DESCRIPTION

Field of application

The present invention relates to a system for unwinding rolls, in particular comprising apparatuses for allowing unwinding a roll of material to be cut and for helping the subsequent feeding thereof into a cutting machine equipped with a conveyor belt. The material to be cut may be for instance synthetic leather, soft PVC, technical or synthetic material, etc., and in general materials adopted in the textile field for the mass production of various components (footwear, leather items, car interiors, clothing, and the like). The following description is made with reference to this application field with the only purpose of simplifying the exposition thereof.

Prior art

In the present field, an ever-increasing development of devices and apparatuses for the automation and optimization of production processes has been underway, reducing or eliminating the need for unnecessarily laborious and/or wasteful operations in terms of time and in terms of number of operators involved, or in any case significantly simplifying these operations.

First of all, there are cutting machines, in particular numerically controlled machines, capable of cutting portions of material in a totally automatic manner according to predefined cutting paths, in which the material is moved through a conveyor belt from a loading area toward a cutting chamber and finally toward a collection area. The material to be cut is initially wound in a roll, which thus is unwound to proceed with the cutting operation.

In many cases, it is desirable to unwound the roll and arrange the unwound portions directly onto the conveyor belt of a machine of the above described type, and to provide for the alignment of said roll during the unwinding. The alignment operation is crucially important for a correct cutting, reason why it is desirable to have a system that facilitates and makes this preliminary step even more accurate.

There is also the desire to ensure the presence of a portion of exceeding material between roll and conveyor belt, in particular preventing the material from being in a state of excessive tension / stretching while the belt advances.

To this end, there are specific unwinders (or unwinding machines), associated at the input with the aforementioned cutting machines, capable of creating and maintaining a bend (curve) of material between the unwinder itself and the machine during the unwinding of the roll. However, it should be noted that many known unwinders have a very complex structure and do not allow an easy displacement and use thereof, for instance making the roll replacement step, or the association of different rolls with each other, complicated. Furthermore, in many known solutions, the alignment step’ is performed either simply just manually by the operators or implemented in an excessively laborious manner with very complex mechanical and control systems.

The technical problem of the present invention is to provide a system for unwinding rolls having structural and functional features so as to allow overcoming the above-mentioned limitations and drawbacks connected to the prior art, in particular that is effective and at the same time has a simplified structure and operation.

Summary of the invention

The solution idea underlying the present invention is to provide a system for unwinding rolls of material to be cut including a plurality of apparatuses for unwinding the rolls, each of them comprising movement means for the roll (in particular including a pair of motors), both for unwinding and transversal alignment thereof, with a very limited encumbrance and reduced to a minimum, with the possibility of easily associating with each other various apparatuses with different rolls for their simple feeding into a cutting machine; in this way, each apparatus is a single module that is connected in series with other modules for feeding different rolls. The unwinding of the roll is automatically controlled based on the position of a reference element, such as a dancer system, (although a fine manual adjustment is still possible), whereas the transversal alignment can be controlled either manually, for example through a joystick or any other manual control, or automatically through a suitable vision or detection system.

Based on this solution idea, the above technical problem is solved by a system for unwinding rolls of material to be cut and for assisting the feeding thereof into a cutting machine, said system comprising a plurality of apparatuses for unwinding the rolls, each apparatus comprising a support frame including at least one support upright extending from a base element, support means for a roll of material on the support frame, said support frame and said support means being configured to allow unwinding the roll along an unwinding direction, reference means (comprising a reference element) configured to detect a tension status of an unwound portion of the roll, and a movement system configured to control a movement of the roll, said movement being both a rotational movement of the roll for unwinding/ rewinding thereof substantially along the unwinding direction, and a movement in a substantially transversal direction with respect to said unwinding direction, wherein the movement system comprises first movement means configured to cause a displacement of the roll substantially in the transversal direction, and second movement means configured to cause the rotation of the roll, the system further comprising a control unit (which may be a single common unit and/or may comprise local units for each apparatus of the system) configured to automatically control the movement system of the apparatus, in particular the second movement means, based on the detection carried out by the reference means for unwinding/ rewinding the roll, and to control said movement system, in particular the first movement means, for adjusting the alignment of the roll in the transversal direction with respect to the unwinding direction, wherein the movement system of the apparatus is configured (structured) in such a way that said apparatus is free from encumbrances along the unwinding direction (corresponding to the longitudinal extension of the roll), and wherein said apparatuses are arranged in series one successively to the other for unwinding a plurality of respective rolls. In particular, each apparatus is free from encumbrances in the portion below the roll toward the ground, which is useful for instance for the passage of material coming from other apparatuses arranged in series. As mentioned, the various apparatuses are arranged in series one after the other for unwinding a plurality of respective rolls, and thus for instance for the formation of a multilayered mattress to be cut.

More particularly, the invention comprises the following additional features, taken individually or in combination if needed.

These aspects are defined in the dependent claims 2-22, singularly or combined with each other.

