Technical Field

The present invention describes a macro perforator apparatus with a revolver mechanism .

Background art

A macro perforator apparatus is an equipment used to make holes in plastic film with various industrial , agricultural and food applications .

The macro perforator is considered a quasi-machine , i . e . , it is incorporated or assembled within other quasi-machines or devices to build a machine and can therefore be integrated, for example , into plastic film and or paper production lines . The operation of the macro perforator follows the speed of the production line , which can for example depend on the thickness of the material being produced .

This equipment can be supplied with one perforation station or with two perforation stations , depending on the profitability and performance required by the customer .

Depending on the minimum perforation distance between consequent perforated holes , a macro perforator can reach material output operational speeds of 120m/min . Consequently, macro perforators comprised with two stations are capable of increasing its performance capabilities by about 40% , with regard to material output operational speeds , thus ensuring better perforation quality and with less wear and tear on the perforating tools . The main problems of the exi sting macro perforation mechanisms are mainly related to the recti fication moment of the cutting and/or counter-cutting tools . When these elements start to cut badly, leaving tears , or not cutting at all , they have to be removed from the machine for replacement and/or recti fication . Depending on the number of electromagnetic tools that the macro perforator comprises , this process can take up to one hour, requiring a complete stoppage of the macro perforator , and of the production machine of the line to which it is attached, thus causing production losses .

To reduce the impact of this change in the course of factory production, some customers tend to try to perform the recti fication and replacement of components without the machine being completely stopped, which results in great danger to the physical integrity of those performing this replacement .

The herein proposed macro perforator apparatus with a revolver mechanism aims to disclose a solution that allows to overcome the above-mentioned problems .

Summary

The present invention describes a macro perforator apparatus comprising a main frame structure , wherein a set of primary tensioning rollers are adapted and positioned to each of a longer side of said structure in a parallel arrangement , and to which a set of upper electromagnetic tools is longitudinally adapted to by means of upper longitudinal support structures ; and a revolver mechanism which is characteri zed by being centrally enclosed and positioned within the main frame structure and mechanically supported by a set of smaller side structures perpendicularly adj acent to the longer sides and positioned in the edge of the main frame structure in order to provide the mechanical support to a rotation of said revolver mechanism .

In a proposed embodiment of present invention, a motor is adapted to the main frame structure through fixation means and is further mechanically adapted through a rotating shaft to ensure rotation movements of the revolver mechanism with regard to a rotation axis .

Yet in another proposed embodiment of present invention, the revolver mechanism comprises an overall structure where a set of lower longitudinal support structures are mechanically fixed thereto .

Yet in another proposed embodiment of present invention, the lower longitudinal support structures enable a set o f lower electromagnetic tools to be fixed thereto .

Yet in another proposed embodiment of present invention, each element of the set of upper electromagnetic tools comprises at least a pin punch, an electromagnetic coil and a spring .

Yet in another proposed embodiment of present invention, each element of the set of lower electromagnetic tools comprises at least a cutting tool , a damping base and a support structure . Yet in another proposed embodiment of present invention, the set of upper electromagnetic tools are configured to promote a pin punch lowering movement with regard to an original position towards the set of lower electromagnetic tools by means of an electromagnetic coil .

Yet in another proposed embodiment of present invention, each element of the set of upper electromagnetic tools is individually aligned with each element of the set of lower electromagnetic tools .

Yet in another proposed embodiment of present invention, the set of primary tensioning rollers is fixed through adj ustable support structures to the main frame structure to promote the tensioning of a film strip passing between the set of upper electromagnetic tools and the set of lower electromagnetic tools .

Yet in another proposed embodiment of present invention, the spring comprised in each element of the set of upper electromagnetic tools is configured to aid the pin punch to return to its original position .

Yet in another proposed embodiment of present invention, the damping base is configured to absorb the impact caused by the pin punch lowering movement towards the cutting tool .

Yet in another proposed embodiment of present invention, the individual alignment between the set of upper electromagnetic tools and set lower electromagnetic tools comprises a concentric alignment between each individual pin punch and cutting tool to improve the cut of the film strip . Yet in another proposed embodiment of present invention, the rotation movements of the revolver mechanism with regard to its rotation axis promote an alternate switch alignment at least between a first set of lower electromagnetic tools and a second set of lower electromagnetic tools thereto adapted with regard to the set of upper electromagnetic tools .

