US3420387A

US3420387A - Blank handling apparatus

Info

Publication number: US3420387A
Application number: US607527A
Authority: US
Inventors: Theodore M Baum
Original assignee: Koppers Co Inc
Current assignee: Beazer East Inc
Priority date: 1967-01-05
Filing date: 1967-01-05
Publication date: 1969-01-07
Anticipated expiration: 1986-01-07

Description

Jan. 7, 1969 T, M, BAUM 3,420,387

BLANK HANDLNG APPARATUS Filed Jan. 5, 1967 INVENTOR. THEODPE M. BA1/M Sheet 2 of 4 Jan. 7, 1969 T. M. BAUM A BLANK HANDLNG APPARATUS Filed Jan. 1967 mi QQ Jan. 7, 1969 T. M. BAUM BLANK HANDLNG APPARATUS Sheet Filed Jan. 5, 1967 'INVENTOR. m5000915 M. BAUM BY w ',d

/ll's dm- Jan. 7, l1969 T. M. BAUM BLANK HANDLING APPARATUS Sheet Filed Jan. 5, 1967 United States Patent O 4 Claims ABSTRACT F THE DISCLOSURE Apparatus for stacking a preselected number of corrugated blanks for tying into a bundle for shipping purposes comprises a first stacker for forming the individual blanks that are fed from a folder-gluer into la stack yby action of an oscillating plate acting against the trailing edges of the blanks to square the blanks and force the leading edges against a feed gate; a reciprocating feeding mechanism for feeding the bottornmost blank from the first stack to a final stacker Where a second stack of blanks of predetermined number is formed on a continuously running conveyor by blanks fed to the underside of the second stack. The conveyor urges the leading edges of the blanks against 'a pair of stop-gates while a front guide for the trailing edges of the blanks prevent the stack from tipping over. The feeding of blanks from the first stack is interrupted upon completion of the final stack and simultaneously the stop-gates are pivoted out of engagement with the second stack to permit the removal of the stack by the conveyor.

This invention relates to stacking apparatus for receiving the individual blanks froma folder-gluer and for stacking the blanks into a stack of a predetermined number of blanks for tying and shipping as a bundle. Blanks folded and glued in conventional folder-'gluer machines often leave the folder-gluer machine in an out of square condition. This condition, of course, must be corrected lbefore the glue dries. It is desirable to have these individual blanks piled in a stack for subsequent bundling. In view of floor space and material handling considerations, it is also desirable to accomplish squaring and stacking in a straight line operation immediately following the foldergluer. It is additionally helpful to have the squaring and stacking accomplished at substantially the same level that the blanks leave the folder-gluer. Since the folderdgluer is capable of processing blanks of various sizes, blanks squaring and stacking machines must possess a capability for handling blanks whose dimensions may vary widely. Besides this, it preferably is adjustable to provide stacks of blanks of preselected varying numbers for subsequent bundling preparatory to shipping.

The present invention provides apparatus for automatically stacking, squaring and delivering stacks of blanks of predetermined number at a position which is in lateral and substantial horizontal alignment with a folder-gluer machine. The invention contemplates a first stacker for receiving individual blanks from the folder-gluer, a final stacker for receiving individual blanks from the first stacker, a feed for feeding individual blanks from the first stacker to the final stacker at a rate greater than the individual blanks are received by the first stacker and a conveyor for discharging from the final stacker a stack of a predetermined number of individual blanks, and controls for stopping the feed during the discharge of the stack from the final stacker.

The above and further objects and novel features of the invention will appear more fully from the following detailed description when the same is read in connection with the accompanying drawings. It is to be expressly understood, however, that the drawings are not intended lCC as a definition of the invention but are for the purpose of illustration only.

In the drawings wherein like parts are marked alike:

FIGURE 1 is perspective view of the novel apparatus as it would appear when used in connection with a foldergluer and delivery conveyor, both of the latter being shown in phantom lines;

FIGURE 2 is a side elevation of the apparatus shown schematically to best illustrate its operation;

FIGURE 3 is a top view of the stopgates in partial crosssection showing the two positions of the gates;

FIGURE 4 is a Schematic diagram for the power train of the machine; and

FIGURE 5 is a wiring diagram of the electrical controls for the machine.

Referring to FIG. 2, there is provided a first stacker 7 for accumulating blanks 10 in 4a stack 11 as they are received in sequence from =belt 12 of a folder-gluer machine 16; a second stacker 13 for accumulating a final stack 15 of a preselected number of blanks; and a feeder comprised of feed rolls 33 and a reciprocating mechanism 34 for operatively connecting the stackers by feeding successive bottornmost blanks from the first stack 11 onto the bottom of the second stack 15 until the desired number of blanks are in the second stack 15, and a control system, FIG. 5, for interrupting the feeding of the bottornmost blanks to the second stack 15 after a desired number of blanks have been fed to the second stack, and for discharging the final stack 15 of blanks from the machine and onto a conveyor 124 during the time that the feeding is interrupted and thereafter for continuing the feeding and stacking sequence.

The blank 10, FIGS. 1 and 2, is shown as it is being discharged from between a conveyor 12 and pressure rollers 14 of a conventional folder-gluer 16. Blank 10 enters into the first stacker 7 and undergoes the first phase of the stacking, squaring, and delivering operation in this portion of the machine that is hereafter referred to as the squaring-compression section. This first phase consists of accumulating the individual blanks 10` as a stack 11 of blanks and concurrently squaring the stack. The blanks have been folded into a tubular knocked-down carton shape in the folder-gluer as indicated generally at 18 in FIG. 1. Blank 10' has a corner tab 20 which has been glued to a corner of the blank. Since the blank may not be folded perfectly square in the folder-gluer 16, 'a squaring plate assembly 28 is provided at stacker 7 to square the blank before the glued tab 20 has a chance to set.

