Relocation Station

Abstract

The repositioning station (200) allows a continuous shingled stream (120) of overlapping semi-rigid planar articles (100) to be conveyed along a conveying loop (204) on an input conveyor (122) to an output conveyor (302), thereby forming a stack that can be carried on the output conveyor (302). The repositioning station (200) includes a lateral deflection assembly (210) and may also include a final positioning assembly (212). The conveying loop (204) within the lateral deflection assembly (210) follows a generally elliptical deflection path to turn the shingled stream (120) and also pivot the articles (100) therein about a curvilinear axis (206) from a face-down position to an upright position. The output conveyor (302) may carry cartons (100) in a direction parallel to the input conveyor (122).

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Patent Application No. 62 / 991,014, filed Mar. 17, 2020. The entire content of the prior patent application is incorporated herein by reference. Field of the Invention

[0003] This field of technology generally relates to the repositioning of a continuous shingled stream of overlapping semi-rigid planar articles, such as folding cartons. Background Art

[0004] Folding cartons are widely used in various industries for packaging products. Cartons are typically manufactured on a production line by folding and gluing a carton blank using a folding and gluing machine. Cartons emerging from such a folding and gluing machine are typically configured in a continuous row on an output conveyor, which receives the cartons on its upper surface as they advance. The cartons are then arranged in an overlapping manner, where they are partially positioned on top of each other. A row of overlapping cartons forms what is hereinafter referred to as a continuous shingled stream. The cartons are also in a flat configuration, i.e., a configuration in which the respective panels of each carton are flat-folded to substantially eliminate or minimize its overall internal volume. The cartons are flat-folded to primarily optimize conveyance and storage space, etc. prior to first use. Cartons are typically transported from the manufacturer to the packer in containers (such as in shipping cartons or boxes). The packer typically has its own machines to form the collapsed cartons into their final expanded shape, thereby creating an internal loading volume for receiving a given product or for a given purpose. This process can also be at least partially done manually by the packer. Other methods and scenarios are possible. Cartons can also be packaged or bundled for conveyance or storage without having to be inserted into a container such as a box or crate. Other variations are possible.

[0005] The cartons can be inserted into a container at a packing station, which is typically located at the end of the production line. This loading process can be done manually by one or more operators with or without mechanical assistance or using a fully automated processing system.

[0006] Each container that can be used to transport or store cartons can hold a given number of these cartons, and in many embodiments, the cartons are automatically counted at some point to ensure that each container or the like will receive the correct number of cartons. The cartons are typically counted before they reach the packing station, typically at the exit of the folding and gluing machine itself before the continuous shingled stream is produced. Counting is needed to determine the start or end position of each group of counted cartons. These groups are hereinafter referred to as batches. The continuous shingled stream will be segmented at some point, typically at the packing station, and each container will receive one or more of these batches.

[0007] Sometimes it is possible to count the cartons once a continuous shingled stream has been formed, but this is generally not advisable as it mainly increases costs and the complexity of the equipment, etc. Similarly, manually counting cartons at a packing station, for example, is usually difficult to implement and generally presents many challenges, unless the productivity is relatively low.

[0008] Different methods can be used to indicate the demarcation between batches in a continuous shingled stream. One possible method is to separate the continuous shingled stream into a series of discontinuous shingled streams before they reach the packing station, each corresponding to a batch and spaced apart from the previous and subsequent shingled streams. However, this method requires an additional processing system to perform the separation process somewhere between the folder-gluer machine and the packing station, thus mainly increasing costs and the floor space required, etc.

[0009] Another possible method is to have a printing system that can place small symbols or similar markings on the first or last carton of each batch in the continuous shingled stream, thereby indicating the positions where the batches are separated from each other at the packing station. If desired, ink that is only visible under an ultraviolet (UV) light source can be used to make the symbols on the marked cartons. Then there will be a way to view the symbols on the marked cartons at the packing station, which will provide a visual indication to be seen by a manual operator with the aid of a light source, such as a UV light source (if the ink can only be seen using it), or by a suitable electronic sensor when a fully automated system is provided. However, using a printing system will increase costs and may even be undesirable in some cases. For example, a packer may not always consider having symbols on some cartons acceptable, even if they are only visible under UV light. The material of the cartons may also prevent the ink from adhering properly or may cause other problems. In addition, once the cartons reach the packing station, for example, if some of the symbols are inadvertently removed from the carton surface after the carton surface briefly contacts an adjacent carton or a given component of a given piece of equipment at a certain point along the conveying loop, then these symbols may be difficult or even impossible to see. Losing count of the cartons, even if only occasionally, is likely to result in an incorrect number of cartons being inserted into some containers, or the need to stop the production line to manually recount the cartons, thus causing an undesirable delay and reducing productivity.

[0010] Another possible method is to laterally offset the position of some of the cartons to indicate the boundaries between batches in a continuous lap-joint stream. Cartons emerging from the output conveyor at the exit of a folding and gluing machine in a continuous lap-joint stream are typically uniformly aligned and oriented. Periodically moving some of the cartons a given distance, e.g., about 25 millimeters, in the edge direction can mark the start or end of each batch, thereby indicating at the packing station the location where the continuous lap-joint stream must be divided into batches. Additionally, this solution does not require using an expensive handling system to physically separate the continuous lap-joint stream into a series of discontinuous lap-joint streams before the cartons reach the packing station, or using a printing system to mark the transition between batches. However, implementing this method can be challenging because the visual cues provided by the edge-offset positioning of some of the cartons can easily be lost. Additionally, the marked cartons may move back into alignment or near alignment with other cartons. This problem is prone to occur with relatively stiff and highly smooth-surfaced cartons. Other factors may also be involved, such as the construction of the equipment handling the lap-joint stream.

[0011] The outer surfaces of folding cartons are typically very smooth because this smoothness is generally desired for different reasons. However, this characteristic also tends to reduce the friction between two adjacent cartons in a lap-joint stream. The relatively light weight of each carton, combined with the fact that they are semi-rigid articles with a relatively high degree of smoothness on their outer surfaces, exacerbates the tendency for offset cartons to easily move back into alignment at certain points in the conveying loop. Other factors such as the cyclic acceleration and deceleration of the conveyor carrying the lap-joint stream and the vibrations generated by numerous associated mechanisms may also increase this tendency. Therefore, the position-offset method itself often poses challenges.

[0012] To name just a few examples, folding cartons are typically made of materials such as cardboard, corrugated board, or micro-perforated board. They typically have at least two main sides, and depending on the above materials and their thickness, some cartons are easily damaged even when slightly bent beyond a critical angle (usually less than 2 degrees from the mid-plane of the carton). Over-bending these cartons may result in generally permanent and aesthetically undesirable deformations such as creases on at least one of their main sides. Therefore, how to manipulate folding cartons by repositioning equipment is often restricted.

[0013] Cartons have at least some edge flexibility. In most cases, stiffness is generally a desirable characteristic as it provides strength and reduces the tendency of the carton to bulge under its weight during use. In this context, folding cartons can be considered semi-rigid. Additionally, they have far more rigidity than articles assembled from a single sheet of paper or even many sheets of paper such as newspapers or magazines, but they typically are not as hard and sturdy as a metal sheet of similar thickness.

