阅读说明：本技术 具有折叠传感机构的转换机 (Conversion machine with folding sensing mechanism ) 是由 瑞安·奥斯特豪特 于 2018-01-18 设计创作，主要内容包括：转换机用于将薄板材料转换成封装模板,以组装成箱子或其他封装。转换机包括转换组件,转换组件在薄板材料上执行横向转换功能和纵向转换功能以形成封装模板。扇式折叠折缝传感机构检测薄板材料中的扇式折叠折缝的存在和位置。根据扇式折叠折缝的位置,要么从薄板材料切掉扇式折叠折缝,要么薄板材料被切割以调整扇式折叠折缝在封装模板中的位置。(Converting machines are used to convert sheet material into packaging templates for assembly into boxes or other packages. The converting machine includes a converting assembly that performs a transverse converting function and a longitudinal converting function on a sheet of material to form an encapsulation template. A fan fold crease sensing mechanism detects the presence and location of a fan fold crease in a sheet of material. Depending on the location of the fan fold creases, either the fan fold creases are cut from the sheet material or the sheet material is cut to adjust the location of the fan fold creases in the packaging template.)

1. A converting machine for converting sheet material into packaging templates for assembly into boxes or other packaging, the converting machine comprising:

a converting assembly configured to perform one or more lateral converting functions and one or more longitudinal converting functions on the sheet material as the sheet material moves through the converting machine in a feed direction, the one or more lateral converting functions and the one or more longitudinal converting functions selected from the group consisting of creasing, bending, creasing, perforating, cutting, and scoring to create the packaging template; and

a fan fold crease sensing mechanism configured to detect the presence and location of a fan fold crease present in the sheet material, the fan fold crease sensing mechanism comprising one or more sensors configured to detect the presence and location of the fan fold crease and to distinguish the presence and location of the fan fold crease and movement of the sheet material closer to or further from the one or more sensors.

2. The converting machine of claim 1, wherein said one or more sensors comprise a laser, a mechanical sensor, an optical sensor, or a visual sensor.

3. The converting machine of claim 1, further comprising a control system configured to receive readings from said one or more sensors to determine the presence and location of a fan-fold crease in said sheet of material.

4. The converting machine of claim 3, wherein said control system is configured to:

the control system causes the converting assembly to cut the leading end of the sheet of material if the sensing mechanism detects the presence of a fan fold crease in a predetermined or user defined range of the leading edge of the sheet of material; and/or

The control system causes the converting assembly to cut off the leading end of the sheet of material if the control system predicts that the fan fold crease will be within a predetermined or user defined range of the trailing edge of the package template.

5. The converting machine of claim 1, wherein said one or more sensors includes a first sensor and a second sensor offset from each other in said feed direction such that only one of said first sensor and said second sensor is located above a fan fold crease at a given time and such that said first sensor and said second sensor are spaced apart by a distance that is at least one of:

a distance of about half the width of the fan fold crease; or

About 7 mm.

6. The converting machine of claim 5, wherein said first sensor and said second sensor are mounted on said converting assembly.

7. The converting machine of claim 5, wherein said first sensor and said second sensor are both located above said sheet of material or below said sheet of material.

8. The converting machine of claim 5, wherein one of said first sensor and said second sensor is located above said sheet of material and the other of said first sensor and said second sensor is located below said sheet of material.

9. A method of converting sheet material into packaging templates for assembly into boxes or other packaging, the method comprising:

detecting the presence and location of a fan-fold crease in the sheet of material with one or more sensors,

distinguishing between the presence and location of the fan fold and movement of the sheet material toward or away from the one or more sensors;

determining that the fan-fold crease is located within a predetermined or user-defined distance of the leading edge of the sheet of material;

cutting a predetermined length or a user-defined length from a front end of the sheet of material to remove a fan-fold crease; and

one or more conversion functions are performed on the remaining sheet material to form a packaging template.

10. The method of claim 9, wherein:

the predetermined distance or the user-defined distance comprises 25mm, 50mm, 75mm, 100mm, or 150mm, and/or

The predetermined length or the user-defined length comprises 25mm, 50mm, 75mm, 100mm, or 150 mm.

