Feeder module for processing machines

Abstract

The present invention relates to a feeder module (10) including a loading surface (26) configured to receive a stack (S) of blanks (2). The feeder module (10) includes an upper feeder assembly (22) and a lower feeder assembly (24). The upper feeder assembly (22) includes a recessed chain (44) provided with a plurality of teeth (52), the teeth (52) configured to enter into the stack (S) between the blanks (2).

Description

[Technical Field]

[0001] The present invention relates to a processing machine for producing packaging items such as paperboard boxes and cardboard boxes. In particular, the present invention relates to a feeder module configured to discharge sheets or blanks one by one into the processing machine. [Background Art]

[0002] Processing machines such as gluers folders are used for producing packaging items such as paperboard boxes and cardboard boxes. These machines are configured to receive sheets or cut and formed blanks, and then fold and bond them to form folded boxes or other similar packaging containers.

[0003] The feeder module is arranged at the inlet of the processing machine. The feeder module includes a loading surface configured to receive a stack of sheets or cut and formed blanks. The feeder module further includes a gauge and a discharge conveyor, and the discharge conveyor is configured to drive the blank positioned at the bottom of the stack through a clearance defined between the gauge and the discharge conveyor.

[0004] In order to provide correct discharge of sheets, there is a need to ensure that blanks are guided under the gauge. The blank needs to be pressed against the discharge conveyor to establish sufficient contact, but excessive pressure may cause deformation marks on the blank. The height and therefore the weight of the stack change during production, that is, cause different contact pressures between the discharge conveyor and the blank. [Prior Art Literature] [Patent Literature]

[0005] [Patent Literature 1] European Patent Application Publication No. 4157625 [Summary of the Invention] [Problem to be Solved by the Invention]

[0006] The objective of this invention is to ensure proper adhesion between the blank and the feeder discharge conveyor. [Means for solving the problem]

[0007] This objective is achieved by the feeder module described in claim 1.

[0008] According to an aspect of the present invention, a feeder module for a processing machine is provided. The feeder module includes an upper feeder assembly and a lower feeder assembly, the lower feeder assembly including a loading surface configured to receive a stack of blanks and a discharge conveyor configured to grip a blank positioned at the bottom of the stack and transport it forward in the transport direction.

[0009] The upper feeder assembly includes at least one gauge configured to abut against the front of the stack, with the tip of at least one gauge positioned at a distance from the discharge conveyor that determines the clearance for the blank positioned at the bottom.

[0010] The upper feeder assembly further includes a recessed chain with multiple teeth, the teeth configured to fit into a stack between blanks.

[0011] This invention is based on the understanding that the weight of a stack can be kept constant when the weight of the upper portion of the stack is supported by protruding surfaces such as the teeth of a chain. In this way, friction can be kept constant and calibrated without damaging the blank.

[0012] In the context of this application, the term "blank" may refer to both cut and shaped blanks and sheets. Sheets may have a rectangular or square shape.

[0013] In this embodiment, the teeth include an upper contact surface configured to abut against the bottom surface of the blank. In this way, the weight of the blank positioned in the upper portion of the stack above the teeth can be supported.

[0014] In this embodiment, the upper contact surface of the tooth is inclined downward in the vertical direction.

[0015] In this embodiment, the tooth includes an upper contact surface, a lower contact surface, and a apex, the contact surface being defined from the valley to the apex, the upper contact surface being longer than the lower contact surface, and thereby the upper contact surface being inclined downward in the vertical direction.

[0016] In the embodiment, the lower contact surface has an extension that coincides with the extension of the upper surface of the blank. Preferably, the lower contact surface has a horizontal extension.

[0017] In this embodiment, the teeth include a lower contact surface configured to abut against the upper surface of the blank and apply a downward force to the blank.

[0018] In this embodiment, the recessed chain is a loop including an exposed portion and a return portion, and the recessed chain is positioned such that only the exposed portion is in contact with the blank.

[0019] The gauge may have an opening through which the exposed portion of the recessed chain extends horizontally.

[0020] In this embodiment, the opening is located above the inclined or rounded entrance portion of the gauge.

[0021] In this embodiment, the recessed chain includes an internal engagement surface, which is in contact with a plurality of free-spinning rollers and electrically driven rollers.

