Patent Application
20050081694
The invention relates generally to automated punching machines for perforating stacks of sheets. More particularly, the invention relates to a fully automated machine for processing a stack of sheets to punch individual lifts therefrom.
In the paper finishing industry, sheet stacks are transferred between processing equipment as various steps are performed on the stacks of sheets. This transfer is typically classified as “in-line” or “off-line,” and sometimes “near-line.”
“In-line” refers to two pieces of processing equipment having their paper paths joined together such that individual sheets are passed from one system to the other sequentially and processed as such. While there are many examples of such “in-line” processing, one such prominent example is designed following the Xerox DFA (Digital Finishing Architecture) Standard. The DFA protocol spells out mechanical and software specifications for attaching finishing machinery to DFA compatible Xerox sheet printers. Many vendors make secondary equipment to create systems using this standard, including Standard Finishing, C. P. Bourg, Duplo, and others.
“In-line” systems are advantageous in that they require minimal operator interaction, and therefore, have lower overhead and least opportunity for operator error. The entire system is locked in a one-to-one speed relationship, however, limiting the performance of the entire system to that of the slowest component. Accordingly, a major disadvantage of the “in-line” system is the lack of a buffer to allow for continued processing by some portions of the system if other portions of the system temporarily cease operations. Another disadvantage is reduced versatility from two types of processing modules that are complexly coupled, inhibiting their separate use for other functions.
“Off-line” refers to sheets being transferred in some non-automatic fashion, usually in stacks of sheets. Examples include simple carts to and from which sheet stacks are manually transferred by an operator. “Off-line” systems have the advantage of being able to match a slower module to a faster device, optimizing overall performance. Additionally, the components of such “off-line” processing are not tightly coupled, allowing for more versatile use of each module. “Off-line” processing, however, necessarily requires greater operator interaction than “in-line” processing, increasing labor costs as well as the opportunity for operator error in the form of both mechanically damaged sheet stacks or movement of the stacks out of sequence, when sequence is important.
“Near-line” refers to a special case of “off-line” processing where the carts are more elaborate and custom mated to automatically receive and discharge sheet stacks. It is commonly accepted that a throughput ratio of 2:1 or greater may be matched with such near-line processing. The stacks may be electronically tracked to ensure sequence of processing, as disclosed in U.S. Pat. No. 6,192,295 BI to Gunther. One example of this type of “near-line” processing is marketed by GTI. In the GTI cart system, stacks are laid on a cart and the cart is manually rolled to a feeder. The GTI cart is designed to custom mate to the GTI stacker and GTI feeder. Although operator error is less than the opportunity with true “off-line” the chance is not eliminated. The GTI cart has a clamping system that secures the stacks from movement, however, the system requires considerable operator effort to operate.
Automatic die-punching machines have been utilized in both “off-line” and “near-line” arrangements to punch regular, repeating patterns of holes through stacks of paper sheets in preparation for binding. Typically, such a machine receives a stack and actuates die pins to punch the appropriate holes through each sheet in the stack or lift at once. The pins are then reset to punch holes in another stack. Since printing or document reproduction businesses, often handle particular binding jobs consisting of a large number of thick stacks, a principal advantage of automatic die-punching machines is their capacity to efficiently perform a uniform, repetitive, high speed punching operation, potentially requiring a high punching force, on a collection of stacks that is fed into the machine.
Although automatic die-punching machines improve the punching process, regular die maintenance or changing the machine's punching parameters for particular punching jobs can be a time-consuming process requiring disassembly of the machine. For example, the size or arrangement of holes, and the number of sheets per stack vary widely among punching jobs, requiring particular configurations or locations of die pins. Also, the service life of die pins varies inversely with frequency of their use. As a result, frequent modification of the punching parameters or regular die pin maintenance requires stopping the machine for disassembly, thus decreasing efficiency of the machine.
Mitigation of these difficulties has been attempted. For example, U.S. Pat. No. 6,047,623 (the '623 patent) to Whiteman, et al., describes an “improved die assembly and mounting means, allowing the die assembly to be quickly installed and removed without bolts, screws, or housing panel removal.” According to the disclosure, “the die assembly need not be bolted to the machine frame . . . and may be quickly removed simply by being unclamped . . . and slid out of the machine housing.” This construction of such devices allows quick and easy maintenance and changeover of the die pins, although it is subject to a number of associated shortcomings.
