Exit module for a converting machine

Abstract

A safety system (12) for an exit module (10) of a converting machine (4), the converting machine for processing of sheet material, the exit module for outlet of a stack (8) of processed sheet material and comprising a conveyor system (16) for transmission of said stack of processed sheet material, the safety system comprising: a presence detection system (22) for detection of an intruding object into an adaptive safety zone (24).

Description

[0001] EXIT MODULE FOR A CONVERTING MACHINE

[0002] TECHNICAL FIELD

[0003] The present disclosure relates to a safety system for an exit module of a converting machine. In particular, the converting machine is for processing of sheet material, and the exit module is for outlet of a stack of processed sheet material and comprises a conveyor system for transmission of said stack of processed sheet material.

[0004] BACKGROUND

[0005] Converting machines are used in the production of blanks including as packaging elements for cardboard boxes or other similar arrangements. To form said blanks, the machines are configured to process sheet material by one or more of: printing, cut-to-shape; forming lines of weakening; folding; glueing, or; other suitable process.

[0006] The formed blanks are supplied by an exit module of the converting machine, often as one or more stacks on a pallet. Said stacks are transported from the exit module by means of a conveyor system. The exit module of the converting machine should not be accessed by a machine operator while the converting machine is in operation. To this effect, various safety systems have been proposed, for example, static barriers such as fences and immaterial barriers such as light curtains.

[0007] A common type of immaterial barriers is designed to enable a stack of blanks to exit from the converting machine, while providing a detection of intrusion if an inadmissible object or a person tries to enter through the immaterial barrier. However, the shortcoming of such a system is the sensitive moment when a stack is being transported out through the immaterial barrier. This is a common weakness in immaterial barriers, and when a stack is transported through the immaterial barrier, there is a risk that a machine operator accesses the machine outlet the back way at the same time. In this scenario, the immaterial barrier may fail to detect the intrusion into the machine outlet.

[0008] SUMMARY

[0009] In view of the prior art, it is an object of the present disclosure to provide an improved safety system for an exit module of a converting machine. This object may be solved by a safety system according to claim 1 . According to an aspect of the present invention, there is provided a safety system for an exit module of a converting machine, the converting machine for processing of sheet material, the exit module for outlet of a stack of processed sheet material and comprising a conveyor system for transmission of said stack of processed sheet material in a direction of transportation, the safety system comprising a presence detection system for detection of an intruding object into the exit module, the presence detection system comprises a stationary presence detection system and an adaptive presence detection system, wherein the stationary presence detection system comprises a stationary component configured to generate a stationary immaterial barrier, and the adaptive presence detection system comprises an adaptive component configured to generate an adaptive immaterial barrier, and wherein an adaptive safety zone is arranged between the stationary immaterial barrier and the adaptive immaterial barrier.

[0010] In an embodiment, the adaptive component is movable and configured to create the adaptive safety zone to accommodate the stack as the stack is conveyed out from the machine outlet.

[0011] In an embodiment, the adaptive component is configured to move together with the stack as the stack is displaced out from exit module by the conveyor system.

[0012] In an embodiment, the stationary component is located downstream of the adaptive component in the direction of transportation.

[0013] In an embodiment, the stationary component is located upstream of the adaptive component in the direction of transportation.

[0014] In an embodiment, the adaptive component is configured to move before the stack as the stack is displaced out from exit module by the conveyor system, and such as to establish an adaptive safety zone with a fixed volume before the stack is conveyed into said safety zone.

[0015] In an embodiment, the adaptive component is configured to follow the stack until the stack is displaced though the stationary component.

[0016] In an embodiment, the preceding claims, wherein the stationary component is an immaterial barrier, preferably a light curtain.

[0017] In an embodiment, the stationary component is arranged for transition from an active mode to an inactive mode for displacement of the stack through the stationary component.

[0018] In an embodiment, the adaptive component comprises a movable immaterial barrier. In an embodiment, the adaptive component of the presence detection system comprises a proximity sensor system for detection of an object entering into the adaptive safety zone.

[0019] In an embodiment, the proximity sensor implements radio waves to determine proximity of the object to the adaptive safety zone.

[0020] In an embodiment, the proximity sensor system implements the adaptive safety zone to include a movable virtual shield in a 2-dimensional plane.

[0021] In an embodiment, the adaptive component is configured to transition between a proximal position which is proximal the outlet of the converting machine, and a distal position distal the outlet of the converting machine, and wherein the adaptive component is in the proximal position before the stack has passed the stationary immaterial barrier, and in the distal position when the stack has passed the stationary immaterial barrier.

[0022] In an embodiment, the safety system further comprising a movable positioning mechanism to move the proximity sensor system to adapt size of the adaptive safety zone.

[0023] In an embodiment, the movable positioning mechanism is arranged to move the proximity sensor system by a translation and / or a rotation.

[0024] In an embodiment, the safety system further comprises an electrical circuitry to: determine a position of the stack on the conveyor system, and; to move the adaptable component of the adaptive safety zone based on said determined position.

[0025] In an embodiment, the adaptive presence detection system is arranged for transition from an inactive mode to an active mode subsequent to one or more of:

[0026] - transition of a stationary presence detection system from an active to an inactive mode;

[0027] - determination of a stack exiting an outlet of the converting machine, and;

[0028] - passing of a stack through the stationary presence detection system.

[0029] In an embodiment, the stationary component is arranged for transition from the inactive mode to the active mode subsequent to subsequent to passing of the stack through the stationary component. In an embodiment, a barrier arrangement is arranged to define sides of the adaptive safety zone and to physically restrict access to the sides of the conveyor system and the stack on the conveyor system.