Yet in another proposed embodiment of present invention, the set of lower electromagnetic tools not aligned with the set of upper electromagnetic tools enables a user to execute maintenance operations in one of the longer sides of said main frame structure .

Yet in another proposed embodiment of present invention, the main frame structure comprises a latch locking system composed of a ground circular shaft and a steel part fixed by means of bolts that ensures a stationary positioning of the revolver, allowing the set of lower electromagnetic tools to be properly aligned and concentric with the set of upper electromagnetic tools .

General Description

The present invention describes a macro perforator apparatus with a revolver mechanism .

The herein technical development disclosure aims to promote teachings on a macro perforator apparatus , that through the incorporation of a revolver device , allows the reduction of machine maintenance downtime and the optimi zation of the cutting perforating system . The typical macro perforator apparatus usually comprises at least five sets of equipment :

- Main macro frame ;

- Support frames ;

- Vacuum system;

- Control system;

- Tooling;

The usual structure of a macro-perforator machine can cover an overall useful operating length comprised between 1000mm and 4000mm, being adaptable to the customer ' s needs . The number of tools comprised in the macro-perforator machine , as well as the mechanical forces each structure will be subj ect to , will therefore vary depending on its useful operating length . The useful operating zone related with the above-mentioned length is cons idered to be the area where the film material to be perforated enters a passage zone comprising at least a roller that will keep the film linearly taut in order to ensure a correct perforation of said film, which in turn will exit through said processing zone through another roller which is usually increased in length .

The support frame is developed to ensure the physical support of the main macro frame operation . Said support can also be adapted to fit correctly the production line where to be inserted .

The vacuum system is configured to vacuum the wasting plastic bits and pieces to a collection container, said leftovers being collected from the cutting tools comprised in the lower electromagnetic tool of the macro perforator with the help of an adapted vacuum pump . There is a main collector individually connected to each lower electromagnetic tool which is further connected to a deposit where the particles are disposed in .

The control system is configured to control the overall operation of the main macro frame in an autonomous manner, or operated by a user, controlling the on and of f switching of the apparatus , as well as the required punching operational speed . Additionally, to the ability to perform all the required setup configurations required by the users , it is also able to determine the production line processing speed where coupled .

The tooling is particularly designed to ensure the correct punching and perforating operations over the film material passing through the rollers . The tool located in the upper part of the structure of the macro apparatus , performs the necessary movement to ensure a precise and accurate cut when the film contacts the lower tool .

The macro perforation procedure consists in carrying out various cutting types over the material disposed between the rollers , i . e . , within a useful operating zone , being the resulting output material appliable to various applications . A macro perforating equipment operation comprises the transportation of the film material along said equipment through a reel located at the front of the main frame and an unwinder at the back of said main frame . The macro perforator is usually installed in production lines , for example , in an extrusion line , a rewinding line , or a slitter . Regardless of where it is installed, the film enters the macro perforator via an accompanying roll and exits the macro perforator already processed via another roll , which in turn is routed from the machine rolls . Both front and back rolls need to be properly synchroni zed with the perforating procedure of the macro to ensure the required quality levels ( concentric and spaced perforation while ensuring the correct measurements between the perforations ) .

Although some macro perforating apparatuses are able to enclose grinding and sharpening systems for the cutters without removing them from the machine where installed, all of them necessarily require the production machine to stop its operation in order to proceed with the grinding and sharpening operations . During operation of said devices , there may be several factors that force the processing procedures to stop, causing production breaks in continuous 24h production lines . The need for maintenance of macro perforation equipment is directly related to the operation and consumption of the equipment ' s wear components . Whenever a cutting tool fails to make the perforations correctly, one of the first actions to be carried out is to stop the machine and dismantle the entire cutting tool set . This set will be later recti fied using a flat grinder, and later repositioned in the machine . Finally, the tuning will be carried out using a device with the maximum possible precision .

