BUNDLE BREAKER HAVING PASS THROUGH SECTION

Abstract

A bundle breaker includes an upstream breaking section and a downstream breaking section and a platen over each breaking section for clamping a log to the respective breaking section. First and second actuators are configured to move the first and second platens, and a third actuator is configured to move the downstream breaking section relative to the upstream breaking section to break a bundle from a log. An input conveyor is located at the input end of the upstream breaking section and has a first portion that is foldable relative to a second portion to create a gap in the bundle breaker through which a worker can pass.

Description

TECHNOLOGICAL FIELD

The present disclosure is directed to a bundle breaker for breaking logs formed from stacked sheets of material, and, more specifically, to a bundle breaker having an input or output section that can be displaced.

BACKGROUND

Many products are manufactured in elongated sheets that can be separated into individual blanks along scored or perforated or partially cut lines. For example, corrugated paperboard blanks, from which boxes and other structures may subsequently be formed, are often formed in this manner.

An elongated sheet of corrugated paperboard may be divided by score lines into, e.g., five separate blanks. The score lines generally run transversely, that is, perpendicular to the length of the elongated sheet. When a plurality of the sheets are arranged in a stack, the score lines are aligned vertically. Such a stack of elongated sheets made up of individual blanks is sometimes referred to as a “log.” During the processing of logs, it is necessary to break individual stacks of sheets from the log along the vertically aligned score lines (sometimes referred to as a “breaking plane” or “breaking junction”). A stack of sheets that has been broken off a log may be referred to as a “bundle.” The individual portions of the log that will be broken off the log may also be referred to as “bundles” even when they are still attached to each other in the log. Therefore, a log will comprise a plurality of bundles joined together at transverse score lines which bundles can be broken off the log one at a time to form individual bundles.

Machines that receive logs and break individual bundles from the logs are known as “bundle breakers.” The bundle breakers generally include two support sections, which may include conveyors, and two platens, one mounted over each support section. The downstream support section can tilt or pivot relative to the upstream support section at a breaking location or breaking plane. In operation, a log is moved along the bundle breaker until a score line between a first bundle of the log and a second bundle of the log is arranged at the breaking location, and the first bundle is then clamped against the downstream support section by the first platen and the second portion of the log is clamped against the upstream support section by the second platen. An actuator then shifts one of the support sections, usually the downstream support section, relative to the upstream support section to break the log along the score lines and separate the first bundle from the log. That first bundle is then moved away from the breaking location, and the log is shifted further downstream until the score lines separating the second bundle of the log from the third bundle of the log arrives at the breaking location at which point the process repeats until all bundles that formed the original log have been separated.

Some bundle breakers are configured to break bundles from multiple logs at the same time. That is, a plurality of logs may be arranged with their score lines at the breaking location and the logs may be simultaneously clamped by the platens and broken simultaneously by the movement of the downstream section relative to the upstream section. For example, three logs may be positioned beneath the first and second platens such that the score lines separating the first bundle of each log from the second bundle of each log is located at the breaking location. The three logs are then simultaneously clamped and simultaneously broken.

During use or maintenance of a bundle breaker, it is sometimes necessary to access both sides of the bundle breaker. Due to the structure of conventional bundle breakers, it may be necessary to provide steps or a scaffold-like arrangement to walk over the input or output section of the bundle breaker. This is inconvenient, especially when a worker or operator needs to move back and forth between the sides of a bundle breaker repeatedly.

SUMMARY

This and other problems are addressed by embodiments of the present disclosure, a first aspect of which comprises a bundle breaker that includes an upstream breaking support and a downstream breaking support, each of which has an input end and an output end and each of which may comprise a conveyor. A first platen is located above the upstream breaking support, and a first actuator is operably connected to the first platen and configured to shift the first platen toward a raised position above the upstream breaking support and toward a lowered position above the upstream breaking support to selectively clamp a first portion of a log between the first platen and the upstream breaking support. A second platen is located above the downstream breaking support, and a second actuator is operably connected to the second platen and configured to shift the second platen toward a raised position above the downstream breaking support and toward a lowered position above the downstream breaking support to selectively clamp a second portion of the log between the second platen and the downstream breaking support. The bundle breaker includes a third actuator configured to shift the input end of the downstream breaking support relative to the output end of the upstream breaking conveyor from a first position to a second position to break the second portion of the log from the first portion of the log. In addition, an input conveyor is located at the input end of the upstream breaking support and has an input section having a substantially planar top surface and an input end and an output section having a substantially planar top surface and an output end. The input conveyor is configured to move the log from the input section of the input conveyor to the output section of the output conveyor and from the output section of the input conveyor directly onto the upstream breaking support. Furthermore, the input section of the input conveyor is foldable relative to the output section of the input conveyor from a first position in which a top surface of the input section of the input conveyor is substantially coplanar with a top surface of the output section of the input conveyor and a second position in which the top surface of the input section makes an angle relative to the top surface of the output conveyor.