[0030] As used herein the term safety system may refer to an arrangement for implementation with the exit module of the converter machine, which is designed to provide safety to humans (e.g. an operator) and or machines in proximity to the converter machine or components associated therewith.

[0031] As used herein the term exit module may refer to a dedicated module or a sub-component of the converting machine, which is arranged for transmission of a stack (including a plurality thereof) from an outlet of the converting machine. The exit module may transmit the stack on a pallet, with the palleted stack being formed by the converting machine.

[0032] As used herein the term presence detection system may refer to an arrangement to provide a safety zone around / in proximity to the stack of the exit module, and which determines if an object has entered into the safety zone.

[0033] As used herein the term object may refer to a human object, e.g. a body or a hand / arm / foot of a human.

[0034] In embodiments, the presence detection system includes an adaptive presence detection system, which comprises a proximity sensor system for detection of an object entering into an adaptive component of the adaptive safety zone. By implementing a proximity sensor to determine if an object has entered into the safety zone the safety system may have improved safety.

[0035] As used herein the term proximity sensor system may refer to an arrangement of one or more sensors arranged to determine a proximity of the object to or in the adaptive safety zone. Examples of which include a proximity sensor that emits radio waves, including a radar system, with an emitter and receiver; an optical system, which is based on a light emitter and detector, and; an infra-red sensor system.

[0036] In embodiments, the proximity sensor system implements the adaptive safety zone to include a movable virtual shield / barrier in a 2-dimensional plane (e.g. it is planar). Such an arrangement may conveniently cover off faces of the stack. In embodiments, the adaptive presence detection system comprises a movable positioning mechanism to move the proximity sensor system to adapt the adaptive component of the safety zone, e.g. to move with and remain in operative proximity to the stack, e.g. a front face thereof.

[0037] In embodiments, the movable positioning mechanism is arranged to move the proximity sensor system to translate and / or rotate the safety zone, e.g. to provide said adaptation. Translation and / or rotational movement may be conveniently implemented with a suitable actuation system, e.g. a solenoid or electrical motor.

[0038] In embodiments, the safety system comprises control circuitry / electrical circuitry to determine a position of the stack on the conveyor system. In embodiments, the electrical circuitry implements adaptation of the adaptable component of the adaptive safety zone based on said determined position, e.g. by control of the movable positioning mechanism.

[0039] The electrical circuitry may determine a position of the stack based on various suitable arrangements including: the provision of a signal from a sensor system to determine a stack exiting the outlet of the converting machine, and / or a position of the stack on the conveyor system may be determined by a speed of the conveyor system; other suitable arrangements e.g. a camera system with image recognition. In embodiments, the movable positioning mechanism is arranged to move with the conveyor, e.g. to translate at the same speed.

[0040] In embodiments, the safety system comprises stationary presence detection system (e.g. an optical emitter and detector arrangement, including a light curtain) arranged to detect intrusion of an object into a stationary component of the adaptive safety zone. In embodiments, the stationary presence detection system is arranged upstream of the adaptive presence detection system / at a transition of the stack from the outlet of the converting machine to the conveyor system. The stationary component of the safety zone is therefore arranged upstream of the adaptive component of the safety zone.

[0041] In embodiments, the stationary presence detection system is arranged for transition from an active mode to an inactive mode for displacement of the stack through the stationary safety zone. By transitioning the stationary presence detection system from an active to an inactive mode, a stack may be enabled to pass through the stationary presence detection system (e.g. without the determination of an object entering the safety zone being triggered). The stationary presence detection system may be automatically transitioned as an approaching stack is detected, e.g. by a sensor system. As used herein the term inactive mode may refer to a muted light curtain, in which the light emission and / or object detection feature is inactive. As used herein the term active mode may refer to the light curtain operable to detect an object in its component of the safety zone.

[0042] In embodiments, the adaptive presence detection system is arranged for transition from an inactive mode to an active mode subsequent to one or more of: determination of a stack exiting an outlet of the converting machine; passing of a stack through the stationary presence detection system; transition of a stationary presence detection system from an active to an inactive mode.

[0043] In embodiments, the stationary presence detection system is arranged for transition from the inactive mode to the active mode subsequent to passing of the stack through the stationary presence detection system.

[0044] In embodiments, the safety system comprises a barrier arrangement arranged to define sides of the adaptive safety zone and to physically restrict access to the sides of the conveyor system and the stack on the conveyor system. A physical barrier may prevent side entry into the safety zone, whilst the presence detection system precents frond and back access.

[0045] The present disclosure provides an exit module of a converting machine comprising the safety system of any preceding embodiment or another embodiment disclosed herein.

[0046] In embodiments, the electrical circuitry is implemented as one or more processors, which are configured to implement control of the automated unit to execute the disclosed steps. The processors may execute program code stored on electronic memory and / or may execute programable logic, e.g., as a logic array, gate array, structured array etc.

[0047] The present disclosure provides a method of implementing a safety zone of a presence detection system of a converting machine, the method may implement any feature of the safety system and / or exit module of any preceding embodiment or another embodiment disclosed herein. In embodiments, the method comprises transmitting the stack with a conveyor system and providing a safety zone.

[0048] In embodiments, the method comprises adapting the safety zone to move with the stack as the stack is displaced by the conveyor system. In embodiment, the method comprises adapting the adaptive safety zone to remain downstream of the moving stack on the conveyor system and / or to move with and remain in operative proximity to the stack. The present disclosure provides electrical circuitry or a computer program (e.g. machine readable code) executable on one or more processors to control the safety system to perform the method and / or another method disclosed herein.

