Patent Application
20230278075
The present disclosure relates to systems and processes for removing debris from plastic sheets.
Certain industries use tier sheets (also called separator sheets or layer pads) to separate layers of goods on pallets. Tier sheets help stabilize the palletized load, reduce contamination, and protect the goods during handling, storage, and transit. For instance, in preparation for shipping empty beverage containers to fillers, the beverage container manufacturer arranges tens or hundreds of containers (depending on the size) in distinct vertically stacked layers on a pallet, with each layer separated by a tier sheet. Tier sheets are typically made from fiberboard or thin plastic and are made in a variety of sizes (such as 40×48 inches, 44×56 inches, 44.75×47.5 inches, and 45×47.5 inches) and a variety of thicknesses (such as 0.025 to 0.1 inches). One benefit of plastic tier sheets is that they can be repeatedly cleaned and re-used, making them a cost-effective solution and reducing waste. There is a continuing need for effective systems and processes for cleaning plastic tier sheets to enable their continued reuse.
Various embodiments of the present disclosure provide a multi-stage system and process for removing debris (such as dry dust particles) from plastic sheets (such as tier sheets or any other suitable sheets formed from any suitable material).
One embodiment of the sheet-cleaning system of the present disclosure comprises a drive assembly comprising a drive roller driven by a drive actuator; an electrostatic-discharge device operable to discharge static electricity; and a cleaning roller assembly comprising a cleaning roller driven by a cleaning-roller actuator, the cleaning roller comprising a cleaning implement on at least part of its outer surface.
One embodiment of the sheet-cleaning process of the present disclosure comprises discharging static electricity from the sheet; engaging the sheet with a cleaning implement of a cleaning roller; and vacuuming the sheet.
While the systems, devices, and processes described herein may be embodied in various forms, the drawings show and the specification describes certain exemplary and non-limiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connection of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting processes, such as coupled, mounted, connected, etc., are not intended to be limited to direct mounting processes, but should be interpreted broadly to include indirect and operably coupled, mounted, connected, and like mounting processes. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.
Various embodiments of the present disclosure provide a multi-stage system and process for removing debris (such as dry dust particles) from plastic sheets (such as tier sheets or any other suitable sheets formed from any suitable material).
Generally, the conveying assembly 100 moves (dirty) sheets to the cleaning assembly 200. The cleaning assembly 200 uses rotating cleaning implements to remove debris from the sheets. The debris collector 400 continuously draws air and debris out of the cleaning assembly 200 via the ducting 450 and into the debris collector 400, where the debris is filtered from the air. The cleaning assembly 200 ejects the (clean) sheets onto the storage assembly 300, which stores the sheets for further processing.
The conveying assembly 100, which is best shown in
The cleaning assembly 200, which is best shown in
The cleaning-assembly frame F200 supports and houses the sheet support 205, the infeed drive assembly 210, the first electrostatic-discharge device 220, the cleaning-roller assembly 230, the vacuum assembly 240, the second electrostatic-discharge device 250, the outfeed drive assembly 260, and the outfeed sheet cleaner 270. The cleaning-assembly frame F200 is formed from any suitable combination of solid members, tubular members, plates, and/or any other suitable components attached to one another.
The sheet support 205 supports the sheet as it moves through the cleaning assembly 200. In this example embodiment, the sheet support 205 includes a plate (though it may be any other suitable component) mounted to the cleaning-assembly frame F200 such that it separates certain upper and lower components of the infeed drive assembly 210, the first electrostatic-discharge device 220, the cleaning-roller assembly 230, the vacuum assembly 240, the second electrostatic-discharge device 250, and the outfeed drive assembly 260. Cutouts (not labeled) formed in the sheet support 205 enable these components to engage or otherwise interact with the sheet as it moves over the sheet support 205 and through the cleaning assembly 200. As shown in
The infeed drive assembly 210 receives the sheet from the conveying assembly 100 (via the sheet-infeed slot IN) and moves the sheet through the cleaning assembly 200. The infeed drive assembly 210 includes an upper infeed drive roller 211, a lower infeed drive roller 212, and one or more infeed drive actuators 219 (referred to in the singular below for clarity). The upper infeed drive roller 211 is mounted to the cleaning-assembly frame F200 above the sheet support 205 via first and second rails 211a and 211b (
The upper and lower infeed drive rollers 211 and 212 are rotatable relative to the cleaning-assembly frame F200 and the sheet support 205 about respective rotational axes A211 and A212. The infeed drive actuator 219 is operably connected to the upper and lower infeed drive rollers 211 and 212 and configured to rotate the upper and lower infeed drive rollers 211 and 212 in opposite directions about their respective rotational axes at a first rotational speed. In this example embodiment, the first rotational speed is 50 revolutions per minute, though it may be any suitable rotational speed in other embodiments.
