IT202100020057A1 - INTEGRATED SYSTEM FOR PROCESSING AND PACKAGING POLYETHYLENE FILM EQUIPPED WITH REINFORCEMENT BANDS AND RELATED MANUFACTURING PROCEDURE - Google Patents

Description

TITLE: << INTEGRATED SYSTEM FOR PROCESSING AND PACKAGING POLYETHYLENE FILMS EQUIPPED WITH REINFORCEMENT BANDS AND RELATED MANUFACTURING PROCEDURE >>

The present invention relates to an integrated system for processing and packaging polyethylene films provided with reinforcing bands and the related manufacturing process.

Polyethylene films equipped with reinforcing bands or, from now on, simply called reinforced, are typically intended for the protection of agricultural crops from atmospheric agents, such as, for example: rain, hail and wind. They, how? known in the relative technique commonly used in the sector, must be equipped with reinforcing bands, usually made of polyethylene, of which at least one pair arranged along the outer side edges of the film (also called ?film?) and possibly a further band (or, sometimes, even more than one) placed internally in the center (if single or in intermediate positions if there are more bands than one and, in any case, all having dimensions in width of the band greater than those placed laterally). Along said lateral and intermediate reinforcing strips, pitched holes are made for various uses, among which, in particular, their connection to the structures for protecting agricultural crops.

The reinforced and perforated film is usually packaged for storage and transport in two different ways:

- wrapped in coils;

- or, folded into packs of various sizes, the latter on a specific order and corresponding to the cuts requested by the user.

The first machines born to carry out these processes were built around the middle of the of the ?nineties? of the last century, even if today they may appear to be a completely precarious and artisanal form compared to those currently existing.

The techniques of extrusion of the reinforcing bands, drilling, packaging and winding in reels are already? commonly known and widespread for a long time.

The prior art currently provides solutions which have the following limitations and drawbacks:

? Speed? average passage of the film through the system that does not exceed 20-25 meters per minute. Such speeds? they are limited by the operation of the folder and the drilling machines set according to design criteria incompatible with the need to increase speed;

? Maximum width of the film equal to 3.5 meters;

? Cooling of the reinforcing bands by immersion in tanks containing refrigerated water. This technique requires the need? to remove? Water through various systems (drip, scrapers, blowing air, etc..) by increasing the passages of the film and the complexity? of the system;

? The presence of? Water causes premature wear of the most? delicate (pneumatic valves, pneumatic cylinders, bearings, etc.) and premature oxidation of all metal components of the system; ? In the prior art, is it not? it is possible to stop, albeit temporarily, the drilling machines without stopping the extrusion of the reinforcing strips;

? There is no rolling machine suitable for rolling up films, previously folded by the folder, made with particularly thick lateral and central reinforcement bands which make the folds themselves very voluminous, with a very large and very variable bending radius. For this reason the rolling phase is carried out manually;

? There is no machine suitable for rolling up folded film with very variable shapes, shapes, dimensions and with any flaps that protrude from the main shape of the folded film;

? Not ? it is possible to vary the position of the reinforcing bands with respect to the edge of the film without stopping the extruders;

? Drilling devices are characterized by premature wear of the components (hinges, sliding components, etc.) and, furthermore, are not suitable for making holes with very high frequencies;

? The drilling devices are not suitable for making holes on films with very thick reinforcing bands (for example 0.8-1 mm) and with variable thickness;

? Bending machines can not follow speed? film passage greater than 20-25 meters per minute.

The company Applicant of the present patent application has proven experience in the industrial automation sector and, in particular, in the sector of design and construction of film processing systems intended for agricultural use. By way of example only, it should be noted that the company applicant for this patent, of which the engineer

? the sole director and technical manager, with the collaboration of the other two inventors

to date, it has even created four complete systems similar to this type of system, being able to do so? have the opportunity to experiment and perfect, over the years, a plurality? of technical expedients of the production method, always bringing new solutions and design settings in order to solve, with the conception of the present solution, the various production problems existing in the prior art.

To date, there are no automated systems and procedures for processing and packaging of polyethylene films similar to the present, as the present integrated system for processing and packaging of polyethylene films equipped with reinforcing bands, together with the related manufacturing process completely solves the problems and drawbacks currently present in known systems. In fact, the disadvantages of this plurality? of automated systems and procedures for the processing and packaging of polyethylene films are basically due to:

- film stretching problems during folding and reinforcement of the lateral, central and/or intermediate areas;

- problems related to excessive heating and/or cooling of the film and the reinforcing strips during processing;

- problems related to machine downtime;

- problems related to scraps;

- problems relating to the creation of a rolling machine suitable for rolling up film of any type, also rendered? particularly voluminous due to the presence of particularly thick lateral and central or intermediate reinforcement bands; - issues related to processing costs and quality? of the final product.

The object of the present invention is, therefore, to provide an innovative and inventive integrated system for processing and packaging polyethylene films provided with reinforcing bands and the relative manufacturing process.

Therefore, the present invention ? was conceived in order to:

? solving the problems existing in the prior art and relating to the stretching of the film during the folding and reinforcement of the lateral, central and/or intermediate zones;

? solve problems related to excessive heating and/or cooling of the film and the reinforcing strips during processing;

? minimize problems related to machine downtime; ? minimize problems related to scraps;

? minimize the problems related to processing costs and quality? of the final product;

? increase the speed? of passage of the film on the line and, consequently, the production volumes;

? provide, with the example given by way of example but not as a limitation, a valid system and the relative automated procedure to obtain a valid and innovative final product. These aims are achieved by realizing the present innovative and inventive integrated system for the processing and packaging of polyethylene films provided with reinforcing bands and the related manufacturing process.

These and other purposes with the consequent advantages, as well as? the characteristics of the invention according to the present invention will be more? clearly evident from the following detailed description of a preferred solution, given by way of non-limiting example with reference to the attached drawings, in which:

? Fig. 1 ? a two-dimensional view, in particular the side view of the integrated system S of the present invention, showing the longitudinal development of the assembly of machines, devices and equipment (unwinder area 1.1, extrusion and cooling area 1.2, unwinder area and side band aligners protection area 1.3, support stand area 1.4 for rolls of reinforcing film cord, accumulator and drilling unit area 1.5, folder area 1.6, inspection belt area 1.7, winder area 1.8, winder area 1.9) necessary for the processing and packaging of polyethylene films with lateral and central or intermediate reinforcing bands;

? Fig. 2 ? an axonometric view of the same system S for processing and packaging polyethylene films provided with reinforcing bands as in Fig.1;

? Fig. 3 ? a schematic isometric view of the folded film F with direction V entering said folder area 1.6;

? Fig.4 ? an axonometric view of the film F rolled up in a direction perpendicular to V, leaving said winder area 1.8;

? Fig. 5 ? a front view of the unwinder section 1.1;

? Fig. 6 ? an axonometric view of the unwinder section 1.1 of Fig.5, from which ? possible to better deduce its component parts, together with details P1, P2, P3 and P4 shown enlarged on its sides;

? Fig. 7 ? a front view of the extrusion and cooling section 1.2;

? Fig. 8 ? an axonometric view of the extrusion and cooling section 1.2 shown in Fig.7, from which ? it is possible to better deduce its component parts, together with details P5 and P6, both shown enlarged on its right side;

? Fig. 9 shows a small-scale isometric view of the representative portion of the extrusion and cooling section 1.2, of which on its right ? plane p1 with section axis A-A has been shown enlarged and detail P7 in the centre, enlarged;

? Fig. 10 ? an isometric view of the 1.2D extrusion roller, from which ? it is possible to deduce the areas where the concentrated cold air blows 1.2P are sent, suitable for optimizing the application phase of the reinforcing bands 1.2U, lateral 1.2U1 and central or intermediate 1.2U2, on the film F;

? Fig. 11 ? a front view of the accumulator 1.51 alone forming the accumulator and drilling unit 1.5, of whose second adjacent area of the drilling units 1.52 ? it is possible to deduce the driving roller 1.52H and the dancer roller 1.52I, together with all the other component elements;

? Fig. 12 ? an axonometric view of the accumulator 1.51 of which in Fig.11, from which ? Is it possible to better deduce its component parts, together with details P8 and P9, both shown enlarged on its left side of the figure, and the representation of the plane p2 with section axis C-C, whose graphical representation is ? shown inside the circumference represented with a dash and dot on the right side of the same figure, to better highlight the details, together with all the other component elements;

? Fig. 13 ? a representation of the view of section B-B of Fig.11, from which ? It is possible to deduce the two pairs of drilling heads 1.52A (of which only one is denoted, as well as being represented, from its opposite side, in the detail of detail P10), together with the three-dimensional view of the same drilling head 1.52A, shown in axonometry, from which ? possible to deduce the axis of rotation 1.52A1 of the lateral and central boring machines 1.52;

? Fig. 14 ? a representation of the axonometric view of the central drilling machines 1.52B and the related exploded detail, to better characterize its component elements;

? Fig. 15 ? a front view of the folder 1.6, from which its component elements and the relative dynamics can be deduced;

