Cutter mechanism

TECHNICAL FIELD
The present invention has its most important application to a laminated sheet trimmer having a pivotable cutting blade used to sequentially cut the leading and trailing edges of opaque sheets laminated between transparent continuous webs as they are stepped in position past the blade. The angle of the blade is automatically adjusted to cut the laminated sheets along these edges, despite the slightly varying angles of these edges. However, certain aspects of the invention have a broader application to the measurement of the offset angles of the straight edges of articles relative to the edges or other reference lines on other apparatus or articles and to the relative positioning of the straight edges of the articles in response to such measurement, so that the article edges have a parallel or other predetermined relationship to the edges or other reference lines on such apparatus or articles. For example, the broader aspects of the invention can be used to orient and apply labels in parallelism to the edges of articles to which they are applied.
BACKGROUND OF THE INVENTION
The use of laminating machines to apply laminate material to such items as menus, place mats, and the like for their protection and increased durability has been common practice for many years. In the mass production of such articles, generally opaque sheets having artistic or informational indicia thereon are laminated between continuous webs usually made of transparent material. In some instances, the borders or margins of the successive sheets are in abutment forming a continuous web of abutting laminated sheets. In other instances, the leading and trailing edges of the opaque sheets are separated from each other by the transparent laminate web material. The present invention applies to the latter web format. Cutting and trimming machines using cutting blades are used to slit such laminated web material along the leading, trailing and side edges of the laminated sheets to separate the individual sheets from the transparent web material to which they are laminated.
Some prior art machines use the opacity of the articles and the transparency of the laminate web material between the sheets to trigger a cutting operation. A single light source and a single light sensor device are placed on opposite sides of the continuous webs of laminated material. Preferably, the light source and light sensor device are placed at a location proximate to the cutting blade.
When the opaque sheets pass between the light source and light sensor, the light beam is interrupted. The passage of the leading edge of a sheet between the light source and sensor initiates such interruption. the passage of the trailing edge thereof terminates such interruption. Either transition can trigger an electronic control device to time control the cutting action of a punch or blade at an appropriate time to sever the leading and trailing edges of the sheets from the rest of the laminate web material.
It is obviously aesthetically preferable that the cutting operation be along and parallel to the edges of the sheets either in alignment with the edges or slightly outward or inward thereof if trimming is desired. This requires the leading and trailing edges of the sheets to be parallel to the cutting blade which cuts along the leading and trailing edges of the sheets. Frequently, the leading and trailing edges of the sheets are at small angle to the cutting blade so that the edges of the laminated sheets have an unattractive uneven appearance.
The prior art has utilized light sources and photocell sensors to vary the lateral and rotational position of an article severing means, like a punch, to properly align the edges of the punch and the article. U.S. Pat. No. 4,541,317 is an example of this prior art. However, the prior art photocell system for automatically positioning the cutting device relative to the straight edges of the article to be severed from the webs have left much to be desired from the standpoint of ease of operation and adjustment of these systems and the reliability and accuracy of the cutting operation.
SUMMARY OF THE INVENTION
In accordance with the laminate article cutting device application of the invention, the apparatus, as in the case of the above described prior art cutting devices, includes means for advancing the laminated webs and controlling the angle of the cutting edge of the blade to be parallel to the angled leading and trailing edges of opaque laminated sheets spaced along the transparent laminating web body. Where the cutting device is a blade which severs the leading and trailing edges of each opaque sheet, the side edges thereof are severed as a separate operation prior to subsequent to the severance of the leading and trailing edges thereof as described herein.
Two different unique techniques are disclosed herein for sensing the incident angle of the leading and trailing edges of each sheet and then rotating the cutting blade so it is parallel thereto. Both respond to differences in the times when the leading and trailing edges of each sheet reach two light sources spaced transversely of the direction of movement of the laminating web body.
One technique is a time measurement technique where a pair of light sources and corresponding sensors spaced apart along a reference line transverse to the direction of web movement operate in an On/Off (Clear/Dark) mode. A measurement of the time difference between the passage of an article edge past the two sensors indicates the edges angle. The laminating webs are "stepped" forward by a stepper motor in discrete increments, to bring successive sheets first past the light sources and their sensors and then to the cutting blade. A microprocessor counts the number of steps between the times when each sensor detects a transition from a clear to a dark or from a dark to a clear mode. For a given distance between the light sources and the number of fixed steps of web advancement which occurs between the times of passage of an article edge past the two sensors, and the identity of the sensor which first senses such a transition, the magnitude and direction of the sheet edge angle, if any, relative to a line between the sensors is determined. In response to this measurement, the blade angle is adjusted to bring the blade edge parallel to the sheet edge involved just prior to a cutting operation.
While this technique is fairly simple, it has the major disadvantage that the resolution (the smallest angle increment that can be calculated) is limited by the step distance that the sheet is advanced during the measurement. The best resolution requirements call for step distances much smaller than the machine would otherwise need to avoid limiting its speed.
Practical machine speeds are accomplished with step lengths of approximately 0.01" per step. This limits the resolution of digital sensing to 0.01" per 6" of sheet width, if the light sources and sensors are spaced apart 6", which would be required to process small (less than 8" width) sheets. This means that when large (say, 24" sheets) are to be cut, angle errors of up to 0.040" may remain in the final cut. Experimental results showed that over a 24" sheet, angle correction needed to be much better than 0.010" to be visually acceptable, with 0.005" correction even better. This means that a practical angle measurement system had to be found with approximately ten times better resolution than that offered by the digital sensing system with 0.01" steps. A 0.001" stepping is not practical due to the severe limitation it would place on machine speed.
The preferred technique is an analog light intensity measuring rather than a step-counting sensing technique. This allows greater resolution in the angle measurement, while not involving the step length of the motor in the equation. Analog sensing starts by inserting between the light sources and their sensors "slots" of known length, separated by a given distance along a line transverse to the direction of web step movement. Now, however, instead of responding with a digital (ON or OFF only) signal, the sensor circuitry produces a progressively varying voltage level indicative of what proportion of the associated slot is actually covered or uncovered by the edge at a particular instant of time. That is, when the slot is fully uncovered, a DC voltage corresponding to a reference "100%" light intensity condition is produced, and when a slot is fully covered, a "0%" output condition is produced thereby. As the sheet progressively steps over the slot, a "curve" is traced out by the analog voltage output of each sensor whose value is an indicator of what part of the slot is "covered" at that moment.
This analog voltage has no resolution limit as with the digital system. By having dual slots separated by a given distance, the phase and amplitude differences between the two analog voltages at any instant of time when both slots are partially covered indicates the direction and magnitude of the sheet edge angle. The machine's microprocessor only needs to take a "snapshot" of the sensors output at any point in time when both sensors are partly covered. A calculation of the sheet edge angle is then straight forward, except for errors introduced by differences in the strengths of the light source or sheet opacity variables. The microprocessor preferably converts the analog sensor output to digital data by an analog-to-digital converter and the digital result is stored. A calculation is carried out by the microprocessor involving a comparison (i.e. a subtraction) of the stored digital snapshot values to determine the direction and number of times a blade rotating step motor must be stepped to bring the blade parallel to the sheet edge involved. Since the analog measuring system has now been divorced from the step length of the machine's web feeding means, the web feeding step length does not affect the cutting angle accuracy.
In summary, the principle of analog sensing is to step the leading or trailing edge of a sheet past a pair of slots which have analog voltage outputs determined by what percent they are "covered" by the sheet. The difference in the analog voltage outputs of the light sensors, also referred to as "eyes", is a measurement of the incident angle as long as a "snapshot" of the eye outputs is taken when both slots are partly covered. The difference voltage can be digitized into 8 or more bits of digital data, as required, to allow a high-resolution angle calculation.
In an ideal "web", the plastic laminate used to form the web would be perfectly clear (i.e. have a light transmission of 100%) and the sheet would be perfectly opaque (i.e. have light transmission of 0%). In the real world, this is not the case. Laminates exist with transmissions of 30 to 90%, and the sheets themselves can have transmissions of 15% or more. When passed under an analog sensor, the absolute voltage levels themselves can no longer be used directly to calculate the absolute position of a sheet edge since the voltage levels of 0% and 100% will not always be obtained. Also, analog circuits are subject to "drift" from temperature, time, etc. which render the task even more difficult, so that these problems pose a significant threat to the practicality of analog sensing. How, in the face of analog circuit drift and the use of varying sheet and laminate materials, could such a system be counted upon to produce accurate, repeatable position sensing down to 0.001"? The answer lies in the fact that all the required information is still available for an angle calculation. It is just a bit more trouble to obtain than in the ideal case. In accordance with another aspect of the invention, an algorithm is provided for cancelling the non-idealitities by a "normalization" routine in the preferred manner to be explained.
Other aspects of the invention include storing data on the last blade position angle, and comparing this data with the slot sensor desired computer blade sensing data, so that a blade rotation operation is carried out only when a change in blade position is required from its last adjusted position.
The manner in which the invention measures the angle of an article edge relative to a line between a pair of sensors is useful in applications other than cutter applications. It applies where article edge positioning relative to any reference line is desired.

BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is perspective view of an apparatus in accordance with a less preferred embodiment of the invention where the angle of the leading and trailing edges of an opaque sheet is determined by measuring the time difference that a pair of light beams aligned transversely of the direction of movement of the sheet are covered and uncovered by movement of said edges to and past such beams;
FIG. 2 is a top view of the invention of FIG. 1, and showing an article being transported through the apparatus;
FIG. 3 is a side perspective view of the apparatus of FIG. 1, and showing the step motor for the cutting blade;
FIG. 4 is a system diagram of a preferred embodiment of the invention, and particularly showing the electronic feedback means and a portion of the blade positioning means;
FIG. 5 is a perspective view of a cutter apparatus designed in accordance with the most preferred form of the invention, wherein the angle of the leading and trailing edges of an opaque sheet is determined by a snapshot time comparison of the different amounts of light passing through a pair of elongated slots interposed between a pair of light sources and sensors at said time when a leading or trailing edge portion of the sheet partially covers or uncovers said slots;
FIG. 6 is a fragmentary perspective view of one of said pairs of light source and light sensors of the apparatus of FIG. 5, where one of the slots of a slotted plate is interposed between one of said light source and light sensor and the entire slot is radiated evenly by the light source;
FIG. 7 is a plan view of the indicating screen and control panel of the control box of the apparatus shown in FIG. 5;
FIG. 7A illustrates a bar graph display on said screen which indicates than an initial maximum light intensity control adjustment has been properly made when the apparatus is prepared for operation;
FIG. 8 is a plan view showing the leading edge of an opaque sheet in a transparent laminating web body, broken away to show the sheet most clearly, the leading edge of that sheet being angled in a counterclockwise direction with respect to a center line between the pair of elongated slots shown in FIG. 5, and when the leading edge portion of the sheet is in a "snapshot" position where one-half of the right slot is intercepted by the sheet and a lesser amount of the other slot is intercepted thereby;
FIG. 9 shows two solid line curves representing the analog outputs of the two light sensors sensing the passage of light through the two slots shown in FIG. 8 as the angled leading edge portion of the opaque sheet shown in as a solid line in FIG. 8 progressively steps along the length of the two slots, and a curve shown as a dashed line representing the progressively changing output of the light sensor associated with the left slot in FIG. 8 for an opaque sheet having the lesser angled leading edge orientation shown as a dashed line in FIG. 8;
FIG. 9A is a diagram showing, among other things, how the distance between the center points of leading edges of differently angled sheets and the center point of a pivoted blade vary with the angle of the edges;
FIG. 10 is a view corresponding to FIG. 8 when the leading edge portion of an opaque sheet having the solid and dashed line orientations shown therein which angle in the opposite direction from that shown in FIG. 8 are partially intercepting the pair of slots shown therein when the sheet is in said "snapshot" position;
FIG. 11 shows two solid line curves representing the analog outputs of the two light sensors sensing the passage of light through the two slots shown in FIG. 10, as the angled leading edge portion of the opaque sheet shown as a solid line therein progressively steps along the length of the two slots, and a curve shown as a dashed line representing the progressively changing output of the light sensor associated with the right slot in FIG. 10 for an opaque sheet having a lesser angled dashed line leading edge portion orientation shown as a dashed line in FIG. 10.
FIG. 12 is a view corresponding to FIG. 8 when the trailing edge of an opaque sheet having the respectively differently angled solid and dashed line trailing edge orientations shown reach said "snapshot" position partially intercepting light to the pair of slots shown in FIG. 5;
FIG. 13 shows two solid line curves representing the analog outputs of the two light sensors sensing the passage of light through the two slots shown in FIG. 12, as the angled trailing edge portion of the opaque sheet shown as a solid line therein progressively steps along the length of the slots, and a curve shown as a dashed line representing the progressively changing output of the light sensor associated with the left slot in FIG. 12 for an opaque sheet having the lesser angled trailing edge orientation shown as a dashed line in FIG. 12;
FIG. 14 is a view corresponding to FIG. 12 when the trailing edge portion of an opaque sheet having the solid and dashed line orientation shown therein which angle in the opposite direction from that shown in FIG. 12 are partially intercepting the pair of slots shown therein when the sheet is said "snapshot" position;
FIG. 15 shows two solid line curves representing the analog outputs of the two light sensors sensing the passage of light through the two slots shown in FIG. 14, as the angled trailing edge portion of the opaque sheet shown as a solid lines in FIG. 14 progressively steps along the length of the slots, and a curve shown as a dashed line representing the progressively changing output of the light sensor associated with the right slot in FIG. 14 for an opaque sheet having the lesser angled trailing edge orientation shown as a dashed line in FIG. 14;
FIG. 16 shows two curves in solid lines representing the analog outputs of the two light sensors where the maximum intensity outputs thereof respectively decrease from undesired different maximum reference levels, as the angled leading edge portion of an opaque sheet progressively steps along the length of the slots shown in FIG. 5, and two dashed line curves which represent the sensor outputs decreasing from the same desired maximum reference level, the figure also showing the variation in the "snapshot" time difference measurements obtained therefrom, one such measurement being corrected by the normalization procedure carried out by the preferred form of the present invention;
FIG. 17 shows two solid line curves representing the analog outputs of the light sensors as the angled leading edge portion of an opaque sheet progressively steps along the length of the associated slots, and wherein these outputs decrease from the same desired upper reference level to minimum values undesirably greater than zero because the sheet is not perfectly opaque, and shows two dashed line curves having desired zero minimum values, the figure also showing the variation in the "snapshot" time difference measurements obtained therefrom, one such measurement corrected by the normalization procedure carried out by the preferred form of the present invention;
FIG. 18 is a detailed block diagram of the electrical microprocessor control system of the FIG. 5 embodiment of the invention;
FIG. 19 shows the preferred architecture of the program forming part of the control system shown in FIG. 18;
FIG. 20 illustrates in detail the roller interrupt handler portion of the program indicated as a single block in FIG. 19;
FIG. 21 illustrates in detail the blade interrupt handler portion of the program shown as a single block in FIG. 19;
FIG. 22 illustrates the "read eyes" portion of the program indicated as a single block in FIG. 19; and
FIG. 23 is a summary of the more important of the steps carried out by the program shown in more detail in the other figures.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF INVENTION
FIGS. 1-4 Digital or Time Measuring Embodiments of the Invention
Referring now to the drawings, and particularly to FIG. 1, the apparatus in accordance with the invention is labeled with the reference numeral 12. This apparatus provides for parallel cutting of the laminated edge of a previously laminated article in a manner to be described.
The apparatus includes a cutting blade 14 oriented substantially perpendicularly to the path of movement of the laminated opaque sheets 16a, 16b, 16c, etc. (FIG. 2) as they pass under that blade. As may be seen, the sheets 16a, 16b, 16c, are laminated between upper and lower transparent webs 18a--18a to form a single, continuous integral laminate web body 18. The webs may be made of a suitable synthetic plastic material.
Referring again to FIG. 1, the apparatus also comprises means for advancing the laminate body 18 to and beyond the blade 14. Here, that means includes a pair of drive rollers 20 and 22 upstream of the cutting blade 14, and an idler roller 24 downstream of the blade 14. The drive rollers 20 and 22 are all indirectly driven by a step motor, as will be described later.
In the present embodiment, rollers 20, 22 are driven by a step motor 40 which may be a type 34T2BEHD, model no. 2434, manufactured by Bodine Electric Company. This motor, without accompanying motor drives that are provided with this embodiment, may be geared for 200 steps per revolution.
A pair of sensing means for determining the extent of deviation of the leading and trailing edge of each sheet from parallelism with the cutting edge 36 of the cutting blade 14. Particularly, these sensing means comprise at least one pair of infrared light beam sources 26 and 28 and a pair of corresponding light sensors 30 and 32.