In particular, the '623 patent fails in its entirety to address the proper positioning of a die assembly within the machine. Placement of the holes along the edge of a stack of sheets includes the considerations not only of centering the holes along the length and insuring that no partial holes are made along the edge of the stack, but also placing the holes the desired distance from the edge of the stack of sheets. The desired hole placement in a paper will be dependent upon not only the size, shape, number, and positioning of the holes, but also the size of the paper itself. Machines in the industry, including that disclosed in the '623 patent, require further manual adjustments in order to account for these considerations. Proper location and placement of the punch in more complex, automated punching machines is further complicated by the sheer size and mechanical functions involved in punching stacks of sheets.
The punch may be structured such that the die set is disposed along the sheet path or in the sheet path. In arrangements where the die set is disposed along the sheet path, the sheet or stack of sheets advance along the sheet path with a side edge of the sheets stopping at the die set, the side edge of the sheets being disposed in the die set. Following the punch action, the sheets continue along the sheet path. In contrast, in arrangements where the die set is disposed in the sheet path, typically, the leading edge of the sheets registers within the die set as it hits a stop, arresting forward movement. Following the punching action, the stop is mechanically moved, and the sheets continue through the open die set.
Both of these arrangements have their limitations and disadvantages, however. For example, in arrangements where the die set is disposed along the sheet path, undesirable catch points can inhibit proper sheet flow. Moreover, the momentum developed in the sheets as they move along the sheet path can cause the sheets to skew in the die set, resulting in poor registration. While die sets disposed in the sheet path may provide better registration, die sets used in such arrangements must be more rigid than die sets disposed along the sheet path. Further, changing out such die sets can be complicated, time consuming and laborious.
It is a primary object of this invention to provide a fully automated punch machine for processing a large stack of sheets, wherein the punch machine provides a truly “near-line” processing. A related object is to provide a punch machine which requires minimum operator intervention.
Another object of the invention is to provide a punch machine that is convenient to operate and requires minimum operator intervention. A related object is to provide such a machine that may process not only a given stack of sheets, but also successive stacks of sheets without operator intervention.
An additional object is to provide a punch machine that provides enhanced operator safety. A related object is to provide a punch machine that operates in a closed environment once the sheet stack is placed at the machine by the user.
A further object of the invention is to provide a punch machine that minimizes the opportunity for operator error in setup, providing die set recognition and fully automatic setup. A related object is to provide a punch machine that automatically provides proper placement of perforations in a stack of sheets upon entry or reading of punch type and paper size.
An additional object of the invention is to provide a punch machine that minimizes jams and provides smooth movement and processing of successive lifts from a stack of sheets. A related object is to provide a punch machine that alerts the operator to potential problems in the system.
A further object of the invention is to provide a punch machine that operates in an entirely automated and enclosed atmosphere from receipt of a stack of sheets to be punched to delivery of a punched stack of sheets in the same order.
Yet another object of the invention is to provide a punch machine that readily and quickly interfaces with a mobile unit for transfer and maintenance of a stack of sheets to be processed and a processed stack of sheets.
Still a further object of the invention is to provide an automated punch machine that may be engaged with other processing machines in an “in-line” arrangement for processing stacks of sheets.
In accordance with these and other features of the invention, there is provided a punch machine that requires minimal or no intervention by an operator in order to process successive stacks of sheets. The machine includes a significantly enclosed housing having two retractable doors for input and output adjacent input and output platforms extending from the housing. The input and output platforms have alternating finger(s) and slot(s), a plurality of belts extending longitudinally about the fingers or other movement arrangement disposed to move stacks of sheets on the platforms in and out of the machine. Similar finger(s) and slot(s) or other movement arrangement from a movable cart may mate with the input and output platforms of the machine to provide easy handling of stacks of sheets. In operation, a stack of sheets is placed on the input platform. At an appropriate time, the retractable input door opens, and the belts or other movement arrangement are activated to move the stack along the platform into the machine to an input elevator having similar engaging fingers disposed between the slots of the rotating belts or alternate engaging arrangement disposed to elevate the stack. A similar output elevator platform is provided adjacent the output of the machine, only instead of feeding the stack of sheets into the machine for processing as in the input elevator, the output elevator receives the processed sheets, moving downward as the output stack increases, and eventually moving the completed output stack from the elevator past the open retractable output door to the output platform.
In processing, the input elevator is driven upward until a sensor is actuated to slow the upward movement of the input elevator. Successive lifts are then picked from the stack and moved along a transport to a punch station. The picker may be set up to lift varied numbers of sheets in a single lift, dependent upon the thickness of the sheets themselves. Such lifts are preferably of a thickness between 20 to 50 thousandths of an inch, which is typically between 4-12 sheets, depending upon sheet thickness, but may range from as little as one sheet to as many as 15 or 20 sheets. In this regard, the lift arrangement preferably provides two sensors, the first of which provides a zeroing effect, and the second of which, a Hall effect potentiometer, measures the thickness of the lift as the elevator continues to move the stack of sheets upward.
