Configurable single insert delivery and placement method and apparatus

Abstract

To provide a transfer apparatus (and an integrated cutting / transfer apparatus) configurable so as to accommodate cutting and transferring of articles of different types and sizes.SOLUTION: A cutting and transfer apparatus 10 comprises: a cutter mechanism 14 configured to cut a web; and a transfer mechanism 12 operable with the cutter mechanism 14 to transfer and rotate a plurality of discrete articles from one web receiving location to an article placement location. The transfer mechanism comprises: a drive shaft rotatable about a transfer axis; a carriage plate mounted to the drive shaft so as to rotate therewith about the transfer axis; and a puck wheel comprising a plurality of carriage units 28, which is fixable to the carriage plate so as to rotate therewith to travel along a transfer path about the transfer axis from the web receiving location to the pad placement location.SELECTED DRAWING: Figure 1

Description

[Background technology]

[0001] Embodiments of the present invention relate to methods and apparatus for receiving a continuous web, cutting and conveying articles or inserts, such as absorbent pads, cut from the web for advancement along a production line in the manufacture of disposable absorbent articles, such as diapers, incontinence control garments or feminine hygiene products, etc. More particularly, embodiments of the present invention relate to such methods and apparatus that provide for the coordination of operation of the methods and apparatus in an efficient manner and thus are configurable to accommodate the cutting and conveying of different types and sizes of articles.

[0002] In the production and manufacturing of disposable products such as sanitary napkins and pant diapers, it is often necessary to produce a component of a product in one direction and then spin the component to a predetermined angle that is the appropriate orientation for use in another step of the production process. As an example, a typical article or web that is reoriented is an absorbent pad. Existing equipment functions to receive a continuous web on a transport mechanism, then cut the web into separate pads, form the pads by cutting pieces from the web, spin the pads to a predetermined angle, and transport the pads for placement on a receiving surface. Furthermore, the equipment can also function to control the speed and pitch between the cut pads to achieve a desired placement pitch on the receiving surface. In the case of a diaper, for example, the pads may be absorbent inserts that are placed on a fluid-impermeable chassis. Thus, the web may be cut with a cutting pitch X, and the receiving pitch, i.e., the distance between successive chassis on the receiving surface, may be represented as Y, where Y is composed of the chassis trailing edge, the spacing space, and the subsequent chassis leading edge.

[0003] With respect to the transport apparatus used to rotate and re-pitch the pads onto the receiving surface, the transport apparatus is generally configured with a large wheel having a number of rotating pucks fixed thereto that are selectively operable to provide rotation and re-pitch of the pads. The wheels are driven and supported by a shaft extending from the drive side of the machine, and the pucks rotate with the wheel. Additionally, each puck functions to spin / turn about its own spin axis to effect a turn (e.g., a 90 degree turn) of the pad.

[0004] While existing transports adequately rotate and re-pitch pads and position them on receiving surfaces, it has been recognized that existing transports have several limitations or shortcomings. Primarily, existing transports are considered to be "non-configurable" in that the number of packs provided on the system is fixed, i.e., the inability to selectively add / remove packs to accommodate different process flows and / or product types. Thus, it is necessary to replace the entire transport to achieve a different process flow or to accommodate a different product type that requires a transport with a different number of packs than the currently used transport. Such replacement of the transport is a difficult process since the transport is a heavy (i.e., several thousand pounds) unit that requires specialized equipment to move and can also be a time consuming process that increases equipment downtime.

[0005] It is therefore desirable to provide a conveying apparatus (and overall cutting / conveying apparatus) that is configurable to accommodate the cutting and conveying of different types and sizes of articles. Such an apparatus / system would provide for selective addition / removal of packs as well as anvil and knife configurations for cutting the continuous web into separate articles / pads to be conveyed onto the conveying apparatus. Summary of the Invention [Means for solving the problem]

[0006] In accordance with one aspect of the invention, a configurable cutting and conveying apparatus includes a cutter mechanism configured to cut an incoming web of material into a plurality of separate articles and a conveying mechanism operable with the cutter mechanism to convey and rotate the plurality of separate 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 carriage plate attached to the drive shaft and rotating with the drive shaft about the conveying axis, and a segmented puck wheel including a plurality of carriage units fixable relative to and repositionable thereon for rotation with the carriage plate 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 selectively operable to provide rotation and re-pitch of the articles between the web receiving location and the pad placement location.

[0007] In accordance with another aspect of the invention, a method of configuring a configurable cutting and conveying apparatus includes providing a cutter mechanism configured to cut an incoming web of material into a plurality of separate articles, and providing a conveying mechanism operable with the cutter mechanism to convey and rotate the plurality of separate articles from at least one web receiving location to an article placement location. Providing the conveying mechanism further includes providing a drive shaft having a carriage plate mounted thereon, the drive shaft and carriage plate rotatable about a conveying axis, and a plurality of carriage units mounted on the carriage plate to form a segmented puck wheel, the plurality of carriage units rotatable with the carriage plate to move along a conveying path about the conveying axis from at least its web receiving location to a pad placement location, each of the plurality of carriage units including a puck operable to effectuate rotation and re-pitch of the articles between the web receiving location and the pad placement location. The configuration of the carriage plate and the plurality of carriage units allows the plurality of carriage units to be mounted on the carriage plate in a plurality of configurations and in various numbers to provide a configurable cutting and conveying apparatus.

[0008] 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]

[0009] The drawings illustrate embodiments presently contemplated for carrying out the invention.

[0010] In the drawings:

[0011] [Figure 1] FIG. 1 illustrates a front perspective view of a configurable cutting and conveying apparatus in accordance with one embodiment of the present invention.

[0012] [Diagram 2] FIG. 2 is a front view of the device of FIG.

[0013] [Diagram 3] 2 is a right side cross-sectional view of the device of FIG. 1 taken along line 1-1.

[0014] [Figure 4] 2 is a perspective view of a transport mechanism included in the apparatus of FIG. 1 according to one embodiment of the present invention.

[0015] [Diagram 5] 4A is a right-side cross-sectional view of the transport mechanism of FIG. 4 taken along line 4-4.

[0016] [Figure 6] FIG. 5 is a perspective view of the transport mechanism of FIG. 4 with the face cam plate and some carriage units removed.

[0017] [Figure 7] 2 is a front perspective view of a carriage unit included in the apparatus of FIG. 1 according to one embodiment of the present invention.

[0018] [Figure 8] FIG. 8 is a rear perspective view of the carriage unit of FIG. 7.