In this example embodiment, at least one of the upper and lower infeed drive rollers 211 and 212 is repositionable relative to the cleaning-assembly frame F200 and the sheet support 205 in the vertical direction (i.e., toward and away from the sheet support 205). This enables an operator to change the spacing between the upper and lower infeed drive rollers 211 and 212 to accommodate sheets of different thicknesses. In this example embodiment, the outer surfaces of the upper and lower infeed drive rollers 211 and 212 are coated in a relatively high-friction material, such as rubber, to aid in receiving the sheets and moving them through the cleaning assembly 200. The outer surfaces are textured in some embodiments. In this example embodiment, the infeed drive actuator 219 includes an electric motor, though it may include any other suitable actuator in other embodiments. The infeed drive actuator 219 is operably connected to the upper and lower infeed drive rollers 211 and 212 via one or more other components, such as sprockets, gearing, screws, tensioning elements, and/or chains.
The first electrostatic-discharge device 220 is downstream of the infeed drive assembly 210 and discharges static electricity from the sheet before the sheet enters the cleaning-roller assembly 230. This weakens or eliminates the bond between certain debris and the sheet, making it easier to remove the debris from the sheet. The first electrostatic-discharge device 220 includes upper and lower ionizing devices 221 and 222. The upper ionizing device 221 is mounted to the cleaning-assembly frame F200 above the sheet support 205, and the lower ionizing device 222 is mounted to the cleaning-assembly frame F200 below the sheet support 205 and opposite the upper ionizing device 211. In this example embodiment, the ionizing devices discharge numerous positive and negative ions onto the sheet. These ions are attracted to and neutralize ions on the sheet itself, thereby discharging any built-up static electricity on the sheet caused by the ions on the sheet. Other embodiments may include any other suitable type electrostatic-discharge device. Further embodiments do not include the first electrostatic-discharge device.
The cleaning-roller assembly 230 is downstream of the first electrostatic-discharge device 220 and cleans the sheet via two different sets of rollers. The cleaning-roller assembly 230 includes an upper first-stage cleaning roller 231; a lower first-stage cleaning roller 232; a first upper shroud 233; an upper first-stage cleaning roller cleaner 233a; a first lower shroud 234; a lower first-stage cleaning roller cleaner 234a; an upper second-stage cleaning roller 235; a lower second-stage cleaning roller 236; a second upper shroud 237; an upper cleaning nozzle 237a; an upper second-stage cleaning roller cleaner 237b; a second lower shroud 238; a lower cleaning nozzle 238a; a lower second-stage cleaning roller cleaner 238b; one or more cleaning-roller actuators 239 (referred to in the singular below for clarity); and brushes 230a, 230b, 230c, 230d, 230e, 230f, 230g, and 230h. In other embodiments the cleaning-roller assembly includes only one pair of cleaning rollers.
The upper first-stage cleaning roller 231 is mounted to the cleaning-assembly frame F200 above the sheet support 205 via first and second rails 231a and 231b (
The cleaning-roller actuator 239 is operably connected to the upper and lower first-stage cleaning rollers 231 and 232 and configured to rotate the upper and lower first-stage cleaning rollers 231 and 232 in opposite directions about their respective rotational axes at a second rotational speed. In this example embodiment, the second rotational speed is greater than the first rotational speed at which the first and second infeed drive rollers 211 and 212 rotate (though in other embodiments it may be less than or equal to the first rotational speed). Here, the second rotational speed is 90 revolutions per minute (though it may be any suitable rotational speed in other embodiments).
In this example embodiment, at least one of the upper and lower first-stage cleaning rollers 231 and 232 is repositionable relative to the cleaning-assembly frame F200 and the sheet support 205 in the vertical direction (i.e., toward and away from the sheet support 205). This enables an operator to change the spacing between the upper and lower first-stage cleaning rollers 231 and 232 to accommodate sheets of different thicknesses. In this example embodiment, the cleaning-roller actuator 239 includes an electric motor, though it may include any other suitable actuator in other embodiments. The cleaning-roller actuator 239 is operably connected to the upper and lower first-stage cleaning rollers 231 and 232 via one or more other components, such as sprockets, gearing, screws, tensioning elements, and/or chains.