? Fig. 16 ? an axonometric view of the bending machine 1.6, together with the representation of the plane p3 with section axis D-D shown below, from which the component elements characterizing the same can be better deduced;

? Fig. 17 ? an axonometric view of the collection belt 1.6G and of the pneumatic jacks 1.6Z to assist in lifting the collection belt 1.6G;

? Fig. 18 ? a front view of the folded film collecting belt 1.6G with pantograph lifters 1.6P;

? Fig. 19 ? a view of a further preferred embodiment of the pressure means 1.6N of the folded film, now having a movement in the vertical direction by means of pneumatic cylinders 1.6S2, in addition to the possibility, in any case, of horizontal displacement of the pressure means 1.6Q, by means of the? aid of 1.6R moving trolleys and any pneumatic cylinders;

? Fig. 20 ? a view of a further preferred embodiment of the collected tape 1.6G of the folded film, from which ? is it possible to deduce the possibility? to get it out on two sides 1.6T1-1.6T2;

? Fig. 21 ? a front view of the rolling machine 1.8 from which ? possible to deduce its fundamental component elements and dynamically moving parts;

? Fig. 22 ? an axonometric view of the packaging machine 1.8 of Fig.21;

? Fig. 23 ? the view of section E-E of the winding machine shown in Fig.22, together with the enlarged graphic representation of details P12, P13 and P14;

? Fig. 24 ? a sectional view of the 1.8L adhesive tape dispenser;

? Fig. 25 ? a view of a further section of the rolling machine 1.8 from which ? possible to deduce further its fundamental component elements and other parts in dynamic movement;

? Fig. 26 schematically shows the flow diagram of the various phases F1-F7 of process P.

From the plurality of the attached figures, an art technician can? easily deduce the inventive idea, the latter inherent in the fact of having devised a valid and innovative integrated system S for the processing and packaging of polyethylene films F equipped with reinforcing bands, together with the industrial manufacturing process P outlined below in the related phases.

The inventive idea basically consists in having resolved said plurality? of problems of the prior art summarized again below, devising an industrial manufacturing process which allows to carry out the voltage and speed regulation at the same time? transit of the film on the production line, all done in a very simple and reliable way, also eliminating:

? the defects? of fold of the film F in the folding phase;

? the defects? of film F during the drilling and reinforcing bandaging phase;

? the undesired deformations of the film F especially in the drilling and reinforcing wrapping phase;

and also obtaining:

? the minimization and/or elimination of waste;

? the minimization of processing costs;

? the optimization of the quality? of processing of the film F produced.

The industrial process P starts on the unwinder area 1.1 where the reels of film F to be processed are loaded.

The unwound film F then passes over the extrusion and cooling zone 1.2, where first at least one pair of reinforcing strips are deposited on the edges (lateral reinforcing strips) of the film F and, possibly, a further reinforcing strip (central reinforcing strip ) or more? in the case of intermediate ranges.

The latter ? made centrally to the film and of greater width dimensions and, subsequently, the film is cooled by contacting it with a triad of water-cooled rollers.

The film then passes into the accumulator and drilling unit 1.5, respectively consisting of the accumulator section 1.51 and the drilling section 1.52. In the latter, lateral and central step-by-step drilling is carried out.

Subsequently the film F arrives on the folding machine 1.6 and then, through the inspection belt 1.7, on the rolling machine 1.8 from which it already exits packaged for delivery to the user.

Instead of packaging, the film F pu? be wound in the form of reels in the reel area 1.9, before being shipped to the customer.

The sequence of the various sections through which the system is articulated represents a first innovative aspect of the present S system. In particular, the accumulator and drilling unit 1.5, which sees the installation of the accumulator section 1.51 before the drilling section 1.52 , according to the forward direction V of the film F in production, thus offering? a double advantage:

? firstly, it allows the momentary stop of the drilling process, for example to make small adjustments on it, without stopping the extrusion operation of the reinforcing bands.

During the aforementioned momentary stop phase, the extruders can, in fact, continue to work, since? movie F is accumulated in section 1.51;

? on the other hand, the same accumulator 1.51, when ? in rest conditions, in the absence of film F accumulating on it, ? in any case equipped with a fair amount? in film length, made to ensure the cooling of the same, so that? the latter reaches a suitable temperature in the subsequent drilling section 1.52.

To realize the functioning of what has been said, ? the extrusion roller 1.2D must be of the motorized type, ie equipped with its own geared motor and not idle as usually occurs in known systems. This constitutes a further innovative element with respect to what is achieved in the common prior art in order to solve both the problem of folding and that of cooling the film.

The further innovative aspect linked to the articulation of the various sections concerns the positioning of the folder 1.6 immediately downstream of the drilling section 1.52.

The folding operation, as described pi? in detail below, consists in carrying out consecutive folds at 180? and subsequent compaction, by means of suitable 1.6N pressing means, of the film F, now including the reinforcing bands.

In a preferred solution, yes? preferred that the bands of reinforcement were not very cooled to be able to take advantage of the greater ductility? and softness that a temperature pi? high gives the bands themselves and consequently obtain folds as pi? compact as possible. Said optimization in the bending phase is obtained by installing the bending machine 1.6, as far as possible, in the most? upstream of the system S, that is to say how much more? close to the extrusion zone.

A further advantage linked to the installation of the 1.6 folder upstream of the S system? related to the reduction of the probability? of crease formation, probability? which increases with the increased distance of the path that the film F carries out before reaching the folding stage. Further subsequent sections and alternatives to the folding process such as, by way of example only, but not limiting, the winding operation on reels, are therefore provided in the final part of the system and have been indicated with the generic position 1.9.

The S system? consisting of a first section called unwinder 1.1, where the first phase F1 of unwinding the film from the reels takes place.

The 1.1 unwinder? consisting of two 1.1A trolleys sliding on 1.1B rails installed on the floor.

The trolleys lead to the relative extremities? two rotating supports 1.1C and are equipped with an expandable axis 1.1D on which the reel 1.1E of the film F to be processed is inserted.

The operation of inserting the 1.1E coils on the 1.1A trolleys takes place in conditions of absolute safety for the operator and is therefore performed without the need to to stop the complete line, but during its normal operation. This ? been obtained thanks to the segregation in a safe position of the towing roller 1.1F, placed at a height such that it cannot be reached normally by the operator who has the need? to enter the operating area of the machine identified with 1.1G.

The adhesion of the initial part of the film F, which is wound on a new reel 1.1E, to the final part of the film present on the reel in the run-out phase, takes place thanks to the tangential contact of these parts obtained by means of two rollers which are part of a device 1.1H referred to as a ?flying attack device?.

Said device ? composed of two idle rollers installed on two frames capable of performing a rotary movement around the axis 1.1H1, which movement determines the approach of the two rollers and the consequent contact and adhesion between said initial and final film edges thanks to to a suitable 1.1I double-sided tape, the latter to be spread beforehand on the initial part of the film of the new 1.1E reel.

A fundamental element of the S system, both for the functioning of the unwinder 1.1 and for the functioning of the whole system S, ? the 1.1L roller called ?entrance dancer roller? 1.1L.

The 1.1L dancer roller, in addition to the common use of regulating the film tension, thanks to the use of suitable pneumatic cylinders, also performs the role of piloting the operation of the film unwinding phase on the 1.1E reels, thanks to the use of a 1.1R incremental rotary transducer installed on the 1.1N synchronization axis. In general, all the roller dancers to which you will? reference in the continuation of the description of the present invention, perform the function of adaptation between the speeds? of sliding of the film on different sections of the system S object of the present invention, generating, according to the different cases, the acceleration, the slowing down or the total stop of the sections of the system S among which the dancer roller itself ? been installed, optimizing also? the folding and winding phases.

Said roller 1.1L, idle type, ? installed on a pair of 1.1M cursors capable of allowing the simultaneous rotation of the same 1.1L roller on its own axis, as well as its translation in the vertical direction.

By means of a synchronization device made with a synchronization roller 1.1N and a pair of closed loop transmissions of chain 1.1O, fixed on the cursors 1.1M and made synchronous by the same synchronization roller 1.1N, the movement of the dancer roller 1.1 is obtained L in vertical direction with axis permanently parallel to s? same. In reference to the film tension adjustment function, ? Is it possible to guarantee with extreme reliability? the constancy of the set operating pressure and therefore the force that the 1.1L dancing roller will exert? on the film being processed, by means of a pair of 1.1P pneumatic cylinders, on which compressed air inlets 1.1Q precision quick release valves have been installed, both in the direction of the increase in the weight of the 1.1L roller itself, and in the opposite direction , up to the complete cancellation of the weight itself, for the whole working stroke of the pneumatic cylinder and up to minimum pressure values equal to about 0.8 bar.

The transition between the different stages of the roller dancer can? also take place in a completely automatic form and allows both to facilitate the phase of attack on the fly between different edges (by lightening the roller), and the optimal adjustment of the film tension during processing (by increasing or reducing the weight of the roller).

With these precautions and modalities? ? was invented and developed a system S that allows you to simultaneously adjust the voltage and speed? unwinding of the film from the 1.1E reel, all done in a very simple and reliable way.

