AUTOMATIC MACHINE FOR CUTTING AND STACKING OF MULTIPLY
FOILS

FIELD OF THE INVENTION

The present invention relates to the fields of cutting and stacking machines. The present invention specifically relates to an automatic machine for cutting and stacking of multiply foils.

BACKGROUND OF THE INVENTION

Generally, multiply foils, particularly amorphous multiply foils, are used in various businesses and industries for different applications. While these foils are initially produced by forming elongated foils wound into rolls of relatively large diameter, it is necessary to cut these elongated rolled foils into desired lengths and stack the cited foils for various applications. Thus, it is needed to accumulate a predetermined number of cut foil sheets in alignment in a relatively neat stack for packaging and shipment.

Conventionally, several machines are utilized with cutting and stacking units for cutting and stacking of desired lengths of the multiply foils. The machines is consisting of a feeder, a shearing unit and a stacking unit, where the stacking unit is assembled with a belt conveyor, a collecting table, a stacking table and a stacking pallet. In one of the conventional cutting and stacking machines, the multiply foils are feuded to the cutting units, which automatically cut the foils into desired lengths. Then, these cited foils are manually collected and stacked in desired alignment. The manual operations in the existing cutting and stacking machines consists of collecting the material at the end of the conveyor table, holding the bunch of the material up to the required thickness and placing the material on the pallet. The next bunch of sheets is manually placed on the pallet with required gap and accordingly, the process can be repeated for cutting and stacking of further bunch of sheets.

With respect to the conventional approaches, since automatic operations takes place up to the shearing unit, the stacking operations like collecting of the cut foils, holding the cut foils, placing the foils on the pallet and maintaining gaps between the bunches of foils should be done manually, which requires more human interference in the stacking process and increases overall time and cost consumption. Moreover, it leads to human error while stacking the bunch of cut foils. In order to overcome the problems associated with the manual stacking operations, the machine should be automated up to the stacking operations. Therefore, it is desirable to provide an automatic machine for cutting and stacking of multiply foils, which is capable of overcoming the aforementioned drawbacks.

SUMMARY OF THE INVENTION

An object of the present invention is to provide an automatic machine for cutting and stacking of multiply foils, which facilitates automatic cutting and stacking of the multiply foils with less human interference.

Another object of the present invention is to provide an automatic machine for cutting and stacking of multiply foils, which is cost effective and minimizes overall time required for cutting and stacking operation.

According to one aspect, the present invention, which achieves the objectives, relates to an automatic machine for cutting and stacking of multiply foils, comprising at least one decoiler means adapted to be loaded with multiply foils and actuated by a Variable

Frequency Drive (VFD) to unwind desired piles of multiply foils. A feeding unit is connected with the decoiler means through at least one guide means. The feeding unit comprises a set of feed rollers that is placed in close proximity to the guide means for feeding desired length of multiply foils unwound from the decoiler means through the guide means. A shearing unit is associated with the feeding unit, and arranged with a set of cutters for shearing and conveying the desired length of multiply foils from the feed rollers. A stacking unit is associated with the shearing unit, and arranged with a set of axis motion paths, a stacking head and a set of guiding trays for stacking the cut length of multiply foils in the stacking head with the help of axis motion paths, once the cut length of multiply foils are rested on the stacking head. A control system is implemented with a programmable logic controller (PLC), which is interfaced to control the decoiler means, the feeding unit, the shearing unit and the stacking unit, such that the desired length of multiply foils is sheared and stacked with predefined groups. Such machine facilitates automatic cutting and stacking of the multiply foils with less human interference. Further, it is cost effective and minimizes overall time required for cutting and stacking operation.
Furthermore, the decoiler means, the guide means, the feeding unit, the shearing unit and the stacking unit are linearly aligned and synchronized with each other. The VFD drive is associated with a set of loop sensors that is programmed to sense continuous loop of the multiply foils during running of the automatic machine. The VFD drive is controlled by the PLC to operate the decoiler means at different speeds in accordance with feed back of the loop sensors in order to maintain the desired length of multiply foils and continuous loop always during running of the automatic machine. The guide means is assembled with an adjustable guiding path, such that width of the guiding path is adjusted in relation to width of the multiply foils.