11. The method of claim 9, wherein detecting the presence and location of a fan-fold crease in the sheet of material comprises comparing readings from a plurality of the one or more sensors.

12. A method of converting sheet material into packaging templates for assembly into boxes or other packaging, the method comprising:

detecting the presence and location of a fan-fold crease in the sheet of material;

predicting a location of a subsequent fan-fold crease in the sheet of material;

determining that the subsequent fan-fold crease will be located within a predetermined distance of a trailing edge of a packaging template formed from the sheet of material;

cutting a predetermined length from a leading end of the sheet of material to move the subsequent fan-folded crease further away from the trailing edge than the predetermined distance; and

performing one or more conversion functions on the remaining sheet of material to form the packaging template.

13. The method of claim 12, wherein:

the predetermined distance comprises 25mm, 50mm, 75mm, 100mm, or 150 mm; and/or

The predetermined length comprises 25mm, 50mm, 75mm, 100mm or 150 mm.

14. The method of claim 12, wherein detecting the presence and location of a fan-fold crease in the sheet of material comprises comparing readings from a plurality of sensors.

15. A converting machine for converting sheet material into packaging templates for assembly into boxes or other packaging, the converting machine comprising:

a converting assembly configured to perform one or more lateral converting functions and one or more longitudinal converting functions on the sheet material as the sheet material moves through the converting machine in a feed direction, the one or more lateral converting functions and the one or more longitudinal converting functions selected from the group consisting of creasing, bending, creasing, perforating, cutting, and scoring to create the packaging template;

a fan fold crease sensing mechanism configured to detect the presence and location of a fan fold crease present in the sheet material, the fan fold crease sensing mechanism comprising one or more sensors configured to detect the presence and location of the fan fold crease and to distinguish the presence and location of the fan fold crease and movement of the sheet material toward or away from the one or more sensors; and

a control system configured to receive readings from the one or more sensors and to:

the control system causes the converting assembly to cut the leading end of the sheet of material if the sensing mechanism detects the presence of a fan fold crease in a predetermined or user defined range of the leading edge of the sheet of material; or

The control system causes the converting assembly to cut off the leading end of the sheet of material if the control system predicts that the fan fold crease will be within a predetermined or user defined range of the trailing edge of the package template.

16. The converting machine of claim 15, wherein said one or more sensors includes a first sensor and a second sensor offset from each other in said feed direction such that only one of said first sensor and said second sensor is located above a fan fold crease at a given time and such that said first sensor and said second sensor are spaced apart by a distance that is at least one of:

a distance of about half the width of the fan fold crease; or

About 7 mm.

17. The converting machine of claim 15, wherein said predetermined or user-defined range comprises 25mm, 50mm, 75mm, 100mm, or 150 mm.

Technical Field

Exemplary embodiments of the present disclosure relate to systems, methods, and apparatuses for converting sheet material. More particularly, exemplary embodiments relate to converting machines for converting paperboard, corrugated board, cardboard, and similar sheet materials into templates for boxes and other packaging.

Background

The transportation and packaging industry often uses paperboard and other sheet material processing equipment that converts sheet material into box forms. One advantage of such an apparatus is that carriers can prepare boxes of a desired size as needed without having to maintain an inventory of standard prefabricated boxes of various sizes on site. Thus, the carrier need not predict the requirements for a particular box size, nor store pre-made boxes of standard sizes. Alternatively, carriers may store one or more bundles of fan folded material (fanfold material) that may be used to create various box sizes at each shipment based on specific box size requirements. This allows the carrier to reduce the storage space typically required for regularly used shipping items and to reduce the waste and costs associated with the inherently inaccurate process of predicting the size requirements of a case, as the items shipped and their corresponding sizes change from time to time.