[0022] In an embodiment, at least one idler roller is configured as a diverting roller, which is configured to position the recessed chain so as to form a horizontal protrusion on the exposed portion of the recessed chain. Preferably, the protruding portion protrudes horizontally through the opening of the gauge.

[0023] In an embodiment, the plurality of teeth are in contact with the blank, and the tooth positioned at the lowermost position of the exposed portion has a shorter horizontal extension than the upper teeth positioned on the exposed portion.

[0024] In an embodiment, the recessed chain is made of a flexible material such that it forms a flexible loop. The material may comprise polymer, thermoplastic polyurethane, or rubber. In a preferred embodiment, the recessed chain is made in one piece. In other words, the recessed chain is not provided with mechanical connectors such as fasteners and links.

[0025] The present invention will now be described below with reference to the accompanying drawings, in which like reference numerals refer to like features. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] [Figure 1] It is a schematic diagram of a processing machine in a configuration of a folder gluer. [Figure 2a] It is a top view of a blank. [Figure 2b] It is a top view of a folded box. [Figure 3] It is a schematic cross-sectional view of a feeder module according to an embodiment of the present invention. [Figure 4] It is a schematic perspective view of an upper feeder assembly according to an embodiment of the present invention. [Figure 5] It is a schematic cross-sectional view of an upper feeder assembly and a stack of blanks. [Figure 6a] It is a schematic cross-sectional view of a recessed feeder chain according to an embodiment of the present invention. [Figure 6b] It is a detailed plan view of the tooth structure of the feeder chain of Fig. 6a. [Figure 6c] Figure 6a is a detailed schematic perspective view of the feeder chain. [Figure 7a] This is a schematic perspective view of the feeder chain assembly from the first side. [Figure 7b] This is a schematic perspective view of the feeder chain assembly from the second side. [Modes for carrying out the invention]

[0027] Refer to the figures, in particular Figure 1 showing a processing machine 1 in the form of a folder-gluer machine 1, and Figures 2a and 2b showing a blank 2 and a folded box 2' to be processed by the processing machine 1. The folder-gluer machine 1 is configured to receive a cut and formed blank 2, such as the one shown in Figure 2b, and then fold and glue the blank 2 to form a folded box 2' or another folded and glued packaging container 2'. Alternatively, the processing machine 1 may be provided with a cutting and paper folding module, so that the processing machine 1 itself is transformed into a blank cut from a square or rectangular sheet. Such a cutting and paper folding arrangement is described in European Patent Application Publication No. 4157625.

[0028] The folding-bonding machine 1 of the present invention comprises a series of different workstations in the form of modules. The modules may include a feeder module 10, an alignment module 11, a folding pre-breaking module 12, an bonding module 14, and a folding module 16, from the entrance to the exit of the processing machine 1 and in the transport direction T. The folding-bonding machine 1 may further include a main user interface 15 and a quality control system 18.

[0029] After the bonding and folding modules, a dispensing module and adjustment section 21 can be provided to count the duplicate streams of the folding boxes 2' and separate them into separate batches.

[0030] The processing machine 1 further includes a transport system 19, which includes a conveyor such as an infinite belt and rollers configured to transport the blank 2 in the transport direction T. The processing machine 1 also includes a central control circuit 20 configured to control the operation of the processing machine 1.

[0031] The feeder module 10 is configured to feed the blanks 2 one by one into the processing machine 1. As shown in Figure 3, the feeder module 10 includes an upper feeder assembly 22 and a lower feeder assembly 24, between which the blanks 2 are transported.

[0032] The lower feeder assembly 24 includes a loading surface 26 configured to receive a stack S of blanks 2. The loading surface 26 is provided with a discharge conveyor 28 configured to drive the blanks 2, positioned at the bottom of the stack S, forward in the transport direction T. The discharge conveyor 28 preferably includes a plurality of conveyor belts positioned side by side, with their longitudinal extensions aligned with the transport direction T. Alternatively, in embodiments not shown, the discharge conveyor 28 may include drive elements in the form of rollers or a single discharge conveyor.

[0033] In another embodiment not shown, the loading surface 26 may further include a movable support surface comprising several elongated rods positioned between several conveyor belts. The movable support surface moves up and down such that a blank 2 positioned at the bottom is brought into contact with several discharge conveyor belts alternately, and then moved away from them.