In order to overcome the known setbacks of state of the art , the present invention aims to

- provide a simple and automatic replacement system for a set of cutting tools enclosed in the macro perforator device without the need to stop the production line machinery;

Provide a mechanism that does not require to make adj ustments in the functioning of the electromagnetic operating tools ( cutters ) ;

- provide a mechanism to ensure a correct alignment and concentricity between the operating upper and lower electromagnetic tools , particularly between the pin punches and the set of cutting tools , while the remaining cutting tools positioned in reserve are able to be serviced .

- Allow the equipment operator to recti fy and sharpen the cutting tool elements in total safety, even when the remaining macro perforating apparatus is still in full operation;

- Provide a simpli fied adj ustment mechanism that promotes the reduction of time in the adj ustment procedure between the punching and cutting tools ; provide a rotation system ( revolver ) for the lower electromagnetic tools comprised therein that does not compromises nor af fects the sharpening procedure of its cutting tools , ensuring its positioning and concentricity with the pin punch comprised in the upper electromagnetic tool ;

- provide an innovative , functional and ef fective system, ensuring high precision and simultaneously high-quality standards .

The herein proposed revolver system is duly adapted to the macro perforating apparatus , so that the cutting tools comprised in the lower electromagnetic tools of said revolver can be positionally adj usted and f ine-tuned, while ensuring a continuous operation of the production line during maintenance procedures . Thus , the revolver system comprised int the macro perforator allows the operator, during the overall perforating machine operation, to change the cutting toolset of a stationarily line of lower electromagnetic tools positioned in another section of the machine revolver, in a particularly safe section for the machine operator . Even during operation, the macro perforator revolver allows to change and receive new adj ustments with the production line in progress , thus meeting the customer ' s requirements and improving the machine ' s usabil ity and sustainability by reducing material waste and production downtime . The cutting tool set replacement procedure , which is adapted and unique to the developed revolver mechanism, is ef fective to the point of minimising the overall waste of material and is substantially more advantageous than stopping the film production entirely, which involves a highly time-consuming process that is costly in terms of production and human resources .

The fundamental exclusivity derived from the development of this machine is the fact that it allows maintenance operations to be performed on the cutting tools of the lower electromagnetic tools without the need to fully stop the production line ( only reduce the production rate ) , the perforating equipment or even to remove the film inside the machine to perform this procedure .

Brief description of the drawings

For better understanding of the present application, figures representing preferred embodiments are herein attached which, however, are not intended to limit the technique disclosed herein .

Fig . 1 - illustrates a detailed perspective view of some of the elements comprised in the macro perforator apparatus with a revolver mechanism ( 100 ) . Fig.2 - illustrates a detailed cut-through inner profile of the macro perforator apparatus with a revolver mechanism (100) .

Fig. 3 - illustrates another detailed cut-through upper perspective view of the macro perforator apparatus with a revolver mechanism (100) . In this image it is also possible to identify in detail a set of upper electromagnetic tools (106) , fixed to the main structure of the macro, and a set of lower electromagnetic tools (107) comprised in the revolver mechanism (105) .

Fig. 4 - illustrates another detailed cut-through upper perspective view of the macro perforator apparatus with a revolver mechanism (100) .

Fig. 5 - illustrates another detailed zoom-in perspective of the macro perforator apparatus with a revolver mechanism (100) . The present image illustrates a zoom on the waiting station, which is out of service, with the section of the upper electromagnetic tools (106) and lower electromagnetic tools (107) expanded.

Fig. 6 - illustrates another detailed cut-through side perspective view of the macro perforator apparatus with a revolver mechanism (100) , particularly illustrating the cross section of the locking latch (111) , the revolver lock which handles the locking of the station in a fixed position to ensure compliance with concentricity within the cutting mechanisms .

Fig. 7 - illustrates another detailed cut-through lateral perspective view of the macro perforator apparatus with a revolver mechanism (100) and in which the rotation drum is illustrated, as well as the positioning relationship between the upper electromagnetic tools (106) and the lower electromagnetic tools (107) .

Fig. 8 - illustrates another detailed cut-through lateral perspective view of the macro perforator apparatus with a revolver mechanism (100) and in which the rotation drum is illustrated, as well as the relationship between the upper electromagnetic tools (106) and the lower electromagnetic tools (107) . In the current illustration, with regard to previous Figure 7, the rotation drum of the revolver (105) , and the lower electromagnetic tools (107) comprised therein, are deviated from the alignment with the upper electromagnetic tools (106) .

