Device for converting a starting material into a padding material for filling the empty volume in a container, and method for operating such a device

Abstract

A device (10) for converting a starting material into a padding material for filling the empty volume in a container comprises a discharging section (14) for discharging the padding material and a finishing unit (32) which is arranged upstream of the discharging section (14) and finishes the padding material. It is proposed that the finishing unit (32) has a translationally movable carriage (34) and a finishing section (46) which is releasably and exchangeably fastened to the carriage (34) and, by movement of the carriage (34), is at least partially movable into a conveying channel (16) for the padding material.

Description

[0001] Title : Device for converting a

[0002] Starting material into a cushioning material for filling the empty volume in a container, and method for operating such a device

[0003] Description

[0004] The invention relates to a device for converting a starting material into a cushioning material for filling the empty volume in a container and to a method for operating such a device according to the preambles of the respective independent claims.

[0005] From the market, devices in the form of

[0006] Cushioning conversion machines are known. These have a driven conveyor device that draws a starting material made of paper, for example a web-shaped or endless one, into a feed section. In the device, the starting material is, for example, crumpled and / or creased, producing a cushioning material that has a larger volume and a lower density than the starting material. The cushioning material is discharged via an output section. A post-processing device in the form of a cutting device cuts the cushioning material into elongated cushioning pads.

[0007] The problem underlying the invention is solved by a device and a method having the features of the independent claims. Advantageous further developments are specified in the dependent claims.

[0008] In the device according to the invention, the post-processing section is arranged detachably and replaceably on the translationally movable carriage. In this way, on the one hand, a worn post-processing section can be easily replaced with a new post-processing section, and on the other hand, it is possible to attach functionally different post-processing sections to the carriage and thus implement different functions of the post-processing device on the otherwise identical device. The flexibility in using the device according to the invention is thus considerably increased. Furthermore, with the method according to the invention, different functions of the post-processing device can be implemented in a simple manner.

[0009] Specifically, this is achieved by a device for converting, for example, an initially web-shaped starting material into a cushioning material for filling the empty volume in a container. Such a device is also referred to as a “cushioning conversion machine”. The initially web-shaped starting material can, for example, be a paper web that is wound up as a roll or provided as a zigzag-folded stack. If it is provided as a roll, the paper web can be unwound flat and even from the roll and then folded over in the cushioning conversion machine, for example at the side edges, and then crumpled. However, it is possible and, in the present case, particularly preferred if the starting material is pulled radially inward from the roll in its axial direction and drawn into the device as a spiral, tube-like starting material.

[0010] The device typically comprises a feed section for feeding the starting material. If the starting material fed to the device is the spirally tubular starting material just mentioned, the feed section can be designed, for example, as a feed hopper. If it is a web-shaped and flat starting material, the feed section can have a forming unit by which the lateral edges of the starting material are folded over as it is drawn in.

[0011] Furthermore, the device typically includes a dispensing section for dispensing the cushioning material. The dispensing section may have a conveyor channel with a dispensing opening from which the finished cushioning material emerges and is dispensed, for example, to a user.

[0012] A driven conveyor device of the cushioning conversion machine serves to convey the starting material or cushioning material. The conveyor device can, for example, comprise two rotating rollers which are arranged in such a way that there is a small gap between their outer surfaces. At least one of the two rollers can be driven. By rotating the rollers, the starting material is forced through the gap and is preferably deformed in the process, for example crumpled and / or creased. However, the conveyor device can also have two pairs of rollers spaced apart from one another in a conveying direction, with the downstream pair of rollers conveying at a lower speed than the upstream pair of rollers. This compresses the material, which also leads to a crumpling effect.In the device according to the invention, a post-processing device is arranged upstream of the output section, which post-processes the cushioning material. Typically, the post-processing device can cut the initially endless strand of cushioning material into individual elongated cushioning pads.

[0013] In this way, the end result is a three-dimensional cushioning material with a comparatively large volume and a comparatively low density. This cushioning material can then be picked up, for example, by a user or automatically by a robot and placed into a container, such as a transport box, to at least partially fill any empty space there. This prevents the objects contained in such a transport box from falling around and becoming damaged during transport.