[0034] The upper feeder assembly 22 includes a front stopper 30 in the form of at least one gauge 30, preferably the front stopper includes two gauges 30a, 30b. The discharge conveyor 28 is positioned at a distance C (see Figure 5) from the vertical tip 32 of at least one gauge 30a, 30b. Thus, distance C defines the clearance C through which a blank 2 positioned at the bottom of the stack S passes. The clearance C is a distance less than the sum of the heights of the two blanks 2 in the vertical direction V. However, preferably, the clearance C corresponds to the height of one blank 2 in the vertical direction V. The clearance C ensures that only one blank 2 can be transported into the processing machine 1 at a time. The gauges 30 can be slidably connected to the chassis 34 of the upper feeder assembly 22 so that the vertical position of the tip 32 of at least one gauge 30a, 30b can be adjusted by moving at least one gauge 30a, 30b in the vertical direction V. In this way, clearance C can be corrected when the vertical thickness of blank 2 changes.

[0035] The discharge conveyor 28 of the lower feeder assembly 24 can extend from the loading surface 26 to the outlet 27 of the feeder module located downstream of the gauge 30. The discharge conveyor 28 is preferably accelerated and decelerated. In this way, the blanks 2 are discharged in a stream with predetermined spacing between them.

[0036] As best seen in Figures 3 and 5, the gauge 30 is configured to abut against the front of the stack S to restrict the horizontal movement of the upper blank 2 of the stack. Preferably, the upper portion of the gauge 30 is provided with a vertical contact surface. In this way, the upper portion of the stack S is maintained vertically.

[0037] An inclined portion 33 can be provided at the lower distal end of the gauge 30, i.e., the tip 32. The inclined portion 33 is positioned at an angle α with respect to the vertical axis V. The angle α is configured to define a surface that is inclined downward in the conveying direction T.

[0038] The inclined portion 33 allows the bottom-positioned blank 2 to be positioned further downstream in the transport direction T than subsequent blanks 2 positioned above the bottom-positioned blank 2. Optionally, the inclined portion 33 of the gauge 30 may also be rounded. The rounded portion 33 smoothly guides the leading edge of the blank 2 below the front stopper 30.

[0039] As can be seen best in Figures 3 and 4, the upper feeder assembly 22 includes an upper conveyor 36 configured to contact the upper side of the blank 2. In this way, the vertical position of the blank 2 can be controlled. The blank 2 is received between the upper feeder assembly 22 and the lower feeder assembly 24 and guided so that they are fed into the processing machine 1 in a straight line without warping.

[0040] The upper conveyor 36 may include a plurality of rollers 38. Springs 42 act on the rollers to bias them against the blank 2. Actuators 43 are operatively connected to the rollers 38 and are configured to provide variable force so that the pressure on the rollers 38 can be modified. Actuators 43 may be pneumatic or hydraulic actuators.

[0041] The upper feeder assembly 22 further includes a recessed chain 44. The recessed chain 44 is a loop containing a number of teeth 52. The teeth 52 are configured to fit into a stack S between the blanks 2.

[0042] As is best seen in Figure 6b, the tooth 52 is defined by a vertex 55, an upper contact surface 54, and a lower contact surface 56. Each tooth is defined by a vertex 55 located between two valleys 57.

[0043] The recessed chain 44 can have a zigzag shape. In a preferred embodiment, each tooth 52 is asymmetrical around a center line Lc passing through the vertex 55. The length L1 of the upper contact surface 54 is longer than the length L2 of the lower contact surface 56. The difference in length between L1 and L2 provides a distorted zigzag shape.

[0044] The interpeak distance P1 between directly adjacent tooth vertices 55 can be selected to correspond to the thickness of a single blank 2. In this embodiment, there is one sheet 2 between each tooth 52.

[0045] However, in a preferred embodiment, the inter-peak distance P1 between adjacent vertices 55 is selected to exceed the maximum thickness of one blank 2. This is advantageous when the same grooved chain 44 is used for different types of blanks 2 having varying thicknesses. The teeth 52 of the chain can be introduced between each blank 2 in the stack. Alternatively, for thinner blanks 2, there are several blanks 2 present between adjacent vertices 55 of the grooved chain 44. In a preferred embodiment, the inter-peak distance is between 5 and 15 mm, preferably about 11 mm. To increase the inter-peak distance P1, there may be a flat distance 53 between each valley 57 of adjacent teeth 52. The valley distance may be between 0 and 10 mm, preferably about 5 mm.

