Absorbent article insert cutting and conveying device with servo motor subsystem

Abstract

The cutting and conveying apparatus includes a cutting system that cuts an incoming web of material into individual articles and a conveying mechanism operable to convey and rotate the individual articles from a web receiving location to an article placement location. The conveying mechanism includes a drive shaft rotatable about a conveying axis and a puck wheel mounted on the drive shaft for rotation about the conveying axis with the drive shaft. The puck wheel includes a plurality of carriage units that rotate about the conveying axis for movement along a conveying path centered about the conveying axis, each carriage unit including a puck that supports an individual article and reorients the article as the puck moves between the web receiving location and the article placement location. A plurality of servo motors are operatively connected to the carriage units via connecting arms for varying positioning of the respective carriage units along at least a portion of the conveying path.

Description

[Technical field]

[0001] Embodiments of the present invention relate to an apparatus for receiving and cutting a continuous web of disposable absorbent articles, such as diapers, incontinence garments, or feminine hygiene pads, as the articles progress along a manufacturing line, and conveying individual articles or inserts, such as absorbent pads, cut from the web. More specifically, embodiments of the present invention relate to an apparatus that is configurable to make timely and efficient adjustments in its operation to accommodate changes in product size, and that is operable to accommodate the cutting and conveying of individual articles falling within a wide variety of types and sizes. To accommodate larger product sizes, the machine is equipped with a servo motor subsystem that allows for an increased pitch range to allow for greater spacing of the articles or inserts. [Background technology]

[0002] In the production and manufacturing of disposable products such as sanitary napkins or pant diapers, it is often necessary to produce components of a product in one orientation and then spin the component parts to a predetermined angle where they are properly oriented for use in another step of the production process. As an example, a typical article or web that is reoriented is an absorbent article. Existing equipment functions to receive a continuous web, cut cut portions from the web to form individual articles, spin the articles to a predetermined angle, and convey the articles for placement on a receiving surface. Furthermore, the equipment can also function to control the speed and pitch between the cut articles to achieve a desired placement pitch on the receiving surface. For example, in the case of a diaper, the article may be an absorbent insert that is placed on a fluid-impermeable chassis. Thus, the web may be cut at a cut pitch while the article is placed on the receiving chassis web at a receiving pitch that corresponds to the distance between successive chassis to be formed, where the receiving pitch is defined by the distance extending from the chassis trailing edge through the intermediate space to the subsequent chassis leading edge.

[0003] Regarding the structure of the apparatus, the apparatus is generally configured to include a conveying device and a cutting system. The conveying device includes a large wheel ("puck wheel") to which multiple rotating pucks are fixed, which are selectively operable to rotate and re-pitch the individual articles. The puck wheel is driven and supported by a shaft extending from the drive side of the apparatus, and the pucks rotate with the wheel. Furthermore, each puck functions to spin / turn about its own spin axis to perform a turn (e.g., a 90 degree turn) of the individual articles. The cutting system includes an anvil wheel and a cutting roll, which interact with each other to cut the continuous web as it is received on the puck of the conveying device. The anvil wheel includes multiple anvils arranged thereon such that the pucks are interspersed. The anvil wheel is driven and supported by a shaft that may be common or separate from the shaft driving the puck wheel, and the anvils rotate around the anvil wheel to periodically contact the blades on the cutting roll, thereby cutting the continuous web and forming the individual articles held by each puck of the conveying device.

[0004] While existing cutting and transfer apparatus such as those described above function well to rotate and re-pitch pads for placement on a receiving surface, it is recognized that these apparatus lack the flexibility desired in many manufacturing settings and implementations. As an example, it is often desirable for a single apparatus to be used to manufacture multiple different disposable product types and sizes, and such "resizing" of the products being manufactured requires, as examples, reconfiguring the apparatus to accommodate different sized articles on the pack, operating the apparatus at different speeds / speed profiles, changing the pitch range of the pack, and changing the positioning of the anvil wheel relative to the pack wheel and / or cutting roll. Thus, in order to implement a different process flow or to accommodate a size change from a currently manufactured product, it is necessary to manually reconfigure, reposition, or replace numerous components within the apparatus, or to replace the apparatus with an apparatus that can accommodate the individual article dimensions and pitch range required by the size change. Making such changes to the cutting and transfer apparatus is a difficult and time-consuming process that requires specialized operator knowledge and can increase equipment downtime. Furthermore, existing cutting and conveying equipment may not be able to accommodate very large product sizes due to limitations, for example, on the achievable pitch range and pack speed and movement.

[0005] It would therefore be desirable to provide a conveying device and an overall cutting and conveying apparatus that is easily configurable to accommodate the conveying and cutting of individual articles of different types and sizes. Such devices and apparatus would ensure that such reconfiguration is accomplished while maintaining proper operation and alignment of the various system components to ensure proper interaction between such components. Such devices and apparatus would also be able to accommodate larger size products. Summary of the Invention [Means for solving the problem]

[0006] Thus, according to one aspect of the invention, a cutting and conveying apparatus includes a cutting system configured to cut an incoming continuous web of material into a plurality of individual articles, and a conveying mechanism operable with the cutting system to convey and rotate the plurality of individual articles from at least one web receiving location to an article placement location. The conveying mechanism further includes a drive shaft rotatable about a conveying axis, and a puck wheel mounted on the drive shaft for rotation about the conveying axis together with the drive shaft. The puck wheel includes a plurality of carriage units rotating about the conveying axis to move along a conveying path centered on the conveying axis from at least the web receiving location to the article placement location, each of the plurality of carriage units including a puck supporting an individual article and selectively operable to reorient the article as the puck moves between the web receiving location and the article placement location. The puck wheel also includes a plurality of servo motors, each servo motor operably connected to a respective carriage unit in the plurality of carriage units via a connecting arm, each of the plurality of servo motors operable to change the positioning of its respective carriage unit along at least a portion of the conveying path.

[0007] According to another aspect of the invention, a pick-and-place system for transporting and rotating a plurality of individual articles from at least one article receiving location to an article placing location is disclosed. The pick-and-place system includes a drive shaft rotatable about a transport axis, a central plate mounted on the drive shaft for rotation about the transport axis with the drive shaft, and a plurality of carriage units positioned about the central plate for rotation with the central plate for movement along a transport path centered on the transport axis from at least the article receiving location to the article placing location, each of the plurality of carriage units including a puck supporting an individual article and selectively operable to reorient the article as the puck moves between the article receiving location and the article placing location. The pick-and-place system also includes a plurality of servo motors mounted on the central plate, each servo motor operably connected to a respective carriage unit in the plurality of carriage units via a connecting arm, each of the plurality of servo motors operable to change the positioning of its respective carriage unit relative to the central plate along at least a portion of the transport path.

[0008] Thus, according to another aspect of the present invention, a cutting and conveying apparatus includes a cutting system configured to cut an incoming web of material into a plurality of individual articles, and a conveying mechanism operable with the cutting system to convey and rotate the plurality of individual articles from at least one web receiving location to an article placement location, the conveying mechanism further including a drive shaft rotatable about a conveying axis, a central plate mounted on the drive shaft for rotation about the conveying axis with the drive shaft, and a plurality of carriage units positioned about the central plate for rotation with the central plate for movement along a conveying path centered on the conveying axis from at least the web receiving location to the article placement location, each of the plurality of carriage units including a puck supporting an individual article and selectively operable to reorient the article as the puck moves between the web receiving location and the article placement location. The cutting system includes an anvil wheel having an anvil hub coupled to and driven by the anvil shaft for rotation about an anvil wheel axis, and a plurality of anvil arms pivotally connected to the anvil hub and extending radially outward from the anvil hub, each of the plurality of anvil arms having an anvil that cooperates with a knife roll of the cutting system to cut an incoming web of material. The plurality of anvil arms are equal in number to the plurality of carriage units, and the plurality of anvil arms are interspersed with the plurality of carriage units such that each anvil arm is positioned between a pair of adjacent carriage units. Each anvil arm is mechanically coupled to a pair of adjacent carriage units between which each anvil arm is positioned to control the positioning of the anvil relative to the pair of adjacent carriage units.

[0009] According to yet another aspect of the invention, a method for constructing a cutting and conveying apparatus includes providing a cutter mechanism configured to cut an incoming web of material into a plurality of individual articles and providing a conveying mechanism operable with the cutter mechanism to convey and rotate the plurality of individual articles from at least one web receiving location to an article placement location. In providing the conveying mechanism, the method further includes the steps of providing a drive shaft having a mounting structure coupled thereto, the drive shaft and the mounting structure being rotatable about a conveying axis, and mounting a plurality of carriage units to the mounting structure such that the plurality of carriage units are rotatable with the mounting structure for movement along a conveying path about the conveying axis from at least the web receiving location to a pad placement location, each of the plurality of carriage units including a puck, the puck supporting an individual article and selectively operable to reorient the article as the puck moves between the web receiving location and the article placement location. The method also includes operably connecting a servo motor to each of the plurality of carriage units via a connecting arm, each servo motor selectively operable to change the positioning of its respective carriage unit relative to the mounting structure by circumferentially displacing the carriage unit along the transport path.

[0010] Thus, according to yet another aspect of the present invention, a cutting and conveying apparatus includes a cutting system configured to cut an incoming web of material into a plurality of individual articles, and a conveying mechanism operable with the cutting system to convey and rotate the plurality of individual articles from at least one web receiving location to an article placement location. The conveying mechanism further includes a drive shaft rotatable about a conveying axis, a mounting structure rotatable about the conveying axis, a plurality of carriage units coupled to the mounting structure and configured to move along a conveying path centered about the conveying axis from at least the web receiving location to the article placement location, and a plurality of pucks coupled to the plurality of carriage units for supporting the individual articles and reorienting the articles as the plurality of pucks move between the web receiving location and the article placement location. The cutting system includes an anvil wheel having an anvil hub coupled to and driven by the anvil shaft for rotation about an anvil wheel axis, and a plurality of anvil arms pivotally connected to the anvil hub and extending radially outward from the anvil hub, each of the plurality of anvil arms having an anvil that cooperates with a knife roll of the cutting system to cut the incoming web of material. The plurality of anvil arms equals the plurality of carriage units in number and are interspersed with the plurality of carriage units such that each anvil arm is positioned between a pair of adjacent carriage units, each anvil arm is mechanically coupled to a pair of adjacent carriage units between which each anvil arm is positioned to control the positioning of the anvil relative to the pair of adjacent carriage units.

[0011] According to other aspects of the present invention, such other aspects further include:

[0012] Here, the puck wheel comprises a central plate mounted to the drive shaft for rotation therewith about the transport axis, a plurality of carriage units mounted to and positioned about the central plate, a plurality of servo motors mounted to the central plate, and each of the plurality of servo motors operable to vary the positioning of its respective carriage unit relative to the central plate along at least a portion of the transport path.

[0013] There is an annular rail structure positioned about the periphery of the center plate, the rail structure including a pitch rail on which a plurality of carriage units are mounted for movement along the rail structure.

[0014] Here, each of the multiple carriage units comprises a chassis including a pair of frame members positioned on either side of the rail structure, a plurality of rollers coupled to the chassis and rollingly engaging with inner and outer edges of the pitch rail so as to secure the carriage unit to the rail structure and translate the carriage unit along the pitch rail, and a puck support positioned on the chassis, the puck support being moveable relative to the chassis via a mating relationship between the rail guide of the puck support and the pitch rail, the puck support being oriented generally perpendicular to the pitch rail and comprising a puck mounting portion at one end configured to receive a puck.

[0015] Here, the carriage unit includes a drag link connecting the connecting arm to the chassis, the drag link being rotatably connected to each of the connecting arms and to a mounting portion of one of the pair of frame members, and the drag link converts rotational motion of the servo motor and the connecting arm into translational motion of the carriage unit along the pitch rail.

[0016] Here, the transport mechanism includes a barrel cam stationarily positioned about the transport axis, the barrel cam having a spin cam race formed around its outer periphery, and each of the plurality of carriage units includes a spin cam follower positioned at the other end of the pack support, the spin cam follower in slidable or rolling communication with the spin cam race so as to spin the packs at least partially about their respective spin axes that are at least substantially perpendicular to the transport axis, thereby reorienting articles supported on the packs.

[0017] Here, the transport mechanism comprises a fixed vacuum manifold positioned adjacent to the central plate and configured to transfer vacuum from a vacuum source to an internal volume of the central plate, and a plurality of vacuum tubes coupled to the central plate, one or more vacuum tubes in the plurality of vacuum tubes fluidly connecting the internal volume of the central plate to a respective carriage unit in the plurality of carriage units to transfer vacuum to the plurality of carriage units.

[0018] Here, the plurality of vacuum tubes comprise telescopic vacuum tubes each rotatably connected to the central plate so as to pivot relative to the central plate, and each of the telescopic vacuum tubes is contractible and extendible to decrease and increase its length, such that when telescopic the length of the vacuum tube can change to accommodate movement of the respective carriage unit along the rail structure.

[0019] Here, the puck support has one or more vacuum channels formed therein to provide a fluid flow path from one or more respective vacuum tubes to the puck mount and to a puck mounted on the puck mount.

[0020] Here, the cutting system includes a knife roll including one or more knives, and an anvil wheel having an anvil hub coupled to and driven by the anvil shaft for rotation about an anvil wheel axis, a plurality of anvil arms pivotally connected to the anvil hub and extending radially outward from the anvil hub, anvils positioned at the ends of each of the plurality of anvil arms, the anvils cyclically cooperating with the one or more knives of the knife roll to cut an incoming web of material, and a linkage system mechanically linking the plurality of anvil arms together.

[0021] Here, the linkage system includes a pair of scissor links provided between each adjacent pair of anvil arms in the plurality of anvil arms, a first link in the pair of scissor links being rotatably connected to a first anvil arm in the adjacent pair of anvil arms, and a second link in the pair of scissor links being rotatably connected to a second anvil arm in the adjacent pair of anvil arms.

[0022] Here, the first link and the second link of each pair of scissor links are rotatably connected to a common attachment point on a respective carriage unit positioned between the first anvil arm and the second anvil arm.