[0014] According to the invention, the post-processing device has a translationally movable carriage. This carriage is a section which is mounted on a housing of the device such that it can move back and forth, for example by means of a linear guide. The carriage is mechanically coupled to a drive which effects the aforementioned back and forth movement of the carriage. Typically, the drive is an electric motor, although a pneumatic or hydraulic drive is also conceivable. A post-processing section is fastened to the carriage in a detachable and replaceable manner. For example, the post-processing section can be positively connected to the carriage and secured to it, for example, by a screw. However, a pure screw connection is also conceivable. Instead of a screw connection, a snap-in connection or something similar could also be provided.For post-processing of the padding material, the post-processing section can be moved at least partially into a conveyor channel for the padding material by moving the carriage. Thus, if the post-processing section is moved into the conveyor channel, it can act on the padding material present there and post-process it.

[0015] In a further development, the post-processing section comprises a cutting section. For example, the cutting section can be designed as a blade, in particular as an inclined blade. A sawtooth-like design of the cutting section is also possible. If such a post-processing section is fully inserted into the conveyor channel, an above-mentioned cushioning pad is separated from the endless strand of cushioning material.

[0016] In the case of further training, it is intended that the

[0017] The post-processing section comprises a perforation section. For example, the post-processing section can have a plurality of needle sections arranged in a row. If such a post-processing section is introduced into the conveyor channel, the needle sections penetrate the cushioning material present there without cutting it off, thereby creating a perforation line. This allows a user to tear off a cushion of the desired length, for example by manually tearing it apart along the perforation line.

[0018] It is possible, and particularly preferred, for the post-processing section to comprise both a cutting section and a perforation section, or to be designed as a combined cutting and perforation section. Depending on the depth of penetration of the post-processing section into the conveyor channel into the cushioning material, the material is then either only perforated (with a lower penetration depth) or separated (with a greater penetration depth).

[0019] In a further development, the post-processing section is one of a set of differently designed post-processing sections. This allows the device to be adapted very quickly to different functional requirements.

[0020] In a further development, the set of post-processing sections comprises post-processing sections of different lengths and / or post-processing sections of different shapes. The same advantages apply here as above. In a further development, the carriage has a slot-like link into which a sliding block engages. This link block is connected to a drive and can execute an eccentric rotary movement. This is mechanically robust and durable.

[0021] In a further development it is provided that the eccentric rotary movement of the sliding block is carried out in one direction of rotation during one finishing process and in the opposite direction of rotation during another finishing process. For example, a cycle which consists of a movement of the finishing section in the direction of the conveyor channel and back again (from a top dead center to a bottom dead center and back again to the top dead center) can be brought about by a 360° rotation of the sliding block along a circular path. In such a case the sliding block could bring about the movement of the finishing section in one cycle by a clockwise rotation and in a subsequent cycle by a counterclockwise rotation. This evens out the wear on the sliding block and the link.

[0022] In a further development it is provided that the sliding block is arranged eccentrically on a drive wheel or on a cranked crank. This is mechanically robust and durable. In a further development it is provided that the drive of the sliding block comprises a stepper motor or a motor with an encoder. This makes it possible to specifically control the drive and move it into a certain position and thus also to specifically control the carriage with the post-processing section into a certain position and thus specifically control or vary the penetration depth of the post-processing section into the conveyor channel, for example, as mentioned above, only to perforate during one post-processing and to separate during another post-processing. The control or regulation is preferably carried out by a corresponding control device or control and regulation device, for example a computer.

[0023] The invention also includes a method for operating a device of the type described above, which comprises the following steps: a. manually actuating an input device to trigger operation of the conveyor device; b. time- or length-controlled automatic brief switching off of the conveyor device during the continued actuation of the input device; c. automatically driving the post-processing device during the brief automatic switching off of the conveyor device such that a perforation is produced; d. ending the manual actuation of the input device; and e. automatically driving the post-processing device after ending the manual actuation of the input device such that the cushioning material is cut.

[0024] An embodiment of the invention is explained below with reference to the accompanying drawings. In the drawings:

[0025] Figure 1 is a perspective view obliquely from the front of a device for converting a starting material into a cushioning material, with parts of the device removed for better visualization;

[0026] Figure 2 is a view similar to Figure 1 with more parts of the device removed;

[0027] Figure 3 is a perspective view from the rear of the device of Figures 1 and 2, with more parts of the device removed;

[0028] Figure 4 is a perspective view obliquely from the front of a post-processing device of the apparatus of Figures 1-3;

[0029] Figure 5 is a perspective view from the rear of the post-processing device of Figure 4;

[0030] Figure 6 is a front view of the post-processing device of Figures 4-5; and Figure 7 is a flowchart of a method for operating the device of Figures 1-6.