With reference to the speed control function, the vertical position of the infeed dancer roller is sensed via an incremental rotary transducer 1.1R and used to control the speed. rotation of the unwinding drive roller 1.1F, which in turn determines the speed? of rotation of the reels 1.1E during unwinding. Subsequently there is the transition from the first phase F1 of unwinding the film from the reels to the second phase of extrusion of the lateral and central or intermediate reinforcing bands F2.

In said subsequent extrusion and cooling zone 1.2, a triad of extruders 1.2A are typically installed, intended for the formation of as many bands of polyethylene, typically to be deposited on the two side edges and on the center of the film itself being processed.

In order to prevent inevitable movements of the film in a direction perpendicular to the direction of scrolling, albeit of an entity? millimetric, could compromise the correct alignment of the lateral reinforcing bands 1.2U1 with respect to the edge of the film being processed, ? the assembly of the extruders 1.2A on special carriages 1.2B has been arranged, as shown in Fig.7, which can be moved in the direction perpendicular to the direction of flow of the film by means of a worm screw device.

The continuous tracking of the edge of the film by the extruders ? carried out through a 1.2C ultrasonic type sensor which, which ? installed on a dedicated trolley, with electric movement 1.2H, which allows to adjust, according to production needs, the position of the ultrasonic type sensor 1.2C at different distances from the axis of the extrusion head 1.2I, effectively modifying the position of the reinforcing band with respect to the edge of the film being processed.

? It is possible to issue the movement commands of the 1.2C sensor both manually and automatically, via software, according to the type of film to be made.

Immediately before the extrusion phase of the reinforcing strips ? it is necessary to eliminate any creases on film F which could compromise the correct adhesion of the 1.2U bands to the film itself.

This problem is solved by using a 1.2T spreader roller.

During the extrusion operation of the reinforcing bands, the film F is supported by a roller coated in silicone material, called 1.2D extrusion roller, therefore resistant to high temperatures, equipped with a movement in the horizontal direction, by means of pneumatic cylinders, which is activated whenever the system S ? when stopped or when the operator needs to intervene in the extrusion area. This function allows you to obtain a double advantage. The first ? that of moving the 1.2D roller away from the extrusion heads, avoiding that residues of high-temperature extruded material can accumulate on the 1.2D extrusion roller, damaging its coating or deforming it, when the system ? in stopped condition.

The second advantage? that of moving the extrusion roller 1.2D away from the extrusion counter-rollers 1.2E, thus eliminating the risk of crushing the limbs by the operator when he has to intervene in the extrusion zone.

The exact and optimized allocation configuration of the rollers involved in the extrusion and cooling phases? the one indicated in Fig.9, where ? It is possible to find, in addition to the aforementioned 1.2D extrusion roller, the 1.2F roller, in aluminium, called support roller and a triad of 1.2G cooling rollers, all equipped with an optimized heat exchange. The configuration and arrangement shown in Fig.9 is the one corresponding to the condition of maximum contact surface of the film with the cooling rollers 1.2G necessary to achieve maximum heat absorption by the just extruded reinforcing strips in the transit time of the film through called 1.2G rolls. The support roller 1.2F serves to support the lateral edges of the film, which, due to the heat absorbed by the cooling of the reinforcing bands just deposited by the extruders, temporarily lose their rigidity. and are folded down under the weight of the reinforcing strips themselves. In the configuration of Fig.9 ? also including a 1.2L metal bar which has the function of collecting and discharging towards the ground the electric charges that accumulate due to electrostatic phenomena on the 1.2D extrusion roller.

Also part of the above configuration is a return roller 1.2S on load cells, through which anomalous operating conditions are continuously identified which could lead to excessive tensioning of the film F as it passes through the cooling rollers 1.2G. This ? obtained by installing the relative return roller on two rotating supports equipped with a load cell.

The most suitable and more likely to intercept any situations of excessive tension of the film F ? the one indicated in Fig.9.

The reciprocal arrangement of the cooling rollers 1.2G indicated in Fig.9, their number equal to three and the internal conformation with high heat exchange all together represent the necessary and sufficient conditions for obtaining adequate cooling of the lateral and central reinforcing bands having a thickness of up to a millimeter, with a speed? flow rate of the film F equal to thirty meters per minute and up to maximum ambient temperature values of thirty degrees centigrade.

The three extrusion counter-rollers 1.2E each serving each of the three reinforcing bands (two lateral and one central) are internally crossed by coolant and have the function of regulating the thickness and giving the reinforced bands a specific profile. The counter-rollers are equipped with a means of regulating their pressure on the reinforcing bands, the latter consisting of a 1.2M elastic spring assisted by the 1.2N handwheel.

Furthermore, the counter-rollers 1.2E are mounted on suitable carriages 1.2O which are in turn rigidly connected to the carriages 1.2B, from which they take motion. In this way ? it is possible to obtain the movement of the counter-rollers in a perfectly synchronous manner with the tracking movement of the edges of the film by the 1.2A extruders.

The integrated cooling system of the film F, as shown in Fig.10, is completed by suitable low temperature air blows located in the internal interface zones 1.2P, the latter located between the edge of the reinforcing bands 1.2U and the polyethylene film support. These 1.2P zones, about twenty millimeters wide, are affected by a large quantity? of heat deriving from the cooling of the bands themselves, which usually causes an early degradation of the characteristics of elasticity? and resistance of the polyethylene film, even causing it to break during use.

The adoption of air jets concentrated in said 1.2P zones allows for rapid cooling of the same, preserving the chemical-physical characteristics of the interface zones.

A further characterization of the present system, not at all verifiable in the prior art, is the new possibility? to easily access the extruders and cooling area 1.2, now made possible both from below and from above. Said easy accessibility? ? obtained by creating a support structure for the extruder carriages 1.2Q (Fig.7) at a height from the floor such as to allow personnel access below the extruders 1.2A easily, without bending the operator?s torso and head and related trolleys 1.2B. Access to extruder level 1.2A ? instead made using appropriate stairs and walkable gratings 1.2R.

The transition from the second phase F2 of extrusion and cooling of the lateral and central or intermediate reinforcing bands to the accumulation zone 1.51 determines the start of the third phase F3, known as accumulation.

The accumulator 1.51, as already? mentioned previously, its function is to temporarily collect the film F being processed coming from the upstream extrusion and cooling section 1.2 whenever there are stops in the sections of system S downstream of the same accumulator 1.51.

This allows you to avoid the shutdown of the 1.2A extruders and all the related negative consequences.

A body of significant importance for the purposes of correct mode? of accumulation? the light recovery roller 1.51A of Fig.11. This roller performs a dual function:

- the first ? that of quickly recovering small and instantaneous variations in the tensioning stress of the film F, which could generate jams during the passage of the film through the cooling rollers 1.2G;

- the second ? that of preventing any situations of excessive tensioning stress on the film F at the inlet of the accumulator 1.51.

This last function? obtained through the continuous control of the maximum vertical stroke of this light recovery roller 1.51A.

A preferred configuration of the accumulation device, consisting of a group of six movable accumulation rollers 1.51B and a group of seven fixed accumulation rollers 1.5B1 ? represented in Section C-C shown at the top right in Fig.12.

Said number of rollers of said preferred configuration represents an optimal operating condition of the system S, as it allows to simultaneously obtain the maximum quantity of film F in accumulation and the absence of conditions of excessive tension of the same film in the accumulation phase.

Said condition is also achieved by having applied a maximum stroke of the movable accumulation rollers equal to approximately four metres. ? in any case possible, by applying the same design approach, obtain greater quantities? of film F in accumulation by assembling a greater number of rollers and carrying out a stroke of the same greater than said four metres.

The mobile accumulation rollers 1.51B are installed on a special support trolley.

In the case of maintenance to be carried out on the accumulator 1.51 in the presence of the personnel in charge underneath said rollers 1.51B, to meet the frequent need to make sure that the race of the 1.51B rollers is always locked in a safe way, yes ? preferred to install, as shown in detail P8 of Fig.12, the parachute devices 1.51C, in a number equal to four, one for each vertex of the trolley.

Said devices 1.51C work with the aid of a pin which, in conditions of arrest of the accumulator group, according to the concept of positive action, are always introduced in suitable slots, formed in the fixed structure of the accumulator group 1.51, preventing the fall by gravity? of all the same accumulation group. When the accumulation group ? in activity, through the pneumatic force of a jack, the force of an elastic spring which keeps the pins in the appropriate housings is opposed and won. The pins are consequently all outside the slots and the accumulation group can? perform its function.

The functioning of the accumulator 1.51 ? regulated by a 1.51D accumulation dancer roller, as shown in Fig.11.

Said roller 1.51D has an identical configuration to that relating to the input dancer roller 1.1L and ? likewise equipped with a means of pneumatic regulation of the pressure through pneumatic cylinders 1.1P, together with the detection of the position through the incremental rotary transducer 1.1R.

To solve the problem of minimization and, in any case, maximum reduction of the mechanical stresses on all the rollers making up the accumulator 1.51, the dancer roller 1.51D is preferably installed downstream of the accumulator 1.51 according to the direction of advancement V of the film F through the is a set made up of the individual groups of the present system S.