According to an aspect of the present invention, the first movement means may comprise a first motor in cooperation with a shifting element driven by the first motor, and the second movement means may comprise a second motor configured to cause the rotation of the roll.

According to an aspect of the present invention, the first motor and the shifting element may be operatively coupled to each other, wherein the first motor is adapted to guide the movement of the shifting element substantially in the transversal direction, and wherein the shifting element is configured to cause, due to the movement thereof, a corresponding displacement of the roll, said first motor being controlled by the control unit for adjusting the alignment of the roll.

According to an aspect of the present invention, the second motor may be operatively coupled with a gear system adapted to be put in rotation by said second motor and configured to cause the rotation of the roll, said second motor being controlled by the control unit for adjusting the rotation of the roll. However, there may also be embodiments in which the second motor is in line with the roll, and thus puts it in rotation without gear, but just through the rotation of its shaft.

According to an aspect of the present invention, the movement system of the roll may comprise a worm screw put in rotation by the first motor and configured to cause the movement of the shifting element.

According to an aspect of the present invention, the gear system may comprise at least one first gear and one second gear.

According to an aspect of the present invention, the movement system may comprise a retention element configured to be inserted at least partially into the core of the roll and to abut onto a free surface of said core of the roll, said retention element thus being configured to make said roll integral with the movement system, wherein a movement of said retention element corresponds to a movement of said roll.

According to an aspect of the present invention, the retention element may be connected to the shifting element and may be configured to be shifted by it.

According to an aspect of the present invention, the second gear may be connected to the retention element in such a way that a rotation thereof causes a rotation of said retention element and thus a corresponding rotation of the roll.

According to an aspect of the present invention, the movement system (in particular the first motor and the second motor) may be arranged at the at least one support upright so as to both act at only one of the two bases (sides) of the roll.

According to an aspect of the present invention, the movement system may be a kit of parts directly or indirectly connected to each other and included in a casing, said kit of parts being associable with the support upright, for instance being itself the support element for the roll.

According to a different embodiment of the present invention, the movement means of the movement system are configured and arranged in a different manner than what was disclosed above.

In particular, according to an aspect of the present invention, the first movement means may be arranged at the base element, and the second movement means may be arranged at the at least one support upright; this ensures very limited encumbrances and ensures space for the portions of the rolls from the other apparatuses. In the case of two support uprights, the second movement means are arranged at only one of them, preferably close to the roll. According to an aspect of the present invention, the first movement means may comprise a worm screw configured to put the at least one support upright (or even two of them) in a translation movement along a guide formed in the base element, and the second movement means may comprise a motor for the rotation of the roll. In this way, according to an aspect of the present invention, the first movement means may be configured to allow a translation of the support frame along the transversal direction in such a way that the support means of the roll move integrally with said support frame along said transversal direction, and the second movement means may be configured to allow a rotation of the roll. In this embodiment, the support means of the roll may comprise a recess that is formed in the support upright and is configured to receive a shaft supporting the roll.

According to an aspect of the present invention, at least one of the apparatuses of the system may comprise a pair of support uprights, and the reference means comprise a reference element in the form of a dancer system which the unwound portion of the roll engages with and which is movably housed in suitable guides formed in said support uprights, said dancer system extending along a longitudinal axis substantially orthogonal to the unwinding direction, the apparatus (in particular the reference means) further comprising measurement means for measuring the position of the dancer system along the guide so as to detect the tension state of the roll based on the position of said dancer system, and wherein the control unit is in communication with said measurement means and with the movement means and is configured to control the latter so as to operate the second movement means for unwinding the roll should the position of the dancer system be different from a reference position corresponding to an optimal tension.

According to an aspect of the present invention, the reference means comprise a reference element in the form of a pivoting element which the unwound portion of the roll engages with and which is fastened, directly or indirectly, to at least one of the support uprights at a hinge point, the apparatus (in particular the reference means) further comprising measurement means for measuring the position of the reference element so as to detect the tension state of the roll based on the position of said reference element, wherein the control unit is in communication with said measurement means and with the movement means and is configured to control the latter so as to operate the second movement means for unwinding the roll should the position of the dancer system be different from a reference position corresponding to an optimal tension.

According to an aspect of the present invention, the system may comprise a vision system configured to acquire images/ videos of unwound portions of the roll (for instance engaged on the dancer system, but not necessarily) and to control the movement system (in particular the first movement means) based on said images/ videos.

According to an aspect of the present invention, the vision system may be configured to acquire images/ videos of the unwound material from the roll and in engagement with the reference element, wherein the control unit is configured to process the acquired images/ videos and to recognize the alignment status of the unwound portion of roll taking the surface of the reference element not engaged by the roll (for instance one or both free ends thereof) as a reference, and by distinguishing the surface of the roll from the free surface (namely not engaged by the roll) of the reference element.

However, other elements may be used for measuring the alignment of the roll, such as one or more photocells.