[0049] The present disclosure provides a method of retrofitting a safety zone to an existing exit module of a converting machine. The method may implement any feature of the safety system and / or exit module of any preceding embodiment or another embodiment disclosed herein. In embodiments, the method comprises, arranging a presence detection system for detection of an intruding object into an adaptive safety zone.

[0050] The preceding summary is provided for purposes of summarizing some embodiments to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the abovedescribed features are merely examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and / or proceeding embodiments may be combined in any suitable combination to provide further embodiments. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following Detailed Description of Embodiments, Brief Description of Figures, and Claims.

[0051] BRIEF DESCRIPTION OF FIGURES

[0052] Aspects, features and advantages of embodiments of the present disclosure will become apparent from the following detailed description of embodiments in reference to the appended drawings in which like numerals denote like elements.

[0053] Figure 1 is a block system diagram showing a system comprising; a converting machine; an exit module; a safety system, and; a stack of blanks.

[0054] Figure 2 is a schematic diagram showing a converting machine of the system of figure 1 .

[0055] Figures 3a to 3e are schematic perspective views of a safety system according to a first embodiment of the present invention;

[0056] Figures 4a to 4f are schematic perspective views of a safety system according to a second embodiment of the present invention;

[0057] Figures 5a to 5f are schematic perspective views of a safety system according to a third embodiment of the present invention; Figures 6a to 6d are schematic perspective views of a safety system according to a fourth embodiment of the present invention; and

[0058] Figure 7 is a schematic perspective view of a safety system according to the first embodiment of the present invention including lateral fencing.

[0059] DETAILED DESCRIPTION OF EMBODIMENTS

[0060] Before describing several embodiments of the system, it is to be understood that the system is not limited to the details of construction or process steps set forth in the following description. It will be apparent to those skilled in the art having the benefit of the present disclosure that the system is capable of other embodiments and of being practiced or being carried out in various ways.

[0061] The present disclosure may be better understood in view of the following explanations:

[0062] As used herein the term “system” may refer to an arrangement that includes hardware comprising a converting machine for repetitively executing a formation process in a predefined manner for the formation of a blank, and may include electrical circuitry as part of a control system to control the converting machine. The system may comprise an exit module to transmit a stack of blanks from an outlet of the converting machine.

[0063] As used herein the term “converting machine” may refer to hardware for executing a formation process for full or partial formation of the blank. The hardware may be arranged as modules, e.g. in distributed in series or as a single unit. The converting machine may be configured to at least partially form the blank from sheet material. The converting machine includes a tool which is manipulated / driven for repetitive mechanical engagement with the sheet material to at least partially form said blank during the formation process. The converting machine may include or be associated with an exit module, which is arranged to receive from an outlet of the converting machine a stack of blanks on which the formation processes has been executed. The stack may be provided on a pallet. As used herein the term “formation process” may refer to a process executed by the converting machine on the sheet material to at least partially form the blank.

[0064] As used herein the term “exit module” may refer to a fully or partially automated system, which is arranged to transmit a stack of blanks from an outlet of the converting machine. The stack may be transmitted to a loading area, e.g. for shipping or for further processing of the stack. As used herein the term “stack arrangement” or “stack” may refer to an arrangement of one or more stacks of blanks. The stack may be arranged on a pallet, palletizing can be implemented by the converting machine. One or more stacks can be arranged on a pallet, e.g. side by side. A pallet of a stack of blanks can be 0.5 - 2 m in heigh and weigh 150-250 kg.

[0065] As used herein the term “sheet material” may refer to a paperboard, cardboard, fibreboard or other material sheet from which the blank formed. As used herein the term “paperboard” or “cardboard” may refer to paper pulp-based board. A thickness of the material may be greater than 0.30 mm and / or a grammage of a grammage above 250 g / m2, hence to distinguish the material from paper. Paperboard may be single-ply or multi-ply. As used herein the term “fibreboard” may refer to wood product that is made out of wood fibres or a kraft-based paperboard. It may include a kraft-based paperboard or corrugated fiberboard.

[0066] As used herein the term “blank” may refer to any object formed by the formation process of the converting machine. The blank may be a planar arrangement of sheet material from which an object such as a packaging element may be formed, for example by one or more of printing, folding, cutting and gluing. The blank itself may be partially folded and / or glued. The blank may be formed from paperboard, cardboard, fibreboard, or other suitable material. Additionally, the blank may be a printed sheet element. Such a printed sheet element may be produced in a flexographic printing press. The printed sheet element may have a square or rectangular form and may have been cut to shape in the converting machine itself, or already be pre-formed.

[0067] A used herein the term “conveyor system” may refer to an arrangement for transmission of a stack, with a suitable mechanical arrangement, e.g. rollers and / or a belt.

[0068] As used herein, the term “electrical circuitry” or “circuitry” or “control electrical circuitry” may refer to one or more hardware and / or software components, examples of which may include: one or more of an Application Specific Integrated Circuit (ASIC) or other programable logic; electronic / electrical componentry (which may include combinations of transistors, resistors, capacitors, inductors etc); one or more processors (e.g. circuitry structure of the processor); a non-transitory memory (e.g. implemented by one or more memory devices), that may store one or more software or firmware programs; a combinational logic circuit; interconnection of the aforesaid. The electrical circuitry may be located entirely at one component of the system, or distributed between a plurality of components of the system (e.g. a server system and / or external device) which are in communication with each other over a computer network via communication resources. As used herein, the term “processor” or “processing resource” may refer to one or more units for processing, examples of which include an ASIC, microcontroller, FPGA, microprocessor, digital signal processor (DSP), state machine or other suitable component. A processor may be configured to execute a computer program, e.g. which may take the form of machine readable instructions, which may be stored on a non-transitory memory and / or programmable logic. The processor may have various arrangements corresponding to those discussed for the circuitry, e.g. on-board or distributed as part of the system. As used herein, any machine executable instructions, or computer readable media, may be configured to cause a disclosed method to be carried out, e.g. by the system or components thereof as disclosed herein, and may therefore be used synonymously with the term method, or each other.