[0019] [Figure 9] 7A is a right-side cross-sectional view of the carriage unit of FIG. 7 taken along line 7-7.

[0020] [Figure 10] FIG. 8 is a front perspective view of the carriage unit of FIG. 7 with the puck mounted on its puck support.

[0021] [Figure 11] FIG. 11 is a bottom perspective view of the pack of FIG. 10 according to one embodiment of the present invention.

[0022] [Figure 12] FIG. 1 illustrates a front view of a configurable cutting and transporting device with a transport mechanism containing eight pucks, according to one embodiment of the present invention.

[0023] [Figure 13] FIG. 1 illustrates a front view of a configurable cutting and transporting device with a transport mechanism containing 14 pucks, according to one embodiment of the present invention.

[0024] [Figure 14] FIG. 2 is a front schematic diagram of a first preferred speed profile of a configurable cutting and conveying device in accordance with an embodiment of the present invention.

[0025] [Figure 15] FIG. 15 is a graphical representation of the preferred velocity profile of FIG.

[0026] [Figure 16] FIG. 15 is a schematic elevational view of the changing puck position relative to the main axis of rotation, with the puck following the velocity profile of FIG.

[0027] [Figure 17] FIG. 2 is a simplified front view of a configurable cutting and conveying apparatus in a first position, according to one embodiment of the present invention.

[0028] [Figure 18] FIG. 18 is a front view of the device of FIG. 17 in a second position, with some details omitted to better illustrate its functionality.

[0029] [Figure 19] FIG. 18 is a front view of the device of FIG. 17 in a third position, with some details omitted to better illustrate its functionality.

[0030] [Figure 20] FIG. 18 is a front view of the device of FIG. 17 in a fourth position, with some details omitted to better illustrate its functionality.

[0031] [Figure 21] FIG. 18 is a front view of the device of FIG. 17 in a fifth position, with some details omitted to better illustrate its functionality.

[0032] [Figure 22] FIG. 18 is a front view of the device of FIG. 17 in a sixth position, with some details omitted to better illustrate its functionality.

[0033] [Diagram 23] FIG. 18 is a front view of the device of FIG. 17 in a seventh position, with some details omitted to better illustrate the functionality.

[0034] [Figure 24] FIG. 18 is a front view of the device of FIG. 17 in an eighth position, with some details omitted to better illustrate its functionality. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention is directed to configurable cutting and conveying apparatus and methods of their operation and assembly. The disclosure herein is detailed and precise to enable one skilled in the art to practice the invention, however, the physical embodiments disclosed herein are merely illustrative 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.

[0036] 1-3, there are shown a front perspective view, a front elevation view, and a right side cross-sectional view, respectively, of a configurable cutting and conveying apparatus 10 (or "apparatus 10") according to one exemplary embodiment of the present invention. Apparatus 10 preferably includes a conveying mechanism 12 and a cutter mechanism 14, each of which may be mounted to a base frame 16 via respective floor plates 18, 20, with conveying mechanism 12 mounted to plate 18 and cutter mechanism 14 mounted to plate 20. Base frame 16 includes a pair of rails 22 upon which floor plates 18, 20 are mounted, and in a preferred embodiment, one or more of floor plates 18, 20 may be linearly translated along rails 22 in the direction 24 to effect movement of conveying mechanism 12 and / or cutter mechanism 14 along rails 22. As described in more detail below, if it is desired to reconfigure the cutting and conveying apparatus 10 to perform a different process flow and / or to accommodate a different product type, the cutter mechanism 14 and / or conveying mechanism 12 may be moved along rails 22 of the frame 16, thereby spacing the mechanisms apart to facilitate access to the components of the apparatus 10 from an operator side 26 of the apparatus (opposite the drive side 27) and to permit selective removal and addition of components to reconfigure the apparatus 10.

[0037] 1-3, the transport mechanism 12 includes a plurality of carriage units 28 that are selectively addable and removable from the transport mechanism 12, each carriage unit 28 including a puck 30 that can be engaged and disengaged from a puck support 32 of the carriage unit 28. The carriage units 28 couple to a carriage plate 34 of the transport mechanism 12 and collectively form a segmented puck wheel 35, the term "segmented" being understood to refer to the fact that the puck wheel 35 is not a unitary member, but is formed from a plurality of individual / modular carriage units 28 that can be selectively added and removed from the carriage plate 34 to form the puck wheel 35 in a desired configuration. The carriage plate 34 is fixedly coupled to a motor drive shaft 36 that provides a substantially operationally constant rotational force to the carriage plate 34, and a motor (not shown) driving the shaft 36 also drives all other motion within the apparatus 10 (i.e., all movers within the transport mechanism 12 and cutter mechanism 14). Thus, carriage plate 34, along with its attached carriage units 28 and pucks 30 on puck wheels 35, are rotated about a primary axis of rotation, puck transport axis 37, to move the pucks around a transport path 38. As used throughout the description of the preferred embodiment, "rotate" and variants thereof refer to the movement of the entire pucks 30 (and carriage units 28) about transport axis 37, and "spin" and variants thereof refer to the radial spinning of pucks 30 about pack spin axis 40, which is substantially perpendicular to puck transport axis 37.

[0038] The cutter mechanism 14 preferably includes an anvil wheel 42 (or "anvil ring") and a knife roll 44, which interact with each other to cut separate pads or inserts from the continuous web provided to the cutting and conveying apparatus 10. The anvil wheel 42 includes a plurality of anvils 46 arranged radially about an anvil wheel axis 48, while the knife roll 44 includes one or more knife blades 50 thereon. According to one embodiment, the anvils 46 include carbide inserts held in place by wedge blocks 52 (secured by socket head bolts). To ensure that the knife blades 50 will successfully cut on the anvils 46 of the anvil wheel 42, the anvils 46 must be equal in height. Although the cutter mechanism 14 is described herein as including an anvil wheel 42 and a knife roll 44, it is recognized that these components may be reversed where a knife wheel and anvil roll are used as compared to the illustrated embodiment. The operation of the knife wheel and anvil roll will be substantially similar to the operation of the anvil wheel 42 and knife roll 44 described herein below.

[0039] Each of the anvil wheel 42 and knife roll 44 are coupled to respective drive shafts 54, 56 which cause them to rotate. In operation, the apparatus 10 receives a continuous web 146 from a source and the web is brought into contact with the packs 30. One of the anvils 46 then rotates and aligns with and cooperates (i.e., contacts) with the knife blade 50 to cut the web adjacent the leading edge of the packs 30. Once the web 146 has been received and cut adjacent the leading edge, the packs 30 advance along the transport path 38 and past the knife roll 44 as the next anvil 46 on the anvil wheel 42 rotates into cooperation with the knife blade 50 and cuts the web adjacent the trailing edge of the packs 30 to cut a segment from the web that includes the insert or pad. As will be described in more detail below, the segment is held to the packs 30 by a vacuum and rotated about the transport path 38.