The sheet path through the machine is preferably that of an “L” shape or the like such that that stack of sheets moves along one leg of the “L” to affirmatively register in the proper position in the die set. Once dropped into the punch station, various alignment features are actuated to align the lift and feed it into the throat of the die set. After punching, the stack of sheets then moves out of the die set in a substantially perpendicular direction, along the other leg of the “L.” In this way, the punching arrangement provides the positive registration features of a die set arrangement that passes the sheets through the die set, while providing the versatility of a die set disposed along the sheet path in the direction of travel. While the preferred embodiment of the invention has the input and output legs of the sheet path disposed at a substantially right angle, it will be appreciated that the legs could alternately be disposed at essentially any angle less than approximately 135° and greater than approximately 45°, so long as the sheets are provided with positive registration at the punch rather than passing along or physically through the punch.
The die set itself includes automatic alignment and positional features that digitally control both the location of the punched holes and the depth of the throat based upon the configurations of the die set and the paper. In initial setup, the die set is slid into an initial feed position at which point a flange or the like on the die set is affirmatively engaged with the machine, and the machine then automatically continues the machine setup for the given die set loaded. In this regard, individual die sets are provided with a bar code or other identifying arrangement, and the machine is provided with an appropriate reader. From the initial position, the machine then draws the die set across the reader and provides a signal to the machine controls to adjust the other features of the machine for the die set loaded. Thus, the machine automatically adjusts not only to the size of paper, but also to the die set, and therefore, punch arrangement provided.
After punching, the lift is transported to an inverter, where it is inverted to an output stack as described above. Safety features are likewise provided at both the inverter and the output stack to ensure proper sheet movement through the system. In this regard, a sensor is likewise provided at the output stack to sense if a problem occurs at the output stack, stopping the machine and alerting the operator in such a case.
Thus, the machine provides minimal necessity for operator intervention, as well as minimal opportunity for operator or other error. Importantly, the machine includes buffering features whereby a stack of sheets may be waiting to be processed on the input platform while a completed stack is seated on the output platform, and a third stack is being processed within the machine itself. Thus, the operator is free to safely load and unload the stacks of sheets as his schedule permits. Moreover, the punch machine requires no specialized or devoted cassettes or the like for ushering the stack of sheets through the system.
These and other objects and advantages of the invention as well as additional innovative features will be apparent from the description of the invention provided herein.
a-c are fragmentary, perspective views of a pick assembly constructed in accordance with teachings of the invention at various stages of operation.
a-e are side elevational views of the punch station of
a-b are perspective views of a cover plate of the output stacker at various stages of operation.
Turning now to the drawings, there is shown in
In accordance with the invention, the operator may load a stack of sheets to be processed at the input 34, provide any necessary information regarding the processing of the stack at the control panel 38, and retrieve the processed stack of sheets from the output 36 without any further intervention during the processing. Alternately, the punch may be mated with an automated processing such that it automatically receives a stack of sheets to be punched and delivers the punched stack for further processing. In order to provide for reliable and easy loading and unloading of stacks of sheets from the machine, the machine includes input and output platforms 40, 42. As described in greater detail in Provisional Patent Application No. 60/341,173 filed Dec. 13, 2001, and PCT Application PCT/US0239834 filed Dec. 13, 2002, both of which are assigned to the assignee of the present application and are hereby incorporated in their entirety for all they disclose, the input and output platforms 40, 42 are preferably slotted, having a plurality of alternating platform fingers 44, 46 and platform slots 48, 50. The platforms 40, 42 further include a plurality of individual belts 52, 54 disposed to rotate longitudinally along the outer surface of the platform fingers 44, 46, respectively. To easily move stacks of sheets between the punch machine 30 and other processing modules or storage, a mobile unit or movable cart 56, such as is shown in
According to an important feature of the invention, stacks of sheets may be supported on both the input and output platforms 40, 42 of the punch machine while actual processing is occurring within the punch machine 30 on a third stack of documents. Moreover, once a stack of sheets to be processed is placed on the input platform 40 and proper information confirmed on or fed into the control panel 38 regarding the stack, no further interface is required from the operator in order to process the stack. That is, once the stack of sheets being processed within the machine 30 is complete, if no other stack is sensed on the output platform 42, the belts 54 will advance the recently completed stack to the output platform 42, and the waiting stack of sheets on the input platform 40 will be automatically received and processed within the machine 30.
