Claims
- 1. Die mounting apparatus, comprising:
- a rotatable die cylinder having a die mounting surface;
- means for connecting an interior of said die cylinder to a source of vacuum;
- at least one valve unit mounted in said die cylinder, said valve unit having an actuating member protruding above said die mounting surface when the valve is closed, depression of said actuating member opening the valve for placing said die cylinder interior in communication with said die mounting surface;
- a rigid die mounted on said die mounting surface over said actuating member and being held on said surface in use by vacuum applied below said die through said valve unit, said actuating member being depressed by said die;
- a seal sandwiched between said die and said die mounting surface, said seal defining a closed area on an underside of said die and to which area the vacuum is in use applied; and
- said seal comprising at least one elongate element having a lengthwise direction and a width transverse to said lengthwise direction, said element having a bubble formed intermediate its width and extending in said lengthwise direction, said bubble being flattened between said die and said die mounting surface when said vacuum is applied to said closed area.
- 2. The apparatus of claim 1, wherein said elongate element comprises two superimposed strips.
- 3. The apparatus of claim 2, wherein one of said strips is flat and the other of said strips is deformed to form said bubble.
- 4. The apparatus of claim 3, wherein said flat strip is adhered to the underside of said die.
- 5. The apparatus of claim 4, wherein said seal is disposed around but spaced inwardly from a periphery of the underside of said die.
- 6. The apparatus of claim 1, wherein said seal is mounted on the underside of said die adjacent a periphery thereof, said seal comprising a plurality of said elongate elements, and the bubble in each of said elongate elements being formed by a tunnel extending along the length of the respective element.
- 7. The apparatus of claim 1, wherein a light reflector is mounted on an upperside of said die.
- 8. The apparatus of claim 1, wherein said die mounting surface has a keyway formed therein, and said die has a key engaged in said keyway.
- 9. The apparatus of claim 8, wherein a light reflector in mounted in said keyway.
- 10. The apparatus of claim 8, wherein said key is elongate, extends parallel and adjacent to a rear edge of said die, and protrudes from said underside of said die towards said die cylinder.
- 11. The apparatus of claim 10, wherein said key is a loose fit in said keyway, and a forward face of said key is rearwardly tapered to facilitate entry of said key in said keyway.
- 12. The apparatus of claim 11, wherein a forward edge of said die is secured to said die cylinder by at least one bolt.
- 13. The apparatus of claim 1, further comprising check valve means, disposed in said connecting means, for preventing flow of air from said vacuum source into said die cylinder interior in the event of failure of said vacuum source.
- 14. The apparatus of claim 1, wherein a plurality of valve units are mounted in said die cylinder, each valve unit having a said actuating member, and these actuating members being rotatable spherical balls on which said die can roll when being positioned on the die cylinder.
- 15. The apparatus of claim 1, wherein said die has at least one handle cutout therethrough, and a vacuum sealing strip surrounds said cutout on the underside of said die.
- 16. The apparatus of claim 1, further comprising:
- a motor for drivingly rotating said die cylinder about an axis;
- means for controlling said motor;
- first and second sensor means, connected to said controlling means, for transmitting and receiving light;
- a first light reflector mounted on said die cylinder;
- a second light reflector mounted on said die, said second reflector being spaced from said first reflector in a direction parallel to said axis;
- said first sensor means functioning via said controlling means to switch said motor off if said first sensor means senses reflected light from said first reflector; and
- said second sensor means functioning via said controlling means to switch said motor off if said second sensor means does not sense reflected light from said second reflector.
- 17. The apparatus of claim 14, wherein said spherical balls protrude through circular orifices, said die has at least one cutting rule mounted therein, said rule being strip-like and having an inner edge supported in use by said die mounting surface, and each of said orifices having a diameter not greater than four times the thickness of said inner edge.
- 18. An apparatus for cutting paperboard sheets, comprising:
- a motor;
- means for controlling said motor;
- a die roll rotatably mounted for rotation by said motor, said die roll having a cylindrical surface;
- a cutting die having a rigid curved shell with at least one cutting rule mounted therein, said shell being mountable on said die roll surface;
- vacuum means for applying a vacuum between said surface and said die for drawing and holding said die against said surface;
- first and second sensor means, connected to said controlling means, for transmitting and receiving electromagnetic waves;
- a first reflector mounted on said die roll and covered in use by said die when mounted on said surface;
- a second reflector mounted on said die;
- said first sensor means functioning to cause said motor to be switched off if said first sensor means senses reflected electromagnetic waves from said first reflector; and
- said second sensor means functioning to cause said motor to be switched off if said second sensor means does not sense reflected electromagnetic waves from said second reflector.