[0040] In one exemplary embodiment, the anvil wheel 42 preferably includes fewer anvils 46 than there are pucks 30 on the transport mechanism 12. Having fewer anvils 46 allows for a larger offset 58 between the anvil wheel axis 48 and the puck transport axis 37. The eccentric offset 58 effectively withdraws the anvils 46, allowing for greater spacing to achieve the desired pitch change between the pucks 30.

[0041] 1-3 and now also referring to FIGS. 4-6, the transport mechanism 12 is shown in greater detail for purposes of better explaining its structure and operation. As noted above, the transport mechanism 12 includes a carriage plate 34 fixedly coupled to and driven by a drive shaft 36 for rotation about a puck transport axis 37. The carriage plate 34 is disposed on the operator side of a fixed base plate 60 and provides a surface for coupling the carriage unit 28 thereto. According to one embodiment, the carriage plate 34 includes fastener holes 62 formed therethrough for fastening the carriage plate 34 to the shaft 36 and fastener holes 64 formed therethrough for coupling the carriage unit 28 thereto, the fastener holes 64 being arranged as two concentric rings / circles on the carriage plate 34. The number / arrangement of the fastening holes 64 is such that it is recognized that the carriage plate 34 can accommodate any of a number of different carriage units 28 thereon, at different positions and different spacing, and that each carriage unit 28 included in the transport mechanism 12 will be secured to the carriage plate 34 via at least four fasteners.

[0042] When mounting the carriage units 28 to the carriage plate 34, the mounting block 66 of each carriage unit 28 is placed on the carriage plate 34 such that the fastening holes 68 of the mounting block 66 are aligned with the fastening holes 64 on the carriage plate 34. Fasteners are then inserted through the fastening holes 68 of the mounting block 66 and the fastening holes 64 of the carriage plate 34 to secure the carriage unit 28 to the carriage plate 34. It is recognized that depending on the number of carriage units 28 mounted on the carriage plate 34, as shown in this embodiment in which eleven carriage units 28 are included in the transport mechanism 12 as an example, gaps 70 may exist between adjacent carriage units 28. These gaps 70 between adjacent carriage units 28 may be left open or may be filled with spacers (not shown) that fit into the gaps 70 and are secured to the carriage plate 34 according to one embodiment.

[0043] To facilitate repositioning of the pucks 30, the transport mechanism 12 also includes a face cam plate 72 located about the transport axis 37 and disposed on the operator side 26 of the carriage plate 34. The face cam plate 72 is disposed a distance away from the carriage plate 34 to allow for attachment of the carriage unit 28 to the carriage plate 34. The face cam plate 72 is preferably a fixed plate having a pitch cam race 74 therein or thereon, the pitch cam race 74 being formed on the side of the face cam plate 72 facing the drive side 27. The face cam plate 72 assists in changing the pitch, i.e., changing the circumferential spacing, of the pucks 30. Although various designs may be used, if the pitch cam race 74 is located further away from the puck transport axis 37, the speed of the pucks 30 will be greater than if the pitch cam race 74 is disposed closer to the transport axis 37. Thus, as described in this preferred embodiment, the maximum pitch change is generally determined by the shape of the pitch cam race 74. The pitch change is accomplished by the use of a pitch cam follower 76 on each carriage unit 28, which is preferably a roller bearing in sliding or rolling communication with the pitch cam race 74. Located preferably near the radially distal edge of each carriage unit 28 is a pair of pitch rails 78 secured to the mounting block 66 which permit controlled circumferential displacement of the puck 30. The puck support 32 is provided with rail guides 80 which are slidably disposed on the pair of pitch rails 78.

[0044] To facilitate the spinning or turning of the pucks 30, the transport mechanism 12 also includes a barrel cam 82 located about the transport axis 37 and disposed on the drive side of the base plate 60. The barrel cam 82 is preferably a stationary ring-shaped member having a spin cam race 84 disposed about its outer edge / surface. A spin cam follower 86 of the carriage unit 28, preferably a roller bearing, is in sliding or rolling communication with the spin cam race 84 to achieve the desired spinning of the pucks 30. In one embodiment, the spin cam race 84 is configured to provide a 90 degree puck rotation, although it will be appreciated that the configuration of the spin cam race 84 will generally be determined by the angle of desired spin of the pucks 30.

[0045] 4-6 and now also referring to FIGS. 7-10, the carriage unit 28 is shown in more detail for the purpose of better explaining its structure and operation. As mentioned above, the carriage unit 28 includes a mounting block 66 and a puck support 32 disposed on the mounting block 66. The mounting block 66 includes fastener holes 68 formed generally in its bottom for fastening the carriage unit 28 to the carriage plate 34. A pair of pitch rails 78 are fastened to the top surface of the mounting block 66 (i.e., the surface that is radially outward when bolted to the carriage plate 34) via rail fasteners 88, the pitch rails 78 running parallel to the machine direction 89 in which the transport mechanism 12 rotates. The pitch rails 78 have a generally arcuate shape that mirrors the shape of the top surface of the mounting block 66 such that a generally circular outline is formed by the top surface of the mounting block 66 when the plurality of carriage units 28 are fastened about the carriage plate 34.

[0046] As best seen in Figures 7 and 8, the puck support 32 is secured to the mounting block 66 via an engagement between the rail guides 80 of the puck support 32 and the pitch rails 78. The puck support 32 is oriented generally perpendicular to the pitch rails 78, with a puck mount 90 provided at one end of the puck support 32 (i.e., the operator side 26 of the apparatus 10) and an idler pulley or sprocket 92 provided at the opposite end of the puck support 32 and attached to an idler shaft 94. The rail guides 80 are slidably disposed on the pair of pitch rails 78 such that the puck support 32 translates thereon in a direction parallel to the machine direction 89 in which the transport mechanism 12 rotates, thereby allowing the position / velocity of the puck support 32 (and pucks 30) to be altered relative to the puck supports 32 of the other carriage units 28. The pack support 32 further includes a take-up frame 96 that extends outwardly from an area adjacent the rail guide 80 to the idler pulley 92, with a belt 98 disposed beneath the take-up frame 96. The belt 98 extends generally the length of the pack support 32 from the idler pulley 92 to a pack side pulley 100 (FIG. 9) disposed beneath the pack mount 90 on a pad turner shaft 102. The belt 98 is driven by its interaction with a spin cam follower 86 contained within a spin cam follower holder 104 (FIG. 9) disposed beneath the take-up frame 96. As the spin cam follower 86 interacts with and rotates within the spin cam race 84, the rotation of the spin cam follower 86 is imparted to the belt 98, which in turn causes rotation of the pack side pulley 100 and pad turner shaft 102, which in turn causes rotation of the pack mount 90 and the packs 30 attached to the pack mount 90.