In the preferred embodiment, each of the infrared light beam sources 26 and 28 are secured within a frame 34, and are disposed on one side of the plane of the laminate web body 18. A reference line between the centers of those beam sources 26 and 28 is transverse to the direction of movement of the laminate body 18 and parallel to the cutting edge 36 (FIG. 3) of the cutting blade 14, when that blade is in a "zero" or "reference" position. Each of the sensors 30 and 32 are secured to another portion of the frame 34. The part of the frame to which the sensors 30 and 32 are secured is separated by the plane of the laminate body 18 from the part of the frame to which the light beam sources 26 and 28 are secured.
As indicated above, light from these light beam sources 26 and 28 will be detected by sensors 30 and 32 when the transparent portion 54 of the laminate web body 18 (FIG. 2) between the sheets (e.g., 16a and 16b) is disposed directly between the beam sources and sensors. In contrast, when an opaque sheet passes between the beam sources and the sensors, the light beams are interrupted, i.e., no light reaches the sensors.
When the leading edge 38 of sheet 16a is perfectly parallel with the cutting edge 36 of the blade 14 in the "zero" or "reference" position, the leading edge 38 will interrupt the beam of light from beam source 26 at precisely the same time as it interrupts the beam of light from beam source 28 to sensor 32. However, in the event that the leading edge 38 of sheet 16a is somewhat offset from perfect parallelism with the reference line between the beam sources, one of the light beams will be interrupted sooner than the other. It is this difference in the time of light beam interruption that triggers the mechanisms rotating the cutting blade 14.
The greater the difference in the time of light beam interruption, the greater the offset of the leading edge 38 from parallelism with this reference line. The extent of this offset is measured by the step motor 40 which drives the drive rollers 20 and 22.
Referring now to FIG. 2, this Figure depicts a sheet article 16a that is offset from perfect parallelism with the blade 14 in the "zero" position. The extent of offset depicted in this Figure is exaggerated for purposes of this description. As the drive rollers 20 and 22 move the laminate web body towards the blade 14, the beam of light provided by infrared light beam 28 to light detector 32 is interrupted by the leading edge 38 of article 16a. The light beam from infrared light beam 26 to light detector 30 is not interrupted, however, until the drive rollers 20 and 22 move the article 16a somewhat further ahead. As the step motor 40 revolves through one step, article 16a is moved forward 0.010" (ten-thousandths of an inch) in the present embodiment.
A signal from this step motor 40 is sent to a second component of the system now being described, the electronic feedback means, for each "step" moved by the motor 40 in the time interval between the interruption of these respective beams.
The electronic feedback means is responsive to the sensors 20 and a pulse source forming part of step motor drive means 48 shown in FIG. 4. The electronic feedback means determine the extent of rotation of the cutting blade 14 necessary so that the blade is oriented parallel to the leading edge 38 of the sheet 16a prior to cutting the laminate material.
The electronic feedback means are shown in FIG. 4 of the drawings. A 110-volt, alternating current unswitched power source 42 is provided to power a controller 44. A transformer 43 provides stepped-down, direct-current power for step motor 40 and a second, smaller step motor 46. This smaller step motor 46, which will be fully described later, effects movement of the cutting blade 14. Motor 46 is also manufactured by Bodine, as model no. 2431.
As is known in the art, step motors require certain voltages and switching schemes in order to create the appropriate stepping. For this purpose, roller step motor 40 and blade step motor 46 are provided with roller motor drive means 48 and a blade motor drive means 50, respectively. Roller motor drive 48 also provides gearing effecting a 2:1 reduction, which effectively renders motor 40 a 400 step per revolution motor.
The roller motor drive 48 and the blade motor drive 50 are driven by "step" signal pulses. The direction of rotation of the blade motor drive 40 may be controlled by a "direction" signal. The "step" signal pulses from the controller 44 signals each motor to move a designated number of steps. The "direction" signal from the controller signals the movement of the blade motor, and ultimately the blade, in the desired clockwise or counterclockwise direction.
A display/keyboard 52 provides a means for user interface. It enables the user to turn the apparatus on and off, adjust its speed, control the length of the articles being cut, and establish the size of the laminate border, if any, surrounding the article.
The interruption and reception of light from infrared light beam sources (LED) 26 and 28 and their respective sensors (RCVR.) 30 and 32 is detected and determined by the controller 44. The sensors may be phototransistors. As indicated above, these sensors 30 and 32: (1) detect the interruption of light from the infrared light beams 26 and 28 when a sheet (16a, 16b, or 16c) is disposed between the sensors and the light beams; (2) detect light from the infrared light beams 26 and 28 when transparent laminate border material 54 is disposed between the detectors and the light beams.
Typically, the apparatus 12 is used with articles, such as sheets, of various widths. The apparatus can best ensure accurate cutting by placing the light beams and their associated detectors as far away from each other as possible. For example, with a 81/2" wide sheet, the light beams and sensors are best placed about 7" apart. With a 14" wide sheet, however, the light beams and detectors are best placed about 12"-13" apart.
Accordingly, in an alternate embodiment of the invention, at least a pair of the light beam sources and associated light source are laterally movable. In this way, sheets of these and other varied widths can best be accommodated. For example, infrared light beam source 28 and its corresponding light sensor or "eye" 32 may be movable into any one of three positions. The controller 44 may include a manually-operable "eye" position switch 56 for moving beam 28 and "eye" 32 to any one of these positions.
In yet another variation of the embodiment of FIGS. 1-4, the apparatus 12 would include several more than two pairs of light sources and their corresponding sensor "eyes" to be selected in accordance with web width. FIG. 4 shows a third pair 28' and 32' thereof spaced from pair 26 and 30 a different distance than is pair 28 and 32. The controller 44 would determine the appropriate pair of beam source eye sets for a given article width from adjustment of eye position control 56 or automatically from the signals sent to controller. Thus, if the light to all three sensors 30, 32 and 32' are interrupted by a sheet, that indicates a wider sheet than if the light to only two sensors is interrupted. Particularly, the controller 44 would select the two most widely separated light source-sensor pairs for the widest sheets and the two closest interrupted light source-sensor pairs for the narrower sheet. As may be seen in both FIGS. 1 and 4, a blade home sensor 58 is provided. The blade home sensor 58 is adjacent the cutting blade 14 and determines its position. Particularly, the blade home sensor 58 in combination with the controller 44 determine the angular position of the blade at any given time. The blade position sensor 58 indicates when the blade is perfectly transverse to the web longitudinal axis (its zero position) and a blade position up-down counter in the controller has a plus or minus count in proportion to the clockwise or counterclockwise position of the blade relative to its zero position.
Referring now to FIG. 4, the controller includes a bale switch 60. This switch 60 is coupled to a bale arm (not shown). The bale arm and switch stop the roller drive motor if a web pair causes excessive tension in the laminate body 18.
During the cutting cycle, i.e., when the blade 14 is being raised or lowered, the web 18 is not being moved. Accordingly, drive rollers 20 and 22 are stationary during the cutting cycle. As may be seen in FIG. 1, a pair of air-actuated cylinders 62 and 64 are provided for lowering and raising the blade 14 at the appropriate intervals.
A cylinder bottom switch 66 and a cylinder top switch 68 are provided to indicate to the controller 44 the positions of the cylinders. The cylinder bottom switch 66 provides a signal to the controller 44 the instant a cylinder 62 or 64 has reached the bottom of its travel. This instant corresponds to the blade 14 reaching its lowermost position. The switches may be located at any desirable position, such as on the cylinder.
Immediately upon receipt of this signal from the cylinder bottom switch 66, the controller 44 powers air cylinders 62 and 64 to move the blade upward into its normal, uppermost position. Upon attaining this uppermost position, cylinder top switch 68 sends its own signal to controller 44. Upon receipt of this signal, the controller 44 restarts the drive rollers 20 and 22.
The output signals of a microprocessor 70 (no. COP 402N, manufactured by National Semiconductor) control the motors and other components of the apparatus 12. The microprocessor 70 itself is controlled by a software program entered into an EPROM 72, or electronically programmable read-only memory. The software program which is entered into this EPROM is attached as an integral part of this specification, appearing immediately before the claims.
