Patent Application
20250074024
The present disclosure is directed to a bridge and truck assemblies for a rotary device. More specifically, the present disclosure is directed to an adaptive or adjustable bridge and truck assemblies for a press die station.
Conventional bridges and trucks in a rotary converting industry are typically manufactured to apply a downward force in two fixed locations over the rotary die's bearers. In order to apply the downward force in varying locations in the press die station, it requires some form of variation(s) in the conventional bridge and truck design. For instance, one variation in the conventional bridge design can be forming a milled slot thereof and employing a slider in the slot to allow the operator to slide a jack screw to a desired location. However, in this configuration, the slot and slider must be loose-fitting causing vibration and noise, and/or additionally, significantly reducing the bridge stiffness. As for regards to variation of the truck design, this requires some sort of sliding bearing block with a set screw to hold the block in place, requiring a tool for adjustments. When the sliding mechanism is a slot in a plate of the truck, this weakens the truck due to the presence of the slot. Moreover, most conventional bridge and truck designs require a tool(s) (e.g., hex key type wrench) for adjustment while adapting and setting up the press between jobs. However, this introduces a potential for tools to drop down into the press. In many cases, it will be difficult for the operator to get down into the press to find the missing tool. Furthermore, in this situation, the operator may unknowingly start the press which can cause damage to the rotary device, the web or even the press drive system should the tool get caught between the rotating assemblies. Moreover, operators typically use mechanical bridge clamps to put pressure on die and anvil rollers, which is a manual process, and operators have to repeat the pressure set-up (by feel) with every changeover.
Therefore, there is a need in the art for a bridge and truck assemblies that do not suffer from the above shortcomings.
In an example embodiment, a rotary device is disclosed which includes a bridge attached to a frame of the rotary device, and a truck disposed adjacent to the bridge and configured to support at least two block assemblies thereof, wherein the at least two block assemblies are configured to be moveable with respect to each other. The truck includes a shaft such that the at least two block assemblies slide on the shaft and locks in place at different locations along the shaft, wherein a downward force is applied against a top portion of the at least two block assemblies to apply pressure against a topmost roller of the plurality of rollers.
Other features and advantages of the present invention will be apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.
The present disclosure provides an adaptive (or adjustable) bridge and truck assemblies that are designed to allow an operator to apply downward force anywhere across a full width of a press without the need to use any additional tools, such as, for example, a hex key type wrench. As such, repeatable and accurate results of the downward force over the press are achieved, i.e., uniform and repeatable pressure across the roller. In addition, the pressing operation is less prone to human error and reduces downtime/costs associated with setup, improves safety by reducing operators from working inside of the press machines, eliminates rotary damage, extends rotary life, produces higher quality and consistent product, and/or increases throughput by eliminating stoppages to address the aforementioned problems. As such, this enables the operator to simplify die pressure setup including setting up quicker between press operations, i.e., makes the press change-over quicker and simpler by offering adjustments and controls that are quick, simple, ergonomic, and tool-free.