According to an aspect of the present invention, the vision system (or also the above mentioned photocell) may be common for all the apparatuses of the system. In other words, one is enough for all of the apparatuses, for instance downstream toward the cutting machine.

According to an aspect of the present invention, the control unit may also comprise a command system having a manual command element and configured to generate, based on a manual input by a user, control commands toward the movement system of the roll, said control commands being adapted to control the operation of said movement system.

According to an aspect of the present invention, the manual command element may be for instance a joystick operable by the user to control the movement of the movement system, or any other suitable manual command such as a washer or suitable buttons.

According to an aspect of the present invention, the system may be adapted to be associated with a cutting machine equipped with a conveyor belt whereon unwound portions of roll are adapted to be arranged. In this case, the movement of the conveyor belt causes the movement of the exceeding portion of roll, thereby raising the dancer system, with the consequent automatic activation of the unwinding of the roll, as above described.

According to an aspect of the present invention, each apparatus of the system may comprise association means for connection with the adjacent apparatus.

The features and advantages of the system according to the invention will become apparent from the following description of an embodiment thereof, given by way of non-limiting example with reference to the accompanying drawings.

Brief description of the drawings

In those drawings:

- figure 1 is a perspective view of an apparatus of a system according to an embodiment of the present invention;

- figure 2 is a side view of the apparatus of figure 1;

- figures 3A and 3B are perspective views of details of a movement system of a roll according to embodiments of the present invention;

- figures 4A and 4B are perspective views of further details of the movement system of the roll according to embodiments of the present invention;

- figure 5 is a sectional view of a portion of the apparatus of the system according to embodiments of the present invention;

- figure 6 is a perspective view of an apparatus of a system according to an alternative embodiment of the present invention;

- figure 7 is a perspective view of the system according to an embodiment of the present invention; and

- figure 8 is a side view of the system of figure 7.

Detailed description

With reference to the enclosed figures, a system for unwinding rolls of material to be cut according to the present invention is globally and schematically indicated with reference number 1000.

It is worth noting that the figures represent schematic views and are not drawn to scale, but instead they are drawn so as to emphasize the important features of the invention. Moreover, in the figures, the different elements are depicted in a schematic manner, their shape varying depending on the application desired. It is also noted that in the figures the same reference numbers refer to elements that are identical in shape or function. Finally, particular features described in relation to an embodiment illustrated in a figure are also applicable to the other embodiments illustrated in the other figures.

Moreover it is noted that, when sequences of process steps are illustrated, they do not necessarily follow the indicated sequence, these steps can be reversed unless otherwise expressly indicated.

As it will be detailed in the following, the system 1000 comprises a plurality of apparatuses for unwinding rolls, each apparatus being herein indicated with the reference number 100. The following description will provide details of said apparatus 100, which is then connected with at least another (identical) apparatus to form the system 1000. A single apparatus 100 will be illustrated, but the same features are common to the other apparatuses.

The apparatus 100 of the system 1000, for instance, allows unwinding a roll (identified with reference R) of material on a conveyor belt of a cutting machine for making components of various type. Essentially, it is therefore an unwinder (or unwinding machine) that can be used advantageously to assist the feeding of the material to be cut wound in a roll into the cutting machine.

The material to be cut may be for instance synthetic leather, soft PVC, technical or synthetic material, and many others; in general, these are materials adopted in the textile field for the mass production of components (footwear, leather items, car interiors, clothing and the like) . Obviously, the present invention is not limited to the above application and many other applications of the system 1000 are possible. It is also noted that, in the present disclosure, the term “fabric” is not limiting the material to be cut and can be considered as synonym of “material to be cut starting from the roll R”.

With reference to figures 1 and 2, each apparatus 100 of the system 1000 comprises a support structure or support frame (herein indicated with reference F), which is the bearing structure adapted to support the main components thereof. In an embodiment, the support frame F is equipped with wheels 3, preferably with a lock system, to allow displacing the entire apparatus 100 on wheels.

The support frame F comprises at least one support upright Fa, preferably two support uprights having substantially vertical extension, in particular extending from a base element B.

Moreover there are support means 2s of the roll R on the support frame F. The support frame F and the support means 2s are thus configured to allow unwinding the roll R along an unwinding direction, which is indicated in the figures by the arrow D (which may coincide with the longitudinal axis of the unwound material) .

The present invention is not limited to a particular conformation and/or arrangement of the support frame F and of its support means 2s, which generally identify means with which the roll R is supported on the support frame F in any suitable way without further limitations of the scope of the present invention.

In an embodiment of the present invention, as shown in figure 1, the support means 2s are arranged on the sides of the roll R (namely near the bases thereof) and are adapted to support a shaft (or rod, herein indicated with reference A) about which the roll R to be cut is arranged. In this case, the roll R does not directly lean on the support frame F but is supported by the shaft A, which is supported in turn by the supports 2s arranged on the uprights Fa. It is noted that, despite figure 1 shows a pair of side supports 2s, a different number of supports may be provided, for instance it is possible to use a single side support on a single upright, as well as a different type of support means may be provided, as it will be discussed below; in general, the support means 2s may be any suitable housing in/on the support frame F for the roll R, in particular for the shaft A thereof.

