Systems and methods for SKEW correction in manufactured components

Abstract

A correction system for a component on a conveyor belt includes a frame, a first wheel coupled to the frame and serving as a drive wheel, a second wheel coupled to the frame and serving as an idler wheel, and a belt wrapped around the first wheel and the second wheel, the belt moving at a first speed. The correction system further includes a compression roller coupled to the frame below the first wheel and the second wheel, and the compression roller is configured to tension the belt such that a gap is formed between the component and the belt. The first speed of the belt is greater than a second speed of the conveyor belt.

Description

SYSTEMS AND METHODS FOR SKEW CORRECTION IN MANUFACTUREDCOMPONENTSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No.63 / 607,214 filed on December 7, 2023, which application is incorporated herein by reference in its entirety.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

[0002] Not applicable.BACKGROUND

[0003] The present disclosure relates to skew correction in manufactured components. More specifically, the present disclosure relates to systems and methods of using speed correction to reduce skew angles in components provided along a manufacturing line.

[0004] Food containers, bags, single-use medical products, absorbent hygiene products, and other disposal products have become a ubiquitous part of our modem lives, which has been accompanied by an increase in the demand of such products in recent years. As a result, manufacturers of consumer products face growing pressure to increase the production quantity and efficiency while preserving or elevating product quality to maintain customer satisfaction. Failure to comply with growing market pressure can result in missed opportunities and loss of market share, as consumers are more likely to choose manufacturers who can provide the products they desire promptly than those who do not. Moreover, meeting consumer demand fosters brand loyalty and positive customer relationships, which in turn can lead to repeated business and word-of- mouth referrals. Thus, a deep understanding and commitment to fulfilling consumer demand is at the core of a successful and enduring manufacturing enterprise.

[0005] One facet of such an understanding is the consideration of how consumers respond to the form of a product. For example, proper arrangement of a finished product in packaging contributes to the aesthetic appeal and presentation of the product, as neatly folded or packaged items convey a sense of quality and professionalism. However, presentation and packaging ofproducts can also directly relate to product functionality and performance. In that regard, many products, including disposable products, rely on precise folding to function correctly. Misfolded items can lead to impaired functionality, reduced durability, and potential issues for end-users, e.g., consumers. For example, misfolded packaging might not provide the necessary protection for its contents, and misfolded products may not fit properly within packaging. Further, proper folding is often a critical quality criterion, and deviations from folding standards can result in rejected or reworked products, increasing production costs and wastage.

[0006] Production costs may also be increased where products are misfolded along assembly line manufacturing processes. To that end, properly folded products are easier to handle, stack, and transport, which streamlines the production process. Misfolded items can disrupt the assembly line and result in delays, increased labor costs, and reduced overall productivity.

[0007] Because of these problems, efforts to limit misfolding of mass-produced products have been ongoing for several years. These efforts have taken various forms, including diverting misfolded products out of the main product flow, increased quality control checks, and more frequent employee training sessions. While such efforts offer some relief to the problems provided by misfolding, they can still impose significant costs to a manufacturer and increase production time. Specifically, such efforts can lead to greater labor costs, which in turn may deter a manufacturer from implementing them. As a result, there remains a need for systems and methods that can prevent products from being misfolded and / or correctly re-fold products along assembly line manufacturing processes to ensure product quality and customer satisfaction are maintained.

[0008] The current disclosure addresses these and other issues.BRIEF SUMMARY

[0009] In one aspect of the disclosure, a correction system for a component on a conveyor belt is provided. The correction system includes a frame, a first wheel coupled to the frame and serving as a drive wheel, and a second wheel coupled to the frame and serving as an idler wheel. The correction system further includes a belt wrapped around the first wheel and the second wheel, the belt moving at a first speed. The first speed of the belt differs from a second speed of the conveyor belt.

[0010] In some aspects, the first speed of the belt may be greater than the second speed of the conveyor belt. The correction system may further include a compression roller coupled to the frame between the first wheel and the second wheel, and a first distance between the compression roller and the conveyor belt is less than a second distance between the conveyor belt and the first wheel. The frame may be moveable in a y-direction to permit adjustment of the first distance between the compression roller and the conveyor belt. The compression roller may include an idler roller and / or a plurality of compression rollers. The plurality of compression rollers may be positioned adjacent one another in a machine direction defined by the conveyor belt. The belt may include a plurality of tubular belts positioned within grooves formed within the first wheel and the second wheel. The belt may be a flat belt.

[0011] In another aspect of the disclosure, a system for folding and correcting one or more components on a conveyor belt is provided. The system includes a first folding apparatus configured to impart at least one first fold in a first component, the at least one first fold aligned along a machine direction of the system defined by the conveyor belt. A first correction system is positioned downstream of the first folding apparatus in the machine direction. The first correction system includes a first frame, a first wheel coupled to the frame and serving as a first drive wheel, a second wheel coupled to the frame and serving as a first idler wheel, and a first belt wrapped around the first wheel and the second wheel. The first belt moves at a first speed, and the first speed of the first belt is different than a second speed of the conveyor belt.

[0012] In some aspects, the system may further include a compression roller coupled to the frame between the first wheel and the second wheel, the compression roller being positioned closer to the conveyor belt than the first wheel and the second wheel. The compression roller may include at least one idler roller and / or a plurality of compression rollers. The plurality of compression rollers may be positioned adjacent one another in a machine direction. The folding apparatus may include a plow folding unit. The system may further include a second folding apparatus positioned downstream from the first correction system and configured to impart at least one second fold in the first component, the at least one second fold aligned along the machine direction of the system. A second correction system can be positioned downstream of the second folding apparatus in the machine direction. The second correction system can include a second frame, a third wheel coupled to the second frame and serving as a second drive wheel, a fourth wheel coupled to the secondframe and serving as a second idler wheel, and a second belt wrapped around the third wheel and the fourth wheel. The second belt may move at a third speed, and the third speed of the second belt may be different than the second speed of the conveyor belt.

[0013] In other aspects, the system can further include a second folding apparatus aligned with the first folding apparatus in a cross-machine direction and configured to impart at least one second fold in a second component spaced at a distance from the first component in the cross-machine direction. A second correction system can be aligned with the first correction system in the crossmachine direction. The second correction system can include a second frame, a third wheel coupled to the second frame and serving as a second drive wheel, a fourth wheel coupled to the second frame and serving as a second idler wheel, and a second belt wrapped around the third wheel and the fourth wheel. The second belt may move at a third speed, and the third speed of the second belt may be different than the second speed of the conveyor belt.

[0014] In yet another aspect of the disclosure, a method of correcting a skewed component on a conveyor belt is provided. The method includes determining a skew angle in the skewed component, adjusting a speed of a belt on a correction system based on the determined skew angle, and passing the skewed component through the correction system such that the belt contacts and overspeeds a first portion of the skewed component relative to a second portion of the skewed component.

[0015] These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawingsBRIEF DESCRIPTION OF THE DRAWINGS

[0016] The features, aspects and advantages of the disclosure will become apparent when consideration is given to the following detailed description thereof. Such detailed description makes reference to the following drawings.

[0017] FIG. 1 is a schematic view of a system for correcting a skewed component using a skew correction station.