The configuration of the accumulator 1.51 represented in Fig.11 ? It was conceived to facilitate the first insertion of the film F through the accumulator.

In said preferred configuration the walkway 1.51E allows access to the extruder area 1.2 and, on the opposite side, to the inlet of the accumulator 1.51, where the operator can? introduce the initial flap of first pass film.

The walkway 1.51F, on the other hand, allows access to the drilling area 1.52 and, on the opposite side, to the accumulator outlet 1.51, where the operator can? take the initial edge of the first pass film. These operations take place easily without the aid of stairs, ramps and other means which can constitute elements of danger during the start-up phase of the production cycle.

This ? a peculiar characteristic of the system S object of the present invention, up to now, not found at all in the prior art.

The transition from the third accumulation phase F3 1.51 determines the start of the fourth phase F4, which affects both the lateral and central or intermediate reinforcing bands, and the film in the areas immediately adjacent to them, for this reason known as drilling.

The lateral drilling heads 1.52A, as shown in Fig.13, are designed to make holes with a diameter of about eight millimeters in the area of the film covered by the lateral reinforcing bands, which can have highly variable hardness, surface conformation and thickness. The maximum workable thickness, however, is around one millimeter thick. Said characteristics of the 1.2U reinforcing strips require the use of a very robust 1.52A0 mobile unit of the 1.52A drilling head, characterized by a high capacity? of penetration in the reinforced bands but, at the same time, from a structural configuration such as to be able to make it go back quickly to the rest position, given the?high frequency of making the holes, minimizing also? the energy that the 1.52A0 mobile element itself transmits to the fixed part of the boring head, following impacts.

Said problem? been solved by realizing a mobile unit 1.52A0 made up of a combination of steel and aluminum details, represented in the attached figure 13, able to rotate around an axis as indicated with the direction of rotation 1.52A1, as well as? to return to its rest position (after having made the holes on the reinforcing bands of the film, moving in an upward vertical direction) under the action of gravity alone.

Another requirement for the correct functioning of the 1.52A side drilling head? the damping of the oscillations of the same, consequent to the impact that is created on the stop stop in the rest position. If these oscillations last too long, this has a negative effect on the drilling frequency. This problem ? This has been solved by adopting an anti-rebound gripper 1.52A2 which blocks the mobile unit 1.52A0 of the drilling head 1.52A, in the rest position, drastically reducing the oscillations. Said solution? been adopted also on the central drilling head 1.52B (Fig.14), on which ? the 1.52D anti-rebound caliper has been inserted.

The central drilling head 1.52B ? also equipped with a 1.52E reinforced hinge, a 1.52L rotating pin around its 1.52L1 rotation axis and 1.52M hardened side bushings with high wear resistance capable of considerably extending the operating life of the drilling head lateral 1.52B, compared to the systems found in the common technique.

Also in this case, the problem relating to the optimal return to the rest position of the mobile drilling head with 1.52N axis, ? been resolved by adopting the solution of being able to return to the rest position (after having made the drilling which can now take place both inside and outside the intermediate and central reinforcing bands of the film, which also move in a vertical direction upwards) under the action of the force of gravity alone.

The side drilling heads 1.52A (Fig.13) are equipped with a pneumatic suction device for the drilling marks 1.52F, which are collected in special containers 1.52G

Fundamental in the functioning of the drilling machines 1.51 ? the drive roller for the accumulator and drilling area 1.52H (Fig.12). Said roller supervises the towing of the film which develops between it and the extrusion roller 1.2D and must be installed immediately downstream of the drilling machines, respecting the advancement direction of the film F in system S, to solve the problem of obtaining optimal sliding of the film under the drilling stations.

The arrangement of the 1.52H roller just illustrated is another peculiarity? of the 1.51 drilling machines object of the present invention, since the film ? now more taut (compared to the prior art) and be subject to drilling in a much more? effective.

The completion of the fourth phase F4 relating to the drilling determines the start of the fifth phase F5A of folding of the film F reinforced with said bands.

As an alternative to said phase transition from F4 to F5A one can? opt for the transition from the same fourth phase F4 to the alternative phase F5B to the previous one or winding phase, which involves winding the film reinforced with bands on reels or reels, before the final packaging phase F7 for shipping the finished product.

The folding machine 1.6 (Figs. 15-16) carries out the folding operation of the film F in the form of a fold.

The characteristics that make the 1.6 folder object of the present invention innovative? the extreme robustness, the high reliability? and the high speed? execution of all operations.

This characterization? due to the fact that the speed? of the film to be folded at the entrance to the machine pu? get to about thirty meters per minute and since? a fold must be made approximately every one hundred and seventy centimeters of length, it can be deduced that the frequency of execution of the folds ? equal to about eighteen folds per minute. Considering that each bend corresponds to the reversal of the direction of travel of a 1.6I trolley weighing around five hundred kilograms? easy to deduce the? entity? of the problems of inertia and wear related to the operation of this machine, which in any case are solved by the present S system. In fact, the 1.6 bending machine? driven by the dancer roller 1.52I input bending machine, which ? of the same type as the other dancer rollers described above, but placed at the end of the drilling unit module 1.52.

The folder 1.6 ? constituted by a series of rollers in the sequence and configuration shown in figures 15 and 16, since said configuration ? necessary for proper operation. According to the running direction of the film, these rollers can be listed as follows: arrival roller 1.6A; return roller 1.6B; upper drive roller 1.6C; 1.6D bottom drive roller; upper counter roller 1.6E; lower counter-roller 1.6F. With the exception of the arrival roller 1.6A, all the other rollers are mounted on a carriage 1.6I capable of moving alternately in the two directions 1.6X (Fig.15).

During normal operation, the upper counter-roller 1.6E (Sect.D-D in Fig.16) and the lower counter-roller 1.6F are in contact, respectively, with the upper driving roller 1.6C and the lower driving roller 1.6D and the film F, synchronously driven between the upper driving rollers 1.6C and 1.6D, is deposited on a folded film collection belt 1.6G (Figs. 17 and 18) on which, by means of the alternating movement 1.6X (Fig.15) of said trolley 1.6I, is distributed in the form of folds with alternating folding directions.

When the desired film length is reached, a circular blade 1.6H (Sect.D-D in Fig.16) is moved, by means of a carriage 1.6L, in a direction perpendicular to the direction of advancement of the film. This linear movement, through a suitable rack and toothed wheel transmission, adds a rotation around its own axis to the circular blade 1.6H, thus enhancing its capacity? cutting.

The cut is carried out effectively and without jams thanks to the correct tensioning of the film obtained by the synchronism of rotation existing between the upper driving roller 1.6C and the lower driving roller 1.6D, as well as the by the pressure exerted on them, respectively, by the upper counter-roller 1.6E and by the lower counter-roller 1.6F.

At the end of the cutting operation, the counter roller 1.6E is moved away from the lower drive roller 1.6D. Therefore, the film flap can? fall freely on the 1.6G folded film pick-up belt. Through the driving action of the upper driving roller 1.6C and the upper counter-roller 1.6E, a further section of film is fed up to the lower driving roller 1.6D, with the lower counter-roller 1.6F it returns again to contact with the lower drive roller 1.6D re-establishing the correct tension of the film and the folding cycle can then resume.

The cutting action of the 1.6H circular blade is ? also obtained with the aid of a 1.6M counter-blade (Sect.D-D in Fig.16). The 1.6M counter blade? equipped with a rotary movement (around the axis indicated with 1.6Y) which moves it away from the film both immediately after cutting and during the descent of the following film, avoiding the accidental adhesion of the new stretch of film to the same 1.6M counter-blade.

Due to the electrostatic effect or the "suction effect", the latter originating from the very smooth nature of the surfaces in contact, there could be accidental adhesions of the film in transit through the folder, both on the upper drive roller 1.6C and on the drive roller lower 1.6D and both on the lower counter-roller 1.6F. This undesirable phenomenon usually causes the complete rolling of the film around one of these rollers.

This problem too? been resolved by adopting 1.6J anti-adhesion strips (Sect.D-D in Fig.16), made up of material characterized by high resistance to abrasion and traction.

The arrangement of said strips at a well-determined pitch on the triad consisting of said rollers (1.6C, 1.6D, 1.6F) avoids the problem of rolling up any portion or edge of the film in an innovative and inventive way.

The compaction of the various folds of the film F, with said folds made alternately, is obtained by suitable 1.6N pressers (Figures 15 and 19).

To obtain the best results in folding and compacting the folds, the pressers must be equipped with a very fast and combined movement in two directions (Fig.15): towards the inside 1.6U1 of the machine and downwards 1.6U2.

This innovative configuration ? obtained by adopting 1.6N pressure means configured as shown in Fig.15 and 19 and based on two 1.6V synchronous levers, with rotation centers placed at different heights (as indicated by the arrows 1.6V1 in Fig.15), which move in each pair a 1.6N1-1.6N2 platform, allowing its vertical and horizontal translation.

The movement of the pressure means? pneumatic type.

The 1.6G Folded Film Collecting Tape ? equipped with a movement in a vertical direction, obtained through a set of four 1.6O chain rings (Fig.16), entirely synchronized through a pair of transversal axes and a further longitudinal chain ring.

