The present invention relates to a conveyor system with an adjustable length for a converting machine.
Converting machines are used in the production of paperboard and cardboard boxes, such as folding boxes. These machines comprise a plurality of workstations which may print, cut, crease, fold, count and stack blanks. The blank is initially placed in a feeder module and is conveyed through the different workstations.
The converting machines need to be adapted to different format of boxes, and this often leads to adjusting the position of a conveyor belt system, or changing transportation lengths of conveyor belt systems.
Document WO22028894 discloses a transfer module for a folder gluer machine. The transfer module comprises a conveyor belt with a displaceable outlet end. The conveyor belt is provided a variable contact length, over which the conveyor belt is in contact with the blanks. The contact length of the conveyor belt is held into shape of by a support structure including a plurality of rollers attached to each other in a chain. When the position of the displaceable outlet end is changed, some rollers enter into a storage area in the transfer module.
In view of the prior art, there is a need to provide a compact and reliable conveyor adjustment mechanism which can be easily integrated into different workstations. This object is solved by a conveyor system according to claim 1.
According to a first aspect of the present invention, there is provided a conveyor system for transporting blanks in a converting machine, the conveyor system comprising an endless first conveyor belt and a support structure, wherein the first conveyor belt is configured to convey the blanks along a direction of transportation, the first conveyor belt having a contact length supported by the support structure and a return length.
The support structure comprises a plurality of rollers, each roller being attached to a roller frame and arranged in a line, the roller frames being connected to each other by a connection mechanism.
A plurality of the roller frames is movable in the direction of transportation, and wherein a displacement mechanism is configured to displace a distal movable roller frame at a displacement distance in the direction of transportation.
The connection mechanism is extendable and retractable in the direction of transportation, such that the contact length of the first conveyor belt is modified and all rollers remain in contact with the first conveyor belt.
A “plurality of roller frames” can be defined as at least some of a plurality of successive and adjacent roller frames.
Preferably, the blanks are only in contact with the first conveyor belt along the contact length.
In an embodiment, at least one distal roller frame is stationary.
The roller frame can also be referred to as a “roller carriage” or “roller block”. With all rollers we mean all the rollers in the line from the distal fixed roller to the distal movable roller. Hence, all rollers remain in contact with the first conveyor belt independently of the change in contact length.
In an embodiment, a plurality of roller frames is slidably mounted to a linear guide rail. The guide rail is connected to a fixed frame portion, connected to a chassis of a work module.
Each roller may be mounted on a separate roller frame. Alternatively, a plurality of rollers is provided on each roller frame.
In an embodiment, the connection mechanism is configured to impart an equidistant displacement distance between the rollers. The equidistant displacement is an equal distribution of the change in contact length.
In an embodiment, the connection mechanism comprises a plurality of pivotable connection links. The pivotable connection links may comprise a first linear connection element and a second linear connection element, and wherein the linear connection elements form a cross, the first and second linear connection elements having their central pivot point and connection to each roller frame in the center of the cross.
The linear elements may be further connected in an upper pivot point and a lower pivot point, and wherein the upper and lower pivot points are horizontally immobile but vertically mobile in response to a displacement distance from the displacement mechanism, and wherein the central pivot point is horizontally movable in the direction of transportation but vertically immobile.
The first and second linear connection elements may each have a first convex shape and a second convex shape, and wherein the central pivot point is located between the first and second convex shapes. The first and second convex shapes may be hollow in the center.
In an embodiment, the conveyor system further comprising a movable compensation roller configured to change the return length of the conveyor belt.
In an embodiment, the conveyor system further comprises a second conveyor belt arranged after the first conveyor belt in the direction of transportation, and wherein the second conveyor belt is supported by a second support structure, and wherein the displacement mechanism is configured to increase the contact length of one conveyor belt, while reducing the contact length of the other conveyor belt with the same amount.
