EP1007344A1 - Machine de transformation de papier en produit de calage comportant un dispositif de mesure de longueur - Google Patents

Machine de transformation de papier en produit de calage comportant un dispositif de mesure de longueur

Info

Publication number
EP1007344A1
EP1007344A1 EP98906659A EP98906659A EP1007344A1 EP 1007344 A1 EP1007344 A1 EP 1007344A1 EP 98906659 A EP98906659 A EP 98906659A EP 98906659 A EP98906659 A EP 98906659A EP 1007344 A1 EP1007344 A1 EP 1007344A1
Authority
EP
European Patent Office
Prior art keywords
assembly
cushioning
iength
conversion
stock material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP98906659A
Other languages
German (de)
English (en)
Inventor
Paul J. Guth
Joseph J. Harding
Richard O. Ratzel
James A. Simmons
Michael J. Lencoski
Daniel T. Fogg
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ranpak Corp
Original Assignee
Ranpak Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ranpak Corp filed Critical Ranpak Corp
Publication of EP1007344A1 publication Critical patent/EP1007344A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D5/00—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles
    • B31D5/0039—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads
    • B31D5/0043—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads including crumpling flat material
    • B31D5/0047—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles for making dunnage or cushion pads including crumpling flat material involving toothed wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D2205/00—Multiple-step processes for making three-dimensional articles
    • B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
    • B31D2205/0011—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads including particular additional operations
    • B31D2205/0017—Providing stock material in a particular form
    • B31D2205/0023—Providing stock material in a particular form as web from a roll
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D2205/00—Multiple-step processes for making three-dimensional articles
    • B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
    • B31D2205/0011—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads including particular additional operations
    • B31D2205/0017—Providing stock material in a particular form
    • B31D2205/0035—Providing stock material in a particular form as fan folded web
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D2205/00—Multiple-step processes for making three-dimensional articles
    • B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
    • B31D2205/0011—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads including particular additional operations
    • B31D2205/0047—Feeding, guiding or shaping the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D2205/00—Multiple-step processes for making three-dimensional articles
    • B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
    • B31D2205/0011—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads including particular additional operations
    • B31D2205/007—Delivering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D2205/00—Multiple-step processes for making three-dimensional articles
    • B31D2205/0005—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads
    • B31D2205/0076—Multiple-step processes for making three-dimensional articles for making dunnage or cushion pads involving particular machinery details
    • B31D2205/0088—Control means

Definitions

  • This invention relates generally as indicated to a cushioning conversion machine including a measuring device for measuring or approximating the length of cushioning product produced by the machine. More particularly, the present invention relates to a cushioning conversion machine including a length measuring device and a controller which cooperatively produce a controlled length of cushioning material in accordance with a length input.
  • a protective packaging material is typically placed in the shipping container to fill any voids and/or to cushion the item during the shipping process.
  • Some commonly used protective packaging materials are plastic foam peanuts and plastic bubble pack. While these conventional plastic materials seem to perform adequately as cushioning products, they are not without disadvantages. Perhaps the most serious drawback of plastic bubble wrap and/or plastic foam peanuts is their effect on our environment. Quite simply, these plastic packaging materials are not biodegradable and thus they cannot avoid further multiplying our planet's already critical waste disposal problems. The non-biodegradability of these packaging materials has become increasingly important in light of many industries adopting more progressive policies in terms of environmental responsibility.
  • paper protective packaging material a very popular alterative. Paper is biodegradable, recyclable and renewable; making it an environmentally responsible choice for conscientious companies. While paper in sheet form could possibly be used as a protective packaging material, it is usually preferable to convert the sheets of paper into a low density cushioning product. This conversion may be accomplished by a cushioning conversion machine, such as those disclosed in U.S. Patent Nos. 4,026, 1 98; 4,085,662; 4, 1 09,040; 4,237,776; 4,557,71 6;
  • Such a cushioning conversion machine converts sheet-like stock material, such as paper in multi-ply form, into low density cushioning pads.
  • a cushioning conversion machine may include a stock supply assembly, a forming assembly, a gear assembly, and a cutting assembly, all of which are mounted on the machine's frame.
  • the stock supply assembly supplies the stock material to the forming assembly.
  • the forming assembly causes inward rolling of the lateral edges of the sheet-like stock material to form a continuous strip having lateral pillow-like portions and a thin central band.
  • the gear assembly pulls the stock material through the machine and also coins the central band of the continuous strip to form a coined strip.
  • the coined strip travels downstream to the cutting assembly which cuts the coined strip into pads of a desired length.
  • the cut pads are discharged to a transitional zone and then, either immediately or at a later time, inserted into a container for cushioning purposes.
  • the gear assembly includes loosely meshed gears between which the unconnected strip travels .
  • the drive gear is fixedly mounted to a rotating shaft which is coupled to a motor.
  • the gear motor rotates the shaft (and thus the drive gear) in an appropriate direction whereby the central band of the strip is grabbed by the gear teeth and pulled downstream through the nips of the gears.
  • the gear assembly is a rotating conversion assembly which determines the production rate of the coined strip and, therefore, the cushioning products, or pads.
  • a cushioning conversion machine By selectively controlling the gear assembly (i.e. , by activating/deactivating its motor) and the cutting assembly, a cushioning conversion machine can create pads of a variety of lengths. This feature allows a single machine to satisfy a wide range of cushioning needs. For example, relatively short pad lengths can be employed in connection with small and/or unbreakable articles, while longer pad lengths can employed in connection with larger and/or fragile articles. Moreover, a set of pads (either of the same or different lengths) can be employed in connection with uniquely shaped and/or delicate articles, such as electronic equipment.
  • a variety of length-controlling systems are used to control pad length.
  • a manual system is available in which a packaging person manually activates the gear assembly (i.e. , steps on a foot pedal) for a time period sufficient to produce a coined strip of the desired length. He/she then manually deactivates the gear assembly (i.e. , releases the foot pedal) and activates the cutting assembly (i.e. , pushes an appropriate button on the machine's control panel) to cut the coined strip. In this manner, a pad of the desired length is created.
  • the system is designed so that a manual deactivation of the gear assembly (i.e., release of the foot pedal) automatically activates the cutting assembly.
  • a time-repeat system Another technique used to control pad length is a time-repeat system.
  • a timer is electrically connected to the gear assembly.
  • the timer is set for a period (i.e. , seconds) which, based on an estimated gear velocity, corresponds to the desired length of the pad .
  • the time-repeat system is designed to automatically activate the gear assembly for the selected period and thereby, assuming the estimated gear velocity is correct and constant, produce a coined strip of the desired length.
  • the system then deactivates the gear assembly and activates the cutting assembly to cut the coined strip into a first pad of the desired length. Thereafter, the system automatically re-activates the gear assembly to repeat the cycle so that, if the timer has not been reset, a multitude of pads of substantially the same length are continuously created.
  • a further available length-controlling system is a removal-triggered system.
  • This system is similar to the time-repeat system in that it deactivates the gear assembly based on the setting of a timer.
  • the removal-triggered system the gear assembly is not automatically reactivated. Instead, it is only re-activated when the cut pad is removed, either manually by the packaging person or mechanically by a conveyor. Upon reactivation, another pad of the same length is produced unless the timer is reset.
  • Yet another length-controlling system includes a length-selection system which allows a packaging person to select certain predetermined pad lengths.
  • a selection panel e.g. , a key pad
  • a plurality of length options e.g., buttons
  • the gear assembly is automatically activated for a period of time (based on estimated gear velocity) corresponding to the selected pad length.
  • the gear assembly is deactivated, and the cutter assembly is activated. The process is then repeated and, unless another length option is manually selected, a subsequent pad of the same length is produced.
  • the packaging person manually sets the timer at a period corresponding to the desired length and a plurality of pads of this length are produced .
  • the packaging person manually selects the desired length option and a plurality of pads of the selected length are produced.
  • single pad length production is insufficient to satisfy cushioning requirements.
  • a series of identical packaging jobs may each require a set of pads of different lengths.