The vertical movement has the function of gradually lowering the collection belt 1.6G, to the extent that the thickness of the folded film increases, in order to keep the distance between the upper part of the folded film and the pressure means 1.6 constant during folding N of the folded film.

To improve the balancing conditions of the chain lifting means, 1.6Z auxiliary pneumatic cylinders have been adopted (Fig.17) equipped with a device for regulating the relative operating pressure, independently of the stroke of the same, also reducing the traction loads on the chains themselves and the torque of the lifting gear motor.

A possible alternative to the 1.6O chain link type lift? the lifting carried out using pantographs 1.6P (Fig.18), the latter driven by a worm screw type transmission. The main advantage of the 1.6O chain ring device? the higher speed? ascent to the initial position of the collection belt for the folded film 1.6G, which takes place at the end of the folding phase which translates into a reduction in the cycle time of the folding machine 1.6.

A possible alternative to the pressure means of the double lever type and combined movement 1.6N (Fig.19), ? represented by the simple movement pressure means identified with 1.6Q.

Said pressure means of the double lever type and combined movement 1.6N are actuated with a movement of the platforms 1.6N1-1.6N2, the latter achieved by means of said synchronous levers 1.6V.

The vertical movement 1.6S1 of these pressure means 1.6Q? equally of the pneumatic type, but ? simple and not of the type combined with other directional movements. From the careful reading of said figure 19, in fact, it is specified that the movement of the carriages 1.6R, along the direction 1.6S2, takes place only before the beginning of the film folding process in order to allow manual adjustment of the same, while the movement along the vertical direction 1.6S1 takes place during the usual bending process.

Said pressure means 1.6Q, while not presenting the same modality? movement of the previously described 1.6N combined movement pressers, however they offer the advantage of being able to be moved more? easily using a 1.6R trolley, as well as manually, also with the aid of further pneumatic cylinders, which can be suitably installed.

Finally, there is an additional operating option for the 1.6 folding machine. This option concerns the possibility? to obtain the exit of the folded film in a direction perpendicular to the largest dimension of the folded film itself 1.6T1 and in a parallel direction 1.6T2.

The solution devised to implement this option? represented in Fig. 20 and ? based on the creation of two different 1.6T conveyor belts, with independent motorisation, both capable of rotating around their own barycentric axis (as graphically represented in Fig.20) according to the rotation directions indicated with 1.6T4. Furthermore, in order to facilitate the rotation of the 1.6T belts, since it is necessary to free up space between the two 1.6T conveyor belts, at least one of them must be equipped with a further translation movement in the 1.6T3 direction, parallel to the transversal dimension of the system S It should be noted that the direction 1.6T2 corresponds to the direction of the folded film outgoing towards the subsequent winder 1.8, through the inspection belt 1.7; instead, the 1.6T1 direction corresponds to the further direction of the folded film outgoing towards other types of final packaging. The conveyor belts (1.6G, 1.7) must allow the passage of the product without damaging or causing jams.

? in fact, it is known that the polyethylene film folded in folds could have flaps that protrude with respect to the main shape of the same, usually getting stuck on any irregular surfaces, edges, and other elements that could get caught.

For that purpose? a conveyor belt was developed, as shown in Fig.17-20, totally free of edges and irregular surfaces. The gear motor? preferably installed in the lower part of the conveyor belt itself, in such a way as to be completely protected with the aid of additional casings.

The conformation of the fixing heads of the bearing supports and of its relative casings, especially the front ones, guarantees the total absence of film jamming points.

This configuration allows to obtain the optimal rotation of the rotary chute 1.7B (Fig.17) for passing the folded product from the folded film collection belt 1.6G to the inspection belt 1.7, with the total and desired absence of jams.

The rolling machine 1.8 (from Fig.21 to Fig.25) has the function of rolling up the film in the direction perpendicular to that achieved by the folding machine 1.6.

The complexity? of? the operation ? linked to the significant irregularity? and variability? of the shape of the folded product due to the very nature of the material, the presence of reinforcing cords and the variability? dimensions resulting from the different widths and lengths of the film.

The further inventive idea consists in having developed a very valid solution for rolling up the folded film, which requires strong stresses for its folding (passage from the folding phase F5A to the rolling phase on itself F6, before the final packaging phase F7 for the shipment of the finished product), as well as continuous pressure actions for its compaction in the rolling phase on itself.

The solution devised? in any case of simple application, of relatively not complex conception and, therefore:

? not subject to risk of jamming and breakage of the mechanical rolling devices and/or unwanted malfunctions; ? suitable for carrying out processing with incoming folded films of various types, both of a plastic nature and of dimensional characteristics, including the case of films with non-compliant folds, edges protruding from the main shape and other innumerable differences;

? realizing a minimized cycle time, with a real and possible increase in speed? and production volumes.

About this ? necessary to point out that, as already? mentioned for the folder, considering a speed? speed of thirty meters per minute and that the films to be rolled could have a length of about fifty to sixty meters, the required rolling rate normally reaches one film every two minutes. The complete cycle devised and better and further described hereinafter must therefore be completed within two minutes.

The 1.8 rolling machine also carries out, during the rolling phase, the coating of the folded film with an additional stretch film for the packaging coming from the 1.8M reel.

The innovative configuration, object of the present invention, which allows to brilliantly solve all the problems described above? the one indicated in said figures 21-25.

The rolling machine 1.8 ? essentially equipped with two pairs of fingers 1.8C mounted on two rotating heads 1.8E, through which said fingers 1.8C can not only rotate according to the direction indicated by 1.8E1 (Figures 21 and 22), but also they are equipped with an opening and closing movement 1.8E2 (Fig.21).

The mechanical systems described up to now are in turn mounted on two translation carriages 1.8D (Fig.21).

Once the? extremity? of folded film 1.8A ? entering the machine, thanks to the driving action of the inspection belt 1.7 and the infeed belt 1.8O, the two translation carriages 1.8D approach the film moving inwards.

Subsequently, the two fingers 1.8C approach each other, grasping the folded film and, at the same time, grasp the edge of stretch film 1.8M1 coming from the reel 1.8M, which is held still by the film blocking clamp 1.8H and released before the start of rolling (Fig.23).

Through the rotation of the rotating heads 1.8E (Figures 21 and 22), the film and the related stretch packaging are rolled up around the rotation axis 1.8E1, while the remaining part of the pack is tensioned by the pair of pressure rollers at the entrance 1.8B, which carry out a compaction of the film F during the rotation by the combined action of a pair of pneumatic cylinders placed on the ends? of the upper roller and braking devices installed on both rollers 1.8B.

Said combined operation between the fingers of the winder 1.8C and the pressure rollers at the infeed of the folded film 1.8B are a characterizing element of the present system S.

Upon reaching the pre-set number of rolling turns, usually higher than that corresponding to the length of the starting folded film, in such a way as to further compact the roll through additional winding turns of the 1.8M1 stretch film, the cutting command is given. 1.8M1 stretch film, using the relative 1.8I cutting blade (detail P14 of Fig.23).

Subsequently to the execution of the cut, the descent of the two dispensers for applying the adhesive tape is commanded in the direction 1.8L1 (detail P13 of Fig.23).

In addition to this last movement of descent and ascent, the 1.8L dispenser? equipped with a further rotation around the axis 1.8L2, through which ? possible to identify the condition of first contact of the application wheel of the 1.8L3 adhesive tape on the roll by the 1.8L dispenser; this rotation movement, in fact, is detected by the electric limit switch 1.8L4 (Fig.24).

The rotary movement around the 1.8L2 axis? necessary to allow the 1.8L3 wheel of the 1.8L dispenser to always remain in contact with the roll on which the adhesive tape is being deposited, despite any inevitable irregularities? of the same.

In addition to the components mentioned so far, the following are component elements of the 1.8L dispenser, whose configuration and arrangement? shown in figures 23 and 24:

? the support wheel 1.8L5;

? the 1.8L6 duct tape reel holder;

? the 1.8L7 protective screen;

? the 1.8L8 rotary arm, the latter equipped with a locking handwheel to facilitate the operations of changing the roll of adhesive tape; ? the 1.8L9 rotary cutting blade, which in turn has a rotary movement around the 1.8L11 axis, the latter obtained via the 1.8L10 pneumatic cylinder.

At the end of the adhesive tape application phase, a pair of 1.8N pack blocking devices (Fig.25), equipped with a rotation around the 1.8N1 axis, grip the rolled up film pack laterally. The winding fingers 1.8C can at this point be axially extracted in a completely easy way from the film so? folded and rolled up (hereinafter also called pack), through the outward movement of the carriages 1.8D (Fig.1.22), since the pack is? held still by the two locking devices 1.8N Fig.1.25). Bringing the blocks 1.8N to the rest position, rotating the infeed belt 1.8O downwards on the rotation axis 1.8O1 and moving the outfeed roller conveyor 1.8P outwards, according to the direction 1.8P1, we obtain the package falling on the discharge roller conveyor 1.8Q.