In addition to reducing inefficiencies associated with storing multiple sized pre-made boxes, forming custom-sized boxes also reduces packaging and shipping costs. In the logistics industry, it is estimated that shipped items are typically packaged in boxes that are greater than about 65% of the shipped items. A box that is too large for a particular item may be more expensive than a box that is sized for that item due to the cost of the excess material used to make the larger box. When articles are packed in an oversized box, filler material (e.g., styrofoam, foam peanuts, paper, air-filled cushions, etc.) is typically placed in the box to prevent the articles from moving within the box and to prevent the box from collapsing when pressure is applied (e.g., when the box is taped closed or stacked). These filler materials further increase the costs associated with packaging the articles in oversized boxes.

Custom-sized boxes also reduce the transportation costs associated with transporting items as compared to transporting items in oversized boxes. A transport vehicle equipped with a box 65% larger than the packaged item is much less cost effective to operate than a transport vehicle equipped with a box sized to fit the packaged item. In other words, a transport vehicle equipped with custom sized packages can carry a greater number of packages, which can reduce the number of transport vehicles required to transport the same number of items. Thus, in addition to (or instead of) calculating the shipping price based on the weight of the package, the shipping price is also typically affected by the size of the shipping package. Therefore, reducing the size of the package of the article can reduce the shipping price of the article. Even when the shipping price is not calculated based on the size of the package (e.g., calculated based only on the weight of the package), using a custom sized package can reduce shipping costs because a smaller custom sized package will weigh less than an oversized package due to the use of less packaging and filler material.

While sheet material converting machines and related equipment can potentially alleviate the inconvenience associated with storing standard sized articles of transportation and reduce the amount of space required to store such articles of transportation, previously available machines and related equipment suffer from various drawbacks. Some of the disadvantages arise from the use of fan folded sheet material to form the box or packaging template. A fan-folded sheet material is a sheet material (e.g., paperboard, corrugated board, cardboard) that is folded back and forth upon itself so that the material can be stacked into a layer. Creases or folds (also referred to herein as "fan fold creases") are formed in the material between each layer to allow the material to be stacked into layers. Fan fold creases can cause some difficulty in forming box forms or packages when the material is unfolded so that it can be converted into a box form or other package. For example, a fan fold crease may cause the sheet material to fold up or fail to flatten (lie flat), which may cause the sheet material to jam a converting machine used to convert the sheet material into a box form or other enclosure.

Fan fold creases can also present some challenges in forming box forms into strong, structurally sound boxes. For example, if the box template is formed with a fan fold crease that extends through the glue flap of the box template (or a portion of the template to which the glue flap is to be adhered), the fan fold crease may cause the glue flap to curl or fold, making it difficult to securely attach the glue flap to another portion of the box template. Similarly, fan-fold creases in other areas of the box template (e.g., in flaps, panels, etc.) can also make it difficult to build (create) boxes with the box template or make the built box structurally weak.

There is therefore still room for improvement in the field of sheet material processing machines.

Disclosure of Invention

Exemplary embodiments of the present disclosure relate to systems, methods, and apparatuses for converting sheet material into boxes. More particularly, exemplary embodiments relate to box forming machines that convert paperboard, corrugated board, cardboard, and similar sheet stock into box forms and fold and bond the box forms to form an erected box.

For example, one embodiment relates to a converting machine for converting sheet material into packaging templates for assembly into boxes or other packages. The converting machine includes a converting assembly configured to perform one or more lateral converting functions and one or more longitudinal converting functions on the web material as the web material moves through the converting machine in the feed direction. The one or more lateral converting functions and the one or more longitudinal converting functions may be selected from the group consisting of creasing, bending, folding, perforating, cutting, and scoring to create a packaging template. The fan-fold crease sensing mechanism is configured to detect the presence and location of a fan-fold crease in the sheet material. The fan fold crease sensor mechanism includes a first sensor and a second sensor offset from each other in the feed direction. Additionally or alternatively, the first sensor is arranged above the sheet material and the second sensor is arranged below the sheet material.

According to another embodiment, a method of converting sheet material into packaging templates for assembly into boxes or other packages is provided. The method includes detecting the presence and location of a fan-fold crease in the sheet of material using a plurality of offset sensors. The fan-fold crease is determined to be within a predetermined or user-defined distance of the leading edge of the sheet of material. A predetermined or user-defined length is cut from the leading end of the sheet of material to remove the fan-fold crease and one or more converting functions are performed on the remaining sheet of material to form the packaging template.