The first stacker or squaring-compression section 7 comprises a pair of

pull rolls

22, 24 for maintaining control of the blanks as they leave the folder-gluer 16; :a feed gate 26 for arresting the forward travel of the blanks and (as will be later described) for metering the flow of blanks to the second stacker or bundle-ejector section 13; an oscillating squaring plate assembly 28 ata position opposite the feed-gate 26 for periodically spanking the trailing edges of the blanks, thereby urging their leading edges against the feed gate 26 with enough force to square the blanks; a feed bed 30 for supporting the blanks :as they settle to form a stack cooperative with the feed gate 26 so that the leading edge of the bed forms a gap 32 between the bed and the bottom of the feed gate 26 for metering only the bottornmost blank into the bundle-ejector section 13; a reciprocating feed mechanism 34 for engaging the trailing edge of the bottornmost blank and urging the blank forward into gap 32 where feed rolls 33 feed it into the bundle-ejector section 13 as the lowermost blank and a feed interruptor 36 which is actuated after a preselected number of blanks have been fed to the second stacker 13 to raise the trailing edge of the stack to prevent engagement by the feeder 34 for an interval of time after which time the stack is lowered and the feed cycle is repeated.

The blank enters stacker 7 by way of a pair of

pull rolls

22, 24 which are journaled for driven rotation between a pair of spaced apart

side frames

38L, 38R. These rolls are positioned at a level to receive the blanks 10 from the folder-gluer in the nip formed by the rolls. Upper roll 22 is journaled in conventional eccentrics (not shown) which can be simultaneously rotated in the known manner to move roll 22 closer to roll 24 to suit the caliper of the blanks.

Upper roll 22 is made by securing a pair of laterally spaced collars 23 for rotation with a shaft 25. The collars 23 preferably have an outer elastomeric covering such as synthetic rubber to aid in gripping the blanks. The collars 23 are adjustable axially of shaft 25 so that they may be positioned to grip the blanks at any desired location, usually near the lateral edges. They may be secured in the selected location by means of set-screws (not shown).

Lower roll 24 is made by securing several laterally spaced collars 27 for rotation with a shaft 31 defining spaces 33 between them having a width about equal to that of collars 27. Col-lars 27 are similar to collars 23 except that they ordinarily remain in a fixed location rather than being adjustable axially.

The forward movement of the blanks is arrested b-y a feed-gate 26 which comprises a lateral plate 40 having each end slidably nested in vertical slots 42 formed in the bundle-

ejector side frames

44L, 44R. The plate 40 is raised or lowered to permit only one blank to pass through the gap 32 into the bundle-ejector section. Vertical adjustment is accomplished by rotating a pair of rods 46 threaded into plate at location 48. Rotation of rods 46 is effected by a pair of conventional miter gear assemblies 50 connected to the rods 46 and to a common cross shaft 52 which is rotatably secured between the side frames 44L, 44K.

The stack of blanks is maintained in alignment or squared by way of an oscillating squaring plate assembly 28, particularly by a plate 54 that is pivotably supported by a cross shaft 56 which, in turn, is supported between

side frames

38L, 38R. When plate 54 is in the vertical position, one face of plate 54 is coplanar with the trailing edges of the blanks in the stack. When the plate is oscillated about shaft 56, plate 54 moves away from the stack at an angle and then returns to coplanar Contact. If any of the blanks are out of square, some of the edges of the blanks will protrude beyond the desired planar surface (both leading and trailing edges), and the plate 54 will force them into alignment by spanking the blank against the feed gate 40. It can be observed that each blank may be subjected to the spanking action several times as the blank moves downward in the stack.

Oscillation of plate 54 is accomplished by connecting the plate by a connecting rod 58 to a drive shaft 60 which has an eccentric 62 connected for rotation therewith. Connecting rod 58 encircles the eccentric 62 so that as the drive shaft rotates, the rod 58 is caused to reciprocate and, being connected to plate 54 by a conventional pin connection 64, causes plate 54 to oscillate about cross shaft 56 to which it is pivoted. In the event the folder-gluer is subsequently improved to the extent that the folded blanks are squared prior to leaving the machine, the squaring plate assembly 28 would not be required. The squaring-compression section would operate substantially in the same manner except that plate 54 could be stationary.

The stack 11 of blanks accumulates or piles up on a feed bed 30. A number of spaced apart slats 66 constituting bed 30 extend longitudinally of blank travel with their downstream ends secured to a cross member 68 mounted between

side frames

44L, 44R. The upstream ends of slats 66 rest in corresponding grooves 69 provided in a cross member 70 mounted between side frames 38L, 38K.

The lowermost blank of stack 11 is fed onwardly toward the second stacker 13 by reciprocating feed mechanism 34 and feed rolls 33. Mechanism 34 is conventional. As illustrated herein, a feed mechanism such as described in Greenwood Patent No. 2,705,143 issued Mar. 29, 1955, is used except that the skip-feed feature described in the Greenwood patent is not required in the present machine. Briefly, the feed mechanism 34 comprises a Whitworth crank mechanism 72 which imparts reciprocating motion through suitable gearing and levers to a pair of

kicker bars

74L, 74R which are slidably situated in a pair of corresponding spaced apart slots 76L, 76K provided in cross member 70. A feeder bar 78 spans the kicker bars and is secured to the bars at each end. Feeder tongues 80 are secured to the feeder bar 78 so that the tongues extend forwardly towards the bottommost blank of the stack resting on feed bed 30. The feeder tongues 80 are spaced intermediate the grooves 69 carrying slats 66 and thus rest on the cross member 70. The forward or leading edge of tongues 80 .are inclined upwardly toward the rear to a point short of intersection with the top plane of the tongue at which point the incline becomes vertical thus forming a ledge 82 which engages the trailing edge of the bottommost blank to urge it forward upon each forward stroke of the feeder bar 78. In this manner, each succeeding bottomrnost blank is fed into the downstream bundle-ejector section until the feeding action is stopped by a feed interruptor 36.