The shaft A may be inserted into a central passage of the roll R, more particularly into a tubular element (herein indicated as core of the roll R) about which the roll R is wound and which thus represent the solid support about which the roll R to be cut is wound.

Moreover there is a control unit C adapted to control and manage the apparatus 100, for instance to generate automatic commands or to receive suitable manual commands. The control unit C is not limited to a particular configuration and/or arrangement and may be any computerized unit. Furthermore it may be a single unit, or it may comprise more units, for instance to control several components. In particular, each apparatus of the system 100 may comprise its control unit C, or the system 1000 may comprise a control unit C common to all the apparatuses 100 (even if also in this case, local unit for each apparatus, e.g. for receiving or sending signals, may be present). Therefore, in general, the system 1000 may comprise a control unit C that may be a single unit and/or comprise local units for the various apparatuses 100.

A space can also be provided, for instance formed in the support frame F, preferably in a side portion thereof, where to house control components of the apparatus 100, or said components may be integrated into the movement means below described.

The apparatus 100 comprises a movement system (generically indicated with reference 11) configured to control the movement of the roll R. Suitably, the controlled movement is both a rotational movement of the roll R (i.e., an unwinding/rewinding thereof substantially along the unwinding direction D) and a movement in a substantially transversal direction (indicated with reference T) with respect to said unwinding direction D.

According to the present invention, the movement system 11 comprises first movement means configured to cause displacement of the roll substantially in the transverse direction T (e.g., it comprise alignment means for aligning the roll R configured to perform a fine adjustment of its transversal position), and second movement means configured to cause the rotation of said roll R.

Generally, the movement system 11 is configured to define and adjust the position of the roll R arranged on the support means 2s, as well as to control the rotation thereof. In general, the movement system 11 is thus configured to perform (control) a movement of the roll R.

More particularly, in a particular embodiment of the present invention, the movement system 11 comprises a first motor 1 la in cooperation with a shifting element 11c transversally guided by it and configured to cause a displacement of the roll R substantially in the transversal direction T with respect to the unwinding direction D. In this embodiment, there is also a second motor l id configured to cause the rotation of said roll R for the unwinding/ rewinding thereof.

The movement system according to this particular embodiment is detailed in figures 3A-3B and 4A-4B, which represent views of said system, and in figure 5, which represents a section of a portion of the apparatus 100.

As above mentioned, and now detailed in the above figures 3A-3B and 4A-4B and 5, the movement system 11 comprises alignment means for aligning the roll R configured to perform a fine adjustment of its transversal position. In particular, the above alignment means comprise at least the following components: the above first motor 11a, a worm screw l ib and the above shifting element 11c operatively connected to each other and configured to cause the displacement of the roll R, for instance to adjust its position along the transversal direction T. The worm screw l ib is put in rotation by the motor 11a, for instance through a motion transmission system comprising a belt. As it will be detailed hereinafter, the shifting element 1 lc is connected to an end of the worm screw l ib and is displaced by it during its rotation. In an embodiment, in order to carry out the actual displacement of the roll R, there is a retention element l lr for said roll R, said retention element l lr for instance being configured to be arranged around the shaft A that supports the roll R and meanwhile to abut against the internal surface of said roll R, in particular against the core of the roll R. As illustrated in the non-limiting example of the figures, the retention element Hr for instance comprises a body having a through-hole for coupling with the shaft A (in which the diameter of the hole substantially coincides with the diameter of the shaft A). The roll R is arranged with a certain clearance about the shaft A, whereas the retention element 1 lr is, on the one hand, fastened to the shaft A (for instance inserted by sliding about said shaft or fastened thereto in any other suitable way), and, on the other hand, it is in contact with the inside of the roll R (for instance it abuts onto the core of the roll R - i.e. it mechanically contacts said core) and thus it remains fastened thereto by mechanical interference; in this way, the retention element 1 lr is integral with the roll R and a movement thereof causes a corresponding movement of the roll R.

In an embodiment, the retention element Hr may be formed integrally with the shaft A, and thus it may be structured so as to form a protruding portion of said shaft A (for instance a conical portion) and configured to abut against the core of the roll R as above illustrated and make the roll R integral with the movement system 11.

As above mentioned, in an embodiment, the retention element Hr has a conical-shaped portion and is also called “towing cone”, wherein the tapered portion of the cone is inserted into the core of the roll R to carry out the mechanical interference, even if it should be noted that said retention element 1 lr is not limited to a particular shape.