In yet another embodiment, a method for converting sheet material into packaging templates for assembly into boxes or other packages comprises: the presence and location of a fan-fold crease in the sheet of material is detected with a plurality of offset sensors and the location of a subsequent fan-fold crease in the sheet of material is predicted. The method also includes determining that a subsequent fan-fold crease will be located within a predetermined distance of a trailing edge of a packaging template formed from the sheet of material, and cutting a predetermined length from a leading end of the sheet of material to move the subsequent fan-fold crease farther from the trailing edge than the predetermined distance. One or more conversion functions are also performed on the remaining sheet material to form a packaging template.

These and other objects and features of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the disclosure as set forth hereinafter.

Drawings

To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrative embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 illustrates a perspective view of an exemplary embodiment of a system for forming a packaging template;

FIG. 2 shows a rear perspective view of a conversion machine from the system shown in FIG. 1;

fig. 3 is a perspective view of a converting cartridge (converting cartridge) from the converting machine of fig. 1 and 2;

FIG. 4 is a side cross-sectional view of the transfer cartridge of FIG. 3;

FIGS. 5 and 6 are side and front perspective views of a fan fold crease sensor mechanism for use with the transfer box of FIG. 3; and

7-9 illustrate schematic views of a fan fold sensing mechanism that detects the presence and location of a fan fold crease in a sheet of material.

Detailed Description

Embodiments described herein relate generally to systems, methods, and apparatuses for processing and converting sheet material into packaging templates. More particularly, the described embodiments relate to converting machines for converting sheet material (e.g., paperboard, corrugated board, cardboard) into templates for boxes and other packaging.

While this disclosure will describe details of the embodiments with reference to particular configurations, the description is illustrative and should not be construed as limiting the scope of the invention. Various modifications may be made to the arrangement shown without departing from the spirit and scope of the invention, as defined by the appended claims. For a better understanding, like parts are marked throughout the several views with the same reference numerals.

As used herein, the term "bale" refers to a stock of sheet material that is generally rigid in at least one direction and may be used to make a box or packaging template. For example, the bale may be formed from a continuous sheet of material or any particular length of sheet material, such as corrugated cardboard and paperboard sheet material.

As used herein, the terms "box template" and "package template" shall refer to a substantially flat stock of material that can be folded into a box-like shape. The box template or enclosing template may have notches, cut-outs, dividers, and/or creases that allow the box template or enclosing template to be bent and/or folded into a box. Additionally, the box template or packaging template may be made of any suitable material generally known to those skilled in the art. For example, cardboard or corrugated cardboard may be used as the template material. Suitable materials may also have any thickness and weight that allows them to be bent and/or folded into a box-like shape.

As used herein, the term "crease" refers to a line along which a sheet of material or box template may be folded. For example, the crease may be an impression in the sheet material. In the case of fan-fold creases, the impressions can be formed by folding the sheet material into a layered stack in a bale. Other creases may be formed in the sheet of material to assist in folding the portions of the sheet of material separated by the creases relative to each other to form the box.

The terms "notch," "cut-out portion," and "cut-out" are used interchangeably herein and shall refer to a shape formed by removing material from a template or by separating portions of a template such that a partition is formed through the template.

Fig. 1 illustrates a perspective view of a system 100 that may be used to form a packaging template. The system 100 includes one or more bales 102 of sheet material 104. System 100 also includes a converting machine 106 that performs one or more conversion functions on sheet material 104, as described in further detail below, to form an encapsulation template 108. Excess or waste sheet material 104 produced during the conversion process may be collected in a collection bin 110. After manufacture, packaging template 108 may be formed into a packaging container, such as a box.

With continued reference to FIG. 1, attention is additionally directed to FIG. 2, which generally illustrates aspects of the conversion machine 106 in greater detail. As shown in fig. 1 and 2, the conversion machine 106 includes a support structure 112 and a conversion assembly 114 mounted on the support structure 112.