In addition, the feed rollers are controlled and operated at different speeds by the PLC through a driving means, preferably for feeding of the desired length of multiply foils within 10 microns. The cutters of the shearing unit are driven by a pneumatic cylinder, which is controlled and governed by the PLC through a driving means. The axis motion paths of the stacking unit are formed of a frictionless oscillated surface and controlled by the PLC through a driving means, where the axis motion paths comprises at least one vertical motion path and at least one horizontal motion path. The stacking head is assembled with a sheet holding block for holding the stacked multiply foils by pressing against the stacking head. The sheet holding block is actuated and controlled by the PLC through a driving means.

Moreover, the set of guiding trays is positioned in line with the stacking head, so that the stacked multiply foils from the stacking head are guided through a frictionless surface of the guiding trays. The guiding trays are actuated and controlled by the PLC through a driving means. The driving means are selected from the group consisting of pneumatic drive, induction drive and servo drive. The multiply foils are selected from the group consisting of amorphous metal sheets, preferably 10-15 plies of amorphous metal sheets. The automatic machine is configured preferably for cutting length of maximum 2000 mm and 213 mm width of the multiply foils. The automatic machine is configured preferably for stacking of the cut multiply foils within 20 microns. The automatic machine is equipped with a SCADA (Supervisory Control and Data Acquisition) system for data entry.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be discussed in greater detail with reference to the accompanying Figures.

FIG. 1 illustrates a schematic diagram of an automatic machine for cutting and stacking of multiply foils, in accordance with an exemplary embodiment of the present invention;

FIG. 2 illustrates a block diagram of a control system associated with the automatic cutting and stacking machine, in accordance with an exemplary embodiment of the present invention;

FIG. 3 illustrates a detailed top view of the automatic cutting and stacking machine, in accordance with an exemplary embodiment of the present invention;

FIG. 4 illustrates a detailed view of a shearing unit of the automatic cutting and stacking machine, in accordance with an exemplary embodiment of the present invention;

FIG. 5 illustrates a detailed view of a guiding tray of the automatic cutting and stacking machine, in accordance with an exemplary embodiment of the present invention; and

FIG. 6 illustrates a detailed view of guide means of the automatic cutting and stacking machine, in accordance with an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a schematic diagram of an automatic machine for cutting and stacking of multiply foils is illustrated, in accordance with an exemplary embodiment of the present invention. The high speed automatic machine is particularly utilized for cutting and stacking of multiply foils (100), in particular amorphous metal foils or sheets.

The automatic machine consists of a drivable decoiler means (1), a set of loop sensors (7), a guide means (6), a feeding unit (2), a shearing unit (3), a stacking unit (5) and a programmable logic control system (200). The drivable decoiler means (1), the set of loop sensors (7), the guide means (6), the feeding unit (2), the shearing unit (3) and the stacking unit (5) are linearly aligned and synchronized with each other.

The decoiler means (1) can be loaded with multiply amorphous metal foil spool, where the decoiler means (1) is operated by an actuating means such as decoiler motor (1a), to unwind desired piles of amorphous foils (100), particularly 10-15 plies of amorphous foils, for cutting operation. Hereafter, the plies or bunch of amorphous foils are referred as multiply amorphous foils (100) only for the purpose of explanation. The cutting and stacking machine can be electrically operated at high speeds and controlled by the programmable logic control system (200). The control system (200) is implemented with a programmable logic controller (PLC) (10), which is associated with a variable frequency drive (VFD) (8) and a set of driving means (9) for controlling it to maintain the desired length of multiply amorphous foils (100), as clearly shown in FIG. 2, which illustrates a block diagram of the control system associated with the automatic cutting and stacking machine, in accordance with an exemplary embodiment of the present invention. The PLC (10) is interfaced to control the decoiler means (1), the feeding unit (2), the shearing unit (3) and the stacking unit (5), such that the desired length of multiply foils (100) is sheared and stacked with predefined groups.