  • a series of widely varying packaging jobs may each require a single pad, but each job may need a different sized pad.
  • a series of non-identical packaging jobs may each require a different set of pads of varying lengths.
  • the non-manual length controlling systems sometimes do not adequately accommodate these latter packaging situations. Specifically, in order to sequentially produce pads of different lengths, the timer on a time-repeat systems and/or a removal-triggered system must be manually reset after each pad. Likewise, if a length-selection system is used, the packaging person must continuously manually change the length option. Thus, a high degree of interaction with the cushioning conversion machine is necessary. Therefore, in order for a packaging person to properly interact with the machine, at least minimal training is necessary. Additionally, while the packaging person is interacting with the machine, he/she is not packaging thereby hindering the overall efficiency of the packaging program.
  • the manual length-controlling system it can certainly be used to sequentially produce pads of different lengths. However, again, a high degree of interaction is necessary thereby requiring trained personnel and/or thereby hindering efficiency. Moreover, in both the manual and non-manual length-controlling systems, the packaging person must determine (either by experience or experiment) the appropriate pad length. For this additional reason, the use of untrained workers in sophisticated packaging situations is often impractical.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply roll through the forming assembly, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length, and a length measuring device including a roller which rolls along the stock material as it is fed from the supply roll and a sensor which senses the rotation of the roller and communicates the amount of rotation to the controller to approximate the length of cushioning material produced as a function of the rotation of the roller.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply roll through the forming assembly, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length, and a length measuring device including a probe which contacts a point on the outer radius of the supply roll and a position sensor which senses the position of the probe relative to a known point and which communicates the position of the probe to the controller to approximate the length of cushioning product produced as a function of the change in the radius of the stock supply roll.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stack of generally fan-folded stock material through the forming assembly, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length, and a length measuring device including a probe which contacts the stack of stock material and a position sensor for sensing the position of the probe and communicating the position of the probe to the controller to approximate the length of cushioning product produced as a function of the change in the height of the stack of supply material.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stack of generally fan-folded stock material through the forming assembly, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length, and a length measuring device including a sensor which senses the removal of a fold of paper beneath the probe and communicates the removal to the controller to approximate the length of cushioning product produced as a function of the removal of folds of stock material from the stack of stock material.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply roll through the forming assembly, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length, and a length measuring device including a sensor for detecting the occurrence of indicia recorded on the stock material as the material is fed past the sensor and for communicating the detection of the occurrence of the indicia to the controller to approximate the length of cushioning product produced as a function of the number of indicia detected.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply roll through the forming assembly, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length, and a length measuring device including a light transmitter for directing light incident on the stock material and a light detector for detecting the occurrence of perforations in the stock material as a function of reflected light as the material is fed past the sensor and for communicating the detection of the occurrence of the perforations to the controller to approximate the length of cushioning product produced as a function of the number of perforations detected.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply through the forming assembly, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length, and a length measuring device including scale for measuring the weight of the stock supply roll and for communicating the weight of the stock supply to the controller to approximate the length of cushioning product produced as a function of the change in weight of the stock supply.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply roll through the forming assembly, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined weight, and a weight measuring device including scale for measuring the weight of the supply roll and for communicating the weight of the roll to the controller to cause the feed motor to stop when the change in the measured weight reaches the predetermined weight.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply roll through the forming assembly; and a length measuring device including a unwinder for unwinding a desired length of stock material from the roll, and a sensor switch for indicating the presence of stock material unwound from the roll and for causing the feed assembly to feed stock material through the forming assembly while the sensor detects the presence of unwound stock material .
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply roll through the forming assembly, a controller, and a length measuring device including an unwinder for unwinding a desired length of stock material from the roll and a linear array of sensors, each sensor of the array for detecting the presence of stock material adjacent the sensor and communicating such detection to the controller, and wherein the controller controls the unwinder and the feed assembly in accordance with the communications from the linear array of sensors to produce a cushioning product of a predetermined length.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply roll through the forming assembly, a severing assembly for severing the stock material fed through the conversion assembly to form a discrete cushioning product, and a length measuring device including a reticle permitting the measurement of stock material manually unwound from the supply roll, and a sensor switch for indicating the presence of stock material unwound from the roll and for causing the feed assembly to feed stock material through the forming assembly while the sensor detects the presence of unwound stock material.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly powered by a feed motor for feeding stock material from a stock supply roll through the forming assembly, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length, and a length measuring device including a pump powered by the feed motor for generating pressurized air, a reservoir for accumulating the pressurized air and a pressure sensor which senses the level of pressure in the reservoir and a switch for communicating to the controller the occurrence of the sensed pressure reaching a value which corresponds to the predetermined length of cushioning product to be produced.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly powered by a feed motor for feeding stock material from a stock supply roll through the forming assembly, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length, and a length measuring device including a pump powered by the feed motor for introducing fluid to a reservoir and a level sensor which senses the level of fluid in the reservoir and a switch for communicating to the controller the occurrence of the sensed level reaching a value which corresponds to the predetermined length of cushioning product to be produced.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly powered by a stepper motor for feeding stock material from a stock supply roll through the forming assembly, a length input device permitting the entry by an operator of a desired length of cushioning material to be produced, and a controller for controlling operation of the stepper motor through pulses generated in accordance with the desired length entered through the length input device.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply through the forming assembly, a feed motor for powering the feed assembly, a clutch assembly for selectively engaging the feed assembly with the feed motor to cause a specified length of cushioning product to be fed through the forming assembly, and a controller for controlling operation of the clutch assembly.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly powered by a feed motor for feeding stock material from a stock supply through the forming assembly, a power sensor for sensing the amount of power supplied to the feed motor, a length input device permitting the entry by an operator of a desired length of cushioning product to be produced, and a controller for correlating the desired length of cushioning product to be produced to the required amount of power necessary to supply to the feed motor for it to feed the appropriate length of stock material through the forming assembly to produce the desired length of cushioning product and for controlling the supply of power to the feed motor in accordance with the length of cushioning product to be produced and the cumulative amount of power supplied to the feed motor as sensed by the power sensor.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a continuous strip of cushioning product, a feed assembly for feeding stock material from a stock supply through the forming assembly, a severing assembly for severing the continuous strip of cushioning product into a discrete length of cushioning product, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length; and a length measuring device including a roller which rolls along the cushioning product after it is formed and prior to being severed, and a sensor which senses the rotation of the roller and communicates the amount of rotation to the controller to determine the length of cushioning material produced as a function of the rotation of the roller.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a continuous strip of cushioning product, a feed assembly for feeding stock material from a stock supply through the forming assembly, a severing assembly for severing the continuous strip of cushioning product into a discrete length of cushioning product a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length; and a length measuring device including a roller which rolls along the cushioning product downstream of the severing assembly, and a sensor which senses the rotation of the roller and communicates the amount of rotation to the controller to determine the length of cushioning material produced as a function of the rotation of the roller.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a continuous strip of cushioning product, a feed assembly for feeding stock material from a stock supply through the forming assembly, an assembly for forming indicia on the cushioning product, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length; and a length measuring device including a sensor which detects the occurrence of indicia on the cushioning material and which communicates such occurrences to the controller to determine the length of cushioning material produced as a function of the number of occurrences of indicia detected .