As shown in fig. 1, the bale 102 may be disposed proximate a rear side of the converter 106 and the sheet material 104 may be fed into the conversion assembly 114. The sheet material 104 may be arranged in a plurality of stacked layers as a bale 102. The layers of sheet material 104 in each bale 102 may have approximately equal lengths and widths and may be folded one over the other in alternating directions.

As best shown in fig. 2, the conversion machine 106 may also have one or more feed guides 124. Each feed guide 124 may include a lower feed wheel 126 and an upper feed wheel 128. In some embodiments, the lower feed wheel 126 or the upper feed wheel 128 may be omitted. Each set of lower feed wheels 126 and upper feed wheels 128 is designed and arranged to guide the sheet material 104 into the converting assembly 114 while producing little, if any, bending, creasing, or creasing in the sheet material 104. For example, the lower feed wheel 126 and the upper feed wheel 128 may rotate to assist in the smooth movement of the sheet material 104 into the conversion assembly 114. Additionally, the lower feed wheel 126 and/or the upper feed wheel 128 may be at least slightly deformable to limit or prevent the formation of bends, creases, or creases in the sheet material 104 as the sheet material 104 is fed into the converting assembly 114.

As the sheet material 104 is fed through the converting assembly 114, the converting assembly 114 may perform one or more converting functions (e.g., creasing, bending, folding, perforating, cutting, scoring) on the sheet material 104 to form the packaging templates 108. A converting assembly 114 may include therein a converting cassette that feeds the sheet material 104 through the converting assembly 114 and performs a converting function thereon.

Fig. 3 and 4 illustrate an exemplary converter cassette 130 separate from the converter 106 and the rest of the conversion assembly 114. As shown in fig. 3 and 4, switch box 130 includes guide channel 132. The guide channel 132 may be configured for flattening the sheet material 104 so as to feed a substantially flat sheet material through the converting assembly 114. As shown, for example, guide channel 132 includes opposing upper and lower guide plates 132a, 132b that are spaced sufficiently apart to allow sheet material 104 to pass therebetween, but sufficiently close to flatten sheet material 104. In some embodiments, as shown in fig. 4, the upper and lower guide plates 132a, 132b may be flared or spaced apart at the open ends to facilitate insertion of the sheet material 104 therebetween.

In the illustrated embodiment, the converting box 130 includes a single guide channel 132 that guides multiple lengths of sheet material 104 through the converting assembly 114. However, it should be understood that the converting box 130 may include a plurality of guide channels for feeding one or more lengths of sheet material 104 (e.g., from a plurality of bales 102) through the converting assembly 114. When a plurality of guide channels are included, the guide channels may be offset horizontally and/or vertically from each other.

As also shown in fig. 3 and 4, the converting box 130 further includes at least one feed roller 134 that draws the sheet material 104 into the converting assembly 114 and advances the sheet material 104 through the converting assembly. The feed roller(s) 134 may be configured to pull the sheet material 104 with limited or no slip, and may be smooth, textured, concave, and/or toothed. Each feed roller 134 may be actively rolled by an actuator or motor to advance the sheet material 104 through the converting assembly 114.

As best shown in fig. 4, converting box 130 includes one or more converting tools (e.g., cross-head converting tool 150 and long-head converting tool 152) that perform a converting function (e.g., creasing, bending, folding, perforating, cutting, scoring) on sheet material 104 to form encapsulation template 108. Some conversion function may be performed on the sheet material 104 in a direction substantially perpendicular to the direction of movement and/or length of the sheet material 104. In other words, some conversion function may be performed across the sheet material 104 (e.g., between the sides of the sheet material). This conversion may be considered a "lateral conversion".

To perform the transverse transformation, the crosshead transformation tool 150 may be moved along at least a portion of the width of the transformation box 130 in a direction that is generally perpendicular to the direction in which the web material 104 is fed through the transformation assembly 114 and/or the length of the web material 104. In other words, the crosshead transition tool 150 may be moved across the sheet material 104 to perform a transverse transition on the sheet material 104. The crosshead transition tool 150 may be movably mounted on rails to allow the crosshead transition tool 150 to move along at least a portion of the width of the transition box 130.