The controller 44 also includes a sensitivity switch 74. This switch 74 is adjustable, and regulates the amount of light that must be sensed by sensors 30 and 32 corresponding to the "light received" condition. This switch 74 accounts for sheets 16 that may be very thin and of relatively low opacity. It also accounts for varying thicknesses and transparencies of the transparent laminate webs 18a and 18b.
Finally, blade positioning means are provided as the third component of the present apparatus. The blade positioning means are communicative with the electronic feedback means. Blade positioning means rotate the cutting blade 14 to a position where that blade is parallel to the leading edge of the article.
The blade positioning means can best be viewed in FIG. 3. Included are blade motor 46 and blade motor drive means 50. As indicated above, blade motor 46 and its associated motor drive means 50 provide 200 discrete steps per motor revolution. The output shaft of motor 46 is a ball screw 76 or threaded drive shaft connected at its end to a rotatable portion 78 connected to an arm 79 connected to an end of blade 14. The blade 14 pivots about a pivot point between its ends comprising, at the top, a brass bushing 80 held in place with a set screw 82 (FIG. 1). At the bottom, the pivot point is defined by a shaft and thrust bearing assembly. Particularly, a 5/8" shaft 84 is reduced at its end to 3/8" in diameter, and this reduced end is rotatable in an Andrews W-5/8" ball and roller bearing 86.
In the present embodiment, as indicated above, one step of the motor 40 moves both rollers 20 and 22 and article 16a forward 0.010". It will be obvious to the skilled artisan that these figures will vary according to the diameter of the rollers used. It will also be obvious to the skilled artisan that the time difference for offset article 16a to break light beam 26 and light beam 28 will depend on the spacing of the light beams from each other.
It will also be understood to the skilled artisan that this apparatus 12 can be used for cutting the article 16a at either its leading edge 38 or its trailing edge 88.
The apparatus 12 does not assume that the leading 38 and trailing edges 88 are offset the same number of degrees. Accordingly, the apparatus 12 will calculate, in the manner described above, two numbers that are stored in the memory of the microprocessor. The first is the offset angle of the leading sheet edge 38, and the second is the offset angle of the trailing edge 88. The computed angle is strictly a function of the number of steps that the motor moves forward between the time the first and second light beams are interrupted, and the distance between the two light beams.
These two angles can be translated into the required motion of the blade 14. In essence, the blade 14 must be turned by blade motor 46 enough to "cancel" the angle of edges 38 or 88 to the blade -4. The extent and direction of rotation of the threaded blade motor drive shaft 76 is determined by the pitch of its threads, the current angle of the blade 14, as read by blade home sensor 58, and the offset of the leading 38 or trailing edges 88 with the blade 14. The controller generates a direction signal in response to which light beam associated with sensors 30, 32 or 32' is first interrupted or re-established as a leading or trailing edge of a sheet reaches or passes by a light beam source-sensor pair.
The apparatus 12 in accordance with this embodiment can easily handle the cuts on the leading and trailing edges of forty articles or more per minute. Thus, eighty adjustments of the angle of cutting blade 14 per minute can be easily handled.
The third pair of sensing means 28' and 32' positioned along the same line L2 along which the other pair of sensing means 26 and 30 and 28 and 32 are located, which line is at right angles to the direction of movement of the laminate body 18 thereby. Controller 44 is designed to be responsive to the outer most pairs of sensing means when the light beams from all three light sources 26, 28 and 28' are interrupted by the passage of the leading edge of one of the sheets of the laminate body 18. Since the time difference between the times the leading edge will intercept the light beam for more widely spaced sensing means would be greater when the same leading edge intercepts the light beams from two more closely spaced sensing means the controller must operate with a different algorithm to determine the number of steps the blade 14 must be turned to effect the desired parallelism. The controller thus responds differently to the situation where all three light beams are interrupted than when only two of them are so interrupted. To simplify the algorithms, it is desireable that three pairs of sensing means are utilized to space each pair of sensing means from the adjacent one by the same distance along the second line L2.
Attached hereto ahead of the claims is the software program necessary for incorporation with the EPROM 72 shown in FIG. 4.
FIGS. 5-23 Analog Sensing Embodiment of the Invention
FIGS. 5 and 6--Cutter Apparatus Structure
The mechanical portions of the cutter mechanism apparatus shown in FIG. 5 is substantially the same as that shown in FIG. 1, except there is shown in FIG. 5 the keyboard 52 and the control box 52' of which the keyboard 52 forms a part, the bale switch arm 61 which stops operation of the apparatus when the tension on the laminate web body 18 indicates a jam in the system so as to cause the feeding of the laminate web body 18 to terminate, and a slotted plate 80 having slots SL1 and SL2 interposed respectively between light sources 26' and 28' and light sensors PC1 and PC2. Also, the size of the light sources and light sensors are such as to provide an even light intensity through the slots SL1 and SL2, so that there is a near linear variation of the sensor outputs as the leading and trailing edges of an opaque sheet steps along the slots.
FIG. 6 shows in greater detail a light source 26', light sensor PC1 and part of the slotted plate 80 which has a slot SL1 having an elongated shape whose longitudinal axis is parallel to the direction of movement of the laminate web body 18 through the cutter apparatus.
FIGS. 8 to 11--Leading Edge Angle Measurement and Web Advancement
Referring now more particularly to FIG. 8, this figure shows the angled leading edge 38 of an opaque sheet 16a located at the mid-point or "snapshot" point of the right slot SL2 and at the beginning of the left slot SL1 just prior to the measurement of the angle of the leading edge, which is followed by the rotation of the blade 14 to be parallel to the edge, the advancement of the edge to the blade and the "front cut" severance of the leading edge. The right light sensor PC2 will thus produce an output which is approximately 1/2 that of its maximum output if its minimum output is ideally zero. This occurs if the opaque sheet is ideally opaque so it blocks all light from sensor SL2 when the slot is completely covered thereby.
The preferred form of the invention repeatedly scans the sensor outputs when the slots are fully covered and uncovered, to correct the measurement of one of the light sensor outputs taken and the opaque sheet is in its "snapshot" position when the other light sensor output is at an exemplary reference mid-point measurement of 120. The measurement correction is referred to as a normalization procedure made by comparing the ideal maximum and zero outputs with those scanned, and making the needed measurement corrections by an equation to be given later on in the specification. These scanned output values can vary from the ideal calibrated maximum value or zero value because, among various reasons, of line voltage fluctuations, and light source or light sensor variables like aging, or when the sheets involved are not perfectly opaque.
With the particular angular position of the solid line leading edge 38 shown in FIG. 8, the output of the left sensor PC1 is at or near its maximum output because the opaque sheet interrupts practically no light passing through the left slot SL1. In the example of the invention being described, the ideal value of this maximum output is assumed to be a digital value of 242 when the apparatus is initially calibrated by an operator adjustment to be described. The leading edge 38 of the opaque sheet 16a is shown tilted at a given counterclockwise angle with respect to a line L2 which extends at right angles to the direction of movement of the laminate web body 18 and passes through the mid points of the slots SL1 and SL2.
A dashed line 38' illustrates the leading edge of a sheet like sheet 16a which is tilted to a lesser counterclockwise angle. It reaches the beginning of the left slot SL1 sooner than the leading edge 38 of the sheet 16a shown in solid lines, and thus the sheet having the lesser angled leading edge 38' will cover more of the slot SL1 than sheet 38 when the leading edge 38' reaches the "snapshot" mid-slot position of the right slot SL2.
The control portions of the cutter apparatus makes a measurement of the outputs of the light sensors PC1 and PC2 in the "snapshot" position of the leading edge of each sheet. The difference in these outputs when the output of sensor PC1 is "normalized" is an accurate measure of the angle of inclination of the leading edge of the opaque sheet. The sensor output which first decreases to the mid-value of 120 indicates whether the leading edge angle makes a clockwise or counterclockwise angle with respect to the reference line L2. The program of the control system detects which sensor decreases to 120 first during the operating mode when the leading edge is next to be cut (referred to as the front cut mode) and sets a flag in data storage indicating whether the leading edge is a clockwise or counterclockwise angle with respect to line L2. The control portion of the apparatus then pivots the cutter blade in the direction indicated by that flag.