[0031] A device for converting a starting material into a cushioning material is designated overall by reference numeral 10 in the figures. It serves to convert a typically initially approximately web-shaped starting material into a cushioning material for filling the empty volume in a container (not shown). The device 10 is also referred to as a "cushioning conversion machine". The initially web-shaped starting material can, for example, be a paper web wound up as a roll or provided as a zigzag-folded stack. If provided as a roll, the paper web can be unwound flat and even from the roll and then folded over and crumpled, for example at the side edges, in the cushioning conversion machine 10.However, it is possible and particularly preferred in the present case if the starting material is pulled out radially from the inside of the roll in its axial direction and is drawn into the device 10 as a spirally tube-shaped starting material.

[0032] The device 10 comprises a feed section 12 for feeding the starting material. In the present example, the feed section 12 is designed as a conical feed funnel. This is particularly suitable for the above-mentioned spirally tube-shaped fed starting material. In an embodiment not shown, in which the fed starting material is web-shaped and even / flat, the feed section can have a forming unit by which, for example, the lateral edges of the starting material are folded over when it is drawn in.

[0033] On the side facing the viewer in Figures 1 and 2, the device 10 further comprises a dispensing section 14, which in the present case comprises a conveying channel 16 with a dispensing opening 18. The finished cushioning material emerges from the dispensing opening 18, where it can be gripped, for example, by a user. The conveying channel 16 in the present case has a rectangular cross-section and is slightly curved downwards as viewed in its longitudinal direction. Furthermore, the cross-sectional area of ​​the conveying channel 16 increases as viewed in the conveying direction relative to the dispensing opening 18.

[0034] The device 10 further comprises a conveyor device 20, with which the starting material or the cushioning material is conveyed within the device 10, i.e., from the feed section 12 via the conveyor channel 16 in the direction of the discharge opening 18. The conveyor device 20 is particularly clearly visible in Figures 2 and 3. In the present case, it comprises a pair consisting of two rotating rollers 22 and 24, one or both of which are driven by a drive 26.

[0035] The two rollers 22 and 24 are arranged in relation to one another in such a way that a certain gap 28 exists between their outer surfaces (without reference symbol). By rotating the rollers 22 and 24 in opposite directions, the starting material is forced through the gap 28 and driven in the direction of the discharge opening 18. In order to be able to adapt the gap 28 automatically to different conditions, one of the two rollers 22 and 24 or both rollers 22 and 24 can be spring-mounted orthogonally to a conveying direction 30. In order to improve the conveying of the material, the outer surfaces of the two rollers 22 and 24 can be provided, for example, with a rubber coating or something similar (e.g. a corrugation).

[0036] When the material is forced through the gap 28, it is typically at least slightly deformed, for example, crumpled and / or creased. Assuming that the starting material is the spirally tube-shaped paper material mentioned above, it is pressed, crumpled, and creased as it is forced through the gap 28, thereby more or less fixing its shape and thus transforming it into the aforementioned cushioning material.

[0037] In an alternative embodiment not shown, the conveyor device can have two pairs of rollers spaced apart from one another in the conveying direction, the downstream pair of rollers being driven at a lower speed than the upstream pair of rollers. As a result, the material is compressed in the conveying direction, which likewise leads to a crumpling effect. In any case, at the end, i.e. at the output section 14, a three-dimensional cushioning material is obtained which has a comparatively large volume and a comparatively low density. This cushioning material can then be gripped, for example, by a user or automatically by a robot and placed into a container, for example a transport carton, in order to at least partially fill any empty volume present there.

[0038] A post-processing device 32 is arranged upstream of the discharge section 14, more precisely, viewed in the conveying direction, between the feed section 12 designed as a funnel and the conveying channel 16. This is shown in greater detail in Figures 4-6.

[0039] The post-processing device 32 initially comprises a carriage 34, which in the present case is designed essentially as a rectangular plate. The carriage 34 has two lateral edges 36, which are vertical in the figures and are received in complementary vertical grooves 38 in lateral guide elements 40. The grooves 38 can be delimited by removable limiting plates 42, which are screwed to a body (without reference numeral) of a guide element 40 (reference numeral 44).

[0040] In an embodiment not shown, the carriage can also be guided by a linear guide with ball or roller bearings. A post-processing section 46 is detachably and replaceably attached to the carriage 34. The post-processing section 46 is designed in this case as an approximately rectangular and elongated thin plate. At its lower edge, the post-processing section 46, shown here as an example in the figures, has a sawtooth-shaped cutting section 48.