The cycle can resume with a new phase of transport of the stretch film, which remained gripped after the relative cut by the gripper 1.8G (Fig.23 and related details), towards the stretch film blocking gripper 1.8H, through the rotary movement of the pendulum 1.8F on the axis of rotation 1.8F1.

The automated procedure P of this system S, in summary, is therefore divided into the following procedural phases:

? First phase F1: unwinding phase of the film from the reels;

? Second phase F2: extrusion and cooling phase of the lateral and central reinforcement strips;

? Third phase F3: possible and temporary accumulation phase of the film (for example during the stopping phases of the folding machine); ? Fourth phase F4: lateral and central or intermediate perforation phase of the film;

? Fifth phase F5A: film folding phase;

? Alternative fifth phase F5B: phase of winding onto reels or reels of the film provided with reinforcing bands, but not folded, according to Z1 of Fig. 26;

? Sixth phase F6: rolling phase of the film folded on itself; ? Seventh phase F7: packaging phase before shipping (consequently, the folded and rolled films arrive at this phase F7 from the rewinder 1.8, the films wound on reels coming from the winder 1.9, through path Z1, and finally, through path Z2 , the films folded by the folding machine 1.6, unloaded from it in the direction 1.6T1, but having too long lengths to be rolled up on themselves in the rolling machine 1.8).

The advantages of this new integrated system S and of the relative process P are innumerable, in particular ? now possible: ? Get speed? average passage of the film through the system exceeding thirty meters per minute;

? Being able to process films wider than 3.5 meters;

? Overcome the obsolete technique of cooling the reinforcement strips by immersion in tanks containing chilled water with concentrated jets of cold air and cooling by direct contact on metal rollers;

? Ensure greater strength and durability of the elements making up the system;

? Making it possible to temporarily stop the drilling machines without stopping the extrusion of the reinforcing strips;

? Carry out holes without any problem on lateral and central or intermediate reinforcement strips of any nature and thickness;

? To create a rolling machine suitable for rolling up any type of film, also rendered particularly voluminous due to the presence of particularly thick lateral and central or intermediate reinforcement bands;

? Build a rolling machine suitable for rolling up folded films with highly variable shapes, sizes and with any flaps that protrude from the main shape of the folded film;

? Making it possible to change the position of the reinforcing bands with respect to the edge of the film, without stopping the extruders at all;

? Make the drilling devices durable, despite the fact that they are forced to make holes with very high frequencies, well above one hundred holes per minute;

? Make the drilling devices suitable for making holes on films with very thick reinforcing bands (0.8-1 metre) and with variable thickness;

? Make the bending machines able to work with speed? passage of the film exceeding twenty-five meters per minute, up to well over thirty meters per minute.

The present system and the relative method therefore have the advantage of perfecting and optimizing all the traditional and known processes applied up to now in the sector.

Another undoubted advantage of the present invention ? that of having further minimized the manufacturing costs of current systems for processing and packaging polyethylene films equipped with reinforcing bands. ? it is also evident that numerous adjustments, adaptations, additions, variations and replacements of elements with other functionally equivalent ones could be made to the embodiments previously described for illustrative but not limiting purposes only, without departing from the scope of protection of the following claims.

LEGEND

1.1 Unwinder(s) or unwinder area or unwinder machine 1.1A Sliding carriage

1.1B Rails

1.1C Rotating media

1.1D Expandable axis

1.1E Coil

1.1F Driving roller

1.1G Operating area of the unwinder

1.1H Flying attack device

1.1H1 Axis of flying attack device rotation

1.1I Double-sided tape joining the edges

1.1L Entry Dancer Roller

1.1M Cursor

1.1N Timing roller

1.1O Chain Drives

1.1P Pneumatic cylinders or jacks

1.1Q Precision Dump Valves

1.1R Incremental rotary encoder

1.2 Extrusion and Cooling Zone

1.2A Extruders for reinforcing bands

1.2B Extruder trolley

1.2C Ultrasonic sensor

1.2D Extrusion Roller

1.2E Extrusion counter-roller

1.2F Support roller

1.2G Chill Roller

1.2H Ultrasonic sensor displacement trolley

1.2I Extrusion head

1.2L Metal bar for collecting electrostatic charges 1.2M Spring

1.2N Flyer

1.2O Trolley for extrusion counter-roller

1.2P Film surfaces where concentrated jets of cold air or jets of cold air are blown

1.2Q Extruder support structure

1.2R Walkable grilles and access stairs

1.2S Return roller on load cell

1.2T Spreader Roller

1.2U Reinforcement bands

1.2U1 Lateral reinforcement bands

1.2U2 Central reinforcement bands

1.3 Unwinders and aligners of the side protection strips 1.4 Support stand for rolls of film reinforcing cord

1.5 Accumulator and drilling group

1.51 Accumulator for film in progress

1.51A Light recovery roller

1.51B Mobile accumulation roller

1.51B1 Fixed accumulation roller

1.51C Parachute device

1.51D Dancer roller for accumulation

1.51E Access walkway to the extruder area 1.2 and accumulator 1.51

1.51F Access walkway to accumulator area and drilling machines 1.52 Lateral and central drilling machines

1.52A Side drilling head

1.52A0 Mobile unit of the drilling head

1.52A1 Direction of rotation of the drilling head axis 1.52A 1.52A2 Anti-rebound pliers for lateral drilling head

1.52B Central drilling head

1.52D Anti-Kickback Pliers for Center Drilling Head

1.52E Reinforced hinge for central drilling machines

1.52F Suction medium for side drilling impressions

1.52G Side drilling impression collection container 1.52H Drive roller for accumulator and drilling machines

1.52I Bending infeed dancer roller

1.52L Center Drill Head Pin

1.52L1 Pivot axis 1.52L

1.52M Side Bushings

1.52N Axis of the mobile drilling head of the central boring machine 1.52 1.6 Folder area or bending machine

1.6A Arrival roller

1.6B Return roller

1.6C Upper drive roller

1.6D Lower driving roller

1.6E Upper counter-roller

1.6F Lower counter-roller

1.6G Folded film collection belt

1.6H Circular blade

1.6I Folding trolley

1.6J Anti-adhesion strips

1.6L Circular blade carriage

1.6M Counter-knife

1.6N Folded film presser means with combined movement 1.6N1 First presser platform with combined movement

1.6N2 Second presser platform with combined movement

1.6O Chain rings

1.6P Scissor lifts

1.6Q Folded film presser with simple movement

1.6Q1 First single action pad 1.6Q2 Second single action pad

1.6R Trolley for simple movement of pressers 1.6S1 Movement in the vertical direction of the presser means 1.6Q 1.6S2 Movement in the horizontal direction of the presser means 1.6Q 1.6T Rotating folded film collection belt

1.6T1 Outfeed direction of the film after the folding process, in the longitudinal direction of the system S

1.6T2 Outfeed direction of the film after the folding process, in the transversal direction of the S system

1.6T3 Translation direction of the 1.6T tape in the direction transversal to the system S

1.6T4 Directions of rotation of the 1.6T belt around its barycentric axis

1.6U1 Movement in the horizontal direction of the pressure means 1.6N 1.6U2 Movement in the vertical direction of the pressure means 1.6N 1.6V Synchronous levers

1.6V1 Synchronous lever rotation axis

1.6X Alternate direction of movement of the folding carriage 1.6Y Indication of the rotational movement of the counter-blade 1.6M 1.6Z Pneumatic cylinders for lifting assistance

1.7 Inspection belt area

1.7A Conveyor belt head

1.7B Rotating chute for passing the folded film

1.8 Rolling machine area or rolling machine

1.8A Folded film for rolling

1.8B Input pinch rollers

1.8C Winding fingers

1.8D Finger translation carriage

1.8D1 Finger translation direction

1.8E Finger rotation head

1.8E1 Finger rotation direction

1.8E2 Finger opening-closing direction

1.8F Pendulum

1.8F1 Pendulum rotation axis

1.8G Stretch film gripper

1.8H Stretch film clamp

1.8I Stretch film cutting blade

1.8L ?Dispenser? application of masking tape

1.8L1 Descent direction ?dispenser?

1.8L2 Rotation axis ?dispenser?

1.8L3 Tape application wheel

1.8L4 Electric limit switch

1.8L5 Support wheel

1.8L6 Adhesive tape reel holder

1.8L7 Protective screen

1.8L8 Rotary arm

1.8L9 Adhesive tape cutting blade

1.8L10 Pneumatic cutting cylinder

1.8L11 Cutting blade rotation axis

1.8M Roll of stretch film

1.8N Pack locking device

1.8N1 Rotation axis locking device

1.8O Infeed Conveyor

1.8 O1 Conveyor belt rotation axis

1.8P Outfeed Roller Conveyor

1.8P1 Outfeed Roller Conveyor Movement Direction 1.8Q Outfeed Roller Conveyor

1.9 Winding area or additional operations on the produced film F

F Film or film

F1 First phase of the procedure or phase of unwinding the film from the reels;

F2 Second phase of the process or phase of extrusion and cooling of the lateral and central or intermediate reinforcing strips;

F3 Third phase of the procedure or possible and temporary accumulation phase of the film (for example during the stopping phases of the folding machine);

F4 Fourth phase of the process or lateral and central or intermediate perforation phase of the film;

F5A Fifth stage of the process or film folding stage;

F5B Fifth stage alternative to the previous one or winding stage (winding the film reinforced with bands onto spools or reels) F6 Sixth stage of winding the folded film on itself alternately

F7 Seventh stage of the process or packaging stage before shipment.