[0018] FIG. 2 is an isometric view of the skew correction station of the system of FIG. 1.

[0019] FIG. 3 is a side view of the skew correction station of FIG. 2.

[0020] FIG. 4 is a rear view of the skew correction station of FIG. 2.

[0021] FIG. 5 is a top view of the skew correction station of FIG. 2.

[0022] FIG. 6 is a cross-sectional view of the skew correction station of FIG. 2, taken through line VI- VI in FIG. 5.

[0023] FIG. 7 is top schematic view of the system of FIG. 1.

[0024] FIG. 8 is an isometric view of a support structure including one or more skew correction stations.

[0025] FIG. 9 is a rear view of the support structure of FIG. 8.

[0026] FIG. 10 is a bottom view of the support structure of FIG. 8.

[0027] FIG. 11 is a side view of the support structure of FIG. 8.

[0028] FIG. 12 is a schematic view of another skew correction process including the support structure of FIG. 8.

[0029] FIG. 13 is a schematic view of yet another skew correction process including multiple skew correction stations and folding stations.

[0030] FIG. 14 is a flow chart of a method of correcting a skewed component using a skew correction station.

[0031] The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals.DETAILED DESCRIPTION

[0032] As generally mentioned above, the present disclosure relates to systems and methods for skew correction in manufactured articles or components. In some examples, manufactured components can include non-disposable or disposable products such as, e.g., paper products, plastic products, medical products, hygiene products, outdoor products, sporting good products, etc. Such components may be mass-produced, e.g., along an assembly line, and manufacturers may desire that such components be uniformly produced to increase their aesthetic appeal and preserve their function. For example, manufactured components can be folded as they are processed along an assembly line so that the components can be packaged properly. In conventional folding processes, a component can be provided to a folding apparatus, e.g., a plow folding unit, along a conveyor belt. The speed and / or traction of the conveyor belt can direct the component throughthe folding apparatus before it exits the folding apparatus as at least a partially folded component. However, conventional folding processes are sensitive to minute variations in real-world conditions, such as, e.g., friction, irregular air flow, irregularly-shaped components, etc. Specifically, many conventional folding processes fail to consider the drag or skew imparted on a component when it is directed through a folding apparatus due to friction between the component and a contact surface of the folding apparatus. As a result, a portion of the component may be misfolded or skewed relative to another portion of the component, which in turn can result in a variety of undesirable consequences to manufacturers and a consumers, as discussed above.

[0033] The present disclosure can provide improvements upon conventional folding processes. In particular, the present disclosure relates to improved skew correction systems that are capable of automatically correcting misfolded or skewed components along a conveyer belt. Additionally, the present disclosure relates to systems and methods of overspeeding and / or underspeeding a misfolded or skewed component to reduce and / or eliminate a skew angle in the component. Further, the present disclosure relates to arrangements of improved skew correction systems along and / or around a conveyor belt, including arrangements of multiple skew correction systems along a single conveyor belt.

[0034] FIG. 1 depicts a non-limiting example of a system 100 for correcting a skewed article of manufacture, e.g., a machine or assembly line configured for the production of disposable components. The system 100 can include, by way of example, a conveyor belt 102 that transports an article or component 104 through the system 100 along a machine direction, a folding apparatus 106 configured to receive and fold the component 104, and a skew correction station 108, which is provided to receive the component 104 downstream of the folding apparatus 106 and correct skewed portions of the component 104. Each of these stages will be described more fully below.

[0035] Referring still to FIG. 1, as described above, a conveyor belt 102 is provided at the input of the system 100, and the conveyor belt 102 can be configured to transport the component 104 through the system 100. The component 104 can be made of, e.g., a woven material, a nonwoven material, paper, plastic, etc., as discussed above. Further, the component 104 can have any particular shape which can be designed to be folded along one or more fold lines. As a non-limiting example, the component 104 can include a first side 110 and a second side 112. In some aspects, the first side 110 and the second side 112 can by symmetrical about a fold line 114 of thecomponent 104, and the component 104 can be arranged on the conveyor belt 102 such that the fold line 114 is parallel with a direction in which the conveyor belt 102 is moving. In some aspects, the fold line 114 is parallel with a centerline 116 of the conveyor belt 102. Relatedly, the component 104 can be seated on the conveyor belt 102 without being directly fastened thereto, e.g., via friction or a vacuum system (not shown), or the component 104 can be directly coupled to the conveyor belt 102 via, e.g., adhesive or fasteners. In some aspects, only one side of the component, e.g., the first side 110, is coupled to the conveyor belt 102, meaning that the first side 110 of the component 104 can be held in place while the second side 112 of the component 104 can be moved or folded relative to the first side 110.

[0036] In this way, the component 104 can travel along the conveyor belt 102 at a first, fixed speed which is equal to the speed of the conveyor belt 102. In some aspects, the speed of the conveyor belt 102 can be controlled by an electronic controller 118 in accordance with a production demand and / or safety regulations of the system 100. The electronic controller can be, for example, a programmable logic controller (PLC), a computer, or an application specific device comprising a microprocessor, memory, and communication components, such as transceivers, wireless communication devices, etc. which can be configured to communicate via network communications, internet protocols, through cellular communications or other types of communications. The electronic controller 118 may be configured to control a plurality or all of the stages of system 100. Alternatively, a plurality of electronic controllers can be provided. For example, each station may include an electronic controller, which may be in communication with other electronic controllers in the system 100.

[0037] Referring still to FIG. 1, the component 104 can be provided to the folding apparatus 106 which can be configured to contact and fold the component 104. In some aspects, the folding apparatus 106 is a plow folding unit and includes one or more surfaces across which the component 104 is dragged to passively fold the component 104, e.g., to impart at least one fold on the component 104. For example, the folding apparatus 106 can include a folding surface 120 which curves upward from conveyor belt 102 and outward from the centerline 116 before curving back downward toward the conveyor belt 102 and inward toward the centerline 116. Folding apparatus 106 may alternatively take the form of any other known folding unit, such as a system including one or more folding rods, a compressed air system, or a system including one or more rotary orstationary folding blades. In some aspects, the conveyor belt 102 provides the component 104 to the folding apparatus 106, and the component 104 follows the curvature of the folding surface 120. In this way, the component 104 can be folded over itself as the component 104 exits the folding apparatus 106. For example, the second side 112 of the component 104 can contact the folding surface 120 of the folding apparatus 106 as the component 104 is transported by the conveyor belt 102, and the second side 112 can be folded upward before being folded over and onto the first side 110 along the fold line 114.

[0038] As discussed above, it is contemplated that real-world factors such as friction may impact folding of a component. Correspondingly, a skew may be imparted on a folded portion of a component, which can cause further issues downstream in the manufacturing process. It is contemplated that a component may be folded more than once along an assembly line, and that more than one skew angle may be present in a mis-folded component. In the non-limiting example illustrated in FIG. 1, a coefficient of friction may exist between the folding surface 120 of the folding apparatus 106 and the second side 112 of the component 104. As a result, the folding surface 120 may drag the second side 112 of the component 104 relative to the first side 110 of the component 104 such that a skew angle 122 can be formed between the sides 110, 112 after the component 104 exits the folding apparatus 106. In some aspects, the skew angle 122 is between about 0 degrees and about 60 degrees, or between about 0 degrees and about 30 degrees, or between about 10 degrees and about 20 degrees.