FIG. 9 illustrates the progressively changing output of the light sensors PC1 and PC2 as the leading edges 38 and 38' respectively of the two different angled opaque sheets move along the slots SL1 and SL2. Thus, the solid line curves PC2-a and PC1-a respectively show that the output of the light sensor PC2 progressively decreases from a maximum value of 242 before the curve PC1-a representing the output of light sensor PC1 begins to decrease from its maximum value. As just explained, when the output of the right light sensor PC2 reaches the mid point measurement of 120, the control apparatus of the invention measures the normalized difference of the outputs of the light sensors PC1 and PC2 at that instant of time and store that value for a computation which will determine the amount of pivot rotation to be imparted to the blade 14.
The dashed curve PC1-a' in FIG. 9 represents the variation in the output of the light sensor PC1 when the lesser angled leading edge 38' is moved along the slots SL1 and SL2. The output of the left light sensor PC1 when such a leading edge passes along the slot SL1 will start decreasing from 242 at a point in time closer to the point in time at which the output of light sensor PC2 starts decreasing from 242, and thus the difference in the outputs of the light sensors PC1 and PC2 at the snapshot time will be of a lesser magnitude. FIG. 9 shows a vertical line d1 representing the lesser difference in the outputs of the light sensors PC1 and PC2 at the snapshot time produced by the more steeply angled leading edge 38, and shows a shorter vertical line d2 representing the difference in these outputs at the "snapshot" time produced by the lesser angled leading edge 38'. The measurement of the light sensor SL1 at this snapshot time is stored for use in computations using an equation where the stored value is identified by the expression eye 1 mid. In this equation, the expressions eye 2 max and eye 1 max, eye 2 min and eye 1 min respectively represent the maximum and minimum sensor outputs scanned in the scanning cycle immediately prior to each "snapshot" position measurement. The scanning of these sensor outputs may be made just after the trailing edge of the preceding opaque sheet passes both slots and just after the leading edge of the opaque sheet involved passes both slots.
Under control of the program, a computation is carried out from the stored data indicating the theoretical direction and degree of rotation of the cutter blade 14 to bring it parallel to the leading or trailing edge involved and the result of this computations is compared with the then current position of the cutter blade indicated by a number stored in a blade position storage register. The number of motor step pulses needed to rotate the cutter blade into a position parallel to the sheet edge involved is then fed to the blade step motor.
The amount of forward movement which must be imparted to the laminate web body 18 after the snapshot measurement referred to is also computed to bring the center point of the sheet edge involved to or near the cutting blade, depending upon the angularity of the edge of the opaque sheet involved and whether a trimming is desired at a point spaced from the edge.
Refer now to FIG. 9A which shows the two differently angled position of the edges 38 and 38' of an opaque sheet in the "snapshot" position. The position of the center point of the more steeply angled edge 38 of the opaque sheet 16a is identified by the letter "X"; the position of the center point of the lesser angled sheet edge 38' is identified by the letter X', and the position of the pivot point of the blade 14 is identified by the letter "B". When the leading edge 38 has the steeped angle indicated and no trim is desired, the center point "X" of the leading edge 38 must be moved to point "B" and then stopped. The center point of the lesser angled edge 38' must be moved a lesser distance to the blade pivot point B. Accordingly, the program of the apparatus performs a computation to be described which computes the number of step pulses to be fed to the roller step motor 40 to effect this result, based on a number of factors including the measurement of the sheet edge angle when the sheet involved is in its "snapshot" position.
FIGS. 10 and 11 correspond to FIGS. 8 and 9 under the circumstances when the leading edges 38 and 38' of an opaque sheet 16a are respectively at greater and lesser angles in a clockwise rather than a counterclockwise direction from the reference line L2 interconnecting the center points of the slots SL1 and SL2. FIG. 11 shows by curve PC1-b that the output of the left sensor PC1 decreases from a maximum level 242 before the output from the right sensor PC2 indicated by curve PC2-b does so. The PC1-b output of the left sensor decreases to 120 first, to indicate that the cutting blade 14 must theoretically be pivoted in a clockwise direction to bring it parallel to the edge 38 or 38', (i.e. if the blade is in a squared or zero angle position). The program of the cutter apparatus effects computation of the difference between these outputs at the snapshot time. This measurement is indicated by the length of the line d1' for the steeper angled leading edge 38 and by the length of the line d2' for the lesser angled leading edge 38'.
FIGS. 12 to 15--Trailing Edge Angle Measurement
FIG. 12 shows the relationship of the greater and lesser counterclockwise angled trailing edges 88 and 88' of the opaque sheet 16a when each edge first reaches the center point of the right slot SL2 at the snapshot time when the sensor output measurement of the left sensor BL1 is taken. Then blade rotation, trailing edge advancement to the cutter blade and a "rear cut" severance of the trailing edge takes place. The slot SL2 is the first slot which becomes progressively uncovered by the greater angled sheet edge 88, causing a gradual increase in the output of the light sensor PC2 from a zero output, as illustrated by the curve PC2-c in FIG. 13. The output of the right sensor PC2 reaches the snapshot level of 120 before the output curve PC1-c representing the output of the left sensor PC1 does so.
As the lesser angled trailing edge 88' progressively uncovers the left slot SL1, it produces the varying output in left sensor PC-1 indicated by curve PC1-c'. The line d3 between the curves PC2-c and PC1-c indicates the difference in the right and left sensor outputs at the snapshot time caused by the greater angles trailing edge 88. The line d3' between the curves PC1-c and PC2-c' indicates the difference in this measure at the snapshot time caused by the lesser angled trailing edge 88'. The program of the cutter apparatus of the invention, when the output of the sensor PC2 first reaches the level of 120, effects the counterclockwise rotation of the cutter blade to bring the cutter blade parallel to the trailing edge involved if the blade 14 is in a squared or zero angle position.
FIGS. 14 and 15 respectively show the relationship of the greater and lesser clockwise angled trailing edges 88 and 88' of an opaque sheet to the slots SL1 and SL2 at the snapshot time, and the progressive variation of the outputs of the associated sensors PC1 and PC2 as the trailing edges progressively uncover the left and right slots SL1 and SL2. In this case, the output of the left sensor PC1 will reach the 120 level first to indicate to the program of the apparatus that the cutter blade 14 must be theoretically rotated in a clockwise direction to bring it parallel to the trailing edges 88 and 88'.
FIGS. 16 and 17--Normalization of Mid-point Snapshot Measurements
Refer now to FIG. 16 which explains the circumstance under which the maximum output of the right light sensor PC2 decreases to zero along curve PC2-a from a maximum value identified at point P1, which is greater than the desired reference maximum of 242, and the left light sensor PC1 decreases to zero along a curve PC1-a from a maximum value identified at point P3 which is less than the desired maximum level of 242. The curves desirably should have decreased to zero from the same desired maximum value of 242 respectively along the dashed line PC2-a' and PC1-a'.
Without normalization, the snapshot value difference between the outputs of light sensors PC1 and PC2 is identified by the line d5, which provides an erroneous measurement for the angle of inclination of the leading edge involved. The desired difference in the outputs of the light sensors PC1 and PC2 at the snapshot time is identified by the line d5', which is much larger than the line d5. The difference in the lengths of these lines d5 and d5' indicates the error in the angular measurement because the maximum intensity outputs of the light sensors PC2 and PC1 decreased from levels other than the desired reference level 242. As previously indicated, by using proper equations and measurements of the actual maximum intensity values of the light sensors PC1 and PC2, a normalization or correction of the snapshot values can be obtained in the preferred form of the invention.
Refer now to FIG. 17 which explains the errors which can be introduced in the angle measurements of the leading edge of an opaque sheet when the minimum sensor output values caused by the opaque sheets being less than fully opaque create minimum values at the outputs of the light sensors PC1 and PC2 which are other than zero. Thus, the solid line PC2-b representing the variation in the output of the right light sensor PC2 decreases from the desired level of 242 to a level indicated by the point P5 which is greater than zero. Similarly, the solid line PC1-b showing a variation in the output of the left light sensor PC1 decreases from the desired maximum value of 242 to a level other than zero at point P6. The difference in the snapshot time values of the output of the light sensors PC1 and PC2 without corrections is indicated by the length of line d6.