[0069] As used herein, the term “computer readable medium / media” or “data storage” may include any medium capable of storing a computer program, and may take the form of any conventional non-transitory memory, for example one or more of: random access memory (RAM); a CD; a hard drive; a solid state drive; a memory card; a DVD. The memory may have various arrangements corresponding to those discussed for the circuitry.

[0070] As used herein, the term “communication resources” or “communication interface” may refer to hardware and / or firmware for electronic information transfer. The communication resources / interface may be configured for wired communication (“wired communication resources / interface”) or wireless communication (“wireless communication resources / interface”). Wireless communication resources may include hardware to transmit and receive signals by radio and may include various protocol implementations e.g. the 802.11 standard described in the Institute of Electronics Engineers (IEEE) and Bluetooth™ from the Bluetooth Special Interest Group of Kirkland Wash. Wired communication resources may include; Universal Serial Bus (USB); High-Definition Multimedia Interface (HDMI) or other protocol implementations. The converting machine may include communication resources for wired or wireless communication with an external device and / or server system.

[0071] As used herein, the term “network” or “computer network” may refer to a system for electronic information transfer between a plurality of apparatuses / devices. The network may, for example, include one or more networks of any type, which may include: a Public Land Mobile Network (PLMN); a telephone network (e.g. a Public Switched Telephone Network (PSTN) and / or a wireless network); a local area network (LAN); a metropolitan area network (MAN); a wide area network (WAN); an Internet Protocol Multimedia Subsystem (IMS) network; a private network; the Internet; an intranet; personal area networks (PANs), including with Bluetooth a short-range wireless technology standard.

[0072] As used herein, the term “external device” or “external electronic device” or “peripheral device” may include electronic components external to the converting machine, e.g. arranged at a same location or remote therefrom, which communicate therewith over a computer network. The external device may comprise a communication interface for communication with the machine and / or a server system. The external device may comprise devices including: a smartphone; a PDA; a video game controller; a tablet; a laptop; or other like device.

[0073] As used herein, the term “server system” may refer to electronic components external to converting machine, e.g. arranged at a same location or remote therefrom, which communicate therewith over a computer network. The server system may comprise a communication interface for communication with the converting machine or the external device. The server system can include: a networked-based computer (e.g. a remote server); a cloud-based computer; any other server system.

[0074] Referring to figure 1 a system 2 comprises: a converting machine 4; blanks 6 arranged as a stack 8; an exit module 10; a safety system 12 and; electrical circuitry 14.

[0075] Referring to figures 1 and 2, the converting machine 4 processes sheet material (not illustrated) to the blanks 6 and arranges the blanks 6 as a stack 8.

[0076] As illustrated in figures 1 to 6d, the exit module 10 is for outlet of the stack 8 of processed sheet material 6 and comprises a conveyor system 16 for transmission of said stack 8 from an outlet 18 of the converting machine 4 to a loading area 20. The safety system 12 may be arranged as part of the exit module 10 of the converting machine 4, and ensures safe transmission of the stack 8, as will be discussed.

[0077] The converting machine 4 implements a formation process under the control of the electrical circuitry 14 to provide the stack 8 of blanks 6. The exit module 10 transfers the stack 8 to the loading area 20 under supervision of the safety system 12, both of which are controlled by the electrical circuitry 14. The electrical circuitry 14 is arranged at the converting machine 4. In variant embodiments, which are not illustrated the electrical circuitry may be distributed over one or more components of the system, including an external device and / or a server system. The conveyor system 16 conveys the stack 8 in a longitudinal direction 100. The stack 8 is supported in a plane defined by the longitudinal direction 100 and a lateral direction 102, which is perpendicular to a depth direction 104. As best seen in figure 3b, the stack 8 comprises a front wall 110, back wall 112 and side walls 114. The front wall 110 is at a greater longitudinal position on the conveyor system 16 than the back wall 112.

[0078] The present invention can be applied to many kinds of converting machines, including flat-bed and rotary printing press machines, flexo-folder gluer machines and rotary die-cutter machines. For simplicity, the present description is referring to a rotary die-cutter machine.

[0079] Referring to figure 2, a converting machine 4 in the configuration of a rotary die-cutter 4 is illustrated. The rotary die-cutter machine 4 comprises a plurality of different work modules which print, cut and crease the sheets 6. From the inlet of the converting machine 4 and in a direction of transportation T of the sheets 6, the converting machine 4 may comprise a loading module 9, a feeder module 11 , a printing module 13 comprising a plurality of flexographic printing modules 15, a converting module 17 in the form of a die-cutting module, and an exit module 19 in the form of a palletizer module 19. The converting machine 4 further comprises a main control circuitry, and an operator interface may also be provided in the proximity of the converting machine 4.

[0080] The direction of transportation T is defined from the inlet to the outlet of the converting machine 2. Hence, the direction of transportation T extends from the loader module to the exit module 19.