[0039] Still referring to FIG. 1, the conveyor belt 102 can provide the component 104 to the skew correction station 108 which can be configured to eliminate or reduce the skew angle 122 of the component 104. For example, the skew correction station 108 can include one or more belts 124 which are wrapped and / or rotated around one or more wheels 126 of the skew correction station 108. The wheels 126 may drive the belts 124 to rotate at a second speed that is different than the first speed of the conveyor belt 102. In some aspects, the second speed is variable, meaning that the second speed of the skew correction station 108, i.e., the belts 124, can be altered based on the skewed component 104. Put another way, the second speed of the skew correction station 108, can be oversped, i. e. , greater than the first speed of the conveyor belt 102, or the second speed of the skew correction station 108 can be undersped, i.e., less than the first speed of the conveyor belt 102. For example, the second speed of the skew correction station 108 can be between about50% and about 150% of the first speed of the conveyor belt 102, or between about 75% and about 125% of the first speed of the conveyor belt 102, or between about 75% and about 100% of the first speed of the conveyor belt 102, or between about 100% and about 125% of the first speed of the conveyor belt, or about 120% of the first speed of the conveyor belt.

[0040] In some aspects, the second speed of the skew correction station 108 can be determined based on a predetermined or known amount of skew present in a component, or the second speed of the skew correction station 108 can be adjusted for each component that is passed therethrough. Put another way, the second speed of the skew correction station 108 may be automatically adjusted based on skew data that is measured for each component. In some aspects, the skew correction station 108 is connected to an optical sensor (not shown), e.g., a photocell, a photo electric sensor, a photo eye, which is configured to detect the presence and magnitude of a skewed portion of a component on a conveyor belt. For example, the skew correction station 108 can be controlled by the electronic controller 118, and the electronic controller 118 can receive data about the skew of a component from the photo eye (not shown). Accordingly, in some examples, the electronic controller 118 can adjust, e.g., increase or decrease, the second speed of the skew correction station 108 based on the skew angles in each component that may be measured by a photo eye (not shown).

[0041] Thus, it will be understood that a speed differential is created between the skew correction station 108, i.e., the belts 124, and the conveyor belt 102, i.e., the component 104 disposed on the conveyor belt 102, to reduce or eliminate the skew in the component 104. In some aspects, the skew correction station 108 is elevated relative to the conveyor belt 102 such that a gap 128 exists therebetween. The conveyor belt 102 can transport the component 104 through the gap 128, meaning that the skew correction station 108 is located above the component 104. Specifically, the belts 124 can contact the component 104 as the component passes under the skew correction station 108. As discussed above, the belts 124 can move at a different speed and / or direction than the conveyor belt 102. Accordingly, it will be understood the portion of the component 104 that is contacting the belts 124 can move at a different speed relative to the portion of the component 104 that is disposed on the conveyor belt 102 due to friction between the component 104 and the belts 124. In this way, a skewed portion, e.g., the second side 112, of the component 104 can be oversped or undersped relative to another, non-skewed portion, e.g., thefirst side 110, of the component 104. As a result, the skewed portion can be pushed forward and aligned with the non-skewed portion, thereby correctly re-folding the component 104. System 100 may alternatively be configured with an inverted conveyor arrangement, in which case the skew correction station 108 would be located below the component 104.

[0042] For example, with continued reference to FIG. 1, a skew angle 122 may be formed between the first and second sides 110, 112 of the component 104 when the second side 112 is folded on top of the first side 110 along the fold line 114, e.g., via the folding apparatus 106. When the component 104 is provided through the gap 128, the belts 124 of the skew correction station 108 can contact the second side 112 without contacting the first side 110. Since the second side 112 is skewed at least partially behind the first side 110, the skew correction station 108 may be oversped relative to the conveyor belt 102, meaning that the first speed of the conveyor belt 102 can be less than the second speed of the skew correction station 108. Due to friction between the second side 112 of the component 104 and the belts 124, the belts 124 may overspeed the second side 112 relative to the first side 110, thereby pushing the second side 112 forward to reduce and / or eliminate the skew angle 122. After the component 104 exits the gap 128, / .<?., when the belts 124 stop contacting the second side 112 of the component 014, the speed of the second side 112 can return to the first speed of the conveyor belt 102. Thus, the component 104 can be re-folded to correct any skew present therein, and the component 104 can then be transported downstream in the system 100 along the conveyor belt 102 in a correctly folded arrangement 130. Accordingly, it is an advantage of the present disclosure that a skew correction station can be used to correct and / or re-fold a misfolded component provided along a conveyor belt, e.g., in an assembly line.

[0043] As discussed above, a skew correction station can be arranged as an assembly including a belts, rollers, wheels, fasteners, and / or other parts. Referring now to FIG. 2, the skew correction station 108 can include one or more belts 124, one or more wheels 126, one or more optional rollers 132, a frame 134, and a frame arm 136. In some aspects, the wheels 126, the rollers 132, and the frame arm 136 can be coupled to the frame 134. For example, the wheels 126 and the rollers 132 can be coupled to a first side 138 of the frame 134, and the frame arm 136 can be coupled to a second side 140 of the frame 134 that is opposite the first side 138. It is contemplated that the wheels 126, the rollers 132, the frame 134, and the frame arm 136 can be formedmonolithically, e.g., as a unitary construction, and that the same can generally be made of plastic or metal.

[0044] In addition, it is contemplated that the belts 124 can include any suitable number of belts, including between 1 and 10 belts. In the non-limiting example illustrated in FIG. 2, the skew correction station 108 can have six tubular belts 124, e.g., a first belt 124 A, a second belt 124B, a third belt 124C, etc. The belts 124 can be made of any material that creates a suitable coefficient of friction with the component 104 (see FIG. 1), such as, e.g., rubber, silicone, polyvinyl chloride (PVC), etc. For example, a coefficient of friction between the component 104 (see FIG. 1) and the belts 124 can be between about 0.4 and about 0.7.

[0045] Further, the belts 124 can be wrapped around and / or rotated by the wheels 126, and the wheels 126 can be configured to control the speed of the belts 124, i.e., the second speed of the skew correction station 108. In some aspects, the skew correction station 108 includes two wheels 126, i.e., a first wheel 126A and a second wheel 126B. Typically, one of the wheels, e.g., the first wheel 126 A, serves as the drive wheel which can be connected to a motor or other power source. The drive wheel can be responsible for driving the belts 124 to rotate around the wheels 126 in the skew correction station 108. The other wheel, e.g., the second wheel 126B, can be an idler wheel which can be positioned opposite the drive wheel. The idler wheel can provide a counterforce to the drive wheel, creating the necessary tension in the belts 124. In some aspects the wheels 126 can be positioned in a parallel configuration such that the first wheel 126 A can be located at a front or first end 142 of the skew correction station 108, and the second wheel 126B can be located at a rear or second end 144 of the skew correction station 108. In addition, the wheels 126 can be constructed, by way of example, of metal, plastic, or rubber, and the wheels 126 can be configured to provide a grip on the belts 124 without causing damage thereto.

