The automatic unit for rewinding, cutting to length, and rolling up material (hereinafter referred to as the “Unit”) is designed to perform the automatic process of rewinding, cutting to length, and rolling up material.

Technical Specifications:

• Unit width, mm – 3700
• Unit length, mm – 5350
• Unit height, mm – 2100
• Unit weight, kg – 4000
• Finished roll:
  • weight, kg – 100
  • diameter, mm – 1400
• Cut length (adjustable), linear meters

– 10

• Winding – Coreless roll
• Roll diameter, mm – 150–155
• Maximum roll weight, kg – 2
• Drive – Electromechanical, pneumatic
• Operation mode – Automatic
• Cutting blade – Mechanical
• Winding type – Tight
• Roll removal – Automatic
• Web threading – Manual
• Operator – 1 person
• Minimum capacity – 2 units/min
• Supply voltage – 380 V, 50 Hz
• Electrical power, kW – max. 10
• Pneumatic system pressure, atm – 6

The production process utilizes high-quality, time-tested components from European manufacturers. Pneumatic actuators and pneumatic control valves manufactured in Germany (Festo), Lenze frequency converters and electric drives, and Siemens sensors and controllers.

Purpose:

The automatic unit for rewinding, cutting to length, and coiling material (hereinafter referred to as the “Unit”) is designed to perform the automatic process of rewinding, cutting to length, and coiling material.

The Unit consists of (see figure):

• An unwinding unit
• A coiling and cutting unit

Operational Description

A roll (100 kg) is delivered to the installation site by a loader and clamped via its core using cones.

The cones (10) are driven; they handle the unwinding and braking of the roll. An integrated system monitors the torque, regulates material tension, and detects the absence of material.

The material passes over a roller (11) equipped with a sensor designed to stop the material if defects (such as variations in material thickness) are detected. Then, it is inserted into the feed rollers 12, passing between the clamping bars 13 and the end-splicing plate 14.

When the material runs out, the bars 13 press the material against the plate 14, and the suction cups 15 are activated. The material is held against the plate by the suction cups; the operator then lowers the bar and trims off the defective end of the material.

Next, after a new reel of material is installed, the leading edge of the material is fed under the lower clamping bar; once clamped, it is secured to the plate by the suction cups. By moving the bar, the operator trims the defective leading edge of the film to ensure a clean, straight edge.

After trimming, the two ends of the material are joined using adhesive tape, and the unit resumes the winding process. Upon initial startup, after the “leading edge” of the material has been trimmed, the material is inserted into the feed rollers (12). The feed rollers are operated by a feed drive, which automatically advances the film.

A sensor positioned between the feed rollers monitors the movement of the material along the machine axis; if any misalignment occurs, alignment cylinders are used to correct the material’s position.

An encoder is mounted on one of the rollers to measure the required length of the material.

The material is guided through the feed rollers, passes between the winding shafts, and enters the roll-forming zone.

The leading edge of the material strikes a deflector and is directed onto a pressure roller that rotates in the direction of the material flow. Pushed by this roller, the material then moves onto another roller, which redirects the leading edge toward the winding shaft. A deflector removes the material from the winding shaft and directs it back toward the incoming material, creating a loop. The loop-forming rollers are controlled by a separate pneumatic line with adjustable pressure, allowing for the regulation of the clamping force. Once the loop is formed, the pressure rollers are lifted by the force exerted by the incoming material. When the encoder registers that the required length has been reached, a control signal is sent to stop all shafts. The pressure rollers are then raised to their uppermost position by pneumatic cylinders. Once formed, the roll is moved by an ejector onto the gripping arms. The material hold-down descends, and a mechanical knife performs the cut. Following the cut, the automated system reverses the rollers by 0.2 m to return the edge to the loop-forming zone.

The cycle repeats.

After the cutting operation, a mechanism engages to fold the edge of the material (the trim remnant). The roll is rotated further and moved into the transport zone. A conveyor gripper assembly, with its jaws open, descends toward the roll. The gripper jaws close, and the folding mechanism releases the roll. The conveyor gripper assembly then rises to its upper position. Pneumatic cylinders, which handle the transport of the roll, are activated. These are controlled via a directional control valve capable of stopping the cylinder at any position; the stop is triggered by a signal from a reed switch. During transport, the conveyor gripper assembly remains in a horizontal position. The assembly moves along guide rails to its extreme position—positioned beneath the sealing unit’s grippers—and “transfers” the roll to the sealing unit’s grippers.

The sealing unit’s grippers push the roll through the heat-shrink film (where the film rolls have been pre-joined). The pneumatic cylinders for the longitudinal sealing jaws are activated. The film is sealed around the roll, and the roll is cut from the film.

A label for the next roll is placed onto the joined film.

The sealed roll rolls down toward the transverse sealing units.

After the transverse sealing process, the roll is discharged onto the conveyor belt of the heat-shrink tunnel.

Advantages

• Automatic roll packaging with a throughput of at least 2 units per minute;
• Capacity to load multiple rolls into a storage tray;
• Adjustable conveyor speeds;
• Modular design allows the line to be configured according to the customer’s specific requirements.

Operation of the Roll Rewinder

The material roll is positioned against the clamping cones and secured by a roll-clamping cylinder; the second cone is driven, serving to either unwind or apply braking force to the roll.

The material passes through a position sensor, which monitors the web’s alignment and makes adjustments using cylinders.

The material then passes over a tension-sensing roller, which synchronizes the unwinding and rewinding drive systems.

An encoder mounted on one of the rollers measures the length of the material segment.

Knives cut the material to the required length.

Suction cups transfer the material from the cutting area to the feed cylinders.

Fork-like mandrels engage with the material to wind it; once winding and cutting are complete, the finished roll is secured with strips of adhesive tape. Then, the roll is gripped by cylinders (not shown in the diagram), the forks open, and the roll is moved into the roll-sealing unit.

Additional Information

12-month warranty
Post-warranty service