Feed interruptor 36 comprises a cross shaft 84 rotatably mounted in side frames 38L, 38R in a position beneath the trailing edge of the stack of blanks 11 resting on feed bed 30. A number of fingers 86 are spaced along the shaft and secured to the shaft so as to fit alternately between the slats 66 and feeder tongues 80. Upon the pivoting of cross shaft 84, fingers 86 engage the bottom of the stack 11 and lifts it upward. Now, the ledge 82 of feeding tongues 80 cannot engage the trailing edge of the bottommost blank.

Shaft 84 is pivoted about 30-60 (the amount is not critical) by a conventional rotary air cylinder 85 attached to one end of the shaft and anchored to one of the side frames 38L or 38R. Air cylinder 85 rotates shaft 84 in response to a signal from one of four conventional rotary limit switches N-15, N-Ztl, N-25, N-30, FIG. 5, geared to drive shaft 60. An air cylinder such as a ROTA-CYL Model 2.5 made by Graham Engineering Company, Palo Alto, California, can be used for this purpose. Shaft 60 completes one revolution for each blank leaving the folder-gluer. One rotary limit switch N-15 is geared to transmit a signal to the air cylinder 85, for example, after fteen blanks have entered the hopper, and the remaining three switches N-20, N-25 and N-3t) are geared to transmit signals corresponding to 20, 25 and 30 blanks entering the hopper. A selector switch 258 connects the air cylinder to the proper rotary switch corresponding to the number of blanks desired in the nal stack 15.

Also included in the squaring-compression section is an air holddown assembly 86. As a blank exits from between the pull rolls 22, 24, assembly 86 directs a jet of air against the top trailing edge of each blank. This forces the trailing edge of the blank down against the top of the stack so that the leading edge of the following blank does not jam against the trailing edge of the foremost blank.

Air holddown assembly 86 comprises an air nozzle 88 in communication with a suitable air supply (not shown) and supported on a cross bar 90 mounted between side frames 38L, 38R. The support may be in the form of a collar 92 around cross bar 90 which can be secured in a selected lateral position by a clamp screw 94. Nozzle 88 is secured to support 92 by means of a U-shaped clamp or the like.

Also included in the squaring-compression section is a jam switch 96 which, when triggered, will signal the main drive for the folder-gluer to stop its operation. "lfhus, if a jam-up occurs, the machine will stop until the obstruction is removed.

J am switch 96 as illustrated in FIG. 2 comprises a flat plate 98 that is placed between pull rolls 22, 24. The upturned end 100 of plate 98 is spaced in front of the pull rolls to aid in guiding the blanks between the rolls. Plate 98 extends in the space between the collars 23 of upper pull roll 22 so as not to interfere with the pulling action of the

rolls

22 and 24 against the blanks. Secured to the top of plate 98 is a rod 102 which extends through a collar 104 resembling collar 92 and secured in similar fashion to cross lbar 90. A spring 105 between a shoulder 106 on rod 102 and the collar 104 maintains the plate 98 in operating position. A stop mounted on the opposite end of rod 102 (not shown) prevents the spring 104 from overextending the plate 98 into the path of the blanks. If for some reason the stack of blanks 11 builds up to the point of interference with blanks leaving the folder-gluer, the plate 98 will be elevated and, through rod 102, trigger a conventional limit switch 103 located adjacent the upper end of rod 102. When triggered by the rod, switch 103 transmits a signal to stop the main drive motor of the folder-gluer. The main drive motor will remain stopped until the plate -98 is returned to its operating position. If preferred, the air holddown assembly can be combined with the jam switch to form an integral assembly.

The lowermost blank that is fed through the gap 32 between gate 26 and support 30 is fed into the second stacker 13 as the lowermost blank of stack 1-5 by Way of feed rolls 33 which are comprised of a pair of driven pull rolls 108, 110. These rolls pull the blanks into the bundleejector 13 as they are fed through the gap 32 formed by the feedgate 26 and the feed bed 30. The movement of the blank is also aided by a driven conveyor assembly 112 that has an upper run 114 slightly higher than the top of feed bed 30. The upper run is supported on the lower pull roll 110 so that the upper run has an upstream inclined portion 116 for guiding each blank under the stack being formed.

Stacker 13 also includes a pair of back-stop assemblies 118, 120 against which the blanks are urged by the upper run 114 of conveyor 112 and a front guide 122 to prevent the stack of blanks from tipping over. An actuator 205, FIGURE 3, pivots the back-stop assemblies 118, 120 about 186 out of the path of travel of the blank, following actuation of the feed interruptor 36. Conveyor assembly 112 now ejects the accumulated stack 15 of blanks onto an idling roller conveyor 124. At this time, no blanks are being fed from stack 11 into the bundle-ejector section because fingers 86 have lifted the trailing edge of stack 11 out of engagement with the feed tongues 80. A manual adjustment 164 adjusts the lineal position of the back-stop assemblies 118, 120 for accommodating preselected lengths of blanks. A motor opening assembly (motor M-4, rack 213) adjusts the lineal position of the bundle-ejector section 13 in relation to the squaring-compression section 7 to adjust the latter section to accommodate the same preselected length of blanks.