To further minimize any opportunity for improper intervention as well as to minimize any opportunity for operator injury, the punch machine 30 includes retractable doors 64, 66 at both the input 34, 36 of the machine 30. The retractable doors 64, 66 are preferably automatically operated such that they open only when a stack of sheets is to be moved in or out of the punch machine 30. In the currently preferred embodiment, the doors 64, 66 are flexible, multipanel doors that are appropriately driven to roll up into door housings 68, 70 provided along the punch machine housing 32. In this way, it will be appreciated that any retaining rolling force on the doors 64, 66 may be released to allow the doors to close merely due to the force of gravity, minimizing the automation required. It will be appreciated, however, that the doors may alternately be opened and closed automatically and that alternate door styles, such as sideways sliding doors, may be provided.
In operation, upon completion of processing a stack of sheets within the machine 30, providing that no processed stack is waiting to be unloaded at the output platform 42, the input and output retractable doors 64, 66 will automatically open, the belts 52, 54 rotated to move a stack of sheets to be processed from the input platform 40 into the machine 30 and a completed stack of sheets out of the machine to the output platform 42. The machine 30 then processes the newly input stack while the operator is free to remove the finished stack from the output platform 42 and load a new stack onto the input platform 40. In the case where no additional stacks will be processed, upon completion of punching a stack, the output retractable door 66 will open. Belts 54 will then be driven to move the completed stack of sheets to the output platform 42, and the retractable door 66 will close. Each of these and other functions of the machine 30 may be controlled by any appropriate arrangement including, for example, a microprocessor or digital control.
Turning now to the functions performed within the machine itself, as shown at the broken away sections of
Turning now to a more detailed disclosure of the operation and function of the various components of the punch machine 30,
Turning now to
As the slotted platform 80 moves upward, the movement will continue until it reaches proper engagement position for picking, or separation, of lifts therefrom. In this regard, and referring to
Returning now to the operation of the picking device 90 itself, in order to separate a lift 112, the picking device 90 includes a pick 94 preferably centrally disposed along the stack of sheets 92 to engage the edge of the stack of sheets 92 and separate a lift 112 therefrom. (See
As shown in
The pincer blade 110 is preferably a relatively flat and thin, elongated blade structure. In the currently preferred embodiment, the pincer blade 110 is approximately one-half inch thick and on the order of 0.076 inch think. In contrast to the roller 111, the pincer blade 110 is mounted to move both linearly and vertically by way of a cam arrangement 115 (see
Thus, in picking the lift 112, the roller 111 and the pincer blade 110 are driven forward toward the stack 92 to dispose roller 111 above the upper surface of the lift 112 and the pincer blade 110 in the opening created by the pick 94 between lift 112 and the stack of sheets 92 (see
Turning now to
To provide proper fore/aft alignment of the lift 112 and to force the lift into the throat 150 of the die 138, a plurality of justifiers 152 are provided. As may best be seen in
As delivered to the punch station 74, the lateral position of the lift 112 may vary considerably. In order to ensure proper centering and accurate punching, alignment plates 142 (see
The ram 154 is actuated by any appropriate mechanism to apply a closing force to the die 138 and drive the pins through the lift 112 received in the throat 150. As the pins retract, several operations are performed in the punch station 74 to cause the punched lift 112 to move toward the inverter 76. As the punch pins retract, the alignment plates 142 drop outward and downward out of engagement with the stack of sheets. One or more rollers 160, here two rollers, rotatably mounted above the lift 112 move downward to force the lift 112 against driven rollers 162 disposed subjacent the lift 112 (as shown in
In the preferred embodiment of the invention, the sheet path by which the sheets enter the punch is preferably substantially perpendicular to the sheet path as the sheets exit the punch and move toward the inverter. It will be appreciated by those of skill in the art that the input and output sheet paths may be alternately disposed so long as the sheets still have positive registration at the punch, yet are not required to pass through the punch. While this right angle provides the most desirable registration, the angle between the input and output sheet paths may vary, for example, from approximately 45° to 135°. Alternately, it will be appreciated that many aspects of the invention would likewise be applicable to “pass along” or “pass through” type punch arrangements.
As the driven rollers 162 advance the punched lift 112 laterally, it is received in a nip 164 formed at yet another transport arrangement 166. As illustrated in
As the inverted lift exits the belts 168, 174 at the drum 176, the momentum of the moving lift causes it to hit the side plate 182 of the output tray 180 before settling onto the output stack 178. In order to minimize any springback resulting from the lift hitting the side plate 182, one or more high friction, one-way rollers 184 are disposed along the upper surface of the lift as it exits the turnover drum 176. In this way, the high friction surface of the rollers 184 prevents or minimizes springback, while the one-way rotation of the rollers 184 allows the forward movement of the lift.