The crosshead transition tool 150 may include one or more transition instruments (e.g., cutting wheels and/or wire rollers) that may perform one or more transverse transitions on the sheet material 104. More specifically, the cutting wheel and/or the score wheel may form creases, bends, creases, perforations, cuts, and/or scores in the sheet material 104 as the crosshead transition tool 150 traverses the sheet material 104.

In addition to being able to produce the transverse transformation with the crosshead transformation tool 150, the transformation function may also be performed on the web material 104 in a direction substantially parallel to the direction of movement and/or length of the web material 104. A transition along a direction substantially parallel to the direction of movement of the sheet material 104 and/or the length of the sheet material may be considered a "longitudinal transition".

The long-head converting tool 152 may be used to produce a longitudinal conversion on the sheet of material 104. More specifically, longhead converting tool 152 may be selectively repositioned along the width of converting box 130 (e.g., back and forth in a direction perpendicular to the length of sheet material 104) to properly position longhead converting tool 152 relative to side 104 of the sheet material. For example, if it is desired to form a longitudinal crease or cut two inches from one edge of the sheet of material 104 (e.g., to trim excess material from the edge of the sheet of material 104), one of the longhead converting tools 152 may be moved vertically across the sheet of material 104 to properly position the longhead converting tool 152 so that the cut or crease can be formed at the desired location. In other words, the long-head converting tool 152 may be moved transversely across the sheet of material 104 to position the long-head converting tool 152 in a position to make a longitudinal conversion on the sheet of material 104.

The long-head converting tool 152 may include one or more converting instruments (e.g., cutting wheels and/or wire rollers) that may perform longitudinal conversion on the web material 104. More specifically, the cutting wheels and/or the score wheels may form creases, bends, folds, perforations, cuts, and/or scores in the sheet material 104 as the sheet material 104 moves under the long-head transition tool 152.

The control system may control the operation of the conversion machine 106. More specifically, the control system may control the movement and/or placement of various components of the conversion machine 106. For example, the control system may control the rotational speed and/or direction of the feed rollers 134 in order to manipulate the direction in which the sheet material 104 is fed (i.e., forward or backward) and/or the speed at which the sheet material 104 is fed through the converter 106. The control system may also manipulate the movement and/or positioning of the conversion tools 150, 152 such that the conversion tools 150, 152 perform the conversion function at the desired location on the sheet material 104.

The control system may be incorporated into the conversion machine 106. In other embodiments, the conversion machine 106 may be connected to and communicate with a separate control system (e.g., a computer) that controls the operation of the conversion machine 106. In other embodiments, portions of the control system may be incorporated into the conversion machine 106, while other portions of the control system are separate from the conversion machine 106. Regardless of the specific configuration of the control system, the control system may control the operation of converting machine 106 that forms box template 108 from sheet material 104.

As shown in fig. 3 and 4 and discussed in more detail below, the converting machine 106 can include a fan-fold crease sensing mechanism 200 (also referred to as sensing mechanism 200) configured to detect a fan-fold crease in the sheet material 104 as the sheet material 104 is fed into the converting machine 106. After sensing mechanism 200 detects a fan fold crease in sheet material 104, the control system may cause converting machine 106 to change the portion of sheet material 104 used to form box template 108. For example, in some embodiments, the control system may cause converting machine 106 to cut off portions of sheet material 104 that include fan fold creases, so that the fan fold creases do not terminate at specific portions of box template 108. In other embodiments, the control system may cause converting machine 106 to cut off the leading edge of sheet material 104 in order to change the position of the fan fold crease within box template 108.

With continued attention to fig. 3 and 4, attention is now directed to fig. 5 and 6, which illustrate an exemplary embodiment of a fan fold crease sensor mechanism 200. In the illustrated embodiment, the sensing mechanism 200 is mounted adjacent the guide channel 132 and is configured to monitor the sheet material 104 as the sheet material 104 is fed into the conversion machine 106 through the guide channel 132. To enable the sensing mechanism 200 to monitor the sheet material 104 as it passes through the guide channel 132, the guide plates 132a and/or 132b may include one or more openings 202 therethrough. The sensing mechanism 200 can interact with the sheet of material 104 through the opening 202 to detect a fan-fold crease in the sheet of material 104.