[0046] Put another way, the wheels 126 can be shaped to retain the belts 124 thereon. In the case of multiple belts, as illustrated in FIG. 2, the wheels 126 can include a number of circumferential grooves 146 formed thereon which correspond to the number of belts 124, e.g., six. Correspondingly, the belts 124 can be positioned withing the grooves 146 on the wheels 126. Alternatively, in the case of a single and / or flat belt (not shown), the wheels can include a crown edge or extended outer edge on each side of the belt, thereby reducing the likelihood that the single belt will slip off of the wheels 126. For example, the wheels 126 can include a crown edge aroundthe outer belts, e.g., the first belt 124A and the sixth belt 124F, in addition to the grooves 146 to further secure the belts 124 on the wheels 126.

[0047] Referring still to FIG. 2, and as discussed above one or more rollers 132 can be coupled to the frame 134. The rollers 132 can be, for example, a plurality of cylindrical compression rollers, bearing rollers, disk rollers, idler rollers, and / or the like that can be configured to further tension the belts 124 and ensure that the belts 124 contact the component 104 (see FIG. 1). To that end, the rollers 132 can ensure that the belts 124 contact a sufficient surface area of the component 104, e.g., at least 10%, or at least 25%, or at least 50%, or at least 75% of a surface area of the component 104. (see FIG. 1). Further, the rollers 132 may provide a constant compressive force to the component 104 (see FIG. 1) as the component 104 (see FIG. 1) travels through the skew correction station 108. In this way, the rollers 132 direct the top surface of the component 104 along a travel path that clears the lower surface of the belts 124 as they travel around the downstream wheel 126, which can prevent the component 104 (see FIG. 1) from being caught in the belts 124, thereby increasing throughput of the skew correction station 108 and reducing machine downtime. It is contemplated that one of the rollers 132 may serve as a drive roller and can be connected to a motor or other power source to drive the belts 124 to rotate around the wheels 126. Alternatively, the rollers 132 may be passive or idler rollers which are not driven by an external power source but which still provide tension to the belts 124.

[0048] As illustrated in FIG. 2, the rollers 132 may be positioned at least partially below the wheels 126 and in between the first wheel 126A and the second wheel 126B such that the belts 124 pass below the wheels 126. It is contemplated that any suitable number of rollers 132 can be used in the skew correction station 108, e.g., between 1 and 5 rollers. In the non-limiting example illustrated in FIG. 2, the skew correction station 108 includes a first roller 132A, a second roller 132B, and a third roller 132C. In some aspects, the rollers 132 can be positioned in a parallel configuration that may be offset from, e.g., below, the parallel configuration of wheels 126. Specifically, the first roller can be positioned adjacent to and / or below the first wheel 126A, the second roller can be positioned in between the first roller 132A and the third roller 132C, and the third roller 132C can be positioned adjacent to and / or below the second wheel 126C. Referring now to FIG. 3, the rollers 132 may also be adjustable so that a bottom-most segment or point 148 of the belts 124 is positioned below the wheels 126. In some aspects, the skew correction station108 can define an x-axis 150 which extends through centers of the wheels 126 that are arranged in a parallel configuration. In addition, the skew correction station 108 can define a y-axis 152 which extends in a direction that is perpendicular to the x-axis 150. In some aspects , the rollers 132 can be positioned adjacent one another in a direction that is parallel to the x-axis 150, e.g. , in a machine direction defined by the conveyor belt 102 (see FIG. 1). Further, the rollers 132 can be coupled to a first mounting plate 154 which itself can be coupled to the frame 134 using one or more fasteners 156. Specifically, the first mounting plate 154 can include one or more mounting apertures 158 that extend therethrough, and the fasteners 156 can be inserted through the mounting apertures 158 and into the frame 134, thereby securing the first mounting plate 154 and the rollers 132 to the frame 134. In some examples, the frame 134 and / or first mounting plate 154 can be moveable and / or adjusted along x-axis 150 and / or the y-axis 152, meaning that the rollers 132 can also be adjusted along the x-axis 150 and the y-axis 152. In this way, the movable frame 134 can permit a distance between the conveyor belt 102 (see FIG. 1) and the rollers 132 to be adjusted in an x- direction and / or in a y-direction. For example, the first mounting plate 154 can be positioned closer to the first wheel 126 A along the x-axis 150 than the second wheel 126B. Alternatively, the first mounting plate 154 can be positioned equidistant to the first wheel 126A and the second wheel 126B along the x-axis 150, or the first mounting plate 154 can be positioned closer to the second wheel 126B along the x-axis 150 than the first wheel 126A. Put another way, the distance between the conveyor belt 102 (see FIG. 1) and the rollers 132 may be less than a distance between the conveyor belt 102 (see FIG. 1) and the first wheel 126A.

[0049] In some aspects, the mounting apertures 158 are shaped to allow the first mounting plate 154 to be raised or lowered along the y-axis 152. Put another way, a height of the rollers 132, i.e., the bottom-most point 148 of the belts 124, may be increased or decreased relative to a height of the wheels 126 to achieve a desired compression force on the component 104 (see FIG. 1). In the non-limiting example illustrated in FIG. 3, a wheel height 160 can be defined as the maximum height of the first wheel 126A measured in a direction that is parallel to the y-axis 152. Correspondingly, a compression height 162 can be measured between the first wheel 126A and the bottom-most point 148 of the belts 124 in a direction that is parallel to the y-axis 152. The compression height can be less than the wheel height. In some aspects, the compression height 162 is less than about 50% of the wheel height 160, or less than about 25% of the wheel height 160, orless than about 10% of the wheel height 160. Further, the rollers 132 may cause the belts 124 to bend downward from the wheels 126 to define the bottom-most point 148. Put another way, a compression angle 164 can be defined between either of the wheels 126 and the bottom-most point 148 of the belts 124. For example, the compression angle 164 can be defined between the first wheel 126A and the bottom-most point 148 of the belts 124, and the compression angle 164 can be less than about 30 degrees, or less than about 15 degrees, or about 10 degrees.

[0050] Thus, it will be understood that the rollers 132 can be positioned below the wheels 126, and that the belts 124 can be rotated around the wheels 126 and the rollers 132. Specifically, the belts 124 can be driven to rotate around the wheels 126 and the rollers 132 by a drive wheel, e.g., the first wheel 126A. Referring now to FIGS. 4 and 5, the first wheel 126A may be directly or indirectly coupled to the frame arm 136, and the frame arm 136 may provide a driving force to the first wheel 126A to drive the belts 124 to rotate, as will be discussed below in greater detail. Correspondingly, the frame arm 136 can be axially aligned with the first wheel 126 A, meaning that the frame arm 136 can be aligned with the first wheel 126A along the x-axis 150 and the y- axis 152 (see FIG. 3). Put another way, the frame arm 136 may be concentrically aligned with the first wheel 126 A.