  • the indicia may be printed on the cushioning product as it is formed. Alternatively, the indicia may include perforations made in the cushioning product as it is formed.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply through the forming assembly and through an output of the machine, a controller, and a length measuring device including a linear array of sensors arranged at the output of the machine, each sensor of the array for detecting the presence of different lengths of cushioning product and communicating such detection to the controller, and wherein the controller controls the feed assemblv in accordance with the communications from the linear array of sensors to produce a cushioning product of a predetermined length.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply roll through the forming assembly, the feed assembly including at least one rotating component, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length, and a length measuring device including a velocity sensor for sensing the velocity of the rotating component and communicating the velocity to the controller to calculate the length of cushioning product produced as a function of integral of velocity over time.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from a stock supply roll through the forming assembly, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length, and a length measuring device including a velocity sensor for sensing the velocity of stock material through the machine and for communicating the velocity to the controller to calculate the length of cushioning product produced as a function of integral of velocity over time.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a continuous strip of cushioning product, a feed assembly for feeding stock material from a stock supply through the forming assembly, a severing assembly for severing the continuous strip of cushioning product into a discrete length of cushioning product, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length; and a length measuring device including a sensor locatable at an adjustable distance from the severing assembly which detects the presence or absence of cushioning material adjacent the sensor and which communicates the detection of the cushioning material to the controller.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a continuous strip of cushioning product, a feed assembly for feeding stock material from a stock supply through the forming assembly and through an outlet, a severing assembly for severing the continuous strip of cushioning product into a discrete length of cushioning product, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length; and a length measuring device including a contact positioned at the outlet for engaging the leading edge of the continuous strip of cushioning product and movable with the cushioning product as it progresses from the exit, and a sensor for sensing the position of the contact and communicating the position of the contact to the controller.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a continuous strip of a cushioning product, a feed assembly for feeding stock material from a stock supply through the forming assembly and through a machine outlet, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined length, and a length measuring device including scale positioned at the outlet for measuring the weight of the continuous strip of cushioning product and for communicating the weight of the cushioning product to the controller to approximate the length of cushioning product produced as a function of its weight.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a continuous strip of a cushioning product, a feed assembly for feeding stock material from a stock supply through the forming assembly and through a machine outlet, a weight input allowing an operator to select the weight of the cushioning material to be produced a controller for controlling operation of the feed assembly to produce a cushioning product of the selected weight, and a weight measuring device including scale positioned at the outlet for measuring the weight of the continuous strip of cushioning product and for communicating the weight of the cushioning product to the controller.
  • a cushioning conversion machine includes a forming assembly which converts a stock material into a cushioning product, a feed assembly for feeding stock material from supply through the forming assembly, an encoder for generating a series of pulses corresponding generally to the iength of pad formed, a controller for controlling operation of the feed assembly to produce a cushioning product of a predetermined Iength, and an automated Iength calibration mechanism including a Iength measuring sensor for measuring the Iength of a pad after formation.
  • a method of calibrating a cushioning conversion machine includes the steps of generating and recording a series of pulses inferring the Iength of pad being produced by the cushioning conversion machine, measuring the Iength of the pad actually produced at the output of the machine; and determining at least one correction factor to correlate the number of pulses recorded to the Iength of a pad actually produced.
  • a method of calibrating a cushioning conversion machine includes the steps of controlling a feed assembly including a feed motor to produce a pad of a predetermined
  • Figure 1 illustrates a plan view of a cushioning conversion machine schematically illustrating a pad-length measuring device in accordance with the present invention
  • Figure 2 is a partial elevation view of the cushioning conversion machine illustrated in Figure 1 ;
  • Figure 3 shows a schematic illustration of one embodiment of a pad-length measuring device which measures the Iength of paper unwound from a supply roll by means of a contact roller;
  • Figure 4 illustrates a schematic embodiment of a pad-length measuring device which infers the iength of pad being produced by the change in the radius of the stock supply roll;
  • Figure 5 shows a schematic illustration of an embodiment of a pad-length measuring device which approximates pad Iength by measuring the change in height of supply stock
  • Figure 6 is a schematic illustration of an embodiment of a pad-length measuring device which measures the iength of pad being produced in accordance with the number of folds of material removed from a stack of stock material
  • Figure 7 is a schematic illustration of an embodiment of a pad-length measuring device which detects the Iength of material removed from a stock supply by detecting printed indicia on the material;
  • Figure 8 is a schematic representation of pad-length measuring device similar to that shown in Figure 7 which detects the Iength of pad being removed from the stock supply by detecting perforations in the material;
  • Figure 9 illustrates schematically an embodiment of a pad-length measuring device which coordinates in the weight of the supply material to a desired Iength input;
  • Figure 1 0 is a schematic illustration of a pad-weight measuring device similar to that shown in Figure 9 but which correlates the change in weight of the stock supply with a weight input
  • Figure 1 1 is a schematic representation of a pad-length measuring device which employs an unwinder to unwind a desired Iength of material from a supply roll and a sensor to determine when the unwound material has been converted into a pad;
  • Figure 1 2 is a schematic illustration of a pad-length measuring device which employs an unwinder for unwinding a length of paper from a stock supply roll and a linear sensing array for determining the amount of paper unwound from the stock supply and for determining the Iength of paper converted into a pad;
  • Figure 1 3 is a schematic representation of an embodiment of a pad-length measuring device which allows for the manual unwinding of material from a stock supply and which senses when all of the material manually unwound from the supply has been converted into a pad;
  • Figure 14 is a schematic illustration of a pad-length measuring device which measures the Iength of pad produced as a function of an increase in pressure
  • Figure 1 5 is a schematic illustration of a pad-length measuring device including a stepper motor which is driven by a number of pulses corresponding to the desired length of pad to be produced;
  • Figure 1 6 is a schematic illustration of an embodiment of a pad-length measuring device which employs a pulse-driven spring wrap clutch to control the amount of material converted into a pad
  • Figure 1 7 is a schematic illustration of a pad-length measuring device which employs a power sensor to determine when power corresponding to a certain pad Iength has been supplied to the feed motor;
  • Figure 1 8 is a schematic illustration of an embodiment of a pad-length measuring device which employs a contact roller to measure the pad as it is being produced;
  • Figure 1 9 is a schematic illustration of a pad-length measuring device similar to that shown in Figure 1 8 with the contact roller positioned in the machine output;
  • Figure 20 is a schematic illustration of a pad-length measuring device including a sensor which detects perforations in the pad formed during the conversion process to measure the Iength of the pad;
  • Figure 21 is a schematic illustration of a pad-length measuring device similar to that shown in Figure 21 which includes a sensor to detect indicia printed on the pad during the conversion process;
  • Figure 22 is a schematic illustration of a pad-length measuring device which employs a linear array of sensors to sense the Iength of a pad as it is being produced;
  • Figure 23 is a schematic representation of an embodiment of a pad-length measuring device which employs an adjustable optical sensor for measuring the Iength of a pad as it is produced;
  • Figure 24 is a schematic representation of a pad-length measuring device which employs a movable barrier which moves with the pad as it is being produced and a linear sensor which senses the position of the barrier to measure pad Iength;
  • Figure 25 is a schematic illustration of a pad-length measuring device which correlates the weight of the pad as it is being produced to a desired pad Iength;
  • Figure 26 is a schematic illustration of an embodiment of a pad-weight measuring device similar to that shown in Figure 25 which correlates the weight of the pad as it is being produced to a weight input; and Figure 27 is a schematic illustration of an embodiment of a pad-length measuring device which measures the Iength of pad produced as a function of velocity.
  • a cushioning conversion machine 1 0 including a conversion assembly 1 2 for converting stock material to a packaging pad, a pad-length measuring device 1 4 (illustrated schematically in Figure 1 ) for measuring the Iength of pad produced, a paper severing assembly 1 6 for severing, cutting, tearing or otherwise disconnecting the pad from the stock material in the conversion assembly and, preferably, a controller 1 8 (illustrated schematically) for controlling operation of the machine.
  • the conversion assembly 1 2 preferably includes a forming assembly 22 and a feed assembly 20 which includes a gear assembly 24 powered by a feed motor 26.
  • Operation of the severing assembly 1 6 is powered by a cut motor 30 selectively engaged with the severing assembly by a clutch 31 .
  • the controller 1 8 controls operation of the feed motor 26, cut motor 30, the clutch 31 , etc., in response to various data and control inputs, such as those from the pad-length measuring device 14.
  • the feed motor 26 powers the gear assembly 24 through a drive arrangement 34 which may include a number of elements such as the sprockets 38, chain 40 and shaft 42 for transferring rotational power to the gear assembly.
  • the gear assembly 24 includes two opposed gears 44 and 46 (see Figure 2) of which one gear, such as gear 44, is a drive gear preferably driven by the drive arrangement 34 while the other gear, in this case gear 46, is in the form of an idler gear.
