplified plan and front views in a centering step of the labeling robot;

[0055] FIGS. 15 and 16 are an axonometric view and a plan view of the step of inserting the labels into the reels;

[0056] FIG. 17 is an axonometric view of the centering step of the second robot, or handling robot;

[0057] FIGS. 18 and 19 are a plan view and an axonometric view of the step of gripping the reel by the second robot;

[0058] FIGS. 20 and 21 are a side view and an axonometric view of the step of simultaneously lifting two reels by the second robot; and

[0059] FIG. 22 is an axonometric view of the depositing step where the reels are deposited by the handling robot on a roller conveyor, with their axes in vertical position.

DETAILED DESCRIPTION

[0060] FIGS. 1 to 4 show a generic reel B to be labeled and handled. The reels consist of web material that may be wound around a tubular element C, also referred to as winding core C, as shown in FIGS. 1 and 2. In other embodiments, the reels simply have a central hole F defining an empty cavity, as shown in FIGS. 3 and 4. In both cases, the reels B have a central opening A that is empty and coaxial with the turns of web material wound in a reel. S indicates the outer surface of the reel and S1 indicates the inner surface of the central opening A. The inner surface S1 may be defined either by the central winding core C or by the innermost turn of web material wound in a reel.

[0061] The reels B can have any diameter, but for many applications the reel diameter can be comprised between 300 mm and 2000 mm. The width, i.e. the axial dimension of the reels B, can also be variable; typically it can be comprised between 20 mm and 2000 mm but, in some cases, can be significantly greater.

[0062] The central opening, or central cavity, of the reels can have highly variable diameters, typically comprised, for example, between 50 mm and 400 mm.

[0063] It is understood that the values indicated above are purely indicative and the present invention can be applied to reels B of any diameter and width (axial dimension).

[0064] FIGS. 5 and 6 show an axonometric view and a plan view of an embodiment of a system or plant 1 according to the invention for labeling and handling reels. The reels B1, B2, B3, . . . , Bn, usually coming from a machine equipped with a system for longitudinally cutting web materials (line cutting machines, rewinders, sheeters) are generally arranged with the axis in horizontal position and are loaded on tables or supports 3. In the illustrated embodiment, the plant 1 comprises two supports 3. This configuration has some advantages in terms of versatility and production speed, but it is also possible to provide a different number of supports 3, for example a single support 3 or more than two supports 3. In general, the supports should adequately be in such a number and position to be within the range of a pair of robots, described below.

[0065] The supports 3 may be directed in horizontal or inclined direction. In any case, they are arranged so that the reels B1-Bn rest on them with their respective cylindrical side surfaces. In this way, the flat surface of the end reel B1 of the series of reels B1-Bn resting on each single support 3 is free, to make the central openings of the reels accessible by the robots described below.

[0066] In the illustrated embodiment, each support forms V-shaped rest surfaces for supporting the reels B1-Bn.

[0067] The reels B1, B2, B3, . . . , Bn, loaded on the same support 3, can have widths (axial dimensions) and diameters different from one another, even if the diameters of the reels B1-Bn resting on a single support generally vary only slightly.

[0068] In some embodiments, as illustrated in the drawing, each table or support 3 comprises two conveyors 5 defining the V-shaped rest surface supporting the reels. The conveyors 5 can be belt conveyors, roller conveyors, chain conveyors, or other conveyors. They can be provided with a movement according to the arrow f5 (FIG. 6) to move forward the series of reels B1-Bn towards the handling and labeling area where the robots are arranged.

[0069] The supports 3 may be equipped with accessories 7 to keep the reels in position, for example in the form of pushers, which facilitate the movement of the reels according to the arrow f5.

[0070] The supports may be equipped with mechanisms 9 to adjust the inclination of the supports and to facilitate both the loading of the reels and the possibility of slightly inclining the axis of the reels relative to the horizontal so as to increase the stability during the labeling and pickup steps.

[0071] The labeling and handling plant 1 also comprises a first robot 11, hereinafter referred to as labeling robot 11, equipped with a specific device 13 for picking the labels up from a label dispenser 15 and for applying the labels to the inner surface S1 of the central opening A of the reels B.

[0072] The first labeling robot 11 is represented in axonometric view in FIG. 7. It preferably has an anthropomorphic arm 17, ending in a head 19, to which the device 13 for picking up and applying the labels is fixed. In some embodiments, the device 13 advantageously comprises a rod-like element 21. The rod-like element 21 can be divided into two linear portions 21A and 21B, extending from an intermediate point, where the rod-like element 21 is connected to the head 19 of the anthropomorphic arm 17 of the first labeling robot 11.

[0073] In other embodiments, more than two linear portions may be provided, for example four linear portions arranged on a plane at 90 from one another and each provided with members for gripping the labels. In further embodiments, (three or more) linear portions are arranged in a three-dimensional rather than planar arrangement.