[0047] Carriage unit 28 also includes a three-way linkage system 106 that functions to transfer the tracking of pitch cam follower 76 to carriage module 28 (i.e., puck support 32 and puck 30), and a puck holder plate 108 that helps secure the three-way linkage system 106 to puck support 32. As shown in FIGS. 7-10 , the three-way linkage system 106 includes a triangular shaped link member 110 having a number of openings 111 therein that receive pitch cam follower 76 and pivot shaft 112 therein, as well as a pin 114 that secures a connecting link 116 of the three-way linkage system 106 to link member 110. The pitch cam follower 76 is secured within one opening 111 in a link member 110, and the pivot shaft 112 extends through another opening 111 into a receptacle 118 formed in the bottom of the mounting block 66, allowing rotation / pivot of the link member 110 relative to the mounting block 66. The connecting link 116 is secured at one end to the link member 110 via a pin 114 and at its other end to a puck holder plate 108 which in turn is secured to one of the rail guides 80. In operation, translation of the pitch cam follower 76 within the pitch cam race 74 causes rotation of the link member 110 about the pivot shaft 112 which in turn imparts movement / rotation to the connecting link 116 and causes the rail guide 80 of the puck support 32 to translate along the pitch rail 78. Thus, movement of the pack support 32 and associated packs 30 is generated in the machine direction 89 at a controlled speed so that the distance between the pack 30 and the packs 30 of adjacent carriage units 28 increases / decreases.

[0048] The carriage unit 28 also includes several components that allow for the transfer of vacuum from a vacuum source (not shown) of the apparatus 10 to the puck 30. As shown in FIGS. 8 and 9, a vacuum plate 120 is secured to the rear surface of the mounting block 66 in an area above the fastening holes 68. The vacuum plate 120 includes one or more openings 122 formed therein that provide air passages to and from the puck support 32 and allow for the transfer of vacuum to the puck 30. When the mounting block 66 is secured to the carriage plate 34, the openings 122 are aligned with openings 124 in the base plate 60 (FIG. 6) such that the vacuum source is fluidly connected to the carriage unit 28. The openings 122 in the vacuum plate 120 are fluidly connected with vacuum passages 126 formed in the puck support 32 that extend through the puck support 32 to the puck mount 90 such that vacuum can be exchanged therethrough. Vacuum is drawn through vacuum passages 126 and is divided into multiple vacuum zones 127 on the pack 30 (FIG. 10), and the orientation of the pack 30 relative to these various zones 127 controls whether the pack 30 is picked up or transported (i.e., enables / disables the vacuum through the pack 30). According to one embodiment, each vacuum pack 30 has four vacuum zones 127 to help hold the pads / inserts during pick-up and transport. As the pack 30 rotates, the front and rear vacuum zones 127 change. The pack rotates 90 degrees after pick-up and then drops the pads / inserts onto a receiving surface (not shown), such as a vacuum transport roll.

[0049] 11, the underside of pack 30 is shown in greater detail for purposes of better illustrating its attachment to the pack mount 90 of carriage unit 28. The underside of pack 30 includes an upper assembly 128 and a pack connector 130. Each of upper assembly 128 and pack connector 130 includes an arrangement of openings 132 therein that provide for vacuum to be transmitted through pack support 32 to pack 30, the transmission of vacuum from pack support 32 to pack 30 as described above. Pack connector 130 is configured to engage with pack mount 90 according to a "quick connector" type engagement, e.g., a "tow receiver" type engagement. In the illustrated example, a flange 134 on the puck connector 130 slidingly engages a lip recess 136 (FIGS. 7 and 8) on the puck mount 90 to secure the puck 30 to the puck support 32 with a slot 137 formed in the flange 134 that engages a protrusion 139 on the puck mount 90 and a tab 141 on the puck mount 90 that allows the puck connector 130 to be snapped in place (FIGS. 7 and 8). The structure of the puck connector 130 and its mating with the puck mount 90 allows pucks 30 to be easily swapped and replaced on the carriage unit 28 based on the particular configuration of the transport mechanism 12. Different sized pucks 30 can be coupled to the carriage unit 28 to accommodate the cutting and transport of different types and sizes of articles.

[0050] 11, one or more shim spacers 138 may be positioned between the upper assembly 128 and the pack connector 130 to selectively adjust the height at which the pack 30 extends from the pack support 32, thereby increasing the vertical positioning or offset of the pack 30 relative to the transport axis 37. That is, it is recognized that in the interaction of the transport mechanism 12 with a receiving surface 140 (e.g., a vacuum transport roll as shown in FIG. 17, etc.) on which the rotated pad / insert is disposed, it is desirable for there to be a suitable spacing or gap between the pack 30 and the receiving surface 140 in the drop position where the pad / insert is disposed from the pack 30 and onto the receiving surface 140 such that the receiving surface 140 is sufficiently close to the articles being carried by the pack 30 so that the vacuum on the receiving surface 140 can attract the articles to the receiving surface 140. To control the size of this gap, shim spacers 138 having a desired thickness may be placed between the upper assembly 128 and the pack connector 130, for example, 0.005 inch (0.127 mm), 0.010 inch (0.256 mm), 0.015 inch (0.381 mm), 0.020 inch (0.508 mm), and 0.025 inch (0.635 mm) shim spacers 138 can be used to selectively control the size of the gap. It is also recognized that multiple shim spacers 138 can be stacked between the upper assembly 128 and the pack connector 130 to set the precise transport gap as needed.

[0051] 1-11, a process for reconfiguring the cutting and conveying apparatus 10 in accordance with an embodiment of the present invention will now be described below. With respect to the process described below, it will be recognized that when reconfiguring the cutting and conveying apparatus 10, only some of the described steps may need to be performed, and the exact process performed will be determined by revised new process flows and / or new product types / sizes to be processed by the cutting and conveying apparatus 10. Thus, it will be understood that the process described below is intended to be an exemplary process only, and that embodiments of the present invention are not limited to only the described process.