  • sheet-like stock material is pulled from a roll of material held by a stock supply assembly 48 and transferred to the conversion assembly 1 2.
  • the sheet-like stock material may consist of three superimposed webs of biodegradable, recyclable and reusable thirty-pound Kraft paper rolled onto a hollow cylindrical tube as shown in Figure 3, or some other number of plies of sheet-like material, or a fan-folded stack of material as shown in Figure 5.
  • the sheet-like stock material (herein, paper) is converted into continuous strip of padding by the conversion assembly 1 2 from where it emerges to be disconnected from the material still in the conversion assembly by the severing assembly 1 6 to form a pad of the desired Iength at the transitional zone 50.
  • the forming assembly causes the lateral edges of the stock material to roll inwardly to form a continuous strip having two lateral pillow-like portions and a central band therebetween.
  • the gear assembly 24 performs a "pulling" function by drawing the continuous strip through the nip of two cooperating and opposed gears of the gear assembly 24 thereby drawing stock material through the forming assembly 22 for a duration determined by the Iength of time that the controller 1 8 instructs the feed motor 26 to rotates the driven gear 44.
  • the gears 44, 46 additionally perform a "coining” or “connecting” function as the opposed gears coin the central band of the continuous strip as it passes therethrough to form a coined strip.
  • the coined strip travels downstream from the gear assembly 24, the leading edge of the strip passes through the severing assembly 1 6 to the transitional zone 50.
  • the controller 1 8 which monitors the Iength of pad produced as determined by the pad-length measuring device 1 4, stops the feed motor 26 once an appropriate Iength of pad has been formed and instructs the severing assembly 1 6 to sever the strip to result in a pad of the desired Iength.
  • the Iength of pad to be produced may be communicated to the controller 1 8 as an input (such as shown schematically by lines 52) by the operator through B keypad, a thumb wheel or some other device.
  • the Iength may be preset or may be a function of adjustment of sensors, as described below .
  • the pad may be deposited onto a slide or chute or may be mechanically transferred to another location for use by an operator.
  • the pad-length measuring device 1 4a includes a roller sensor 60 in contact with the paper 62 fed from the roll of paper 64. With the feed motor 26 turning, as paper 62 is pulled from the roll 64 by engagement with the turning gears 44, 46 of the gear assembly 24, the paper causes a friction wheel 66 of the roll sensor 60 in contact with the paper to rotate thus transferring the linear movement of the paper into rotational movement by the friction wheel as it roils along the moving paper. The roll sensor 60 translates the rotation of the wheel 66 into pulses which are sent to the controller 1 8 along signal line 68.
  • the controller 1 8 counts the pulses and when the accumulated number of pulses corresponds to a desired Iength of pad, the controller 1 8 deactivates the feed motor 26 via control line 70 so that no additional paper is fed from the roll. The controller then instructs the cutter mechanism 32 (which represents the severing assembly 1 6, the cut motor 30 and the clutch 31 ) via control line 72 to cut the pad at the desired Iength.
  • the pad Iength is determined by the state of a Iength input device 74 which may include a key pad through which the operator can set the pad lengths to be formed as well as through a thumb wheel or similar device.
  • the selected pad Iength is communicated to the controller 1 8 over the signal line 76.
  • the desired Iength of the pad is stored in a memory device accessible by the controller 1 8. It is noted that while the pad-length measuring device 1 4a shown in
  • Figure 3 as well as several other embodiments of the pad-length measuring device 1 4 described below, do not measure the pad directly, but rather measure the paper before it is converted, the ratio of the Iength of paper to the pad is relatively constant for most conversion operations and thus can be compensated for within a few percent by the controller 1 8.
  • the paper-length measuring device 1 46 includes a position-sensing device 80 for directly or remotely sensing the position of the periphery 82 of the paper supply roll 64.
  • the position-sensing device 80 periodically senses and reports an indication of the radius of the paper supply roll 64 to the controller 1 8 over the data line 84.
  • the controller 1 8 determines the linear Iength of paper that has been unwound from the paper supply roll since the last cut as a function of the last reported paper supply roll radius and the stored paper roll radius at the time of the last cut.
  • the controller 1 8 deactivates the feed motor 26 thus stopping the gear assembly from pulling additional paper from the paper roll and instructs the cutter mechanism 32 to cut the pad by engaging the cut motor 30 with the severing assembly 1 6 to sever the pad at the desired Iength.
  • the controller 1 8 then stores the last read paper supply roll radius for use in computing the Iength of the next pad .
  • the position-sensing device 80 preferably includes a positional probe 86, such as that shown in Figure 4, in the form of contact roller which is biased against and rolls with the periphery of the paper supply roll 64 as paper is unwound, and a linear sensor 88 for determining the distance between the positional probe 86 and a fixed reference 90, such as the machine frame.
  • the linear sensor 88 provides the radius information to the controller 1 8 in the form of a data signal indicating the radius of the supply roll 64 over line 84.
  • FIG. 5 there is shown an embodiment for a length-measuring device 1 4c which senses the Iength of pad formed by keeping track of the height of the folded paper supply stack 92.
  • a length-measuring device 1 4c which senses the Iength of pad formed by keeping track of the height of the folded paper supply stack 92.
  • Such an embodiment of the Iength measuring device is particularly applicable when the supply paper is in the form of fan-folded paper which is stacked in a continuous zig-zag or accordion arrangement.
  • a cushioning conversion machine operable to convert such stock material to cushioning material is disclosed in U.S. Patent No. 5,387, 1 73 which is incorporated herein by this reference.
  • the Iength measuring device 1 4c may directly or remotely sense the height of the paper supply stack 92 relative to a fixed location 94, such as a fixed point on the machine frame, and provides the indication of height or change in height to the controller 1 8 via line 96. In the instance where absolute height is supplied to the controller 1 8, the controller subtracts the height of the stack 92 when the last cut occurred and correlates this change in height information with information which translates the height information to linear Iength of the pad produced. When the pad-length measuring device 14d provides the relative paper supply height to the controller 1 8, the information may be provided in the form of a pulse which is generated and transmitted to the controller 1 8 each time a certain increment of paper has been removed from the paper supply stack 92.
  • the controller 1 8 Upon receipt of the height information from the pad-length measuring device 1 4d, the controller 1 8 will determine the Iength of pad which has been produced based on the decrease in the height of the paper supply stack 92 since the last pad was produced and compare the amount produced to that desired. If the amount produced is greater than or equal to the amount desired, the controller 1 8 will cease pad production and instruct the cutting mechanism 32 to perform a cut, as described more fully above.
  • the pad-length measuring device 1 4d may include a contact arm 98 which contacts the top of the paper supply stack 92 and a positional sensor 1 00 which senses the position of the contact arm and provides an indication of the position of the arm to the controller 1 8 via the line 96, or some other means of sensing the stack height.
  • the positional information generated by the positional sensor 1 00 may be in the form of a signal indicating the height of the paper supply stack 92 as an analog or digital value or the information may be in the form of a pulse generated when each time the height has decreased by a certain amount.
  • FIG 6 there is shown a pad-length measuring device 1 4e which employs a trip switch which senses each time that a fold of paper on one edge of the paper stack 92 has been removed from the stack.
  • the pad-length measuring device 14e generates a pulse each time that it has detected that a fold of paper has been removed from the stack and transmits the pulse to the controller 1 8 via the line 1 02.
  • the controller 1 8 can determine the Iength of paper pulled from the stack 92 for conversion to a pad then, once the appropriate Iength of paper has been removed as determined by the Iength input device 74, the controller will instruct the feed motor 26 and cutter mechanism 32 to stop the production of additional padding and to sever the pad at the appropriate Iength.
  • the pad-length measuring device 1 4e may include a trip switch 1 04 having an extending contact arm 106 which contacts the top of the paper supply stack 92 and provides an indication, such as through its movement, to the trip sensor 1 04 when a fold of paper beneath the contact arm has been removed from the stack.