[0023] Here, through the linkage system and the connection of the first link and second link of each respective pair of scissor links to their respective carriage units, each anvil arm of the multiple anvil arms remains centered between a respective pair of carriage units positioned on either side of it.

[0024] Here, each of the multiple anvil arms has a linear slide by which a respective link in the linkage system is connected to each of the multiple anvil arms, the linear slide providing radial inward and outward movement of the pivot point at which the link is connected to the anvil arm.

[0025] Here, the cutting system further includes a belt drive that drives the anvil shaft to rotate the anvil wheel, and a knife roll servo motor connected to the knife roll to drive rotation of the knife roll, the knife roll servo motor being separate from the belt drive such that the knife roll is driven separately from the anvil wheel via cam action of the knife roll servo motor.

[0026] Here, the cutting system further comprises a lower cutter box assembly having a track formed along an upper surface thereof, an upper cutter box assembly positioned above the lower cutter box assembly and movable laterally relative to the lower cutter box assembly along the track, and an adjustment mechanism operable to move the upper cutter box assembly laterally along the track, wherein each of the anvil wheel and knife roll are mounted to the upper cutter box assembly such that lateral movement of the upper cutter box assembly moves the anvil wheel and knife roll laterally relative to the transport mechanism.

[0027] A human-machine interface (HMI) is configured to receive operator input directed to reconfiguring the transport mechanism and / or the cutting system and generate commands in response to the operator input that cause one or more operational settings of the transport mechanism and / or the cutting system to be changed, the one or more operational settings including at least one of the rotational speed of the drive shaft, the pitch between adjacent pucks, the speeds of the multiple servo motors, the lateral positioning of the anvil wheel and knife roll, the rotational speed of the anvil shaft, and the speed of the knife roll servo motor.

[0028] There are slip rings positioned on the drive shaft and communication and / or power connections to the multiple servo motors are routed through the slip rings.

[0029] Here, the connecting arm comprises a curved, arcuate connecting arm.

[0030] Here, the central plate is provided with an annular rail structure positioned on its outer periphery, the rail structure including a pitch rail on which a plurality of carriage units are mounted for movement along the rail structure.

[0031] Here, each of the multiple carriage units comprises a chassis including a pair of frame members positioned on either side of the rail structure, a plurality of rollers coupled to the chassis and rollingly engaging with inner and outer edges of the pitch rail so as to secure the carriage unit to the rail structure and translate the carriage unit along the pitch rail, and a puck support positioned on the chassis, the puck support being moveable relative to the chassis via a mating relationship between the rail guide of the puck support and the pitch rail, the puck support being oriented generally perpendicular to the pitch rail and comprising a puck mounting portion at one end configured to receive a puck.

[0032] Here, the carriage unit includes a drag link connecting the connecting arm to the chassis, the drag link being rotatably connected to each of the connecting arms and to a mounting portion of one of the pair of frame members, and the drag link converts rotational motion of the servo motor and the connecting arm into translational motion of the carriage unit along the pitch rail.

[0033] Here, the transport mechanism includes a barrel cam stationarily positioned about the transport axis, the barrel cam having a spin cam race formed around its outer periphery, and each of the plurality of carriage units includes a spin cam follower positioned at the other end of the pack support, the spin cam follower in slidable or rolling communication with the spin cam race so as to spin the packs at least partially about their respective spin axes that are at least substantially perpendicular to the transport axis, thereby reorienting articles supported on the packs.

[0034] The pick and place system comprises a fixed vacuum manifold positioned adjacent to the central plate and configured to transfer vacuum from a vacuum source to an interior volume of the central plate; and a plurality of vacuum tubes coupled to the central plate, one or more vacuum tubes in the plurality of vacuum tubes fluidly connecting the interior volume of the central plate to a respective carriage unit in the plurality of carriage units to transfer vacuum to the plurality of carriage units, each vacuum tube being rotatably coupled to the central plate to pivot relative to the central plate, and a length and / or configuration of each vacuum tube being variable to accommodate movement of a respective carriage unit along the rail structure.

[0035] a plurality of motor drives secured to the central plate, the plurality of motor drives operatively connected to the plurality of servo motors to control operation thereof; and a human machine interface (HMI) in communication with the plurality of motor drives to provide commands to the plurality of motor drives, the HMI configured to receive operator input directed to a reconfiguration of the pick and place system, and to provide commands to the plurality of motor drives to cam the plurality of servo motors according to a predetermined velocity profile associated with the operator input, thereby altering positioning of the plurality of carriage units relative to the central plate along at least a portion of the transport path.

[0036] Here, the anvil wheel includes a linkage system that mechanically connects the multiple anvil arms together, the linkage system including a pair of scissor links provided between each adjacent pair of anvil arms in the multiple anvil arms, a first link in the pair of scissor links being rotatably connected to the first anvil arm in the adjacent pair of anvil arms, and a second link in the pair of scissor links being rotatably connected to the second anvil arm in the adjacent pair of anvil arms.

[0037] Here, the first link and the second link of each pair of scissor links are rotatably connected to a common mounting point on the chassis of each carriage unit positioned between the first anvil arm and the second anvil arm.

[0038] Here, through the linkage system and the connection of the first link and second link of each respective pair of scissor links to the chassis of each carriage unit, each anvil arm of the multiple anvil arms remains centered between a respective pair of carriage units positioned on either side of it.

[0039] Here, each of the multiple anvil arms has a linear slide by which a respective link in the linkage system is connected to each of the multiple anvil arms, the linear slide providing radial inward and outward movement of the pivot point at which the link is connected to the anvil arm.

[0040] Here, the cutting system further includes a belt drive that drives the anvil shaft to rotate the anvil wheel, and a knife roll servo motor connected to the knife roll to drive rotation of the knife roll, the servo motor being separate from the belt drive such that it is driven separately from the anvil wheel.

[0041] Here, the cutting system further comprises a lower cutter box assembly having a track formed along an upper surface thereof, an upper cutter box assembly positioned above the lower cutter box assembly and movable laterally relative to the lower cutter box assembly along the track, and an adjustment mechanism operable to move the upper cutter box assembly laterally along the track, wherein each of the anvil wheel and knife roll are mounted to the upper cutter box assembly such that lateral movement of the upper cutter box assembly moves the anvil wheel and knife roll laterally relative to the transport mechanism.

[0042] Here, the transport mechanism comprises a plurality of servo motors mounted on a central plate, each servo motor operatively connected to a respective carriage unit in the plurality of carriage units via a connecting arm, and each of the plurality of servo motors is operable, via its cam action, to alter the positioning of its respective carriage unit relative to the central plate by displacing the carriage unit circumferentially along at least a portion of the transport path.

[0043] Here, the mounting structure includes a central plate, and the step of mounting the multiple carriage units includes mounting the multiple carriage units on an annular rail structure positioned around an outer periphery of the central plate, the rail structure including a pitch rail on which the multiple carriage units are mounted so as to be movable along the rail structure.

[0044] The method further includes coupling a respective puck to each of the plurality of carriage units to provide a puck corresponding to a desired size of articles to be produced by the cutting and conveying apparatus.

[0045] The method further includes providing input to the cutting and conveying device from a human machine interface (HMI) indicating a size of a product to be produced by the cutting and conveying device, and positioning a cutter mechanism relative to the conveying mechanism based on the input from the HMI, where positioning the cutter mechanism includes positioning an anvil wheel and a knife roll of the cutter mechanism relative to the conveying mechanism based on the input from the HMI to cut the incoming web of material at a cutting position.

[0046] The method further includes controlling the rotational speed of the drive shaft and the anvil wheel based on input from the HMI, where the rotational speed of the drive shaft and the rotational speed of the anvil wheel are kept equal, controlling the rotational speed of a servo motor based on the input from the HMI, and controlling the rotational speed of the knife roll via cam action of a knife roll servo motor operatively connected to the knife roll based on the input from the HMI.

[0047] 1. A method for initiating a product changeover in a web transport apparatus, the web transport apparatus including a puck wheel and an anvil wheel driven by at least one drive shaft, a plurality of carriage units operatively coupled along a periphery of the puck wheel, each carriage unit including a replaceable puck, the anvil wheel having a plurality of anvil arms pivotally connected to an anvil hub and extending radially outwardly therefrom, a pair of scissor links pivotally coupled between each adjacent pair of anvil arms, each pair of scissor links pivotally coupled to a respective carriage unit at a common center point, and a rotating blade cooperating with the anvil arms, the method optionally comprising removing each puck having a first size from its corresponding carriage unit, optionally fastening a puck having a second size to each corresponding carriage unit, and the following operations: providing a human machine interface (HMI) to perform the operations of: varying a rotational speed of at least one drive shaft to vary a speed of a pack wheel and anvil wheel, the rotational speed being proportional to a throughput of discrete articles cut from a continuous web of material fed to the pack wheel; accelerating a selected carriage unit to linearly displace it from a first position to a second position along a portion of a circumference of the pack wheel, the displacement of the selected carriage unit changing an angular position of a corresponding anvil arm adjacent the selected carriage unit; adjusting the rotational speed and angular position of the rotating blades such that the rotating blades contact a distal end of a corresponding anvil arm and cut a continuous web of material disposed between the rotating blades and the distal end of the corresponding anvil arm; and decelerating the selected carriage unit to linearly displace it from the second position to the first position.

[0048] Here, the steps of removing each pack of the first size and installing each pack of the second size are performed by a robotic mechanism or by a human.

[0049] Here, the HMI may be a computer, a controller, a wireless communication device, or a laptop computer.

[0050] Further including providing a servo motor to control the acceleration and deceleration of each carriage unit.

[0051] Further comprising providing a servo motor for controlling the rotational speed and angular position of the rotating blades.

[0052] Here, a first position of a selected carriage unit along a portion of the circumference of the puck wheel reflects equal spacing between adjacent carriage units near the product receiving surface.

[0053] Here, a second position of the selected carriage unit along a portion of the circumference of the puck wheel reflects a desired spacing between adjacent carriage units in the vicinity of the rotating blade.

[0054] The method further includes connecting a surface portion of each puck to a vacuum source for selectively supporting individual articles cut from the continuous web of material.

[0055] This includes providing each carriage unit with quick connector type engagement features or fastener-less fittings to facilitate efficient replacement of each pack on its corresponding carriage unit.

[0056] The linear position of the rotating blade is controlled to move the rotating blade radially outward and radially inward relative to the distal end of a selected anvil arm, where the selected anvil arm is radially aligned with the rotating blade.

[0057] Further comprising providing a servo motor or stepper motor to control the linear position of the rotating blade.

[0058] The method further includes maintaining a constant rotational speed of the pack wheel relative to the anvil wheel via a belt drive connecting a drive shaft fixedly attached to the pack wheel to a drive shaft fixedly attached to the anvil wheel.

[0059] The method further includes adjusting the servo motor to linearly displace selected carriage units along a periphery of the puck wheel to achieve a predetermined circumferential spacing between adjacent carriage units.

[0060] The method further includes spinning the puck of the selected carriage unit along a spin axis prior to positioning the selected carriage unit adjacent the product receiving surface.

[0061] Further comprising providing a servo motor or barrel cam arrangement to spin the puck.

[0062] A method for initiating a product changeover in a conveying apparatus, the conveying apparatus including a puck wheel and an anvil wheel driven by at least one drive shaft, a plurality of carriage units operatively coupled along a periphery of the puck wheel, each carriage unit including a replaceable puck, the anvil wheel having a plurality of anvil arms pivotally connected to an anvil hub and extending radially outwardly therefrom, and a rotating blade cooperating with the anvil arms, the method optionally including removing each puck having a first size from its corresponding carriage unit, optionally installing a puck having a second size onto each corresponding carriage unit, and controlling a drive shaft motor, a plurality of carriage unit motors, and a blade motor. and sequentially or simultaneously sending commands to one or more controllers controlling a drive shaft that changes the rotational angle of the drive shaft to change the speed of the puck wheel and the anvil wheel, accelerate a selected carriage unit to linearly displace it from a first position to a second position along a portion of a circumference of the puck wheel, adjust the rotational speed and angular position of the rotating blade, and decelerate the selected carriage unit to linearly displace it from the second position to the first position, such that the displacement of the selected carriage unit changes the angular position of a corresponding anvil arm adjacent the selected carriage unit, such that the rotating blade contacts a distal end of the corresponding anvil arm and cuts a continuous web of material disposed between the rotating blade and the distal end of the corresponding anvil arm.

[0063] Here, optionally, the steps of removing each puck of the first size and installing each puck of the second size are performed by a robotic mechanism or a human.

[0064] This includes providing each carriage unit with quick connector type engagement features or fastener-less fittings to facilitate efficient replacement of each pack on its corresponding carriage unit.

[0065] Further including providing a servo motor to control the acceleration of each carriage unit.

[0066] The method further includes providing a servo motor that controls the rotational speed and angular position of the rotating blade so that the rotating blade contacts the distal end of the corresponding anvil arm and cuts a continuous web of material disposed between the rotating blade and the distal end of the corresponding anvil arm.

[0067] 1. A conveying device configured to transport and rotate a plurality of individual articles cut from a continuous web of material, the conveying device comprising: a puck wheel configured to rotate about a rotational axis; a plurality of carriage units operatively connected along a periphery of the puck wheel, each carriage unit having a puck selectively operable to support an individual article; an anvil wheel having an anvil hub and a plurality of anvil arms pivotally connected to the anvil hub and extending radially outwardly from the anvil hub; and a linkage system including a pair of scissor links pivotally connected between each adjacent pair of anvil arms, each pair of scissor links pivotally connected to a respective carriage unit at a common center point, wherein displacement of a selected carriage unit along the periphery of the puck wheel changes the angular position of adjacent anvil arms relative to the periphery of the puck wheel.

[0068] Each includes a plurality of servo motors operatively coupled to a respective carriage unit via a connecting arm and configured to displace a corresponding carriage unit along a portion of the circumference of the puck wheel.