Pull

rods

108, 110 of feed roll unit 33 are journaled for driven rotation between spaced apart side frames 44L, 44K at a level to receive in the nip between them the blank that is being fed through the gap 32 between feed gate 26 and bed 30 by the reciprocating feed mechanism 34. Advantageously, upper roll 108 is journaled in conventional eccentrics (not shown) which can be rotated in the known manner to move roll 108 closer to roll 110 and change the nip openings to suit the caliper of the blanks. Lower roll 110 is made by securing several laterally spaced collars 126 for rotation with a shaft 128 defining spaces 130 therebetween. Upper roll 108 is made by securing a correspon-ding number of laterally spaced collars 132 for rotation with a shaft 134 in radial alignment with lower collars 126. Upper collars 132 are preferably steel and lower collars 126 are preferably covered with synthetic rubber around their outer periphery. Thus, the

blanks 10 are gripped between the opposing

collars

136 and 126 and forced under stack 15 as the lowermost blank.

Conveyor assembly 112 for cooperating with feed roll unit 33 comprises a plurality of conveyor belts 136 eucircling aligned pairs of

pulleys

138, 140. Pulleys 138 are secured for rotation with a driven pulley shaft 142 spaced downstream from lower pull roll 110. Pulleys are mounted around bushings (not shown) situated on lower pull roll shaft 128 in the spaces 130 between the lower pull roll collars 126. This arrangement permits pulleys 140 to free-wheel around shaft 128. Pulleys 140 have an outer diameter smaller than the outer diameter of pull roll collars 126 so that the conveyor belts 136 encircling the pulley do not protrude vertically above the periphery of the lower pull roll collars into the nip between them and the upper pull roll. As best illustrated in FIG. 2, a pair of idler rolls 144, 146 are provided to support the upper run 114 of belts 136 at a level slightly higher than the top surface of feed bed 30. Preferably, idler rolls 144, 146 are journaled for rotation in slide blocks 148, 150 placed in a slot 152 in side frames 44L, 44R.

The upstream and downstream pairs of slide blocks 148, 150 are adjustable towards and away from each other and can be clamped in position by any convenient clamping means. Thus, it can be seen that this adjustment prolvides means for adjusting the inclined portion 116 of belts 135 between lower pull roll 128 and idler roll 144 and an inclined portion 154 between idler roll 146 and pulley shaft 142. It may be ldesirable to adjust the amount of incline depending on the length of blank being handled to prevent tipping of the stack. Pulley shaft 142 is driven at about one-eighth pull roll speed for minimum length blanks and up to one-half pull roll speed for maximum length blanks. This provides an additional measure of control over the blanks to prevent tipping of the stack being Iformed.

A conventional belt tightener 156 is provided for maintaining the desired tension on conveyor belts 136.

Since the dimensions of the blanks being stacked may vary, stacker 13 is made adjustable. Accordingly, backstop assemblies 118, 120` for the stack 15 of blanks are mount-ed for lateral adjustment on a pair of cross-rods 158. Cross-rods 158 are supported in slide carriages 160L, 160R through which racks 162 pass in meshing engagement with toothed pinions 164 secured to the ends of one of the cross-rods 158 which is rotatable. Racks 162 are supported between upstanding portions 159 of the side frames 44L, 44K. An end 164 on the rotatable cross-rod extends through carriage 160L and is adapted to receive a ratchet wrench (not shown) for rotating the cross-rod for moving the carriages 160L, 160R upstream or downstream. A conventional pinch type clamp 165 is provided on cross-rod end 164 to lock the cross-rod against rotation once it has been rotated to the desired position. In this manner, back-stop assemblies 118, 120 are move-d toward or away from front guide 122 to correspond to the length of blanks being handled. It should be understood that a suitable gear motor can be provided for rotatable connection Iwith cross-rod end 164 to replace the manual adjustment just described.

Front guide 122 for the stack 15 comprises an upstanding plate suitably secured between side frames 44L, 44R immediately behind upper pull roll i108. The top of front guide 122 extends 'a little beyond the maximum height of the stack to be formed. The bottom of the guide terminates above the lower` surface of the upper pull roll 108 so as not to interfere with the blanks being fed onto the bottom of the stack.

To provide for lateral adjustment of back-stop assemblies 118, 120 to accommodate the width of the blanks being handled, the back-stop assemblies have corresponding side plates 166, 168. A pair of threaded

screws

170, 172 are provided adjacent to and parallel with cross-rods 158. Each threaded screw has threads formed thereon beginning near the lateral center of the machine with the threads on one screw extending to the left iand on the other to the right-hand side of the machine. A pair of holes 174, 176 are provided in side plates 166, 168 of which alternate ones are threaded for engagement with one of the pair of

screws

170, 172 passing through the holes. The unthreaded hole slides along the unthreaded portion of the adjacent screw. The ends of

screws

170, 172 are supported for rotation in slide carriages 1601., 160R. Thus, it can be seen that simultaneous rotation of both screws causes the back-stop assemblies to eithermove toward or away from the center of the machine depending upon the direction of rotation of the screws. One end of each threaded

screw

170, 172 is secured for driven rotation with one of two gearmotors 174 mounted to slide carriage 168K. Suitable pushbutton controls are provided to run the gearmotors in the appropriate direction to position the backstop assemblies relative to the center of the machine.

