Patent Application
20090188212
Some coupon insertion devices separate the forwardmost coupon from a continuous web (coupon source) and eject the separated coupon into a container as the container passes a designated location for insertion. The present invention relates to an apparatus for automatically adjusting the pressure (or space) between a pair of opposed rollers to effectuate coupon separation.
It is a common advertising and promotional technique to place coupons or other items into containers, such as cartons for breakfast cereal or snack items, along with the product to be sold. The consumer may use the coupon for whatever purpose intended, such as for discounts on future purchases or a rebate. Many devices have been provided for depositing coupons into containers in the present day packaging industry.
It is to be understood that the word “coupon” is used in its broadest possible sense to include any coupon, card, sheet, receipt, warranty, ticket prize, premium or other part, whether two-dimensional or three-dimensional, that can advantageously be handled as described hereinafter. Similarly, “container” is used in the broadest possible sense to include containers such as boxes, tubs, cans and vessels of all kinds as well as any other coupon-receiver which can advantageously be used with the present system.
Commonly assigned U.S. Pat. Nos. 5,784,861, 5,588,286, and 5,941,053, each fully incorporated by reference herein, disclose coupon insertion devices receiving a supply of coupons from a reel and inserting them sequentially into an array of containers. The coupons are fed between first and second pairs of opposing rollers. The rollers may be a single roller, a pair of rollers or more than two rollers. When more than one roller is utilized, it is contemplated that a belt is secured by the two rollers to effectuate movement in the direction of the rollers. Differential speeds of the first and second pairs of rollers create what is known by those skilled in the art as “bursting” through which the forwardmost coupon is separated and projected into the container. Bursting is where the faster of the pairs of rollers is able to effectuate separation of an entering coupon from the coupon source.
While prior devices are effective in inserting flat or two-dimensional coupons into containers, there has been a need for similar equipment used for three-dimensional coupons having a height or thickness which is greater than conventional flat coupons, and/or which are irregular in configuration. In instances where the coupon is three-dimensional, damage to the coupon as a result of too much pressure being applied is a possibility.
Coupon insertion devices have been introduced in which the opposing pairs of rollers are vertically adjustable relative to each other to accommodate coupons of varying sizes and shapes. Such systems typically employ drive belts to power the rollers in the opposing sets and a crank shaft to adjust the space between the rollers. However, a corresponding design issue is maintaining desired pressure applied between opposing sets of rollers as the apparatus is adjusted to accommodate coupons of varying thicknesses.
Conventional coupon insertion devices have addressed similar problems through the use of manual cranks for adjusting pressure applied to the coupons. However, these systems increase the complexity of the apparatus and the associated manufacturing and repair cost. In addition, these systems have been found to increase wear of the drive belts. Also, these systems did not address the situation where there was “slipping” of a coupon, i.e., where the entering coupon was directed to be torn off the coupon source but did not separate.
The above-listed needs are met or exceeded by the present apparatus for automatic belt pressure adjustment for coupon separation which features a control system for automatically moving the upper rollers relative to the lower rollers to adjust the spacing for accommodating coupons of varying shapes or thicknesses. A moving carriage system includes a main carriage housing that supports the upper rollers. The main carriage housing is adapted to be slidably adjustable between the closed and open positions, such that in the closed position, the space between the upper rollers and lower rollers is relatively small. In addition, the present system includes a coupon sensor disposed between the opposed pairs of rollers to determine whether a coupon has passed from one pair of rollers to the second. In the event that the coupon does not pass, an automated belt adjustment is initiated to apply more pressure (decrease the space between the upper and lower rollers) to the surface of the entering coupon so that more pressure is applied to allow the coupon to effectuate separation from the first set of rollers to the second set of rollers.
More specifically, a coupon insertion apparatus for inserting coupons from a coupon source into receiving containers is provided, including a machine frame, at least one pair of opposed rollers including at least one upper roller and at least one lower roller mounted to the machine frame and being adjustable between a closed position and an open position. A moving carriage system includes a main carriage housing having the at least one upper roller automatically slidably adjustable between the closed and open positions, when in the closed position, the main carriage pressures a surface of an entering coupon for effectuating separation of the entering coupon from the coupon source. A control system is constructed and arranged for automating movement of the main carriage relative to the machine frame.