The dashed lines PC2-b' and PC1-b' represents the variation in the output of the light sensors PC1 and PC2 as they decrease from 242 to ideal zero. The difference in the snapshot time values of the outputs of the light sensors under the actual conditions is identified by the length of line d6, and the ideal condition when they decrease to zero by the length of the line d6'. The difference in the lengths of the lines d6 and d6' is the error measurement which would occur if a normalization procedure was not carried out.
FIG. 18--Control System Block Diagram
Refer now to the block diagram of FIG. 18 which shows the basic electrical control system of the cutter apparatus now being described. The angular position of the blade 14 at any instant is determined by a position number stored in a blade position counter 44h. This blade position counter is an up-down counter which has a median number greater than zero stored therein when the blade 14 is in a perfectly square position, meaning perfectly transverse to the direction of movement of the web body 18. That number progressively increases from this number as the blade is rotated progressively increases in one direction from this squared position and progressively decreases from this number toward zero as the blade is progressively rotated in the opposite direction. The blade 14 carries an opaque piece 14' which, when the blade is square, intercepts a light beam source directed to a sensor 49.
When the blade motor screw 76 rotates in a direction to pivot the blade 14 in a clockwise direction, the blade position counter 44h receives count pulses from a blade pulse position control means 44d to which a pulse source 44e continuously feeds pulses at a predetermined pulse rate. The pulse blade control means 44d acts as a gate circuit gating pulses from the pulse source 44e to the blade step motor 46 on a line 44d-3 and to the blade position counter or storage means 44h on a line 44d-1. These pulses advance or reduce the count in the counter 44h and rotate the blade 14 in a direction depending upon the direction signal fed from the pulse source control means 44d to the motor 46 on a line 44d-4 and to the counter 44h on a line 44d-2.
The blade pulse control means 44d is controlled from program control means 44a which, along with the other control means shown in FIG. 18, are part of a microprocessor controller operating in a manner similar in some respects to the controller 44 in FIG. 4 which operates the embodiment of the invention of FIGS. 1-4, but modified to perform the different angle measurement programs to be described.
The measurements which are taken by the cutter apparatus under control of the program, such as the measurements of the outputs of sensors PC1 and PC2, are fed respectively on lines 44c-1 and 44c-1' to an analog to digital converter means 44c which converts the analog measurements of the light sensors PC1 and PC2 to digital signals fed through the program control means 44a to a data storage means 44b.
During the setup of the apparatus, the operator adjusts a pair of potentiometers 27 and 29 which control the magnitude of the current through the light sources 26 and 28 so that the output of light sensors PC1 and PC2 respectively have an output level of 242. The measurements are indicated on a screen 52b forming part of the keyboard 52' to be described. As previously indicated, the outputs of sensors PC1 and PC2 are repeatedly scanned under the condition where the slots SL1 and SL2 are completely blocked and unblocked to establish actual minimum and maximum reference values (eye 1 max, eye 2 max, eye 1 min and eye 2 min) which are stored in data storage means 44h and used in the "normalization" procedure previously referred to. As previously indicated, this normalization procedure, modifies the snapshot measurement value to a value which would have been obtained if the actual maximum and minimum values of sensors PC1 and PC2 were 242 and 0, respectively.
A pulse source 44g is fed to the web feed pulse control means 44f which is a gate circuit similar to the blade pulse control means 44b, and is controlled by the program control means 44a. The program control means 44a carries out a computation to determine the desired distance between the center point of the leading or trailing edge of the opaque sheet involved at the snapshot time and the pivot point of the blade, which distance varies with the angle of the edge involved and trim and deceleration factors to be described, so that the feeding of the opaque sheet can stop at the desired point beneath the cutting edge of the blade 14. The output of the web feed pulse control means 44f is thus fed to the roller step motor 40 which drives the web feed rollers 20 a proper amount to effect this result.
The various computations which are carried out by the program control means 44a will now be described.
Equations Carried Out By Apparatus Program
The following Equation 1 for front cut mode computes a value referred to as "eye 1 normal", which is the normalized or corrected snapshot time measurement ("eye 1 mod") for the output of the left light sensor when the output of the right light sensor decreases to 120: ##EQU1##
Similarly, the following Equation 2 for front cut mode computes a value referred to as "eye 2 normal", which is the normalized or corrected snapshot time measurement of the output ("eye 2 mid") of the right light sensor SL2 when the output of the left light sensor decreases to 120. ##EQU2##
The following Equation 3a for front cut mode is a factor in Equation 4 which Equation 3a identifies at snapshot time the location of the leading edge center relative to the center of line L2 between the slot centers, in terms of the number of step pulses which must be fed to the roller step motor 40 to move the center point of the leading edge to the line L2, when the leading edge makes a clockwise angle with respect to the line L2: ##EQU3## (Where C1 is a constant depending on the spacing between the center of slots SL1 and SL2. It is 24 when the center points of slots SL1 and SL2 are spaced 6" apart and each pulse applied to the roller step motor 40 will advance the web 0.01").
The following Equation 3b for front cut mode is a factor in Equation 4 which Equation 3b identifies at snapshot time the location of the leading edge center with respect to the line L2 in terms of the number of step pulses which must be fed to the roller step motor 40 to move the center point of the leading edge to the line L2, when the leading edge makes a counterclockwise angle with respect to the line L2: ##EQU4##
The following Equation 3c for front cut and rear cut mode is a constant identifying one-half the slot size in terms of roller motor step pulses needed to move the edge center, and is a factor in Equations 4 and 4':
Equation 3c (for front or rear cut modes):
Center to Edge=(Center of eye 1 or 2 to edge of eye 1 or 2) .times.Steps per inch
(This center to edge distance is given in terms of the number of pulses fed to the roller step motor 40 necessary to move the web one-half of a slot length.) This equals 10 where the spacing between the center point of the slots SL1 or SL2 and the edge of the slot nearest the cutting blade is 0.001".
Equation 4 for a front cut mode computes the number of pulses which must be fed to the roller step motor 40 to move the center point of the leading edge of the sheet in a snapshot position to or adjacent the pivot point of the blade which varies depending upon whether a trim cut is to be made. It is understood that, to avoid overrun due to inertial effects where necessary for accuracy, the step pulse rate is gradually reduced so that there will be no significant error-causing overrun at the receipt of the last pulse:
Equation 4 (for front cut mode):
Roller motor forward advance=material center+center to edge +front cut-(trim)
(where "front cut" is the distance of the slot edge closest to the cutting blade to the cutting blade in terms of step motor pulses; the "trim" factor is the amount in terms of step motor pulses one desires to cut beyond the leading edge).
The following Equation 5 computes for front cut mode the number of step pulses to be fed to the blade step motor when the blade in an ideal squared position to bring the cutting blade parallel to the leading edge involved, the step pulses causing the blade step motor to rotate the blade in one direction or the other depending upon the direction control signal fed to the blade step motor:
Equation 5 (for front cut mode):
Blade motor forward or backward rotation=C2.times.(eye 2 normal, or eye 1 normal-eye 1 normal, or eye 2 normal)
(where C2 is a constant depending upon the distance between the point the blade motor screw 76 connects with the blade and the pivot point of the blade). The constant C2 has a value which varies with the distance between the center points of the slots and the incremental angle which the shaft of the step motor 46 moves in response to each step pulse received by the motor to vary the angle of the blade. For very small angles between the adjusted angle of the blade 14 and the squared position of the blade, it is assumed that the increments in angle variation vary in linear relationship to the number of pulses fed to the blade step motor 46.