[0014] Many embodiments require the cartons to be stacked vertically at the packing station, so these cartons are in an upright position. This facilitates the handling of batches, such as inserting them into containers or the like. Then the cartons must be repositioned accordingly at some point in the conveying loop of the cartons. The real challenge is to find a suitable and general method.

[0015] U.S. Patent No. 4,332,124 of June 1, 1982 discloses an apparatus for delivering and packing folding cartons in an overlapping stacked relationship. Some of the folding cartons can be moved laterally or sidewise to define a batch. However, the apparatus requires the input conveyor and the output conveyor to be vertically arranged. This may not always be feasible or appropriate in some embodiments, especially in cases where the floor space is very limited. A part for pivoting the folding cartons about a central axis is also relatively long.

[0016] There is still some room for further improvement in the technology in this regard. Summary of the Invention

[0017] The proposed concept relates to a repositioning station for handling a continuous shingled stream of overlapping semi-rigid planar articles such as folding cartons.

[0018] In one aspect, there is provided a repositioning station for a continuous shingled stream of overlapping semi-rigid planar articles, wherein the articles are carried onto an input conveyor in a flat configuration and in a face-down position, enter the repositioning station in a first horizontal direction, and are then conveyed by the repositioning station in a second horizontal direction onto an output conveyor to form a stack of articles in an upright position, the stack being carried away on the output conveyor in a third horizontal direction, the repositioning station defining a conveying loop and including: a lateral deflection assembly located at the entrance of the repositioning station, the lateral deflection assembly including a plurality of roller units arranged longitudinally, the conveying loop following a generally elliptical deflection path along these roller units to turn the shingled stream from a first direction to a second direction, and also pivoting the articles in the shingled stream from a face-down position to an upright position about a curved axis that coincides with the innermost and bottommost boundary of the conveying loop throughout the lateral deflection assembly.

[0019] In another aspect, there is provided a repositioning station as described, shown, and / or suggested herein.

[0020] In another aspect, there is provided a system for handling a continuous shingled stream as described, shown, and / or suggested herein.

[0021] In another aspect, there is provided a method of handling a continuous shingled stream as described, shown, and / or suggested herein.

[0022] Based on the following detailed description and the corresponding drawings, more details of various possible combinations of different aspects and technical features of the proposed concept will become apparent. Description of the Drawings

[0023] Figure 1 is a semi-schematic view showing a general example of a semi-rigid planar article, which in this case is a folding carton.

[0024] Figure 2 is a semi-schematic view showing a general example of a continuous interlocking stream of overlapping cartons.

[0025] Figure 3 is an isometric view showing an example of a system with a repositioning station according to the proposed concept.

[0026] Figure 4 shows how the interlocking stream passes through Figure 3 a semi-schematic isometric view of the transfer of the interlocking stream through the repositioning station in the system shown.

[0027] Figure 5 is similar to Figure 4 the view, but shows an embodiment in which the interlocking stream turns to the right.

[0028] Figure 6 is similar to Figure 4 the view, but shows an example of an embodiment in which the cartons in the interlocking stream are oriented in different directions and the output conveyor transports the stacked cartons in a countercurrent direction.

[0029] Figure 7 is Figure 3 an isometric view of the system shown in, but observed from another angle and without the interlocking stream.

[0030] Figure 8 is Figure 7 the top view shown.

[0031] Figure 9 is a side view observed from the entrance of the repositioning station of Figure 7 the one shown.

[0032] Figure 10 shows a part of one of the roller units arranged along the lateral deflection assembly of the repositioning station shown in Figure 7 an enlarged isometric view.

[0033] Figure 11 is Figure 7 an enlarged isometric view of the repositioning station shown.

[0034] Figure 12 shows only Figure 7Side view of the lateral deflection assembly of the repositioning station shown.

[0035] Figure 13 Is similar to Figure 12 the view, but without the top rollers and support arms of the roller unit.

[0036] Figure 14 Is Figure 13 the top view shown.

[0037] Figure 15 Is Figure 7 the isometric view of the first transfer unit of the repositioning station shown.

[0038] Figure 16 Shows Figure 7 the enlarged isometric view of the final positioning assembly of the repositioning station shown.

[0039] Figure 17 Is similar to Figure 16 the view, but the first transfer unit is set at a different vertical position.

[0040] Figure 18 Shows Figure 7 the isometric view of the second transfer unit of the repositioning station shown.

[0041] Figure 19 Is Figure 18 the top view shown.

[0042] Figure 20 Is a top view depicting an example where some of the cartons form a stack on the output conveyor in the repositioning station shown in Figure 7 shown.

[0043] Figure 21 Is similar to Figure 20 the view, but for illustration, significantly narrower cartons are used.

[0044] Figure 22 Is an enlarged side view representing another example of the roller unit for the repositioning station.

[0045] Figure 23 Is similar to Figure 22 the view, but shows a shorter support arm.

[0046] Figure 24 Is Figure 3 the isometric view of the system shown, but with the repositioning station temporarily bypassed.

[0047] Figure 25Is an isometric view showing another example of the system, where the repositioning station includes a second transfer unit mounted on a support frame that can pivot relative to a lateral bottom axis, thereby creating a bypass similar to Figure 24 as shown in

[0048] Figure 26 Is Figure 25 an isometric view as shown in

[0049] Figure 27 Is Figure 25 and 26 an enlarged isometric view of the first transfer unit as shown in

[0050] Figure 28 Is a view showing an enlarged isometric view of the final positioning assembly of the first transfer unit provided with Figure 25 as shown in

[0051] Figure 29 Is Figure 28 the top view as shown in

[0052] Figure 30 Is a top plan view similar to Figure 20 but showing another example of the repositioning station, where the first transfer unit includes a vertical endless belt and can move laterally

[0053] Figure 31 Is a view similar to Figure 30 but, for illustration purposes, uses a significantly narrower cardboard box

[0054] Figure 32 Is Figure 30 the top view of the first transfer unit constructed and set as shown in

[0055] Figure 33 Is a view similar to Figure 32 but where the first transfer unit is constructed and set in an extended position as shown in Figure 31 as shown in

[0056] Figure 34 Is Figure 30 an isometric view of the second transfer unit in the repositioning station as shown in

[0057] Figure 35 Is a view similar to Figure 34 but observed from another angle

[0058] Figure 36 And 37 are isometric views showing having as Figure 34 and 35An example of a system of a second transfer unit is shown, which can move laterally relative to the output conveyor to create a bypass similar to Figure 24 the bypass shown. DETAILED DESCRIPTION

[0059] Figure 1 is a semi-schematic view showing a general example of a semi-rigid planar article, which in the current instance is a folding carton 100. The general carton 100 shown is just one example among many possibilities. It is also important to understand that the article is not necessarily limited to a folding carton, as other types of articles can also be repositioned as described herein. The following detailed description and drawings present the article as a carton for simplicity only.

[0060] Such as Figure 1 A planar article such as the carton 100 shown in is said to be semi-rigid because the flexibility of the main board is relatively limited, sometimes only having edge flexibility, but not completely without flexibility. They can be made of materials such as cardboard, compact fiberboard, corrugated cardboard, plastic, microgrooved cardboard, etc. Some cartons can be made of more than one material. Other materials are also possible.