P Industrial manufacturing process

P1 Detail of the 1.1R incremental rotary transducer

P2 Detail of 1.1P air cylinders and 1.1Q precision quick exhaust valves

P3 Detail of the cursor 1.1M and of the chain transmissions 1.1O P4 Detail of the double-sided tape 1.1I for joining the edges P5 Detail of the return roller on the load cell 1.2S

P6 Detail of the 1.2C ultrasonic sensor displacement carriage 1.2H

P7 Detail of the extrusion and cooling area

P8 Detail of the parachute device

P9 Detail of the light recovery roller

P10 Detail of the suction means where ? it is possible to deduce the lateral drilling imprints 1.52F and of the relative container 1.52G

P11 Detail of the head 1.7A of the inspection conveyor belt P12 Detail of the locking gripper 1.8H of the packaging machine 1.8 P13 Detail of the ?dispenser? of application of adhesive tape P14 Detail of the pendulum 1.8F, the gripper 1.8G and the cutting blade 1.8I

S System according to the present invention

V Film translation direction F

Z1 Alternative path after drilling to spooling

Z2 Alternative path of the folded film towards the final packaging without rolling on itself

Claims (36)

1) Integrated system (S) for processing and packaging polyethylene films equipped with reinforcing bands, said system (S) comprising a set of machines, devices and equipment installed in sequence in an unwinder area (1.1), a extrusion and cooling (1.2), an area for the unwinders and aligners (1.3) of the lateral protection band, an area for support stands (1.4) for rolls of film reinforcement cord (F), an area for the accumulator and drilling unit (1.5), a folding area (1.6), an inspection belt area (1.7), a winding area (1.8), a winding area (1.9), all necessary for the processing and packaging of polyethylene films equipped with reinforcing bands, called system (S) characterized by the fact that it provides for the installation of at least one accumulator (1.51) before the drilling machines (1.52), thus allowing unexpected stops of drilling operations for checks, adjustments and adjustments, without the need? to stop the extrusion operation of the reinforcing bands, also obtaining the possibility? to increase the cooling times of the film before drilling. 2) Integrated system (S), according to the preceding claim, characterized in that the installation of the folder area (1.6) is ? expected in the position pi? possible upstream of the same system (S), i.e. immediately after the drilling area (1.52), thus allowing? to make the most of the characteristics of greater plastic deformation and greater ductility? of the reinforcing bands, to obtain more compact folds and, therefore, a folded film of smaller dimensions? contained in output from said folding machine (1.6), also minimizing? the probability? of formation of folds on the film, in how much? minimized the space covered by the film before the folding phase carried out by the folder (1.6). 3) Integrated system (S), according to all the preceding claims, characterized in that ? equipped with a roller dancer (1.1L) supported at its ends? by a pair of cursors (1.1M), which give the same the possibility? to rotate around its own axis and translate in a vertical direction, keeping the parallelism of the axis of rotation constant in all its vertical positions, all by means of a mechanism based on a synchronization roller (1.1N) and a pair of transmissions with chain rings (1.1A) bound to the sliders (1.1M) and set in motion through gears inserted at the ends? of the sync roller (1.1N); said roller dancer (1.1L) also? equipped at the ends? of a pair of pneumatic cylinders (1.1P) in turn equipped, at the points of entry of the compressed air, with rapid discharges capable of guaranteeing with extreme precision the constancy of the desired value of the operating pressure of the cylinders themselves and, therefore, of the force that the dancer roller (1.1L) exerts on the film during processing, for all said positions in the vertical direction of the dancer roller itself and up to a minimum pressure value of about eight tenths of a bar. 4) Integrated system (S), according to all the preceding claims, characterized in that said dancer roller (1.1L) ? otherwise? equipped with an incremental rotary transducer (1.1R), installed on its synchronization roller (1.1N), through which ? Is it possible to detect the vertical position of the same dancer roller (1.1L) and control the speed? rotation of the drive roller (1.1.F), as well as?, consequently, the speed? of unwinding of the reels (1.1E) of the incoming film. 5) Integrated system (S), according to all the preceding claims, characterized in that ? endowed with a plurality of carriages (1.2B, 1.2H) on which the extruders (1.2A) are installed, which become so? movable in the perpendicular direction with respect to the direction of flow of the film, by means of a worm screw, as well as? suitable for carrying out the continuous tracking of the edge of the film, by means of an ultrasound-type sensor (1.2C), which, in turn mounted on an additional carriage dedicated to it (1.2H) and with electric movement, allows you to adjust according production requirements the position of said sensor (1.2C) at various distances from the axis of the extrusion head (1.2I), effectively changing the position of the reinforcing band with respect to the edge of the film being processed. 6) Integrated system (S), according to all the preceding claims, characterized in that ? equipped with an extrusion roller (1.2D) in silicone material, resistant to high temperatures, which acts as a support for the polyethylene film (F), as well as? able to move horizontally by means of pneumatic cylinders, every time the plant? in a safe stop condition or whenever the operator needs to access the extrusion area. 7) Integrated system (S), according to all the preceding claims, characterized in that ? equipped with a motorized extrusion roller (1.2D) and, therefore, not crazy, so? allowing the continuation of normal operation of the extruders in all cases in which the downstream plant is temporarily stopped. 8) Integrated system (S), according to all the preceding claims, characterized in that ? equipped with a configuration and arrangement of said extrusion roller (1.2D), of the extrusion counter-rollers (1.2E), of the support roller (1.2F) and of the triad of cooling rollers (1.2G, as represented in Fig .9), this configuration being the condition of maximum contact between the cooling rollers (1.2G) and the reinforcing bands on the film (F) being processed. 9) Integrated system (S), according to all the preceding claims, characterized in that ? equipped with a support roller (1.2F) suitable for supporting the lateral reinforcement bands (1.2U1) of the film (F), thus making up for the to their loss of rigidity? and preventing the undesired deformation due to bending due to the heating suffered following the extrusion phase (F2). 10) Integrated system (S), according to all the preceding claims, characterized in that ? equipped with means suitable for creating intense blows of low temperature air located in the interface zones (1.2P) between the edges of the reinforcing bands (1.2U1, 1.2U2) and the support polyethylene film (F), these zones being (1.2P) around the central or intermediate band (1.2U2), usually about twenty millimeters wide, affected by a large quantity? of heat deriving from the cooling of the bands themselves, cooling them quickly and preserving their chemical-physical characteristics. 11) Integrated system (S), according to all the preceding claims, characterized in that ? equipped with an? accessibility? greatly facilitated access to the extrusion and cooling area (1.2), both from below and from above, as a support structure for the extruder carriages (1.2Q) is provided at a height from the normal walking surface, in such a way as to easily allow, i.e. without bending of the operator?s back and head, the access of the personnel under the extruders (1.2A), under the relative carriages (1.2B), as well as to the area of the cooling rolls (1.2 G), as well as guaranteeing access from above to the level of the extruders (1.2A), to the extrusion roller (1.2D) and to the adjacent rollers via suitable ladders and treadable gratings (1.2R). 12) Integrated system (S), according to all the preceding claims, characterized in that ? equipped with a light recovery roller (1.51A, as shown in Fig.11) performing a dual function, i.e., a first in quickly recovering the small and instantaneous variations in film tension (F) generating possible jamming situations, especially between the cooling rollers (1.2G), as well as? a second one in intercepting situations of excessive tension of the film at the entrance of the accumulator (1.51), through a continuous control of the maximum vertical stroke of said light recovery roller (1.51A). 13) Integrated system (S), according to all the preceding claims, characterized in that ? equipped with a further accumulation dancer roller (1.51D), installed downstream of the accumulator (1.51) according to the direction of advancement (V) of the film (F) through the system and having an identical configuration to that of said dancer roller input (1.1L), therefore equipped with a means of pneumatic pressure regulation via pneumatic cylinders (1.1P) and position relief via incremental encoder (1.1R), act as follows? to minimize the mechanical stresses on all the rollers making up the accumulator (1.51). 14) Integrated system (S), according to all the preceding claims, characterized in that ? endowed with a plurality of drilling heads (1.52A) whose mobile unit (1.52A0) ? consists of a combination of steel and aluminum elements, able to rotate around an axis (1.52A1, as illustrated in Fig.13), thus allowing? to minimize the energy that the mobile unit of the drilling head (1.52A0) transfers to the fixed part of the head (1.52A), consequently reducing the wear of the component elements themselves. 15) Integrated system (S), according to all the preceding claims, characterized in that said lateral and central drilling heads (1.52A, 1.52B) are respectively equipped with an anti-rebound gripper (1.52C, 1.52D), this ?Last able to block its own mobile unit (1.52A0) for the lateral drilling head (1.52A) and for the central drilling head (1.52B) its axis (1.52N) on the relative rest positions, thus reducing drastically the oscillations and allowing the command of the same drilling head at working frequencies higher than the usual ones. 16) Integrated system (S), according to all the preceding claims, characterized in that said lateral and central drilling heads (1.52A, 1.52B) perform a drilling operation on the film (F) running in a vertical direction from the bottom towards the it is high, returning to its rest position quickly and reliably due to the force of gravity. 