In order to further ensure alignment of the trailing edge of the lift leaving the inverter 76, one or more side justifiers 190 are provided opposite the side plate 182 of the output tray 180. Following each lift, the side justifiers 190 pivot toward the output stack 178 and square up the edge of the stack closest to the inverter 76. As may be seen in
The side plate 182 may be adjusted by any appropriate means in order to accommodate various paper sizes. In the embodiment illustrated, the side plate 182 includes a bracket 222 having a threaded section 224 movably disposed along a threaded rod 228, which is rotatably mounted and driven to adjust the location of the bracket 222 and, accordingly, the side plate 182. As with the kickers 136, justifiers 152, and alignment plates 142, the side plate may be adjusted either manually, or automatically in response to controls indicating the size of the sheets to be punched.
As may be seen in
The movement of the perforation cover plate 188 is likewise determined by rotating rods and a cam arrangement. More particularly, the movement of the perforation cover plate 188 is determined by pins, or followers 234, 235 disposed in slots 236, 237. It will be noted that the upper slots 236 are relatively straight, while the lower slots 237 have an S-shape or an offset. In this way, as the perforation cover plate 188 moves upward and the pins 234 reach the offset end of slots 237 (see
Thus, the punch machine provides a highly automated punching and processing arrangement that requires minimal intervention and input by an operator. This minimal input consequently minimizing the opportunity for operator or other error with regard to the processing instructions. In keeping with these primary objectives, the punch station 174 includes features which allow the automatic adjustment of and positioning of the die set 138.
As shown in
In order to provide for automated adjustment of the lateral position of the die set 138 within the machine 30, as well as the depth of the die throat 150, the punch station 74 further includes an arrangement for reading the die set 138 to determine its arrangement, size, etc., and adjusting the lateral location of a die set 138 and depth of the die throat 150. To this end, there is provided a mating engagement structure, here, a detent, or hook 270 which receives the engagement shaft 258, and effectively locks thereto. This engagement and locking may be obtained as a result of the operator sliding the die set 138 into position and physically causing engagement, or the punch station 74 may be provided with a mechanism by which the machine physically continues sliding the die set 138 into the engagement position. In any event, once the engagement shaft 258 is secured to the hook 270, the machine 30 automatically activates to draw the die set 138 in across a bar code reader or other identifying mechanism. The die set 138 identifying marker may include alternate structure, such as, for example, a radio frequency tag or an array of mechanical switches. In this regard, movement of the hook 270 is provided by a small motor 272 or other means to rotate the threaded shaft 274 (see
Once the machine has recorded the die set pertinent information and the paper size to be punched, the machine digitally determines and moves the die set 138 to the appropriate lateral position. It will thus be appreciated by those of skill in the art that by moving the position of the die set 138 itself, the machine eliminates the necessity of any repositioning of the alignment features related to the feeding of the individual lifts themselves. It is to be noted that, in some punch and paper configurations, some pins may require manual pulling from the die set 138. Under these circumstances, inasmuch as the machine has processed data related to both the die set and paper configurations, the instructions for pulling said pins may optionally be displayed on the control panel 38 or an alternate control panel on the machine.
It will be appreciated by those of skill in the art that such a slide arrangement for receiving the die set 138 relative to the ram 154, the centerline of the plurality of die pins 250 will always be disposed along substantially the same ram position in the machine. That being the case, under certain conditions, it may be desirable to adjust the distance of the resulting punched holes from the edge of the paper. In accordance with an important feature of the invention, the depth of the throat 150, which determines the aftmost position of the lift in the die set 138, may be adjusted. Referring to
In summary, the automated punch machine provides a fully automated, digital machine for processing stacks of sheets. Minimal to no user interface is required during the actual processing of a stack. Upon entering or otherwise reading the paper size, by sensors or the like, various elements of the punch machine, such as the kickers 136, the justifiers 152, the alignment plates 142, the die set 138, the back plate 284, and the side plate 182 may be automatically or digitally adjusted in response to controls indicating the size of the sheets to be punched, thus providing a compete digital set up. Further, the machine provides a buffering system in that successive stacks of sheets may be processed without user intervention.
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
This application is a continuation of International Patent Application No. PCT/US2003/012304 filed Apr. 22, 2003, which claims priority to U.S. Provisional Patent Application No. 60/374,428 filed Apr. 22, 2002.
| Number | Date | Country | |
|---|---|---|---|
| 60374428 | Apr 2002 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/US03/12304 | Apr 2003 | US |
| Child | 10970770 | Oct 2004 | US |