Some specific features associated with the present truck and bridge assemblies include, for example, but not limited to:
As shown, each end portion of rollers 11, 12, 13 (via shafts) is placed in an opening 16 at each side portion 17 of the frame 15 and secured in place. At a top portion 18 of the frame 15, a bridge 40 is attached to the frame 15 thereof. It should be appreciated that the bridge 40 can be removed from the frame 15 for quick die pressure set up changeover or maintenance. The bridge 40 is configured to hold and secure two hydrajacks 22 (manufactured by RotoMetrics) for applying pressure to the rollers 11, 12, 13. More specifically, the hydrajacks 22 apply pressure directly to (top) roller 11. The hydrajacks 22 allow press operators to easily monitor die cutting force, and as a result, decrease downtime and increase the operating life of the die. Further, the hydrajacks 22 include an adjustable handle 23 for adjusting the pressure and a pressure gauge 24 to measure and monitor the applied pressure. In one implementation, the hydrajacks 22 are calibrated in pounds of force to certified national standards. For example, hydrajacks 22 can produce pressures of approximately 500 psi to 3000 psi. It should be appreciated that the hydrajacks 22 can be sized so that 1 psi pressure equals 1 pound of downward force. As shown in
Referring now to
The bridge 40 further includes two slide block assemblies 45 that can move (i.e., translate, slide) (as shown by arrows A) along two round shafts 44a, 44b, which are attached between each end block 41. In some implementations, the two slide block assemblies 45 can move towards each other or the two slide block assemblies 45 can move away from each other. The movement of the two slide block assemblies 45 works in conjunction with the truck 80. That is, the translational movements allow for the two slide block assemblies 45 to be directly above the truck 80 for applying pressure via the hydrajacks 22. This enables a precise and accurate displacement of the slide block assemblies 45. On top of each slide block assembly 45 includes a support 47 for supporting the jacking screw 27 of the hydrajack 22. In an example embodiment, the support 47 includes a cam lock assembly 51 and a cam lock adapter plate 52 (
As shown in
Referring now to
Referring now to
In some implementations, the lock pin assembly 70 includes a lock pin 71 and a lock pin magnet 72 that cooperatively engage with each other. For example, a portion of the lock pin 71, (e.g., an outer circumference) can be made from a magnetic material which acts with the lock pin magnet 72. In one implementation, the lock pin 71 and the lock pin magnet 72 can be neodymium magnets acting as permanent magnets. By way of example, when the lock pin 71 is rotated (i.e., ¼ of a turn), as shown in
As shown in
Referring now to
In some implementations, the truck 80 includes an end block 81 disposed at each end of the truck 80. The end blocks 81 are configured to be inserted into and held in the slot 16 of the side portion 17 of frame 15. In one implementation, each end block 81 contains a set screw 83 to fix a shaft 85 in its place and prevent the shaft 85 from moving. Similarly, the truck 80 also includes two slide block assemblies 82 that can move (i.e., translate, slide) (as shown by arrows B) along the shaft 85, attached between each end block 81. In some implementations, the two slide block assemblies 82 can move towards each other or the two slide block assemblies 82 can move away from each other. In other implementations, the two slide block assemblies 82 can move in tandem. In other words, the two slide block assemblies 82 move together (or concurrently) in the same direction. It should be understood that the movement of the two slide block assemblies 82 works in conjunction with the bridge 40 disposed above. That is, the translational movements allow for the two slide block assemblies 82 to be directly below the bridge 40 that supports the hydrajacks 22, allowing for a precise and accurate displacement of the slide block assemblies 82. On top of each slide block assembly 82 includes the metal contact pad 98 for receiving the jacking screw 27 of the hydrajack 22. It should be appreciated that the metal contact pad 98 is configured as a wear-resistant surface to apply the downward force against thereof.