As above illustrated, in an embodiment, the first motor 1 la is configured to put the worm screw l ib in movement, which is connected to the shifting element 11c (which may be for instance shaped as a plate connected at one point, for instance at a lower end, with the worm screw l ib) and causes the displacement of the latter, in particular a translation in the direction substantially orthogonal to the unwinding direction D of the roll R. The shifting element 1 lc is connected to the retention element l lr (for instance, it may be shaped to house a portion of the retention element l lr or more generally to couple thereto) and, due to the movement thereof, causes the displacement of said retention element l lr and thus of the roll R.

In this way, in an example embodiment, a face of the retention element l lr (for instance the base of the cone) is in direct contact with a face of the shifting element 1 lc (for instance a face of the plate). Obviously, this configuration is not limiting of the scope of the present invention and other configurations are also possible.

Essentially, the first motor 11a and the shifting element 11c are operatively coupled to each other, wherein the first motor 1 la is adapted to guide the movement of the shifting element 11c substantially in the direction T, wherein said shifting element 1 lc is configured to cause, due to the movement thereof, a corresponding displacement/ movement of the roll R. In this way, suitably, a single motor provides for the translation of the roll R. Still more particularly, in an embodiment, the worm screw l ib is provided, which is put in rotation by the first motor 11a and is configured to displace/ move the shifting element 1 lc. The first motor 1 la thus allows a translation of the roll R, allowing a fine alignment of the material.

In this embodiment, the movement system 11 also comprises the second motor l id that is operatively coupled to a gear system adapted to be put in rotation by said second motor l id and configured to cause a controlled rotation of the roll R, so as to control the unwinding and/or rewinding thereof. More particularly, this gear system comprises a first gear l ie and a second gear I lf. The first gear l ie, called “conductor”, is put in rotation by a rotation shaft l lh, which in turn is put in rotation by the second motor l id. Instead the second gear I lf, called “conducted”, is connected to the retention element l lr so that its rotation causes the rotation of said retention element l lr and thus the corresponding rotation of the roll R.

For instance, the retention element l lr may be shaped so as to comprise a portion inserted into a through-hole of the second gear I lf, so as to be directly fastened thereto; in this way, a rotation of the second gear I lf corresponds to a rotation of the retention element l lr and thus of the roll R.

Essentially, the second motor 1 Id is thus operatively coupled to the gear system, in which the gears adapted to be put in rotation by said second motor l id and configured to cause a rotation of the roll R. Still more particularly, the above gear system comprises at least one first gear l ie and one second gear I lf.

The apparatus 100 further comprises reference means 4’ configured to detect and possibly to keep a tension (or stretching) state/ condition of unwound portions of the roll R. The reference means may comprise a reference element 4 (such as a mobile dancer system or any other object which portions of roll may engage to) and measurement means for measuring the position of the reference element 4.

In an embodiment, the reference element 4 is a dancer system (still indicated with reference 4) movably housed in suitable guides G formed in the support uprights Fa. The dancer system 4 is not limited by a particular shape or size, and in general it extends along a longitudinal axis H-H that is substantially orthogonal to the unwinding direction D. In other embodiments, the reference element 4 may also be a pivoting element fastened, directly or indirectly, to the support frame F at one or more hinge points (also in this case, the same considerations made for the aforementioned dancer system apply).

As indicated, measurement means for measuring the position of the dancer system 4 along the guide G are present, so as to detect the tension state of the roll R based on said position (position with respect to the vertical axis); in particular, the control unit C is in communication with said measurement means and with the movement system 11 and is configured to control the latter so as to operate the second movement means (e.g., the second motor l id of the above example) to cause the unwinding of the roll R in case the position of the dancer system 4 along the guide G is different from a reference position corresponding to an optimal tension. The reference position may be for instance the lower endstroke position, namely the one closest to the ground whereon the apparatus 100 rests. The measurement means for instance may comprise a suitable photocell configured to detect the presence of the dancer system in the end-stroke position, though the present invention is not limited thereto, and other solutions are possible (for instance it is possible the adoption of another type of sensor, and/or the presence of an encoder - which is useful when a pivoting reference element is used, or a different arrangement of the photocell, and the like). In the context of the present invention, the assembly comprising the reference element 4 and the measurement means forms the reference means 4’.

Obviously other embodiments may also be provided in which the reference element 4 has a different configuration and the dancer system or any other mobile element is not present, for instance in which the reference element is simply a suitable sensor configured to measure the height of the unwound portion of roll R with respect to the ground (therefore, in this case, the reference means only comprise the above mentioned sensor), even if the above embodiment in which it is a mobile dancer system is the preferred one.

In general, the purpose of the reference element 4 is to define a housing zone for the unwound portion of roll arranged between the roll itself and the conveyor belt of a cutting machine, always ensuring an exceeding portion of roll that is not in tension/ stretching and that substantially forms a bend, so as to reduce the tension state of the material subject to cutting.