[0052] If it is desired to reconfigure the cutting and conveying apparatus 10 to implement a different process flow and / or to accommodate different product types / sizes, the various components of the cutting and conveying apparatus 10 can be replaced and / or rearranged. As a first step in such a process, the cutter mechanism 14 can be moved away from the conveying mechanism 12 to provide easier access to the components of each mechanism from the operator side of the apparatus 10. In moving the cutter mechanism 14, the plate 20 to which the cutter mechanism 14 is attached slides along rails 22 in direction 24 to move the cutter mechanism 14 away from the conveying mechanism 12.

[0053] In the next step of the reconfiguration process, the anvil wheel 42 can be removed from the drive shaft 36 to which it is attached and replaced with an anvil wheel 42 of a different configuration. That is, anvil wheels 42 having a different number of anvils 46 thereon can be substituted in the apparatus 10 based on any planned configuration changes made to the transport mechanism 12 (i.e., adding / removing carriage units 28 / packs). It is recognized that in order to maximize access to the apparatus, it may be desirable to use anvil wheels 42 having the smallest diameter and minimum number of anvils 46 suitable for use with the configured apparatus 10, and anvil wheels 42 are envisioned as being utilized with the apparatus 10 having 3-up, 4-up, 5-up, 6-up, or 7-up anvil counts, although it is recognized that other configurations / counts may be used.

[0054] It is recognized that during reconfiguration, repositioning of the anvil wheel 42 in the machine direction 89 may be required to accommodate the change in size of the anvil wheel 42 when replacing it with the desired anvil wheel 42. That is, the new anvil wheel 42 mounted on the drive shaft 54 ​​may have a different diameter compared to the removed anvil wheel 42, such that the anvil wheel 42 may no longer be spaced from the knife roll 44 the proper distance that would provide for severing of the fed web. Thus, as part of the reconfiguration, the anvil wheel 42 and the drive shaft 54 ​​to which it is mounted may be translated in the machine direction 89 along a track 142 provided on an anvil wheel stand 144 ( FIG. 1 ) on which the drive shaft of the anvil wheel 42 is mounted. By translating the anvil wheel 42 and the drive shaft 54 ​​along the track 142 the desired amount in the desired direction, the newly installed anvil wheel 42 is properly positioned relative to the knife roll 44 so that their interaction can sever the web during operation of the apparatus 10.

[0055] The reconfiguration process may continue with the removal of face cam plate 72 from transport mechanism 12. Face cam plate 72 is removed from its position on drive shaft 36 to allow replacement with a face cam plate 72 having a different configuration and / or to provide access to carriage unit 28 of transport mechanism 12. According to one embodiment, face cam plate 72 is removed and replaced with a face cam plate 72 having a different size / configuration of pitch cam race 74 to allow for different speed and pitch control of pucks 30 of carriage unit 28.

[0056] With the face cam plate 72 removed, an operator can access the carriage units 28 of the transport mechanism 12, which are attached to the carriage plate 34 via a number of fasteners. Then, in reconfiguring the transport mechanism 12, the operator can add or subtract carriage units 28 to the carriage plate 34 as desired to provide the desired number of carriage units 28 (and pucks 30). It is recognized that depending on the number of carriage units 28 attached to the carriage plate 34, gaps 70 may exist between adjacent carriage units 28. These gaps 70 between adjacent carriage units 28 may be left open or, according to one embodiment, may be filled with spacers (not shown) that fit into the gaps and are secured to the carriage plate 34. 12 and 13 show two cutting and transporting apparatus 10 where the transport mechanism 12 includes different numbers of carriage units 28, i.e., eight carriage units 28 in the transport mechanism 12 (FIG. 12) and fourteen carriage units 28 in the transport mechanism 12 (FIG. 13). The number of carriage units 28 mounted on the carriage plate 34 is determined by the cutting and transporting process performed by the apparatus 10 and is based, at least in part, on the type / size of inserts to be cut and transported on the apparatus 10.

[0057] In addition to controlling the number of carriage units 28 included in the transport mechanism 12 when performing a reconfiguration, it is recognized that the individual pucks 30 included on the carriage units 28 may also be replaced during the reconfiguration. The pucks 30 are configured to include puck connectors 130 that slidably engage the puck mounts 90 to secure the pucks 30 to the puck supports 32 of the carriage units 28. The structure of the puck connectors 130 and their mating with the puck mounts 90 allow the pucks 30 to be easily replaced and exchanged on the carriage units 28 based on the particular configuration of the transport mechanism 12. Different sized pucks 30 may be coupled to the carriage units 28 to accommodate the cutting and transport of different types and sizes of articles.

[0058] Once the cutting and conveying apparatus 10 has been reconfigured and its individual components interchanged as desired, the apparatus can be reassembled and the cutter mechanism 14 moved back into alignment with the conveying mechanism 12. Thus, the apparatus 10 can be reconfigured to process different types / sizes of products as compared to the conventional configuration, and the reconfiguration is performed without the need to replace the entire conveying apparatus 12 and / or its individual heavy components (i.e., base plate 60, barrel cam 82, etc.) or without the need to use specialized equipment. Thus, the reconfiguration can be performed in a fast and efficient manner such that downtime of the cutting and conveying apparatus 10 is minimized.

[0059] 14-24, the operation of the configurable cutting and conveying apparatus 10 will be described in more detail for purposes of better illustrating embodiments of the present invention. While the apparatus is shown with a conveying mechanism 12 including an arrangement of nine pucks 30 thereon, it will be appreciated that the operation of the apparatus will be the same with more or fewer pucks 30. Additionally, while the operation of the apparatus 10 will be described with a single puck 30a and a single anvil 46a, it will be appreciated that the operation of the remaining pucks 30 and anvil 46 will be at least substantially similar. Additionally, while the operation is described in FIGS. 17-24 with reference to separate puck positions, it will be appreciated that the operation is preferably generally continuous. The separate positions aid in the explanation of the operations being performed.

[0060] Referring initially to Figures 14 and 15, and also to Figures 17-24, exemplary pack velocity profiles are shown as each pack 30 rotates through various portions of its transport path 38. The pack transport mechanism 12 rotates about the pack transport axis 37 at a relatively constant speed VS. As the pack 30 receives the continuous web material 146, the pack 30 may move at a substantially constant first speed V1. A pad 148 is then cut from the continuous web 146. To create the pad 148, a first cut 150 is made proximate the pack leading edge 152 and a second cut 154 is made proximate the pack trailing edge 156. Immediately after the pad 148 is cut from the web material 146, the pack 30 may be accelerated 158 to avoid collision with a subsequent adjacent pack 30, and then decelerated 160 back to a substantially constant speed 162, which may be the first speed V1. After the trailing edge cut 154, the puck 30 is spun to the desired angle and the speed of the puck 30 is changed 164 to achieve the desired predetermined circumferential spacing before placing 168 the pad 148 on the receiving surface 140. Upon or after reaching a substantially constant 166 second speed V2, the pad 148 is placed 168 on the receiving surface 140. After pad placement 168, the puck 30 is decelerated 170 to a substantially constant 172 first speed V1 and spun back to the web receiving orientation. The process then begins anew.