[0081] To prevent intrusion into the converting machine, a safety system 12 is provided, whereby at least some work modules are closed off such as to create safety zones.

[0082] As illustrated in figures 3a to 6d, the present safety system 12 comprises a presence detection system 22 (see fig. 3a) which includes a stationary presence detection system 40 and an adaptive presence detection system 30. The control circuitry 14 of the safety system 12 is configured to receive control signals from both the stationary presence detection system 40 and the adaptive presence detection system 30. This will be further described in the following.

[0083] [Stationary presence detection system I Light curtain at the machine outlet]

[0084] The outlet 18 of the converting machine 4 is controlled by the stationary presence detection system 40. In the illustrated embodiments, the stationary presence detection system 40 comprises a stationary component 29 which is configured to generate a stationary immaterial barrier 28. That the immaterial barrier 28 is “stationary” means that it remains in the same position when securing the exit of a stack from the outlet 18 of the converting machine 4.

[0085] For each job batch, the stationary immaterial barrier 28 may remain in the same position. However, this does not exclude that the position of the stationary immaterial barrier 28 may be modified if needed to calibrate the setup machine setup.

[0086] This stationary immaterial barrier 28 is designed to enable the stack 8 to exit from the converting machine 4, while providing a detection of intrusion if an inadmissible object (i.e. a human or an object different from the stack) tries to enter through the stationary immaterial barrier 28. However, when a stack 8 is transported through the stationary immaterial barrier 28, there is a risk that a machine operator accesses the machine outlet 18 the back way at the same time. In this scenario, the stationary immaterial barrier 28 may fail to detect the intrusion into the machine outlet 18.

[0087] The stationary component 29 may comprise a proximity sensor system 42. The proximity sensor system 42 is configured to detect an object entering into the safety zone 23 (see fig. 3a). In a first example, the proximity sensor system 42 is implemented as a light curtain, with an emitter and receiver to emit and light to determine whether an object has entered through the light curtain 42.

[0088] The proximity sensor system 42 may be visualised as creating, as the stationary immaterial barrier 28 of the adaptive safety zone 24, a virtual shield / barrier in a 2-dimensional plane (herein a plane defined by the lateral direction 102 and the depth direction 104).

[0089] As illustrated in figures 3a to 6d, the adaptive presence detection system 30 is configured to establish an adaptive safety zone 24 downstream or upstream of the stationary immaterial barrier 28 in the direction of transportation of the stack 8.

[0090] To this effect, the adaptive presence detection system 40 comprises an adaptive component 27. The adaptive component 27 is configured to generate an adaptive immaterial barrier 26, which forms a virtual shield / barrier in a 2-dimensional plane. The adaptive component 27 is movable such as to displace the adaptive immaterial barrier 26.

[0091] The adaptive safety zone 24 is thus arranged between the stationary immaterial barrier 28 and the adaptive immaterial barrier 26. The adaptive component 27 is configured to create the adaptive safety zone 24 to accommodate the stack 8 as the stack 8 is conveyed out from the machine outlet 18. Advantageously, the adaptive safety zone 24 is momentarily established. This means that the adaptive safety zone 24 can be activated to escort a stack 8 out from the stationary immaterial barrier 28 and then deactivated until a following stack 8 arrives. The safety system 12 further comprises a barrier arrangement 44 (see figure 7) to close the sides of the adaptive safety zone 24. In this manner a human cannot access the sides 114 of the stack 8 on the conveyor system 16. The barrier arrangement 44 may be in the form of physical fencing (e.g. made from metal or like), or immaterial barriers such as light curtains.

[0092] In such a way, the barrier arrangement 44 creates a closed off adaptive safety zone 24 by closing off the sides which are not closed off by the stationary component 29 and the adaptive component 27.

[0093] The adaptive safety zone 24 is defined by the position of an adaptive component 27, the stationary component 29, and the barrier arrangement 44 designed to close off the remaining circumference of the safety zone.

[0094] The adaptive component 27 is connected to a movable positioning mechanism 34 which is configured to move adaptive component 27 such that the adaptive immaterial barrier 26 is displaced. The adaptive safety zone 24 is adaptive in that it can be momentarily established while the stack 8 is transported therethrough.

[0095] The stationary presence detection system 40 is arranged in an inactive mode to enable the stack 8 to cross the stationary component 29 of the adaptive safety zone 24. This may also be referred to as “muting” the stationary presence detection system 40.

[0096] As the stationary presence detection system 40 is transitioned to the inactive mode, the adaptive presence detection system 30 is transitioned from the inactive mode to the active mode. This transition is preferably effectuated such that both the stationary presence detection system 40 and the adaptive presence detection system 30 are in an active mode before the stationary presence detection system 40 is entered into an inactive mode.

[0097] As illustrated in the figures, there are various embodiments of creating an adaptive safety zone 24 for escorting the stack 8 through the stationary immaterial barrier 28.

[0098] As illustrated in the embodiments of figures 3a to 3e, 5a to 5f and 6a to 6d, the stationary immaterial barrier 28 may be configured as an inlet port into the adaptive safety zone 24.

[0099] The adaptive component 27 moves the adaptive immaterial barrier 26 to remain downstream of the stack 8 as the stack 8 is displaced (e.g. away from the converting machine outlet 18) by the conveyor system 16. As illustrated in the embodiment of figures 3a to 3e, 4a to 4f and 5a to 5f, the movement of the adaptive component 27 can be effectuated by a linear translation. This movement is effectuated by a movable positioning mechanism 34 which is implemented by translation.