The first upper shroud 233 is mounted to the cleaning-assembly frame F200 such that it surrounds most of the upper first-stage cleaning roller 231. Similarly, the first lower shroud 234 is mounted to the cleaning-assembly frame F200 such that it surrounds most of the lower first-stage cleaning roller 232. The first upper and first lower shrouds 233 and 234 are in fluid communication with the debris collector 400 (described below) such that the debris collector 400 draws air and debris out of the interior of the first upper and first lower shrouds 233 and 234.
In this example embodiment, the outer surfaces of the upper and lower first-stage cleaning rollers 231 and 232 include cleaning implements. In this example embodiment, the cleaning implements on the outer surfaces of both the upper and lower first-stage cleaning rollers 231 and 232 include bristles (and specifically, 0.5 millimeter diameter nylon bristles). As the upper and lower first-stage cleaning rollers 231 and 232 rotate, the bristles engage the sheet and either loosen debris on the sheet or remove debris from the sheet. The debris collector 400 draws any removed debris into and then out of the first upper and/or the first lower shrouds 233 and 234 and into the ducting 450. In other embodiments, the upper first-stage cleaning roller 231 includes a different cleaning implement than the lower first-stage cleaning roller 232.
The cleaning roller cleaners are configured to remove debris from the first-stage cleaning rollers as the first-stage cleaning rollers rotate. The upper first-stage cleaning roller cleaner 233a is mounted within the first upper shroud 233 in the rotational path of the cleaning implement of the upper first-stage cleaning roller 231. As the upper first-stage cleaning roller 231 rotates, the cleaning implement (here, the bristles) engages the upper first-stage cleaning roller cleaner 233a (here a baffle plate). This interaction removes debris from the cleaning implement into the air within the interior of the first upper shroud 233, and the debris collector 400 then draws the debris out of the first upper shroud 233 and into the ducting 450. Similarly, the lower first-stage cleaning roller cleaner 234a is mounted within the first lower shroud 234 in the rotational path of the cleaning implement of the lower first-stage cleaning roller 232. As the lower first-stage cleaning roller 232 rotates, the cleaning implement (here, the bristles) engages the lower first-stage cleaning roller cleaner 234a (here a baffle plate). This interaction removes debris from the cleaning implement into the air within the interior of the first lower shroud 234, and the debris collector 400 then draws the debris out of the first lower shroud 234 and into the ducting 450.
The brushes 230a and 230b are mounted to the cleaning-assembly frame F200 above and below the sheet support 205, respectively, downstream of the first electrostatic-discharge device 220 and upstream of the upper and lower first-stage cleaning rollers 231 and 232. Brushes 230c and 230d are mounted to the cleaning-assembly frame F200 above and below the sheet support 205, respectively, downstream of the upper and lower first-stage cleaning rollers 231 and 232. These brushes are positioned to engage the upper and lower surfaces of the sheet to loosen debris on the sheet or remove debris from the sheet as it moves past the brushes. Although described as brushes, they may be any suitable type of cleaning implement.
The upper second-stage cleaning roller 235 is mounted to the cleaning-assembly frame F200 above the sheet support 205 via first and second rails 235a and 235b (
The cleaning-roller actuator 239 is operably connected to the upper and lower second-stage cleaning rollers 235 and 236 and configured to rotate the upper and lower second-stage cleaning rollers 235 and 236 in opposite directions about their respective rotational axes at the second rotational speed.
In this example embodiment, at least one of the upper and lower second-stage cleaning rollers 235 and 236 is repositionable relative to the cleaning-assembly frame F200 and the sheet support 205 in the vertical direction (i.e., toward and away from the sheet support 205). This enables an operator to change the spacing between the upper and lower second-stage cleaning rollers 235 and 236 to accommodate sheets of different thicknesses. The cleaning-roller actuator 239 is operably connected to the upper and lower second-stage cleaning rollers 235 and 236 via one or more other components, such as sprockets, gearing, screws, tensioning elements, and/or chains.