The control unit C is thus configured to automatically control the movement system 11 (in particular the second movement means) based on the detection of the reference element 4, (in particular, in the preferred embodiment, based on the position of the dancer systems), for instance to command the activation of the second motor l id (or in general to a motor of the second movement means) so as to unwind the roll R when the dancer system 4 is not in the reference position (for example when it is in a raised position with respect to the end-stroke position, which indicates a greater tension of the material that has caused the lifting of the dancer system, for instance due to the movement del conveyor belt of the cutting machine); the rotation of the roll R thus allows bringing the dancer system back to the reference position, with an appropriate bend between the system 1000 and the conveyor belt of the machine which it is associated with.

However, the functions of the control unit C do not end here, and it is also configured to control the movement means 11 , in particular the first movement means (for instance the first motor 11a), for adjusting the alignment of the roll R. In fact, during the unwinding, creases or surface imperfections may form, which are to be fixed through an alignment procedure of the roll R. In order to align the material to be cut and make said material more suitable to cutting, the control unit C is thus able to perform the alignment of the roll R. In this case, the control may be performed manually by the operator or automatically.

As for the manual control, the system 1000 comprises a command system, herein identified with reference 20, which includes at least one un manual command element 21 configured to generate, based on a manual input by a user (for instance based on a movement imparted by the user), control commands, indicated with reference Cmd, toward movement system 11 of the roll R. In this way, suitably, the control commands Cmd generated by the movement of the manual command element 21 are adapted to control the movement of the movement system 11 , which can therefore be driven based on said control commands Cmd imparted by the user. The command system 20 is thus part of the control unit C and can be considered an operational portion thereof. Also in this case, the command system may be common to all the apparatuses 100 of the system 1000, and/or there is a command system for each apparatus.

In an embodiment, the manual command element 21 of the command system 20 is a joystick (or control lever) operable by the user to control the adjusting movement of the movement system 11.

The first movement means (e.g., the first motor 11a) and the second movement means (e.g., the second motor 1 Id) are adapted to receive the control commands Cmd generated by the manual command element 21 of the command system 20 and can be driven based on said control commands Cmd. The first movement means may be operated further to a movement (for instance on the right and/or on the left, e.g. transversally to the unwinding direction of the roll) of the manual command element 21, causing a corresponding movement of the roll R (for instance on the right and/or on the left, e.g. transversally to the unwinding direction of the roll, wherein the terms right and left should not be intended as limiting of the scope of the present invention, but indicating a movement in a direction that is substantially transversal to the unwinding direction of the roll and with a particular orientation). Likewise, the second movement means may be moved further to a movement (for instance forward or backward) of the manual command element 21, with a corresponding unwinding/ rewinding of the roll R.

In other words, the first movement means (e.g., the first motor 11a) is configured to receive the control commands Cmd generated by the manual command element 21 of the command system 20 and can be driven based on said control commands Cmd, as well as the second movement means (e.g. the second motor 1 Id) is configured to receive the control commands Cmd generated by the manual command element 21 of the command system 20 (for instance a different type of command) and can be driven based on said control commands Cmd. More generally, the movement means (e.g., motorized means) of the movement system 11 are thus configured to receive the control commands Cmd generated by the manual command element 21 of the command system 20 and can be driven based on said control commands Cmd.

In this way, it is possible to fix/adjust the imperfections of the unwound material efficiently through simple commands imparted by the joystick 21.

In an embodiment, the command Cmd from the command system 20 is directly sent to the movement means (e.g., to the motors); alternatively said command may be sent through suitable control systems connected to the movement means (e.g., to the motors), which will provide for the movement thereof for the fine alignment of the roll; even in this case, the present invention is not limited to a particular configuration and other suitable control systems may be implemented.

In general, the possibility to control the transversal movement of the movement system 11 through the command system 20 of the control unit C is advantageous since it allows a unique operator to align the material to be cut in a simple and effective manner, eliminating the unwanted creases through a simple movement of the joystick 21, as well as to unwind and/or rewind the roll according to needs.

In an embodiment, the command system 20 comprises a body 20’ adapted to engage for instance with the cutting machine, or in general to any other suitable component. The body 20’ of the command system 20 is preferably box-like shaped, even if other shapes and configurations are obviously possible and fall within the scope of the present invention.

Additionally or alternatively, in an advantageous embodiment of the present invention, the system 1000 also comprises a vision system 30 configured to acquire images of unwound portions of the roll R in engagement with the dancer system (namely portions sliding on said dancer system). In this case, the control unit C is configured to process the acquired images and to recognize the alignment status/ condition of the unwound portion of roll R taking the dancer system 4 (in particular the surface thereof) as a reference, with particular reference to the longitudinal axis H-H thereof, distinguishing the surface of the roll from the surface of the dancer system (for instance distinguishing the different colors of the two components), so as to verify the alignment status based on the relative position of the roll on the dancer system 4. Since the material of the roll has a different color from the dancer system 4, based on the acquired images from the vision system 30, the control unit C is configured to discriminate between different colors or color shades and to determine the portion of dancer system not engaged by the roll at one (or both) ends of said dancer system (for instance by comparing with a reference value), said determination thus providing information on the alignment.

