Machine and method for winding reels of web material

Abstract

The rewinding machine comprises: a first winding member ( 3 ) and a second winding member ( 9 ) defining a winding cradle ( 19 ); a winding rod inserter ( 25 ) for introducing a winding rod (A 1 ; A 2 ) in the winding cradle ( 19 ) to wind a reel (B 1 ) of web material (N) on said winding rod. The inserter ( 25 ) is arranged and designed for introducing the winding rod (A 2 ) against the first winding member ( 3 ) towards the winding cradle ( 19 ) and the second winding member ( 5 ) is designed and arranged to allow a previously formed reel (B 1 ) to be unloaded from the winding cradle ( 19 ).

1 . A rewinding machine comprising:
 at least a first winding member and a second winding member defining a winding cradle;   a winding rod inserter for introducing a winding rod in said winding cradle to wind a reel of web material on said winding rod, said winding rod inserter being arranged and designed so as to introduce said winding rod against the first winding member towards said winding cradle, said second winding member having a variable configuration and being designed and arranged to allow a reel, formed around a first winding rod, to be unloaded from said winding cradle, through a change in the configuration of said second winding member, said winding rod inserter, said first winding member and said second winding member being controlled so that said first reel of web material wound around said first winding rod is unloaded from said winding cradle through a change in the configuration of the second winding member, while said winding rod inserter moves a second winding rod towards the first winding member and said first winding member brings said second winding rod into rotation, whereby winding a second reel is started, said first winding member comprising a first winding roller and said second winding member comprising a plurality of further winding rollers controlled to be in contact with the reel of web material, one or more of said further winding rollers being movable such that said first reel moves away from said first winding member towards an unloading area maintaining said first reel in rotation and continuing to wind said web material on said first reel while said first reel is transferred toward said unloading area and said winding rod inserter moves said second winding rod towards said first winding member.   
     
     
         2 . A rewinding machine as claimed in  claim 1 , wherein said winding rod inserter is controlled to maintain said second winding rod resting on said first winding member for a first phase of winding of the web material around said second winding rod, before said second winding rod is brought to rest on the second winding member. 
     
     
         3 - 11 . (canceled) 
     
     
         12 . A rewinding machine as claimed in  claim 1 , wherein said second winding member comprises a second winding roller, a third winding roller and a fourth winding roller. 
     
     
         13 . A rewinding machine as claimed in  claim 12 , wherein said first winding roller and said second winding roller define a rest and rotation nip for the reel in winding phase. 
     
     
         14 . A rewinding machine as claimed in  claim 12 , wherein an auxiliary winding roller is arranged between said first winding roller of the first winding member and said second winding roller of said second winding member. 
     
     
         15 . A rewinding machine as claimed in  claim 12 , wherein said third winding roller and said fourth winding roller are arranged and controlled to move the first reel away from the first winding member and to transfer the first reel towards said unloading area. 
     
     
         16 . A rewinding machine as claimed in  claim 15 , wherein said third winding roller and said fourth winding roller are arranged and controlled to transfer said first reel maintaining said first reel in contact with the second winding roller. 
     
     
         17 . A machine as claimed in  claim 12 , wherein said second winding roller, said third winding roller and said fourth winding roller are controlled to decelerate and subsequently to stop the rotation of said first reel, said winding rod inserter bringing said second winding rod against said first winding roller starting the winding of a second reel around said second winding rod in contact with said first winding roller. 
     
     
         18 . A rewinding machine as claimed in  claim 1 , further comprising guiding surfaces associated with said first winding member, against which the winding rod inserter rests said winding rods. 
     
     
         19 . A rewinding machine as claimed in  claim 18 , wherein said guiding surfaces are arranged and designed to define a trajectory for introducing the winding rods, extending around the first winding member and moving gradually towards said first winding member from a non-contact position to a contact position of the winding rod with the web material driven around said first winding member. 
     
     
         20 . A rewinding machine as claimed in  claim 19 , wherein said winding rod inserter comprises an engaging system for the winding rods close to ends of said winding rods, said engaging system maintaining the winding rods resting against said guiding surfaces. 
     
     
         21 . A rewinding machine as claimed in  claim 18 , wherein said guiding surfaces are movable to impart an angular acceleration to said winding rods. 
     