The displacement mechanism may further comprise a connection frame connected to the distal movable roller frames of the support structures of the first conveyor belt and the second conveyor belt, respectively. The connection frame is configured to perform a reciprocating movement in the direction of transportation.
In an embodiment, the connection frame is further attached to a compensation roller of the first conveyor belt and a compensation roller of the second conveyor bel, whereby a displacement of the connection frame both modifies the contact lengths and the return lengths of the first and second conveyor belts.
The displacement mechanism may comprise a motor and a displacement conveyor, and wherein the displacement conveyor is attached to the connection frame.
Alternatively, the displacement mechanism comprises a linearly movable piston actuator connected to the connection frame.
The invention will now be described with reference to the appended drawings, in which like features are denoted with the same reference numbers and in which:
Referring to the figures and in particular to
The present folder gluer machine 1 comprises a series of different workstations in the form of modules. The modules include, from an inlet to an outlet: a feeder module 10, a fold pre-breaking module 12, a gluing module 14 and a folding module 16. After the folding and gluing modules, a conditioning section 20 can be provided in order to count and separate a shingled stream of folding boxes 2 into separate batches and to arrange them together in banded stacks. The conditioning section 20 of the folder gluer 1 may comprise a counter and separator module 22, optionally a shingle inverter 24, a transfer module 26 arranged after the shingle inverter 24, a stacker module 28 configured to arrange the folding boxes 2 in stacks, and a banding module 29.
Several types of modules sometimes need to have their conveyance adapted to the format of the boxes 2 to be produced. Such examples include for example a transfer module 26 as illustrated in
As best seen in
The inventors have found that work modules of a converting machine 1 can be provided with a conveyor system 30 with a variable contact length Lc of at least one conveyor belt 32. Such a variation in contact length Lc may have different advantageous technical effects and applications in terms of variable positions, distances, and transportation speeds.
As illustrated in
As illustrated in
A possible application for this configuration is a conveyor system 30 for a separator module 22, where a batch of boxes 2 is separated and spaced apart from an upstream shingled stream of boxes 2. This is preferably done by a separator head 94 which momentarily stops an upstream-located shingled stream of boxes 2 while accelerating the batch to be separated at an increased speed in the direction of transportation D.
As illustrated in
The trajectory of the return path Lr is supported by a plurality of guide rollers 42, a compensation roller 44 and a drive sprocket 46. The compensation roller 44 is configured to change the trajectory of the conveyor belt 32 in the return path Pr. The compensation roller 44 thus accommodates for changes in the contact length Lc by modifying the return length Lr of the conveyor belt 32 in the return path Pr.
As best seen in
The drive sprocket 46 is connected to a motor (not illustrated) and is configured to drive the conveyor belt 32 in motion. The conveyor belt 32 may comprise engagement means, such as a dented surface which engages with the drive sprocket 46.
As best seen in
The contact length Lc of the conveyor belt 32 is thus supported by support rollers 52 arranged in a line and extending in the direction of transportation D. Over the contact length Lc, a first distal roller 34′ may be configured as the inlet roller 34′ and a second distal roller 36′ may be configured as the outlet roller 36′. Each support roller 52 is rotatably attached to a roller frame 54 by a pin 58. The support rollers 52 are preferably idle.
The conveyor system 30 may have one of the inlet roller 34′ and outlet roller 36′ stationary arranged, while the other roller 34′, 36′ is movable in the direction of transportation D. The roller frame 54 of the stationary arranged roller 34′, 36′ can be fixedly connected to the longitudinal frame member 60 of the work module. Alternatively, and as illustrated in
The sliders 57a of the roller frames 54 are slidably mounted onto the guide rail 57b. The guide rail 57b is fixedly mounted to the longitudinal frame member 60. The guide rail 57b restricts the movement of the roller frames 54 to the direction of transportation D.