In the illustrated embodiment, the sensing mechanism 200 includes a first sensor 204 and a second sensor 206. As best shown in fig. 5, the sensors 204, 206 are mounted within the converting machine 106 such that the first sensor 204 and the second sensor 206 are offset from one another in a direction (represented by arrow a in fig. 5) in which the sheet material 104 is fed through the converting machine 106. This deviation of the sensors 204, 206 may be referred to as a longitudinal deviation or a feed direction deviation. The sensors 204, 206 may be longitudinally offset from each other such that only one of the sensors 204, 206 is disposed over the fan fold crease at a given time. In some embodiments, it may be desirable to position the sensors 204, 206 as close as possible while only one of the sensors 204, 206 is disposed over the fan fold crease. In some embodiments, the closer the sensors 204, 206 are to each other (e.g., the shorter the longitudinal offset), the more forgiving (more tolerant) the sensors 204, 206 become. In other words, by positioning the sensors 204, 206 closer together (while still having sufficient spacing such that only one of the sensors 204, 206 is above the fan-fold crease at a time), the movement of the sheet material 104 (e.g., up and down; closer to or further from the sensors 204, 206) can prevent a less chance of accurately detecting the fan-fold crease. In some embodiments, the sensors 204, 206 have a longitudinal offset of about 5mm, about 7mm, about 10mm, or more, or any value therebetween.

The sensors 204, 206 may be in communication with a control system. For example, each of the sensors 204, 206 may transmit a signal to the control system indicating whether the sensors 204, 206 detect the possible presence of a fan fold crease. The control system may include a filter or algorithm that compares the signals from the sensors 204, 206, and optionally other system data (e.g., the rotational speed and/or direction of the feed rollers 134, the speed at which the web material 104 is fed through the converter 106, etc.) to determine whether a fan-fold crease is present or has been detected.

For example, a filter or algorithm of the control system may determine whether both sensors 204, 206 have detected the possible presence of a fan fold crease. If both sensors 204, 206 detect the possible presence of a fan fold crease, a filter or algorithm may determine whether each sensor 204, 206 has detected the presence of the same potential fan fold crease. For example, a filter or algorithm may determine a time displacement (e.g., a time difference) between signals from each sensor 204, 206 indicating the possible presence of a fan fold crease.

The filter or algorithm may use the time shift and other system data to determine whether the sensors 204, 206 have detected the same potential fan fold crease. For example, the filter or algorithm may use the time shift and the speed at which the sheet material 104 is fed through the converting machine 106 to determine whether the sensors 204, 206 have detected the same potential fan-fold crease. If the filter or algorithm determines that the sensors 204, 206 have detected the same potential fan fold crease within a predetermined distance, the filter or algorithm will determine that the sensors 204, 206 have detected the actual fan fold crease. The predetermined distance may vary between different embodiments. For example, the predetermined distance may be about 5mm, about 7mm, about 10mm, about 12mm, about 15mm, or more, or any value therebetween. In some embodiments, the predetermined distance may be adjustable (e.g., by a user based on the thickness of the sheet material, etc.).

As shown in fig. 5 and 6, the sensors 204, 206 may optionally be offset from each other in a direction generally perpendicular or transverse to the feed direction. In other embodiments, the sensors 204, 206 may not be offset from each other in a direction perpendicular or transverse to the feed direction. For example, the sensor 206 may be positioned directly behind (in the feed direction) the sensor 204.

The sensors 204, 206 may detect the presence or absence of the sheet material 104 within the converting machine 106 and, more particularly, within the guide channel 132. The sensors 204, 206 may communicate to the control system whether the sheet material 104 is present. If the sensors 204, 206 do not detect the presence of the sheet material 104, the control system may provide an alert that the sheet material 104 needs to be loaded into the converting machine 106. In some embodiments, the system may include a feed changer that selectively feeds different sheet materials into the converting machine 106. The sensors 204, 206 may also detect whether sheet material from the feed changer is properly loaded or unloaded, and the control system may provide an alert regarding it.