[0046] The upper contact surface 54 of the tooth 52 is configured to contact the lower side of the blank 2. As is best seen in Figures 5, 7a and 7b, the recessed chain 44 has an exposed portion E that contacts the blank 2. Preferably, the exposed portion E is located at the entrance portion I of the gauge 30.

[0047] In this way, the upper portion S1 of the stack, positioned above the teeth 52 of the exposed portion E, is held by the recessed chain 44. The recessed chain 44 is configured to at least partially support the weight of the upper portion S1 of the stack S.

[0048] In addition, the lower contact surface 56 of the teeth 52 can be configured to grip the front edge of the blank 2 and guide them vertically downward relative to the lower discharge conveyor 28.

[0049] The lower contact surface 56 of each tooth 52 is preferably designed to have an extension that coincides with the upper surface of the blank 2. This extension preferably coincides with the horizontal direction H. In this way, the tooth 52 is provided with a flat surface that presses against the blank 2, thus avoiding the risk of cut marks. Preferably, the lower contact surface has a length between 3 and 8 mm, preferably about 4 to 5 mm.

[0050] Optionally, the weight of the lower portion of the stack S2 can be used to generate passive pressure, and the pressure applied by the recessed chain 44 can be reduced while still obtaining a calibrated contact pressure between the blank 2 positioned at the bottom and the discharge conveyor 28.

[0051] The exposed portion E includes multiple teeth 52 that contact the blank 2 simultaneously. Thus, the recessed chain 2 contacts multiple blanks 2. In the illustrated embodiment, there are three teeth 52 protruding into the stack S. However, the number of teeth 52 that engage with the blank 2 simultaneously can be variable.

[0052] At least one of the gauges 30a, 30b may be provided with an opening 46 through which the exposed portion E of the recessed chain 44 extends. The opening 46 is preferably located above the entrance portion I of the gauge 30. Ideally, the lower portion 46a of the opening 46 is positioned between 50 and 80 mm, preferably about 65 mm, from the tip 33 of the gauge 30. This allows for precise transport of the blanks 2 as they are positioned in the entrance path to the clearance C. Each tooth 52 may have a lateral length between 30% and 50% of the width of the gauge. This lateral length may be between 10 mm and 20 mm.

[0053] Alternatively, in an embodiment not shown, the feeder chain 44 is positioned laterally to the gauge 30. The recessed chain 44 can be attached to another frame member.

[0054] The recessed chain 44 also preferably applies a force F to the blank 2 such that the contact pressure between the bottom-positioned blank 2 and the loading surface 26 is sufficient for the lower release conveyor 28 to grip the bottom-positioned blank 2 and drive it forward in the conveying direction. The force F may be in the range of 20 to 180 Newtons.

[0055] The recessed chain 44 can be configured to support the weight of the upper part S1 of the stack while applying pressure to the lower part S2 of the stack.

[0056] Due to the trajectory of the recessed chain 44, the lowest positioned tooth 52 has a higher inclination angle than the uppermost positioned tooth 52. In addition, the lowest positioned tooth 52 in contact with the blank 2 has a smaller horizontal projection P than the tooth 52 positioned vertically above and in contact with the blank 2. The difference in horizontal projection P is achieved using the trajectory of the recessed chain 44. In this way, the blank 2 can be released from the upper contact surface 54 of the tooth 52 and positioned below the lower contact surface 56 of the tooth 52.

[0057] The recessed chain 44 has a contact side 47a and an electrically engaged side 47b. The electrically engaged side 47b is positioned inside the loop defined by the recessed chain 44. The contact side 47a contacts the blank 2 of the stack S. The recessed chain 44 has a direction of movement M such that the teeth 52 move vertically downward within the exposed portion E.

[0058] As shown in Figures 7a and 7b, the recessed chain 44 is guided by a series of free-spinning recessed rollers 48 and electrically driven rollers 50. The electrically driven rollers 50 are driven to rotate by a motor 51. The motor 51 can be configured to vary its torque so that the pressing force F on the blank 2 can be modified. In this way, the force can be adapted to the material and shape of the blank 2. The free-spinning rollers 48 and the driven rollers 50 are provided with gears configured to engage with corresponding internal recessed engagement surfaces 47 on the recessed chain 44.