- 19. The apparatus of claim 18, further comprising locating means, cooperative between said die and said die roll, for correctly locating said die on said die roll surface.
- 20. The apparatus of claim 19, wherein said locating means comprises a key on said die engageable in a keyway in said die roll and said first reflector is located in said keyway.
- 21. The apparatus of claim 20, wherein said key is disposed adjacent a trailing edge of said die, said key is a sloppy fit in said keyway, and a forward portion of said key is tapered to facilitate entry of said key into said keyway when locating said die on said die roll surface.
- 22. The apparatus of claim 21, wherein said locating means includes at least one bolt secured through said die into said die roll at a location adjacent a leading edge of said die.
- 23. The apparatus of claim 18, wherein said die has a seal mounted on an underside of said shell and extending around a periphery of said shell, said seal including a bubble extending along said seal, said bubble being flattened when said vacuum means causes said die to be drawn against said die roll surface.
- 24. Die mounting apparatus, comprising:
- a motor;
- a die cylinder mounted for rotation by said motor;
- a die mountable on an exterior surface of said die cylinder;
- means for generating a vacuum and being selectively switchable on or off;
- means for applying said vacuum between said surface and said die when mounted on said surface;
- a light reflector mounted on said die; and
- means for sensing light reflected from said reflector when said die cylinder is rotating, and for causing said motor to be switched off if said vacuum generating means is switched on and no reflected light is received by said sensing means.
- 25. The apparatus of claim 24, wherein said sensing means also functions to transmit a beam of light.
- 26. The apparatus of claim 24, wherein said vacuum applying means includes check valve means, between said die cylinder and said vacuum generating means, for allowing air to flow from said die cylinder to said vacuum generating means but preventing air flowing in the opposite direction should said vacuum generating means fail.
- 27. The apparatus of claim 24, further comprising means for sensing the vacuum being generated by said vacuum generating means when switched on, and for causing said motor to be switched off if the sensed vacuum is less than a predetermined amount below atmospheric pressure.
- 28. The apparatus of claim 24, wherein a seal is mounted on an underside of said die, said seal surrounding an area of said underside, said seal having a bubble of air extending therealong and said bubble being open to atmosphere, and said bubble being flattened and air being expelled from said bubble when said die is mounted on said die cylinder surface and said vacuum is applied therebetween.
- 29. The apparatus of claim 24, wherein said vacuum applying means includes balls protruding from said surface and on which said die can roll when being positioned on said surface before application of said vacuum.
- 30. A method of mounting on a die cylinder a cutting die having a wooden shell, comprising the steps of:
- locating a key on the die in an axial keyway in the die cylinder to position the die circumferentially on the die cylinder; then
- moving the die axially on the die cylinder and aligning a bolt hole in the die with a selected bore in the die cylinder to position the die axially on the die cylinder; then
- inserting a bolt through said bolt hole into said bore
- during said moving and inserting steps, causing a protruding but readily collapsible seal on said die to bridge gaps occurring between the die and the die cylinder due to the wooden shell of the die being distorted and not conforming exactly to the die cylinder, and causing said seal to define a closed area between said die and said die cylinder; and then
- applying vacuum to said closed area between the die and the die cylinder to draw the die towards and into surface conformity with the die cylinder and to flatten said seal.
- 31. The method of claim 30, wherein said seal comprises two superimposed strips of material with an air bubble therebetween, said air bubble protruding from the die but collapsing when squeezed between the die and the die cylinder during said step of applying vacuum.
- 32. A method of mounting a rotary cutting die, having a substantially rigid shell, on a die cylinder, comprising the steps of:
- placing said die on said die cylinder at a desired lateral and circumferential location with a collapsible seal protruding from said rigid shell contacting a mounting surface of said die cylinder, said seal defining a closed area between said shell and said mounting surface; and
- applying vacuum to said closed area to draw said shell into intimate surface contact with said mounting surface and simultaneously collapse said seal.
- 33. A method of mounting and controlling use of a rotary cutting die, comprising the steps of:
- mounting a rotary cutting die on a die cylinder;
- applying vacuum between said die and said die cylinder to hold said die on said die cylinder;
- drivingly rotating said die cylinder while still applying said vacuum;
- transmitting first and second signals towards the rotating die and die cylinder;
- stopping said drivingly rotating of said die cylinder in response to absence of said first signal being reflected by a first reflector on said die;
- also stopping said drivingly rotating of said die cylinder in response to presence of said second signal being reflected by a second reflector on said die cylinder; and
- continuing said drivingly rotating of said die cylinder in response to said first signal being reflected by said first reflector and said second signal not being reflected by said second reflector.