[0051] In some aspects, the frame arm 136 can be coupled to the frame 134, e.g., the second side 140 of the frame 134, using any suitable fastening technique, e.g., fasteners, adhesive, welding, etc. The frame arm 136 may be formed monolithically, i.e., as a unitary component, or the frame arm 136 can include a variety of components. Further, it is contemplated that the frame arm 136 can be provided in any suitable shape and / or combination of shapes, such as, e.g., a cylindrical profile, a rectangular profile, an undulating profile, etc. In the non-limiting example illustrated in FIGS. 4 and 5, the frame arm 136 includes an arm housing 166 and a corner housing 168. The arm housing 166 can be provided to cover one or more internal components (see FIG. 6) in the frame arm 136, and the comer housing 168 can serve as a connection point between the skew correction station 108 and an external power source. In some aspects, the comer housing 168 can be a power source, e.g., a motor. The arm housing 166 can be coupled to the second side 140 of the frame 134 by one or more fasteners, and the corner housing 168 can be coupled to the arm housing 166 opposite of the frame 134 by additional fasteners.

[0052] As discussed above, the arm housing 166 may cover one or more internal components in the frame arm 136. In particular, the frame arm 136 can include one or more power components, such as motors, which can be configured to generate rotational force and / or to transfer the rotational force to the wheels 126 to drive the belts 124 to rotate. In some aspects, a power component can be connected to one of the wheels 126 in a cavity formed in the frame 134.

[0053] Referring now to the non-limiting example illustrated in FIG. 6, the frame 134 can include one or more apertures 170 therethrough, e.g., a first aperture 170A and a second aperture 170B, and the wheels 126 can be connected to the frame 134 within the apertures 170. In some aspects, the wheels 126 can each have shafts 172 that extend into the apertures 170, and the shafts 172 can abut bearings 174 disposed in the apertures 170. In this way, the shafts 172 can be rotated, which in turn can allow the wheels 126 to rotate and drive the belts 124. The bearings 174 can be, for example, ball bearings, roller bearings, thrust bearings, flange bearings, etc., and it will be apparent that any suitable number of bearings may be used.

[0054] Specifically, a first shaft 172A can extend rearwardly from the first wheel 126A into a first aperture 170A in the frame 134, and a second shaft 172B can extend rearwardly from the second wheel 126B into a second aperture 170B in the frame 134. The bearings 174 can be disposed between the frame 134 and the shafts 172, thus allowing the shafts 172 to rotate. In some examples, recesses 176 can be formed in the wheels 126, and one or both of the wheels 126 can include channels that extend through the shafts 172. As illustrated in FIG. 6, a channel 178 can extend through the first shaft 172A, and the channel 178 can be in fluid communication with a first recess 176A formed in the first wheel 126A. It is contemplated that the first recess 176A and the channel 178 can decrease the weight of the first wheel 126A, which may allow the first wheel 126A to be rotated faster using less force, e.g., rotational force generated by a power component.

[0055] In some aspects, the frame arm 136 can define an interior space that is configured to contain a power component, e.g., a rotor 180 therein. The rotor 180 can be rotated about a rotor axis 184 by a motor or another power source, which may optionally be positioned in the corner housing 168 or outside of the skew correction station 108. In some aspects, the speed of the rotor 180 can be controlled by the electronic controller 118 based upon a determination that the component 104 (see FIG. 1) is skewed, as discussed above. Further, the rotor 180 can include a rod 186 that can extend along the rotor axis 184 and into the first aperture 170A in the frame 134.In some aspects, the first shaft 172A can also extend along the rotor axis 184, meaning that the first shaft 172A and the rod 186 can be radially aligned with one another. Further, the rod 186 can be inserted and secured within the channel 178, thereby connecting the first wheel 126A to the rotor 180. Accordingly, rotational force generated by the rotor 180 can be transferred from the rod 186 to the first shaft 172, which in turn can drive the first wheel 126A to rotate and serve as the drive wheel in the skew correction station 108. Alternatively, the rotor 180 can be coupled to the second wheel 126B if the second wheel 126B is desired as the drive wheel.

[0056] Referring still to FIG. 6, it is contemplated that the frame 134 can be formed as a unitary component, or the frame 134 can be arranged as an assembly with multiple components. In some examples, the frame 134 can have two distinct portions or halves which may be joined, adhered, or otherwise fastened together to form the frame 134. For example, the frame 134 can have a first half 134A and a second half 134B. The first aperture 170 A can extend through the first half 134 A, meaning that the first wheel 126 A and the frame arm 136 can be coupled to the first half 134A of the frame 134. Correspondingly, the second aperture 170B can extend through the second half 134B, meaning that the second wheel 126B can be coupled to the second half 134B of the frame 134. Further, one or more fasteners, e.g. pins 188, can be used to secure the first half 134A to the second half 134B, or the first half 134A and the second half 134B can be welded or adhered together using adhesives or other connectors.

[0057] Therefore, it will be understood that the wheels 126 in the skew correction station 108 can be configured to drive the belts 124 to rotate around the wheels 126 and the compression rollers 132 which are located at least partially below the wheels 126, with respect to the y-axis 152 (see FIG. 3). Now referring to FIG. 7, a top schematic view is illustrated of the system 100, including the component 104, the folding apparatus 106, and the skew correction station 108. Initially, the component 104 can be provided, e.g., by the conveyor belt 102 (see FIG. 1), in an unfolded state 190 to the folding apparatus 106. For example, the unfolded state 190 can be an arrangement in which the first side 110 of the component 104 has not yet been folded onto the second side 112 and across the fold line 114. The folding apparatus 106 can guide, e.g, along the folding surface 120, the second side 112 of the component 104 to fold up and over the fold line 114. However, due to friction between the component 104 and the folding apparatus 106, the component 104 may exit the folding apparatus 106 in a skewed state 192, e.g., an arrangement in which a skew angle122 is formed between the first side 110 and the second side 112. In some aspects, the skewed state 192 may be characteristic of the folding apparatus 106 dragging the second side 112 behind the first side 110 due to friction.

[0058] Referring still to FIG. 7, the component 104 can be provided to the skew correction station 108 after the skewed state 192 is identified, e.g., the skew angle 122 is known or is detected using a photo eye. Before the component 104 contacts the belts 124 of the skew correction station 108, the belts 124 and the wheels 126 can be set at a speed that is different than the speed at which the first side 110 of the component 104 is travelling. Put another way, the belts 124 can be oversped or undersped relative to the speed of the conveyor belt 102 (see FIG. 1). The belts 124 can also be set at a predetermined height to ensure that contact is made with the component 104. In this way, the skew correction station 108 may be used to correct a skewed portion of the component 104 relative to the rest of the component 104. For example, the belts 124 can contact the second side 112 of the component 104 and overspeed the second side 112 relative to the first side 110, i.e., a non-skewed or normal portion of the component 104, thus reducing and / or eliminating the skew angle 122. In addition, the rollers 132 can further ensure that contact is made with the component 104 by compressing the component 104. For example, the rollers 132 can be set at a height that is at least partially less than a height of the wheels 126, measured along the y-axis 152 (see FIG. 3). Put another way, the rollers 132 can be positioned closer to the component 104 than the wheels 126, relative to the y-axis 152. As a result, the component 104 can exit the skew correction station 108 in a correctly folded state 194, e.g., the correctly folded arrangement 130 (see FIG. 1), in which the skew angle 122 has been reduced or eliminated. Thus, it is an advantage of the present disclosure that a skew correction station can be used to correct and / or re-fold a misfolded component provided along a conveyor belt, e.g., in an assembly line.