Fig. 9 - illustrates another detailed outer perspective view of some of the elements comprised in the macro perforator apparatus with a revolver mechanism (100) as well as the rotation directions of the revolver (105) over the same axis, horizontal axis in the proposed illustration, with a threshold between the operating and rest position of +/- 90° .

Fig. 10 - illustrates another detailed outer perspective view of some of the elements comprised in the macro perforator apparatus with a revolver mechanism (100) , where the rotation procedure is demonstrated as well as the rotation directions of the revolver over the same axis with a threshold between the operating and rest position of +/- 90° . Description of Embodiments

With reference to the figures, some embodiments are now described in more detail, which are however not intended to limit the scope of the present application.

Hereinafter, a brief description of the essential elements of the invention will be mentioned in an attempt to reproduce its behaviour as a whole.

As above cited, Figure 1 illustrates an overall detailed perspective view of some of the elements comprised in the macro perforator apparatus (100) with a revolver mechanism (105) . The macro perforator apparatus (100) in of the possible embodiments can be to be fitted to a main support frame or incorporated or assembled within other production machine (not illustrated) and additionally connected to a vacuum system that performs the extraction of the perforated remains. The main frame of macro perforator apparatus (100) with a revolver mechanism comprises, in one of the preferred embodiments of the present invention, at least two primary tensioning rollers (101) , each one of them located on each of the longer sides of said frame (100) in a parallel arrangement, fixed through adjustable support structures to promote the tensioning and alignment of the film material (10) passing through the perforating structure. In one of the smaller lateral sides of the suggested structure of the macro perforator (100) illustrated in the disclosed figures, perpendicular to the longer side of the frame (100) where the tensioning rollers (101) are adjacently installed, a motor (110) is adapted to the external structure of the frame (100) , which is further adapted to a centrally positioned revolver (105) , with regard to the structure of the macro perforator (100) , in order to ensure its rotation procedures within a preferred range of +/- 90° with regard to a vertical positioning of the lower electromagnetic tools (107) as suggested in figure 7. The revolver (105) is installed in the inner structure of the main frame (100) , in a parallel position with regard to the tensioning rollers (101) and is a component which allows alternating the use of the lower electromagnetic tools (107) , swapping them by means of the rotation mechanism enclosed and controlled by the motor (100) .

As shown in the cross-section of Figure 2, which discloses the main frame (100) in a vertical side profile cut illustration, the revolver (105) rotates over an horizontal axis supported at each of its end on the main frame structure of the macro perforator (100) , in this case, at the smaller lateral sides of the structure (100) , to ensure alternation between the lower electromagnetic tools (107) on the revolver structure (105) . In order to guarantee the execution of a perfect cut, the alignment between the lower electromagnetic tools (107) installed on the revolver (105) and the upper electromagnetic tools (106) must be guaranteed. The upper electromagnetic tools (106) are vertically aligned with the lower electromagnetic tools (107) , and are installed in the main frame structure (100) by a set of upper longitudinal support structures (108) positioned in an adjacently elevated position with regard to said lower electromagnetic tools (107) . Accordingly with the illustration of figure 7, the film (10) to be perforated by the action/reaction promoted by the set of upper electromagnetic tools (106) and lower electromagnetic tools (107) will pass in a continuous and linear manner through the said set. In the provided illustrations it is visually possible to foresee several proposed embodiments for the proposed invention, wherein the cylinder-shaped revolver mechanism (105) is centrally positioned within and along the length of the main frame (100) ; the primary tensioning rollers (101) are in a parallel position with regard to the revolver (105) and to the set of upper longitudinal support structures (108) . The set of upper electromagnetic tools (106) are installed and fixed to the set of upper longitudinal support structures (108) which are centrally arranged along the longest side of the frame (100) parallelly and between the set of primary tensioning rollers (101) . Also, the set of lower electromagnetic tools (107) is visibly installed and fixed to at least a set of lower longitudinal support structures (109) centrally arranged along the longest side of the frame (100) and longitudinally coupled by fixation means to the revolving mechanism (105) in order to promote the rotation/swap between therein comprised lower electromagnetic tools (107) . The film (10) to be perforated, in one of the preferred embodiments of the present invention, will be provided from a higher position with regard to the macro perforator (100) , ideally in a vertical, tensioned and parallel arrangement, being available to at least one tensioning roller (101) installed on an upper side face of the device, passing subsequently between the upper electromagnetic tools (106) and the lower electromagnetic tools (107) , parallel to the revolver (105) , and passing subsequently through at least a second tensioning roller (101) to be further again vertically routed.