The following Equation 1' for rear cut mode computes a value referred to as "eye 1 normal", which is the normalized or corrected snapshot time measurement ("eye 1 mid") for the output of the left light sensor when the output of the right light sensor increases to 120: ##EQU5##
Similarly, the following Equation 2' for rear cut mode computes a value referred to as "eye 2 normal", which is the normalized or corrected snapshot time measurement ("eye 2 mod") of the output of the right light sensor when the output of the left light sensor increases to 120. ##EQU6##
The following Equation 3a' for rear cut mode is a factor in Equation 4' which Equation 3a' identifies the location at snapshot time of the leading edge center relative to the center line L2 between the slot centers in terms of the number of step pulses which must be fed to the roller step motor 40 to move the center point of the trailing edge to the line L2, when the trailing edge is a counterclockwise angle with respect to the line L2: ##EQU7## (where C1 is a constant depending on the spacing between the center of slots SL1 and SL2. It is 24 when the center points of slots SL1 and SL2 are spaced 6" apart and each pulse applied to the roller step motor 40 will advance the web 0.01").
The following Equation 3b' for rear cut mode is a factor in Equation 4' which Equation 3b' identifies at snapshot time the location of the trailing edge with respect to the line L2 in terms of the number of step pulses which must be fed to the roller step motor 40 to move the center point of the trailing edge to the line L2, when the leading edge makes a counterclockwise angle with respect to the line L2. ##EQU8##
Equation 4' for rear cut mode computes the number of pulses which must be fed to the roller step motor 40 to move the center point of the leading edge of the sheet in a snapshot position to or adjacent the pivot point of the blade, which varies depending upon whether or not a trim cut is to be made. It is understood that to avoid overrun due to inertial effects that, where necessary for accuracy, the step pulse rate is gradually reduced so that there will be no significant error-causing overrun at the receipt of the last pulse.
Equation 4' (for rear cut mode):
Roller motor forward advance=material center+center to edge+rear cut+trim
(where "rear cut" is the distance of the slot edge closest to the cutting blade in terms of step motor pulses; the "trim" factor is the amount in terms of step motor pulses one desires to cut beyond the trailing edge.
The following Equation 5' for rear cut mode computes the number of step pulses to be fed to the blade step motor when the blade is in an ideal squared position to bring the cutting blade parallel to the leading edge involved, the step pulses causing the blade step motor to rotate the blade in one direction or the other depending upon the direction control signal fed to the blade step motoring:
Equation 5' (for rear cut mode):
Blade motor forward or backward rotation=C2.times.(eye 2 normal, or eye 1 normal-eye 1 normal, or eye 2 normal)
(where C2 is a constant depending upon the distance between the point the blade motor screw 76 connects with the blade and the pivot point of the blade). The constant C2 has a value which varies with the distance between the center points of the slots and the incremental angle which the shaft of the step motor 46 moves in response to each step pulse received by the motor to vary the angle of the blade. For very small angles between the adjusted angle of the blade 14 and the squared position of the blade, it is assumed that the increments in angle variation vary in linear relationship to the number of pulses fed to the blade step motor 46.
FIGS. 7 and 7A--Indicating Panel Operation
The indicator and control panel 52 preferably has a main power on-off switch 52a. The panel 52 also has four depressible keys 52c, 52d, 52e, and 52f. Adjacent the key 52c is an upwardly pointing arrow 52c'; adjacent the key 52a is a downwardly pointing arrow 52d'; adjacent the key 52e appears the word "MODE"; adjacent the key 52f are the words "RUN" and "STOP"; and above the key 52f are red and green lamps 52f' and 52f". When the main power switch 52a is on, the operator still has control to operate the equipment in a "RUN" mode or a "STOP" mode. If depressing the key 52f lights the red light 52f', then the apparatus is effectively shut down. If when the key 52f is depressed, the green light 52f" is lit, that indicates that the equipment is in a running condition.
Below the screen 52b is a "COUNT" light 52g, a "SPEED" light 52h, a "FRONT CUT" light 52i and a "REAR CUT" light 52j. When the "MODE" switch is successively depressed, it will successively light the lights 52g, 52h, 52i, and 52j. When the "SPEED" light 52h is lit, there will appear on the screen 52b a number indicating the feeding rate of the web body 18. When the "FRONT CUT" light 52i is lit, there appears on the screen 52b a number which indicates the desired trimming distance that the cutting knife 14 will cut through the web body 18 at a given selected distance from the leading edge involved. When the "REAR CUT" light 52j is lit, a number appears on the indicating screen which indicates the amount of trim beyond the trailing edge of the sheets the cutting operation will produce. The "SPEED", "FRONT" and "REAR CUT" numbers appearing on the indicating screen 52b can be adjusted up and down by depressing the UP and DOWN keys 52c and 52d. These adjustments respectively affect the web feeding speed, and the "FRONT" and "REAR" trim distances.
If a "CUT" length setting is decreased below zero, the word "OFF" appears on the indicating screen 52b. The sheet counter resets to zero when power is applied, and will count up to a maximum count of 9,999. The counter may be reset at any time with the power "ON" by pressing both the "UP" and "DOWN" keys 52c and 52d simultaneously.
The "UP" and "DOWN" keys 52c and 52d will preset a sheet counter to the number of sheets desired to be severed from the web body 18. When started, the counter will count down while cutting until the counter zero on the indicating screen 52b, at which time the machine will turn itself off. Also, the equipment preferably has an automatic-OFF mode which the equipment halts itself to the sheet counter concept 9,999 or if no sheet edges are detected, after about one foot of travel of the web body 18.
The apparatus is preferably self-calibrating when power is turned "ON". To do this, the "CLEAR" part of the web body between the opaque sheets must be placed under the light source 26'. Thus, at power "ON", the indicating screen 52b shows "0", the operator knows that the sensors are properly calibrated to produce the desired maximum intensity of 242 and the apparatus is ready to be run. If the indicating screen 52b shows "EYES", that means that the sensors must be calibrated using the calibration mode, in part previously described, when the adjustment of the potentiometers 27 and 29 shown in FIG. 18 are made as described. To obtain the calibration mode when power is turned on, any key is pressed and the indicating screen shows two sets of horizontally elongated rectangles 53a-53b-53c and 53a'-53b'-53c'. The left potentiometer 27 is adjusted until the center rectangle of the left set of rectangles is fully lit, and the right potentiometer 29 is adjusted until the center rectangle 53 b' of the right set of rectangles is fully lit. The machine is so designed that upon completion of the calibration of the sensors, if power is turned "OFF" and then back "ON", and a "0" display appears, that indicates the machine is ready to run.
FIG. 19--Program Architecture
The description of the block diagram of FIG. 19 (and of FIGS. 19-22 now to be briefly described) do not refer to all the blocks therein because the program functions performed thereby are apparent from the block indicia. The comments to be made herein therefore describe only some of the functions performed by some but not all of the program elements represented by the block.
FIG. 19 illustrates the preferred multitasking architecture of the software. All elements thereof will not be described herein since the blocks are generally self identifying. The comments to follow summarize some of the functions performed by these elements.
"Multitasking" refers to an architecture in which several separate tasks appears to be done simultaneously. These tasks are preferably done at the same time. In FIG. 19, task 1 is a loop which, after system initialization, the program scans the keyboard controls, updates the machine's display if required, and calculates the next required blade position angle, if blade movement is required.
Task 2 is triggered by a variable timer which, when required, calls the "roller interrupt handler" 44-6 which will read the machine's "eyes" PC1 and PC2 and/or step the machine's rollers 20. Task 3 is triggered by the "blade timer" 44-5' which initiates either stepping of the blade motor 46 which adjusts the blade angle or activates the blade's up/down cutting stroke sequence.
The key point in FIG. 19 is that this architecture results in these three tasks apparently occurring simultaneously; that is, motion of the web via the roller motor 40 and the blade via the blade motor 46 can occur simultaneously. The advantage of this is that both the rollers 20 and the blade 14 can be actively in motion at the same time, reducing positioning time and increasing thruput.
FIG. 20--Roller Interrupt Handler 44-6
In the multitasking architecture, the roller interrupt handler 44-6 is called whenever the internal roller timer 44-5 (FIG. 19) generates an interrupt. This timer is variable because the roller speed is controllable via the keyboard 52', and also up/down ramping for high speed operation is controlled here. Where ramping is necessary, the pulse rate must be gradually ramped up and down to or from the maximum rate.