Referring to
As similarly discussed above, in order to lock and release the slide block assembly 82 from shaft 85, the slide block assembly 82 includes a spring-loaded brake leaf 87 at each side portion 88 of the slide block assembly 82. One end 89 of the spring-loaded brake leaf 87 is attached (or inserted into) to a slot portion 90 (
In some implementations, each slide block assembly 82 includes two ball bearings 95 that are free to spin on a bearing pin 96. The bearing pin 96 is held against the slide block assembly 82 and fastened with a fastener 97, i.e., a screw, for example. In some implementations, the ball bearings 95 are lubricated so as extend the life of the ball bearings 95 as well as the rotary tooling in the press. In one implementation, the ball bearings 95 are lubricated via felt cords 100 that directly or indirectly contact the ball bearings 95. For example, the felt cords 100 are three short cut-offs that contact the ball bearings 95, where lubricant (e.g., oil) is contained in an oil cup assembly 99. It should be appreciated that there may be less than or more than a three-corded felt design. The oil cup assembly 99 includes a cup portion 102 for containing and receiving the lubricant and a tube 104 that distributes the oil to the felt cords 100. The tube 104 extends into a cut-out portion 105 formed in the body of the slide block assembly 82 near the opening 86 (
In other configurations, the oil cup assembly 99 is not required to lubricate the felt cords 100. For example, as shown in
In some implementations, the rotary system 10 can include a control unit (not shown) including a controller functionally coupled to a sensor(s) for determining the exact location of the block assemblies on the shaft bar for proper applied pressure against the rollers or dies. This ensures a precise and accurate pressure application of the rotary system. In other implementations, the sensor(s) can be used to determine at least one characteristic property of a material or product used to be treated of the rotary device. Such characteristic property could be type of material being treated, specific parts of the material being treated, thickness of a specific material, or specific tools required for changeover, such as, but not limited to, rotary dies, nip rollers, bridge and trucks, cables, hand tools, roll lift/crane, etc. In such a way, the sensor(s) can determine a type of profile of each material or product and transmit such data to the control unit which can operate the pressure (up to 1000 psi, for example) using information provided by the sensor(s). As such, it is possible to treat, via pressure, the materials, having individual and varying characteristics in the rotary device. In other implementations, sensor(s) can be a load cell sensor so as to sense misalignment or tolerance stack-ups that cause positional variation between the truck and the rollers or dies depending on the block assembly position along the bar shaft.
In other implementations, sensor(s), as controlled by the controller, can determine the type of material or product and applied pressure thereof subsequent to being directed to the press. Subsequently, a database of historical runs (stored in a storage, for example) corresponding with the same or similar material can be used to lookup what pressure was used to produce desirable results in the past. Moreover, the controller is adapted or configured to provide alerts/logging information and receive historical run data or updates to software or firmware from the storage or storage device such as cloud storage or the Internet of Things (“IoT”) as is well known and not further discussed herein.
The articles “a” and “an,” as used herein, mean one or more when applied to any feature in embodiments of the present disclosure described in the specification and claims. The use of “a” and “an” does not limit the meaning to a single feature unless such a limit is specifically stated. The article “the” preceding singular or plural nouns or noun phrases denotes a particular specified feature or particular specified features and may have a singular or plural connotation depending upon the context in which it is used. The adjective “any” means one, some, or all indiscriminately of whatever quantity.
“At least one,” as used herein, means one or more and thus includes individual components as well as mixtures/combinations.
The transitional terms “comprising”, “consisting essentially of” and “consisting of”, when used in the appended claims, in original and amended form, define the claim scope with respect to what unrecited additional claim elements or steps, if any, are excluded from the scope of the claim(s). The term “comprising” is intended to be inclusive or open-ended and does not exclude any additional, unrecited element, method, step or material. The term “consisting of” excludes any element, step or material other than those specified in the claim and, in the latter instance, impurities ordinarily associated with the specified material(s). The term “consisting essentially of” limits the scope of a claim to the specified elements, steps or material(s) and those that do not materially affect the basic and novel characteristic(s) of the claimed disclosure. All materials and methods described herein that embody the present disclosure can, in alternate embodiments, be more specifically defined by any of the transitional terms “comprising,” “consisting essentially of,” and “consisting of.”
Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It will be understood that, if an element is referred to as being “connected” or “coupled” to another element, it can be directly connected, or coupled, to the other element or intervening elements may be present. In contrast, if an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.).
Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,” “upper” and the like) may be used herein for ease of description to describe one element or a relationship between a feature and another element or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, for example, the term “below” can encompass both an orientation that is above, as well as, below. The device may be otherwise oriented (rotated 90 degrees or viewed or referenced at other orientations) and the spatially relative descriptors used herein should be interpreted accordingly.
Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures). As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, may be expected. Thus, example embodiments should not be construed as limited to the particular shapes of regions illustrated herein but may include deviations in shapes that result, for example, from manufacturing.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
While the disclosure has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