The roller frames 54 are connected to each other in a line by the connection mechanism 62. The connection mechanism 62 is extendable and retractable in the direction of conveyance D such that a distance d1 between the support rollers 52 can be changed.
The connection mechanism 62 comprises a plurality of pivotable connection links 64. A pivotable connection link 64 is arranged between each of the roller frames 54. The connection mechanism 62 is configured such that a change in contact length ΔLc of the conveyor belt 32 is distributed over the plurality of pivotable connection links 64 in an equidistant displacement. The pivotable connection links 64 are thus configured to impart an equidistant displacement Ad between the roller frames 54. This means that when one of the roller frames 54 is displaced at a distance Δd, the remaining roller frames 54 are displaced at the same distance Δd.
The equidistant displacement may be calculated as:
Δd=ΔLc/N
where:
In order to restrict the displacement to be equidistant and to maintain an equal distance d1 between the rollers 56, the pivotable connection link 64 comprises a central pivot 66 connected to each roller frame 54, an upper pivot 68 and a lower pivot 70. The pivotable connection links 64 can be provided by two linear elements 64a, 64b.
In a preferred embodiment, the pivotable connection link 64 is symmetrical about a horizontal axis H extending through the central pivot 66. The horizontal axis H is coinciding with the longitudinal extension L of the support structure 38.
In this configuration, the pivotable connection links 64 form a plurality of “X-shapes” where the central pivot 66 is connected to each roller frame 54. By connecting the roller frames 54 to the central pivot 66, the horizontal position of the central pivot 66 is kept constant. However, a distance h1 between the central pivot 66 and the upper pivot is variable. As best seen in
The pivotable connection links 64 can be provided by two linear elements 64a, 64b, each provided with a first convex shape 65a and a second convex shape 65b. The convex shape allows the strain to be better distributed in the connection links 64. Alternatively, as illustrated in
As illustrated in
In another embodiment, and as illustrated in
The connection frame 76 may also be connected to a compensation roller 44 and configured to provide an equal displacement of the movable distal roller 36′ and the compensation roller 44. In such a way, the absolute amount of displacement in the contact length Lc and the return length Lr is equal. If the contact length Lc increases with a length ΔLc, the return length Lr decreases with a length ΔLc, and vice versa.
Referring to back to
As illustrated in
This is further illustrated in
Preferably, and as best seen in
As illustrated in
The conveyor system 30 illustrated in
As best seen in
The separator head 94 is configured to move up and down in the vertical direction V between a counting position A and a separating position B. A batch is separated from an upstream shingled stream of boxes 2 when the separator head 94 descends from the counting position A into the separating position B.
The separator head 94 is provided with a thrust plate 96 (also referred to as “stop plate”) and an evacuation conveyor 98. The evacuation conveyor 98 comprises at least one evacuation conveyor belt 99. Preferably, the evacuation conveyor 98 comprises two parallel evacuation conveyor belts 99. This allows the evacuation conveyor 98 to transport the boxes 2 while preventing rotation of the boxes 2.
The thrust plate 96 is configured to abut against the front leading edges 5a of the upstream shingled stream of boxes 2 such that they are momentarily stopped. A longitudinal separation point Ps can be defined by the position of the thrust plate 96. While the upstream-located boxes 2 are stopped, the evacuation conveyor belts 99 are moved at a speed V3. Preferably, the speed of the evacuation belts 99 changes from zero to V3.
The counting device 92 is configured to count the number of boxes 2 passing by the counting device 92. The counting device 92 may comprise a photoelectric cell, which optically detects the front leading edge 5a of the boxes 2. Alternatively, a mechanical counting device 92 may be used. For instance, a counting wheel can be in contact with the shingled stream of boxes 2 and can be configured to count in response to a registered up and down movement of the counting wheel.
When a desired number of boxes 2 has passed the counting device 92, the separator head 94 is moved downwardly into the separating position B to stop the remaining shingled stream of boxes 2. The separated batch can then be further conveyed to towards the banding module 29.