- 34. The method of claim 33, further including the step of continuously monitoring said vacuum, and stopping said drivingly rotating of said die cylinder if said vacuum drops below a predetermined level.
- 35. A method of mounting a rotary cutting die, having a substantially rigid shell, on a rotatable die cylinder, comprising the steps of:
- placing said die on said die cylinder to be held thereon in use by application of vacuum between said die and said die cylinder;
- beginning rotation of said die cylinder with said die thereon;
- sensing whether a signal is coming from the rotating die; and
- stopping said rotation of said die cylinder in response to absence of said signal coming from said die when said application of vacuum has occurred.
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending application Ser. No. 858,934 filed May 1, 1986 (and to issue as U.S. Pat. No. 4,744,297) which is a continuation-in-part of patent application Ser. No. 776,775 filed Sept. 17, 1985 and issued as U.S. Pat. No. 4,683,822 on Aug. 4, 1987. Insofar as any of the disclosure in copending patent application Ser. No. 858,934 and any of the disclosure in U.S. Pat. No. 4,683,822 is omitted from the specification and drawings of the present application, all of such omitted disclosure is hereby incorporated herein by reference.
This invention relates in general to vacuum mounting of dies on die cylinders. It is particularly applicable to mounting cutting dies in container blank processing machinery, for example rotary die cutting apparatus used in the production of corrugated paperboard carton blanks.
It is well known to mount dies on die cylinders for carrying out various operations on paperboard sheets, e.g. cutting, creasing, printing etc. Some of these dies are heavy and formed with a rigid base shell, e.g. a curved wooden die board. Such rigid dies are mounted on and secured to an appropriate die cylinder by bolts. A large number of bolts are inserted through bolt holes all over the surface of the die, and these bolts screwed into screw-threaded bores in the die cylinders to draw the die against and into general conformity with the die cylinder.
Due to distortion of such wooden die boards, after inserting the first one or two bolts, it often becomes increasingly difficult to align subsequent bolt holes in the die with the screw-threaded bores in the die cylinder. Due to the weight and awkwardness of these wooden die boards, particularly the larger ones, the process of inserting and then tightening the large number of mounting bolts is usually time consuming and somewhat tedious. Subsequently, to remove such dies, it is also fairly time consuming to loosen and remove the large number of mounting bolts.
U.S. Pat. No. 4,683,822, assigned to the assignee of the present invention and disclosure from which has above been incorporated herein by reference, discloses, inter alia, an arrangement for vacuum mounting rigid cutting dies on die cylinders. This approach for vacuum mounting wooden die boards, although very promising, still required further refinement to improve its acceptability commercially.
The present invention is concerned with improving the above approach for vacuum mounting wooden cutting dies. By "vacuum" is meant the use of less than atmospheric pressure.
The present invention is also concerned with providing an improved approach and system for vacuum mounting rigid, and particularly heavy, dies on die cylinders.
Various features of the present invention are the employment of a special collapsible seal preferably around the edge of the die, the employment of a key on the die shell engageable in a keyway in the die cylinder, the employment of balls in the surface of the die cylinder to function both as a ball conveyor and vacuum distribution valves, and the employment of sensing systems to locate whether a correct die is present. These and other features, individually or in combination, contribute to achieving the objects of the present invention.
Accordingly, there is provided by one aspect of the present invention die mounting apparatus comprising a rotatable die cylinder having a die mounting surface, means for connecting an interior of the die cylinder to a source of vacuum, and a plurality of valve units mounted in the die cylinder, each valve unit having an actuating member protruding above the die mounting surface when the respective valve is closed, depression of the actuating member opening the respective valve for placing the vacuum within the die cylinder interior in communication with the die mounting surface. A rigid die is mounted on the die mounting surface and held thereon in use by the vacuum applied below the die through those of the valve units which underlie the die and are opened by depression of their actuating members by the die. A seal is sandwiched between the die and the die mounting surface, the seal defining a closed area on an underside of the die and to which area the vacuum is in use applied, and the seal comprising at least one elongate element having a lengthwise direction and a width transverse to the lengthwise direction, the element having a bubble formed intermediate its width and extending in the lengthwise direction, the bubble being flattened between the die and the die mounting surface when the vacuum is applied to said closed area.
Preferably, the elongate element comprises two superimposed strips, one of the strips may be flat and the other of the strips may be deformed to form the bubble.
