Count and Build Fingers for Interfolder Pack Separation
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Solution Overview
Problem
Existing methods for separating stacks of folded or interfolded sheets into packs are inefficient, particularly in terms of speed and flexibility, and often result in increased downtime due to jamming issues and inflexible final folding operations.
Innovation Solution
The apparatus employs count fingers and build fingers to initiate and complete packs, allowing for the separation and transportation of packs while maintaining continuous operation, with features like pivotable motion and deflection to handle jams, and includes a method for flexible final folding of panels using strip fingers and fluid emitters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods are used for separating stacks of folded sheets into packs, then the equipment can perform separation operations, but the operational speed is limited and downtime increases due to jamming issues
Solution Approach 1:
The apparatus divides the separation operation into discrete segments using individual separator fingers that can independently engage and disengage from the sheet stack. Each separator finger operates autonomously to separate individual packs, allowing continuous operation without system-wide interruptions when jams occur.
Solution Approach 2:
The separator fingers are designed with pivotable motion capabilities, transitioning from a static separation mechanism to a dynamic one. The fingers can pivot into and out of engagement positions, enabling them to adapt to varying sheet conditions and clear jams by retracting when obstructions are detected, thus maintaining continuous operation.
2Productivity
If traditional separation methods are used, then packs can be separated, but the final folding operations are inflexible and reduce system operation speed
Solution Approach 1:
The panel folding fingers are designed with pivotable motion, allowing them to dynamically adjust their position and orientation during the folding process. This dynamic capability enables the system to handle various sheet configurations and folding patterns, increasing both speed and flexibility of final folding operations.
Solution Approach 2:
The apparatus performs preliminary folding actions on panels before final pack completion. By pre-positioning and pre-folding panels using the pivotable fingers, the system prepares sheets for final packaging more efficiently, reducing overall operation time while maintaining flexibility for different product configurations.
3Reliability
If separator fingers are positioned to engage folds, then packs can be separated, but the fingers may cause jamming issues
Solution Approach 1:
The separator fingers transition from fixed position to pivotable motion, allowing them to dynamically adjust during operation. When a jam is detected or anticipated, the fingers can pivot out of the way, preventing jams while maintaining reliable separation during normal operation. This dynamic adjustment resolves the contradiction between engagement reliability and jam prevention.
Solution Approach 2:
The apparatus incorporates preliminary anti-action by positioning and orienting separator fingers to anticipate potential jamming conditions before they occur. The pivotable design allows pre-positioning of fingers to engage folds optimally, and the ability to retract or pivot away when abnormal conditions are detected, preventing jams before they disrupt operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly increases operational speed and reduces downtime by decoupling pack separation from other processes, enabling faster system operation and improved handling of jams and misfeeds.
Implementation Method 1
fluid emitters
Data Source
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AI summary
An interfolder separator apparatus and method utilize a pair of count fingers that are movable longitudinally along and transversely to a stream of folded sheets, for temporarily supporting each successive pack formed by the separator and then releasing each successive pack when partly completed to alternating build fingers, so that the operation of separating successive packs from one another is performed separately from the operations of completing the build of each pack and transporting the completed packs to downstream operations. The count fingers may be mounted to pivot about axes that are movable longitudinally along and transversely to the stream of sheets. A first or last panel of the completed pack may also be folded back partly upon itself, after the partly completed pack is released by the count fingers. Some or all of the fingers may be spring loaded and automatically resettable for clearing jams.