This information on the alignment status is then used by the control unit C to proceed with the automatic alignment of the roll, acting on the movement means of the movement system 1.

It is noted that the vision system is not limited by a particular type; in general it may comprise a camera/ video camera suitable for the purpose.

Clearly, in its general form, the apparatus 100 may comprise the possibility both of manual and automatic alignment.

Furthermore, the vision system 30 must not necessarily record the dancer system 4, but in other embodiments it may also acquire images of the material unwound on the conveyor belt; what matters is that through the control unit (automatically or manually), it is possible to align the material. The embodiment of the figures is advantageous in case of many apparatuses 100 arranged in series, as it will be described hereinafter. It is also observed that the present invention is not limited to the vision system 30 and other system for detecting the alignment status of the roll may be use, such as one or more photocells, providing information on the alignment status of the roll R that is then used by the control unit C to proceed with the automatic alignment, acting on the movement means of the movement system 1.

According to an embodiment, the movement system 11 is such as to be arranged at one of the support uprights Fa, so as to act at one of the two bases (sides) of the roll R. In this way, preferably by acting only on one of the two sides of the roll, the movement system 11 is configured so that each apparatus 100 is free from encumbrances along the entire longitudinal extension H’-H’ of the roll R. In other words, in an embodiment, the first motor 11a and the second motor l ib are arranged at the at least one support upright Fa so that they act only at one of the two bases of the roll R. In this example, the movement system 11 may thus be seen as a kit of connected parts included in a casing Cs, which is connected to the support frame F. In particular, said kit of parts is associable with the support upright Fa, for instance being itself the support means 2s of the roll R.

In general, thanks to the simplicity of the movement system 11 , the encumbrances are significantly reduced, thus reducing the weight and the cost as well of each apparatus 100.

The movement system 11 may also provide for supporting the roll R, thanks to the connection with the support uprights Fa, the roll R being directly connected to said movement system 11. Obviously, the above configuration is just an example embodiment and does not limit the scope of protection of the present invention and the movement system 11 may be associated with the roll in any other suitable way.

In another, preferred, embodiment of the present invention, as shown in figure 6, the support frame F of the apparatus 100 is slightly different and also the movement means of the movement system 11 are arranged differently.

In this embodiment, the support frame F comprises two support uprights Fa vertically extending from the base element B, thereby defining a U- shaped structure. In any case, the apparatus 100 is not limited to a particular shape and other configurations are possible, for example including only one upright in a L configuration.

It is observed that all the features disclosed above in relation to the reference means and the control of the movement system 11 also apply to this embodiment.

As for the previous embodiment, the apparatus 100 comprises movement means configured to move under the command of the operator or also automatically the roll. In particular, in this embodiment, the movement means are such to move the support frame F or the roll R, depending on the circumstances.

In particular, in this embodiment, the first movement means (now indicated as 11’) are arranged at the base element B, and the second movement means (now indicate as 11”) are arranged at the support upright Fa, in particular at one of the support uprights.

As for the previous embodiment, this mechanical structure is very simple and the movement system 11 is configured so that each apparatus 100 is free from encumbrances along the entire longitudinal extension H’-H’ of the roll R. In general, thanks to the simplicity of the movement system 11, the encumbrances are significantly reduced, thus reducing the weight and the cost as well of each apparatus 100, allowing an easy association of several apparatuses 100 in order to form the system 1000.

For example, the first movement means comprise a worm screw configured to put the at least one support upright Fa in a translation movement along a guide formed in the base element B, whereas the second movement means comprise a motor for the rotation of the roll R, for example embedded in the support upright. In this way, the first movement means are configured to allow a translation of the support frame F along the transversal direction T in such a way that the support means 2s of the roll R move integrally with said support frame F along said transversal direction T, whereas the second movement means are configured to allow a rotation of the roll R. The control of the movement means may be exactly as disclosed above for the previous embodiments.

In this embodiment, preferably, the support means 2s of the roll R comprise also a recess 2sr that is formed in the support upright Fa and is configured to receive a shaft A (in particular an end thereof) supporting the roll R. The shaft A may therefore be simply inserted in the recess 2sr of the support upright Fa. The other upright, if present, may have a suitable housing for the other end of the shaft A. This is useful to receive a shaft from other machines (for example machines supporting a plurality of shafts) .

In any case, as previously mentioned, the support means 2s may be of any shape, and they may be simply in the form supports formed on the uprights to support the shaft A, as shown in figure 6, containing both solutions.

Further, in this case, a photocell 4f is used instead of the vision system 30 to detect the alignment of the roll R, but the principles are the same of the previous embodiment.

In general, all the general teaching of the control of the apparatus 100 are applied also to the embodiment of figure 6, and this embodiment ensures an effective movement of the roll and extremely reduced encumbrances.