Besides being adjustable to `accommodate various size blanks, back-stop assemblies 118, 120 are designed to arrest for-ward travel of the blanks as a stack is being formed and then to be disengaged from the stack at the proper interval to permit the stack to be ejected from the bundle-ejector section and onto, for example, a roller table 124 where the stack may be tied with string for handling and shipping. This is accomplished by providing gatestops 180L, 180k, against the leading edges of the blanks and pivotable about a vertical axis to a position out of engagement with the stack immediately following engagement of feed interruptor 36. With the gate-

stops

180L, 180R out of engagement, conveyor assembly 112, which runs continuously, moves the stack of blanks downstream for further handling.

Preferably an upstanding side roller 182 is provided to engage each side of the stack when the gate-stops are re.- tracted to provide a reduced friction side guiding surface for the stack as it is ejected. This roller engages the side of the stack so that all the blanks move forward simultaneously.

The construction of the right-hand back-stop assembly 118 may be more readily understood by reference to FIG. 3 wherein there is illustrated sideplate 168 for loosely engaging the side of the stack. The lower portion of sideplate 168 terminates just short of touching the tops of conveyor belts 136 and the upper portion extends above the top of the stack wherein the aforementioned holes for cross-rods 158 and threaded

screws

170, 172 are provided.

A pair of spaced apart upper and lower lugs 184 are formed on the outside of sideplate 168 between which a pivot rod 186 is supported. Gate-stop 180K includes a pair of arms 188 through which pivot rod 186 passes for pivotal support. Another pair of arms 190 are formed substantially diametrically opposite arms 188 for mounting side roller 182.

Arms 190 include an enlarged portion 192 with a hole 194 through which a pin 195 is kept in an extended position by means of a coil spring 196 between a shoulder portion 198 Iand enlarged portion 192. Pins 194 have vertically aligned holes 202 for receiving reduced diameter end portions 204 of rotatable rubber covered side roller 182.

The geometry of

arms

188 and 190 is such that when gate-stop 180R is engaging the leading edges of the blanks, side roller 182 is out of engagement with the sides of the blanks. When gate-stop 180R is pivoted out of engagement about pivot rod 186, side roller 182 moves into engagement with the sides of the blanks. The proportions are such that spring 196 is compressed by engagement of side roller 182 with the blanks so that the roller compensates for any unevenness of the blanks.

The alternate position of the gate-stop and side roller is indicated by phantom lines in FIG. 3. To pivot the gateslop 180R from the engaged to the disengaged position there is provided a conventional rotary air cylinder 205 (such as described for use with the feed interruptor) whose output shaft 206 is connected to pivot rod 186 by means of meshing

spur gears

208 and 210 of which gear 288 is secured for rotation to output shaft 206 and gear 210 is secured for rotation with pivot rod 186. Since gatestop 180k preferably rotates about 45 from one position to the other and output shaft 206 rotates about the ratio of gear 210 is about 2:1 With gear 208. This ratio is not critical and other arrangements can be used if desired.

Rotary air cylinder 205 can be mounted by means of suitable brackets (not shown) to side plate 168. A conventional double acting solenoid air value is provided in the air supply to cylinder 205 to rotate output shaft 206 in one desired direction. The valve is triggered by a signal from one of the rotary limit switches N-15, N-20, N-25 or N-30 being used to signal the feed interruptor 36. Thus, when the feed interruptor 36 stops the feeding of blanks into the bundle-ejector section 13, the gate-stops L, 188K swing out of contact with the blanks, the side rollers 182 engage the side of the stack, and conveyor 112 moves the stack out of the machine onto idling conveyor 124 for subsequent handling.

To adjust the lineal position of the bundle-ejector sectiJn in relation to the squaring-compression section to accommodate the selected blank length, there is provided a pair of rails 212 anchored to the floor. These rails are adapted to guide a number of roller cages 214 secured to the bottom of side frames 44L, 44R. A toothed rack 213 is secured to the inside wall of each rail 212. Meshing with each rack is a pinion gear on the output shaft of a pair of miter gear boxes (not shown) each of which is respectively secured adjacent the rack on the inside of side frames 44L, 44K. The gear boxes are linked for simultaneous rotation by a shaft which is connected to a gearmotor M-4 mounted to side frame 44L. Thus, upon rotation of gearmotor M-4, the pinion gears meshing with the racks 213 pull the bundle-ejector section towards or away from the squaring-compression section. This, of course, moves feed gate 40 in relation to the oscillating squaring plate 54 for setting the proper distance between them for the blank selected. The mechanism just described for moving one section relative to another is conventionally used on box machines such as printer-slotters.

The power train, FIGURE 4, for running the machine is comprised of conventional elements Stich as chains and sprockets, spur gears, and clutches. The manner in which `thcy are mounted and connected is well known in the art so that only a brief description is deemed necessary. Referring now to FIG. 4, the machine is powered by a chain drive 350 from a take-off sprocket 352 on the folder-gluer to a sprocket 354 on the end lof drive shaft 60. Sprocket 354 rotates drive shaft 60 through a conventional manual clutch 356 having an engaging/disengaging handle 358. A friction clutch such as bronze bushing type 8B made by Link-Belt Company, 301 W. Pershing Road, Chicago, Ill., is satisfactory for this purpose. Its operating handle may be used to disengage the clutch from the chain drive. In this manner, the squaring-compression section or the bundle-ejector section can be easily maneuvered. For example, the oscillating squaring plate 54 can be manually pivoted to its extreme upright position for gauging the hopper opening when setting up for a different size blank. The chain drive 350 and clutch 356 are enclosed in a suitable guard 360 as shown in FIG. 1.