[0059] However, it will be understood that more than one skew correction station can be used along a production or assembly line. In some examples, a product may be folded in multiple stages at folding stations arranged in series in the machine direction. In such cases, multiple skew correction stations may be utilized, with a skew correction station located downstream of each folding station. In some examples, more than one lane of a component may be transported along a conveyor belt in an assembly line, or non-identical components may be transported together alonga conveyor belt in an assembly line. Thus, it can be advantageous to use multiple skew correction stations along an assembly line.

[0060] Referring now to FIG. 8, a support structure 200 is illustrated which can have one or more skew correction stations, e.g., the skew correction station 108 (see FIG. 2), secured, i.e., mounted, thereto. The support structure 200 can be positioned along an assembly line, e.g., to the side and / or above a conveyor belt, so as to be downstream of a folding apparatus. For example, the support structure 200 can include base plates 202 that can be secured to another structure along an assembly line via, e.g., welding, adhesive, fasteners, or the like. In some aspects, the base plates 202 can be unfastened from another structure in an assembly line, meaning that the support structure 200 can be moved to different positions along an assembly line if desired. For example, the base plates 202 may be coupled to rails (not shown) on either side of a conveyor belt (not shown), and the support structure 200 can be fastened to a particular position along the rails (not shown) or slid between different positions therealong. Further, support arms 204 can extend upward from the base plates 202, and a support bar 206 can extend between the support arms 204 at a top or first end of the support structure that is opposite base plates 202. It is contemplated that the base plates 202 can be coupled to the support arms 204 and the support arms 204 can be coupled to the support bar 206 via, e.g., welding, adhesive, fasteners, or the like. Additional aspects of the support arms 204 and the support bar 206 will be discussed below in greater detail.

[0061] In addition, one or more skew correction stations 208 can be coupled to the support arms 204 and / or the support bar 206. In the present embodiment, elements that are shared with, i.e., that are structurally and / or functionally identical or similar to — elements present in the previous embodiment, i.e., the skew correction station 108 as illustrated in FIGS. 1-7, are represented by like reference numerals In the interest of brevity, some features of the present embodiment that are shared with the examples illustrated in FIGS. 1-7 are numbered or labeled in FIGS. 8-12 but are not discussed in the specification. However, reference is made to a list of reference numerals used in the description herein.

[0062] Referring specifically to FIG. 8, the skew correction stations 208, e.g., a first skew correction station 208A and a second skew correction station 208B, can be coupled to one or more mounting assemblies 210, e.g., a first mounting assembly 210A and a second mounting assembly 210B. Correspondingly the mounting assemblies 210 can be coupled to the support arms 204and / or the support bar 206. In some aspects, the mounting assemblies 210 are slidably coupled to the support bar 206, meaning that the mounting assemblies 210 and the skew correction stations 208 can be slidably adjusted along the support bar 206. Further, the mounting assembly 210 can be vertically adjustable, i. e. , in a direction that is parallel to the direction in which the support arms 204 extend. Thus, the skew correction stations 208 can also be adjusted in a vertical direction. In some aspects, the support structure 200 can define a vertical or y-axis 212 which is parallel to the support arms 204. In addition, the support structure 200 can include a z-axis 214 which extends in a direction that is perpendicular to the y-axis 212 and parallel to the support bar 206, and an x-axis 216 which is perpendicular to the y-axis 212 and the z-axis 214. Accordingly, it will be understood that skew correction stations 208 and the mounting assemblies 210 can be adjusted vertically along the y-axis 212 and / or laterally along the z-axis 214, and the support structure 200 can be adjusted along the x-axis 216. To that end, the support structure 200 and the skew correction stations 208 can be positioned in accordance with the dimensions of a particular component, e. , the component 104 (see FIG. 1) that is transported along an assembly, which in turn can increase skew correction accuracy and production efficiency.

[0063] In some aspects, the first skew correction station 208A and the second skew correction station 208B can be symmetric, i.e., mirrored, about y-axis 212. Similarly, the first mounting assembly 210A and the second mounting assembly 210B can also symmetric, i.e., mirrored, about the y-axis 212. Alternatively, the skew correction stations 208 and the mounting assemblies 210 may not be mirrored about the y-axis 212.

[0064] Referring now to FIGS. 8-10, the support bar 206 can include a top or first rail 218 that extends downward therefrom, or the first rail 218 can be a separate component that is coupled to an underside of the support bar 206. Correspondingly, each mounting assembly 210 can include a top or first mounting plate 220 that can be secured to the first rail 218 and / or is slidable therealong. In this way, and with specific reference to FIGS. 9 and 10, a spacing length 222 can be adjusted, i.e., a length measured between the first skew correction station 208 A and the second skew correction station 208B in a direction that is parallel to the z-axis 214 can be adjusted. In addition, the support structure 200 can include one or more stability rods 224, e.g., a first stability rod 224A and a second stability rod 224B, which can extend in a direction that is parallel to the z-axis 214. The stability rods 224 can be configured to further secure the mounting assembly 210 to the supportstructure 200, for example, by providing additional connection points between the support structure 200 and the mounting assembly 210. In some aspects, knobs 226 are attached to the stability rods 224, and the knobs 226 can be used to tighten and / or loosen the mounting assembly 210 from the first rail 218. For example, loosening the knobs 226, e.g., turning the knobs 226 in a counterclockwise, may allow the first mounting plate 220 to slide along the first rail 218, while tightening the knobs 226, e.g, turning the knobs 226 in a clockwise direction, can secure the first mounting plate 220 to a particular position along the first rail 218.

[0065] Referring now to FIGS. 8 and 11, each mounting assembly 210 can further include a second mounting plate 230 which can be coupled to the first mounting plate 220. For example, the second mounting plate 230 can be coupled to an outer side of the first mounting plate 220 via, e.g., welding, adhesive, fasteners, and / or the like. In some aspects, a vertical or second rail 232 is coupled to the second mounting plate 230, and the second rail 232 can extend in a direction that is parallel to the y-axis 212. Further, a side panel 234 can be slidably coupled to the second rail 232, and the side panel 234 can also be coupled to the skew correction station 208. For example, the side panel 234 can be coupled to the second side 140 of the frame 134 of the skew correction station 208 via, e.g., welding, adhesive fasteners, and / or the like. Accordingly, the side panel 234 can be slidably adjusted along the second rail 232, i.e., along a direction that is parallel to the y- axis 212. This in turn can allow the skew correction station 108 to be slidably adjusted in a direction that is parallel to the y-axis 212.

[0066] Still referring to FIGS. 8 and 11, a handle 236 that can be made of plastic or metal can be coupled to the side panel 234, and the handle 236 can be used to slide, e.g., pull and / or push, the skew correction station 208 and the mounting assembly 210 along the first rail 218 and / or the second rail 232. In other examples, the skew correction station 208 and the mounting assembly 210 can be automatically adjusted along the first rail 218 and / or the second rail 232 by an electronic controller (see FIG. 1). In addition, a slide stop 238 can be coupled to the second mounting plate 230 and the side panel 234. The slide stop 238 can be L-shaped, and can include a longitudinal slot 240, e.g., an ovular slot that extends in a direction that is parallel to the y-axis 212, therein, and a lever 242 can be coupled to the second mounting plate 230 through the slot 240. The slot 240 can define the vertical distance that the skew correction station 208 and the side panel 234 can be adjusted along, and the lever 242 can be used to lock the skew correction station 208 and theside panel 234 at a desired height with respect to the y-axis 212. For example, the lever 242 can be manually and / or automatically actuated between a locked position and an unlocked position. In the locked position, the skew correction station 208 and the side panel 234 can be prevented from being adjusted, i.e., slid vertically along the second rail 232. In the unlocked position, the skew correction station 208 and the side panel 234 can be adjusted, i.e., slid vertically along the second rail 232. Accordingly, the lever 242 can prevent the skew correction station 208 and the side panel 234 from slipping along the second rail 232, which in turn can ensure that the skew correction station 208 stays at a desired height to contact a skewed or misfolded component.