[0074] Each of the two linear portions 21A, 21B of the rod-like element 21 can have one or more gripping members 23 configured to grip single labels and to apply them inside the central opening A of the reels B. In the illustrated example, each linear portion 21A, 21B comprises two gripping members 23. As mentioned, the gripping members can be of the pneumatic type, and can have a suction pad, to which the non-glued surface of a label adheres by suction. The suction pad, once brought inside the central opening A of the reel B, is pressed on the inner surface S1 of the central opening A and, by stopping the suction and, if necessary, generating a flow of air or other fluid, it can be detached from the label gripping member and made adhere to the inner surface S1 of the central opening A of the reel.

[0075] Since each linear portion 21A, 21B has two label gripping members 23, a total of four inner labels can be attached on four reels B, two for each support 3, in every work cycle that will be described below.

[0076] In general, the label dispenser 15 can have any configuration; it can be adapted to dispense labels that have been already produced in a previous step, or can generate the labels, for example by printing them, or, when the label includes an RFID tag, it can store thereinside the requested information. Therefore, in some embodiments, the label dispenser 15 for the labels (that generally can consist of thin elements, which may have an adhesive surface) can comprise a printer generating the labels, a system for writing data in a RFID tag, a system for peeling off labels attached on a specific support and wound on reels, a system for dispensing labels one by one, or a combination thereof.

[0077] The gripping members 23 generally have a shape similar to the label to be handled, and can be made of different materials and have holes or grooves connected to the suction system through suitable pipes. The gripping members 23 can be generally arranged on springs or other elastic systems.

[0078] Once the gripping members 23 have taken the labels from the label dispenser 15, the labeling robot 11 moves the device 13 towards the axis of the reels to be labeled. Prior to, or simultaneously with, the movement of the device 13, a centering system 9 provides the labeling robot 11 with the position that the device 13 must take for the correct application of the labels. The centering system, i.e. the system for searching the center of the reels, is schematically indicated with 12 and can be provided on the head of the labeling robot 11.

[0079] The centering system can be constituted by a vision system, a scanner, various sensors, electromechanical or pneumatic devices, and can be installed on the labeling robot 11, or in a fixed position or on the support 3.

[0080] Knowing the position of the axis of the reels B1, B2, B3, . . . , Bn, the labeling robot 11 inserts either of the linear portions 21A, 21B of the rod-like element 21 inside the central openings A of the reels and applies the previously taken labels to the inner surface S1 of the central opening A of the reels.

[0081] In the illustrated example, each linear portion 21A, 21B has two gripping members 23 and therefore it is possible, for example, to apply two labels to two adjacent reels B1, B2 arranged on one of the two supports 3 by means of a linear portion 21A, 21B and to apply the other two labels to two reels B3, B4 adjacent to each other and arranged on the other of the two supports. In some cases, when the axial dimension of the reels is large, each linear portion 21A, 21B can apply only a single label to a single reel. It is also possible to apply more labels inside the same reel, if this is necessary due to the type of information to be associated with the reel.

[0082] The labels can be applied by moving the head of the labeling robot 11 in radial direction and making each label gripping member 23 press against the inner surface S1 of the respective reel B, B1, B2, B3, . . . , Bn. In this way, a contact pressure is generated, which allows the adhesive provided on the labels to make the label adhere to the inner surface S1. However, other methods can also be used for applying the labels, for example blows of air or other gas, electrostatic systems or other.

[0083] In addition to the label dispenser 15 and the labeling robot 11, the plant 1 can also comprise an outer labeling machine, able to apply labels to the outer surface S of the reels B, B1, . . . . Bn. In FIG. 5, the outer labeling machine is indicated with 27 and is provided under the end of the supports 3 closest to the labeling robot 11. The outer labeling machine 27 can be movable according to the double arrow f27 to apply labels to the reels supported by the two supports 3. The outer labeling machine 27 may be also provided with a movement according to the double arrow f27X, in a direction orthogonal to the direction of the double arrow f27, so as to translate under any one of several reels resting on the same support 3 and therefore to label two or more axially aligned reels. To this end, the outer labeling machine 27 can be mounted on a movable slide numerically controlled according to two orthogonal translation axes.

[0084] The outer labels can be applied by means of the outer labeling machine 27 in a time interval overlapping the time interval during which the inner labels are applied by means of the labeling robot 11.

[0085] The plant 1 also comprises a second robot 31, hereinafter referred to as handling robot 31; a plan view thereof is shown in FIG. 8, an axonometric view thereof is shown in FIG. 9. In advantageous embodiments, the second robot or handling robot 31 comprises an anthropomorphic arm 33 with a head 35, on which members for gripping and handling the reels B, B1, B2 . . . . Bn are applied.