[0069] Here, the pack wheel comprises a central plate attached to the drive shaft and configured to rotate with the drive shaft about a rotational axis, and an annular rail disposed on an outer peripheral edge of the central plate, and the multiple carriage units are attached to the annular rail and are movable along a portion of the annular rail.

[0070] A cutting device is operatively connected to the conveying device and configured to cut the continuous web of material into a plurality of individual articles.

[0071] Here, the cutting apparatus includes a knife roller having at least one knife attached thereto, and an anvil positioned at the end of each of a plurality of anvil arms, the anvil cooperating periodically with the at least one knife to cut the incoming web of material during rotation of the pack wheel and anvil wheel.

[0072] The carriage unit further includes a vacuum manifold operatively connected to the central plate and configured to transfer vacuum from a vacuum source to the interior volume of the central plate, and a tubular arrangement in fluid communication between the interior volume of the central plate and each respective carriage unit to transfer vacuum to the carriage units.

[0073] Here, the tubular configuration comprises a plurality of telescoping tubes.

[0074] Here, each of the multiple anvil arms includes a distal linear slide portion to which the end points of two scissor links are connected at a pivot point, the linear slide providing radially inward and radially outward movement of the pivot point to correspond to displacement of a selected carriage unit along the circumference of the pack wheel.

[0075] 1. A cutting and conveying system comprising: a cutting device configured to cut an incoming continuous web of material into a plurality of individual articles; and a conveying device operatively coupled to the cutting device and configured to convey and rotate the plurality of individual articles from at least one web receiving location to an article placement location, the conveying device comprising: a puck wheel configured to rotate about a rotational axis; a plurality of carriage units operatively coupled along a periphery of the puck wheel, each carriage unit having a puck selectively operable to support an individual article, each carriage unit being independently displaceable along a portion of the periphery of the puck wheel; an anvil wheel having an anvil hub and a plurality of anvil arms pivotally connected to the anvil hub and extending radially outwardly from the anvil hub; and a pair of scissor links pivotally coupled between each adjacent pair of anvil arms at opposite ends and pivotally coupled to respective carriage units at a common center point, wherein displacement of a selected carriage unit along the periphery of the puck wheel changes an angular position of an adjacent anvil arm relative to the periphery of the puck wheel via the scissor links.

[0076] A plurality of servo motors are included, each servo motor operatively coupled to a respective carriage unit via a connecting arm and configured to translate a corresponding carriage unit along a portion of the circumference of the puck wheel.

[0077] Here, the pack wheel comprises a central plate attached to the drive shaft and configured to rotate with the drive shaft about a rotational axis, and an annular rail disposed along an outer peripheral edge of the central plate, and the multiple carriage units are attached to the annular rail and are movable along a portion of the annular rail.

[0078] Here, the cutting device includes a knife roller having at least one knife attached thereto and an anvil positioned at a distal end of each of a plurality of anvil arms, the anvil cooperating periodically with the at least one knife to cut the incoming web of material during rotation of the pack wheel and anvil wheel.

[0079] The carriage unit further includes a vacuum manifold operatively connected to the central plate and configured to transfer vacuum from a vacuum source to the interior volume of the central plate, and a tubular arrangement in fluid communication between the interior volume of the central plate and each respective carriage unit to transfer vacuum to the carriage units.

[0080] Here, the tubular configuration comprises a plurality of telescoping tubes.

[0081] Here, each of the multiple anvil arms has a linear slide portion to which the end points of two scissor links are connected at a pivot point, and the linear slide provides radially inward and radially outward movement of the pivot point to correspond to displacement of a selected carriage unit along the periphery of the pack wheel.

[0082] 1. A cutting and conveying system comprising: a cutting device configured to cut an incoming continuous web of material into a plurality of individual articles; and a conveying device operatively coupled to the cutting device and configured to convey and rotate the plurality of individual articles from at least one web receiving location to an article placement location, the conveying device comprising: a puck wheel; and a drive shaft configured to rotate the puck wheel and the anvil wheel about a rotational axis, the puck wheel comprising a central plate, an annular rail disposed on an outer periphery of the central plate, a plurality of carriage units operatively mounted along the annular rail and independently movable along a portion of the annular rail, a plurality of pucks, each puck coupled to a corresponding carriage unit, each puck selectively operable to support a respective article, and a plurality of pucks, each puck operatively coupled to a respective carriage unit via a connecting arm, and each puck coupled to a corresponding carriage unit. and a plurality of servo motors configured to displace the anvil arms along a portion of a circumference of the puck wheel, the anvil wheel further comprising an anvil hub, a plurality of anvil arms pivotally connected to the anvil hub and extending radially outward from the anvil hub, and a pair of scissor links pivotally coupled between each adjacent pair of anvil arms at opposite ends and pivotally coupled to a respective carriage unit at a common center point, wherein displacement of a selected carriage unit along the annular rail changes the angular position of adjacent anvil arms relative to the circumference of the puck wheel via action of the scissor links.

[0083] Here, the anvil wheel is attached to the anvil drive shaft, the pack wheel is attached to the pack drive shaft, and the pack wheel and anvil wheel are driven by the drive shafts.

[0084] Here, the cutting apparatus includes a knife roller having at least one knife attached thereto, and an anvil positioned at the end of each of a plurality of anvil arms, the anvil cooperating periodically with the at least one knife to cut the incoming web of material during rotation of the pack wheel and anvil wheel.

[0085] The carriage unit further includes a vacuum manifold operatively connected to the central plate and configured to transfer vacuum from a vacuum source to the interior volume of the central plate, and a tubular arrangement in fluid communication with the interior volume of the central plate and in fluid communication with each of the carriage units to transfer vacuum to each of the carriage units.

[0086] Here, each carriage unit is configured to rotate the puck about the spin axis using a servo motor or a mechanical cam arrangement operatively connected to the periphery of the puck wheel.

[0087] These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention, which are provided in connection with the accompanying drawings. [Brief description of the drawings]

[0088] The drawings illustrate embodiments presently contemplated for carrying out the invention.

[0089] In the drawings:

[0090] [Figure 1] FIG. 2 is a front perspective view of a configurable cutting and conveying apparatus according to one embodiment of the present invention.

[0091] [Diagram 2] FIG. 2 is a rear perspective view of the device of FIG. 1.

[0092] [Diagram 3] FIG. 2 is a front view of the apparatus of FIG. 1 with the cutter box assembly removed.

[0093] [Figure 4] FIG. 2 is a front view showing the arrangement of the anvil wheel and the carriage unit in the apparatus of FIG. 1 in a separated state.

[0094] [Diagram 5]FIG. 2 is a detailed perspective view of a carriage unit mounted on a center plate of the transport mechanism of the apparatus of FIG. 1;

[0095] [Figure 6] FIG. 2 is a rear perspective view of a plurality of servo motors mounted on a center plate of the transport mechanism of the apparatus of FIG. 1.

[0096] [Figure 7] FIG. 2 is a detailed perspective view of a carriage unit that engages with the spin cam race of the barrel cam of the device of FIG. 1.

[0097] [Figure 8] 2 is a top perspective view of a carriage unit included in the device of FIG. 1 according to one embodiment of the present invention. [Figure 9] 2 is a top perspective view of a carriage unit included in the device of FIG. 1 according to one embodiment of the present invention.

[0098] [Figure 10] 1. FIG. 10 is a perspective view of the carriage unit of FIGS. 8 and 9 connected to the transport mechanism and cutting system of the apparatus of FIG.

[0099] [Figure 11A] 1 is a flow chart illustrating a process for reconfiguring a cutting and conveying apparatus in accordance with one embodiment of the present invention.

[0100] [Figure 11B] 11 is a flow chart illustrating a process for reconfiguring a cutting and conveying apparatus according to another embodiment of the present invention.

[0101] [Figure 12] FIG. 2 is a front schematic diagram of a first preferred speed profile of a configurable cutting and conveying device in accordance with one embodiment of the present invention.

[0102] [Figure 13] FIG. 13 is a graphical representation of the example velocity profile of FIG. 12.

[0103] [Figure 14] FIG. 13 is a front schematic view of the changing puck position relative to the conveying axis of rotation as the puck follows the velocity profile of FIG. 12 .

[0104] [Figure 15] FIG. 2 is a simplified front view of a configurable cutting and conveying device in a first position according to one embodiment of the present invention.

[0105] [Figure 16] FIG. 16 is a front view of the device of FIG. 15 in a second position, with some details omitted to better illustrate its function.

[0106] [Figure 17] FIG. 16 is a front view of the device of FIG. 15 in a third position, with some details omitted to better illustrate its function.

[0107] [Figure 18] FIG. 16 is a front view of the device of FIG. 15 in a fourth position, with some details omitted to better illustrate its function.

[0108] [Figure 19] FIG. 16 is a front view of the device of FIG. 15 in a fifth position, with some details omitted to better illustrate its function.

[0109] [Figure 20] FIG. 16 is a front view of the device of FIG. 15 in a sixth position, with some details omitted to better illustrate its function.

[0110] [Figure 21] FIG. 16 is a front view of the device of FIG. 15 in a seventh position, with some details omitted to better illustrate its function.

[0111] [Figure 22]FIG. 16 is a front view of the device of FIG. 15 in an eighth position, with some details omitted to better illustrate its function.

[0112] [Figure 23] FIG. 13 is a graphical representation of a speed profile of a configurable cutting and conveying device in accordance with another embodiment of the present invention.

[0113] [Figure 24] FIG. 13 is a graphical representation of a speed profile of a configurable cutting and conveying device in accordance with another embodiment of the present invention.

[0114] [Diagram 25] FIG. 13 is a graphical representation of a speed profile of a configurable cutting and conveying device in accordance with another embodiment of the present invention.

[0115] [Figure 26] FIG. 13 is a front view of a configurable cutting and conveying device according to another embodiment of the present invention.

[0116] [Figure 27] FIG. 13 is a perspective view of a pick and place system in accordance with another embodiment of the present invention. [Figure 28] FIG. 13 is a front view of a pick and place system in accordance with another embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0117] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention relates to a configurable cutting and conveying apparatus having a servo motor subsystem for facilitating conveying of absorbent article inserts. The disclosure herein is described in sufficient detail to enable one of ordinary skill in the art to practice the invention, however, the physical embodiments disclosed herein are merely exemplary of the invention, which may be embodied in other specific configurations. Although preferred embodiments have been described, details may be changed without departing from the invention.

[0118] 1-3, there is shown a diagram of a cutting and conveying apparatus 10 (or "apparatus 10") according to one embodiment of the present invention. Apparatus 10 preferably includes a conveying mechanism 12 and a cutting system 14 along with a frame 16 to which the conveying mechanism 12 and the cutting system 14 may be mounted. Operation of each of the conveying mechanism 12 and the cutting system 14 within apparatus 10 may be controlled via an associated human machine interface (HMI) 18. According to one embodiment, as shown in FIG. 1, HMI 18 may be separate from apparatus 10 and provided as part of a remote computing device, such as a laptop computer or a remotely located dedicated controller, that communicates with apparatus 10 via web-based communications or other wireless communications protocols. According to another embodiment, HMI 18 may be included as part of a control panel provided with apparatus 10 to enable direct communications with apparatus 10. In either embodiment, the HMI 18 may include a processor and memory (not shown) therein that serve to receive operator commands and perform the control functions of the HMI 18 by executing one or more programs that may be contained within the memory, and the memory included with the HMI stores values ​​for execution (such as predetermined product configuration settings for the device 10) and programs.

[0119] As described in more detail below, the machine 10 may be reconfigured to perform different process flows and / or accommodate different product types by changing operational settings of the cutting system 14 and / or the transport mechanism 12 via operator input to the HMI 18 in accordance with what is referred to herein as “push-button” changes to the machine 10. Push-button changes to the machine 10 provided via the HMI 18 allow at least some of the operational settings of the cutting system 14 and / or the transport mechanism 12 to be changed in an automated manner in response only to commands from the HMI 18, including embodiments in which all operational settings of the cutting system 14 and / or the transport mechanism 12 are changed in an automated manner and / or components are replaced in an automated manner (e.g., robotic replacement of components). However, it is recognized that even when push-button changes are enabled by the HMI 18, at least some manual reconfiguration of the machine 10 may still be required, a concept that is described in more detail below.

[0120] As best shown in FIGURE 2, the transport mechanism 12 includes a plurality of carriage units 20, each of which includes a puck 22 that can be engaged and disengaged. The carriage units 20 are coupled to (and are moveable on) a mounting structure of the transport mechanism 12, which in the exemplary embodiment is a center plate 24, and the carriage units 20 and center plate 24 collectively form a puck wheel 26 of a desired configuration. In the illustrated embodiment, the puck wheel 26 includes a total of eight carriage units 20 and pucks 22 positioned on the center plate 24, although it will be recognized that in another non-limiting example, more or fewer carriage units 20 and pucks 22 may be provided, such as, for example, nine.

[0121] The center plate 24 is fixedly coupled to a motor drive shaft 28 which provides a substantially operationally constant rotational force to the center plate 24. The center plate 24 is formed with fastener holes (not shown) for fastening the center plate 24 to the shaft 28, which extends from the center plate 24 at the drive side 30 of the apparatus 10. The center plate 24, together with the carriage unit 20 and the pucks 22 attached thereto, are thus rotated about a primary rotational axis, a puck transport axis 32, thereby moving the pucks about a transport path 34. As used throughout the description of the preferred embodiment, "rotate" and variants thereof refer to the translation of the entire pucks 22 (and carriage unit 20) about the transport axis 32, and "spin" and variants thereof refer to the radial spinning of the pucks 22 about a puck spin axis 36 which is substantially perpendicular to the puck transport axis 32, as will be further described below.