[0041] In an embodiment not shown, the post-processing section has a perforation section, which can be formed, for example, by a plurality of needle sections arranged in a row. A combination of perforation section and cutting section is also conceivable, in which sharp cutting sections are present between the needle sections.

[0042] In the present example, the post-processing section 46 is positively connected to the carriage 34. For this purpose, the carriage has a recess 50 that is open downwards in the figures, the contour of whose inner wall is complementary to the outer contour of the upper section of the post-processing section 46 in the figures. The post-processing section 46 is secured to the carriage 34 by means of a screw 52.

[0043] In an embodiment not shown, a purely screw connection is also conceivable. Instead of a screw connection, a snap-in connection or something similar could also be provided. By loosening the screw 52, ​​the post-processing section 46 can be removed from the carriage 34 and replaced, for example, with a new or different post-processing section.

[0044] The carriage 34 is mechanically coupled to a drive 54. For this purpose, the carriage 34 has a link 56. The link 56 is designed as a horizontal slot in an upper region of the carriage 34 in the figures. A link block 58 of the drive 54, designed here as a rotatable roller, engages in the link 56 and is arranged on a projecting end of a cranked crank 60. In an embodiment not shown, the link block could also be arranged eccentrically on a drive wheel.

[0045] The crank 60 is connected at the end opposite the sliding block 58 to a drive shaft of an electric motor drive 62. The electric motor drive 62 can comprise an electric motor and a gear unit flanged thereto, but the crank 60 can also be mounted directly on a drive shaft of the electric motor. An axis of rotation of the crank 60 is shown in dash-dotted lines in Figure 5 and provided with the reference numeral 64.

[0046] When the crank 60 rotates 360° clockwise about the axis of rotation 64 (arrow 66 in Figures 4-6), the sliding block 58 moves in a circular path (eccentric rotary movement) towards the right-hand edge of the link 56 in Figures 4 and 6 and then back to the center (bottom dead center). In this position, the carriage 34 and the post-processing section 46 are moved as far downwards as possible in the figures (double arrow 68 in Figures 4-6). In this way, the post-processing section 46 with the cutting section 48 is moved through a slot 70 (Figures 1 and 2) into the conveyor channel 16, in the present example such that the cutting section 48 completely traverses the conveyor channel 16.

[0047] If the crank 60 is moved further clockwise until the sliding block 58 is in the maximum upper position in the figures (top dead center), the carriage 34 and the post-processing section 46 are moved upwards again in the figures until the post-processing section 46 has completely released the conveyor channel 16 again, i.e. has been completely retracted from it. It is understood that the conveyor device 20 is preferably not in operation during operation of the post-processing device 32. The movement of the cutting section 48 into the conveyor channel 16 cuts through the cushioning material located in the conveyor channel 16, so that a cut-off cushioning pad is produced from the initially endless strand, which can be removed by a user, for example, from the output opening 18.

[0048] After a finishing operation in which the crank 60 has been moved 360° clockwise 66, the crank 60 can be moved 360° counterclockwise in a subsequent finishing operation, according to the arrow 72 in Figures 4-6.

[0049] A sensor 71 (Figure 3) is provided to control the electric motor drive 62, which detects when the sliding block 58 is at top dead center. In an embodiment not shown, the electric motor drive can also be equipped with a stepper motor or a motor with an encoder. This allows the position of the sliding block on the circular path, and thus the vertical position of the carriage and the post-processing section, to be precisely controlled and adjusted.

[0050] It was mentioned above that, in an embodiment not shown, the post-processing section may comprise a combination of a cutting section and a perforating section. If, in this case, the post-processing section only enters the conveyor channel with the perforating section, the cushioning material present there would only be perforated. If, however, the post-processing section enters the conveyor channel further or completely and then also with the cutting section, the cushioning material would be severed and cut off. This could be utilized in a corresponding method for operating the device 10 as follows (Figure 7):

[0051] In a functional block 74, an input device is manually actuated to trigger operation of the conveyor device 20. The input device can be, for example, a foot switch. This causes the rollers 22 and 24 to rotate, and the material is transported from the feed section 12 through the gap 28 between the rollers 22 and 24 into the conveyor channel to the discharge opening 18.