[0061] During periods of acceleration and deceleration, the puck 30 changes position relative to the puck transport axis 37, which is the primary axis of rotation. This is best seen with reference to FIG. 16. A first reference point 174 represents a point on the shaft 36 (FIG. 1) that spins about the puck transport axis 37 at a relatively constant speed VS during operation of the transport mechanism 12. A second reference point 176 represents the position of the puck 30. The shaft reference 174 may rotate at a constant speed about the puck transport axis 37, but the position of the puck reference 176 relative to the shaft 36 may be changed by any desired amount, such as an increase of 10 degrees or more of rotation during acceleration, or a decrease of 10 degrees or more of rotation during deceleration. Illustratively, the shaft reference 174 is generally radially aligned with the puck reference 176 during the cuts 150, 154. At the end 160 of the first acceleration, the puck reference 176 has changed position by a first distance 178 relative to the shaft reference 174. At the end of the first deceleration period 162, the datums 174, 176 are again aligned. Prior to pad placement 168, the puck 30 is accelerated again and at the end of the second acceleration 166, the puck datum 176 has advanced past the shaft datum 174 by a second distance 180. The first distance 178 may be the same or different from the second distance 180. Finally, at the end of the second deceleration period 172, both datums 174, 176 are aligned and ready for the next rotation.

[0062] 17 shows a representative pack 30a at a first position P1. At the first position P1, the pack 30a receives a continuous web material 146 moving in a first direction 182 at a first speed. A vacuum is drawn through the carriage unit 28 (through the mounting block 66, the pack support 32, and the pack 30a) to support the web material 146 on the surface of the pack 30a. While receiving the web 146, the pack 30a moves about the pack transport axis 37 in a second direction 89 (i.e., the machine direction) to which the first direction 182 is preferably substantially tangent at this point P1. The pack 30a continues to move in the second direction 89 until it reaches a second position P2.

[0063] Figure 18 shows pack 30a in a second position P2, where pack 30a is at the leading edge cut 150 of Figure 14. Here, knife blade 50 of knife roll 44 cooperates with representative anvil 46a of anvil wheel 42 to sever web 146 adjacent leading edge 152 of pack 30a. After receiving web 146 and making a cut adjacent leading edge 152, pack 30a continues past knife roll 44 in second direction 89 to a third position P3.

[0064] Figure 19 shows pack 30a in a third position P3, where pack 30a is at trailing edge cut 154 of Figure 6. At this position P3, knife blade 50 of knife roll 44 cooperates with anvil 46 to cut web 146 adjacent trailing edge 156 of pack 30a, cutting segment 148a from web 146. Segment 148a is held to pack 30a by the pre-drawn vacuum. After the cut is made adjacent trailing edge 304a, pack 30a continues in second direction 89 to reach fourth position P4.

[0065] FIG 20 shows the puck 30a in the fourth position P4. As previously mentioned, it is often desirable to spin the cut pieces 148a to some predetermined angle before placement on the receiving surface 140. Here, the puck 30a is shown in the midst of spinning. Although FIG 20 shows the puck 30a rotating in the fourth position P4, the puck 30a can be rotated to any desired angle in the third direction 184 at any time after the trailing edge is cut at the third position P3 and before placement on the receiving surface 140.

[0066] In addition to rotating and spinning the pucks 30, the apparatus 10 can also vary the circumferential spacing of the pucks 30a, resulting in a placement pitch that is different from the pitch at which the web material 146 was cut. The eccentricity of the puck transport axis 37 and the anvil wheel axis 48 allows the pucks 30a to fall away from the anvil wheel 42, which provides a greater angular motion capability than if the anvil 46 remained between successive pucks 30. The final circumferential spacing of the pucks 30 at the receiving surface 140 is a function of the desired placement pitch 186 and the speed at which the receiving surface 140 moves. In a preferred embodiment, the circumferential spacing is achieved by the configuration of the desired pitch cam race 74. Although the terms "circumferential" and "rotational" are used herein to describe the transport motion of the pucks 30, it should be understood that the invention is not limited to applications utilizing circular motion, and the transport path 38 of the pucks 30 can be defined, for example, by the shape of the cam plate used, or by the path of any supporting pitch rails used.

[0067] Upon achieving the desired circumferential spacing, the pack 30a reaches a fifth position P5, which is shown in FIG. 21 at the fifth position P5. At this position P5, the pack 30a is in the middle of the placement time 168 shown in FIG. 14. The pack 30a is positioned at a precise placement pitch or distance 186 relative to the pack 30 preceding it. At this pitch or distance 186, the piece 148a is transferred to the receiving surface 140. During placement, the vacuum drawn through the pack support 32 and the pack 30a can be removed from at least a portion of the pack 30a, thereby allowing the cut-out insert 148a to be smoothly transferred from the pack 30a to the receiving surface 140. After placing the piece 148a on the receiving surface 140, the pack 30a continues in the second direction 89 to reach a sixth position P6.

[0068] 22 shows the pack 30a in a sixth position P6. The pack 30a is shown with the cut out pieces 148a released onto the receiving surface 140. The pack 30a continues to move in the second direction 89 until it reaches a seventh position.

[0069] FIG 23 shows the pack 30a in a seventh position P7. If the pack 30a and pad 148a are rotated to an angle after cutting and then placed on the receiving surface 140, it may be necessary to adjust the pack 30a to a web-receiving orientation. Although FIG 23 shows the pack 30a spinning in the seventh position P7, the pack 30a can be spun in a fourth direction 188 at any time after the pieces 148a are placed on the receiving surface 140 and before the continuous web 146 is received. The fourth direction 188 can be the same as or different from the third direction 184.

[0070] Finally, the pack 30a is shown in an eighth position P8 in FIG. 24. The eighth position P8 is substantially similar to the first position P1, except that the anvil 46a has advanced a number of positions forward of the pack 30a. The number of positions advanced is a function of the difference between the number of packs 30 and the number of anvils 46. In this working example, there are nine packs 30 and eight anvils 46. Thus, in the eighth position P8, the anvil 46a is one position ahead of its position in the first position P1.