[0122] Also positioned on the drive side 30 of the apparatus 10 is a vacuum system 38 that provides vacuum to the individual carriage units 20 and pucks 22 of the transport mechanism 12. A vacuum source (not shown) provides vacuum to an arrangement of tubes 40 that feed a stationary vacuum manifold 42 positioned adjacent the center plate 24 of the drive side 30. The stationary vacuum manifold 42 transfers vacuum to the interior of the rotating center plate 24, from which the vacuum is then transferred to the carriage units 20 via a number of telescoping tubes 44 connected therebetween. The telescoping tubes 44 are connected to the center plate 24 via rotatable bearings (not shown) such that the telescoping tubes 44 can pivot relative to the center plate 24. The pivotability of the telescoping tubes 44, together with the telescoping structure that allows them to increase / decrease in length, accommodates movement of the carriage units 20 and pucks 22 relative to the center plate 24 (i.e., displacement of the carriage units 20 and pucks 22 along the center plate) and still allow transfer of vacuum to the pucks 22, as described in more detail below.

[0123] As best shown in Figures 1 and 3, the cutting system 14 preferably includes an anvil wheel 46 and a knife roll 48 that interact with one another to cut individual articles, such as absorbent pads or inserts, from a continuous web provided to the cutting and conveying apparatus 10. Although the cutting system 14 is described herein as including an anvil wheel 46 and a knife roll 48, it will be appreciated that these components may be reversed using a knife wheel and anvil roll as compared to the illustrated embodiment. The operation of the knife wheel and anvil roll is substantially similar to the operation of the anvil wheel 46 and knife roll 48 described below.

[0124] The anvil wheel 46 includes a central anvil hub 50 from which a plurality of anvil arms 52 extend radially outwardly across the 360° extent of the anvil wheel 46. Each of the anvil arms 52 is coupled to the anvil hub 50 via a pivot connection 54, the pivot connections 54 being equidistantly spaced from one another around the anvil hub 50. Each of the anvil arms 52 includes an anvil 56 positioned at an end opposite the pivot connection 54. The anvils 56 are configured to interact with one or more knife blades 58 on the knife roll 48 to cut material when the respective anvil 56 is positioned in a cutting position adjacent the knife blades 58. According to one embodiment, the anvils 56 include a carbide insert 60 held in place by a wedge block 62. Alternatively, the anvils 56 may be made of cast iron or other suitable material. The number of anvils 56 (and anvil arms 52) on the anvil wheel 46 matches the number of packs 22 provided on the transport mechanism 12, and the anvils 56 and anvil arms 52 are positioned relative to the packs 22 so that the anvils 56 and anvil arms 52 are positioned between each adjacent pair of packs 22.

[0125] As shown in FIG. 1 and also in FIG. 4, which shows the anvil wheel 46 (as well as the carriage unit 20 and the puck 22) from the drive side 30 of the apparatus 10, the anvil wheel 46 further includes a linkage system 64 that mechanically couples the anvil arms 52 together. A pair of links (i.e., "scissor links") 66 is provided between each adjacent pair of anvil arms 52 of the anvil wheel 46, with a first end 68 of each link 66 coupled to an arm link attachment 70 on the respective anvil arm 52 of the adjacent pair and a second end 72 of each link 66 coupled to a common attachment 74 on the carriage unit 20. The connection at each of the first and second ends 68, 72 of the links 66 to the arm link attachment 70 on each anvil arm 52 and the attachment 74 on each carriage unit 20 is a pivotable connection that allows the links 66 to rotate relative to each other and relative to the anvil arms 52 and the carriage unit 20. Thus, as will be described in more detail below, the positioning of each anvil arm 52 can be controlled during operation of the apparatus 10 based in part on the positioning of each carriage unit 20 and the associated pucks 22 positioned on either side thereof, with the anvil 56 and anvil arm 52 maintained centered between its adjacent pucks 20 via the connection of the anvil arm 52 to two adjacent carriage units 22 by links 66.

[0126] 4, according to one embodiment, arm link attachment 70 on each anvil arm 52 is included on a linear slide 71 that allows attachment 70 to move radially inward and outward along anvil arm 52. Positioning arm link attachment 70 on linear slide 71 allows for pivot point adjustment on anvil arm 52 to accommodate various puck 22 (insert) sizes on transport mechanism 12, providing greater adaptability to the overall apparatus 10.

[0127] With respect to the cutting system 14, each of the anvil wheel 46 and knife roll 48 are coupled to and rotate on respective shafts 76, 78, as shown in FIG. 1. The hub 50 of the anvil wheel 46 is attached to the anvil shaft 76, which in one embodiment is a belt-driven shaft (via belt drive 80) that is driven at a 1:1 ratio to the pack wheel 26 via a jack shaft 83 that couples the motion of the anvil wheel 46 with the motion of the pack wheel 26 of the transport mechanism 12. The anvil shaft 76 rotates about an anvil axis 81 that may be aligned with the shaft 28 that drives the transport mechanism 12 (i.e., aligned with the transport axis 32) or may be slightly laterally offset from the shaft 28. In the illustrated embodiment, the knife roll 48 is mounted on a drive roll shaft 78 and driven separately by a drive roll servo motor 82, although it will be appreciated that the knife roll 48 can be coupled to an anvil drive (i.e., the belt drive 80 drives both the anvil shaft 76 and the drive roll shaft 78). Each of the anvil wheel 46 and the knife roll 48 and their respective shafts and drive mechanisms (i.e., the belt drive 80 and the servo motor 82) are collectively included as part of an upper cutter box assembly 84 of the cutting system 14. The upper cutter box assembly 84 is mounted to a fixed lower cutter box assembly 86. The upper cutter box assembly 84 is laterally movable relative to the lower cutter box assembly 86 via a pair of tracks 88 on the upper surface of the lower cutter box assembly 86, and a manual hand crank or servo driven lead screw adjuster 90 translates the upper cutter box assembly 84 along the tracks 88. The upper cutter box assembly 84 is linearly translatable in a direction 92 along the track 88 to effect movement of the anvil wheel 46 and knife roll 48 relative to the transport mechanism 12 .As described in more detail below, if it is desirable to reconfigure the cutting and conveying apparatus 10 to perform a different process flow and / or to accommodate different product types or sizes, the upper cutter box assembly 84 can move along a track 88 to properly position the anvil wheel 46 and knife roll 48 relative to the conveying mechanism 12, thereby maintaining the proper positioning of the components for cutting the incoming continuous web of material being fed to the apparatus 10.

[0128] In operation, the apparatus 10 receives a continuous web from a source, which contacts the packs 22. One of the anvils 56 is then rotated into position to align with a knife blade 58 on the knife roll 48 and cooperate with (i.e., contact) the knife blade to cut the web adjacent the leading edge of the packs 22. After receiving the web and cutting it adjacent the leading edge, the packs 22 advance along the transport path 34 and pass the knife roll 48, at which point the next anvil 56 on the anvil wheel 46 rotates into position to cooperate with the knife blade 58 to cut the web adjacent the trailing edge of the packs 22 to cut individual cut portions from the web to form individual articles, such as inserts or pads. As described in more detail below, the individual cut portions are held to the packs 22 by vacuum and rotated about the transport path 34.

[0129] As described above, the carriage unit 20 of the transport mechanism 12 is coupled to the center plate 24 so as to be movable thereon. Specifically, the center plate 24 includes a body 93 on which a rail structure 94 is positioned, which in an exemplary embodiment is positioned on the outer periphery of the body as shown in FIG. 2 and also as shown in FIG. 5. The rail structure 94 is a ring-shaped structure consisting of a pair of tracks or rails 96 (hereinafter referred to as "pitch rails 96"), each pitch rail 96 being coupled to the body 93 of the center plate 24 via an intermediate spacer member 98. As a result, each pitch rail 96 is spaced apart in the width direction from the body 93 of the center plate 24. As mentioned above, each pitch rail 96 has an annular shape such that both the inner edge or face 100 of the pitch rail 96 and the outer edge or face 102 of the pitch rail 96 function as tracks along which the carriage units 20 may translate, although it will be appreciated that the pitch rails 96 may be configured such that the carriage units 20 translate along only one of the inner edge / face 100 or the outer edge / face 102. The pitch rails 96 extend parallel to the machine direction 104 in which the transport mechanism 12 rotates to enable controlled circumferential displacement of the carriage units 20 and pucks 22 relative to the center plate 24 in the machine direction 104, thereby enabling changes in pitch or circumferential spacing of the pucks 22. It should be understood that although the displacement of the carriage units 20 and pucks 22 is described herein as being "circumferential," aspects and embodiments of the present invention are not limited to applications utilizing circular motion, and the transport path 34 of the carriage units 20 and pucks 22 may be defined, for example, by the path of any supporting pitch rails 96 used.

[0130] Although not shown in Figures 2 and 5, it will be appreciated that alternative configurations of rail structure 94 may be utilized according to other embodiments. As an example, rail structure 94 may be provided on opposing flat sides of center plate 24 rather than on the outer periphery (and not facing radially outward) of center plate 24. In such an embodiment, pitch rails 96 are provided on each of the opposing flat sides of center plate 24 and face outwardly and away from each side. As with the previous embodiment, pitch rails 96 on the sides of center plate 24 extend parallel to the machine direction 104 in which transport mechanism 12 rotates to allow controlled circumferential displacement of carriage units 20 and pucks 22 relative to center plate 24 in machine direction 104, thereby allowing for changes in pitch or circumferential spacing of pucks 22.

[0131] To facilitate circumferential displacement of the carriage units 20 and pucks 22 along the pitch rail 96, the transport mechanism 12 includes a plurality of servo motors 106, as shown in FIG. 2, and here in FIG. 6, although it is understood that the term "servo motor" as used herein may refer to a servo motor system including only one servo motor, or a combination of a servo motor and a gearbox. Each carriage unit 20 is provided with a dedicated servo motor 106 to enable independently controlled displacement of that carriage unit 20 (and pucks 22) along the pitch rail 96. In one embodiment, the servo motors 106 are mounted to the drive side 30 of the center plate 24, which defines a plurality of openings 108 through which the servo motors 106 extend, and an output end 110 (i.e., the side that outputs rotational power) of each servo motor 106 extends through the center plate 24 and into a cutter side 112 of the apparatus 10.

[0132] As best shown in FIG. 5, a connecting arm 114 is coupled to the output end 110 of each servo motor 106 and is displaced (i.e., rotated) in response to the rotational output of the servo motor 106. In an exemplary embodiment, the connecting arm 114 has a curved arcuate profile, although in other embodiments, the connecting arm 114 can have a straight arm configuration. A first end 116 of the connecting arm 114 is fixedly coupled to the output end 110 of the servo motor 106 and a second end 118 of the connecting arm 114 is rotatably coupled to the respective carriage unit 20 via a drag link 120. In operation, the servo motor 106 can rotate both clockwise and counterclockwise, causing the connecting arm 114 to move back and forth in a reciprocating wiper-type pattern. Thus, through this movement of the connecting arm 114, and through the drag link 120 that rotatably connects the connecting arm 114 to the carriage unit 20, the rotational movement of the servo motor 106 can be converted into linear movement (i.e., movement in the machine direction 104) that displaces each carriage unit 20 circumferentially along the pitch rail 96.

[0133] As shown in FIG. 6, each of the servo motors 106 may be controlled by a respective motor drive 122 or other controller configured to operate the servo motors 106 according to a desired speed profile input to the motor drive 122 via commands from the HMI 18 ( FIG. 1 ), such as by receiving a wireless control signal from the HMI 18. In one embodiment, pre-programmed speed profiles may be stored in the HMI 18 (i.e., in the memory of the HMI 18) associated with the product configuration settings of the machine 10 for the product type / size to be produced, and these pre-programmed speed profiles are transmitted to the motor drive 122. Based on the input speed profile, the drive 122 may be programmed to operate the respective servo motor 106 at a desired speed, based, in one example, on the circumferential position on the puck wheel 26. The drive 122 for each servo motor 106 is programmed in the same manner (by input from the HMI 18) such that each servo motor 106 operates in the same manner and according to the same speed profile. Exemplary operation of the servo motors 106 to control the circumferential displacement of the pucks 22 is described in further detail below. In one embodiment, the drives 122 are positioned adjacent to each servo motor 106 on the drive side 30 of the center plate 24, and communication and power connections may be routed to the drives 122 and servo motors 106 through the use of slip rings 124 ( FIG. 2 ) positioned on the drive shaft 28, although it will be recognized that wireless communication and power transmission to the drives 122 and servo motors 106 may alternatively be utilized.

[0134] As previously mentioned, in addition to providing rotation of the carriage units 20 and pucks 22 about the transport axis 32, the transport mechanism 12 also provides radial spinning of each puck 22 about the puck spin axis 36. To facilitate this spinning of the pucks 22, the transport mechanism 12 also includes a barrel cam 126 disposed about the transport axis 32 and positioned on the drive side 30 of the center plate 24, as shown in Figures 1 and 3, and here in Figure 7. The barrel cam 126 is preferably a ring-shaped fixed member having a spin cam race 128 disposed about its outer edge / face. To achieve the desired spinning of the pucks 22, a spin cam follower 130 of the carriage units 20, preferably a roller bearing, is in slidable or rolling communication with the spin cam race 128. In the exemplary embodiment, the spin cam race 128 is configured to provide ninety degrees (90°) of puck rotation, although it will be appreciated that the configuration of the spin cam race 128 will be determined generally by the desired spin angle of the pucks 22. Although barrel cam 126 is illustrated and described herein as being configured as a cylindrical barrel having a spinning cam race 128 disposed about its outer edge / face, it will be appreciated that in accordance with alternative embodiments, barrel cam 126 may instead be configured as a ring-like annular member having a spinning cam race 128 disposed about its inner edge / face, i.e., an inverted barrel cam ring.

[0135] With continued reference to Figures 1-7, and now also with reference to Figures 8-11, the carriage unit 20 is shown in greater detail for purposes of better illustrating its structure and operation that enables its rotation, circumferential displacement, and spinning. The carriage unit 20 generally includes a chassis 132 and a puck support 134 disposed on the chassis 132. The chassis 132 generally secures the carriage unit 20 to the rail structure 94 of the center plate 24 and displaces the carriage unit 20 circumferentially along the pitch rail 96. The chassis 132 includes a pair of chassis frame members 136, 138 joined together in a spaced apart arrangement to accommodate positioning of the rail structure 94 therebetween. A plurality of rollers 140, 142 are coupled to the chassis frame members 136, 138 in an arrangement that enables the carriage unit 20 to be secured on the rail structure 94 and that translates the carriage unit 20 along the pitch rail 96. In one example, a pair of upper rollers 140 and a pair of lower rollers 142 are provided on each of the chassis frame members 136, 138, with the two lower rollers 142 engaging the inner edge or surface 100 of the respective pitch rail 96 and the two upper rollers 140 engaging the outer edge or surface 102 of the respective pitch rail 96.