In another embodiment, a coupon insertion system is configured for sequentially inserting coupons into receiving containers. The coupon insertion system includes a portable frame, at least one pair of opposed rollers mounted to the frame and adjustable between a closed position and an open position. A moving carriage system includes a main carriage automatically slidably adjustable between the open and closed positions. When in the closed position the main carriage pressures a surface of an entering coupon for effectuating separation of the entering coupon from the coupon source. A control system is also provided for automating movement of the main carriage.
In still another embodiment, a method for inserting coupons from a coupon source to a receiving container is provided. The method includes the steps of feeding an entering coupon from the coupon source into at least one pair of opposed rollers which are adjustable between a closed and an open position. The at least one pair of opposed rollers includes an upper roller mounted to a main carriage housing and a lower roller mounted to a frame. Next, the position of a main carriage system including the main carriage housing is automatically slidably adjusted using a motor to apply pressure to the entering coupon to effectuate separation of the entering coupon from the coupon source by positioning the at least one pair of rollers in the closed position. Lastly, the opposed rollers are driven in both the closed and open positions such that the entering coupon is separated from the coupon source and directed across a second pair of opposed rollers and into a receiving container.
Generally, the present coupon insertion apparatus receives a continuous web of separatable coupons (also known as a coupon source), pulls the entering coupon away from the coupon source, such as a reel of coupons, and dispenses the separated coupon at a predetermined time into a moving container as it passes a predetermined location. The present coupon insertion apparatus automatically adjusts the position between a pair of opposed rollers on the surface of the entering coupon. The rollers may be a single roller, a pair of rollers or more than two rollers. When more than one roller is utilized, it is contemplated that a belt is secured by the more than one roller. For purposes of the present application, the rollers are described individually or as a pair. It is to be understood, however, that in many embodiments of the present invention, a belt is secured by the rollers to effectuate movement in the direction of the rollers. The closer together the rollers are is known as the closed position, while when the rollers are further apart, is known as the open position. A main carriage housing is automatically slidably adjustable to adjust the space between the rollers to account for varying dimensions of the coupon, such that a three-dimensional coupon can be separated from a coupon source as easily has a two-dimensional coupon. An exemplary conventional coupon insertion apparatus is described in greater detail in commonly assigned U.S. Pat. No. 5,784,861, hereby fully incorporated by reference.
Referring now to
The apparatus 10 includes a machine frame 16. Machine frames 16 for use in the present invention can be of any rigid material, preferably sufficiently rigid so as to withstand the torque being applied by the motor 28 on the main carriage housing 26, also referred to herein as the main carriage. It is contemplated that the machine frame 16 be a continuous sheet of metal large enough to accommodate at least one pair of opposed rollers, the moving carriage housing 26 and drive belts as described above. It is also contemplated that the machine frame 16 may be hollow, such that the frame only includes areas where the rollers or main carriage 26 are attached to it. This is desired, for example, in portable applications where it is desired that the apparatus be as light as possible. Importantly, it is contemplated that certain embodiments of the present coupon separation apparatus are easily maneuverable, such that the apparatus may be mounted on wheels or able to be easily disassembled and reassembled. The present frame remains stationary during coupon insertion, and to which are mounted a drive frame 17 and a plurality of opposed upper and lower positioning rollers 18 and 20, each plurality of rollers being surrounded by a respective suitable endless conveyor belt 22, 24. The belts 22, 24 are preferably made of a resilient, rubber or rubber-like material with enhanced coupon gripping properties to facilitate the movement of coupons through the apparatus 10.