[0086] More specifically, a first member for gripping and handling the reels, indicated with 37, can be arranged on the head 35. The first gripping and handling member 37 is adapted to engage the reels from the center, i.e. by entering the central opening A of the reels. In the illustrated embodiment, the gripping and handling member 37 comprises two expandable portions 37A, which are provided with a radial movement away from each other so as to expand once the gripping and handling member 37 has been inserted into the central openings A of one or more axially aligned reels. The movement of the portions 37A of the gripping and handling member 37 away from and towards each other can be controlled by any suitable actuator, for example a pneumatic, hydraulic, electric, magnetic actuator or the like.

[0087] In the illustrated embodiment, the head 35 of the handling robot 31 comprises a second member 39 for gripping and handling the reels. The second gripping and handling member 39 comprises outer gripping members, adapted to engage the outer surface S of one or more reels B. In the illustrated embodiment, the second gripping and handling member 39 comprises two jaws 39A provided with a radial movement to engage and release the outer surfaces S of the reels B, B1, . . . . Bn. The gripping and handling members 37 and 39 can be used alternatively or in combination, for example depending upon the type of web material of which the reels B, B1, . . . , Bn are made and/or on the winding conditions, for example the compactness of the reels.

[0088] The gripping members are adapted to simultaneously engage a number of reels equal to or lower than those labeled by the labeling robot 11 in every working cycle.

[0089] In some embodiments, the head 35 of the handling robot 31 can comprise a sheet handler 41 for handling separating sheets or cover sheets, which may be arranged above and below a stack of reels put vertically over one another as illustrated below. The sheet handler 41 can comprise suction cups 43 adapted to engage the sheets by suction.

[0090] The plant 1 may also comprise one or more support surfaces 45, for example in the form of roller conveyors, conveyors, pallets or other, on which stacks P can be formed, comprised of reels B arranged vertically over one another with their axes in a vertical position, by means of the handling robot 31, through operations described below. Each of the support surfaces 45 can also consist of, or integrate, a conveyor (not shown), for example a roller conveyor, a belt conveyor or the like, to move the stacks P of reels away from the plant 1. Under the reel in the lowest position and/or above the reel in the highest position of each stack P, a preferably circular sheet F can be arranged, taken by the handler 41 of the handling robot 31 from a sheet storage 47. If necessary, sheets F1 can also be interleaved between reels.

[0091] A single stack or a plurality of stacks of reels can be formed on each support surface.

[0092] The operating cycle of the plant 1 described above is illustrated in detail in the sequence of FIGS. 10 to 22, showing different views of various operational steps. For greater clarity, in FIGS. 10 to 22 some parts of the plant 1 have been omitted. In particular, in these figures only one table or support 3 is shown, and the outer labeler 27 has been omitted. In some figures, the roller conveyors 45 are also omitted.

[0093] The operational cycle is as follows. FIGS. 10, 11 and 12 show respectively a side view, a plan view and an axonometric view of the pickup step wherein the labeling robot 11 takes the labels from the label dispenser 15. FIGS. 13 and 14 show respectively a plan view and a front view of the centering step, i.e. the step of searching the center of the reels B to insert the rod-like element 21 into the axial opening of the reels.

[0094] FIG. 15 shows an axonometric view of the step wherein the rod-like element 21 of the labeling robot 11 is inserted into the central opening A of the two reels closest to the robot 11.

[0095] FIGS. 16 and 17 show respectively a plan view and an axonometric view of the centering step wherein the handling robot 31 searches the center of the reel. The center of the reel can be identified using a single centering system, the detection whereof is used by both robots 11 and 31. After the labeling robot 11 has applied one or more labels to one or more reels, the labeling robot 11 can be moved away from the reels and can perform a new step of taking the labels from the label dispenser 15.

[0096] FIGS. 18 and 19 show respectively a plan view and an axonometric view of the gripping step wherein the gripping and handling members of the handling robot 31 grip two reels.

[0097] FIGS. 20 and 21 show the lifting step wherein the handling robot 31 raises the two reels.

[0098] Once the reels have been lifted, the head of the handling robot turns them, arranging them with the respective axis vertical, and places them on one or the other of the roller conveyors or other support surfaces 45, as shown in FIG. 22.

[0099] The operations described above can be repeated for all the reels of both the two supports or tables 3, to form one or more stacks of identical or different reels on one or more roller conveyors 45.

[0100] In some embodiments of the labeling and handling method which can be implemented through the plant 1, it is possible to label and remove all the reels of one of the two supports 3 and then all the reels of the other of the two supports 3. In this case, when a first support 3 has been emptied, the robots 11 and 31 can process the reels of the second support 3, while a new series of reels to be labeled is loaded onto the first support. In other embodiments of the method, the reels can be labeled and taken from one and the other of the two supports 3, for example to group the reels in homogeneous vertical stacks (for example reels with the same axial dimension), taking reels collected in non-homogeneous fashion on the two tables 3.