[0136] According to an alternative embodiment, where the rail structure 94 is provided on the opposing flat sides of the center plate 24 as previously described, the location and orientation of the rollers 140, 142 are modified to properly secure the carriage unit 20 on the rail structure 94 and allow translation of the carriage unit 20 along the pitch rail 96. That is, the chassis frame members 136, 138 are provided with a "first side" pair of rollers and a "second side" pair of rollers that engage the pitch rails 96 provided on the opposing flat sides of the center plate 24, respectively.

[0137] As best seen in Figures 8 and 9, the puck support 134 is fixed to the chassis 132. The puck support 134 is oriented generally perpendicular to the chassis 132 (and rail structure 94) in a direction 135 and has a puck mounting portion 144 at one end of the puck support 134 (i.e., at the cutter side 112 of the apparatus 10) and a spinning cam follower 130 at an opposite end of the puck support 134. The puck support 134 includes a body 146 fixedly coupled to the chassis 132 on its top or outwardly facing surface, the body 146 straddling the chassis frame members 136, 138 for positioning on the rail structure 94 when the carriage unit 20 is mounted thereon.

[0138] 8 and 9, the spin cam follower 130 of the puck support 134 is coupled to a body 146 via a take-up frame 148. The take-up frame 148 is connected to the body 146 and includes a number of mechanisms thereon that function to transfer the motion of the spin cam follower 130 to the puck mount 144 and the puck 22 mounted thereon. That is, the movement of the spin cam follower 130 is transferred to the puck mount 144 and puck 22 via the pick-up frame 148 and associated mechanisms to cause the puck 22 to rotate (i.e., spin) in a desired manner.

[0139] The carriage unit 20 also includes a number of mounting features that couple the carriage unit 20 to the respective servo motors 106 and anvil wheels 46 to provide interoperability therebetween. Specifically, the chassis frame member 136 on the cutter side 112 of the center plate 24 includes a drag link mounting portion 160 and a scissor link mounting portion 74 thereon, by which the servo motors 106 and anvil wheels 46 may be operatively connected to the carriage unit 20, as shown in FIG. 8. The drag link mounting portion 160 may be provided as a cylindrical protrusion that is centered on the chassis frame member 136 in the machine direction 104. The scissor link mounting portion 74 may be provided as a mounting hole formed in a protrusion that extends outwardly from an edge of the lower (i.e., radially inward) portion of the chassis frame member 136.

[0140] The drag link mount 160 provides a connection point where the drag link 120 is coupled to the carriage unit 20, thereby connecting the carriage unit 20 to the servo motor 106 (via the connecting arm 114 and the drag link 120), as shown in Figures 8 and 5. The drag link 120 is rotatably coupled to the drag link mount 160 (via a bearing attachment) such that the drag link 120 can rotate relative to the frame 136. During operation of the transport mechanism 12, each servo motor 106 can be controlled to rotate the connecting arm 114 coupled thereto. Through the connecting arm 114 and the drag link 120, the rotational motion of the servo motor 106 is transferred to the carriage unit 20, causing the chassis 132 to translate along the rail structure 94 via the rollers 140, 142 that slide along the pitch rail 96 of the rail structure 94. Thus, the carriage units 20 can be displaced circumferentially along the center plate 24 via operation of the respective servo motors 106 to control the pitch between the carriage units 20 of the pack wheel 26 and adjacent carriage units 20 thereto.

[0141] As shown in Figures 8 and 10, the scissor link attachment 74 provides a connection point at which a pair of scissor links 66 of the anvil wheel linkage system 64 are connected to the carriage unit 20, and a cylindrical spacer 164 is fixed to the scissor link attachment 74 and extends outwardly therefrom to provide a connection point for the links 66 about which the links 66 can pivot. As previously mentioned, in controlling the circumferential displacement of the carriage unit 20, the positioning of the anvil arm 52 and anvil 56 between two adjacent carriage units 20 can be controlled via a pair of scissor links 66 provided between each adjacent pair of anvil arms 52 of the anvil wheel 46, with a first end 68 of each link 66 pivotally connected to an arm link attachment 70 of a respective anvil arm 52 of the adjacent pair of anvil arms 52, and a second end 72 of each link 66 pivotally connected (via a spacer 164) to a common scissor link attachment 74 provided on the carriage unit 20, as shown in Figure 4. Thus, each of the respective anvil arms 52 is connected to a carriage unit 20 via a link 66 which extends therefrom in respective opposite directions and is connected to the scissor link attachments 74 of those carriage units 20. The connection of an anvil arm 52 to its two adjacent carriage units 20 via the link 66 controls the positioning of that anvil arm 52 relative to the carriage units 20 such that the anvil arm 52 remains centered between the carriage units 20 throughout operation of the transport mechanism 12, regardless of the pitch / spacing between the carriage units 20 or the particular operating speed of the transport mechanism 12. Furthermore, the connection of anvil arms 52 to its two adjacent carriage units 20 ensures that the speed of the anvil 56 during cutting is tied to the speed of the carriage unit 20 and puck 22 to which that anvil 56 (anvil arm 52) is connected (controlled by servo motor 106), thereby ensuring that each anvil 56 matches the speed of the incoming continuous web of material during cutting.

[0142] As an example of controlling the positioning of the anvil arm 52 and anvil 56 between two adjacent carriage units 20, if a carriage unit 20 forward of the respective anvil arm 52 (in the machine direction 104) is displaced circumferentially further forward by its associated servo motor 106, the scissor link 66 connecting the carriage unit 20 to the anvil arm 52 (on the chassis frame member 136 at the chassis link attachment 74) will cause the anvil arm 52 to angularly rotate forward toward the carriage unit 20. At the same time, the scissor link 66 connecting the anvil arm 52 to its subsequent carriage unit 20 will limit the amount of forward angular rotation of the anvil arm 52. Thus, the positioning of the anvil arm 52 between two adjacent carriage units 20 remains relatively constant and any contact / collision between the anvil arm 52 and the adjacent carriage unit 20 is prevented.

[0143] Also included in the carriage unit 20 are components that provide vacuum communication to the puck to allow for the securing of cut pads or cut portions to the puck 22. As best shown in FIG. 9, the body 146 of the puck support 134 is formed as a semi-hollow member with a vacuum channel 166 formed therein, and in the illustrated embodiment, a pair of vacuum channels 166 are shown. The vacuum channel 166 extends over most of the length of the body 146 and allows for the communication of vacuum from a vacuum source (not shown) of the apparatus 10 onto the puck attachment 144 and the puck 22 to allow for the retention of individual articles or pads on the puck 22. When the carriage unit 20 is positioned on the center plate 24, an opening 168 of the vacuum channel 166 is connected with a vacuum transmitting telescopic tube 44 of the transport mechanism 12, as shown in FIG. 2. As previously described, the vacuum source applies a vacuum to the stationary vacuum manifold 42 positioned adjacent the center plate 24, and the vacuum travels to the interior of the center plate 24 and then through the telescopic tube 44 to the carriage unit 20.

[0144] With the carriage unit 20 fluidly connected to a vacuum source, the vacuum channel 166 communicates vacuum to the puck mount 144 such that vacuum can be communicated to the puck mount. Vacuum is drawn through the vacuum channel 166 and communicated to one or more vacuum zones 170 of the puck 22 (FIGS. 8 and 9), and the orientation of the puck 22 to the one or more zones 170 controls whether the puck 22 is picked up or transported (i.e., activates / deactivates the vacuum through the puck 22). According to one embodiment, each vacuum puck 22 has four vacuum zones 170 to help hold the pads / inserts during pick-up and transport. As the puck 22 rotates, the leading and trailing vacuum zones 170 change. The puck rotates 90 degrees after pick-up and then drops the pads / inserts onto a receiving surface (not shown), such as a vacuum transport roll.

[0145] With respect to the pucks, it is recognized that the pucks 22 are removable from the puck mount 144 to accommodate the particular setup of the transport mechanism 12, and that the pucks 22 can be replaced / modified as desired. When mounting the pucks 22 to the puck mount 144 of the carriage unit 20, one of a variety of connection mechanisms can be utilized, including fastener-type or fastener-less attachments. As an example, the pucks 22 may be configured to engage with the puck mount 144 according to a "quick connector" type engagement, such as a "hitch and receiver" type engagement. The structure of the pucks 22 and their mating relationship with the puck mount 144 allows the pucks 22 to be easily swapped or replaced on the carriage unit 20 based on the particular setup of the transport mechanism 12. Different size pucks 22 can be connected to the carriage unit 20 to accommodate cutting and transporting various types and sizes of articles.

[0146] 1-10, and now also with reference to FIG. 11A, a process 172 for configuring or reconfiguring the cutting and conveying apparatus 10 will be described in accordance with one embodiment of the present invention. Although the process 172 will be described below as a reconfiguration of an existing setup of the apparatus 10, it will be appreciated that the process is also applicable to an initial configuration of the apparatus 10. With respect to the reconfiguration process 172, it will be appreciated that only a portion of the steps described may need to be performed when reconfiguring the apparatus 10, and the exact process performed will be determined by the modified new process flow and / or new product type / size to be processed by the apparatus 10. Thus, it will be appreciated that the process 172 described below is meant to be an exemplary process only, and that embodiments of the present invention are not meant to be limited to only the described process.

[0147] If it is desired to reconfigure the machine 10 to perform a different process flow and / or to accommodate a different product type / size, push-button changes to the machine 10 may be implemented, such as via the HMI 18 of the machine 10. Operator input to the HMI 18 may cause all or at least a portion of the operational settings of the cutting system 14 and / or the transport mechanism 12 to be changed in an automated manner, thereby providing automatic or semi-automatic changeover and reconfiguration of the machine 10.

[0148] As an optional first step in the reconfiguration process 172, the transport mechanism 12 may be modified by mounting and replacing pucks 22 on each carriage unit 20 to provide pucks 22 capable of accommodating new pad / product sizes produced by the updated cutting and transport process, as shown in step 174. As previously mentioned, in one embodiment, the pucks 22 may be configured to engage with the puck mounts 144 by a quick connector type engagement to secure the pucks 22 to the puck supports 134 of the carriage units 20. The structure of the pucks 22 and their mating relationship with the puck mounts 144 allow the pucks 22 to be easily swapped or replaced on the carriage units 20 based on the particular setup of the transport mechanism 12. The swapping and replacement of different pucks 22 may be performed manually, or in alternative embodiments, through the use of a robotic system or other modification means. Due to the change in the pucks 22 mounted on the carriage units 20, the effective diameter of the overall puck wheels 26 may increase or decrease, and the pitch maintained between adjacent pucks 22 during operation of the transport mechanism 12 may also change.

[0149] As another step in the reconfiguration process 172, the cutting system 14 is altered in response to an input to the HMI 18 indicating a product size change for the next use of the apparatus 10, as shown in step 176. Specifically, the positioning of the anvil wheel 46 and knife roll 48 are adjusted relative to the transport mechanism 12 to account for the reconfiguration of the transport mechanism 12, such as an increased / decreased effective diameter of the puck wheel 26. In one embodiment, the positioning of the anvil wheel 46 and knife roll 48 is adjusted automatically in response to operator input provided to the HMI 18, with the servo driven lead screw adjuster 90 operating to laterally translate the upper cutter box assembly 84 along the track 88 relative to the lower cutter box assembly 86. Thus, the anvil wheel 46 and knife roll 48 are repositioned laterally relative to the transport mechanism 12 such that the anvil 56 is accurately positioned relative to the puck 22 when the cut is made to the incoming continuous web of material at the cut location between the anvil 56 and the knife roll 48.

[0150] As part of the reconfiguration process 172 of the cutting system 14, the operation of the knife roll 48 may also be altered to provide proper interaction with the anvil wheel 46, as shown at step 178. That is, reconfiguration of the transport mechanism 12 may alter the speed at which the pack wheel 26 is driven (via controlled operation of the motor drive shaft 28, which is also part of step 178), and thus the speed at which the anvil wheel 46 is driven is also altered (via controlled operation of the belt drive 80) to maintain a 1:1 speed relationship between the anvil wheel 46 and the pack wheel 26. The speed of the knife roll 48 is also altered to maintain proper phasing and operation of the knife roll 48 relative to the pack wheel 26 and anvil wheel 46. Thus, camming of the knife roll 48 is accomplished during the reconfiguration process 172 via selective operation of the drive roll shaft 78 and the servo motor 82 which drives the knife roll 48.

[0151] The push button reconfiguration process 172 of the machine 10 also includes reprogramming or changing the control scheme of the servo motors 106, as shown in step 180. That is, for any change in the speed or rate at which the puck wheels 26 rotate, there may also be a corresponding change in the speed or rate at which the servo motors 106 cause circumferential displacement of the carriage unit 20 along the center plate 24. Changing the control scheme of the servo motors 106 may be readily accomplished through reprogramming of the associated drives 122 in response to input commands from an operator of the machine 10 to the HMI 18.

[0152] 11A with steps 174-180 occurring sequentially, the steps of process 172 may occur in an order other than that shown in FIG. 11A. Additionally, some of steps 174-180 may occur simultaneously. One alternative embodiment of process 172 is shown in FIG. 11B. In step 173, one or more operator inputs are provided to HMI 18 during a product changeover sequence. These operator inputs may include, by way of non-limiting example, a selection of a product size (e.g., size 1, size 2, size 3, etc.), a selection of a product name (e.g., product A, product B, etc.), or specific product dimensions such as product pitch and insert length, by way of example.