  • the trip switch sensor 1 04 is mounted relative to the machine frame 94 in such a way that its height is adjustable so that the contact arm 1 06 will maintain contact with the paper supply stack 92 as paper is removed.
  • a pad-length measuring device 1 4f which employs a sensor responsive to indicia on the stock material to determine the Iength of paper being pulled from a roll of stock material 64 is illustrated in Figure 7.
  • the pad-length measuring device 1 4f includes a sensor 1 08 which detects the presence of certain indicia encoded on the paper 1 1 0 as it passes by the sensor 1 08. Length information may be encoded on the paper 1 1 0 in the form of visible gradations 1 1 2, as shown in Figure 7a, which are detected by the sensor 1 08 as the gradations pass by the sensor. Alternatively, the sensor 1 08 may operate on invisible or ultraviolet wavelengths of light to detect suitable indicia printed on the paper 1 10. As the sensor 1 08 detects a gradation, such as 1 1 2, on the paper 1 1 0 it generates a pulse which is communicated to the controller 1 8 over the line 1 1 2.
  • the controller 1 8 can determine the Iength of paper having been pulled from the paper supply roll 64, and thus the Iength of the pad having been formed, since the last cutting operation. When the Iength of pad produced since the last cutting operation is equal to or greater than the Iength input provided by the Iength input device 74, the controller will then instruct the feed motor 26 and cutter mechanism 32 appropriately to sever the paper to produce a pad of the desired Iength.
  • FIG. 8 and 8a there is shown an embodiment of a pad-length measuring device 1 4g similar to that illustrated in Figure 7, but which detects perforations 1 1 4 in paper stock 1 1 6 as the paper passes by a sensor 1 1 8.
  • the sensor 1 1 8 detects the presence of a perforation 1 1 4 by sensing the difference in light reflection to the sensor when the light ray generated by the sensor is incident through a perforation as opposed to incident on the paper.
  • a light reflecting or absorbing media 1 20 is positioned below the perforations 1 1 4 in the paper stock 1 1 6 to enhance the difference in light reflected to the sensor 1 1 8 when a perforation 1 1 4 is in the path of incident light generated by the sensor.
  • the media 1 20 may be reflective thus enhancing the amount of light reflected to the sensor 1 1 8 when a perforation passes by the sensor, in which case the sensor will detect these increases in the amount of light reflected as corresponding to the presence of a perforation, or the media 1 20 may be light absorbing in which case the sensor 1 1 8 will detect the decrease in light reflected to the sensor as indicating the presence of a perforation.
  • the sensor 1 1 8 generates a pulse each time a perforation 1 14 is detected in the paper stock 1 1 6 and transmits the pulse to the controller 1 8 via line 1 20.
  • the controller 1 8 counts the received pulses since the last time that paper was severed to form a pad in order to determine the Iength of a pad currently being produced.
  • the controller 1 8 then instructs the feed motor 26 and cutter mechanism 32 appropriately to produce a pad of the desired Iength. Referring to Figure 9 there is shown a pad-length measuring device
  • the controller 1 8 can determine the weight, and thus the Iength of paper removed from the paper supply since the last pad was formed.
  • the pad-length measurement device 1 4h preferably includes a scale
  • the paper weight as sensed by the indicator shown schematically at 1 26 is provided to the controller over the line 1 22.
  • the weight of the paper supply stack 92 may be provided to the controller as a real weight value or the change in weight may be provided as a pulse in which the indicator 1 26 sends a pulse to the controller 1 8 each time a certain amount of weight is removed from the paper supply stack 92.
  • the controller 1 8 then functions as described above based on the Iength input to control the feed motor 26 and cutter mechanism 32 to provide a discrete pad of the appropriate iength.
  • a pad-weight measuring device 1 4i similar to that described above with respect to Figure 9 but which receives the desired weight of the pad to be produced as an input as opposed to the Iength input is illustrated in Figure 1 0.
  • the pad-length measuring device 1 4i includes the scale 1 24 and indicator 1 26 as described above for providing weight information to the controller 1 8 via line 1 22.
  • Figure 9 illustrates a supply stack of fan-fold stock material 92
  • Figure 1 0 illustrates a paper supply roll 64
  • either paper supply could be used interchangeably with the systems described relative to Figures 9 and 1 0.
  • the controller 1 in addition to receiving the information regarding the weight of the paper supply roll 64 from the pad-length measuring device 1 4i, also receives a weight input 1 28 over the line 1 30.
  • the weight input 1 28 may be an operator input provided through a keypad or some other means.
  • the controller 1 8 determines when the weight of paper pulled from the paper supply roll 64 is equal to or greater than the desired weight for the pad as supplied by the weight input 1 28. The controller 1 8 then instructs the feed motor 26 and cutter mechanism 32 to cut the pad to the appropriate Iength having the desired weight.
  • Such an embodiment is particularly suitable for instances in which it is desired that the package which is to be filled with the padding is to have a specified weight, such as when it is desired to keep the weight below a certain value so as to reduce postal costs, for example.
  • FIG. 1 1 there is shown a pad-length measuring device 1 4j which includes an unwinder 1 32 for unwinding paper from the paper supply roll 64 and a sensor 1 34 for controlling the operation of the feed motor 26 in accordance with whether paper 1 36 which has been unwound from the supply roll is available for conversion into a pad or whether the material which has been unwound has already been converted into a pad.
  • the controller 1 8 instructs the unwinder 1 32, which may include one or more rollers 1 38 powered by a motor 1 40, to unwind paper from the paper supply roll 64 for a time period sufficient to unwind the desired Iength of paper to be converted into a pad as determined by the input from the Iength input device 74.
  • the sensor 1 34 may include a probe, such as a contact roller 1 42, and a position sensor 1 44 for sensing the position of the contact roller.
  • a probe such as a contact roller 1 42
  • a position sensor 1 44 for sensing the position of the contact roller.
  • the sensor 1 44 will instruct the feed motor 26 via line 1 46 to cease feeding paper through the forming assembly 22. Once an adequate time has lapsed for the paper 1 36 unwound from the supply roll 64 to be converted into a pad, the controller 1 8 will instruct the cutter mechanism 32 to sever the converted strip of paper into a pad of the desired Iength. Alternatively, the sensor 1 44 may provide a direct input to the controller 1 8 to inform the controller when the paper 1 36 festooned from the stock supply roll 64 has been fully converted into a pad as determined by the position of the contact roller 142.
  • FIG. 1 2 there is shown a pad-length measuring device 1 4k which includes an unwinder 1 54 for unwinding paper 1 56 from a roll of stock paper 64 and a linear array of sensors 1 58 for determining the Iength of unwound paper 1 56 having been fed to the forming assembly 22 of the cushioning conversion machine by the feed motor 26.
  • the unwinder 1 54 is controlled by the controller 1 8 over the line 1 60 and unwinds paper 1 56 from the stock supply roll 64 until the controller determines, based on an input over line 1 62 from the sensor array 1 58 that the desired amount of paper has been unwound from the supply roll .
  • the sensor array 1 58 preferably includes a number of sensors, for example, sensors 1 58a through 1 58h illustrated in Figure 1 2, which are sufficient to detect various discrete Iength of paper 1 56 unwound from the stock supply roll 64 and falling into a festoon before the sensor array.
  • the number of sensors 1 58a through 1 58h and the spacing of the sensors is adequate to ensure that the desired Iength of pad, over various increments, can be produced.
  • the controller 1 8 will instruct the unwinder 1 54 via line 1 60 to unwind paper 1 56 from the stock supply roll 64.
  • the paper As the paper is unwound from the stock supply roll 64 it sags into a festoon generally indicated at 64 progressing from the first sensor 1 58a across the various sensors 1 58b through 1 58h as more paper is unwound . If, for example, a five foot pad were to be produced, and each of the sensors 1 58a through 1 58h were spaced one-half foot apart, as paper was unwound and was detected by each sensor 1 58, the sensor would report the detection of the paper to the controller 1 8 over line 1 62.