The second upper shroud 237 is mounted to the cleaning-assembly frame F200 such that it surrounds most of the upper second-stage cleaning roller 235. Similarly, the second lower shroud 238 is mounted to the cleaning-assembly frame F200 such that it surrounds most of the lower second-stage cleaning roller 236. The second upper and second lower shrouds 237 and 238 are in fluid communication with the debris collector 400 (described below) such that the debris collector 400 draws air and debris out of the interior of the second upper and first lower shrouds 237 and 238.
In this example embodiment, the outer surfaces of the upper and lower second-stage cleaning rollers 235 and 236 include cleaning implements. In this example embodiment, the cleaning implements on the outer surfaces of both the upper and lower second-stage cleaning rollers 235 and 236 include a fabric covering (and specifically, fine cotton fabric). As the upper and lower second-stage cleaning rollers 235 and 236 rotate, the fabric engages the sheet and either loosens debris on the sheet or removes debris from the sheet. The debris collector 400 draws any removed debris into and then out of the second upper and/or the second lower shrouds 237 and 238 and into the ducting 450. In other embodiments, the upper second-stage cleaning roller 235 includes a different cleaning implement than the lower second-stage cleaning roller 236. While in this embodiment the upper and lower first-stage cleaning rollers have different cleaning implements than the upper and lower second-stage cleaning rollers, in other embodiments all four cleaning rollers have the same cleaning implement.
The nozzles and cleaning roller cleaners are configured to remove debris from the second-stage cleaning rollers as the second-stage cleaning rollers rotate. The upper cleaning nozzle 237a is mounted within the second upper shroud 237 such that air emitted from the upper cleaning nozzle 237a is in the rotational path of the cleaning implement of the upper second-stage cleaning roller 235. Similarly, the upper second-stage cleaning roller cleaner 237b is mounted within the second upper shroud 237 in the rotational path of the cleaning implement of the upper second-stage cleaning roller 235. As the upper second-stage cleaning roller 235 rotates: (1) air emitted from the upper cleaning nozzle 237a impinges on the cleaning implement (here, the fabric) of the roller to loosen or remove debris from the cleaning implement into the air within the interior of the second upper shroud 237; and (2) the cleaning implement (here, the fabric) then engages the upper second-stage cleaning roller cleaner 237a (here a baffle plate), which removes debris from the cleaning implement into the air within the interior of the second upper shroud 237. The debris collector 400 draws this debris out of the second upper shroud 237 and into the ducting 450.
Similarly, the lower cleaning nozzle 238a is mounted within the second lower shroud 238 such that air emitted from the lower cleaning nozzle 238a is in the rotational path of the cleaning implement of the lower second-stage cleaning roller 236. Similarly, the lower second-stage cleaning roller cleaner 238b is mounted within the second lower shroud 238 in the rotational path of the cleaning implement of the lower second-stage cleaning roller 236. As the lower second-stage cleaning roller 236 rotates: (1) air emitted from the lower cleaning nozzle 238a impinges on the cleaning implement (here, the fabric) of the roller to loosen or remove debris from the cleaning implement into the air within the interior of the second lower shroud 238; and (2) the cleaning implement (here, the fabric) then engages the lower second-stage cleaning roller cleaner 238a (here a baffle plate), which removes debris from the cleaning implement into the air within the interior of the second lower shroud 238. The debris collector 400 draws this debris out of the second lower shroud 238 and into the ducting 450.
The brushes 230e and 230f are mounted to the cleaning-assembly frame F200 above and below the sheet support 205, respectively, downstream of the brushes 230c and 230d and upstream of the upper and lower second-stage cleaning rollers 235 and 236. Brushes 230g and 230h are mounted to the cleaning-assembly frame F200 above and below the sheet support 205, respectively, upper and lower second-stage cleaning rollers 235 and 236. These brushes are positioned to engage the upper and lower surfaces of the sheet to loosen debris on the sheet or remove debris from the sheet as it moves past the brushes. Although described as brushes, they may be any suitable type of cleaning implement.
The vacuum assembly 240 is downstream of the cleaning roller assembly 230 and removes loosened debris remaining on the sheet after the sheet passes through the cleaning-roller assembly 230. The vacuum assembly 240 includes an upper vacuum housing 241 having an inlet 241a; an opposing lower vacuum housing 242 having an inlet 242a; and brushes 240a, 240b, 240c, and 240d. The upper vacuum housing 241 is mounted to the cleaning-assembly frame F200 above the sheet support 205, and the lower vacuum housing 242 is mounted to the cleaning-assembly frame F200 below the sheet support 205. The upper and lower vacuum housings 241 and 242 are positioned such that their respective inlets 241a and 242a are opposite one another and slightly spaced-apart from the sheet (when the sheet is passing through the vacuum assembly 240). The upper and lower vacuum housings 241 and 242 are in fluid communication with the debris collector 400 such that the debris collector 400 draws air and debris out of the interiors of the upper and lower vacuum housings 241 and 242 and into the ducting 450.