[0061] Figure 1 The general carton 100 depicted in represents a carton in a flat configuration coming out of a folding and gluing machine on a production line. Cartons manufactured by a folding and gluing machine are typically conveyed on a conveyor at their exit. Then, the main boards of the carton 100 are flat-folded onto each other, thereby substantially eliminating or nearly eliminating its internal volume to minimize the space for its conveyance and storage before initial use. The carton 100 still has a small internal volume due to the elasticity of some of its parts when flat-folded and is still considered to have a flat configuration.

[0062] As Figure 1 The carton 100 in the flat configuration shown has a length, a width, and a thickness. In this general example, the length corresponds to Figure 1 the X-axis of the depicted coordinate system, the width corresponds to the Y-axis, and the thickness corresponds to the Z-axis. In this example, the thickness is a dimension much smaller than the length and the width. The axes X and Y define the middle plane of the carton 100. The carton 100 also includes four outer edges that define the middle plane, namely edges 102, 104, 106, and 108, which are substantially straight and unbroken in the illustrated example. When the carton 100 is unfolded for the first time during use, the X-axis will be oriented vertically upward. Before that, the carton 100 will remain in its flat configuration. Other configurations and arrangements are also possible. In addition, although Figure 1The carton 100 shown is more or less rectangular and has uninterrupted straight edges, but other shapes and configurations are also possible. For example, one or more edges of the carton can be non-linear or discontinuous. The exact construction or configuration of the carton 100, including the ratio between its length, width and thickness, and the correlation between these dimensions and the X, Y and Z axes, can vary in some embodiments. Other variations are also possible.

[0063] Figure 2 is a semi-schematic illustration showing a general example of a continuous shingled stream 120 of overlapping cartons 100. These cartons 100 are in a face-down position. For example, this represents the cartons being conveyed towards a packaging station for insertion into a container. The cartons 100 are arranged in a row, and the length of the gap between two adjacent cartons 100 is referred to as the pitch.

[0064] It should be noted that, for simplicity, Figure 2 only includes a limited number of schematically depicted cartons 100. In an actual embodiment, the shingled stream 120 typically remains uninterrupted from the start to the end of the production cycle, which can typically last for several hours or more. The cartons 100 in the shingled stream 120 can be the same as or similar to those shown in Figure 1 or they can be completely different, depending on the actual embodiment. Other constructions and arrangements are also possible. In addition, the shingled stream 120 does not have a minimum duration considered to be continuous, and in some cases the production cycle can be relatively short. Other variations are also possible.

[0065] Figure 2 The cartons 100 within the shown shingled stream 120 of

[0066] are simply resting on the conveyor by gravity, for example on the horizontal upper surface of a loop belt conveyor 122, as schematically depicted. When the shingled stream 120 is carried onto the conveyor 122, the shingled stream typically advances in a substantially horizontal and straight direction as depicted by the arrow 124. It can be seen that the bottom surface of each carton 100 only partially contacts the conveyor 122 because each carton 100 overlaps with the adjacent carton 100. Only the initial cartons of the continuous shingled stream are typically fully located on the upper surface of the conveyor 122, for example at the start of a new production cycle. If desired, the movement of the shingled stream 120 can be stopped and resumed from time to time, but the shingled stream 120 will generally remain unchanged. Variations are also possible.

[0066] Assume that the cartons 100 provided in the shingled stream 120 of Figure 2 are all like Figure 1Positioned as depicted in Figure 2 Figure 1, the X-axis is parallel to direction 124 and both edges 102, 104 are transverse edges extending longitudinally. Then the Y-axis is perpendicular to direction 124 and both edges 106, 108 are transverse edges, where in this example edge 106 is the leading edge 106 and edge 108 is the trailing edge. The trailing edge 108 is the trailing edge that engages the upper surface of the conveyor 122 in

[0067] Figure 2 Figure 1. Other configurations and arrangements are possible. Additionally, the carton 100 can be oriented or arranged in different ways within the shingled stream 120, such as having an orientation where edge 108 is the leading edge and edge 106 is the trailing edge. Other types of conveyors can be used, and the conveyor 122 is not necessarily an endless belt conveyor in all embodiments. For example, some embodiments can include one or more conveyors having a series of laterally spaced rollers. The tops of these rollers then form the equivalent of the upper surface. Other variations are possible. Figure 2 Figure 1 further shows one of the cartons 100, which for explanatory purposes is hereinafter referred to as carton 100′, and this carton is laterally offset in position compared to the other cartons because it extends from the lateral side of the shingled stream 120, i.e., in a direction perpendicular to

[0068] The container for receiving the carton 100 can be a shipping container, such as a receiving portion, like a box or a case with an open side that can be closed once the carton 100 is inserted. In some embodiments, other kinds of containers are also possible. The container can consist of, for example, one or more strips that hold the cartons 100 together, with or without any other parts, or an enclosure such as a plastic wrapping. Another example can be a tray for placing batches of cartons 100, where the batches are separated from each other by corresponding spacers or by changing the orientation of adjacent batches. Many other methods or combinations of methods are also possible.

[0069] Figure 3 is an isometric view of an example of a system 130 showing an example of a repositioning station 200 according to the proposed concept. It shows a continuous shingled stream 120 of overlapping cartons 100 being processed. The repositioning station 200 can have an inlet for receiving the shingled stream 120 conveyed on a conveyor 122, which is, for example, the outlet of a folder gluer machine 150. This conveyor is hereinafter referred to as the input conveyor 122 as it conveys the cartons 100 of the shingled stream 120 towards the repositioning station 200.

[0070] The repositioning station 200 allows the shingled stream 120 to be transferred onto an output conveyor 302. As shown in the illustrated example, this output conveyor 302 can be part of a packaging station 300. The shingled stream 120 is conveyed through the repositioning station 200 along a conveying loop 204( Figure 8 ). Other configurations and arrangements are also possible. Additionally, the folder gluer machine 150 can be located elsewhere, and in some embodiments, the input conveyor 122 may not have to receive the cartons 100 directly from the folder gluer machine. Similarly, the packaging station 300 can be located further downstream or even elsewhere, and in some embodiments, the output conveyor 302 may not necessarily be part of the packaging station. Thus, the repositioning station 200 can operate in the case where the folder gluer machine or the packaging station or even both are not close to the system 130. The repositioning station 200 can also be provided as a stand-alone device, for example, for installation on an existing system. The input conveyor 122 and the output conveyor 302 described and shown herein are merely examples, and the repositioning station 200 can be provided in a system using different kinds or models of conveyors. Other variations are also possible.

[0071] Figure 3The repositioning station 200 can be subdivided into two main sections. One section, called the lateral deflection assembly 210, is located at the entrance, and one section, called the final positioning assembly 212, is located at the exit. The lateral deflection assembly 210 is positioned on one side of the output conveyor 302 and is supported by a corresponding frame 220, which can be directly attached to the support frame 310 disposed below the output conveyor 302, as shown in the illustrated example. The final positioning assembly 212 of the repositioning station 200 can be supported by the frame 310. Other configurations and arrangements are possible. In addition, the lateral deflection assembly 210 or the final positioning assembly 212, or even both, can be constructed differently or supported using other types of frames or arrangements. Other variations are possible.