While the lower positioning rollers 20 are positioned on the drive frame 17 at a fixed location, the upper positioning rollers 18 are vertically movable between a closed position (
The vertical adjustment of the upper rollers 18 is accomplished using a motor 28 to automatically slidably adjust the position of the main carriage housing 26, which is mounted on a linear slide 30 and includes a main support block 32 secured to the machine frame 16. A captured, rotatable threaded rod 34 (
In the preferred coupon insertion apparatus 10, there are two sets of upper rollers, the upper positioning rollers 18, and a plurality of upper feed rollers 36, also provided with a corresponding endless conveyor belt 38. The upper feed rollers 36 oppose a corresponding set of lower feed rollers 40, also provided with a corresponding conveyor belt 42. The belts 22, 24, 38 and 42 are preferably of similar construction. It will be understood that the feed rollers 36, 40 are duplicates of the positioning rollers 18, 20, and as such the following description of the positioning rollers will apply to the feed rollers as well.
The feed rollers 36, 40 receive the coupons from the feed roll or bandolier (coupon source), depending on the particular coupon, and passing the coupons to the positioning rollers 18, 20, which ultimately transmit or project the coupons into the waiting container. However, as discussed above, the apparatus 10 is usable in either direction, so that the feed rollers 36, 40 can become the positioning rollers 18, 20.
During bursting or separation of the entering coupon from the coupon source, the positioning rollers 18, 20 are driven at a predetermined rotational speed by a drive source 52 such as a servo drive motor. Other motors may also be used, as would be appreciated by those skilled in the art. At the same time, the feed rollers 36, 40 are stopped. The feed rollers 36, 40 draw a web of coupons toward a bight 48 formed by the positioning rollers 18, 20.
At a predetermined time, the positioning rollers 18, 20 tear the forwardmost coupon from the next succeeding coupon along the perforated line of separation and inject forwardmost coupon at a predetermined location. The feed rollers 36, 40 then cause the leading edge of the forwardmost coupon to enter the bight 48 between positioning rollers 18, 20. At least one coupon sensor 50 is provided in operational relationship to the rollers 18, 20 and 36, 40 to provide a control system with sensed coupon location information. The location of the sensor 50 may vary to suit the application. For example, a sensor may be provided between the lower, fixed rollers. As is known in the art, and described in greater detail in U.S. Pat. No. 5,784,861, variations in the speeds of the motors 44, 46 cause coupons to be sequentially separated from the web of coupons and projected at high speed into a designated container.
Referring now to
The present coupon separation apparatus 10 also preferably includes a control system 60 that is constructed and arranged for automating movement of the main carriage housing 26 relative to the machine frame 16 along the axis of the threaded rod 34. Once a coupon enters the bight 48 between the rollers 18, 20 the control system 60 signals the motor 28 to move the opposed rollers to the closed position, to obtain the coupon separation as described above. The control system 94 automates the amount of torque applied via the threaded rod 34 for moving the main carriage housing 26 to the closed position (as well as the open position).
The moving carriage system preferably also includes an orientation sensor 62 that is constructed and arranged for determining the orientation of the coupon separation apparatus 10 and communicating the orientation to the control system 60. It is contemplated that the coupon separation apparatus 10 may be positioned in any manner convenient to separate the coupon from the coupon source and distribute the coupon into a container or the like. Moreover, it is contemplated that orientation sensor 62 may be positioned anywhere on the machine, including on the moving carriage, on the frame or internally, for example, in an electric box.
It is also contemplated that an existing assembly line may not have sufficient room to allow addition of a separate coupon separation apparatus. Therefore, it is contemplated that the present coupon separation apparatus may be angled, or raised, or even inverted to accommodate being added to an existing assembly line. Since gravity assists the movement of the main carriage housing 26 toward the open position, if the apparatus 10 is inverted, the motor 28 will have to work harder to move the main carriage housing to the same position, since the unit will be operating against gravity. Thus, the control system 60 is configured to accommodate such changes in motor loading.