[0153] In response to an operator input, the HMI 18 may optionally generate an indication that a pack 22 must be replaced as part of a product changeover process. If a pack 22 is to be replaced, the transport mechanism 12 is modified by replacing the packs 22 on each carriage unit 20 to provide a pack 22 that can accommodate the new pad / product size produced by the updated cutting and transport process, as shown in step 174. If a pack 22 is to be replaced, the process 172 includes a step 176 in which the positioning of the anvil wheel 46 and knife roll 48 are adjusted relative to the transport mechanism 12 to account for the reconfiguration of the transport mechanism 12. Step 176 may be performed before or after the pack 22 is replaced, and may be performed automatically based on a command generated via the HMI 18, or manually in the same manner as described with respect to FIG. 11A.

[0154] An operator input to the HMI 18 indicating a product changeover can also cause changes in the rotational speed of the transport mechanism 12, anvil wheel 46, and / or knife roll 48 to accommodate the change in machine speed (i.e., parts per minute) associated with the product changeover, as shown in optional step 178. Such changes may be performed automatically, via programming changes, in the same manner as described with respect to FIG. 11A, without further operator input.

[0155] An operator input to the HMI 18 indicating a product changeover may also generate an automatic reprogramming of the servo motor drive 122, as shown in step 180, to change the cam / rotation speed of the carriage unit in a manner similar to that described with respect to FIG. 11A.

[0156] Thus, the push-button reconfiguration process 172 of the apparatus 10 as described above allows for efficient handling of different product types / sizes as compared to the previous setup and configuration of the apparatus, and the reconfiguration is performed semi-automatically and without the need to replace the entire conveying mechanism 12 and / or cutting system 14. Thus, the reconfiguration process 172 can be performed in a fast and efficient manner such that downtime of the cutting and conveying apparatus 10 is minimized.

[0157] 12-22, an exemplary operation of the configurable cutting and conveying apparatus 10 will be described in more detail for the purpose of better illustrating an embodiment of the present invention. Although the apparatus 10 is shown as having a conveying mechanism 12 including an arrangement of eight pucks 22 thereon, it will be recognized that the operation of the apparatus 10 is the same with a greater or lesser number of pucks 22. Furthermore, while the operation of the apparatus 10 is described with reference to a single puck 22a and a single anvil 56a, it will be understood that the operation of the remaining pucks 22 and anvil 56 is at least substantially similar. Furthermore, while the operation is described in FIGS. 15-22 with reference to individual puck positions, it will be understood that the operation is preferably generally continuous. The individual positions serve to illustrate the operation being performed. Furthermore, the apparatus 10 may be configured to rotate generally clockwise, as shown in FIGS. 15-22, or generally counterclockwise in the case of an opposite-hand operated machine configuration.

[0158] 12-14, and with further reference to FIGS. 15-22, exemplary puck velocity profiles are shown as each puck 22 rotates through various portions of its transport path 34. The puck transport mechanism 12 rotates at a relatively constant velocity Vs about the puck transport axis 32, but, as previously mentioned, the servo motors 106 of the transport mechanism 12 can be selectively operated to control the rate at which the pucks 22 (on their associated carriage units 20) move / displace circumferentially along the central plate, and the connecting arms 114 and drag links 120 communicate the operation of the servo motors 106 to the carriage units 20 to which the pucks 22 are attached to accelerate / decelerate the pucks 22 and displace them circumferentially along the central plate 24. Accordingly, any description provided below with respect to acceleration or deceleration of a puck 22 will be understood to refer to operation of the respective servo motor 106 causing a corresponding change in the velocity of the pucks 22 (and carriage units 20) operatively connected thereto. An exemplary puck velocity profile is described below, however, it will be appreciated that different puck velocity profiles can be implemented through selective control and operation of the servo motor 106.

[0159] As the pack 22 receives the continuous web material 186, the pack 22 may move at a substantially constant first velocity V1. A cut portion of material, hereafter referred to as an insert or pad 188, is then cut from the continuous web 186. To create the pad 188, a first cut 190 is made near the pack leading edge 192 and a second cut 194 is made near the pack trailing edge 196. As previously described, the cutting of the continuous web is made by positioning each anvil 56 in the proper cutting position relative to the pack 22 and knife roll 48. The positioning of each anvil 56 (and anvil arm 52) between its two adjacent carriage units 20 is maintained relatively constant (i.e., midway between the carriage units) via its connection to the carriage units 20 by the scissor link 66. This controlled positioning of each anvil 56 ensures that the anvils 56 are in the proper position between adjacent packs 22 when it is time to cut the continuous web material 186, such as the first and second cuts 190, 194 shown here.

[0160] Immediately after the pad 188 is cut from the web material 186, the puck 22 may be accelerated 198 and then decelerated 200 to a substantially constant speed 202, which may be a first speed V1. After the trailing edge cut 194, and before placing 204 the pad 188 on the receiving surface 206, the puck 22 may be spun (via the interaction of the spin cam follower 130 and the spin cam race 128) to a desired angle, and the speed of the puck 22 may be varied 208 (via the operation of the servo motor 106) to achieve the desired predetermined circumferential spacing. Upon or after reaching a substantially constant 210 second speed V2, the pad 188 is placed 204 on the receiving surface 206. After pad placement 204, the puck 22 is decelerated 212 to a substantially constant 214 first speed V1 and spun back to the web receiving orientation. The process then begins anew.

[0161] During periods of acceleration and deceleration, the puck 22 changes position relative to the primary axis of rotation, i.e., the puck transport axis 32, and the puck may be displaced circumferentially. This is best seen in FIG. 14. A first reference point 216 represents a point on the shaft 28 (FIG. 1) which spins about the puck transport axis 32 at a relatively constant speed VS during operation of the transport mechanism 12. A second reference point 218 represents the position of the puck 22. The shaft reference 216 may rotate at a constant speed about the puck transport axis 32, but the position of the puck reference 218 relative to the shaft 28 may be varied by any desired amount. Again, the position of the puck reference 218 relative to the shaft 28 and its increase / decrease in degree of rotation in response to acceleration / deceleration of the puck 22 is controlled via selective operation of a servo motor associated with the puck 22.

[0162] As shown in FIG. 14, the shaft datum 216 is generally radially aligned with the puck datum 218 at the cut 190, 194. At the end of the first acceleration 200, the puck datum 218 has changed position relative to the shaft datum 216 by a first distance 220. At the end of the first deceleration period 202, the datums 216, 218 are again aligned. Prior to pad placement 204, the puck 22 is again accelerated and at the end of the second acceleration 210, the puck datum 218 has advanced past the shaft datum 216 by a second distance 222. The first distance 220 may be the same as or different from the second distance 222. Finally, at the end of the second deceleration period 214, both datums 216, 218 are aligned and ready for the next rotation.

[0163] 15 shows a representative pack 22a at a first position P1. At the first position P1, the pack 22a receives a continuous web material 186 moving at a first speed in a first direction 224. A vacuum is pulled through the carriage unit 20 (through the pack support 134 and the pack 22a) to support the web material 186 on the surface of the pack 22a. While receiving the web 186, the pack 22a is moving in a second direction (i.e., the machine direction 104) about the pack transport axis 32, and at this point P1, the first direction 224 is preferably substantially tangent to the second direction. The pack 22a continues to move in the second direction 104 to a second position P2.

[0164] FIG. 16 shows pack 22a in second position P2, where pack 22a is at leading edge cut 190 of FIG. 12. Here, knife blade 58 of knife roll 48 cooperates with representative anvil 46a of anvil wheel 56 to sever web 186 adjacent leading edge 192 of pack 22a. As previously described, anvil 56a is moved to the proper cutting position between a leading pack and a succeeding pack 22 adjacent to the leading pack via their connection to carriage unit 20 by scissor link 66. After receiving web 186 and making a cut adjacent leading edge 192, pack 22a proceeds in second direction 104 past knife roll 48 to third position P3.

[0165] Figure 17 shows the pack 22a in a third position P3, where the pack 22a is at the trailing edge cut 194 of Figure 12. At this position P3, the knife blades 58 of the knife roll 48, in cooperation with the anvil 56, cut the web 186 adjacent the trailing edge 196 of the pack 22a to cut pads 186a from the web 188. The pads 188a are held to the pack 22a by the previously drawn vacuum. After being cut adjacent the trailing edge 196, the pack 22a continues in the second direction 104 to a fourth position P4.

[0166] FIGURE 18 shows the puck 22a in the fourth position P4. As previously mentioned, it is often desirable to spin the cut pad 188a to some predetermined angle before being placed on the receiving surface 206. Here, the puck 22a is shown spinning. Although FIGURE 18 shows the puck 22a spinning in the fourth position P4, the puck 22a may be spun to the desired angle at any time after the trailing edge cut made in the third position P3 and before being placed on the receiving surface 206.

[0167] In addition to rotating and spinning the pucks 22, the apparatus 10 can also vary the circumferential spacing of the pucks 22. As previously described, the servo motors 106 associated with each puck 22, and the individual control of each servo motor 106, allow for variation in the circumferential spacing of the pucks 22 and selective control of the pitch between each of the pucks 22, with the servo motors 106 allowing a large angular range of movement for each of the pucks 22. Thus, displacement of the pucks 22 via the servo motors 106 provides a placement pitch for the cutting pads 188 that is different from the pitch at which the web material 186 was cut, and the final circumferential spacing of the pucks 188 at the receiving surface 206 for placement of the pads 22 thereon is a function of the desired placement pitch 226 and the speed at which the receiving surface 206 is moving.

[0168] Upon achieving the desired directional spacing, the pack 22a reaches a fifth position P5. The pack 22a is shown in the fifth position P5 in FIG. 19. At this position P5, the pack 22a is in the middle of the placement time 204 shown in FIG. 12. The pack 22a is positioned at the correct placement pitch or distance 226 relative to the pack 22 preceding it. At this pitch or distance 226, the pad 188a is transferred to the receiving surface 206. During placement, the vacuum drawn through the pack support 134 and the pack 22a can be removed from at least a portion of the pack 22a, thereby allowing smooth transfer of the cut-out insert 188a from the pack 22a to the receiving surface 206. After placing the pad 188a on the receiving surface 206, the pack 22a continues to travel in the second direction 104 to a sixth position P6.

[0169] 20 shows the puck 22a in a sixth position P6. The puck 22a is shown releasing the cut-out pads 188a onto the receiving surface 206. The puck 22a continues to move in the second direction 104 to a seventh position.

[0170] Figure 21 shows the puck 22a in a seventh position P7. If the puck 22a and pad 188a were rotated to an angle after cutting and before being placed on the receiving surface 206, the puck 22a may need to be adjusted to the web-receiving orientation. Although Figure 21 shows the puck 22a spinning in the seventh position P7, the puck 22a may be spun any time after the pad 188a is placed on the receiving surface 206 and before the continuous web 186 is received.

[0171] It will be appreciated that the operation of the configurable cutting and conveying apparatus 10 described above in Figures 12-22, including the illustrated puck speed profiles, is for illustrative purposes only, that is, according to additional embodiments of the invention, the rotation of the pucks 22 about the conveying path 34 may follow a different suitable speed profile and / or the spin of the pucks 22 may differ from that described, and such embodiments will be appreciated to be within the scope of the invention.

[0172] 23 illustrates an exemplary alternative puck velocity profile. The puck 22 moves at a substantially constant first velocity V1 while a first cut 190 is made near the puck leading edge 192 and a second cut 194 is made near the puck trailing edge 196. Following the second cut 194, the puck 22 is accelerated 198 to a third velocity V3 and then decelerated 200 to a substantially constant 210 second velocity V2 to achieve the desired predetermined circumferential spacing between adjacent pucks 22. After the trailing edge cut 194, the puck 22 spins (via interaction of the spin cam follower 130 and the spin cam race 128) to a desired angle and the velocity of the puck 22 is changed 208 (via operation of the servo motor 106) before placing 204 the pad 188 on the receiving surface 206. Upon or after reaching the substantially constant 210 second velocity V2, the pad 188 is placed 204 on the receiving surface 206. After pad placement 204, the puck 22 is accelerated 213 to a third velocity V3, then decelerated 212 to a substantially constant 214 first velocity V1 and spun back to the web receiving orientation. The process then begins anew.

[0173] FIG. 24 illustrates another exemplary alternative puck velocity profile. The puck 22 moves at a substantially constant first velocity V1 during which the first cut 190 is made and the second cut 194 is made. Following the second cut 194, the puck 22 is accelerated 198 to a substantially constant 210 second velocity V2 to achieve the desired predetermined circumferential spacing between adjacent pucks 22. After the trailing edge cut 194, the puck 22 spins (through the interaction of the spin cam follower 130 and the spin cam race 128) to a desired angle before placing 204 the pad 188 on the receiving surface 206. At some point after reaching the second velocity V2, the pad 188 is placed 204 on the receiving surface 206. After pad placement 204, the puck 22 is decelerated 212 to a substantially constant 214 first velocity V1 and spun back to the web receiving orientation. The process then begins anew.

[0174] 25 illustrates yet another exemplary alternative puck velocity profile. The puck 22 moves at a substantially constant first velocity V1 while a first cut 190 is made near the puck leading edge 192 and a second cut 194 is made near the puck trailing edge 196. Following the second cut 194, the puck 22 is accelerated 201 to a fourth velocity V4 and then to a substantially constant 210 second velocity V2 to achieve the desired predetermined circumferential spacing between adjacent pucks 22. After the trailing edge cut 194, the puck 22 spins (via the interaction of the spin cam follower 130 and the spin cam race 128) to a desired angle before placing 204 the pad 188 on the receiving surface 206. Upon or after reaching the substantially constant 210 second velocity V2, the pad 188 is placed 204 on the receiving surface 206. After pad placement 204, the puck 22 is accelerated 212 to a fourth velocity V4, then accelerated 215 to a substantially constant 214 first velocity V1 and spun back to the web receiving orientation. The process then begins anew.