In order to facilitate the description of some proposed embodiments of the present invention, let us consider two sets of lower electromagnetic tools (107) comprised in the revolver (105) . As supported in figure 7, the first set of lower electromagnetic tools (107) is vertically aligned with the upper electromagnetic tools (106) , while the second set of lower electromagnetic tools (107) , also aligned with the upper electromagnetic tools (106) in terms of horizontal positioning on the revolver as illustrated for example in figure 3, is offset 90° with respect to the first set of lower electromagnetic tools (107) , being therefore accessible, through a lateral positioning in the macro (100) , for maintenance procedures to be executed by an machine operator. The set of lower electromagnetic tools (107) comprised in the revolver (105) and which is suspended from production, this is the second set, will be available to the maintenance operation on one side of the macro perforator (100) , and, and therefore, at an angle of 90 degrees with regard to the first set of lower electromagnetic tools (107) which is in production. Ideally, the revolver (105) comprises movements of 90 degrees over its rotational axis and with regard to the position illustrated in the figures (vertical) in order to ensure the integrity of the air suction hoses, minimizing torsional actions on them caused by said axis movement .

Some of the disclosed illustrations disclose a lateral profile of the main frame (100) where the set of lower electromagnetic tools (107) is fixed to the revolver mechanism (105) by means of the lower longitudinal support structures (109) , said revolver mechanism (105) comprising two sets of lower longitudinal support structures (109) and lower electromagnetic tools (107) therein attached, but the rotating mechanism (105) might comprise several sets of lower electromagnetic tools (107) and support structures (109) assembly. The number of matching sets of lower electromagnetic tools (107) and support structures (109) in the proposed and disclosed embodiments only suggest two perpendicular arrangements about the rotary axis of the revolver mechanism (105) . However, the number of combination alternatives and positioning angles between them shouldn't be considered to be an issue since, being the space limitations on the revolver (105) the only mater to consider when promoting the installation of guide rails (109) on its structure. A greater number of lower electromagnetic tools

(107) allows the owner/user of the equipment (100) to choose the best equipment to apply, or how many spare sets it is possible to have on the revolver (105) with different types of lower electromagnetic tools (107) formats.

Also illustrated within the figure illustrations is a partially exploded perspective view of the main frame structure of the macro perforator apparatus (100) wherein the reference numbers refer to a set of parallelly mounted primary tensioning rollers (101) ; the cylinder-shaped revolving mechanism (105) rotating around its longest central axis, said revolver (105) comprising at least a set of lower longitudinal support structures (109) centrally arranged along the longest side and longitudinally coupled to the surface of the cylinder-shaped rotary mechanism (105) ; and a set of lower electromagnetic tools (107) installed and fixed to the set of lower longitudinal support structures (109) . The upper electromagnetic tools (106) are installed and fixed to a set of upper longitudinal support structures

(108) centrally arranged along the longest side and upper support structure of the macro perforator apparatus (100) . In one of the proposed embodiments, the film (10) will pass in a tensioned manner between the tensioning rollers (101) located in both sides of the frame (100) of the machine, said material will also pass through between both of the vertically aligned upper electromagnetic tools (106) and the lower electromagnetic tools (107) .

Figure 6 illustrates a perspective view section of the main frame structure (100) on which a locking system (111) is adapted in order to promote the positioning and the steady fixation of the revolver mechanism (105) , and a rotary engine (110) configured to automatically ensure the rotation of the revolver (105) , providing therefore several lower electromagnetic tools (107) solutions based on its positioning .

Throughout the illustration disclosures provided by Figures 2 to 4, it is possible to verify that each upper electromagnetic tool (106) is individually vertically and lengthwise aligned with each individual lower electromagnetic tool (107) in order to promote the most effective and accurate cut.

The macro perforator apparatus (100) , in a proposed embodiment of the present invention, is subjected to mechanical forces exerted by the processing perforating tools, i.e., the upper electromagnetic tools (106) acting over the lower electromagnetic tools (107) , at a frequency of 40Hz, and its' structure frame (100) was engineered to withstand these operating conditions.