[0071] It will be appreciated that the operation of the configurable cutting and conveying apparatus 10 shown and described above in Figures 14-24, including the depicted puck velocity profiles, is for illustrative purposes only. That is, in accordance with additional embodiments of the invention, the rotation of the pucks about the conveying path may follow different suitable velocity profiles and / or the spin of the pucks may differ from that described, and such embodiments will be appreciated to be within the scope of the invention.

[0072] Advantageously, therefore, embodiments of the present invention provide a configurable cutting and conveying apparatus and methods of configuring and operating such an apparatus, providing for adjustments during operation of the apparatus to accommodate cutting and conveying of various types and sizes of articles. The apparatus provides for selective addition / removal of carriage units and associated pucks from the conveying mechanism, as well as replacement of pucks on each carriage unit. Additionally, the anvil wheels and knives of the cutting mechanism can be configured and positioned in a selected manner to accommodate any changes in the conveying mechanism, thereby achieving cutting of the continuous web into separate articles / pads to be conveyed onto the conveying apparatus. Such reconfiguration of the cutting and conveying apparatus can be accomplished without the use of specialized equipment, and can be performed in a fast and efficient manner that minimizes downtime of the cutting and conveying apparatus.

[0073] Thus, in accordance with one embodiment of the present invention, a configurable cutting and conveying apparatus includes a cutter mechanism configured to cut an incoming web of material into a plurality of separate articles, and a conveying mechanism operable with the cutter mechanism to convey and rotate the plurality of separate 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 carriage plate attached to the drive shaft and rotating with the drive shaft about the conveying axis, and a segmented puck wheel including a plurality of carriage units fixable relative to and repositionable thereon for rotation with the carriage plate 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 selectively operable to provide rotation and re-pitch of the articles between the web receiving location and the pad placement location.

[0074] According to another embodiment of the present invention, a method of configuring a configurable cutting and conveying apparatus includes providing a cutter mechanism configured to cut an incoming web of material into a plurality of separate articles, and providing a conveying mechanism operable with the cutter mechanism to convey and rotate the plurality of separate articles from at least one web receiving location to an article placement location. Providing the conveying mechanism further includes providing a drive shaft having a carriage plate mounted thereon, the drive shaft and carriage plate rotatable about a conveying axis, and a plurality of carriage units mounted on the carriage plate to form a segmented puck wheel, the plurality of carriage units rotatable with the carriage plate to move along the conveying path about the conveying axis from at least its web receiving location to a pad placement location, each of the plurality of carriage units including a puck operable to effectuate rotation and re-pitch of the articles between the web receiving location and the pad placement location. The configuration of the carriage plate and the plurality of carriage units allows the plurality of carriage units to be mounted on the carriage plate in a plurality of configurations and in various numbers to provide a configurable cutting and conveying apparatus.

[0075] 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 configurable cutting and conveying device (10), comprising: a cutter mechanism (14) configured to cut the incoming web of material into a plurality of separate articles; a transport mechanism (12) operable with the cutter mechanism (14) to transport and rotate the plurality of separate articles from at least one web receiving location to an article placement location, the transport mechanism (12) comprising: a drive shaft (36) rotatable about a conveying axis (37); a carriage plate (34) attached to the drive shaft (36) and rotating together with the drive shaft (36) about the conveying axis (37); a segmented puck wheel (35) including a plurality of carriage units (28) fixable relative to and repositionable on said carriage plate (34) for rotation therewith for movement along a transport path about said transport axis (37) at least from said web receiving position to a pad placement position, each of said plurality of carriage units (28) including a puck (30) selectively operable to provide rotation and re-pitch of said article between said web receiving position and said pad placement position; Equipped with The conveying mechanism (12) a face cam plate (72) stationarily positioned about said conveying axis (37), disposed on a side of said segmented pack wheel (35), facing said carriage plate (34), and having a pitch cam race (74) therein on its side facing said segmented pack wheel (35); a barrel cam (82) stationarily positioned about said conveying axis (37), disposed on a side of said carriage plate (34), facing said segmented pack wheel (35), and having a spin cam race (84) therein at its periphery; Each of the plurality of carriage units (28) a pitch cam follower (76) in sliding or rolling communication with the pitch cam race (74) for varying the positioning of the puck (30) relative to the segmented puck wheel (35) along at least a portion of the transport path; and a spin cam follower (86) in sliding or rolling communication with the spin cam race (84) for spinning the pucks (30) at least partially about a spin axis of each puck (30) that is at least substantially perpendicular to the conveying axis (37).

2. Each of the plurality of carriage units (28) a mounting block (66) fixed to the carriage plate (34) and having a pair of pitch rails (78) fixed thereto and oriented parallel to the direction of the transport path; a pack support (32) disposed on the mounting block (66), the pack support (32) being movable relative to the mounting block (66) via engagement between a rail guide (80) of the pack support (32) and the pitch rail (78), the pack support (32) being oriented generally perpendicular to the pitch rail (78) and having a pack mount (90) at one end thereof configured to receive the pack (30); and a linkage system (106) operatively coupled to the puck support (32) and the pitch cam follower (76) to transfer motion of the pitch cam follower (76) to the puck support (32) and cause motion of the puck support (32) along the pitch rail (78) to vary circumferential displacement of the puck relative to the carriage unit (28) along at least a portion of the transport path.

3. 3. The apparatus (10) of claim 2, wherein the carriage plate (34) includes a plurality of mounting holes (62, 64) arranged as two concentric circles on the carriage plate (34), and wherein a mounting block (66) of each carriage unit (28) has fastener holes (68) arranged to align with several of the mounting holes (62, 64) on the carriage plate (34) to provide positioning of fasteners passing through the carriage plate (34) to secure the carriage unit (28) to the carriage plate (34) in a desired position.

4. The puck support (32) in each of the plurality of carriage units (28) a spin cam follower holder (104) configured to receive a portion of the spin cam follower (86) therein; a belt (98) operatively coupled to the puck support (32) and the spin cam follower (86) for transferring motion from the spin cam follower (86) to the puck mount (90) to cause the puck (30) mounted to the puck mount (90) to spin about the spin axis.

5. The transport mechanism (12) includes a base plate (60) disposed around the carriage plate (34) and connected to the barrel cam (82); The carriage unit (28) a vacuum plate (120) disposed between a portion of the mounting block (66) and the base plate (60), the vacuum plate (120) having one or more openings (122) formed therein providing an air passageway into and out of the puck support (32); a vacuum channel (126) formed in the puck support (32) providing a fluid passageway from the opening (122) in the vacuum plate to the puck mount (90) and the puck (30) mounted thereon.