[0175] It is further recognized that aspects of the transport mechanism 12 described above may be implemented in other systems or apparatus, according to additional embodiments of the present invention. Such systems or apparatus may include a cutting and transport apparatus of a different configuration than the apparatus 10 described above, in which case the transport mechanism therein is identical to the transport mechanism 12, but includes a cutting system of a different configuration. Such systems or apparatus may also include a pick and place system operable to receive (or "pick") a product or component in one orientation, spin the component to a desired predetermined angle, and then transport (or "place") the component onto another web or component for use in another step of the manufacturing process. Such a pick and place system would include a transport mechanism identical to the transport mechanism 12 described above, but would not include any type of cutting system 14 therein.

[0176] An example of a cutting and transporting apparatus 230 according to one embodiment is shown in FIG. 26. As shown, the apparatus 230 includes the transport mechanism 12 as detailed above, having a plurality of carriage units 20 and pucks 22 arranged about a central plate 24 to collectively form a pack wheel 26 of a desired configuration. The puck wheels 26 are coupled to a motor drive shaft 28, which causes the puck wheel 26, including the carriage units 20 and pucks 22, to rotate about a puck transport axis 32. The transport mechanism 12 includes a plurality of servo motors 106 to facilitate circumferential displacement of the carriage units 20 and pucks 22 along a pitch rail 96 disposed about the periphery of the central plate 24. Each carriage unit 20 is provided with a dedicated servo motor 106 to enable displacement of that carriage unit 20 (and pucks 22) along the pitch rail 96. In operation, the servo motor 106 can rotate both clockwise and counterclockwise such that the connecting arm 114, which couples the servo motor 106 to the carriage unit 20 (through the drag link 120), moves back and forth in a reciprocating wiper-type pattern. Thus, through this movement of the connecting arm 114, and through the drag link 120, which couples the connecting arm 114 to the carriage unit 20, the rotational movement of the servo motor 106 can be translated into circumferential displacement of the respective carriage unit 20 along the pitch rail 96. In addition to such circumferential displacement of the carriage units 20 and pucks 22, each puck can be spun radially about the pack rotation axis 36 as previously described (i.e., through the interaction of a spin cam follower 130 on the carriage unit 20 with a spin cam race 128 provided on a barrel cam 128 positioned about the transport axis 32, as shown in FIG. 1).

[0177] The apparatus 230 also includes a cutting system 232 including an anvil wheel 234 and a knife roll 236 that interact with each other to cut individual pads or inserts from the continuous web provided to the cutting and transporting apparatus 10. The anvil wheel 234 is sized smaller than the transporting mechanism 12 (i.e., the diameter of the anvil wheel 234 is smaller than the diameter of the transporting mechanism) such that the anvil wheel 234 is positioned generally within the periphery of the transporting mechanism 12. The anvil wheel 234 includes a plurality of anvil arms 238 (each having an anvil 240) extending radially outwardly from a central hub 242, the anvil arms 238 being disposed at fixed positions about the hub. The hub 242 is coupled to a drive shaft (not shown) aligned along an anvil wheel axis 244, which is offset from the puck transport axis 32. In the illustrated embodiment, the anvil wheel 234 has fewer anvils 240 than there are pucks 22 provided on the transport mechanism 12, which allows for a larger offset 246 between the anvil wheel axis 244 and the puck transport axis 32. The eccentric offset effectively retracts the anvils 240 from between adjacent pucks 22 when they are not in the cutting position where they are desired to interact with the knife roll 236 to sever the continuous web.

[0178] An example of a pick and place system according to one embodiment is shown in Figures 27 and 28. As previously mentioned, the pick and place system 250 (hereinafter "system") is generally equivalent in structure and operation to the previously described transport mechanism 12, but with the cutting system 14 removed. That is, in operation of the system 250, individual articles previously formed in a previous step of the manufacturing process (e.g., separate inserts, pads, cut portions of web material, etc.) are provided directly to the puck 22 for pick-up and transport, and no cutting of the incoming continuous web occurs. Thus, the system 250 includes a plurality of carriage units 20 and pucks 22 arranged about a central plate 24 to collectively form a puck wheel 26 of a desired configuration. The puck wheel 26 is coupled to a motor drive shaft 28, which causes the puck wheel 26, including the carriage units 20 and pucks 22, to rotate about a puck transport axis 32. The transport mechanism 12 includes a number of servo motors 106 to facilitate circumferential displacement of the carriage units 20 and pucks 22 along a pitch rail 96 provided around the center plate 24. Each carriage unit 20 is provided with a dedicated servo motor 106 to enable displacement of that carriage unit 20 (and puck 22) along the pitch rail 96. In operation, the servo motors 106 can rotate both clockwise and counterclockwise such that a connecting arm 114 that couples the servo motor 106 to the carriage units 20 (via a drag link 120) moves back and forth in a reciprocating wiper-type pattern. Thus, through this movement of the connecting arm 114, and through the drag link 120 that couples the connecting arm 114 to the carriage units 20, the rotational movement of the servo motor 106 can be translated into circumferential displacement of the respective carriage unit 20 along the pitch rail 96. In addition to such circumferential displacement of the carriage unit 20 and packs 22, each pack can be spun radially about the pack spin axis 36 through interaction of a spin cam follower 130 on the carriage unit 20 with a spin cam race 128 provided on a barrel cam 126 positioned about the transport axis 32 and on the drive side 30 of the center plate 24.

[0179] Thus, advantageously, embodiments of the present invention provide separate article conveying and cutting / conveying apparatuses that allow adjustment of their operation to accommodate conveying (and cutting) of various types and sizes of articles. These apparatuses can accommodate the production of a wide range of product sizes due to the speed capabilities and circumferential pack displacement range provided by the conveying mechanism. That is, the use of servo motors in the conveying mechanism to drive the individual carriage units allows for larger angular displacement and pitch spacing between packs to accommodate larger chassis sizes (and pack sizes) on the conveying mechanism. With respect to the cutting / conveying apparatus, the structure of the cutting system in which the anvil wheel and knife roll are movable relative to the conveying mechanism allows the cutting system to accommodate the production of a wide range of product sizes as well. Repositioning of the anvil wheel and knife roll can be performed in conjunction with changes in size and / or operating speed of the conveying mechanism without the need to replace components of the cutting system. Also, camming of the knife roll is provided by the use of a separate servo motor such that the operation of the knife roll can be synchronized with changes in the operating parameters of the conveying mechanism. Most or all of the reconfiguration of the cutting / conveying apparatus can be accomplished via push button switching, minimizing the amount of manual reconfiguration of the apparatus required to minimize downtime of the apparatus when performing size change adjustments.

[0180] Further advantages are provided by the structure of the cutting system and its mechanical connection to the transport mechanism: the anvil wheels are configured such that each anvil arm is pivotable relative to the central anvil hub, while each anvil arm is also connected to the chassis of the two carriage units between which it is located. Each anvil arm is connected to its adjacent carriage unit chassis via a scissor link extending between them, the scissor link being pivotally connected to the carriage unit chassis and the anvil arm. The connection of each anvil arm to its two adjacent carriage units via the scissor link keeps the anvil arm centered between the carriage units, displacing the carriage units circumferentially via the respective servo motors, thus determining the placement of the anvil arms. Thus, the anvil arms are prevented from colliding or coming into contact with the carriage units (pucks), regardless of the particular configuration of the transport mechanism for a particular resizing operation and / or in the event of a malfunction of the servo motors, thereby providing a means of safety in the operation of the device.

[0181] Thus, according to one embodiment of the present invention, a cutting and conveying apparatus includes a cutting system configured to cut an incoming continuous web of material into a plurality of individual articles, and a conveying mechanism operable with the cutting system to convey and rotate the plurality of individual articles from at least one web receiving location to an article placement location. The conveying mechanism further includes a drive shaft rotatable about a conveying axis, and a puck wheel mounted on the drive shaft for rotation about the conveying axis together with the drive shaft. The puck wheel includes a plurality of carriage units rotating about the conveying axis to move along a conveying path centered on the conveying axis from at least the web receiving location to the article placement location, each of the plurality of carriage units including a puck supporting an individual article and selectively operable to reorient the article as the puck moves between the web receiving location and the article placement location. The puck wheel also includes a plurality of servo motors, each servo motor operably connected to a respective carriage unit in the plurality of carriage units via a connecting arm, each of the plurality of servo motors operable to change the positioning of its respective carriage unit along at least a portion of the conveying path.

[0182] According to another embodiment of the present invention, a pick and place system for transporting and rotating a plurality of individual articles from at least an article receiving location to an article placing location is disclosed. The pick and place system includes a drive shaft rotatable about a transport axis, a central plate mounted on the drive shaft for rotation with the drive shaft about the transport axis, and a plurality of carriage units positioned about the central plate for rotation with the central plate for movement along a transport path centered on the transport axis from at least the article receiving location to the article placing location, each of the plurality of carriage units including a puck supporting an individual article and selectively operable to reorient the article as the puck moves between the article receiving location and the article placing location. The pick and place system also includes a plurality of servo motors mounted on the central plate, each servo motor operably connected to a respective carriage unit in the plurality of carriage units via a connecting arm, each of the plurality of servo motors operable to change the positioning of its respective carriage unit relative to the central plate along at least a portion of the transport path.

[0183] According to yet another embodiment of the present invention, a cutting and conveying apparatus includes a cutting system configured to cut an incoming web of material into a plurality of individual articles and a conveying mechanism operable with the cutting system to convey and rotate the plurality of individual articles from at least one web receiving location to an article placement location, the conveying mechanism further including a drive shaft rotatable about a conveying axis, a central plate mounted on the drive shaft for rotation about the conveying axis with the drive shaft, and a plurality of carriage units positioned about the central plate for rotation with the central plate for movement along a conveying path about the conveying axis from at least the web receiving location to the article placement location, each of the plurality of carriage units including a puck supporting an individual article and selectively operable to reorient the article as the puck moves between the web receiving location and the article placement location. The cutting system includes an anvil wheel having an anvil hub coupled to and driven by the anvil shaft for rotation about an anvil wheel axis, and a plurality of anvil arms pivotally connected to the anvil hub and extending radially outward from the anvil hub, each of the plurality of anvil arms having an anvil that cooperates with a knife roll of the cutting system to cut an incoming web of material. The plurality of anvil arms are equal in number to the plurality of carriage units, and the plurality of anvil arms are interspersed with the plurality of carriage units such that each anvil arm is positioned between a pair of adjacent carriage units. Each anvil arm is mechanically coupled to a pair of adjacent carriage units between which each anvil arm is positioned to control the positioning of the anvil relative to the pair of adjacent carriage units.

[0184] According to yet another embodiment of the present invention, a method for constructing a cutting and conveying apparatus includes providing a cutter mechanism configured to cut an incoming web of material into a plurality of individual articles, and providing a conveying mechanism operable with the cutter mechanism to convey and rotate the plurality of individual articles from at least one web receiving location to an article placement location. In providing the conveying mechanism, the method further includes the steps of providing a drive shaft having a mounting structure coupled thereto, the drive shaft and the mounting structure being rotatable about a conveying axis, and mounting a plurality of carriage units to the mounting structure such that the plurality of carriage units are rotatable with the mounting structure for movement along a conveying path about the conveying axis from at least the web receiving location to a pad placement location, each of the plurality of carriage units including a puck, the puck supporting an individual article and selectively operable to reorient the article as the puck moves between the web receiving location and the article placement location. The method also includes operably connecting a servo motor to each of the plurality of carriage units via a connecting arm, each servo motor selectively operable to change the positioning of its respective carriage unit relative to the mounting structure by circumferentially displacing the carriage unit along the transport path.

[0185] According to yet another embodiment of the present invention, a cutting and conveying apparatus includes a cutting system configured to cut an incoming web of material into a plurality of individual articles and a conveying mechanism operable with the cutting system to convey and rotate the plurality of individual articles from at least one web receiving location to an article placement location. The conveying mechanism further includes a drive shaft rotatable about a conveying axis, a mounting structure rotatable about the conveying axis, a plurality of carriage units coupled to the mounting structure and configured to move along a conveying path centered about the conveying axis from at least the web receiving location to the article placement location, and a plurality of pucks coupled to the plurality of carriage units for supporting the individual articles and reorienting the articles as the plurality of pucks move between the web receiving location and the article placement location. The cutting system includes an anvil wheel having an anvil hub coupled to and driven by the anvil shaft for rotation about an anvil wheel axis, and a plurality of anvil arms pivotally connected to the anvil hub and extending radially outward from the anvil hub, each of the plurality of anvil arms having an anvil that cooperates with a knife roll of the cutting system to cut the incoming web of material. The plurality of anvil arms equals the plurality of carriage units in number and are interspersed with the plurality of carriage units such that each anvil arm is positioned between a pair of adjacent carriage units, each anvil arm is mechanically coupled to a pair of adjacent carriage units between which each anvil arm is positioned to control the positioning of the anvil relative to the pair of adjacent carriage units.

[0186] While the present invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the present invention is not limited to such disclosed embodiments. Rather, the present invention can be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the present invention. Moreover, while various embodiments of the present invention have been described, it should be understood that aspects of the present invention may include only some of the described embodiments. Thus, the present invention should not be deemed limited by the foregoing description, but is limited only by the appended claims.

Claims

1. A cutting and conveying device, a cutting system configured to cut the incoming continuous web of material into a plurality of discrete articles; a transport mechanism operable with the cutting system to transport and rotate the plurality of individual articles from at least one web receiving location to an article placement location; The transport mechanism includes: a drive shaft rotatable about a conveying axis; a puck wheel mounted on the drive shaft for rotation therewith about the conveying axis; The pack wheel a plurality of carriage units that rotate about the transport axis to move along a transport path about the transport axis from at least the web receiving position to the article placement position, each of the plurality of carriage units including a puck that supports an individual article and is selectively operable to reorient the article as the puck moves between the web receiving position and the article placement position; a plurality of servo motors, each operably connected to a respective carriage unit in the plurality of carriage units via a connecting arm, each of the plurality of servo motors operable to change the positioning of the respective carriage unit along at least a portion of the conveying path.