[0067] Referring now to FIG. 12, a top view is illustrated of another system 300 for correcting a skewed component provided along a conveyor belt, e.g., a conveyor belt 302 extending along a machine direction. The system 300 can be similar to the system 100 illustrated in FIGS. 1 and 7, except that the system 300 includes multiple lanes of a component, multiple folding apparatuses, and the support structure 200 with multiple skew correction stations 208. Specifically, the system 300 can include a conveyor belt 302, and two components 304 A, 304B can be arranged on the conveyor belt 302 in a parallel configuration, e.g., spaced at a distance from one another along a cross-machine direction that is perpendicular to the machine direction. Put another way, two lanes 306A, 306B of component can be provided on the conveyor belt 302. In the first lane 306A, the first component 304A is provided to a first folding apparatus 308 A, and the first component 304A may exit the first folding apparatus 308A in a skewed state 192, as discussed above. Correspondingly, the second component 304B is provided to a second folding apparatus 308B, and the second component 304B may exit the second folding apparatus 308B in the skewed state 192. Put another way, the first component 304A can have a first skew angle 310A after exiting the first folding apparatus 308 A, and the second component 304B can have a second skew angle 310B after exiting the second folding apparatus 308B.

[0068] Still referring to FIG. 12, the conveyor belt 302 can then provide the components 304 to the support structure 200 including, by way of example, the first skew correction station 208A and the second skew correction station 208B. As the components 304 travel through the respective skew correction stations 208, the belts 124 can overspeed and / or underspeed a skewed portion, e.g., a second side (see FIG. 1), of each of the components 304 relative to a speed of the conveyor belt 302. In this way, the skew correction stations 208 can reduce or eliminate any skew that ispresent in the components 304. In some aspects, first component 304 A may be skewed differently than the second component 304B. Thus, to ensure that both of the components 304 are correctly adjusted, the speed of the belts 124 in the first skew correction station 208A may be set differently than the speed of the belts 124 in the second skew correction station 208B. Alternatively, if one or both of the components 304 are not skewed, the speed of the belts 124 in one or both of the skew correction stations 208 can be set equal to the speed of the conveyor belt 302.

[0069] Referring now to FIG. 13, a top view is illustrated of another system 400 for correcting a skewed component provided along a conveyor belt, e.g., a conveyor belt 402. The system 400 can be similar to the system 100 illustrated in FIGS. 1 and 7, except that the system 400 includes multiple folding apparatuses and skew correction stations arranged in series, e.g., in a downstream machine direction, relative to one another. However, it is also contemplated that multiple folding apparatuses and skew correction stations may be arranged in series, e.g., in a cross-machine direction. In the non-limiting example illustrated in FIG. 13, the system 400 can include a conveyor belt 402, and a component 404 can be arranged on the conveyor belt 402. Further, the system 400 can include a first folding apparatus 406A, a first skew correction station 408A arranged downstream of the first folding apparatus 406A, a second folding apparatus 406B arranged downstream of the first skew correction station 408A, and a second skew correction station 408B arranged downstream of the second folding apparatus 406B. The component 404 is provided to the first folding apparatus 406A which is configured to impart at least one first fold in the component 404 aligned along the machine direction, e.g., to fold a first side 410 of the component 404 on top of a second side 412 of the component 404. However, the component 404 may exit the first folding apparatus 406A in a skewed state 192, as discussed above. For example, the first side 410 of the component 404 may be angled at a first skew angle 414A relative to the second side 412.

[0070] Still referring to FIG. 13, the conveyor belt 402 can then provide the component 404 to the first skew correction station 408 A. Similar to the skew correction station 108 illustrated in FIGS. 1-7, the first skew correction station 408 A can include a first belt or belts 424A wrapped around a first wheel 426A and a second wheel 426B, one or more rollers 434, and a first frame 436A coupled to the wheels 426A, 426B. In some aspects, the first wheel 426A serves as a first drive wheel, and the second wheel 426B serves as a first idler wheel. As the component 404 travelsthrough the first skew correction station 408A, the first belt(s) 424A can overspeed and / or underspeed a skewed portion, e.g., the second side 412, of the component 404 relative to a speed of the conveyor belt 402. Put another way, the first belt(s) 424A can define a first speed that is different than a second speed defined by the conveyor belt 402. In this way, the first skew correction station 408A can reduce or eliminate any skew that is present in the component 404 as a result of passing through the first folding apparatus 406A. Alternatively, if the component 404 is not skewed, the speed of the first belt(s) 424A can be set equal to the speed of the conveyor belt 402.

[0071] Further, the component 404 can then be provided to the second folding apparatus 406B which is configured to impart at least one second fold in the component 404 aligned along the machine direction, e.g., to fold the second side 412 back over the top of the first side 410 of the component 404. However, the component 404 may exit the second folding apparatus 406B in a skewed state 192, as discussed above. For example, the second side 412 of the component 404 may be angled at a second skew angle 414B relative to the first side 410.

[0072] Still referring to FIG. 13, the conveyor belt 402 can then provide the component 404 to the second skew correction station 408B. Similar to the first skew correction station 408 A, the second skew correction station 408B can include a second belt or belts 424B wrapped around a third wheel 426C and a fourth wheel 426D, one or more rollers 434, and a second frame 436B coupled to the wheels 426C, 426D. In some aspects, the third wheel 426C serves as a second drive wheel, and the fourth wheel 426D serves as a second idler wheel. As the component 404 travels through the second skew correction station 408B, the second belt(s) 424B can overspeed and / or underspeed a skewed portion, e.g., the first side 410, of the component 404 relative to a speed of the conveyor belt 402. Put another way, the second belt(s) 424B can define a third speed that is different than the second speed defined by the conveyor belt 402. In this way, the second skew correction station 408B can reduce or eliminate any skew that is present in the component 404 as a result of passing through the second folding apparatus 406B. Alternatively, if the component 404 is not skewed, the speed of the second belt(s) 424B can be set equal to the speed of the conveyor belt 402.

[0073] Referring now to FIG. 14, the present disclosure provides a method 500 of correcting a skewed component along a conveyor belt, e.g., in an assembly line system. At step 502, aconveyor belt can be used to provide a component, e.g., a paper product, a plastic product, a disposable product, a medical product, a personal hygiene product, etc., to a folding apparatus and pass the component through the folding apparatus to fold the component. For example, a curved surface of the folding apparatus can guide a first side of a component to fold on top of a second side of the component. At step 504, the system can determine if the component is skewed, e.g., if the second side of the component is offset from the first side of the component as a result of friction between the curved surface of the folding apparatus and the component. This determination may take place before the component is folded if, by way of example, the folding apparatus is known to impart a particular skew on a component. Alternatively, the determination at step 504 can be made using data obtained via an optical sensor arranged downstream of the folding apparatus, such that the skew in a component is determined each time a component exits the folding apparatus. In yet other embodiments, the estimated amount of skew on the component is a predetermined value based on previously acquired measurements taken by an operator or vision system.