The VFD drive (8) is connected to the decoiler motor (1a) of the decoiler means (1) for driving and operating the decoiler means (1) at different speeds, where the VFD drive (8) is controlled by the PLC (10). The operating speed of the decoiler means (1) can be programmed in the PLC (10) to maintain desired cutting length of the multiply amorphous foils (100) and to maintain continuous loop always during running in accordance with the feed back of the loop sensors (7) In particular, the VFD drive (8) is controlled by the PLC (10) to operate the decoiler means (1) at different speeds in accordance with feed back of the loop sensors (7) in order to maintain the desired length of multiply foils (100) and continuous loop always during running of the automatic machine. The VFD drive (8) is connected to the loop sensors (7) that are programmed to sense continuous loop of the multiply amorphous foils (100) during the running of the machine. The decoiler means (1) is connected with an adjustable guide means (6) having a guiding path (6a) and an adjusting part (6b). The adjustable guide means (6) receives and guides the multiply amorphous foils (100) from the decoiler means (1) to the feeding unit (2), which avoids any width wise deviation in the multiply amorphous foils (100).

The guide means (6) are placed before a pair of feed rollers (2c) of the feeding unit (2), so that the feed rollers (2c) conveys desired length of the multiply amorphous foils (100) from the guide means (6) to the shearing unit (3). The feeding unit (2) feeds the predefined lengths of multiply amorphous foils (100), which is inline with the decoiler means (1), the shearing unit (3) and the stacking unit (5).

Referring to FIG. 3, a detailed top view of the automatic cutting and stacking machine is illustrated, in accordance with an exemplary embodiment of the present invention. The high-speed feeding unit (2) is arranged with an actuating means (2a) such as feeding motor, a gear box (2b), feed rollers (2c) and a connecting rod (2d), in such a way that the feed rollers (2c) are electrically driven and operated by the feeding motor (2a) through the connecting rod (2d). The gear box (2b) is connected with the pair of feed rollers (2c) for actuating and operating the pair of feed rollers (2c) at different speeds. The feed rollers (2c) are placed in close proximity to the guide means (6) for feeding the desired length of multiply foils (100) unwound from the decoiler means (1) through the guide means (6). The feeding motor (2a) is controlled and governed by the PLC (10) through one of the driving means (9), which drives the feed rollers (2c) to supply the desired length of multiply amorphous foils (100) to the shearing unit (3), where feeding accuracy of the multiply amorphous foils (100) is 10 microns. The feeding unit (2) is associated with the shearing unit (3), so that the desired length of multiply amorphous foils (100) from the feed rollers (2c) can be sheared using cutters (33, 34) in the shearing unit (3).

Referring to FIG. 4, a detailed view of the shearing unit (3) of the automatic cutting and stacking machine is illustrated, in accordance with an exemplary embodiment of the present invention. The shearing unit (3) is supported using a supporting frame (32). The shearing unit (3) is assembled with a pneumatic shearing cylinder (31) and high-speed cutters (33, 34) that includes movable cutter (34) and fixed cutter (33). The movable cutter (34) is movably connected with the pneumatic shearing cylinder (31) whereas the fixed cutter (33) is firmly attached to a holding frame (35), which is secured to the supporting frame (32). The pneumatic shearing cylinder (31) is controlled and governed by the PLC (10), so that the movable cutter (34) is pneumatically operated with respect to the fixed cutter (33) for cutting the desired length of multiply amorphous foils (100), once the unwound predefined length of multiply amorphous foils (100) are fed to the cutters (33, 34) from the feed rollers (2c). The control system (200) is composed of PLC (programmable logic controller) (10) for controlling all the operational sequence, and calculates the incremental predefined lengths of multiply amorphous foils (100) as per the design requirements. Once the predefined length of multiply amorphous foils (100), i.e. 10-15 plies, is reached, the multiply amorphous foils (100) are cut using the pneumatic operated cutters (33, 34), where the cutters (33, 34) are formed of special steel of blades. The pneumatic shearing cylinder (31) of the shearing unit (3) is formed of a rod lock cylinder mounted horizontally to provide inch movement for setting of the cutters (33, 34) for better cutting and cutter life. The impact of pneumatic system can be minimized by gas springs. The shearing unit (3) is associated with the stacking unit (5), such that the cut amorphous foils (100) from the cutters (33, 34) are conveyed to the stacking unit (5).