On the opposite end of drive shaft 60, a spur gear 362 is mounted for meshing engagement with

spur gears

364, 366 on the ends of pull rolls 24 and 22 through an idler gear 368 mounted to the side frame to provide the correct direction of rotation. Gear 364 rotates lower pull roll 24 through an overrunning clutch 221 as previously mentioned, so that when the lower roll is rotated by the auxiliary motor M-l, gear 368 does not try to back-drive the remainder of the machine. A satisfactory clutch to per- 9 form this function is a Formsprag FSO-500 type made by Formsprag, 23601 Hoover Road, Warren, Mich.

A crank gear 370 mounted to the side frame is driven by gear 362 through a pair of idler gears 372, 374 which are also mounted to the side frame. The idlers provide the proper `direction of lrotation for crank gear 370. As previously mentioned, crank gear 370 is used to provide reciprocation of the feed mechanism 34. It has also been pointed out that a connecting rod 58 between the drive shaft 60 and the squaring plate 54 operates to oscillate the squaring plate.

A bevel gear box 376 is mounted t-o the side frame and connected to crank gear 370 by an idler 378 also mounted to the side frame. Gear box 376 contains conventional bevel gears for changing the output direction of the power train at right angles to the input. This arrangement permits connection of a line shaft 380 between gear box 3 76 and a corresponding bevel gear box 382 mounted to the side frame of the bundle-ejector section. Power is transmitted to the latter section through the line shaft 380 where it again changes direction to rotate gear 381 on the end of lower pull roll 110 through an idler gear 384 mounted to the side frame. The line shaft 380 has a sliding, splined connection with bevel gear 386- in gear box 382 so that the bundle-ejector section can be moved toward and away from the squaring-compression section without affecting the power transmitted by line shaft 380.

A pair of

gears

388, 390 on the ends of pull rolls 110 and 108 mesh to provide driven rotation for upper roll 108.

A variable ratio pulley unit 392 has its input driven from the opposite end of lower pull roll 110. Input pulley 394 is connected to output pulley 396 by a belt 398. A hand-rotated control (not shown) is provided for changing the relative diameters of

pulleys

394, 396 to provide a variable output speed on a shaft to which a spocket 400 is mounted. An example of a pulley unit satisfactory for this purpose is a variable pulley No. 412 made by Leuellen Manufacturing Company, Columbus, Ind. Conveyor shaft 142 is driven by a sprocket 402 mounted on its end connected with sprocket 400 by a chain 404. In this manner, the speed of conveyor 112 can be varied between one-eighth and one-half blank speed as previously pointed out.

The gear and sprocket diameters are chosen to give the ratios required t-o operate the various parts of the machine at different speeds, as desired. Since the selection of such ratios is commonplace, no further description is considered necessary in this regard.

FIG. 5 is a wiring diagram illustrating the various electrical controls for the machine. The portion of the circuit for each control function is labeled to correspond to that portion of the machine being controlled. The motors M1, M2, M3 and M2 are conventional and may, for example, as illustrated be energized by 220/ 440 volt three phase- 60 cycle current supplied through leads L1, L2, and L3. The various relays, limit switches, etc. are energized by 110 v. single -phase 60 cycle current supplied through leads X1 and X2 from a contr-ol tranformer 218. A fuse 220 is provided in X1 to prevent damage to transformer 218 in the event of a malfunction.

The first control function is for the pull rolls 22 and 24 for which provision is made to keep the rolls rotating for a predetermined length of time after the main drive is stopped so that the last blank leaving the folder-gluer will be fed into the squaring-compression section, and to permit manual control of the rolls during set-up of the machine or to clear a jam-up.

Unidirectional motor M1is provided to rotate pull rolls 22 and 24 through a conventional overrunnig clutch 221 mounted to one end of the lower roll 24. The upper roll 22 is driven by a gear 366 mounted on one end in mesh with a gear 364 mounted on the corresponding end of the lower roll 24.

To control motor M1 the control circuit is divided into a manual and automatic portion. The automatic portion comprises an auto-manual switch 224 (common to -both portions of the circuit) in series with CR contacts (control relay) located inthe main drive cabinet for the foldergluer. CR contacts automatically close when the main drive is energized and with the auto-manual switch on automatic, the circuit is completed to energize motor M1. When this portion of the circuit is completed, a coil TD1 is energized to close relay contacts N1 (230) in the supply line to motor M1. Coil TD1 also closes time delay relay contacts TD1 (231) which remain closed X seconds after coil TD1 is deenergized (X can be adjusted). Thus, when the main drive is stopped, CR contacts open, breaking the circuit. But, time delay relay contacts TD1 cornplete the circuit through push-pull switch 226 (in the start position), thus, coil N1 is energized to keep contacts N1 closed to energize -motor M1. After X seconds have elapsed, time delay contacts TD1 open, breaking the circuit to the motor. In this manner, the pull rolls are rotated by motor M1 for X seconds after the main drive is stopped.

To operate motor M1 manually, switch 224 is pushed to the manual position. Push-pull switch 226 is pulled to the start position. Start button 228 is pushed which completes the circuit through coil N1 which closes relay contacts N1 (231)) after which start button 228 may be released. Contacts 230 complete the circuit to motor M1.

It will be observed that there are thermal overload switches NlOL in the line between relay contacts N1 and motor M1. These contacts open in the event of overload and automatically open the normally closed reset relay contacts N1 in the manual circuit. When the overload ceases, reset contacts N1 are used to reset overload switches N1OL. In the event of an overload occurrence when operating in the automatic mode, similar reset contacts are opened in the main drive (not shown).

Each of the other circuits shown contain similar overload and reset relay switches and no further description of these is necessary.