Another embodiment of the disclosure comprises a bundle breaker that includes an upstream breaking support and a downstream breaking support, each of which has an input end and an output end and each of which may comprise a conveyor. A first platen is located above the upstream breaking support, and a first actuator is operably connected to the first platen and configured to shift the first platen toward a raised position above the upstream breaking support and toward a lowered position above the upstream breaking support to selectively clamp a first portion of a log between the first platen and the upstream breaking support. A second platen is located above the downstream breaking support, and a second actuator is operably connected to the second platen and configured to shift the second platen toward a raised position above the downstream breaking support and toward a lowered position above the downstream breaking support to selectively clamp a second portion of the log between the second platen and the downstream breaking support. The bundle breaker includes a third actuator configured to shift the input end of the downstream breaking support relative to the output end of the upstream breaking conveyor from a first position to a second position to break the second portion of the log from the first portion of the log. In addition, an output conveyor is located at the output end of the downstream breaking support and has an input section having a substantially planar top surface and an input end and an output section having a substantially planar top surface and an output end. The output conveyor is configured to move a bundle that has been broken off the log from an output end of the downstream breaking support to the output end of the output conveyor. Furthermore, the output section of the output conveyor is foldable relative to the input section of the output conveyor from a first position in which a top surface of the output section of the output conveyor is substantially coplanar with a top surface of the input section of the output conveyor and a second position in which the top surface of the output section makes an angle relative to the top surface of the input section of the output conveyor.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects and features of the invention will be better understood after a reading of the following detailed description in connection with the attached drawings wherein:

FIG. 1 is a perspective view of a bundle breaker according to an embodiment of the present disclosure.

FIG. 2 is a side elevational view of the bundle breaker according to FIG. 1 showing a log positioned on the bundle breaker with a first bundle of the log between an upstream breaking conveyor and a first platen and a second bundle of the log positioned between a downstream breaking conveyor and a second platen.

FIG. 3 is a side elevational view of the bundle breaker according to FIG. 2 showing the second platen pressing the first bundle against the downstream breaking conveyor and the first platen pressing the second bundle against the upstream breaking conveyor.

FIG. 4 is a side elevational view of the bundle breaker according to FIG. 2 showing the downstream breaking conveyor shifted relative to the upstream breaking conveyor and the first bundle broken off the log.

FIG. 5 is side elevational view of the bundle breaker according to FIG. 2 showing the downstream breaking conveyor returned to a starting position with its top surface substantially coplanar with the top surface of the upstream breaking conveyor and the first bundle moved away from the log.

FIG. 6 is a top plan view of the input conveyor of the bundle breaker of FIG. 1 in a raised position.

FIG. 7 is a side elevational view of the input conveyor of FIG. 6.

FIG. 8 is a top plan view of the input conveyor of FIG. 6 in a lowered position.

FIG. 9 is a side elevational view of the input conveyor of FIG. 8.

FIG. 10 is a side elevational view of an alternate embodiment of the input conveyor of FIG. 6 that includes a drive for shifting the input conveyor between the raised and the lowered positions.

DETAILED DESCRIPTION

Referring now to the drawings, wherein the showings are for purposes of illustrating presently preferred embodiments of the invention only and not for the purpose of limiting same, FIGS. 1 and 2 show a bundle breaker 10 according to the present disclosure. The bundle breaker 10 includes a frame 12 supporting an upstream breaking conveyor 14 (an upstream breaking support) and a downstream breaking conveyor 16 (a downstream breaking support). A first platen 18 is mounted to the frame 12 above the upstream breaking conveyor 16, and a second platen 20 is mounted to the frame 12 above the downstream breaking conveyor 16.

