Sheet Deceleration Apparatus with Kicker and Vacuum Conveyor
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Solution Overview
Problem
Existing sheet stacking machines have limitations in increasing stacking capacity beyond a certain speed due to sheet bouncing and damage from high-speed projection against backstops, and existing deceleration methods face challenges with machine wear and drive issues at higher speeds.
Innovation Solution
A sheet deceleration apparatus using rotatable rollers with reciprocal movement and a vacuum conveyor to reduce sheet speed before reaching the stacking hopper, allowing for increased conveyor speed without sheet damage and reduced machine wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the entry conveyor speed is increased to improve stacking capacity, then the number of sheets stacked per unit time increases, but the sheets bounce back toward the entry conveyor and may damage protruding tabs or flaps on the leading edge
Solution Approach 1:
A deceleration apparatus is introduced as an intermediary device between the entry conveyor and the stacking hopper. This apparatus includes a series of rollers that progressively reduce sheet speed, allowing the conveyor to run at high speeds while delivering sheets at controlled, safe speeds to prevent bouncing and damage.
Solution Approach 2:
The deceleration apparatus performs speed reduction in advance, before sheets reach the stacking hopper. By progressively slowing sheets through multiple roller stages prior to stacking, the system prepares sheets for safe reception at the hopper while maintaining high conveyor throughput.
2Speed
If fixed rollers are used to decelerate sheets by ramping speed up and down repeatedly, then sheet speed can be controlled, but machine wear and tear increases due to repeated high speed acceleration and deceleration
Solution Approach 1:
The deceleration function is divided into multiple independent roller stages rather than using a single roller that must repeatedly accelerate and decelerate. Each roller or small group of rollers maintains relatively constant speed, performing only a portion of the total deceleration task, which eliminates repeated high-speed cycling and reduces wear.
Solution Approach 2:
The system dynamically distributes the deceleration load across multiple rollers that can independently adjust their contribution to speed reduction. This dynamic distribution allows each component to operate within optimal, steady-state conditions rather than subjecting any single component to repeated extreme accelerations and decelerations.
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
The apparatus effectively decelerates sheets to prevent bouncing and damage, enabling higher stacking capacities while minimizing machine wear and maintaining continuous operation at elevated speeds.
Implementation Method 1
A vacuum conveyor is further provided along the travel path subsequent the first and second rollers to control delivery of the sheet to a stacking hopper
Data Source
AI summary
A sheet deceleration apparatus includes a pair of rotatable rollers, being rotatable about first and second axes, the rollers positioned on opposite sides of the travel path. At least one of the rollers is moveable relative to the other to nip the sheet between the rollers to reduce the travel speed of the sheet. A vacuum conveyor is further provided along the travel path subsequent the pair of rollers to control delivery of the sheet to a stacking hopper. A third rotatable roller, or similar apparatus, may be included in some embodiments, for pushing the sheet of material away from the vacuum conveyor at the appropriate time.