In a proposed embodiment of the current invention, each element of the set of upper electromagnetic tools (106) comprises a pin punch, an electromagnetic coil and a spring. On the other hand, each element of the set of lower electromagnetic tools (107) is comprised of a cutting tool, a damping base and a support structure. In short, the electro-magnet coil integrated in the upper electromagnetic tools (106) forces the pin punch therein comprised to move downwards, toward the film (10) and the lower electromagnetic tools (107) , and the spring integrated in it will assist the pin punch return to its initial resting position. The lower electromagnetic tools (107) also comprise a damping base, whose main function is to absorb the impacts caused by the pin punches in their downward movement towards the cutting tool of the said tool (107) . The lower electromagnetic tool (107) , which is mechanically fixed on a set of lower longitudinal support structures (109) , is also configured to collect the leftovers from the cut and/or punched material procedure that will be further collected by a vacuum system.

In the present invention, the macro perforation procedure derived of the contact of the pin punch from the upper electromagnetic tools (106) with the cutting tool of the lower electromagnetic tool (107) is enhanced by the use of the electromagnetic coils, usually referred as to a solenoids, which promote the movement and lowering of the pin punch towards the cutting tool by means of a magnetic discharge, thus pushing the film (10) towards the lower tool (107) , which through a blade incorporated therein will guarantee the expected cut in the processing film (10) . Sizing the optimal positioning of the electromagnetic coil at the moment of impact, i.e., the contact between both the pin punch (106) and the cutting tool (107) , is also essential, due to the presence of an ideal point where the solenoids can draw its maximum force. The presence and positioning of a spring in the upper electromagnetic tool (106) make it possible to ensure a performant retraction procedure of the pin punch after the discharge of the electromagnetic coil , or solenoid, providing a correct return backwards to its initial position . The spring has to be properly dimensioned in order to guarantee an opposite force to the movement promoted by the electromagnetic coil so that the speed at which this process occurs guarantees higher speed levels . The correct dimensioning of the spring in terms of thickness , diameter and cut configuration, allows the recovery of the punching element , leading to an important improvement in performance and quality of the cut performed, improving the drag of the film along the useful operating zone supported by the set of tensioning rollers ( 101 ) , reducing the above referenced undesired tear ef fect .

In this sense , the movement of the pin punch comprised in the upper electromagnetic tool ( 106 ) is performed towards a fixed cutting tool comprised in the lower electromagnetic tool ( 107 ) , promoting the contact between both parts in order to cut the film material ( 10 ) located between those two components .

The importance of the features herein referred is related to another factor that has a relevant impact on the development of solutions with high cadence and beating between two components (punch and cutting tool ) , which is related to the balancing of the hardness of the materials , so that the use of steel materials is usual . In this use , there is another factor to take into account , which is related to the di f ference in hardness between the two surfaces in contact , which promotes the early deterioration of the surface with lower hardness , thus requiring long maintenance stops with strong impact on productivity and economic viability of the solution . Additionally, the cutting procedure promotes heating of the involved parts , in particular in the guiding system due to the physical movement of the punch mechanism . To minimi ze heating ef fects promoted by friction between these components , one of the proposed embodiments suggests the use of bronze parts . Therefore , the use of solutions that guarantee cooling is essential to ensure that the equipment meets the quality standards and reliability required for the macro perforating process . Additionally, and to ensure a stable temperature within the operating moving parts of the upper electromagnetic tool ( 106 ) and the lower electromagnetic tool ( 107 ) , additional cooling devices , or systems , with cooling abilities can be used . This thermal stability of the tools ( 106 , 107 ) will determine the ability of the material of retaining its structural properties at required temperatures while ensuring an increased extended service time between procedures .