[0059] At least one free-running roller 48a is configured as a switching roller 48a. The switching roller 48a is positioned outside of an axis A defined by a straight line extending from the center of the drive roller to the center of the free-running roller 48b positioned distally at the bottom. The switching roller 48a changes the direction of the recessed chain 44 to produce a protruding portion P that projects horizontally from the opening 31 of the gauge 30.

[0060] The axis B of the exposed portion E can be determined by a line extending through the rotation axis of the switching roller 48a and the free-spinning roller 48b positioned at the bottom.

[0061] The axis of the exposed portion E can be adjusted horizontally to change the position of the length of the horizontal projection P. This allows for adaptation of the position of the teeth 52 and adaptation to the properties of materials such as cardboard and paperboard.

[0062] The recessed chain 44 can be manufactured as a single piece without any joints. In a preferred embodiment, the recessed chain 44 is made from a flexible material. The material may include polymers such as thermoplastic polyurethane and rubber.

[0063] The manufacturing process for recessed chains may involve molding or sintering. However, it is advantageous to use additive manufacturing processes, i.e., 3D printing processes. [Explanation of symbols]

[0064] 10 Feeder Modules 22 Upper feeder assembly 24 Lower feeder assembly 26 Discharge conveyor 28 Loading surface T Conveying direction

Claims

1. Including an upper feeder assembly (22) and a lower feeder assembly (24), The lower feeder assembly includes a loading surface (26) configured to receive a stack (S) of blanks (2), and a discharge conveyor (28) configured to grip the blanks (2) positioned at the bottom of the stack and transport them forward in the transport direction (T). The upper feeder assembly includes at least one gauge (30) configured to abut against the front side of the stack, the tip (32) of the at least one gauge positioned at a distance from the discharge conveyor, the distance determining the clearance (C) for the blank. A feeder module (10) for a processing machine (1), The upper feeder assembly further includes a recessed chain (44) having a plurality of teeth (52), The teeth are configured to fit into the stack between the blanks. A feeder module characterized by the following features.

2. The feeder module according to claim 1, wherein the teeth include an upper contact surface (54) configured to contact the bottom surface of the blank.

3. The feeder module according to claim 1 or 2, wherein the teeth include a lower contact surface (56) configured to contact the upper surface of the blank and apply a downward force (F) to the blank.

4. The feeder module according to claim 2 or 3, wherein the upper contact surface of the tooth is inclined downward in the vertical direction (V).

5. The shape of the tooth includes an upper contact surface (54), a lower contact surface (56), and a vertex (55), and the contact surface is defined from the valley (57) to the vertex. The upper contact surface is longer than the lower contact surface. The feeder module according to claim 4.

6. The feeder module according to claim 5, wherein the lower contact surface has an extension that coincides with the extension of the upper surface of the blank.

7. The recessed chain is a loop including an exposed portion (E) and a return portion. The recessed chain is positioned such that only the exposed portion contacts the blank. A feeder module according to any one of claims 1 to 6.

8. The feeder module according to claim 7, wherein the gauge is provided with an opening (46) through which the exposed portion of the recessed chain extends horizontally.

9. The feeder module according to claim 8, wherein the opening is located above the inclined or rounded inlet portion (1) of the gauge.

10. The recessed chain includes an internal engaging surface, The engagement surface is in contact with a plurality of free-spinning rollers (48a, 48b) and an electric drive roller (50). The feeder module according to claim 9.

11. At least one free-spinning roller (48b) is configured as a switching roller (48b), The conversion roller is configured to position the recessed chain such that it generates a horizontal projection (P) on the exposed portion of the recessed chain. The feeder module according to claim 10.

12. The feeder module according to claim 11, wherein the horizontal projection protrudes through the opening (46) of the gauge.

13. Multiple teeth are in contact with the blank, The tooth positioned at the lowest part of the protruding portion has a horizontal extension that is shorter than the upper tooth positioned in the exposed portion (E). The feeder module according to claim 12.

14. The aforementioned recessed chain is made from a flexible material. The aforementioned recessed chain forms a flexible loop. A feeder module according to any one of claims 1 to 13.

15. The feeder module according to claim 14, wherein the flexible material comprises a polymer, thermoplastic polyurethane, or rubber.

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