An input conveyor 22 includes an output section 24 connected to an input end of the upstream breaking conveyor 14 and an input section 26. The input section 26 is hingedly connected to the output section 24 and is shiftable between a raised position, illustrated in FIGS. 1, 6 and 7 and a lowered position illustrated in FIGS. 8 and 9. In the raised or operating position, the top surface of the input section 26 is substantially coplanar with the top surface of the output section 24, and the top of the upstream breaking conveyor 14. In the lowered, or pass-through position, the top surface of the input section 26 is angled relative to the top surface of the output section 24 at an obtuse or right angle. In the raised position, the input conveyor 22 helps deliver logs to the breaking conveyors 14, 16 and to support downstream portions of the logs during a breaking operation. In the lowered position, an operator can pass through the bundle breaker to access the far side of the bundle breaker 10 to reach equipment located on the far side of the bundle breaker 10. A similarly configured output conveyor can optionally be located downstream of the downstream breaking conveyor 16 as shown in FIG. 1. For example, if the bundle breaker of FIG. 1 were operated in reverse, the input conveyor 10 would function as an output conveyor.

The input conveyor 22 includes a continuous belt 30 supported by an input end support shaft 32, an output end support shaft 34 and a center support shaft 36, the center support shaft being located at the hinged connection between the input section 26 and the output section 24. A lock bar 38 holds the input section 26 in the raised position, and a gas spring 40 helps control the transition of the input section 26 from the raised to the lowered position.

The input conveyor 22 can be shifted manually between the raised and lowered positions. Alternately, an optional drive 70, illustrated in FIG. 10, can be attached to the frame 12 below the output section 24 and connected to a plate 72 on the underside of the input section 26 by an assembly 74 comprising a rod 76 telescopically mounted in a tube 78. The rod and tube assembly 74 can be, for example, a hydraulic or pneumatic actuator, an electrically operable linear actuator, a ball-screw assembly or any other assembly that allows the rod 76 to be extended and retracted in the tube 78 to apply force against the underside of the input section 26 of the input conveyor 22. The drive 70 can be controlled by a switch (not illustrated) at the input conveyor 22 or can be connected to a controller that controls the overall operation of the bundle breaker 10.

The input end support shaft 32 is mounted between two plates 41 which plates 41 are each slidably mounted on a pair of rods 43 and biased away from the output section 24 by a pair of springs 45. The force produced on the input end support shaft 32 maintains a suitable tension on the belt 30 during use. In addition, changes in the length of the belt 30 that occur when the input section 26 is shifted between the raised and lowered positions are accommodated by the sliding movement of the plates 41 along the rods 43. This configuration maintains a substantially constant tension on the belt 30 and allows the belt to operate when the input section 26 is in the raised or lowered position as well as while the input section 26 is being moved between the raised and lowered positions. The plates 41, rods 43 and springs 45 may be referred to in combination as a “spring-loaded take up assembly.”

The input conveyor 22 also includes a drive 42 operably connected to a drive sprocket 44 (FIG. 7) for driving the input conveyor 22. The input conveyor 22 can be controlled independently or, preferably, controlled by a controller (not illustrated) that controls the operation of the bundle breaker 10 to help coordinate the movement of the belts of the input conveyor 22, the upstream breaking conveyor 14 and the downstream breaking conveyor 16. The controller can comprise a microprocessor or other circuitry configured to control the operation of the bundle breaker 10.

The first platen 18 is connected to the frame 12 by a first platen support 46, and the second platen 20 is connected to the frame 12 by a second platen support 48. The first platen support 46 will primarily be discussed hereafter, it being understood that the second platen support 48 is substantially identical thereto. The first platen support 46 includes a bottom frame 50 to which the first platen 18 is attached and first and second side plates 52, and a motor mount 54 supported by the bottom frame 50 at a location between the first and second side plates 52 and a motor 56 supported by the motor mount 54. Each of the side plates 52 has inner sides that face the motor 56 and outer sides that face away from the motor 56. Each of the side plates includes a notch 58, and a drive shaft 60 extends from either side of the motor 56 through the notches 58. A drive gear 62 is mounted at each end of the drive shaft 60 on the outer sides of the side plate 52.