[0052] In a functional block 76, a time- or length-controlled automatic, brief shutdown of the conveyor device 20 occurs during the continued actuation of the input device. The term "automatic" is understood here to mean that a control device controls the corresponding component in a desired manner without any intervention by an operator. The control device can be a computer, for example. In other words: the user continues to hold down the input device, and yet the conveyor device 20 stops automatically.

[0053] In a function block 78, with the input device still actuated, the drive 54 of the post-processing device 32 is automatically started up. However, the control system automatically moves the post-processing section 46 only far enough into the conveyor channel 16 so that the cushioning material present there is not severed, but merely provided with a perforation. The post-processing section 46 is then completely and automatically withdrawn from the conveyor channel 16. After that, in a function block 80, the drive 26 with the rollers 22 and 24 is automatically started up again, whereby material is again conveyed from the feed section 12 to the output opening 18 (and further out of this). The cushioning material emerging from the output opening 18 is now provided with a perforation.

[0054] This process can be continuously repeated, time- or length-controlled, as long as the operator operates the input device. "Time- or length-controlled" in this case means that, as long as the input device is operated, steps 76-80 are continuously repeated either after a certain time has elapsed or after a certain length of material has been conveyed. In this way, a perforation is continuously introduced into the cushioning material at specific intervals.

[0055] This continues until, in a function block 82, the operator stops the manual operation of the input device, for example by taking his foot off the foot switch.

[0056] This results in the drive 26 with the rollers 22 and 24 being automatically stopped in a function block 84, and in the post-processing device 32 being automatically driven in a function block 86 such that the post-processing section 46 is completely immersed in the conveyor channel 16, as a result of which the cushioning material is severed or cut off. The post-processing section 46 can be one of a set of several differently designed post-processing sections. For example, the set of post-processing sections can have post-processing sections that are different lengths or different widths. Alternatively or additionally, the set of post-processing sections can have post-processing sections that are differently shaped.For example, one post-processing section in the set may include a cutting section, another post-processing section in the set may include a perforating section, and another post-processing section in the set may include a combined cutting and perforating section. All post-processing sections in the set are identical in the area of ​​their coupling to the carriage 34, meaning they can all be coupled to the same carriage 34.

Claims

Patent claims 1. Device (10) for converting a starting material into a cushioning material for filling the empty volume in a container, comprising a dispensing section (14) for dispensing the cushioning material and a post-processing device (32) arranged upstream of the dispensing section (14) which post-processes the cushioning material, characterized in that the post-processing device (32) has a translationally movable carriage (34) and a post-processing section (46) detachably and interchangeably attached to the carriage (34), which can be moved at least partially into a conveying channel (16) for the cushioning material by a movement of the carriage (34).

2. Device (10) according to claim 1, characterized in that the post-processing section (46) comprises a cutting section (48).

3. Device according to at least one of the preceding claims, characterized in that the post-processing section comprises a perforation section.

4. Device (10) according to at least one of the preceding claims, characterized in that the post-processing section (46) is made of a A set of differently configured post-processing sections. Device according to claim 4, characterized in that the set of post-processing sections comprises post-processing sections of different lengths and / or differently shaped post-processing sections. Device (10) according to at least one of the preceding claims, characterized in that the slide (34) has a slot-like cam (56) into which a cam block (58) engages, which is connected to a drive (54) and which can perform an eccentric rotary movement. Device (10) according to claim 6, characterized in that the cam block (58) is arranged eccentrically on a drive wheel or on a cranked crank (60). Device (10) according to at least one of the preceding claims 6-7, characterized in that the drive (54) of the cam block (58) comprises a stepper motor or a motor with an encoder.Method ( 10 ) according to at least one of the preceding claims 6-8 , characterized in that the eccentric rotary movement of the cam block (58 ) during a post-processing operation is in one direction of rotation and during another. The post-processing operation is carried out in the opposite direction of rotation.

10. A method for operating a device according to at least one of the preceding claims, characterized in that it comprises the following steps: a. manual actuation (74) of an input device to trigger operation of the conveying device (20); b. time- or length-controlled automatic short-term shutdown (76) of the conveying device (20) during the continued actuation of the input device; c. automatic drive (78) of the finishing device (32) during the short-term automatic shutdown of the conveying device (20) such that a perforation is produced; d. termination (82) of the manual actuation of the input device; and e. automatic drive (86) of the finishing device (32) after termination of the manual actuation of the input device such that the cushioning material is cut.

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