Referring now to
In operation, the entering coupon from the coupon source is initiated into the coupon separation apparatus 10. Upon initiation of the first coupon, a sensor (not shown), either preferably within the belt of either the upper or lower roller or upon entry of the first ticket onto the lower roller, signals the control system 60 to initiate the process of coupon separation. Upon initiation, the control system 60 signals the motor 28 to raise the main carriage housing to the fully open position, as depicted in
Referring now to
Next, the main carriage 26 will move to the closed position for a predetermined time period at 116, preferably six seconds. This time period is based on the particular embodiment shown in
When the main carriage housing 26 has been lowered for six seconds, the motor 28 automatically stalls, thereby stopping any further movement by the main carriage housing. This is designed to prevent any damage to the coupon and any possible over-exertion of pressure from the top roller 18 on the main carriage housing 26 onto the lower roller 20. Again, it is contemplated that a time period other than six seconds may be utilized depending on the application. Such instances would occur when the coupon, for example, is a three-dimensional object. In such cases, it would take less time for the main carriage housing 26 to be in contact with a top surface of the entering coupon and to exert the desired pressure to the top surface of the coupon. As such, movement of the main carriage housing 26 to the closed position is halted upon exerting pressure on the coupon. It is contemplated that a sensor could be in place to detect this pressure.
Once movement of the main carriage housing 26 to the closed position has been halted, either by the passing of six seconds or by the motor 28 stalling out due to height of the coupon, the position mode is entered at 120. The position mode 120 will hold the carriage housing in its current position. The position mode process is described above with respect to
As shown in
The coupon sensor 64 and torque sensor or monitor can preferably sense when the forwardmost coupon is not successfully burst from the web (passes the second set of rollers 36, 40). If the coupon is burst, the coupon sensor 64 will note the passage of the coupon and the torque sensor or monitor will confirm the amount of torque being applied. This information can then be communicated to the control system 60, which will allow the coupon source to continue feeding coupons to the first set of opposed rollers. In the event that the coupon sensor 64 and torque sensor or monitor detect that a coupon is not passed from the first set of opposed rollers 18, 20 to the second set of opposed rollers 36, 40, the coupon sensor 64 and torque sensor or monitor communicate such information to the control system 60.
In response, the control system 60 exerts more pressure utilizing the motor 28 to adjustably slide the main carriage housing 26 even further to the closed position, on the surface of the next coupon to promote separation of the coupon between the first and second pair of opposed rollers 18, 20. The coupon sensor 64 will then detect again following the exertion of more pressure on the surface of the coupons.
Provided that the coupon has passed on this attempt, the control system 60 will be signaled to maintain the new pressure (also known as the new closed position) exerted on the surface of the each coupon from the coupon source. In the event that the coupon has still not passed, more pressure will be signaled, again utilizing the motor 28 to adjustably slide the main carriage housing 26 further in the closed position, to be placed onto the surface of the next coupon. This process continues until the coupon sensor detects that the coupon has passed.
It is also contemplated by the present coupon separation apparatus can be dynamic, and adapt to using multiple types of coupons without having to stop the insertion process and manually reset the settings of the apparatus, including the space of the closed position. For example, in certain instances it may be desired to insert 100 two-dimensional coupons followed by 100 plastic three-dimensional rings and back again. It is contemplated that the 100 coupons and 100 rings may be from the same coupon source, i.e., the last coupon is separately attached to the first ring. Additionally, or alternatively, it is contemplated that a feeding system is used to feed the coupons/rings into the apparatus. In the instance where the two different coupons are from the same coupon source, the first 100 coupons will be distributed as previously described. Upon entry of the first ring, however, the control system will automatically cause the main carriage housing to move to the fully open position. It is also contemplated that differing coupons may be alternated, such that a coupon is followed by a ring and then followed by another coupon. Thus, it is contemplated that individual pressure measurements may be taken and dynamically adjusted between coupons. The pressure measurements can be taken by a combination of a coupon sensor and a torque sensor or monitor. Once the correct torque has been determined, the main carriage housing will shift to either the closed position or the open position to exert the correct amount of pressure on the coupon as has been described herein. It is contemplated that the control system may also be programmed to automatically adjust for the differences in coupons. Due to the difference in height of the two coupons, the main carriage will close until exerting pressure on the top of the first ring. Once the correct closed position has been determined, the process of separation will continue as described herein.
While a particular embodiment of the present coupon insertion apparatus has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.