The operation of the bundle breaker 10 will now be described. FIG. 1 shows three transversely spaced logs L1, L2 and L3 supported on the input conveyor 22 and the upstream breaking conveyor 14. the logs L1, L2, L3 could have been placed in this location in any manner or could have arrived at the input conveyor from another conveyor (not illustrated). FIG. 2 shows the logs (of which only log L3 is visible) moved downstream by movement of the input conveyor 22, the upstream breaking conveyor 14 and the downstream breaking conveyor 16 so that the downstream-most bundle of the log L3 overlies the downstream breaking conveyor 16 and the junction (score line, perforation, etc.) between the first and second bundles of the logs is located at the breaking plane or the junction between the upstream breaking conveyor 14 and the downstream breaking conveyor 16.

FIG. 3 shows the second platen support 48 in contact with the downstream-most bundle of the log L3 and the first platen support 46 in contact with an adjacent bundle. With the first bundles of the three logs L1, L2 and L3 clamped between the second platen 20 and the downstream breaking conveyor 16 and the second bundles in each log clamped between the first platen 18 and the upstream breaking conveyor 14, the downstream breaking conveyor 16 is shifted relative to the upstream breaking conveyor 14 by an actuator that includes a drive 72, a drive disk 74 and a drive rod 78 to break the downstream-most bundle from the logs. The downstream breaking conveyor 16 is then operated to move the broken bundle away from the bundle breaker 10 while the input conveyor 22 and the upstream breaking conveyor 14 are operated to advance the logs L1, L2, L3 until the junction between the new downstream-most bundle and the adjacent bundle of each log is located at the junction of the upstream and downstream breaking conveyors 14, 16 at which time the above process is repeated.

At times when no log is supported by the input section 26 of the input conveyor 22, the input section 26 can be shifted from a raised position, shown, for example, in FIG. 7, to a lowered position as shown for example in FIG. 9. This is done by releasing the lock bar 38 holding the input section 26 in place releasing the input conveyor section 26 so that it can be lowered at a controlled rate the by gas spring 40. Or, if a drive 70 and rod and tube assembly 74 is present, the input conveyor section 26 can be lowered automatically. During the transition from the raised to lowered position, the length of the belt 30 may change somewhat, and this change in length is accommodated by the spring-loaded take up assembly formed by the plates 41, rods 43 and springs 45. This creates an opening through the bundle breaker 10 though which an operator or technician can pass to access the rear side of the machine. For safety reasons, it is preferable that the bundle breaker 10 be stopped when the input section 26 of the conveyor section is lowered and raised; however, as long as the upstream-most bundle of the log being processed is downstream of the input section 26 and a next log to be processed has not yet reached the input section 26, the input section 26 can be raised and lowered without affecting the ability of the output section 24 to support and convey logs toward the upstream breaking conveyor 14 because the input conveyor 22 is configured to operate in either the raised or lowered position and during transition between these two positions.

The present invention has been described above in terms of presently preferred embodiments. Modifications and additions to these embodiments will become apparent to persons of ordinary skill in the art upon a reading of the foregoing description. It is intended that all such modifications and additions form a part of the present invention to the extent they fall within the scope of the several claims appended hereto.

Claims

1. A bundle breaker comprising: an upstream breaking support having an input end and an output end,a first platen located above the upstream breaking support,a first actuator operably connected to the first platen and configured to shift the first platen toward a raised position above the upstream breaking support and toward a lowered position above the upstream breaking support to selectively clamp a first portion of a log between the first platen and the upstream breaking support,a downstream breaking support having an input end and an output end,a second platen located above the downstream breaking support, anda second actuator operably connected to the second platen and configured to shift the second platen toward a raised position above the downstream breaking support and toward a lowered position above the downstream breaking support to selectively clamp a second portion of the log between the second platen and the downstream breaking support,a third actuator configured to shift the input end of the downstream breaking support relative to the output end of the upstream breaking support from a first position to a second position to break the second portion of the log from the first portion of the log, andan input conveyor having an input section having a substantially planar top surface and an input end and an output section having a substantially planar top surface and an output end, the input conveyor being configured to move the log from the input section of the input conveyor to the output section of the output conveyor and from the output section of the input conveyor directly onto the upstream breaking support,wherein the input section of the input conveyor is foldable relative to the output section of the input conveyor from a first position in which a top surface of the input section of the input conveyor is substantially coplanar with a top surface of the output section of the input conveyor and a second position in which the top surface of the input section makes an angle relative to the top surface of the output section.