[0072] Figure 4 shows how the shingled stream 120 is conveyed through Figure 3 the repositioning station 200 in the system 130 shown. Thus, for illustration purposes, the shingled stream 120 is shown without the repositioning station 200 and without the output conveyor 302. In this embodiment, the shingled stream 120 turns to the left and the carton 100 arrives at the output conveyor 302 from its right hand side to form a stack. It can be seen that the laterally offset carton 100' is now an upwardly offset carton 100', and the transition between batches is still clearly marked.

[0073] Figure 5 is similar to Figure 4 but shows an embodiment in which the shingled stream 120 turns to the right.

[0074] Figure 4 and 5 also show that the innermost edge of the carton 100 follows the curved axis 206. The term "innermost" refers to the side of the turn. As shown, the curved axis 206 can be substantially horizontal and single - planar, and the lateral alignment of the carton 100 at the entrance can correspond to the vertical alignment at the exit of the lateral deflection assembly 210. The curved axis 206 coincides with the innermost and bottommost boundaries of the conveying loop 204 ( Figure 8 ). Other configurations and arrangements are possible. For example, the conveying loop 204 can include a small variation in the vertical height between its inlet and outlet ends. This variation will typically be less than a few centimeters, but in other cases it may be larger, for example to clear local obstructions on the floor or for other reasons. Other variations are possible.

[0075] The carton 100 in the shingled stream 120 is in a face-down position at the entrance of the repositioning station 200. The horizontal direction 124 forms what is hereinafter referred to as the first direction. The shingled stream 120 exits the repositioning station 200 along a second horizontal direction 202 and onto the output conveyor 302 as they fall onto it under the influence of gravity. The cartons 100 are then in an upright position and form a stack that is carried away on the upper surface of the output conveyor 302 advancing along a third horizontal direction 304. Figure 3 The input conveyor 122 and the output conveyor 302 are offset laterally in position, and the first direction 124 and the third direction 304 can be substantially parallel to each other. As shown, the repositioning station 200 can thus have a first section located on one side of the output conveyor 302 and a second section that spans and extends above the output conveyor 302. When the shingled stream 120 is in the final section of the conveying loop 204, the cartons 100 are conveyed along the second direction 202. This second direction 202 can be substantially perpendicular to the first direction 124 and thus also perpendicular to the third direction 304, as shown in the illustrated example. Other configurations and arrangements are possible. In addition, although the first direction 124 and the third direction 304 have the same orientation in the Figure 3 example, in some embodiments the third direction 304 can be countercurrent with respect to the first direction 124, for example depending on how the cartons 100 are positioned in the shingled stream 120. Figure 6 is similar to Figure 4 the view, but shows an example of an embodiment in which the cartons 100 in the shingled stream 120 are oriented in a different direction and the output conveyor 302 conveys the stack of cartons in a countercurrent direction, i.e., along the third direction 304. In addition, the accuracy of the perpendicularity and parallelism between the directions 124, 202, 304 can be relatively low, and the phrases "substantially parallel" and "substantially perpendicular" encompass deflections of up to about 15 degrees. In certain embodiments, the deflection can be up to about 25 degrees. The repositioning station 200 can be implemented without making the first direction 124 and the third direction 304 parallel or even substantially parallel, or without making the second direction 202 parallel to the first direction 124 or the third direction 304. Other variations are possible.

[0076] Figure 7 is Figure 3 an isometric view of the system 130 shown in, but observed from another angle and without the shingled stream. The shingled stream is not shown for simplicity only.

[0077] As shown, the repositioning station 200 may include a lateral guiding device 230 positioned upstream and adjacent to the inlet of the lateral deflection assembly 210. The lateral guiding device 230 may be used to correct the position of the input paper tray, such as the angular position, so that its innermost edge is aligned with the curved axis 206 at the inlet of the lateral deflection assembly 210. Only the marked paper trays 100' are not aligned by the lateral guiding device 230 because their offset positions are intentional. They are offset towards the other lateral side. Other configurations and arrangements are possible. Additionally, in some embodiments, the lateral guiding device 230 may be differently configured or positioned. The lateral guiding device may also be omitted in other embodiments. The repositioning station 200 may process the shingled stream 120 that does not have edge-offset paper trays 100'. Other variations are possible.

[0078] Figure 8 is Figure 7 A top view of the illustrated system 130. It can be seen that the lateral deflection assembly 210 includes a plurality of longitudinally arranged roller units 240 along which the conveying loop 204 follows a generally elliptical deflection path to deflect the shingled stream 120 from the first direction 124 to the second direction 202 while pivoting the paper tray 100 from a face-down position to an upright position. Other configurations and arrangements are possible.

[0079] It should be noted that, unlike existing processing systems, the position of the shingled stream 120 within the illustrated repositioning station 200 is not based on the geometric center of the paper tray 100. Instead, it is based on the innermost boundary of the conveying loop 204. This feature can greatly simplify the setup when transitioning from paper trays of one model to another when the two models have different widths because the innermost boundary of the conveying loop 204 can remain the same. Additionally, since the paper tray 100 is repositioned about two axes simultaneously, the conveying loop 204 can be made shorter, thereby minimizing the footprint required by the device. Variations are possible.

[0080] Figure 9 is viewed from the inlet of the repositioning station 200 Figure 7 The side view shown. This figure shows that the curved axis 206 is horizontal in this example.

[0081] Figure 10 is a magnified isometric view showing a part of one of the roller units 240 arranged along the Figure 7 lateral deflection assembly 210 of the illustrated repositioning station 200.

[0082] Each roller unit 240 may include one or more powered lower rollers 242, which may be commonly driven by one or more electric motors 244, as shown in the illustrated example. Some of the rollers 242 may be directly driven by direct couplings, while adjacent rollers are indirectly driven using an endless belt that extends from one roller 242 to another and passes over drive grooves 246 formed, for example, on each roller 242, as shown. In the illustrated example, there are two spaced-apart electric motors 244 for driving the lower rollers 242, such as Figure 12 and 13 shown. It has been found that this configuration is sufficient to generate the required torque in the roller unit 240 of the lateral deflection assembly 210 in this embodiment. Adding more motors generally will not produce a significant benefit that would justify the additional cost involved. However, other configurations and arrangements are possible. Additionally, other types of rollers, motors, or linkages may be used. Other variations are possible.

[0083] Each lower roller 242 may include a plurality of perimeter rings 248, which are spaced apart along each of them, as shown in the illustrated example. These rings 248 may be made of a rubber material or any other material that may increase the friction with the outer surface of the carton 100. This may improve the drive contact and may reduce the risk of damaging the carton 100 or leaving marks thereon. Other configurations and arrangements are possible. Additionally, this feature may be unnecessary in some implementations and may therefore be omitted entirely. Other variations are possible.