[0074] Continuing, at step 506, a speed of the skew correction station, i.e., belts on a skew correction station, can be set or adjusted based on the determination in step 504, z. e. , the determined skew angle. For example, the speed of the belts on a skew correction station can be set manually by an operator or controlled using an electronic controller that is in communication with an optical sensor and / or a production line management network. At step 508 the component is passed through the skew correction station to overspeed a portion of the component that is determined to have been skewed. In some examples, the belts on a skew correction station can contact the skewed portion of the component and overspeed the component relative to a speed of the conveyor belt, i.e., a speed of a non-skewed portion of the component. In this way, skewed portion of the component can be correctly re-folded such that the degree of skew in the component is reduced and / or eliminated.

[0075] The described systems enable the correction of skew angles imparted on components that are manufactured along an assembly line, while maintaining a high throughput and minimizing manufacturing costs. As described above, this type of system is useful in high-volume assembly lines which may produce a variety of components or products, e.g., paper products, plastic products, disposable products, personal hygiene products, etc. There are, however, many other applications for these types of correction systems, including, for example, manufacturingprocesses related to houseware products, automotive and industrial products, food packaging, and many other products.

[0076] Within this specification, embodiments have been described in a way which enables a clear and concise specification to be written, but it is intended and will be appreciated that embodiments may be variously combined or separated without parting from the invention. For example, it will be appreciated that the features described herein are applicable to all aspects of the embodiments described herein. Further, it is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the description or illustrated in the drawings. The present disclosure is capable of other configurations and of being practiced or of being carried out in various ways. For example, although a specific ordered series of steps is described above, the order of these steps can be varied. For example, in some applications providing components to a skew correction station can be performed at alternate stages of the process.

[0077] Additionally, although one or two skew correction stations are illustrated in the systems above, it will be apparent that, in some applications, additional skew correction stations may be desirable and three or more skew correction stations may be used along an assembly line. Further, it is contemplated two or more skew correction stations can be arranged in parallel and / or in series along a conveyor belt.

[0078] Additionally, it will be apparent that, in some applications, the speed of the belts in any one skew correction station can be adjusted independently of the speed of the belts in any additional skew correction station.

[0079] Thus, it will be appreciated by those skilled in the art that, while the disclosure has been described above in connection with particular non-limiting examples and examples, the disclosure is not necessarily so limited, and numerous other non-embodiments, examples, uses, modifications and departures from the non-limiting examples, examples and uses are intended to be encompassed by the claims attached hereto. The figures, similarly, depict selected configurations and are not intended to limit the scope of the present disclosure. The present disclosure is to be accorded the widest scope consistent with the principles and features disclosed herein.

[0080] Various features and advantages of the invention are set forth in the following claims.

Claims

CLAIMSI Claim:

1. A correction system for a component on a conveyor belt, the correction system comprising: a frame; a first wheel coupled to the frame, the first wheel serving as a drive wheel; a second wheel coupled to the frame, the second wheel serving as an idler wheel; a belt wrapped around the first wheel and the second wheel, the belt moving at a first speed; and wherein the first speed of the belt differs from a second speed of the conveyor belt.

2. The correction system of claim 1 wherein the first speed of the belt is greater than the second speed of the conveyor belt.

3. The correction system of claim 1 further comprising a compression roller coupled to the frame between the first wheel and the second wheel and wherein a first distance between the compression roller and the conveyor belt is less than a second distance between the conveyor belt and the first wheel.

4. The correction system of claim 3, wherein the frame is moveable in a y-direction to permit adjustment of the first distance between the compression roller and the conveyor belt.

5. The correction system of claim 3, wherein the compression roller comprises an idler roller.

6. The correction system of claim 3, wherein the compression roller comprises a plurality of compression rollers.

7. The correction system of claim 6, wherein the plurality of compression rollers are positioned adjacent one another in a machine direction defined by the conveyor belt.

8. The correction system of claim 1 wherein the belt comprises a plurality of tubular belts positioned within grooves formed within the first wheel and the second wheel.

9. The correction system of claim 1 wherein the belt comprises a flat belt.

10. A system for folding and correcting one or more components on a conveyor belt, the system comprising: a first folding apparatus configured to impart at least one first fold in a first component, the at least one first fold aligned along a machine direction of the system defined by the conveyor belt; and a first correction system positioned downstream of the first folding apparatus in the machine direction, the correction system comprising: a first frame; a first wheel coupled to the frame, the first wheel serving as a first drive wheel; a second wheel coupled to the frame, the second wheel serving as a first idler wheel; a first belt wrapped around the first wheel and the second wheel, the first belt moving at a first speed; and wherein the first speed of the first belt is different than a second speed of the conveyor belt.

11. The system of claim 10 further comprising a compression roller coupled to the frame between the first wheel and the second wheel, the compression roller positioned closer to the conveyor belt than the first wheel and the second wheel.

12. The system of claim 11, wherein the compression roller comprises at least one idler roller.

13. The system of claim 11, wherein the compression roller comprises a plurality of compression rollers.

14. The system of claim 13, wherein the plurality of compression rollers are positioned adjacent one another in the machine direction.

15. The system of claim 10, wherein the folding apparatus comprises a plow folding unit.

16. The system of claim 10, wherein the system further comprises: a second folding apparatus positioned downstream from the first correction system and configured to impart at least one second fold in the first component, the at least one second fold aligned along the machine direction of the system; and a second correction system positioned downstream of the second folding apparatus in the machine direction, the second correction system comprising: a second frame; a third wheel coupled to the second frame, the third wheel serving as a second drive wheel; a fourth wheel coupled to the second frame, the fourth wheel serving as a second idler wheel; a second belt wrapped around the third wheel and the fourth wheel, the second belt moving at a third speed; and wherein the third speed of the second belt is different than the second speed of the conveyor belt.

17. The system of claim 10, wherein the system further comprises: a second folding apparatus aligned with the first folding apparatus in a cross-machine direction and configured to impart at least one second fold in a second component spaced at a distance from the first component in the cross-machine direction, the at least one second fold aligned along the machine direction of the system; and a second correction system aligned with the first correction system in the cross-machine direction, the second correction system comprising: a second frame; a third wheel coupled to the second frame, the third wheel serving as a second drive wheel; a fourth wheel coupled to the second frame, the fourth wheel serving as a second idler wheel; a second belt wrapped around the third wheel and the fourth wheel, the second belt moving at a third speed; and wherein the third speed of the second belt is different than the second speed of the conveyor belt.

18. A method of correcting a skewed component on a conveyor belt, comprising: determining a skew angle in the skewed component; adjusting a speed of a belt on a correction system based on the determined skew angle; and passing the skewed component through the correction system such that the belt contacts and overspeeds a first portion of the skewed component relative to a second portion of the skewed component.

Images