[0100] As illustrated in the embodiment of figures 3a to 3e, the adaptive safety zone 24 is configured such that it surrounds the part of the stack 8 extending through the stationary immaterial barrier 28 as the stack 8 is being conveyed from the machine outlet 18 and out through the stationary immaterial barrier 28. When the stack 8 is determined to have passed the stationary immaterial barrier 28, the stationary immaterial barrier 28 is re-activated (see fig. 3c) and the adaptive component 27 returns to its upstream position (see fig. 3d and 3e). To facilitate the detection of the trajectory and location of the adaptive component 27, position sensors 39 may be provided (see fig. 7).

[0101] As the adaptive component 27 is transitioned from a distal position (figure 3d) to a proximal position (figure 3e), the adaptive presence detection system 30 is transitioned from the active mode to the inactive mode. Distal and proximal can be defined as relative the outlet 18. The distal position can be defined as at the loading area 20. When the movable adaptive immaterial barrier 26 is in the distal position, the adaptive safety zone 24 is in its largest size and accommodates the entire stack 8.

[0102] The proximal position can be defined as closer to the stationary immaterial barrier 28 and thus closer to the machine outlet 18. The proximal position advantageously is selected as a distance downstream of the stationary immaterial barrier 28 which is smaller than a passage for a human. That is, the distance is selected such that a human cannot enter in-between the stationary immaterial barrier and the adaptive immaterial barrier 26. For instance, this distance can be set to between 10 and 20 centimetres.

[0103] When the adaptive immaterial barrier 26 is in the proximal position, the adaptive safety zone 24 is in its smallest size. The electrical circuitry 14 may automatically implement said transition as an approaching stack 8 is detected, e.g. by one of the aforedescribed position determining arrangements.

[0104] Alternatively, as illustrated in figures 6a to 6d, the movement of the adaptive component 27 can be effectuated by a rotation. This movement is effectuated by a movable positioning mechanism 34 which is implemented by rotation. Other aspects of the embodiment of figures 6a to 6d will be described in the following. In other embodiments, and as illustrated in figures 4a to 4f, the stationary immaterial barrier 28 is configured as an outlet port from the adaptive safety zone 24. The adaptive component 27 is thus arranged upstream of the stationary component 29 in the direction of transportation T of the stack 8.

[0105] The adaptive component 27 moves to remain upstream of the stack 8 as the stack 8 is displaced (e.g. away from the converting machine outlet 18) by the conveyor system 16. This allows the stationary component to 29 be muted while ensuring a closed access to the machine outlet 18 with the adaptive component 27.

[0106] As illustrated in the embodiments of figures 4a to 4f and 5a to 5f, the adaptive component 27 may be configured to establish an adaptive safety zone 24 with dimensions to accommodate the entire stack 8 before the stack 8 passes the stationary immaterial barrier 28 to enter into the adaptive safety zone 24.

[0107] This is particularly advantageous when the conveyor 16 defines an angled outlet portion, such as a 90 degree outlet angle for the stack 8.

[0108] This is achieved by allowing the adaptive component 27 to scan the adaptive safety zone 24 and position itself to establish an outlet from the adaptive safety zone 24. The adaptive safety zone 24 may be closed off by at least one adaptive immaterial barrier 26 and fencing 44 (not illustrated).

[0109] As illustrated in figures 4a to 4f, the adaptive component 27 is linearly movable between an upstream position and a downstream position. As illustrated in figure 5a, a stack 8 arrives to the outlet 18 while the stationary component 29 is in an active state. The adaptive component 27 is disabled to let the stack 8 pass into the adaptive safety zone 24. After the stack 8 has passed the adaptive component 27, the adaptive component 27 activates the adaptive immaterial barrier 26 and follows the stack 8 as it is transported in the direction of transportation T. The stationary immaterial barrier 28 is then muted such that the stack 8 can pass through the stationary component 29 (see figures 5c and 5d). The adaptive component 27 stops at a distance upstream of the stationary component 29. This distance is smaller than a space potentially occupied by a human. For instance, the distance may be between 5 and 20 cm. The stationary immaterial barrier 28 is then re-activated, and the adaptable component 27 returns to its upstream position.

[0110] In a further variant (illustrated in figures 6a to 6d), at least a first adaptive component 27a and a second adaptive component 27b are provided. The adaptive safety zone 24 is closed off by fencing at least along the side 102. The first and second adaptive components 27a, 27b are rotatably arranged and are configured to cooperate and rotate in unison to scan the adaptive safety zone 24 before erecting a safety shield at the outlet of the adaptive safety zone 24. Once the stack 8 has passed the stationary component 29, the stationary immaterial barrier 28 is reactivated and the first and second adaptive components 27a, 27b rotate back to their original position (as of figure 7a). During the return to their original positions, the first and second adaptive components 27a, 27b are preferably in an inactive state.

[0111] In another variant (non-illustrated), a single rotatably arranged adaptive component 27 is provided. The adaptive safety zone 24 is closed off by fencing along the sides 100 and 102. The adaptive component 27 is rotatably arranged and is configured to scan the adaptive safety zone 24 before erecting a safety shield 26 at the outlet of the adaptive safety zone 24.

[0112] The presence detection system 22 is configured for detection of an intruding object (not illustrated) into the adaptive safety zone 24. In the event an object penetrates into the adaptive safety zone 24 the presence detection system 22 determines a breach of the adaptive safety zone 24. In response to the determination of said breach the electrical circuitry 14 may control one or more of: a hard stop of the conveyor system 16; disabling the palletizer module of the converting machine, disabling the entire converting machine, a notification via a user interface, e.g. a visual and / or audible notification.