  • the controller 1 8 would stop the feed motor 26 and instruct the cutter mechanism 32 to engage the severing assembly 1 6 with the cut motor 30 to cut the converted paper into a pad of the desired Iength.
  • a further embodiment of a pad-length measuring device 1 4j which allows an operator to manually determine the Iength of paper to be converted into a pad by pulling the desired Iength of paper from the paper supply roll 64 is shown in Figure 1 3.
  • the pad-length measuring device 1 4j includes a scale or reticle 1 66 which the operator can use to measure the Iength of paper pulled from the paper supply roll 64 and a sensor switch 1 68 which controls the feed motor 26 and cutter mechanism 32 in accordance with whether the paper in an area 1 70 in a path of an alignment roll 1 72 through the conversion assemblies is slack, indicating that all of the paper which the operator unwound from the paper supply roll 64 had not yet been converted into padding, or whether the paper 1 70 is taut indicating that all of the paper pulled from the supply roll had been converted into a pad.
  • the sensor switch 1 68 preferably includes a contact roller 1 74 for rolling contact with the paper in the area 1 70 in communication with a positional sensor 1 76 which acts as a switch according to the position of the contact roller 1 74.
  • a positional sensor 1 76 acts as a switch according to the position of the contact roller 1 74.
  • FIG. 1 4 there is shown an embodiment of a pad-length measuring device 14k which includes an air pump 1 80 which is operated along with the drive gear 44 by the shaft 42, a reservoir 1 82 for accumulating pressure and a pressure sensor 1 84 for sensing the pressure in the reservoir.
  • the controller 1 8 instructs the feed motor 26 over line 70 to pull paper through the forming assembly 22 by driving the drive gear 44 via the sprockets 38, the chain 40 and the shaft 42.
  • the air pump 1 80 generates increased air pressure over the line 1 86 to the reservoir 1 82.
  • the pressure buildup in the reservoir 1 82 is sensed by the pressure sensor 1 84 which, through an offset switch 1 88, instructs the controller 1 8 when a pressure exceeding the offset of the offset switch has been achieved in the reservoir.
  • the offset switch 1 88 is offset or biased by the Iength input so that the pressure which actuates the switch to indicate to the controller 1 8 that the appropriate amount of padding has been produced is a function of the Iength input device 74.
  • the controller 1 8 will instruct the cutter mechanism 32 over line 72 to cause the cutter mechanism 32 to sever the converted paper into a pad.
  • the pressure in the reservoir 1 82 is relieved through the pressure valve 1 90 controlled over the line 1 92.
  • the pressure accumulated in the reservoir 1 82 could be used to power or assist in powering the severing assembly 1 6.
  • the embodiment described above utilizes air pressure to measure the Iength of pad being produced
  • a similar pressure sensing device using hydraulic fluid could be used.
  • the level of hydraulic fluid accumulated in a reservoir could be sensed and that level could be used to instruct the controller 1 8, such as through the offset switch 1 88, when the appropriate level of fluid corresponding to a desired pad Iength has been reached.
  • Figure 1 5 illustrates an embodiment of a pad-length measuring device 1 41 which employs a stepper motor 26' operated by pulses produced by the controller 1 8. Based on the desired Iength of pad as input by the Iength input device 74, the controller 1 8 will generate an equivalent number of pulses, illustrated at 1 96, over the line 70 to cause the stepper motor 26' to rotate through the desired number of steps, thus causing the drive gear 44 to turn a known distance to pull an equivalent distance of paper through the forming assembly 22.
  • controller 1 8 will instruct the cutter mechanism 32 to engage the severing assembly 1 6 with the cut motor 30 to sever the converted paper into a pad of the desired Iength.
  • FIG. 6 there is shown an embodiment of a pad-length measuring device 1 4m which employs a multiposition, wrapped spring clutch 200 which engages the drive gear 44 with the feed motor 26 as appropriate to form a pad of the desired Iength.
  • the feed motor 26 is continuously operating rotating the sprockets 38 through chain
  • the upper sprocket 38 is selectively engaged with the shaft 42 which powers the drive gear 44 to pull stock material through the forming assembly 22 as determined by the state of the wrapped spring clutch 200.
  • the wrapped spring clutch 200 is controlled by the controller 1 8 via line 202.
  • the spring clutch 202 includes a number of incremental stops permitting the clutch to engage the shaft 42 with the sprocket 38 for a given degree of rotation. Each time the spring clutch 200 is provided with a pulse from the controller 1 8 it will advance to the next stop thereby engaging the shaft 42 with the sprocket 38 for that degree of rotational advance.
  • the number of rotations of the drive gear 44, and thus the Iength of stock material which is converted into a pad, can thus be controlled by providing a set number of pulses to the spring clutch corresponding to the desired iength of pad to be produced.
  • the controller 1 8 is provided, as discussed above, with a Iength input from the Iength input device 74 and can correlate the desired Iength input with the correct number of pulses to send to the spring clutch 200. Once the controller 1 8 has caused the spring clutch 200 to engage the drive gear 44 with the feed motor 26 to create a pad of the appropriate Iength, the controller 1 8 then instructs the cutter mechanism 32 to sever the converted material into a pad.
  • a pad-length measuring device 1 4n which is operable to approximate the Iength of pad produced by the machine by converting the desired Iength of pad to be produced into the amount of power needed to supply the feed motor 26 for the feed motor to operates for a duration sufficient to feed the appropriate Iength of material through the forming assembly 22.
  • the pad-length measuring device 1 4n includes a power sensor 206 in communication with the controller 1 8 via lines 208 and 21 0 for sensing the power supply to the feed motor 26 and indicating the level of power provided to the feed motor 26 to the controller 1 8.
  • the controller 1 8 will translate the desired Iength of pad to be produced as input by the Iength input device 74 into the amount of power necessary to supply to the feed motor to produce a pad of that iength .
  • the controller 1 8 will then cause power to be supplied to the feed motor 26 via line 21 0 to begin the formation of a pad.
  • the power sensor 206 senses the power supplied and feeds an indication of the power supplied back to the controller 1 8 over the line 208.
  • the controller 1 8 then monitors the line 208 and causes the power to be terminated to the feed motor 26 once an adequate amount of power has been supplied to the feed motor 26, as sensed by the power sensor 206, to produce a pad of the desired Iength.
  • the feed motor supplies rotational power to the drive gear 44 through the sprockets 38, the chain 40 and the shaft 42, without the need of the clutch assembly 200 discussed immediately above.
  • Figure 1 8 illustrates a cushioning conversion machine 1 0 employing a pad-length measuring device 14p which measures the Iength of a pad after it has been formed and before it has been severed.
  • the Iength measuring 1 4p includes a rotating mechanism 21 2 disposed between the gear assembly 24 and the severing assembly 1 6 which frictionally engages and rolls with the pad as it progresses from the gear assembly to the severing assembly.
  • the rotating mechanism 21 2 may include a contact roller, a gear, a sprocket or some other means for converting the linear movement of the pad into rotational movement.
  • An encoder 21 4 translates the rotational movement of the rotating mechanism 21 2 into a signal, such as a pulse signal, which is provided to the controller 1 8 over the line 21 6.
  • the controller 1 8 will instruct the feed motor 26 to power the drive gear 44 of the gear assembly 24 thus pulling stock material through the forming assembly 22 and through the nip portion 21 5 of the gears 44 and 46 and causing the pad material to progress across the rotating mechanism 21 2, through the severing assembly 1 6 and into the transitional zone 50.
  • the encoder 214 supplies an indication of the Iength of pad produced to the controller 1 8 which monitors the encoded indication of pad produced and stops the feed motor 26 when the desired Iength of pad has been produced .
  • the cutter mechanism 32 is then caused to engage the severing assembly 1 6 with the cut motor 30 to sever the cushioning product into a pad of the desired Iength.
  • FIG 1 9 there is shown a pad-length measuring device 1 4q very similar to the pad-length measuring device 1 4p shown in Figure 1 8.