Each of the backstop assemblies 118 and 120 are laterally positioned by motors M2 and M3 as previously described. Since the control circuits are identical for each motor, only the circuit for motor M2 will be described. The circuit is divided into two portions, one of which closes relay contacts N2 (232) to run motor M2 in one direction and the other which closes contacts N2 (234) to run motor M2 in the opposite direction. A three-position selector switch 235 is common to both portions and when in the in position completes the circuit through a normally closed limit switch LS1, a normally closed relay N2 (238), a coil N2 and a normally closed reset relay N2. With the circuit completed, coil N2 closes contacts N2 (232) to motor M2. Coil N2 also opens normally closed relay N2 (242), as a safety precaution, to prevent accidental closing of both contacts N2 (232 and 234) simultaneously. The other portion of the circuit operates in similar fashion when the selector switch 235 is in the out position. In this position, coil N2 (246) opens normally closed relay N2 (238).

The limit switches LS1 and L82 are mounted on sorne stationary portion of the machine with LS1 being near the center of the machine and LS2 being near the side frame in alignment with the backstop assembly 118. They are positioned to limit the amount of lateral travel of the backstop assembly so that it does not move too far in either direction. When the backstop assembly hits either of the switches, the circuit is broken and the selector switch 235 must be turned to the opposite position to operate the motor M2 in the opposite direction. This will restore the activated limit switch to its normal position.

The motor opening circuit is used to control motor M4 to adjust the bundle-ejector section 13 in relation to the squaring-compression section 7. Motor M4 is reversible and controlled by a divided circuit similar to the circuit used for the backstop assemblies. There are two differences, of which the first is the limit switches LSS and LS6'. These switches are mounted to the side rail 212 in a position to be actuated respectively by a cam 237 secured to the frame 44L. The purpose of the switches is to prevent the bundle-ejector section from being positioned beyond designed for maximum and minimum distances from the squaring-compression section.

Also shown in the motor opening circuit are opening circuit jacks 248 which are provided as a matter of convenience to permit the selector switch 250 to be plugged into the circuit.

The remainder of the control circuit is for controlling the feed interruptor 36 and the pivoting backstop assemblies 118 and 120. The rotary air cylinder 85 previously mentioned rotates clockwise or counterclockwise in response to pressurized air directed in the appropriate directions by a solenoid operated air valve. Rotation of the air cylinder raises or lowers the stack of blanks by the rotation of fingers 86.

The rotary air cylinder 205 previously mentioned pivot-s the stop-gates IStlL, 180R in the appropriate direction in the same manner.

The air solenoid for operating the feed interruptor 36 is illustrated at 254 and the air solenoid for operating the stop-gates 1801., 180R is illustrated at 256. These solenoids are energized by one of four separate circuits designated as N-15, N-20, N-25 and N-30. Each of these circuits are energized by a selector switch 258 which is manually turned to place the desired pair of contacts in series with one of circuits N-IS, N-20, N-25 or N-30. Each of the latter circuits comprise conventional rotary limit switches geared to drive shaft 60 so that N-15 will operate after the drive shaft has rotated l revolutions; N-20 will operate after the drive shaft has rotated revolutions and so on. Since one blank enters the squaring-compression section hopper for each revolution of the drive shaft and the remainder of the machine is in timed sequence, it is obvious that a stack in the bundle-ejector section will be dicharged with the desired number of blanks as selected by selector switch 258.

Each rotary limit switch has cooperating pairs of contacts S1, S2, S3, and S4. The switch is arranged so that upon operation after the correct number of revolutions of the drive shaft 60 occurs, S1 contacts close to energize solenoid 254 to actuate the feed interruptor. Thereafter, S3 contacts close to energize solenoid 256 to pivot

gatestops

180L, 180R out of engagement with the stack in the bundle-ejector section. The switch is adjustable to vary the time interval between closing of contacts S1 and S3. The adjustment is made to allow sufiicient time for the last blank being fed, after actuation of the feed interruptor, to contact the gate-stops before they are opened to discharge the final stack. Thereafter, contacts S2 and S4 close simultaneously to energize both

solenoids

254 and 256 to return the feed interruptor 36 and the gate-

stops

180L, 180R to their original positions for the next cycle. An example of a rotary limit switch suitable for this purpose is a standard 4 cam type 200G-92 made by Gemco Electric Company, Clawson, Mich.

It should be understood that other type switches can be used to count the blanks and at other locations on the machine. For example, ratchet-type limit switches could be provided for triggering by the leading edge of the blanks as they enter gap 32 between feed bed 30 and feed gate 40. Four switches could be used of which one would furnish a signal after being triggered l5 times, another would furnish a signal after 2O times and so on. A selector switch as described above would be used to determine which limit switch was to be activated.

Operation To operate the machine, one of the blanks to be handled is placed on the feed bed 30 with its trailing edge resting against the oscillating squaring plate 54 which is in the upright position. (This position can be obtained by jogging the machine by actuating the main drive control until the plate is vertical.) The selector switch 250 is used to move the bundle-ejector section towards (or away from) the squaring-compression section until the feed gate 40 rests loosely against the leading edge of the blank.

The same blank may then be used to set up the bundleejector section by placing the blank on the conveyor 112 with its trailing edge resting against front guide 122. Shaft end 164 is rotated manually to move the gate stop assemblies 118, loosely against the leading edge of the blank. Shaft 158 may be locked in position by clamp 165. Switches 235 may then be used to operate motors M2 and M3 to move the backstop assemblies 118 and 120 into edgewise contact with the blank. If desired, the inclined portion 116 of conveyor 112 may be adjusted to suit the length of blank being handled.

If the thickness of the blanks is different from the preceding order, both upper pull rolls 22 and 108 may be adjusted to give the proper gap between them and the lower pull rolls 24 and 110.