[0113] To this effect, the adaptive presence detection system 30 may comprise a proximity sensor system 32 for detection of said object entering into the adaptive safety zone 24.

[0114] In a first example, the proximity sensor system 32 is a radar system, with an emitter and receiver to emit and receive radio waves to determine whether an object has entered the adaptive safety zone 24.

[0115] In other examples, other suitable sensors are implemented, e.g. a camera system or infra-red sensors.

[0116] The proximity sensor system 32 may be visualised (as shown in figure 3) as creating, as the adaptive immaterial barrier 26, a virtual shield / barrier in a 2-dimensional plane.

[0117] The adaptive presence detection system 30 comprises a movable positioning mechanism 34 to move the adaptive component 27 to adapt the size of the adaptive safety zone 24, e.g. to establish and close the adaptive safety zone 24 at a position upstream or downstream of the stack 8. In a first example, and as illustrated in figures 3a-3f, 4a - 4f, and 5a-5f, the movable positioning mechanism 34 is implemented by translation. As can be seen in these figures, the movable positioning mechanism 34 comprises a translational movable support 36, which is driven to translate by a drive system 38. The drive system 38 may be connected to the conveyor system 16 so that the movable support 36 moves with the conveyed stack 8. Alternatively, a dedicated drive system 38 is separate to the conveyor system 16 but is configured to match the movement of the conveyor system 16.

[0118] Alternatively, and as illustrated in figures 6a -6d, the movable positioning mechanism 34 is implemented by rotation. This embodiment may advantageously be used when the outlet 18 and the loading area 20 are arranged at an angle in relation to each other, such as 90 degrees. As can be seen in figure 8, the movable positioning mechanism 34 comprises first and second rotationally movable supports 36. which are driven to rotate about an axis aligned to the depth direction 104 by a drive system 38. The drive system 38 can be a suitable rotary actuator.

[0119] In variant embodiments, which are not illustrated, the movable positioning mechanism 34 is implemented with other movement actions, including a combination of rotation and translation, e.g. as a combination of the first and second examples.

[0120] As best seen in figure 7, one or a plurality of sensors 39 may be provided at the conveyor 18 at a distance from the stationary component 29. The sensors 39 may advantageously be provided to the embodiments where the ... is moved by translation. The one or plurality of sensors 39 are configured to detect the passage or proximity of the adaptive component 27. The one or plurality of sensors 39 may for instance be induction sensors. The sensors will detect the passage or proximity of the adaptive component 27. In such a way, the activation and inactivation of the stationary immaterial barrier 28 and the adaptive immaterial barrier 26 may be controlled. This will be further described in the following.

[0121] For the movable positioning mechanism 34 examples, the electrical circuitry 14 controls the movable positioning mechanism 34 to position the adaptive component 27 as required, for example to remain downstream or upstream of the front face 112 of the stack 8 as the stack is moving between the outlet 18 and the loading area 20.

[0122] Specifically, the electrical circuitry 14 can determine a position of the stack 8 on the conveyor system 16 and implement the adaptive safety zone 24 to accommodate the stack 8. The electrical circuitry 14 may determine a position of the stack 8 based on various suitable arrangements including:

[0123] A) the provision of a signal from a sensor system (not illustrated) to determine a stack 8 exiting the outlet 18 of the converting machine 4, and a position of the stack on the conveyor system 16 may be subsequently determined by a speed of the conveyor system 16;

[0124] B) camera system with image recognition;

[0125] C) other suitable arrangements, e.g. other proximity sensors or motion tracking systems.

[0126] The electrical circuitry 14 is configured to transition the adaptive presence detection system 30 from an active mode to an inactive mode for displacement of the stack 8 through the adaptive component 28 of the safety barrier.

[0127] The electrical circuitry 14 is configured to transition the stationary presence detection system 40 from an active mode to an inactive mode for displacement of the stack 8 through the stationary immaterial barrier 28. The electrical circuitry 14 may automatically implement said transition as an approaching stack 8 is detected, e.g. by one of the aforedescribed position determining arrangements.

[0128] As the stationary presence detection system 40 transitions from the active mode to the inactive mode, the adaptive presence detection system 30 can be transitioned from the inactive mode to the active mode.

[0129] The electrical circuitry 14 is configured to transition the stationary presence detection system 40 from the inactive mode to the active mode for reactivation of the stationary component 29 after the stack 8 has passed. The electrical circuitry 14 may automatically implement said transition as an approaching stack 8 is detected, e.g. by one of the aforedescribed position determining arrangements.

[0130] A method of implementing an adaptive safety zone 24 of a presence detection system 22 of a converting machine 4 advantageously comprises:

[0131] Step 1 : Transporting a stack 8 towards the outlet 18 of the converting machine 4. The stationary presence detection system 40 is arranged in an active mode. The stationary component 29 is in an active mode such as to generate the stationary immaterial barrier 28. Step 2: Transferring the stack 8 from the outlet 18 by the conveyor system 16 and conveying the stack 8 in a direction towards the stationary immaterial barrier 28.

[0132] Step 3: Activating the adaptive component 27 to generate the adaptable immaterial barrier 26 before the stack 8 touches the stationary immaterial barrier 28. Moving the adaptive component with the positioning mechanism such as to create an adaptive safety zone 24. The adaptive safety zone closing...

[0133] Step 4: Deactivating (i.e. muting) the stationary component 29 to allow the stack 8 to pass the stationary immaterial barrier 28.