17) Integrated system (S), according to all the preceding claims, characterized in that said central drilling heads (1.52B) are equipped with a reinforced hinge (1.52E), since it is equipped with contact members with high resistance to wear, such as the axis of rotation (1.52L) and the bushings (1.52M), with said hinge (1.52E) so? capable of significantly extending the operating life of the central drilling head (1.52B). 18) Integrated system (S), according to all the preceding claims, characterized by the fact that said lateral drilling heads (1.52A) are equipped with a pneumatic suction system for the drilling impressions (1.52F), with the latter collected in special containers (1.52G). 19) Integrated system (S), according to all the preceding claims, characterized in that ? equipped with a drive roller (1.52H) for accumulator and drilling machines installed immediately downstream of the drilling machines (1.52), according to the direction of advancement (V) of the film (F), said roller (1.52H) so? designed to supervise the towing of the film that develops between it and the previous extrusion roller (1.2D), thus obtaining? optimal flow conditions of the film under the drilling stations. 20) Integrated system (S), according to all the preceding claims, characterized in that said folding machine (1.6) ? equipped with the following rollers: arrival roller (1.6A), return roller (1.6B), upper driving roller (1.6C), lower driving roller (1.6D), upper counter-roller (1.6E), counter- lower roller (1.6F), with all said rollers with the exception of the arrival roller (1.6A), installed on a folding carriage (1.6I) capable of moving alternatively along the movement direction (1.6X). 21) Integrated system (S), according to all the preceding claims, characterized in that said folder (1.6) has, during normal operation, the upper counter-roller (1.6F) and the lower counter-roller (1.6G) contact respectively with the upper drive roller (1.6C) and the lower drive roller (1.6D), realizing a drive of the folded film (F) in a synchronous manner between the upper (1.6C) and lower drive rollers (1.6D ), positioning said film (F) on the collection belt (1.6G) in the form of folds and with alternating folding directions, through the alternate movement of said folding carriage (1.6I). 22) Integrated system (S), according to all the preceding claims, characterized in that said folding machine (1.6) ? otherwise? equipped with a circular blade (1.6H), moved in a direction perpendicular to the advancement direction of the film (F) by a carriage (1.6L), with said linear movement which, by means of a rack and toothed wheel transmission, performs a rotation of said blade (1.6H) around its axis, enhancing its ability? cutting. 23) Integrated system (S), according to all the preceding claims, characterized by the fact that said folder (1.6) allows the correct tensioning of the film with an effective cut and without jams during the production process, said tensioning obtained through a perfect rotation synchronism for the presence of a means of synchronization, such as for example a chain, existing between the upper towing roller (1.6C) and the lower towing roller (1.6D), as well as? of a pressure exerted on said rollers (1.6C, 1.6D), respectively, by the upper counter-roller (1.6E) and by the lower counter-roller (1.6F), until the end of the cutting operation, when the counter- lower roller (1.6F) is moved away from the lower drive roller (1.6D), making the folded edge of film (F) fall freely onto the collection belt (1.6G), after which, through the driving action of the upper drive (1.6C), a further stretch of film is fed up to the lower drive roller (1.6D), with the new restart of the production cycle. 24) Integrated system (S), according to all the preceding claims, characterized in that a counter-blade (1.6M) ? placed in aid of said circular blade (1.6H) with a rotary movement (1.6Y), the latter suitable for moving said counter-blade (1.6M) away from the film (F) after its cutting. 25) Integrated system (S), according to all the preceding claims, characterized in that said folder (1.6) compacts film folds alternately by at least one pair of pressure means (1.6N), having a very fast movement and combined in two directions, namely towards the inside (1.6U1) of the machine and downwards (1.6U2), with said combined movement ensured by the particular configuration of the pressure means with pneumatic movement (1.6N in Fig.19) and by the presence of a pair of levers (1.6V) with rotation centers (1.6V1) placed at different heights. 26) Integrated system (S), according to all the preceding claims from the first to the twenty-fourth, characterized in that said folder (1.6) compacts film folds alternately by means of at least one pair of pressure means of the simple movement type ( 1.6Q), translatable, via a trolley system (1.6R), manually or automatically, in the latter case with the aid of pneumatic cylinders. 27) Integrated system (S), according to all the preceding claims, characterized in that said folding machine (1.6) ? equipped with at least a series of anti-adhesion strips (1.6J) arranged at intervals of about half a meter on the upper driving roller (1.6C), on the lower driving roller (1.6D) and on the lower counter-roller (1.6F) , thus preventing any accidental rolling up of the edges of the film on the same reels. 28) Integrated system (S), according to all the preceding claims, characterized in that the exit of the folded film from the folder (1.6) occurs both in a parallel direction (1.6T2) and in a perpendicular direction (1.6T1) to the longitudinal dimension of the folding machine (1.6 in Fig.20), by means of a pair of conveyor belts (1.6T), with independent motorisation, able to rotate around an axis passing through their center of gravity (1.6T4), and with at least one of said belts ( 1.6T) equipped with a further translation movement in a direction parallel to the longitudinal dimension (1.6T3) of the folder (1.6), this movement being necessary to free up space inside the two conveyor belts to allow them to rotate. 29) Integrated system (S), according to all the preceding claims, characterized by the fact that said exit of the folded film after the folding process, in the longitudinal direction of the system S (1.6T1), through a second alternative path (Z2), allows the final packaging for the customer of films too long to be rolled up on themselves on the rolling machine (1.8). 30) Integrated system (S), according to all the preceding claims, characterized in that ? equipped with a rolling machine (1.8) having two pairs of winding fingers (1.8C) mounted on two heads (1.8E) rotating according to the direction (1.8E1), said fingers equipped with an opening and closing movement (1.8E2) , as well as equipped with a mutual approaching and moving away through their carriages (1.8D), called winding fingers (1.8C) so? suitable for rolling up the folded film on itself and, at the same time, covering it with a further stretch film. 31) Integrated system (S), according to all the preceding claims, characterized in that said rolling machine (1.8) ? further equipped with a pair of dispensers (1.8L) suitable for applying the adhesive tape on packs of highly variable and irregular shape through a system of adaptation to the shape of said film rolled up on itself, the latter achieved with movement of the dispenser (1.8L ) on its two axes (1.8L1, 1.8L2), respectively, of descent and rotation. 32) Integrated system (S), according to all the preceding claims, characterized in that said dispenser (1.8L in Fig.23) for applying the adhesive tape ? equipped with a tape application wheel (1.8L3), an electric limit switch (1.8L4), a reel support wheel (1.8L5), a reel holder (1.8L6) for self-adaptive adhesive tape, a protective screen ( 1.8L7) to protect the adhesive tape unwinding mechanism in case of contact with the roll, a rotating arm (1.8L8) to facilitate the phase of changing the adhesive tape reel, a rotating blade for cutting the adhesive tape (1.8L9) on one?axle (1.8L11) and with pneumatic movement (1.8L10). 33) Integrated system (S), according to all the preceding claims, characterized in that said wrapping fingers (1.8C), at the end of the rolling phase, are extracted from the folded and rolled film by means of a pair of pack locking devices ( 1.8N), acting tangentially with respect to the shape of said film. 34) Integrated system (S), according to all the preceding claims, characterized in that said folded and rolled film is unloaded from the rolling machine (1.8) in a very rapid and reliable manner by means of a downward rotation of the infeed belt (1.8A ) around its rotation axis (1.8O1), with outward displacement of the exit roller conveyor (1.8P) in its direction (1.8P1) and with fall due to gravity? on an additional discharge roller conveyors (1.8Q). 35) Integrated system (S), according to all the preceding claims, characterized in that said rolling machine (1.8) ? further equipped with a pendulum (1.8F) which provides in a very rapid and reliable way, for each cycle, to cut the stretch film, using a blade (1.8I) and to transport the initial edge of the film for the next cycle towards a gripper block (1.8H), by means of a further gripper (1.8G) and with a rotary movement of the pendulum itself (1.8I) around its axis of rotation (1.8F1). 36) Automated procedure (P) for an integrated system (S) for the processing and packaging of polyethylene films equipped with reinforcing bands, divided into the following phases: - First phase (F1): unwinding phase of the film from the reels; - Second phase (F2): phase of extrusion and cooling of the lateral and central or intermediate reinforcement strips; - Third phase (F3): possible and temporary accumulation phase of the film, for example during the stopping phases of the folding machine; - Fourth phase (F4): lateral and central or intermediate perforation phase of the film; - Fifth phase (F5A): film folding phase; - Fifth alternative phase (F5B): alternative phase to the previous one or winding phase (F5B), with winding on reels or reels of the film reinforced with reinforcing bands, according to a first alternative path (Z1); - Sixth phase (F6): phase of rolling up the folded film on itself; - Seventh phase (F7): packaging phase before shipment.