So far, a single apparatus 100 of the plurality of apparatuses has been described.

As mentioned, advantageously according to the present invention, the above illustrated configuration for the movement means 11, thanks to their simple configuration and with little encumbrance, allows combining various apparatuses 100 to each other so as to obtain the system 1000 comprising a plurality of apparatuses 100 of the above discussed type, which are arranged in series one successively to the other for unwinding a plurality of respective rolls supported thereby (for example to form a multilayer of material on the conveyor belt of the cutting machine) .

As illustrated in figures 7 and 8, each apparatus 100 may thus be seen as an independent module connectable to the other modules, said apparatuses following one after the other along the unwinding direction D of the respective rolls.

In figures 7 and 8, five apparatuses are illustrated, four of which bearing a respective roll R, even if any other suitable number may be implemented; in this embodiment, the roll R of an apparatus 100 engages with the reference element 4 of the following apparatus (reason why the apparatus downstream - namely the one furthest to the right according to the reference of the figures - does not bear any roll), and the vision system 30 (or any other suitable detection system, which may be in common as detailed hereinafter) is preferably arranged at the this apparatus downstream. This configuration is advantageous; however it is not limiting of the scope of the present invention.

Each apparatus 100 comprises own association means 40 (or connection means) for connection with the adjacent apparatus. For instance, the association means 40 may comprise a guide or a recess configured to house a projection or engagement element of another apparatus, thus obtaining the desired connection (even if a system of screws and bolts can also be provided). It is noted that this is not necessarily a fixed connection between the various apparatuses 100, in general it is enough for portions thereof to be shaped so as to allow a simple interpenetration between them.

As mentioned, it is noted that, even in this case, it is possible to provide for a single common vision system 30 (or a common photocell), exactly as previously illustrated, said vision system 30 or photocell being common for each of the dancer systems 4 (and more generally reference elements) of the apparatuses of the system 1000.

Clearly, also the possibility of a detection system for each apparatus is provided, for example one or more photocells for each apparatus 100, in connection with the control unit C.

In the case of a common vision system 30, to allow the visibility of the dancer systems of the apparatuses furthest from the vision system 30, the movement of the interposed dancer systems (i.e. of the interposed apparatuses) is suitably controlled (for instance they are completely raised), thus suitably synchronizing the various movements. In other words, to see the most distant dancer systems, the interposed dancer systems are raised, for example by rewinding the relative roll; all of this can be done in an automatic alignment cycle, with video cameras placed on the last apparatus at a suitable height (for instance intermediate).

Therefore, according to an advantageous embodiment, the control unit C is thus configured to perform an automatic alignment cycle in which the intermediate reference elements 4 between the vision system 30 and the one to be detected are raised by rewinding the roll engaged with them (namely by operating the second movement means); once the images have been acquired, the alignment is possibly carried out and the reference elements 4 are brought back to the working position.

In case of photocells for each apparatus, the alignment circle may be done without raising the dancer systems.

As mentioned before, the control unit may have a common unit for all the apparatuses of the system.

The common vision system 30 may be arranged downstream of the apparatuses in series, namely between them and the cutting machine, for instance it may be connected to the latter apparatus downstream (i.e. the one furthest to the right). The system 1000 is very advantageous since it is possible to obtain a system for unwinding/ winding many rolls (for instance four or more rolls) in a simple but extremely effective way, which is very useful for instance for cutting multilayers. The encumbrance of the movement means of each apparatus is very reduced, and the material of a roll may be made to pass under the roll of the following apparatus, then forming a multilayered mattress on the cutting machine associated with the system 1000. In the example of the figures the material of the apparatus upstream is located lower, then slowly in the others it rises up to the upstream apparatus (which can also potentially act as a transmission element) . As mentioned before, the last apparatus (the one closest to the cutting machine) may not support a roll, but only its reference element is used (since the reference element of an apparatus is used to engage with the roll of the previous apparatus).

In conclusion, the present invention thus allows brilliantly overcoming the technical problem, by providing the above system and solving all of the drawbacks of the prior art.

Advantageously according to the present invention, the encumbrances are very reduced since the movement system is simple and takes up little space, thus obtaining a light apparatus, easily movable and economical. It is also possible to easily create a system having a series of apparatuses bearing different rolls and connected to each other, possibly with a single video camera for the automatic alignment.

The configuration of several apparatus arranged in series is innovative, wherein the material from a previous apparatus is transferred to the reference element (e.g., the dancer system) of the following apparatus, and then to the last apparatus (i.e., the one closest to the cutting machine, downstream) which is only used to support all the portions of the various rolls.

It is also possible to easily obtain the control of the movement of the roll, by commanding the proper movement means through the joystick, so as to eliminate unwanted creases in the material to be cut even manually and to obtain a more accurate and regular cutting.

Obviously, a person skilled in the art, in order to meet particular needs and specifications, can carry out several changes and modifications to the system described above, all included in the protection scope of the invention as defined by the following claims.