A stack of blanks is then placed in the squaring-compression section hopper to the height of the oscillating plate 54. The pull roll drive selector switch 224 is placed on automatic. The bundle selector switch 258 is positioned to the selected number of blanks desired in the final stack. The machine is now ready to run.

The ratios of the gears in the power train is such that the pull rolls 22 and 24 in the squaring-compression section rotate at blank speed. The drive shaft 60 also rotates at blank speed, that is, it makes one revolution for each blank entering the hopper. Thus, the rotary limit switches N-15, N-20, N-25 and N-30 geared to the drive shaft determine the desired number of blanks in the final stack by counting the appropriate number of revolutions of the drive shaft.

A factor in the successful operation of the machine lies in running the feed mechanism 34 to remove blanks from the first stack 11, during the feed cycle, at a faster rate than they are deposited on top of this stack. Otherwise, during a dwell period of the cycle, i.e., the time that feed interruptor 36 is operative to permit discharging the final stack 15 from the bundle-ejector section 13, the blanks from the folder-gluer would pile up on top of the stack and jam the machine. Thus, by removing more blanks than are added in an interval of time, a reservoir on top of the stack is created to store the blanks added during the discharge cycle. As an example of the operation, the folder-gluer supplies blanks to

rolls

22, 24 at the rate of 5 per second, feeder 34 operates for 2 seconds and the interruptor 36 maintains the feeder in a dwell period for 1 second. Then l0 blanks are added to the stack 11 in 2 seconds. The discharge cycle for stack 15 which is to contain 15 blanks requires one second, i.e., it is operative to discharge during the dwell period. The l5 blanks are removed from the stack 11 in two seconds. This depletes the reservoir of stack 11 by 5 additional blanks during the two second interval in which blanks are being fed from stack 11 but this number is replenished during the one second discharge interval during which a dwell period exists in the feed to stack 15.

Suitable ratios for the gears in the power train to establish this rate are provided in accordance with wellknown formulae for such gears.

The pull rolls 108 and 110 in the bundle-ejector section run faster than the blanks are fed by the feed mechanism 34. This will result in a space between succeeding blanks passing between the pull rolls to insure that the trailing edge of the preceding blank has cleared the pull rolls before the next blank is fed. Otherwise, the blanks would not be fed one under the other.

Having thus described my invention in its best embodiment and mode of operation, what I desire to claim by Letters Patent is:

1. Apparatus for forming a final stack of blanks of predetermined number from a sequential supply of said blanks, comprising:

first stacking means receiving blanks from said sequential supply for forming a first stack of blanks; final stacking means for forming said final stack of blanks; feeding means forming a part of said first stacking means and engaging said first stack for feeding blanks consecutively from said first stack to the underside of said final stack at a rate faster than the rate at which blanks are received by said first stack; said final stacking means including a continuously driven conveyor having an upper run forming the bottom of said final stacking means and supporting said final stack and having an inclined portion for receiving blanks from said first stack; interrupting means for disengaging said first stack from said feeding means to yinterrupt the ow of blanks to said final stack when the final stack contains said predetermined number of blanks; discharging means for discharging said final stack of blanks from said final stacking means during said interruption of flow of blanks from said first stacking means, said discharging means including a pair of back-stops each having a first portion for engaging the leading edge of said blank to arrest the forward travel and a second portion for engaging the lateral edges of said blanks; and actuator means operative during the interruption of the ow of yblanks for moving said first portion of said back-stops out of engagement with said leading edges and said second portion into engagement with the lateral edges of said blanks so that said conveyor unoves the stack forward to discharge it from said final stacking means. 2. The apparatus of claim 1, and in addition: adjusting means for varying the size of said first and final stacking means to correspond to the blank size being handled, comprising:

mounting means for fixing said feed gate to said final stacking means; first adjusting means for moving said final stacking means lineally relative to said first stacking means whereby the space between said feed gate and said squaring means is varied to correspond to the length of the blanks; second adjusting means connecting said back-stops for lineal adjustment relative to the inclined portion of said conveyor whereby the space dened -by said back-stops and said inclined portion is varied to correspond to the length of blanks; and

third adjusting means connecting said back-stops for lateral adjustment relative to one another whereby the space between the back-stops lis varied to correspond to the width of the blanks.

3. The apparatus of claim 2, and in addition:

pneumatic pressure means comprising a nozzle secured to said first stacking means adjacent said trailing edge of the blanks lin said first stack and in communication with a supply of air under pressure for directing a jet of air against the trailing edge of the blank entering said first stacking means to prevent the leading edge of the successive blank from jamming against the trailing edge of the preceding blank.

y4. The apparatus of claim 2, and in addition:

a jam switch for shutting down a main drive motor in response to jammed conditions within said first stacking means comprising a plate and a signal means, said plate being located in a normal position immediately above the level of travel of blanks entering said first stacking means and in resilient engagement with said signal means for actuating the latter to signal said drive motor in response to a displacement of Said plate from said normal position.

References Cited UNITED STATES PATENTS 1,865,308 6/1932 Evans et al. 214-6 X 2,133,260 10/1938 Wolff 271-86 X 2,466,544 4/ 1949 Harred 214-6 X 2,697,388 12/1954 Hansen et al 214-6 X 2,779,592 1/ 1957 Hartman. 2,963,177 12/ 1960 Shields 214-6 3,122,242 2/1964 Lopez et al 214-6 3,194,127 7/1965 Larsson 214-6 X 3,334,784 8/1967 Morrison 221-13 X 3,345,063 10/ 1967 Swanson.

FOREIGN PATENTS 791,600 3/ 1958 Great Britain.

GERALD M. FORLENZA, Primary Examiner.

R. .T SPAR, Assistant Examiner.

U.S. Cl. X.R.