2. the puck wheel includes a center plate attached to the drive shaft for rotation with the drive shaft about the transport axis, the plurality of carriage units are attached to and positioned about the center plate, and the plurality of servo motors are attached to the center plate; 2. The cutting and conveying apparatus of claim 1, wherein each of said plurality of servo motors is operable to vary the positioning of its respective carriage unit relative to said center plate along at least a portion of said conveying path.

3. 3. The cutting and conveying device of claim 2, further comprising an annular rail structure positioned on an outer periphery of the center plate, the rail structure including a pitch rail to which the plurality of carriage units are mounted so as to be movable along the rail structure.

4. Each of the plurality of carriage units includes: a chassis including a pair of frame members positioned on either side of the rail structure; a plurality of rollers coupled to the chassis and rollingly engaging inner and outer edges of the pitch rails to secure the carriage unit to the rail structure and translate the carriage unit along the pitch rails; 4. The cutting and conveying device of claim 3, further comprising: a puck support positioned on the chassis, the puck support being movable relative to the chassis via a mating relationship between a rail guide of the puck support and the pitch rail, the puck support being oriented generally perpendicular to the pitch rail and including a puck mounting portion at one end configured to receive the puck.

5. the carriage unit includes a drag link connecting the connecting arm to the chassis, the drag link being rotatably connected to each of the connecting arms and a mounting portion of one of the pair of frame members; 5. The cutting and conveying device according to claim 4, wherein the drag link converts rotational movement of the servo motor and the connecting arm into translational movement of the carriage unit along the pitch rail.

6. the conveying mechanism includes a barrel cam stationarily disposed about the conveying axis, the barrel cam having a spin cam race formed around its outer periphery; 5. The cutting and conveying apparatus of claim 4, wherein each of the plurality of carriage units includes a spin cam follower positioned at the other end of the puck support, the spin cam follower slidably or rollingly associated with the spin cam race to spin the puck at least partially about a spin axis of the respective puck that is at least substantially perpendicular to the conveying axis, thereby reorienting the articles supported on the puck.

7. The transport mechanism includes: a stationary vacuum manifold positioned adjacent to the central plate and configured to transfer a vacuum from a vacuum source to an interior volume of the central plate; 5. The cutting and conveying device of claim 4, further comprising: a plurality of vacuum tubes coupled to the central plate, one or more vacuum tubes in the plurality of vacuum tubes fluidly connecting the interior volume of the central plate to a respective carriage unit in the plurality of carriage units to transmit vacuum to the plurality of carriage units.

8. 8. The cutting and conveying device of claim 7, wherein the plurality of vacuum tubes each comprise a telescopic vacuum tube rotatably coupled to the central plate so as to pivot relative to the central plate, each telescopic vacuum tube being contractible and extendable to decrease and increase its length, whereby the length of the telescopic vacuum tube can be changed to correspond to movement of each carriage unit along the rail structure.

9. 8. The cutting and transport apparatus of claim 7, wherein the puck support includes one or more vacuum channels formed therein to provide a fluid flow path from one or more respective vacuum tubes to the puck mount and the puck mounted on the puck mount.

10. The cutting system comprises: a knife roll including one or more knives; and Equipped with an anvil wheel, The anvil wheel an anvil hub connected to and driven by the anvil shaft so as to rotate about the anvil wheel axis; a plurality of anvil arms pivotally connected to the anvil hub and extending radially outward from the anvil hub; an anvil positioned at the end of each of the plurality of anvil arms, the anvil cyclically cooperating with the one or more knives of the knife roll to cut the incoming web of material; 10. The cutting and transport device of claim 1, further comprising: a linkage system that mechanically couples the plurality of anvil arms together.

11. 11. The cutting and transport device of claim 10, wherein the linkage system comprises a pair of scissor links provided between each adjacent pair of anvil arms in the plurality of anvil arms, a first link in the pair of scissor links being rotatably connected to a first anvil arm in the adjacent pair of anvil arms, and a second link in the pair of scissor links being rotatably connected to a second anvil arm in the adjacent pair of anvil arms.

12. 12. The cutting and conveying device of claim 11, wherein the first link and the second link of each pair of scissor links are rotatably connected to a common attachment point on a respective carriage unit positioned between the first anvil arm and the second anvil arm.

13. 13. The cutting and transporting device of claim 12, wherein each anvil arm in the plurality of anvil arms remains centered between a respective pair of carriage units positioned on either side thereof via the linkage system and the connection of the first link and the second link in each respective pair of scissor links to the respective carriage units.

14. 12. The cutting and transport device of claim 11, wherein each of the plurality of anvil arms comprises a linear slide, the linear slide connecting a respective link in the linkage system to each of the plurality of anvil arms, the linear slide providing radial inward and outward movement of a pivot point at which the link is connected to the anvil arm.

15. The cutting system comprises: a belt drive that drives the anvil shaft to rotate the anvil wheel; a knife roll servomotor coupled to the knife roll to drive rotation of the knife roll; 11. The cutting and conveying apparatus of claim 10, wherein the knife roll servomotor is separate from the belt drive such that the knife roll is driven separately from the anvil wheel via cam action of the knife roll servomotor.

16. The cutting system comprises: a lower cutter box assembly having a track formed along an upper surface thereof; an upper cutter box assembly positioned above the lower cutter box assembly and movable laterally relative to the lower cutter box assembly along the track; an adjustment mechanism operable to laterally move the upper cutter box assembly along the track; 16. The cutting and transport apparatus of claim 15, wherein each of the anvil wheel and the knife roll is mounted to the upper cutter box assembly such that lateral movement of the upper cutter box assembly causes the anvil wheel and the knife roll to move laterally relative to the transport mechanism.

17. receiving operator input directed to reconfiguring the transport mechanism and / or the cutting system; generating commands in response to operator input that change one or more operational settings of the transport mechanism and / or the cutting system; and a human-machine interface (HMI) configured to:

11. The cutting and conveying apparatus of claim 10, wherein the one or more operational settings include at least one of a rotational speed of the drive shaft, a pitch between adjacent pucks, a speed of the plurality of servo motors, a lateral positioning of the anvil wheel and the knife roll, a rotational speed of the anvil shaft, and a speed of the knife roll servo motor.

18. 18. The cutting and conveying apparatus of claim 17, further comprising a slip ring positioned on the drive shaft, wherein communication and / or power connections to the plurality of servo motors are routed through the slip ring.

19. The cutting and conveying device of claim 1 , wherein the connecting arm comprises a curved, arcuate connecting arm.

20. 1. A pick and place system for transporting and rotating a plurality of individual items from at least one item receiving location to an item placing location, comprising: a drive shaft rotatable about a conveying axis; a center plate attached to the drive shaft for rotation therewith about the conveying axis; a plurality of carriage units positioned about the central plate to rotate with the central plate for movement along a conveying path about the conveying axis from at least the article receiving position to the article placing position, each of the plurality of carriage units including a puck supporting an individual article and selectively operable to reorient the article as the puck moves between the article receiving position and the article placing position; a plurality of servo motors mounted on the center plate, each of the plurality of servo motors operatively connected to a respective carriage unit in the plurality of carriage units via a connecting arm, each of the plurality of servo motors operable to change the positioning of its respective carriage unit relative to the center plate along at least a portion of the transport path.

21. 21. The pick and place system of claim 20, wherein the center plate comprises an annular rail structure positioned on an outer periphery thereof, the rail structure including a pitch rail to which the plurality of carriage units are mounted for movement along the rail structure.

22. Each of the plurality of carriage units includes: a chassis including a pair of frame members positioned on either side of the rail structure; a plurality of rollers coupled to the chassis and rollingly engaging inner and outer edges of the pitch rails to secure the carriage unit to the rail structure and translate the carriage unit along the pitch rails; 22. The pick and place system of claim 21, comprising: a puck support positioned on the chassis, the puck support movable relative to the chassis via a mating relationship between the rail guides of the puck support and the pitch rails, the puck support oriented generally perpendicular to the pitch rails and including a puck mount at one end configured to receive the puck.

23. the carriage unit includes a drag link that connects the connecting arm to the chassis, the drag link being rotatably connected to each of the connecting arms and a mounting portion of one of the frame members of the pair of frame members; 23. The pick and place system of claim 22, wherein the drag link converts rotational motion of the servo motor and connecting arm into translational motion of the carriage unit along the pitch rail.

24. a barrel cam stationarily disposed about the conveying axis, the barrel cam having a spin cam race formed around its outer periphery; 23. The pick and place system of claim 22, wherein each of the plurality of carriage units includes a spin cam follower positioned at the other end of the puck support, the spin cam follower in slidable or rolling communication with the spin cam race to spin the puck at least partially about a spin axis of the respective puck that is at least substantially perpendicular to the transport axis, thereby reorienting the articles supported on the puck.

25. a stationary vacuum manifold positioned adjacent to the central plate and configured to transfer a vacuum from a vacuum source to an interior volume of the central plate; a plurality of vacuum tubes coupled to the center plate, one or more vacuum tubes in the plurality of vacuum tubes fluidly connecting the interior volume of the center plate to a respective carriage unit in the plurality of carriage units to transmit vacuum to the plurality of carriage units; 22. The pick and place system of claim 21, wherein each vacuum tube is rotatably coupled to the central plate so as to pivot relative to the central plate, and wherein the length and / or configuration of each vacuum tube is variable to accommodate movement of a respective carriage unit along the rail structure.

26. a plurality of motor drives secured to the central plate, the motor drives operatively connected to the plurality of servo motors to control their operation; a human machine interface (HMI) in communication with the plurality of motor drives to provide commands to the plurality of motor drives; The HMI includes: receiving operator input directed to reconfiguring the pick and place system; providing commands to the plurality of motor drives to cam the plurality of servo motors according to a predetermined velocity profile related to the operator input, thereby altering the positioning of the plurality of carriage units relative to the center plate along at least the portion of the transport path; 22. The pick and place system of claim 21 configured to:

27. 1. A method for configuring a cutting and conveying device, comprising: providing a cutter mechanism configured to cut the incoming web of material into a plurality of individual articles; providing a transport mechanism operable with the cutter mechanism to transport and rotate a plurality of individual articles from at least one web receiving location to an article placement location; The step of providing the transport mechanism includes: providing a drive shaft having a mounting structure coupled thereto, the drive shaft and the mounting structure being rotatable about a conveying axis; mounting a plurality of carriage units to the mounting structure such that the plurality of carriage units are rotatable with the mounting structure for movement along a transport path about the transport axis from at least the web receiving position to the pad placement position, each of the plurality of carriage units including a puck supporting a respective article thereon and selectively operable to reorient the article as the puck moves between the web receiving position and the article placement position; operatively connecting a servo motor to each of the plurality of carriage units via a connecting arm, each servo motor selectively operable to change the positioning of its respective carriage unit relative to the mounting structure by circumferentially displacing the carriage unit along the transport path.

28. 28. The method of claim 27, wherein the mounting structure comprises a center plate, and wherein mounting the plurality of carriage units comprises mounting the plurality of carriage units on an annular rail structure positioned around an outer periphery of the center plate, the rail structure having pitch rails on which the plurality of carriage units are mounted for movement along the rail structure.

29. 28. The method of claim 27, further comprising coupling a respective puck to each of the plurality of carriage units to provide pucks corresponding to desired article sizes to be produced by the cutting and conveying apparatus.

30. providing an input to the cutting and conveying device from a human machine interface (HMI) indicating the size of the product to be produced by said cutting and conveying device; and positioning the cutter mechanism relative to the transport mechanism based on the input from the HMI; 36. The method of claim 35, wherein positioning the cutter mechanism includes positioning an anvil wheel and knife roll of the cutter mechanism relative to the transport mechanism based on the input from the HMI to cut the incoming web of material at a cutting location.

31. controlling the rotational speed of the drive shaft and the anvil wheel based on the input from the HMI, wherein the rotational speed of the drive shaft and the rotational speed of the anvil wheel are kept equal; controlling the rotational speed of the servo motor based on an input from the HMI; 31. The method of claim 30, further comprising controlling the rotational speed of the knife roll via cam action of a knife roll servo motor operatively connected to the knife roll based on the input from the HMI.

32. 1. A method for initiating a product changeover in a conveying device, comprising: the transport device includes a puck wheel and an anvil wheel driven by at least one drive shaft; a plurality of carriage units operatively connected along the periphery of the puck wheel, each carriage unit including a replaceable puck; the anvil wheel having a plurality of anvil arms pivotally connected to an anvil hub and extending radially outward from the anvil hub; and a rotating blade cooperating with the anvil arms; The method comprises: Optionally, removing each puck having the first size from its corresponding carriage unit; Optionally, attaching a puck having a second size to each corresponding carriage unit; Sequentially or simultaneously sending commands to one or more controllers that control the drive shaft motor, the plurality of carriage unit motors, and the blade motor, resulting in: Varying the rotational angle of the drive shaft to vary the speed of the puck wheel and the anvil wheel; accelerating a selected carriage unit to linearly displace it from a first position to a second position along a portion of the periphery of the puck wheel, the displacement of the selected carriage unit changing the angular position of a corresponding anvil arm adjacent the selected carriage unit; adjusting the rotational speed and angular position of the rotating blade so that the rotating blade contacts the distal end of the corresponding anvil arm and cuts the continuous web of material disposed between the rotating blade and the distal end of the corresponding anvil arm; decelerating the selected carriage unit to linearly displace the selected carriage unit from the second position to the first position.

33. 33. The method of claim 32, optionally wherein removing each puck of the first size and installing each puck of the second size is performed by a robotic mechanism or a human.

34. 33. The method of claim 32, including providing each carriage unit with quick connector type engagement structure or fastener-less fittings to facilitate efficient replacement of each pack on its corresponding carriage unit.

35. 33. The method of claim 32, further comprising providing a servo motor to control the acceleration of each carriage unit.

36. 33. The method of claim 32, further comprising providing a servo motor that controls the rotational speed and angular position of the rotating blade so that the rotating blade contacts the distal end of a corresponding anvil arm and cuts the continuous web of material disposed between the rotating blade and the distal end of the corresponding anvil arm.

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