  • the pad-length measuring device 14q includes a rotating mechanism 21 2' and an encoder 214' which translates the rotational movement of the rotating mechanism into a signal which is sent to the controller 1 8 over the line 21 6' .
  • the pad-length measuring device 1 4q differs from the pad-length measuring device 14p in that the rotational mechanism 21 2' is disposed in the transitional zone 50.
  • the transitional zone 50 may include an output chute, a constraining assembly or a conveyor, for example. In operation, the pad-length measuring device 1 4q will function as discussed above for the pad-length measuring device 14p.
  • Figures 20 and 21 show alternate embodiments of the pad-length measuring devices 1 4p and 1 4q in which an optical sensor 220 replaces the rotating mechanism 21 2 and encoder 21 4.
  • the optical sensor 21 8 senses indicia printed on, encoded on, impressed in, or punched through the pad P as the pad is formed or shortly thereafter.
  • one of the gears 44, 46 such as the top gear 46, preferably includes an extension 21 7 on one of the gear teeth for causing a perforation 220, shown in Figure 20A, in the coined region or central band of the pad P.
  • the optical sensor 21 8 which preferably includes an optical transmitter and optical receiver
  • light transmitted from the sensor passes through a perforation 220 and is reflected to the sensor by a reflector 222.
  • the detection of a perforation, by the increased light reflection, is signaled to the controller 1 8 over the line 224 which counts the detected perforations to determine the pad Iength .
  • the reflecting media 222 can be a light-absorbing media in which case the optical sensor 21 8 would detect instances of decreased light reflection to indicate the presence of a perforation.
  • the controller 1 8 counts the detections of the perforations and correlates the count with the desired Iength of the pad to be produced and controls the feed motor 26 and cutter mechanism 32 appropriately, as discussed above, to produce a desired pad.
  • the pad-length measuring device 14s illustrated in Figure 21 , detects an indicia 226, as shown in Figure 21 a, printed on the pad P, during or shortly after the pad passes through the gears 24.
  • one or more of the gear teeth of a gear 44, 46 may include a projection 228 which contacts an inking roller (not shown) as the projection rotates and which prints a line indicia 226 on the pad P as it contacts the pad P as the projection is pulled through the nip 21 8 of the gears.
  • the indicia 226 could be printed on the paper prior to conversion into the pad, such as prior to it being rolled onto the stock supply roll or folded into a fan- fold stack.
  • the optical sensor 21 8' detects the variances in reflected light caused by the indicia 226 and provides a pulse or similar signal to the controller 1 8 over the line 224 to indicate the detection of the indicia.
  • the optical sensor 21 8' could be replaced with an ultrasonic sensor or some other type of sensor, which senses depressions, impressions, ridges and/or valleys in the pad P to measure the Iength of pad as it progresses past the sensor.
  • a pad-length measuring device 1 4t which includes a linear array of sensors 234 disposed along an output extension 240 to determine the Iength of the pad P.
  • Each of the sensors 236a through 236e is preferably an optical sensor having a corresponding optical media 238a through 238d associated therewith disposed on the other side of the pad P and output extension 240 for either reflecting or absorbing light transmitted by the optical sensors 236a through 236e.
  • the optical sensors 236a through 236d of the linear array 234 are preferably spaced so as to detect certain likely increments of pad lengths to be selected.
  • Each of the optical sensors 236a through 236e is disposed at the selected distance relative to a opening or light transmissive region 241 in the output extension 240 allowing for an uninterrupted optical path between an optical sensor and its associated optical media 238 in the absence of a pad P.
  • the leading edge of the pad P progresses through the output 50 and across the extension 240, it will first interrupt the optical path between the optical sensor 236a and associated optical media 238a and the sensor 236a will communicate the detection of the pad to the controller 1 8 over the line
  • the controller 1 8 can determine the Iength of the pad as it is produced. Once the pad P produced is equal to or exceeds the desired Iength as communicated by the Iength input device 74 the controller 1 8 will stop the feed motor 26 and instruct the cutter mechanism 32 to cut the pad to the desired Iength.
  • FIG 23 is shown a pad-length measuring device 1 4u which employs a linearly adjustable sensing device for determining when a pad has reached a certain adjustable Iength.
  • the pad-length measuring device 1 4u includes an optical sensor 242 which is linearly adjustable along a support 244 oriented relative to the output extension 246 such that the optical sensor 242 has a view of the pad P when in position in the output extension .
  • the output extension 246 is preferably provided with a scale or reticle 248 which allows the operator to determine the Iength, such as in inches, at which to position the optical sensor 242. In operation, the optical sensor 242 is adjusted to the position on the support 242 desired for the appropriate Iength pad.
  • the controller 1 8 will then instruct the feed motor 26 to begin feeding stock material through the forming assembly 22 to produce the pad P.
  • the optical sensor 242 may detect the presence of the pad P by increased reflection from the pad as opposed to when the pad is absent or the optical sensor may be provided with a corresponding reflective media (not shown) which provides a significant amount of reflective light in the absence of a pad and thus allows the sensor to easily detect the presence of a pad by the reduction in the amount of light reflected by the pad P to the optical sensor.
  • the optical sensor 242 detects a pad P, it sends a signal or pulse along the line 250 to the controller 1 8.
  • the controller 1 8 Upon receipt of the signal from the optical sensor 242, the controller 1 8 will instruct the feed motor 26 to cease producing additional pad and the controller 1 8 will instruct the cutter mechanism 32 to cause the pad P to be severed at the appropriate Iength.
  • FIG. 24 A further embodiment of a pad-length measuring device 1 4v is illustrated in Figure 24.
  • the pad-length measuring device 14v includes a moving barrier 254 coupled to a linear sensor 256 for sensing the position of the movable barrier.
  • the movable barrier 254 and linear array 256 may be embodied in such a way that the movable barrier will contact the pad P very near the output 50 of the machine and move with the pad with the linear sensor recording the position of the movable barrier and reporting that position to the controller 1 8 along the line 258. In such a case, the controller
  • the controller 1 8 would monitor the position of the movable barrier 254 as provided by the linear sensor 256 over line 258 and once the position of the movable barrier was consistent with the Iength input as provided to the controller 1 8 by the Iength input device 74, the controller 1 8 would cause the feed motor 26 to stop producing additional pad and would instruct the cutter mechanism 32 to sever the pad.
  • the movable barrier 254 could be adjustable at a position relative to the output extension 246 and could operate such that once the pad reached the preset point of the movable barrier 254 and moved the barrier beyond this position, as detected by the linear sensor 256, the movable barrier and linear array would act as a trip switch and send a pulse to the controller 1 8 along the line 258 once the pad had contacted and moved the movable barrier.
  • the Iength input device 74 would not be necessary and the controller 1 8 would need only to wait for the detection of a pulse from the linear sensor 256 in order to cease the feed motor 26 operation and instigate a severing operation of the pad.
  • FIGs 25 and 26 there is shown an embodiment of a pad weight or length-measuring device in which the weight of the pad P on an output scale 260 is sensed and reported to the controller 1 8 along the line 262.
  • the controller 1 8 receives a Iength input from the Iength input device 74 and translates the desired Iength input into the weight of the pad P for such a Iength. Consequently, as the pad P emerges from the machine output 50, the scale 260 will report the weight over the line 262 to the controller 1 8 which will compare the weight to the weight corresponding to the desired Iength input. Once the desired weight has been reached or exceeded, the controller 1 8 will then cause the feed motor 26 to stop and the cutter mechanism 32 to cause the pad P to be severed.
  • the controller 1 8 is provided with a weight input from the weight input device 1 28. As the pad P progresses from the machine output 50, the controller 1 8 will monitor the weight of the pad as provided by the scale 260 via line 262 and compare the sensed weight to the input weight. Once the sensed weight equals or exceeds the weight input, the controller 1 8 will cause the feed motor 26 to stop the production of additional pads and activate the cutter mechanism 32 to sever the pad P at the appropriate weight.
  • a pad-length measuring system 1 4y which employs a velocity sensor 270 to sense the velocity of one of the rotating components of the cushioning conversion assembly 1 2, or the velocity of the paper through the machine, to determine the Iength of a pad being formed.