To further space the separated batch apart from the upstream shingled stream of boxes 2, the transportation speed of the separated batch may advantageously be increased downstream of the separation point Ps. In order to provide an increased transportation speed, the batch of boxes is accelerated after the location of the thrust plate 96.
In order to provide a speed difference, the lower conveyor system 30 is provided with a first conveyor belt 32a and a second conveyor belt 32b as illustrated in
The first conveyor belt 32a is driven at a speed V1. The first speed V1 may be the same speed as an upstream-located module.
The second conveyor belt 32b is configured to be accelerated between a second speed V2 and a third speed V3. The second speed V2 may be equal to the first speed V1 of the first conveyor belt 32a. The third speed V3 is higher than the first speed V1. The third speed V3 is also higher than the second speed V2.
The descent of thrust plate 96 is preferably located over the second conveyor belt 32b. Alternatively, the thrust plate 96 can be located in the transition point T between the first conveyor belt 32a and the second conveyor belt 32b.
When the separator head 94 is in the counting position A, the second conveyor belt 32b of the lower conveyor may be driven at the same speed V1 as the first conveyor belt 32a of the lower conveyor system 30.
The upper evacuation conveyor belts 99 and the lower evacuation conveyor belt 32b are moved at the same speed V3 when the separator head is in the evacuation position B. Both the upper evacuation conveyor belts 99 and the lower evacuation conveyor belt 32b are accelerated once the separator head 94 reaches the evacuation position B.
The conveyor system 30 may be further connected to a control system 100 comprising a control unit 102 and a memory 104. The control system 100 is configured to determine the longitudinal position (in the direction of transportation D) of the separator head 94 in relation to the number of boxes 2 to be included in each bundle and the format of the boxes 2. The longer the boxes 2 are in the direction of transportation D and/or the more boxes 2 to be included in each bundle, the longer accumulation distance L_coll (see
The control system 100 may be configured to determine a theoretical longitudinal separation point Ps of the separator head 94 based on box dimensions entered into the control system 100. However, there may be some variations in the conveyance of the boxes 2. Therefore, the separator head 94 may be further configured to adapt its longitudinal position in response to information from the counting device 92.
The counting device 92 indicates the number of boxes 2 that has passed downstream of the separation point Ps. At the passage of the last box 2 in a predefined number of the bundle, the counting device may also provide a time of passage of the front edge 5a of the last box 2 which indicates a register position to the separator head 94. In such a way, the separator head 94 can descend with precision and keep a constant and predetermined number of boxes 2 in each bundle.
The transition point T between the first conveyor belt 32a and the second conveyor belt 32b can be determined from the position of the separator head 94. For instance, the transition point T may be located at a predetermined distance ds from the separator head. The transition point T between the first and the second conveyor belts 32a, 32b may dynamically follow the longitudinal position of the separator head 94 for each batch of boxes 2.
A first mechanism enabling such an adjustment is a top frame portion 95 of the counter-separator module to which the separator head 94 is movably mounted. The top frame portion 95 may comprise a slide rail 93 (see
The boxes 2 are pinched in between the upper evacuation conveyor belts 99 and the lower evacuation conveyor 32b. This provides an improved stability of the shingled stream of boxes 2 and smaller formats of boxes can be handled with increased stability as they are supported on both the top and the bottom sides.
The conveyor system 30 may comprise a first lower conveyor system 30a and a second lower conveyor system 30b arranged parallel in relation to each other. Hence, both conveyor systems comprise a first conveyor belt 32a and the second conveyor belt 32b. In this embodiment, the upper evacuation conveyor also preferably comprises a first and a second evacuation conveyor belt 99. In such a way, the boxes 2 are pinched between four conveyor belts.
Number | Date | Country | Kind |
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21217128.4 | Dec 2021 | EP | regional |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2022/086930 | 12/20/2022 | WO |