[0084] Each roller unit 240 may also include an overhead roller 250 positioned above one or more corresponding lower rollers 242, as shown in the illustrated example. The overhead roller 250 may apply a force on the top side of the carton 100 passing through the lateral deflection assembly 210. Each overhead roller 250 may be part of a biasing device 252 that maintains the shingled flow 120 in driving engagement with the lower roller 242. The biasing device 252 may also include a cantilevered support arm 254 and a pneumatic actuator 256 configured and arranged to push the corresponding overhead roller 250 toward one or more corresponding lower rollers 242, as shown in the illustrated example. The support arm 254 may pivot about a corresponding pivot axis 255. One end of the actuator 256 may be pivotally attached to a side extension 257 at the rear end of the support arm 254. The pressure in each actuator 256 may be controlled using one or more pneumatic pressure regulators or the like. With the pneumatic force generation system, the types of cartons being processed can generally be handled quickly and directly. As shown, the lower roller 242 of the roller unit 240 may be supported using a retaining member 258. The retaining member 258 may be mechanically connected to other parts of the roller unit 240 by a main bracket 259, which is also the location where the support arm 254 is pivotally attached. Other configurations and arrangements are possible. Additionally, a mechanical spring or the like may be used. The force generation mechanism may be based solely on gravity, for example using a counterweight for at least some of the roller units 240. Different types of mechanisms may be present in the same lateral deflection assembly 210. The various rollers may be configured and arranged differently. Additionally, the configurations and arrangements of components such as the support arm 254, the retaining member 258, and the main bracket 259 may be different. For example, some of these components may be omitted, replaced with other types of components, or integrated with other components. Other variations are possible.

[0085] Each overhead roller 250 may be made of a relatively extensible material having a plurality of voids, as shown in the illustrated example. This configuration is referred to as a pressureless roller, and the overhead roller 250 can generally press against the carton 100 without causing physical damage or visual markings. Other configurations and arrangements are possible. Additionally, the overhead roller 250 may be made of other materials and not include voids. The diameter and width of the overhead roller 250 may be different, for example larger, compared to that shown. Other variations are possible.

[0086] It should be noted that Figure 10Only a part of the roller unit 240 is shown because, in the illustrated example, there is an overhead roller 250 between two lower rollers 242. In other words, the roller unit 240 can include two lower rollers 242 and one overhead roller 250, as shown. The overhead roller 250 can be located at an intermediate position relative to two corresponding lower rollers 242. Having fewer overhead rollers 250 than lower rollers 242 reduces the number of components, thereby reducing manufacturing costs and complexity. However, other configurations and arrangements are possible. Additionally, the exact position of the overhead roller 250 relative to the corresponding lower rollers 242 can vary. It is also possible to use proportionally more or fewer overhead rollers 250, but using fewer overhead roller units 240, such as one for every three lower rollers 242, can further reduce manufacturing costs but may create complexity in handling the shingled stream 120 in some cases and may increase the risk of some cartons 100 slipping near the end of the lateral deflection assembly 210. Different configurations of the roller unit 240 can exist along the same lateral deflection assembly 210. Other variations are possible.

[0087] Figure 11 is Figure 7 An enlarged isometric view of the repositioning station 200 shown. The drawing shows the transition from the lateral deflection assembly 210 to the final positioning assembly 212. The lateral deflection assembly 210 ends with the last lower roller 242. The final positioning assembly 212 can include a first transfer unit 260 that drives one side of the carton 100 when the carton 100 is in an upright position. As shown, it can also include bottom rollers 270 to guide the innermost of the cartons 100 along the curved axis 206 on the side edge of the output conveyor 302 in case some of them are too low for some reason. As shown, the final positioning assembly 212 can also include a second transfer unit 280 that drives the other side of the carton 100 in the final section of the conveying loop 204. Other configurations and arrangements are possible. Additionally, the first transfer unit 260 and the second transfer unit 280 can be configured and arranged differently. In some embodiments, they can be replaced by another arrangement. The bottom rollers 270 can be positioned and configured differently, or it can be replaced by a curved surface or an inclined surface, etc., and can even be omitted in some embodiments. Other variations are possible.

[0088] Figure 12 is only shown Figure 11 A side view of the lateral deflection assembly 210 of the repositioning station 200 shown.

[0089] Figure 13 is similar to Figure 12view, but without the overhead roller 250 and the support arm 254 of the roller unit 240.

[0090] Figure 14 is Figure 13 the top view shown.

[0091] Figure 13 and 14 schematically shows different stages through which the carton 100 in the shingled stream 120 passes along the conveying loop 204, where the carton 100 starts in a face-down position at the entrance and ends in an upright position at the exit. As described above, the cartons 100 of the shingled stream 120 passing through the lateral deflection assembly 210 and following a part of the conveying loop 204 therein will transition from a face-down position to an upright position. They will also turn from the first direction 124 to the second direction 202 simultaneously on the way. As shown in the illustrated example, the pivoting movement from the face-down position to the upright position can exceed about 90 degrees. Similarly, as shown, the change in direction about the vertical axis can be a pivoting movement of more than about 90 degrees. The lateral deflection assembly 210 thus causes the shingled stream 120 to follow a generally elliptical deflection path along the conveying loop 204. Other configurations and arrangements are also possible. In addition, the parallelism between the inner edge of the carton 100 and the curved axis 206 does not have to be perfect. An average deviation of up to about 25 degrees is usually acceptable. Some models of the cartons 100 coming out of the folding and gluing machine may sometimes have an average misalignment of more than 25 degrees, which is a situation where having a lateral guiding device 230 or an equivalent may be useful. Otherwise, in some embodiments, excessive misalignment may lead to undesirable reliability problems. The vertical height of the upper surface at the end of the input conveyor 122 is substantially the same as the upper surface of the output conveyor 302, and the curved axis 206 is substantially horizontal and single-plane in the example, and the position of the innermost edge of the carton 100 can be set such that this edge will reach only a few millimeters or less above the upper surface above the output conveyor 302 at the exit of the lateral deflection assembly 210. This alignment of the innermost edge of the carton 100 at the entrance of the lateral deflection assembly 210 can correspond to the output height of the vertically oriented carton 100 at the exit of the lateral deflection assembly 210. In Figure 14 the illustrated example, if the lateral guiding device 230 is positioned too far to the left, the curved axis 206 may terminate below the upper surface of the output conveyor 302, resulting in the leading edge 106 of the carton 100 possibly colliding with the side of the output conveyor 302. On the other hand, if the lateral guiding device 230 is in Figure 14If the center is positioned too far to the right, the curve axis 206 may terminate too far above the upper surface of the output conveyor 302, resulting in the position of the offset carton 100' being indistinguishable from adjacent cartons when forming a stack on the output conveyor 302 in some embodiments. Therefore, the lateral guide device 230 can also function as a device for adjusting the output height at the outlet of the lateral deflection assembly 210. However, as described above, it can be omitted in some embodiments.

[0092] Figure 14 The conveying loop 204 within the lateral deflection assembly 210 of the illustrated example is shown to be generally divided into four consecutive sections A, B, C, and D. These sections are for illustrative purposes only. As shown, the carton 100 can pivot about a vertical axis in section A at a rate that increases compared to subsequent sections, specifically in sections C and D. However, the carton 100 can pivot about the curve axis 206 at a lower rate in section A, and this rate can gradually increase in subsequent sections. This configuration can vary from one embodiment to another, but in many cases, initially having an increasing pivoting rate of the carton 100 about the vertical axis at the start and causing the carton 100 to pivot about the curve axis 206 at an increasing rate towards the end for transitioning from a face-down position to an upright position can minimize the footprint. Other configurations and arrangements are also possible. Additionally, these sections can be configured differently. Other variations are also possible.