  • the velocity sensor 270 may be an optical sensor, a magnetic sensor, etc., which through some means determines the velocity of the paper or of a cushioning conversion component and provides a digital or analog indication of the velocity over time to the controller 1 8 via line 272.
  • the controller 1 8 can convert the velocity data to Iength by calculating the integral of the velocity as a function of the pad formation duration and multiplying the result by a constant which accounts for gear ratios, etc., depending on where the velocity was sensed.
  • the controller 1 8 determines the iength of pad to be produced by referring to the Iength input 74 and instructs the feed motor 26 to begin feeding paper through the forming assembly 22. As the sensed cushioning conversion component, such as the drive gear 44, begins to rotate, the velocity sensor 270 will begin transferring velocity data to the controller 1 8 over the line 272. The controller 1 8 will calculate the Iength of pad produced from the velocity data and compare the converted Iength with the desired Iength. Once the calculated Iength of paper converted into a pad equals the desired pad Iength, the controller 1 8 will instruct the feed motor
  • Iength measuring device 1 4 A further embodiment of the Iength measuring device 1 4 is described in co-owned U.S. Patent No. 5,571 ,067, which is incorporated in its entirety by this reference.
  • Iength of the formed pad is determined by sensing the rotation of the gears 44 and 46 using an electro-optical device.
  • the feed motor 26 after being instructed to stop by the controller 1 6 may coast or overrun before coming to a complete stop.
  • Other factors include the type and condition of the stock material and the moisture content of the stock material, for example.
  • the calibration may be performed manually which typically requires interaction between the operator and the cushioning conversion machine or more preferably in an automated fashion. Such calibration may be performed at prescribed time or usage intervals, as requested by an operator, such as by depressing a calibration button associated with the controller 1 8, or each time a pad is produced.
  • K is a constant that relates to the Iength of pad produced per encoder pulse
  • K 2 is a constant that relates to Iength of pad produced by feed motor 26 overrun after the motor is turned off. If the constants K, and K 2 are known for a conversion machine, the Iength of pad produced by the machine can thus be accurately controlled by monitoring the encoder pulses. Considering, for example, a cushioning conversion machine having a
  • the Iength of a pad is determined by the controller 1 8 which multiplies the number of encoder pulses received from the encoder by the constant K, and adds to the product the constant l ⁇ 2 .
  • Other encoders can also be used such as that described in pending U.S.
  • Patent No. 5,571 ,067 which sense the rotation of the drive gears 44 and 46 or encoders which sense the rotation or linear movement of other parts of the cushioning conversion machine, such as the drive shaft 42, from which pad Iength production can be inferred.
  • the constants K, and K 2 are determined through the use of a second sensor, such as the optical sensor 242 described above relative to Figure 23, positioned a known distance from the blade of the severing assembly 1 6.
  • the optical sensor 242 can be placed anywhere along the output extension 246 provided that the controller 1 8 is provided with this known distance.
  • the optical sensor 242 is located generally around eight to twelve inches from the blade of the severing assembly 1 6 as this is a typical pad
  • the controller 1 8 turns on the motor 26 and counts the number of pulses received from the encoder 21 4 until the optical sensor 242 detects the end of a pad .
  • the controller 1 8 then calculates the constant K ⁇ as follows:
  • K 7 distance between blade and optical sensor 242 recorded encoder 214 pulses
  • the controller 1 8 will continue to leave the feed motor 26 running until the desired or preset pad Iength is produced whereupon the controller 1 8 will turn off the feed motor. After the feed motor 26 is turned off the controller 1 8 will then record the number of additional pulses received from the encoder 21 4 due to feed motor overrun, etc. The controller 1 8 can then calculate the constant K 2 as follows:
  • K 2 K 1 * (additional recorded encoder 214 pulses)
  • the controller 1 8 in producing further pads may then use the updated values of the constants K-, and K 2 to calculate pad Iength.
  • a number of calibration procedures could be performed with the averages of the constants taken before the constants are updated . This provides the advantage that a single calibration procedure does not result in a significant difference in the pad iength calculation. The system is thus less susceptible to errors in a calibration procedure due to disturbances in the calibration technique or interference by the operator, for example.
  • the pad Iength measuring system 14t of Figure 22 described above could be used in a fashion where the series of optical sensors 236 provide to the controller 1 8 an indication of actual pad Iength from which the controller 1 8 could determine a correction factor.
  • the optical sensors 236 are located at a known distance from the blade of the severing assembly 1 6 and at a known spacing, such as a one inch spacing, when the controller 1 8 instructs the feed motor 26 to produce a 1 2 inch pad, for example, the outputs of the optical sensors can be examined by the controller to determine the actual Iength of the pad produced to an accuracy constrained by the spacing of the sensors. The controller 1 8 can then make any necessary corrections to produce an appropriately lengthened pad.

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Abstract

La présente invention concerne une machine de transformation de papier en produit de calage comprenant un dispositif de formage qui transforme une matière brute en un produit de calage, un dispositif d'alimentation fournissant la matière brute provenant d'une réserve d'alimentation au dispositif de formage, un contrôleur permettant de commander le fonctionnement du dispositif d'alimentation de façon à produire un bloc d'une longueur prédéterminée et un dispositif de mesure de longueur de bloc. Ledit dispositif de mesure de longueur de bloc peut comporter un dispositif permettant de mesurer la longueur, le poids, le rayon ou la hauteur du papier retiré ou déroulé à partir d'un dispositif d'alimentation, ou un dispositif de mesure de la longueur ou du poids du bloc lors de la production.
EP98906659A 1997-02-14 1998-02-17 Machine de transformation de papier en produit de calage comportant un dispositif de mesure de longueur Withdrawn EP1007344A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US80032397A 1997-02-14 1997-02-14
US800323 1997-02-14
PCT/US1998/003525 WO1998035826A1 (fr) 1997-02-14 1998-02-17 Machine de transformation de papier en produit de calage comportant un dispositif de mesure de longueur

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EP1007344A1 true EP1007344A1 (fr) 2000-06-14

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EP (1) EP1007344A1 (fr)
AU (1) AU6182398A (fr)
WO (1) WO1998035826A1 (fr)

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Publication number Priority date Publication date Assignee Title
FR2786124B1 (fr) * 1998-11-20 2000-12-29 Naturembal Sa Machine a cycles de production de matelas de longueurs differentes
DE102008039550A1 (de) * 2008-08-25 2010-03-04 OCé PRINTING SYSTEMS GMBH Verfahren und System zum Erzeugen von Polsterelementen
DE102018009733A1 (de) * 2018-12-11 2020-06-18 Sprick Gmbh Bielefelder Papier- Und Wellpappenwerke & Co. Vorrichtung mit Elektromotor zum Bereitstellen von Verpackungsmaterial und Verfahren zum Betreiben einer Verpackungsmaterialbereitstellungsvorrichtung
CN112678601B (zh) * 2020-12-18 2023-05-26 杭州丙甲科技有限公司 包装用衬垫的生产方法

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Publication number Priority date Publication date Assignee Title
US4619635A (en) * 1985-11-04 1986-10-28 Ranpak Corp. Automatic feed circuit for dunnage converter
CA2133420C (fr) * 1992-03-31 1998-08-18 Edwin P. Beierlorzer Methode et appareil de fabrication d'un produit d'emballage elastique ameliore
DE69433887T2 (de) * 1993-11-19 2005-07-14 Ranpak Corp., Concord Verpackungssystem und verpackungsverfahren
NL9400606A (nl) * 1994-04-15 1995-11-01 Ranpak B V Inrichting voor het vervaardigen van lintvormig verpakkingsmateriaal van gelaagd papier of dergelijke.
ATE319620T1 (de) * 1994-07-22 2006-03-15 Ranpak Corp Vorrichtung und verfahren zum verpacken von gegenständen

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Title
See references of WO9835826A1 *

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AU6182398A (en) 1998-09-08
WO1998035826A1 (fr) 1998-08-20

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