The brushes 240a and 240b are mounted to the cleaning-assembly frame F200 above and below the sheet support 205, respectively, downstream of the brushes 230g and 230h and upstream of the inlets 241a and 242a of the upper and lower vacuum housings 241 and 242. The brushes 240c and 240d are mounted to the cleaning-assembly frame F200 above and below the sheet support 205, respectively, downstream of the inlets 241a and 242a of the upper and lower vacuum housings 241 and 242. These brushes are positioned to engage the upper and lower surfaces of the sheet to loosen debris on the sheet or remove debris from the sheet as it moves past the brushes. Although described as brushes, they may be any suitable type of cleaning implement.
The second electrostatic-discharge device 250 is downstream of the vacuum assembly 240 and discharges static electricity from the sheet before the sheet exits the cleaning assembly 200. This reduces the likelihood that the sheets will stick together when stacked in the storage assembly 300 after cleaning. The second electrostatic-discharge device 250 includes upper and lower ionizing devices 251 and 252. The upper ionizing device 251 is mounted to the cleaning-assembly frame F200 above the sheet support 205, and the lower ionizing device 252 is mounted to the cleaning-assembly frame F200 below the sheet support 205 and opposite the upper ionizing device 251. In this example embodiment, the ionizing devices discharge numerous positive and negative ions onto the sheet. These ions are attracted to and neutralize ions on the sheet itself, thereby discharging any built-up static electricity on the sheet caused by the ions on the sheet. Other embodiments may include any other suitable type or electrostatic-discharge device. Further embodiments do not include the second electrostatic-discharge device.
The outfeed drive assembly 260 is downstream of the second electrostatic-discharge device 250 and ejects the sheet from the cleaning assembly 200 (via the sheet-outfeed slot OUT) to the storage assembly 300. The outfeed drive assembly 210 includes a first upper outfeed drive roller 261, a first lower outfeed drive roller 262, a second upper outfeed drive roller 263, a second upper outfeed drive roller 264, and one or more outfeed drive actuators 269 (referred to in the singular below for clarity).
The first upper outfeed drive roller 261 is mounted to the cleaning-assembly frame F200 above the sheet support 205 via first and second rails 261a and 261b (
The second upper outfeed drive roller 263 is mounted to the cleaning-assembly frame F200 above the sheet support 205 and downstream of the first upper outfeed drive roller 261 via first and second rails 263a and 263b (
The outfeed drive actuator 269 is operably connected to the first upper and lower outfeed drive rollers 261 and 262 and configured to rotate the first upper and lower outfeed drive rollers 261 and 262 in opposite directions about their respective rotational axes at a third rotational speed. Similarly, the outfeed drive actuator 269 is operably connected to the second upper and lower outfeed drive rollers 263 and 264 and configured to rotate these outfeed drive rollers in opposite directions about their respective rotational axes at the third rotational speed. In this example embodiment, the third rotational speed is greater than the first rotational speed at which the infeed drive rollers 211 and 212 rotate and less than the second rotational speed at which the cleaning rollers 231, 232, 235, and 236 rotate (though in other embodiments it may be greater than, less than, or equal to the first rotational speed and/or the second rotational speed). Here, the third rotational speed is 60 revolutions per minute (though it may be any suitable rotational speed in other embodiments).
In this example embodiment, at least one of the first upper and lower outfeed drive rollers 261 and 262 is repositionable relative to the cleaning-assembly frame F200 and the sheet support 205 in the vertical direction (i.e., toward and away from the sheet support 205). This enables an operator to change the spacing between the first upper and lower outfeed drive rollers 261 and 262 to accommodate sheets of different thicknesses. Similarly, at least one of the second upper and lower outfeed drive rollers 263 and 264 is repositionable relative to the cleaning-assembly frame F200 and the sheet support 205 in the vertical direction (i.e., toward and away from the sheet support 205). This enables an operator to change the spacing between the second upper and lower outfeed drive rollers 263 and 264 to accommodate sheets of different thicknesses. In this example embodiment, the outer surfaces of the first and second upper and lower outfeed drive rollers 261-264 are coated in a relatively high-friction material, such as rubber, to aid in receiving the sheets and discharging them from the cleaning assembly 200. The outer surfaces are textured in some embodiments. In this example embodiment, the outfeed drive actuator 269 includes an electric motor, though it may include any other suitable actuator in other embodiments. The outfeed drive actuator 269 is operably connected to the first and second upper and lower outfeed drive rollers 261-264 via one or more other components, such as sprockets, gearing, screws, tensioning elements, and/or chains. In other embodiments the outfeed drive assembly includes only one pair of outfeed drive rollers.