6. 6. The apparatus (10) of claim 5, wherein the vacuum channel (126) is fluidly connected to a plurality of vacuum zones (127) on the puck (30), and wherein orientation of the puck (30) about the spin axis controls fluid communication between the vacuum channel (126) and the plurality of vacuum zones (127) to enable selective pick-up and transport of respective articles into and out of the puck (30).

7. 2. The apparatus (10) of claim 1, wherein the puck (30) of each carriage unit (28) includes a puck connector (130) connectable to the puck mount (90), the puck connector (130) including a quick connect connector configured to secure the puck (30) to the puck mount (90).

8. 8. The apparatus (10) of claim 7, further comprising one or more shim spacers (138) disposed on the puck connector (130), the one or more shim spacers (138) increasing a height that the puck (30) extends from the puck support (32).

9. The cutter mechanism (14) a first cutter component (42) located mostly within said transport path; and a second cutter component (44) a majority of which is located outside of the conveying path, the second cutter component (44) adapted to cooperate periodically with the first cutter component (42) to form a cutting nip.

10. the first cutter component (42) includes an anvil wheel (42) having a plurality of anvils (46) circumferentially spaced about an anvil wheel axis, the anvil wheel (42) being driven by a drive shaft (54) to rotate about the anvil wheel axis; 10. The apparatus (10) of claim 9, wherein the second cutter component (44) includes a knife roll (44) having one or more knives (50) thereon, the one or more knives (50) cooperating cyclically with the anvil (46) to form the cutting nip.

11. 11. The apparatus (10) of claim 10, wherein the anvil wheel (42) and drive shaft (54) are mounted to an anvil wheel stand (144), the anvil wheel stand (144) including a track (142) along which the anvil wheel (42) and drive shaft (54) can translate to vary the distance between the anvil wheel (42) and knife roll (44).

12. 2. The apparatus (10) of claim 1, further comprising a base frame (16) on which each of the cutter mechanism (14) and the transport mechanism (12) is mounted, the base frame (16) having a pair of rails (22) along which at least one of the cutter mechanism (14) and the transport mechanism (12) is movable to increase the distance between the cutter mechanism (14) and the transport mechanism (12).

13. A method for configuring a configurable cutting and conveying device (10), the method comprising: providing a cutter mechanism (14) configured to cut an incoming web of material into a plurality of separate articles; providing a transport mechanism (12) operable with said cutter mechanism (14) to transport and rotate said plurality of separate articles from at least one web receiving location to an article placement location; The step of providing a transport mechanism (12) comprises: providing a drive shaft (36) with a carriage plate (34) mounted thereon, said drive shaft (36) and carriage plate (34) being rotatable about a conveying axis (37); mounting a plurality of carriage units (28) to said carriage plate (34), said plurality of carriage units (28) rotatable with said carriage plate (34) for movement along a transport path about said transport axis (37) at least from said web receiving position to a pad placement position, each of said plurality of carriage units (28) comprising a puck (30) operable to effect rotation and re-pitch of said article between said web receiving position and said pad placement position; the configuration of the carriage plate (34) and the plurality of carriage units (28) allows for mounting of the plurality of carriage units (28) in a plurality of configurations and varying numbers on the carriage plate (34) to provide a configurable cutting and conveying apparatus (10); The step of providing a transport mechanism (12) comprises: providing a face cam plate (72) stationarily positioned about said conveying axis (37), disposed on a side of said segmented pack wheel (35), facing said carriage plate (34), and having a pitch cam race (74) therein on its side facing said segmented pack wheel (35); providing a barrel cam (82) stationarily positioned about said conveying axis (37), disposed on a side of said carriage plate (34), facing said segmented pack wheel (35), and having a spin cam race (84) therein at its periphery; operatively connecting a pitch cam follower (76) of each of the plurality of carriage units (28) to the pitch cam race (74) to permit alteration of positioning of the puck (30) relative to the segmented puck wheel (35) along at least a portion of the transport path; operatively connecting a spin cam follower (86) of each of the plurality of carriage units (28) to the spin cam race (84) to enable spinning of the pucks (30) at least partially about a respective spin axis of the pucks (30) that is substantially perpendicular to at least the transport axis (37).

14. 14. The method of claim 13, wherein mounting the plurality of carriage units to the carriage plate includes aligning fastener holes in each of the plurality of carriage units with fastener holes in the carriage plate to receive fasteners passing through the carriage plate to mount the plurality of carriage units to the carriage plate, the fastener holes on the carriage plate being arranged as two concentric circles on the carriage plate.

15. In providing the rotation and re-pitch of the articles between the web receiving position and the pad placement position for the pucks (30) of each carriage unit (28), the method further comprises: operatively connecting the pitch cam follower (76) to a pack support (32) on which the packs (30) are mounted to transmit motion of the pitch cam follower (76) to the pack support (32) to thereby vary circumferential displacement of the packs (30) relative to the carriage unit (28) along at least a portion of the transport path; and operatively connecting the spin cam follower (86) to the puck support (32) to transmit motion of the spin cam follower (86) to the puck (30) mounted to the puck mount (90) to spin the puck (30) about the spin axis.

16. Operable connection of the pitch cam follower (76) to the puck support (32) providing a pair of pitch rails (78) in said carriage unit (28) oriented parallel to the direction of said transport path; slidingly connecting the pack support (32) to the pair of pitch rails (78) via rail guides (80) on the pack support (32); 16. The method of claim 15, comprising operably connecting the puck support (32) to the pitch cam follower (76) via a linkage system (106) of the carriage unit such that motion of the pitch cam follower (76) is transmitted to the puck support (32) via the linkage system (106) to cause motion of the puck support (32) along the pitch rail (78) to alter circumferential displacement of the puck (30) relative to the carriage unit.

17. 16. The method of claim 15, wherein operatively connecting the spin cam follower to the puck support includes operatively connecting the spin cam follower to a belt of the puck support, the belt transmitting motion from the spin cam follower to a puck mount of the puck support to which the puck is mounted to cause the puck mounted to spin about the spin axis.

18. 14. The method of claim 13, further comprising coupling the pucks (30) of each carriage unit (28) to a puck support (32) of the carriage unit (28), the pucks (30) being attached to a puck mount (90) of the puck connector (130) via a quick connect connection.

19. 17. The method of claim 16, further comprising providing one or more shim spacers (138) to the puck (30) to increase the height that the puck (30) extends from a puck support (32).

Images