Preferably, the valve actuating members are rotatable spherical balls on which the die can roll when being positioned on the die cylinder.
Check valve means may be disposed in said connecting means for preventing flow of air from the vacuum source into the die cylinder interior in the event of failure of the vacuum source.
According to another aspect of the present invention there is provided an apparatus for cutting paperboard sheets, comprising a motor, means for controlling the motor, a die roll or cylinder rotatably mounted for rotation by the motor, the die roll having a cylindrical surface, and a cutting die having a rigid curved shell with at least one cutting rule mounted therein, the shell being mountable on the die cylinder surface. Locating means, cooperative between the die and the die cylinder, are employed for correctly locating the die on the die cylinder surface. Vacuum means apply vacuum between the surface and the die for drawing and holding the die against the surface. First and second sensor means are connected to the controlling means for transmitting and receiving light, a first reflector being mounted on the die cylinder and covered by the die when correctly located on the surface by the locating means, a second reflector being mounted on the die, the first sensor means functioning to cause the motor to be switched off if the first sensor means senses reflected light from the first reflector, and the second sensor means functioning to cause the motor to be switched off if the second sensor means does not sense reflected light from the second reflector.
Although light is referred to above and preferred, any form of electromagnetic waves may be transmitted, reflected and received to perform this sensing function.
The apparatus may be provided with a selector switch manually actuatable between a vacuum mode, when the vacuum means is to be operative, and a standard mode when the vacuum means is rendered inoperative and conventional boltdown dies are used.
According to yet another aspect of the present invention, there is provided a die mounting apparatus comprising a drive motor, a die cylinder mounted for rotation by the motor, a die mountable on an exterior surface of the die cylinder, and means for generating a vacuum and being selectively switchable on or off. Means are provided for applying the vacuum between the die cylinder surface and the die when mounted on the die cylinder. A light reflector is mounted on the die, and means are provided for sensing light reflected from said reflector when the die cylinder is rotating, and for causing the drive motor to be switched off if the vacuum generating means is switched on and no reflected light is received by the sensing means.
According to yet a further aspect of the invention, there is provided a method of mounting a cutting die having a wooden shell on a die cylinder, comprising the steps of locating a key on the die in an axial keyway in the die cylinder to position the die circumferentially on the die cylinder, moving the die axially on the die cylinder and aligning a bolt hole in the die with a selected bore in the die cylinder to position the die axially on the die cylinder, inserting a bolt through the bolt hole into the bore, during the moving and inserting steps causing a protruding but readily collapsible seal on the die to bridge gaps occurring between the die and the die cylinder due to the wooden shell of the die being distorted and not conforming exactly to the die cylinder, and causing the seal to define a closed area between the die and the die cylinder. Then applying vacuum to the closed area between the die and the die cylinder to draw the die towards and into surface conformity with the die cylinder and to flatten the seal.
According to yet another aspect of the present invention there is provided a method of mounting a rigid shell cutting die on a rotatable die cylinder comprising the steps of placing the cutting die on a mounting surface of the die cylinder and positioning the die at a predetermined lateral and circumferential location relative to the die cylinder, allowing a hollow, collapsible seal on the die to bridge any gaps between the die and the mounting surface due to any distortion of the rigid shell of the die, drawing the die into close contact with and causing the rigid shell to conform to the mounting surface by applying vacuum to an area between the rigid shell and the mounting surface closed by the collapsible seal, and this drawing step simultaneously collapsing the seal between the rigid shell and the mounting surface.
Preferably the collapsible seal comprises an air bubble.
Other aspects of the present invention also provide methods of sensing the presence or absence of reflected signals from reflectors on a cutting die intended for vacuum mounting and a rotatable die cylinder adapted to vacuum mount cutting dies. The drive to the die cylinder being switched off if a wrong reflected signal is received or a correct one is not received. Preferably, the reflectors are light reflectors and the sensing detects light beams reflected by the light reflectors; however, other types of reflectors, wave forms and sensing could be used.
Other objects, features and advantages of the present invention will become more fully apparent from the following detailed description of the preferred embodiment, the appended claims and the accompanying drawings.
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| Number |
Date |
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| 691312 |
May 1967 |
BEX |
| 2196910 |
Mar 1974 |
FRX |
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Sep 1980 |
JPX |
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Continuation in Parts (2)
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Number |
Date |
Country |
| Parent |
858934 |
May 1986 |
|
| Parent |
776775 |
Sep 1983 |
|
Patent Grant
4878407