Another important factor is related with the suction procedure of the surplus material resulting from the perforation procedure . The electrostatic energy generated by the moving elements in contact with the film material ( 10 ) limits the correct extraction of the material contained in the hole of the cutting tool ( 107 ) and therefore requires adequate vacuum extraction capacity dimensioning . The aspiration of the cutting wastes resulting from the compression of the original material between the upper electromagnetic tool ( 106 ) and the lower electromagnetic tool ( 107 ) is an essential procedure to ensure the correct functioning of the macro perforator apparatus with a revolver mechanism ( 100 ) . The vacuum pump ensures that between each cutting moment , including the contact between the pin punch of the and the cutting tool , the residues of said cut are correctly aspirated, thus ensuring that they do not remain inside the cutting tool during the next cutting process , which would certainly lead to a loss of ef ficiency of the macro perforator ( 100 ) .

Non less important is the angle of attack/contact of the pin punch with the cutting tool , which is also an essential factor in ensuring ef ficient perforation of the processing target film material ( 10 ) . This is an important prerequisite for the operation of the macro perforator ( 100 ) , particularly ensuring the inclusion of an optimum cutting angle of the device . In one of the preferred embodiments , improvement can be introduced to the perforation procedure providing the featured pin punch with a 45-degree inclination grinding and concentric tuning against the cutting tool at the moment of contact between both elements . Additional performance improvement and cutting quality keeping the same 45 degrees of inclination and using a round spherical type taper that leads to the increase of the concentricity and improves the final cutting capacity, promoting less execution faults caused by bad tuning of the cutting tools .

The quality levels of the resulting perforations are mainly related to the concentricity between the pin punch and the cutting tool , and also with the elimination of the tear ef fect by dragging the film in relation to the cut , ensuring homogeneity .

The proposed macro perforator ( 100 ) comprises high precision, high quality and strong stability . The equipment in a preferred embodiment is made of steel and aluminium . The correct dimensioning and use of steel in the constructive structure of the equipment guarantees the capacity to support vibratory loads and the moment of inertia. The pin punch, the support structures and the cutting tools are usually made of steel with superior hardness and wear resistance.

Thus, and as previously suggested, the presently disclosed main macro frame (100) structure comprises a revolving system (105) that allows switching/alternate between a first lower electromagnetic tool (107) that is in operation performing the perforations in the film (10) , and a second alternative/reserve lower electromagnetic tool (107) that may be subject to maintenance operations.

The mounting of the perforating equipment, i.e., both the upper and lower electromagnetic tools (106, 107) , comprises the use of positioning and centering pins on the macro support frame (100) to allow alignment along the operating area. The revolver (105) structure is composed of two or more machined steel wafers that serve the purpose of revolving, i.e., rotating centrally the lower electromagnetic tool (107) mechanisms. This structure (105) comprises aluminium profiles, on wherein the lower tools are fitted, and reinforcement and fixing bars. All the elements that are part of the cutting system are fixed to the cylindrical revolving rotation system.

The rotation system of the revolver (105) comprises a latch locking system (111) composed of a ground circular tube and a steel part fixed by means of bolts that ensures the entire structure of the revolver (105) to be stationary in the desired position, allowing the lower electromagnetic tools (107) to be properly aligned and concentric with the upper electromagnetic tools (106) . The movement of the locking system (111) may be guaranteed by the operation of two pneumatic cylinders in one of the preferred embodiments.

Additionally, a hollow shaft motor (110) with encoder attached to the frame (100) is used, connected by means of pilot bearings connected by shafts to the entire frame. At least two accompanying tensioning rollers (101) are also placed on the structure so that the film always passes through the upper part of the macro perforator (100) so that the lower part is free.

The changing/swap procedure between lower electromagnetic tools (107) may be actuated by means of the electrical panel and requires a decrease in the operating speed of the production machine that supplies the film for subsequent perforation. In this procedure, pneumatic cylinders that promote the latch collection, are unlocked. A motor (110) promotes the rotation of the revolver (105) at 90° (in both directions of rotation, from left to right, or from right to left) depending on the actual positioning standby bench.

Once the correct parking positioning has been reached and depending on a number of " steps/pulses " , the unit pneumatically activates the locking system (111) to lock the area of the revolution system again.

Once the revolution operation of the revolver (105) is complete, it is again possible to increase the speed of the perforation operation and the corresponding increase in film production speed. The lower electromagnetic tools (107) that are in the maintenance position are removed in order to allow the sharpening of the cutting tools. Also in the developed system, in particular in the control system that comprehends the use of commands and control operations , it is veri fied the electrical impulse value provided to the solenoid to optimise the cutting procedure .