     
         22 . A rewinding machine as claimed  claim 1 , wherein said winding rod inserter, said first winding member and said second winding member are arranged and controlled so that while said first reel is unloaded from the winding cradle, the second winding rod is brought to cooperate temporarily with only the first winding member, through which the winding of the web material around said new winding rod starts before said new winding rod starts to co-act with the second winding member, while said second winding member unloads said reel. 
     
     
         23 . A rewinding machine as claimed in  claim 1 , wherein said first winding member and said second winding member are controlled so as to decelerate said first reel at the end of winding of the first reel and before an introduction of the second winding rod. 
     
     
         24 . A rewinding machine as claimed in  claim 1 , wherein said winding rod inserter is associated with means for angular acceleration of the second winding rod to drive said second winding rod into rotation. 
     
     
         25 . A method for producing reels of web material around winding rods, the method comprising the steps of:
 winding a first reel of web material around a first winding rod in a winding cradle comprising a first winding member and a second winding member;   at an end of winding of said first reel of web material, unloading said first reel of web material from said winding cradle, inserting a second winding rod in said winding cradle, and winding a second reel of web material around said second winding rod, said first reel of web material being unloaded from said winding cradle through a change in an arrangement of the second winding member, while said second winding rod is driven into rotation by moving said second winding rod towards the first winding member;   arranging a first winding roller and a second winding roller to define a seat for supporting and rotating one of the first reel and the second reel during winding;   arranging a third winding roller and a fourth winding roller with movable axes;   winding said first reel in said support and rotation seat in contact with at least said first winding roller and said second winding roller;   continuing winding said first reel of web material between said first winding roller, said second winding roller, said third winding roller, and said fourth winding roller;   moving said first reel of web material away from said first winding roller and maintaining said first reel of web material in rotation by means of at least said second winding roller and said fourth winding roller and reducing the rotation speed of the reel from a winding speed to a replacement speed, said replacement speed being less than the winding speed;   bringing said second winding rod against said first winding roller and engaging the web material between said first winding roller and said second winding rod;   severing the web material between the second winding rod and the first reel;   starting winding said second reel around said second winding rod;   moving the first reel of web material away from the second winding roller;   bringing the second reel in contact with said second winding roller.   
     
     
         26 - 28 . (canceled) 
     
     
         29 . A method as claimed in  claim 25 , further comprising the step of:
 moving said first reel of web material away from said first winding roller maintaining said first reel of web material into rotation by means of said second winding roller, said third winding roller, and said fourth winding roller.   
     
     
         30 . A method as claimed in  claim 25 , wherein, while the first reel is moved away from the first winding roller, the third winding roller is moved away from the first reel and said first reel is transferred towards the unloading area through the fourth winding roller. 
     
     
         31 . A method as claimed in  claim 25 , further comprising the steps of:
 reducing the rotation speed of the first reel by slowing down the second winding roller, the third winding roller and the fourth winding roller;   moving the third winding roller and the fourth winding roller away from the first reel;   accelerating said third winding roller and said fourth winding roller to the winding speed and engaging said second winding rod and the second reel being formed there around with said third winding roller and said fourth winding roller.   
     
     
         32 . A method as claimed in  claim 25 , further comprising the steps of:
 forming a loop of web material between said first reel and said second winding rod by slowing down the rotation speed of said first reel; and   holding said loop of web material between said second winding rod and said first winding member and causing the severing of the web material between said first reel and said second winding rod.   
     
     
         33 . (canceled) 
     
     
         34 . A rewinding machine as claimed in  claim 2 , wherein said second winding member comprises a second winding roller, a third winding roller and a fourth winding roller. 
     
     
         35 . A rewinding machine as claimed in  claim 34 , wherein said first winding roller and said second winding roller define a rest and rotation nip for one of the first reel and the second reel in winding phase. 
     
     
         36 . A rewinding machine as claimed in  claim 34 , wherein an auxiliary winding roller is arranged between said first winding roller of the first winding member and said second winding roller of said second winding member. 
     
     
         37 . A method as claimed in  claim 29 , wherein, while the first reel is moved away from the first winding roller, the third winding roller is moved away from the first reel and said first reel is transferred towards the unloading area through the fourth winding roller.