The outfeed sheet cleaner 270 is downstream of the outfeed drive assembly 260 and removes loose debris from the sheet as the sheet exits the cleaning assembly 200. In this example embodiment, the outfeed sheet cleaner 270 comprises a microfiber pad mounted to the cleaning-assembly frame F200 adjacent the sheet-outfeed slot OUT. The outfeed sheet cleaner 270 is positioned to engage the upper and lower surfaces of the sheet as the sheet exits the sheet-outfeed slot OUT and remove loose debris from the sheet as the sheet moves past the outfeed sheet cleaner 270.
The storage assembly 300, which is best shown in
The debris collector 400 includes a housing (not labeled) defining an inlet and an outlet, one or more filters (not shown) within the housing, an impeller within the housing, and a motor operably connected to the impeller to rotate the impeller. The inlet of the debris collector is in fluid communication with components of the cleaning assembly 200 (as described above) via the ducting 450. The components of the debris collector are sized, shaped, positioned, and otherwise configured such that, when the debris collector is operating and the impeller is rotating, the impeller draws air (and debris) from the cleaning assembly 200 into the inlet of the housing (via the ducting 450), draws the air through the one or more filters—which capture debris and remove it from the air—and expels the air from the housing through the outlet, which is typically open to the surrounding atmosphere.
The sheet sensor 500 is any suitable type of sensor configured to detect the sheet when the sheet is ejected from the cleaning assembly 200 and onto the storage assembly 300 and to send a corresponding signal to the controller 600. In this example embodiment, the sheet sensor 500 includes an optical sensor mounted to the cleaning-assembly frame F200 adjacent the sheet-outfeed slot OUT, though the sheet sensor 500 may be mounted in any suitable position that enables the sheet sensor 500 to detect sheets.
The controller 600 includes a processing device (or devices) communicatively connected to a memory device (or devices). For instance, the controller may include a programmable logic controller. The processing device may include any suitable processing device such as, but not limited to, a general-purpose processor, a special-purpose processor, a digital-signal processor, one or more microprocessors, one or more microprocessors in association with a digital-signal processor core, one or more application-specific integrated circuits, one or more field-programmable gate array circuits, one or more integrated circuits, and/or a state machine. The memory device may include any suitable memory device such as, but not limited to, read-only memory, random-access memory, one or more digital registers, cache memory, one or more semiconductor memory devices, magnetic media such as integrated hard disks and/or removable memory, magneto-optical media, and/or optical media. The memory device stores instructions executable by the processing device to control operation of the system 10 (such as to carry out the process 900 described below with respect to
As shown in
Operation of the system 10 to carry out the process 900 for a dirty sheet (not shown) is now described. Initially: the conveyor actuator 199 is driving the conveyor 110; the infeed drive actuator 219 is driving the infeed drive rollers 211 and 212; the first electrostatic-discharge device 220 is operating; the cleaning roller actuator 239 is driving the cleaning rollers 231, 232, 235, and 236; the second electrostatic-discharge device 250 is operating, the outfeed drive actuator 269 is driving the outfeed drive rollers 261, 262, 263, and 264; the debris collector 400 is operating; and the storage assembly 300 is not storing any sheets.
To clean the dirty sheet, an operator positions the sheet on the conveyor 110 of the conveying assembly 100. The conveyor actuator 199 drives the conveyor 110 to move the sheet in the sheet-movement direction toward the cleaning assembly 200 and into the sheet-infeed slot IN. The infeed drive rollers 211 and 212 engage the sheet and move the sheet in the sheet-movement direction D. The sheet passes between the upper and lower ionizing devices 221 and 222 of the first electrostatic-discharge device 220. This discharges static electricity from the sheet, thereby weakening (or eliminating) the bond between certain debris and the sheet.