2. The bundle breaker according to claim 1, wherein the downstream breaking support comprises a downstream breaking conveyor.

3. The bundle breaker according to claim 2, wherein the upstream breaking support comprises an upstream breaking conveyor.

4. The bundle breaker according to claim 3, wherein the input conveyor comprises a first support shaft at the input end of the input section, a second support shaft at the output end of the output section, and an endless belt supported by the first and second support shafts, the endless belt being configured to be driven about the first and second shafts.

5. The bundle breaker according to claim 4, including a center support between the first and second support shaftswherein the endless belt is guided by the center support when the input section is in the second position.

6. The bundle breaker according to claim 4, wherein the non-parallel angle is an obtuse angle or a right angle.

7. The bundle breaker according to claim 4, including a drive configured to shift the input section of the input conveyor between the first position and the second position.

8. The bundle breaker according to claim 4, wherein the output section of the input conveyor is fixed relative to the upstream breaking conveyor.

9. The bundle breaker according to claim 4, wherein the bundle breaker includes a frame supporting the upstream breaking conveyor and the downstream breaking conveyor and the first platen and the second platen and at least the output end of the output section of the input conveyor.

10. The bundle breaker according to claim 3, wherein the upstream breaking conveyor and the input conveyor are supported by an integral frame.

11. The bundle breaker according to claim 3, wherein the input section includes a spring-loaded take up assembly configured to maintain a tension of the belt when the input section shifts between the first position and the second position.

12. The bundle breaker according to claim 4, wherein the first support shaft is supported by first and second end supports, andwherein the first and second end supports are slidably mounted on a frame of the input section.

13. The bundle breaker according to claim 12, wherein the first and second end supports are spring-biased toward the input end.

14. A method comprising: providing the input conveyor of claim 4; andshifting the input section from the first position to the second position while driving the endless belt.

15. A bundle breaker comprising: an upstream breaking support having an input end and an output end,a first platen located above the upstream breaking support,a first actuator operably connected to the first platen and configured to shift the first platen toward a raised position above the upstream breaking support and toward a lowered position above the upstream breaking support to selectively clamp a first portion of a log between the first platen and the upstream breaking support,a downstream breaking support having an input end and an output end,a second platen located above the downstream breaking support, anda second actuator operably connected to the second platen and configured to shift the second platen toward a raised position above the downstream breaking support and toward a lowered position above the downstream breaking support to selectively clamp a second portion of the log between the second platen and the downstream breaking support,a third actuator configured to shift the input end of the downstream breaking support relative to the output end of the upstream breaking support from a first position to a second position to break the second portion of the log from the first portion of the log, andan output conveyor having an input section having a substantially planar top surface and an input end and an output section having a substantially planar top surface and an output end, the output conveyor being configured to move a bundle broken off the log from an output end of the downstream breaking support toward the output end of the output conveyor,wherein the output section of the output conveyor is foldable relative to the input section of the output conveyor from a first position in which a top surface of the output section of the output conveyor is substantially coplanar with a top surface of the input section of the output conveyor and a second position in which the top surface of the output section of the output conveyor makes an angle relative to the top surface of the input section of the output conveyor.

16. The bundle breaker according to claim 15, wherein the output conveyor comprises a first support shaft at the input end of the input section, a second support shaft at the output end of the output section, and an endless belt supported by the first and second support shafts, the endless belt being configured to be driven about the first and second shafts.

17. The bundle breaker according to claim 16, including a center support between the first and second support shaftswherein the endless belt is guided by the center support when the output section is in the second position.

18. The bundle breaker according to claim 17, wherein the output section of the output conveyor is fixed relative to the downstream breaking conveyor.

19. The bundle breaker according to claim 17, wherein the bundle breaker includes a frame supporting the upstream breaking conveyor and the downstream breaking conveyor and the first platen and the second platen and at least the input end of the input section of the output conveyor.

20. The bundle breaker according to claim 17, wherein the downstream breaking conveyor and the output conveyor are supported by an integral frame.