The roller interrupt handler can be thought of as the part of the program which handles all positioning requirements of the machine's rollers 20. When the roller timer 44-5 generates an interrupt, calling the roller interrupt handler 44-6, the system checks first to see if the roller is in the "STOP" mode in program step 144-6a; this is the case if a "CUT" is in progress. If no "CUT" is in progress, the blade 14 is disabled from cutting (stop blade mode). If the material to be cut is not yet in final position, the program decides to step the roller motor 40 (step roller mode in program step 144-6b). At this time the program checks to see if ramping is required by comparing the selected rate of the rollers 20 to the maximum rate allowable without ramping. In the ramp mode carried out by a program step 144-6c, the roller timer (FIG. 19) is software controlled to ramp up and down at a predetermined rate to avoid abrupt starts and stops, which would cause accuracy losses. The roller interrupt handler will continue to step the material forward until the web is in the desired position for a cut, indicated by the roller interrupt handler setting a flag to indicate the roller ready mode; that is, a flag which indicates the material is in its final position and a cut may now be made.
FIG. 21--Blade Interrupt Handler
When the blade timer 44-5' (FIG. 14) generates an interrupt, the blade interrupt handler is called into operation. This handler can be thought of as handling all control and positioning functions for the blade 14. On initialization, the handler squares the blade, i.e., establishes a reference by reading the sensor 49 (FIG. 18) on the machine frame which tells the controller the blade 14 is square to the frame. After this operation, the controller remembers the blade position as it is moved and thereby avoids periodic re-squaring of the blade. In normal operation, a separate part of the program reads the sensors and calculates a new blade position; that is, the "correct" angle of the blade for the next cut. When the "new blade position", as determined by that routine, becomes available, the blade interrupt handler, when called, checks to see if the "current" blade position agrees with the "new" blade position. If they are different, indicating the blade angle needs to be adjusted, the blade mode is set to "not ready" and the handler steps the blade angle in the desired direction (step blade mode). Eventually, the blade 14 will reach its destination, and when the interrupt handler detects this, the blade ready mode is entered, signifying that the blade is ready to cut. If the roller interrupt handler also indicates that the rollers 20 are ready for a cut (roller ready mode), the blade UP/DOWN modes are executed as described in connection with the FIGS. 1-4 embodiments of the invention. This is the routine that activates the blade DOWN/UP modes stroke of the blade to actually cut the material.
In summary, the roller interrupt handler controls all roller positioning duties under the control of a roller timer. The blade is controlled by the blade interrupt handler. Each handler sets a flag to indicate if the roller and/or the blade are "in position" and ready to cut. When both the roller and blade status are ready, the actual cut sequence is initiated. Both roller and blade position are determined by mathematical operations and formulae obtained as part of the "READ EYES" operation. Reading of the "EYES" is done as part of the roller interrupt handler since this must occur on each machine step.
FIG. 22--Read Eyes State Diagram
FIG. 22 is easier to understand if it is remembered that the analog eye readings are passed through an analog/digital converter 44c (FIG. 18). Its output can be a number from 0 through 255, and that a low number (less than 10) is read when a sensor slot is completely covered, and that a high number (greater than 220) is read when a sensor slot is completely uncovered. A "MID" reading of 120 would indicate a sensor which is about half-covered (or half-uncovered).
Before getting into detail about FIG. 22, a recall that the theory behind analog sensing of the sheet angle was that a "snapshot" is taken of the sensor outputs and the two resulting analog voltages from those sensors could be used for high-resolution measuring of the sheet angle. The task of the controller (which includes a microprocessor) is to measure the "normalize" slot readings to accurately measure the edge angle when a sheet is approximately half-covering or uncovering one of the slots.
FIG. 22 illustrates that each sensor is read on each roller step. As a starting point, assume that sensor 1 is either less than 20, indicating it is covered completely, or that it is greater than 220, indicating it is open completely. This "no operation" mode indicates that an edge is not actively crossing the sensor slots.
The "NO" operation mode is exited when the output of one of the sensors crosses the threshold 120 either going down from an open condition or up from a closed condition. In other words, when a sensor output crosses the threshold 120, indicating the associated slot is about half-covered, the snapshot is taken; that is, the outputs of both sensors PC1 and PC2 are read, and their respective "MID" values are stored. If this threshold is crossed going down, it is read as a front cut (front cut mid mode) and if crossed going up, it is read as a rear cut (rear cut mid mode). All that remains is to get the MAX and MIN sensor readings for both sensors. This may be accomplished as follows:
Ten steps after a front cut mid value is read where both slots are covered, the sensors are read again and the "MIN" values are assigned to the sensors are stored.
The steps after a rear cut mid value is read assuring that the slots are completely uncovered, the "MAX" values of the sensors are measured and stored.
In other words, the Read Eyes routine extracts and stores the following numbers while a sheet is stepped across the slot-eyes:
a. Eye 1 Mid--Eye 1 PC1 sensor output when sheet edge approximately half-covers slot SL2.
b. Eye 2 Mid--Eye 2 PC2 sensor output when sheet edge approximately half-covers slot SL1.
c. Eye 1 Max--Maximum (clear) value for sensor 1.
d. Eye 2 Max--Maximum (clear) value for sensor 1.
e. Eye 1 Min--Minimum (dark) value for sensor 1.
f. Eye 2 Min--Minimum (dark) value for sensor 2.
With these values, the program proceeds to the normalization routine, where absolute positioning capability of the measurements can be restored, and the roller and blade positions can be calculated in accordance with the equations previously described.
The "Read Eyes" state diagram of FIG. 22 shows various other functions performed by the program, which functions for the most part have already been described.
FIG. 23--Program Summary Diagram
FIG. 23 is a summary of the most important program steps shown in much more detail than the previous figures. Thus, in FIG. 23, blocks 144a-144a' are the front cut control program steps which inquire whether it is the output of light sensor PC2 or PC1 which decreases to 120 to indicate whether the leading edge involved has a counterclockwise or clockwise angle with respect to the line L2 connecting the mid points of the slots SL2 and SL1. Similarly, the blocks 144b-144b' are the rear cut program control steps which inquire whether it is the output of light sensor PC2 or PC1 which increases to 120. These program steps control program steps identified by the blocks 144c-144c' and 144d-144d' wherein the output of the sensor other than the sensor which first produces the output 120 is stored along with flags which indicate whether a counterclockwise or clockwise rotation of the blade appears to be called for, and a flag indicating whether a rear cut or front cut mode is involved. After this storage operation takes place, the steps of the program perform the various required computations identified in block 144e come into operation including the normalization corrections referred to. These compute the angle of the edge involved and the distance which the center of the edge involved must be moved to bring it into a desired position adjacent the blade 14.
Next, the program steps identified in block 144f compare the computed blade angle with the current blade angle position and generates the necessary signals which produce the required number of pulses necessary to step the blade motor the proper number of steps to rotate the motor shaft in the proper direction. Also, the results of the computations carried out by the program steps identified in block 144e produce the number of pulses needed to step the roller step motor 40 to bring the center of the sheet edge opposite the blade 14. These pulses are produced by the program steps contained with the block 144g.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the broader aspects of the invention. Also, it is intended that broad claims not specifying details of a particular embodiment disclosed herein as the best mode contemplated for carrying out the invention should not be limited to such details. ##SPC1##

Number	Name	Date
3197353	Williams et al.	Jul 1965
3407690	Stanley	Oct 1968
4475422	Lawson	Oct 1984
4541317	Van Humbeeck et al.	Sep 1985
4697485	Raney	Oct 1987
4794962	Knudson	Jan 1989

Cutter mechanism

Information

Patent Number

Date Filed

Date Issued

Inventors

Original Assignees

Examiners

Agents

CPC

US Classifications

Field of Search

US

International Classifications

Abstract

Description

Claims

RELATED APPLICATION

US Referenced Citations (6)

Continuation in Parts (1)