The stacking unit (5) is arranged with a stacking receiver or head (4) fitted to the machine, two axis motion paths (5a), in particular one for vertical motion and another for horizontal motion, and sheet guiding trays (5b). The stacking head (4) is assembled with a sheet holding block (4a) and an actuating means (4b). The stacking head (4) is associated with the motion paths (5a) for receiving and stacking the cut multiply amorphous foils (100), once the cut amorphous foils (100) are rested on the stacking head (4). In particular, the cut lengths of multiply amorphous foils (100) are accurately stacked with predefined groups and sections in the stacking head (4) with the help of two motion paths (5a). Each motion path (5a) of the stacking unit (5) is arranged with a low friction pneumatically oscillated surface and is driven by appropriate actuating means (5c) and one of the driving means (9), which are controlled by the PLC (10). The movement of the stacking head (4) is actuated in such a way to provide the required number of predefined groups and sections of the multiply amorphous foils (100) with the help of control system (200). The sheet holding block (4a) is operated by the actuating means (4b) to hold the stacked multiply amorphous foils (100) by pressing against the stacking head (4), where the actuating means (4b) is connected with one of the driving means (9) controlled by the PLC (10).

Referring to FIG. 5, a detailed view of the guiding tray (5b) of the automatic cutting and stacking machine is illustrated, in accordance with an exemplary embodiment of the present invention. The stainless steel trays (5b) are placed after the shearing unit (3) for guiding the plies for better surface finish. The guiding trays (5b) are operated in line with the stacking head (4), so that the stacked multiply amorphous foils (100) from the stacking head (4) are guided through surface of the guiding trays (5b). The guiding trays (5b) are configured for repeatedly guiding the cut lengths of multiply amorphous foils (100) to the next station. The guiding trays (5b) is formed of low friction and low wear stainless steel surface, which enables easy passage for the multiply amorphous foils (100) to avoid any sticking or jamming. The guiding trays (5b) are operated and controlled by the PLC (10) through one of the driving means (9). The actuating means (1a, 2a, 4b, 5c) used in the cutting and stacking machine include but are not limited to induction motor and servo motor. Similarly, the driving means (9) used in the cutting and stacking machine include but are not limited to induction drive and servo drive. The machine is also equipped with a SCADA (Supervisory control and data acquisition) system, which is user friendly for data entry. Such automatic machine is designed for less human interference in the cutting and stacking process, and is suitable for cutting a length of maximum 2000 mm and 213 mm width of multiply amorphous foils, where the finishing accuracy of the stacked cut multiply amorphous foils is within 20 microns. The machine facilitates automatic high speed precise cutting and stacking of the multiply foils with less human intervention. Further, it is cost effective and minimizes overall time required for cutting and stacking operation.

Referring to FIG. 6, a detailed view of the guide means (6) of the automatic cutting and stacking machine is illustrated, in accordance with an exemplary embodiment of the present invention. The mechanical guide means (6) is placed before the feed roller (2c) of the feeding unit (2) for guiding the 10- 15 plies of amorphous foils (100) to the shearing unit (3), which avoids lateral displacement of the multiply amorphous foils (100). The guide means (6) is assembled with an adjusting part (6b) and a guiding path (6a), on which the multiply amorphous foils (100) are guided. The adjusting part (6b) is associated with the guiding path (6a) in such a way that width of the guiding path (6a) is adjusted in relation to width of the multiply amorphous foils (100). Such arrangement of the machine facilitates smooth operation to automatically group and stack the cut multiply foils using programmable logic controls, which avoids the need for high speed conveyor belt and collecting tables.

The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purpose of illustration only. It is evident to those skilled in the art that although the invention herein is described in terms of specific embodiments thereof, there exist numerous alternatives, modifications and variations of the invention. It is intended that all such modifications and alterations be included insofar as they come within the spirit and scope of the invention as claimed or the equivalents thereof. Hence all variations, modifications and alternatives that falls within the broad scope of the appended claims comes under the gamut of the invention.