[0134] Step 5: Conveying the stack through the stationary immaterial barrier 28 while the adaptable immaterial barrier 26 is in an active state. As the stack 8 reaches a loading area 20, the movable positioning mechanism 34 ceases to move the adaptive component 27 as it has reached its distal position.

[0135] Step 6: Re-activating the stationary component 29 to generate the stationary immaterial barrier 28.

[0136] Step 7: Disabling the adaptive presence detection system 30. Hence, the adaptive presence detection system 30 is transitioned from the active mode to the inactive mode.

[0137] Step 8: Moving the adaptive component 27 from its distal position towards its proximal position. Hence, the adaptive component 27 is returned to its initial position.

[0138] Step 9: Arranging the stack 8 in the loading area 20 such that it may be extracted (not illustrated).

[0139] Variants of the above method are to be contemplated, including those that may be introduced by the various embodiments disclosed herein. For example, the second example where the movable positioning mechanism is implemented by rotation, similar function between the steps is implemented.

[0140] It will be appreciated that any of the disclosed methods (or corresponding apparatuses, programs, data carriers, etc.) may be carried out by either a host or client, depending on the specific implementation (i.e. the disclosed methods / apparatuses are a form of communication(s), and as such, may be carried out from either ‘point of view’, i.e. in corresponding to each other fashion). Furthermore, it will be understood that the terms “receiving” and “transmitting” encompass “inputting” and “outputting” and are not limited to an RF context of transmitting and receiving radio waves. Therefore, for example, a chip or other device or component for realizing embodiments could generate data for output to another chip, device or component, or have as an input data from another chip, device or component, and such an output or input could be referred to as “transmit” and “receive” including gerund forms, that is, “transmitting” and “receiving”, as well as such “transmitting” and “receiving” within an RF context.

Claims

CLAIMS1 . A safety system for an exit module of a converting machine, the converting machine for processing of sheet material, the exit module for outlet of a stack of processed sheet material and comprising a conveyor system for transmission of said stack of processed sheet material in a direction of transportation, the safety system comprising a presence detection system for detection of an intruding object into the exit module, the presence detection system comprises a stationary presence detection system and an adaptive presence detection system, wherein the stationary presence detection system comprises a stationary component configured to generate a stationary immaterial barrier, and the adaptive presence detection system comprises an adaptive component configured to generate an adaptive immaterial barrier, and wherein an adaptive safety zone is arranged between the stationary immaterial barrier and the adaptive immaterial barrier.

2. The safety system according to claim 1 , wherein the adaptive component is movable and configured to create the adaptive safety zone to accommodate the stack as the stack is conveyed out from the machine outlet.

3. The safety system according to claim 1 or 2, wherein the adaptive component is configured to move together with the stack as the stack is displaced out from exit module by the conveyor system.

4. The safety system according to claim 3, wherein the stationary component is located downstream of the adaptive component in the direction of transportation.

5. The safety system according to claim 3, wherein the stationary component is located upstream of the adaptive component in the direction of transportation.

6. The safety system according to claim 1 or 5, wherein the adaptive component is configured to move before the stack as the stack is displaced out from exit module by the conveyor system, and such as to establish an adaptive safety zone with a fixed volume before the stack is conveyed into said safety zone.

7. The safety system according to claim 3, wherein the adaptive component is configured to follow the stack until the stack is displaced though the stationary component.

8. The safety system according to any one of the preceding claims, wherein the stationary component is an immaterial barrier, preferably a light curtain.

9. The safety system according to any one of the preceding claims, wherein the stationary component is arranged for transition from an active mode to an inactive mode for displacement of the stack through the stationary component.

10. The safety system of any preceding claim, wherein the adaptive component comprises a movable immaterial barrier.11 . The safety system of any preceding claim, wherein the adaptive component of the presence detection system comprises a proximity sensor system for detection of an object entering into the adaptive safety zone.

12. The safety system of claim 11 , wherein the proximity sensor implements radio waves to determine proximity of the object to the adaptive safety zone.

13. The safety system of either of claims 11 or 12, wherein the proximity sensor system implements the adaptive safety zone to include a movable virtual shield in a 2-dimensional plane.

14. The safety system of any preceding claim, wherein the adaptive component is configured to transition between a proximal position which is proximal the outlet of the converting machine, and a distal position distal the outlet of the converting machine, and wherein the adaptive component is in the proximal position before the stack has passed the stationary immaterial barrier, and in the distal position when the stack has passed the stationary immaterial barrier.

15. The safety system of any preceding claim, further comprising a movable positioning mechanism to move the proximity sensor system to adapt size of the adaptive safety zone.

16. The safety system of claim 15, wherein the movable positioning mechanism is arranged to move the proximity sensor system by a translation and / or a rotation.

17. The safety system of any preceding claim comprising electrical circuitry to: determine a position of the stack on the conveyor system, and;to move the adaptable component of the adaptive safety zone based on said determined position.

18. The safety system of any preceding claim, wherein the adaptive presence detection system is arranged for transition from an inactive mode to an active mode subsequent to one or more of:- transition of a stationary presence detection system from an active to an inactive mode;- determination of a stack exiting an outlet of the converting machine, and;- passing of a stack through the stationary presence detection system.

19. The safety system of any preceding claim, wherein the stationary component is arranged for transition from the inactive mode to the active mode subsequent to subsequent to passing of the stack through the stationary component.

20. The safety system of any preceding claim comprising a barrier arrangement arranged to define sides of the adaptive safety zone and to restrict access to the sides of the conveyor system and the stack on the conveyor system.

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