[0093] Figure 15 is Figure 7 An isometric view of the first transfer unit 260 of the repositioning station 200 shown. This first transfer unit 260 drives one side of the shingled stream 120 onto the upper surface of the output conveyor 302 at the outlet of the lateral deflection assembly 210. It is provided on the same side as the roller 242. The first transfer unit 260 can include a vertically arranged endless belt 261. In this example, only the planar section of the belt 261 is exposed and engages the shingled stream 120. The belt 261 is supported by a plurality of rollers installed inside the housing of the first transfer unit 260. It can be seen that the first transfer unit 260 is constructed and arranged to have a very small radius at the corner 263. Rollers with a very small radius can be used to support the belt 261 near this corner 263. This allows the corner 263 to be effectively at a right angle. This is useful for minimizing potential contact with the trailing edge of the carton 100 arriving on the output conveyor 302. The belt 261 of the first transfer unit 260 can be driven by a corresponding motor, such as an electric motor. Other configurations and arrangements are also possible. The first transfer unit 260 can be configured differently, such as without an endless belt. Another motor can be used. Other variations are also possible.

[0094] Figure 16 is shown Figure 7An enlarged isometric view of the final positioning assembly 212 of the system 130 shown. For illustration, a single carton 100 is present next to the first transfer unit 260. In this example, the first transfer unit 260 is vertically positioned near the upper surface of the output conveyor 302.

[0095] Figure 17 is similar to Figure 16 the view, but the first transfer unit 260 is set at a higher vertical position to handle different models of cartons 100. Due to the gap at the bottom end of this model of carton, the first transfer unit is at a higher position. The higher position will allow each carton 100 to contact the first transfer unit 260 over a longer distance. In this example, a slotted bracket 262 and a corresponding locking arrangement are used to adjust the vertical position. Other configurations and arrangements are possible. In addition, other systems for adjusting the vertical position of the first transfer unit 260 can be used. In some embodiments, this adjustment may not be performed. Other variations are possible.

[0096] Figure 18 is Figure 7 an isometric view of the second transfer unit 280 of the repositioning station 200 shown. Figure 19 is Figure 18 the top view shown. The second transfer unit 280 can convey cartons 100 across the width of the output conveyor 302 until their leading edges strike the end plate 284. This end plate 284 can be part of a plate assembly 286. The second transfer unit 280 can thus be used to ensure that the cartons 100 will reach the desired positions on the output conveyor 302. As shown, the second transfer unit 280 can include a vertically arranged endless belt 281. This belt 281 is supported by a plurality of rollers. These rollers are mounted on a support structure. The belt 281 is driven by an engine 283, such as an electric motor, etc. Other configurations and arrangements are possible. At least some of these parts can be designed differently and even omitted in some embodiments. Other types of engines can be used. Other variations are possible.

[0097] As shown, the second transfer unit 280 may include an exit roller and a plate assembly 286. It may form an end of the conveying loop 204 at which the forward movement of the shingled stream 120 is interrupted and diverted to movement along the third direction 304. The exit roller and plate assembly 286 may move along the conveying loop 204 on parallel axes and may be adjusted to the length of the carton 100. The opening between the end plate 284 and the entry plate 264 corresponds to the length of the carton 100 plus an additional clearance to reduce the risk of jamming. The end plate 284 receives the edge of the carton 100 and may be mounted on a mechanical isolation portion to which the vibration device 288 is attached. Vibration of the end plate 284 may assist in the smooth transition of the shingled stream 120 from the second direction 202 to the third direction 304. Other configurations and arrangements are possible. In addition, one or more of the features presented herein may be configured differently or omitted entirely in some embodiments. Other variations are possible.

[0098] The second transfer unit 280 may include an entry roller assembly 282 having a planar section where the belt 281 traveling through the second transfer unit 280 will face directly the belt of the first transfer unit 260. The entry roller assembly 282 may also be configured to move laterally so as to dynamically change the position of the planar section based on the thickness of the shingled stream 120. In addition, it may include a pneumatic actuator in which a pressure may be set to maintain an appropriate force. One side of the shingled stream 120 may have a relatively non-uniform profile and that side may be the side facing the lower roller 242 and then the first transfer unit 260. Due to the carton geometry and the spacing of the shingled stream 120, the shingled stream 120 may have relatively sides with varying heights. That side will be the side engaged by the overhead rollers 250. These overhead rollers 250 may move position and the entry roller assembly 282 may also adjust the position of the planar section to follow the height variations of this side of the shingled stream 120. Other configurations and arrangements are possible. Some of these features may be omitted in some embodiments. Other variations are possible.

[0099] Figure 20 depicts some of the cartons 100 being Figure 7 example of a top view showing a stack formed on the output conveyor 302 at the end of the repositioning station 200 as shown. Figure 21 is similar to Figure 20 but with a significantly narrower carton 100.

[0100] Figure 22is an enlarged side view showing another example of the roller unit 240 for repositioning the station 200. The roller unit 240 of this model mainly includes a support arm 254 in two parts. The length of the support arm 254 can be modified to change the position of the overhead roller 250 relative to the pivot axis 255. The distal part of the support arm 254 can slide relative to the proximal part. The overhead roller 250 is located at the end of the distal part, and a locking mechanism 320 is provided between the distal part and the proximal part to fix these two parts during operation. The locking mechanism 320 can include a pair of spaced positioning screws, which can be loosened to slide these two parts along the intermediate slot and tightened to prevent their relative movement. As shown, the rotation axis 332 of the overhead roller 250 can be parallel to the longitudinal direction of the support arm 254.

[0101] Figure 23 is similar to Figure 22 the view, but shows a shorter support arm 254.

[0102] When cartons 100 of various shapes and sizes are conveyed through the repositioning station 200, it may be useful to adjust the length of the support arm 254. Some cartons 100 may include voids or have protruding features. It may be desirable to change the position of the overhead roller 250 to prevent damage to these features or because another position would be better. Other configurations and arrangements are also possible. In addition, the exact construction of the parts and their relative positions or orientations may vary from one embodiment to another. The locking mechanism 320 can be different from that shown and described. Other types of adjustment methods can be added to the roller unit 240. In some embodiments, the support arm 254 with adjustable length can be omitted. Many other variations are also possible.

[0103] Figure 22 and 23 further shows that the roller unit 240 can include a torsion spring 330. This torsion spring 330 replaces the Figure 10 shown pneumatic actuator 256. A torsion spring is provided to apply a force to push the overhead roller 250 downward against the lower roller 242. Other configurations and arrangements are also possible. In addition, the exact nature, position, and construction of the spring system within each roller unit 240 can vary from one embodiment to another. The roller unit 240 can include more than one spring or rely solely on gravity. Springs can be provided in cases where the length of the support arm 254 is not adjustable. Many other variations are also possible.