The infeed drive rollers 211 and 212 continue moving the sheet in the direction D so it passes through and is cleaned by the cleaning-roller assembly 230. Specifically, the sheet first passes between the first-stage cleaning rollers 231 and 232, which engage the sheet with their respective cleaning implements (here, bristles) and loosen or remove debris from the sheet. The debris collector 400 draws removed debris into and from the first upper and first lower shrouds 233 and 234 and into the ducting 450. The first sheet then passes between the second-stage cleaning rollers 235 and 236, which engage the sheet with their respective cleaning implements and loosen or remove debris from the sheet. The debris collector 400 draws removed debris into and from the upper and lower second shrouds 237 and 238 and into the ducting 450.
The infeed drive rollers 211 and 212 continue moving the sheet in the sheet-movement direction D so it passes through the vacuum assembly 240, wherein the debris collector 400 draws loose debris from the sheet and into the ducting 450. The infeed drive rollers 211 and 212 continue moving the sheet in the sheet-movement direction D so it passes between the upper and lower ionizing devices 251 and 252 of the second electrostatic-discharge device 250. This discharges static electricity from the sheet.
The sheet then moves between and is engaged by the first outfeed drive rollers 261 and 262 and then the second outfeed drive rollers 263 and 264. The outfeed drive rollers 261-264 engage the sheet and move the sheet in the direction D so the sheet is ejected from the sheet-outfeed slot OUT of the cleaning assembly 200 and onto the storage tray 320 of the storage assembly 300. As this occurs, the outfeed sheet cleaner 270 wipes the sheet to remove any remaining loose debris, and the sheet sensor 500 detects the sheet exiting the cleaning assembly 200 and sends a corresponding signal to the controller 600. In response, the controller 600 controls the storage-assembly actuator 399 to operate the lift 310 to slightly lower the storage tray 320 so the sheet does not block the sheet-outfeed slot OUT, which makes room for the storage tray 320 to receive the next sheet.
In certain embodiments, the cleaning assembly is configured to automatically adjust to sheets of varying thicknesses. In these embodiments, the cleaning assembly includes one or more height-adjusting actuators operably connected to the rollers of the cleaning assembly. The controller is operably connected to the one or more height-adjusting actuators and configured to operate the one or more height-adjusting actuators to move the rollers to accommodate for a sheet of different thickness. For instance, if the rollers are at a height appropriate to clean a 0.025 inch thick sheet and the next sheet to-be-cleaned is 0.1 inches thick, the controller controls the one or more height-adjusting actuators to move one or more of the rollers further from the sheet support to accommodate the thicker sheet. In some of these embodiments, the sheet-cleaning system includes a sheet-thickness sensor configured to detect the thickness of the sheet before or as the sheet enters the cleaning assembly and to send a corresponding signal to the controller. The controller is configured to determine the thickness of the sheet based on that signal, and if necessary control the one or more height-adjusting actuators to adjust the height of the rollers.
In various embodiments, the sheet-cleaning system includes an on/off sensor configured to detect a sheet before or as the sheet enters the cleaning assembly. The on/off sensor is configured to generate and send an appropriate signal to the controller upon detecting the sheet, and in response the controller is configured to activate the debris collector and the various components and actuators of the cleaning assembly so the cleaning assembly cleans the sheet. After a designated period of time expires without the on/off sensor having detected a sheet, the controller is configured to deactivate the debris collector and the various components and actuators of the cleaning assembly, which conserves electricity (thereby saving money) and reduces wear on the components.
The various components of the cleaning assembly are shown in the Figures and described above as being positioned in a particular order with respect to the downstream direction D. This is merely one example ordering of these components, and in other embodiments the components may be arranged in any other suitable order.
In the embodiment of the sheet-cleaning system described above and shown in the Figures, the sheets are oriented generally horizontally (i.e., parallel to the floor) when moving through the sheet-cleaning system. In other embodiments, the sheet-cleaning system is oriented so the sheets are oriented generally vertically (i.e., perpendicular to the floor) when moving through the sheet-cleaning system.
In the embodiment of the sheet-cleaning system described above and shown in the Figures, no liquid is used to remove debris from or otherwise clean the sheets, though in other embodiments the sheet-cleaning system may incorporate liquid to remove debris from the sheets.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202041038238 | Sep 2020 | IN | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IN2021/050791 | 8/17/2021 | WO |