WE CLAIM:

1. An automatic machine for cutting and stacking of multiply foils, comprising: at least one decoiler means adapted to be loaded with multiply foils and actuated by a Variable Frequency Drive (VFD) to unwind desired piles of multiply foils;

a feeding unit connected with said decoiler means through at least one guide means, said feeding unit comprises a plurality of feed rollers that is placed in close proximity to said guide means for feeding desired length of multiply foils unwound from said decoiler means through said guide means;

a shearing unit associated with said feeding unit and arranged with a plurality of cutters for shearing and conveying the desired length of multiply foils from said feed rollers;

a stacking unit associated with said shearing unit and arranged with a plurality of axis motion paths, a stacking head and a plurality of guiding trays for stacking the cut length of multiply foils in said stacking head with the help of axis motion paths, once the cut length of multiply foils are rested on said stacking head; and

a control system implemented with a programmable logic controller (PLC), which is interfaced to control said decoiler means, said feeding unit, said shearing unit and said stacking unit, such that the desired length of multiply foils is sheared and stacked with predefined groups.

2. The automatic machine as claimed in claim 1, wherein said decoiler means, said guide means, said feeding unit, said shearing unit and said stacking unit are linearly aligned and synchronized with each other.

3. The automatic machine as claimed in claim 1, wherein the VFD drive is associated with a plurality of loop sensors that is programmed to sense continuous loop of the multiply foils during running of the automatic machine.

4. The automatic machine as claimed in claim 1 or 3, wherein the VFD drive is controlled by said PLC to operate said decoiler means at different speeds in accordance with feed back of said loop sensors in order to maintain the desired length of multiply foils and continuous loop always during running of the automatic machine.

5. The automatic machine as claimed in claim 1, wherein said guide means is assembled with an adjustable guiding path, such that width of said guiding path is adjusted in relation to width of the multiply foils.

6. The automatic machine as claimed in claim 1, wherein said plurality of feed rollers of said feeding unit is controlled and operated at different speeds by said PLC through a driving means, preferably for feeding of the desired length of multiply foils within 10 microns.

7. The automatic machine as claimed in claim 1, wherein said plurality of cutters of said shearing unit is driven by a pneumatic cylinder, which is controlled and governed by said PLC through a driving means.

8. The automatic machine as claimed in claim 1, wherein said plurality of axis motion paths of said stacking unit is formed of a frictionless oscillated surface and controlled by said PLC through a driving means.

9. The automatic machine as claimed in claim 1 or 8, wherein said plurality of axis motion paths comprises at least one vertical motion path and at least one horizontal motion path.

10. The automatic machine as claimed in claim 1, wherein said stacking head is assembled with a sheet holding block for holding the stacked multiply foils by pressing against said stacking head.

11. The automatic machine as claimed in claim 10, wherein said sheet holding block is actuated and controlled by said PLC through a driving means.

12. The automatic machine as claimed in claim 1, wherein said plurality of guiding trays is positioned in line with said stacking head, so that the stacked multiply foils from said stacking head are guided through a frictionless surface of said guiding trays.

13. The automatic machine as claimed in claim 1, wherein said plurality of guiding trays is actuated and controlled by said PLC through a driving means.

14. The automatic machine as claimed in any preceding claims, wherein said driving means comprises pneumatic drive, induction drive and servo drive.

15. The automatic machine as claimed in claim 1, wherein the multiply foils comprise amorphous metal sheets, preferably 10-15 plies of amorphous metal sheets.

16. The automatic machine as claimed in claim 1, wherein the automatic machine is configured preferably for cutting length of maximum 2000 mm and 213 mm width of the multiply foils.

17. The automatic machine as claimed in claim 1, wherein the automatic machine is configured preferably for stacking of the cut multiply foils within 20 microns.

18. The automatic machine as claimed in claim 1, wherein the automatic machine is equipped with a SCADA (Supervisory Control and Data Acquisition) system for data entry.