[0104] Figure 24 is Figure 3An isometric view of the system 130 shown, but with the repositioning station 200 temporarily bypassed. In this embodiment, the output conveyor 302 can be directly aligned with the end of the input conveyor 122, for example because the particular model of the carton 100 being manufactured does not require any repositioning using the repositioning station 200. It can be seen that the second transfer unit 280 moves upward to avoid the shingled stream 120, which flows directly from the first conveyor 122 to the output conveyor 302 on its path to the packaging station 300 or any other downstream equipment or location. The second transfer unit 280 can include a support frame 214, for example having two opposing vertical columns and an overhead transverse horizontal beam, and the second transfer unit 280 can be modified along the support frame. The output conveyor 302 is generally easier to reposition than the input conveyor 122, and the output conveyor 302 can be aligned with the input conveyor 122 until the repositioning station 200 is needed again. Wheels may already be present under the support frame 310 to facilitate movement, and support legs can be used thereafter to hold the parts in place during operation. Although being able to create a bypass is not a direct result of the operation of the repositioning station 200, it can still be a key feature for some manufacturers as it allows them to have a repositioning station when needed while still being able to quickly reconfigure the footprint when required. Other configurations and arrangements are also possible. Additionally, this feature can be completely omitted or differently configured in some embodiments. Other variations are also possible.

[0105] Figure 25 is an isometric view showing another example of the system 130, where the repositioning station 200 includes a second transfer unit 280 mounted on a support frame 214 that can pivot relative to a transverse bottom axis, thereby creating a bypass similar to that Figure 24 shown in. As shown, the opposing bottom ends of the support frame 214 can be pivotally attached to the support frame 310. If desired, a lifting system (not shown) can be provided to assist in handling or moving the entire section using an actuator or the like. Other configurations and arrangements are also possible.

[0106] Figure 26 is Figure 25 the isometric view shown in but observed from another angle.

[0107] Figure 25 and 26 further shows that the first transfer unit 260 can include one or more rollers instead of a loop belt system. In the illustrated example, the first transfer unit 260 includes adjacent rollers. These rollers can be similar to the rollers 242. Other configurations and arrangements are also possible. Additionally, the number of rollers in such a first transfer unit 260 and their shape can be different. Other variations are also possible.

[0108] Figure 27 Yes Figure 25 And 26 An enlarged isometric view of the first transfer unit 260 as shown. For ease of illustration, in Figure 27 not shown in Figure 25 And 26 the second transfer unit 280 and various other parts that can be seen in Figure 27 Shows that the first transfer unit 260 can be configured as a continuation of the lateral deflection assembly 210, for example, enabling its rollers 340, 342 to engage in torque transmission with the adjacent rollers 242 of the lateral deflection assembly 210. The two rollers 340, 342 of the first transfer unit 260 can rotate about a vertical axis and can be mounted using corresponding support housings 344, as shown in the illustrated example. Other configurations and arrangements are possible. In addition, the rollers of the first transfer unit 260 can be driven using their own engines or using another arrangement. They can also be supported by another arrangement rather than the support housing 344. In some embodiments, the axes of rotation of the rollers can be oriented differently. Other variations are possible.

[0109] Figure 28 Is an enlarged isometric view showing the final positioning assembly 212 having the first transfer unit 260 as shown in Figure 27 Figure 28 Also shown for illustration purposes only is a single carton 100. As shown, the final positioning assembly 212 can include a vertical side plate 350 that extends parallel to the third direction 304 and is positioned immediately after the last roller 342 of the first transfer unit 260. Other configurations and arrangements are possible. In addition, at least some of the features described in this paragraph or shown in the corresponding drawings or both can be omitted in some embodiments. They can also be designed or arranged differently. Other variations are possible.

[0110] Figure 29 Yes Figure 28 The top view as shown, except for the carton 100.

[0111] Figure 30 Is similar to Figure 20 but shows another example of the repositioning station 200, where the first transfer unit 260 includes a vertical annular belt and can move laterally to handle a narrower carton 100.

[0112] Figure 31 Is similar to Figure 30 but with a significantly narrower carton 100. The stack of cartons 100 is now adjacent to the left side of the output conveyor 302 relative to the third direction 304. Different from the Figure 21 similarly narrow stack shown in​Figure 31 The carton 100 in [[ ]] is now near the opposite side of the output conveyor 302. Figure 30 and 31 The first transfer unit 260 in [[ ]] includes a plurality of rollers, and some of these parts can be mounted on a frame that can be repositioned laterally, so that the front end of the first transfer unit 260 moves closer to or farther from the opposite side. Then in the example, the vertical side plate 350 is also repositioned. The narrower carton 100 in the illustration will be carried laterally over a longer distance between the two transfer units 260, 280 to reach its destination. Although this arrangement is more complex compared to other arrangements, it may be useful in certain situations, such as in embodiments where the operator or the machine at the packaging station will be on this side. Other configurations and arrangements are also possible. In addition, at least some of the features described in this paragraph or shown in the corresponding drawings or both can be omitted in some embodiments. They can also be designed or arranged differently. Other variations are also possible.

[0113] Figure 32 is as Figure 30 a top view of the first transfer unit 260 constructed as shown. Figure 33 is similar to Figure 32 but shows the first transfer unit configuration in an extended position as shown in Figure 31

[0114] Figure 34 is Figure 30 and 31 an isometric view of the second transfer unit 280 in the repositioning station 200 as shown in [[ ]] and [[ ]].

[0115] Figure 35 is similar to Figure 34 but a view observed from another angle.

[0116] Figure 36 and 37 are isometric views showing an example of the system 130 with the second transfer unit 280 as shown in [[ ]] and [[ ]], the second transfer unit 280 being movable laterally relative to the output conveyor 302 so as to form a bypass similar to that shown in Figure 34 and 35 Figure 24 The support frame 240 is constructed and arranged such that the parts of the second transfer unit 280 can move to the side.

[0117] ​​This detailed description and the accompanying drawings are merely exemplary, and those skilled in the art will recognize that changes can be made upon review of the present disclosure without departing from the proposed concepts. Additionally, unless otherwise explicitly stated, no part, element, characteristic, or feature, or any combination thereof, should be construed as essential to the invention merely because it exists in one or more of the examples described, illustrated, and / or suggested herein.

[0118] Reference numeral

[0119] 100 Carton

[0120] 100' Horizontally offset carton

[0121] 102 (Edge of carton 100)

[0122] 104 (Edge of carton 100)

[0123] 106 (Edge of carton 100)

[0124] 108 (Edge of carton 100)

[0125] 120 Continuous shingle stream

[0126] 122 Input conveyor

[0127] 124 First direction

[0128] 130 System

[0129] 150 Folder gluer machine

[0130] 200 Relocation station

[0131] 202 Second direction

[0132] 204 Conveyor loop

[0133] 206 Curved axis

[0134] 210 Lateral deflection assembly

[0135] 212 Final positioning assembly

[0136] 214 Support frame

[0137] 220 (Support frame of lateral deflection assembly)

[0138] 230 Lateral guide device

[0139] 240 Roller unit

[0140] 242 Lower roller

[0141] 244 Engine

[0142] 246 groove

[0143] 248 ring

[0144] 250 overhead roller

[0145] 252 biasing device

[0146] 254 support arm

[0147] 255 pivot axis (of support arm)

[0148] 256 pneumatic actuator

[0149] 257 side extension (of support arm)

[0150] 258 retaining member

[0151] 259 main bracket

[0152] 260 first transfer unit

[0153] 261 endless belt

[0154] 262 slotted bracket

[0155] 263 corner

[0156] 264 access plate

[0157] 265 engine

[0158] 270 bottom roller

[0159] 280 second transfer unit

[0160] 281 endless belt

[0161] 282 entry roller assembly

[0162] 283 engine

[0163] 284 end plate

[0164] 286 exit roller and plate assembly

[0165] 288 vibrating device

[0166] 300 packaging station

[0167] 302 output conveyor

[0168] 304 third direction

[0169] 310 support frame (of output conveyor)

[0170] 320 locking mechanism

[0171] 330 torsion spring

[0172] 332 Rotation axis (of the top roller)

[0173] 334 Rotation axis (lower roller)

[0174] 340 Roller (for the first transfer unit)

[0175] 342 Roller (for the first transfer unit)

[0176] 344 Support housing

Claims

1. A repositioning station (200) for a continuous shingled stream (120) of overlapping semi-rigid planar articles (100), wherein the articles (100) are carried in a flat configuration and face-down position onto an input conveyor (122), enter the repositioning station (200) along a first horizontal direction (124), and are then conveyed by the repositioning station (200) along a second horizontal direction (202) onto an output conveyor (302) to form a stack having the articles (100) in an upright position, the stack being carried away on the output conveyor (302) along a third horizontal direction (304), the repositioning station (200) defining a conveying loop (204) and comprising: A lateral deflection assembly (210) located at the entrance of the repositioning station (200), the lateral deflection assembly (210) including a plurality of roller units (240) longitudinally arranged, the conveying loop (204) following an oval offset path along the roller units (240) to deflect the shingled stream (120) from the first horizontal direction (124) to the second horizontal direction (202), and also pivoting the articles (100) in the shingled stream (120) from the face-down position to the upright position about a curved axis (206) coinciding with the innermost and bottommost boundaries of the conveying loop (204) throughout the lateral deflection assembly (210).

2. The repositioning station (200) according to claim 1, wherein the second horizontal direction (202) is perpendicular to the first horizontal direction (124), and the third horizontal direction (304) is parallel to the first horizontal direction (124).

3. The repositioning station (200) according to claim 1, wherein the repositioning station (200) includes a final positioning assembly (212) located at the exit of the repositioning station (200) and including at least one transfer unit (260, 280) to convey the article (100) along the second horizontal direction (202) from the exit of the lateral deflection assembly (210) to the end of the conveying loop (204), the final positioning assembly (212) extending at least partially across the output conveyor (302).

4. The repositioning station (200) according to claim 2, wherein the repositioning station (200) includes a final positioning assembly (212) located at the exit of the repositioning station (200) and including at least one transfer unit (260, 280) to convey the article (100) along the second horizontal direction (202) from the exit of the lateral deflection assembly (210) to the end of the conveying loop (204), the final positioning assembly (212) extending at least partially across the output conveyor (302).

5. The repositioning station (200) according to claim 1, Characterized in that, The repositioning station (200) includes a final positioning assembly (212) located at the exit of the repositioning station (200) to convey the article (100) along the second horizontal direction (202) from the exit of the lateral deflection assembly (210) to the end of the conveying loop (204), and the final positioning assembly (212) includes: A first transfer unit (260) positioned at the exit of the lateral deflection assembly (210); and A second transfer unit (280) extending across the output conveyor (302), and the second transfer unit (280) has a portion facing the corresponding portion of the first transfer unit (260).

6. The repositioning station (200) according to claim 2, Characterized in that, The repositioning station (200) includes a final positioning assembly (212) located at the exit of the repositioning station (200) to convey the article (100) along the second horizontal direction (202) from the exit of the lateral deflection assembly (210) to the end of the conveying loop (204), and the final positioning assembly (212) includes: A first transfer unit (260) positioned at the exit of the lateral deflection assembly (210); and A second transfer unit (280) extending across the output conveyor (302), and the second transfer unit (280) has a portion facing the corresponding portion of the first transfer unit (260).

7. The repositioning station (200) according to claim 5, Characterized in that, The second transfer unit (280) is configured and arranged to move away from the output conveyor (302) when the shingled flow (120) has to temporarily bypass the repositioning station (200).

8. The repositioning station (200) according to any one of claims 5 to 7, Characterized in that, The first transfer unit (260) is configured and arranged to be height adjustable.

9. The repositioning station (200) according to any one of claims 5 to 7, Characterized in that, The second transfer unit (280) includes a vertically arranged endless belt (281) driven by a corresponding motor.

10. The repositioning station (200) according to claim 8, Characterized in that, The second transfer unit (280) includes a vertically arranged endless belt (281) driven by a corresponding motor.

11. The repositioning station (200) according to any one of claims 5 to 7, Characterized in that, The first transfer unit (260) includes a vertically arranged endless belt (261) driven by a corresponding motor.

12. The repositioning station (200) according to claim 8, Characterized in that, The first transfer unit (260) includes a vertically arranged endless belt (261) driven by a corresponding motor.

13. The repositioning station (200) according to any one of claims 5 to 7, Characterized in that, The first transfer unit (260) includes at least one roller.

14. The repositioning station (200) according to claim 8, wherein, the first transfer unit (260) includes at least one roller.

15. The repositioning station (200) according to any one of claims 1 to 7, 10, 12, and 14, wherein, the roller unit (240) includes: a plurality of motorized lower rollers (242) that extend vertically relative to the conveying loop (204) to engage a first side of the shingled stream (120); a plurality of overhead rollers (250) positioned above the lower rollers (242) to engage a second side of the shingled stream (120); and a plurality of biasing devices (252), each of the plurality of biasing devices (252) pushing a corresponding one of the overhead rollers (250) toward the lower rollers (242).

16. The repositioning station (200) according to claim 8, wherein, the roller unit (240) includes: a plurality of motorized lower rollers (242) that extend vertically relative to the conveying loop (204) to engage a first side of the shingled stream (120); a plurality of overhead rollers (250) positioned above the lower rollers (242) to engage a second side of the shingled stream (120); and a plurality of biasing devices (252), each of the plurality of biasing devices (252) pushing a corresponding one of the overhead rollers (250) toward the lower rollers (242).

17. The repositioning station (200) according to claim 15, wherein, at least some of the motorized lower rollers (242) are in torque - transmitting engagement with each other.

18. The repositioning station (200) according to claim 16, wherein, at least some of the motorized lower rollers (242) are in torque - transmitting engagement with each other.

19. The repositioning station (200) according to any one of claims 1 to 7, 10, 12, 14, 16 to 18, wherein, the curved axis (206) is horizontal and single - planar within the lateral deflection assembly (210).

20. The repositioning station (200) according to any one of claims 1 to 7, 10, 12, 14, 16 to 18, wherein, it further includes a lateral guiding device (230) immediately upstream of the lateral deflection assembly (210).

21. The repositioning station (200) according to claim 19, wherein, it further includes a lateral guiding device (230) immediately upstream of the lateral deflection assembly (210).

22. The repositioning station (200) according to any one of claims 1 to 7, 10, 12, 14, 16 to 18, wherein, the input conveyor (122) and the output conveyor (302) are endless belt conveyors.

23. The repositioning station (200) according to claim 20, characterized in that, the input conveyor (122) and the output conveyor (302) are endless belt conveyors.

24. The repositioning station (200) according to claim 21, characterized in that, the input conveyor (122) and the output conveyor (302) are endless belt conveyors.

Images