The sensors 204, 206 may also detect the presence and/or location of fan fold creases in the sheet material 104. The unfolded fan-fold crease may take the form of a depression or a protrusion on or in the surface of the sheet material 104 when the sheet material 104 is unfolded from the bale 102. The sensors 204, 206 may detect depressions or protrusions on or in the surface of the sheet material 104 as the sheet material 104 is fed into the converting machine 106 and, in particular, through the guide channel 132. The detection of such a depression or protrusion provides an indication of the presence and location of a fan-fold crease in the sheet material 104.

The control system may use the detected position of the fan fold crease to predict the location of the upcoming fan fold crease. A typical bale 102 of sheet material has a relatively uniform layer size (e.g., the distance between the fan-folded creases on opposite ends of the layer). Thus, the fan fold creases are relatively evenly spaced. For example, some bales 102 have fan-folded creases spaced about 47 inches apart.

Using the detected and/or predicted location of the fan fold crease, the control system may cause the converting machine 106 to cut portions of the sheet material 104 and/or adjust which portions of the sheet material 104 are used to form box template 108. For example, if the sensors 204, 206 detect that a fan fold crease is near the front end of the sheet material 104, the control system may cause the converter 106 to cut off the front portion of the sheet material 104 that includes the fan fold crease. By cutting away the front portion of the sheet material 104, including the fan fold crease, the risk of the leading edge of the sheet material 104 curling or folding and jamming the converter 106 is greatly reduced.

In some cases, the leading end of sheet material 104 is used to form a glue tab (glue tab) portion of box template 108. If the fan fold crease extends through the glue flap, the glue flap may curl or fold or decrease in strength, making it difficult to securely attach the glue flap to the panels of box template 108. For example, a sticker with a fan fold crease may not lay flat, which may make it difficult to securely attach the sticker to another portion of box template 108 because the sticker will attempt to curl or fold away from the other portion of the box template. As a result, the glue joint formed by the glue flap with the fan fold crease may fail prematurely. Similarly, the front end of the sheet material 104 may be used to form a panel of a box formwork to which the adhesive sheet will be attached. If the fan fold crease is located near the edge of the panel to which the adhesive sheet is to be secured, the edge of the panel may curl or fold or decrease in strength, making it difficult to securely attach the adhesive sheet to the panel. To avoid such problems, the control system may cause the converter 106 to cut off the front of the sheet material 104 where the fan fold crease is detected by the sensors 204, 206.

In some embodiments, if the sensors 204, 206 detect the presence of a fan-fold crease within a predetermined or user-defined range of the leading edge of the sheet material 104, the control system may cause the converting machine 106 to cut off a predetermined or user-defined amount of the leading edge of the sheet material 104 that includes the fan-fold crease. For example, in some embodiments, the predetermined range may be the first 25mm, 50mm, 75mm, 100mm, or 150mm of the sheet of material 104. In this case, the control system may cause the converting machine 106 to cut off the first 25mm, 50mm, 75mm, 100mm, or 150mm of the leading edge of the sheet of material 104, including the fan fold crease therein. A box template 108 may then be formed using a subsequent sheet of material 104 that does not include a fan fold crease within a predetermined or user-defined range of the leading edge of the subsequent sheet of material 104.

As mentioned above, the fan fold creases are generally relatively evenly spaced from each other. Thus, once the sensors 204, 206 detect the location of the fan-fold crease in the sheet material 104, the control system can predict the location of the upcoming fan-fold crease. Continuously detecting the location of the fan fold creases (via sensors 204, 206) and predicting the location of upcoming fan fold creases may allow fan fold creases to be avoided in areas of box template 108 other than just near the front end thereof.

For example, detecting a fan fold crease (via sensors 204, 206) and predicting a future fan fold crease location may allow the control system to determine whether the fan fold crease will be within a predetermined range (e.g., 25mm, 50mm, 75mm, 100mm, or 150mm) or user-defined range of the ends of box template 108. Having a fan fold crease near the trailing edge of box template 108 (e.g., within the last 25mm, 50mm, 75mm, 100mm, or 150mm) may result in similar problems as discussed above when the fan fold crease is located near the leading end of box template 108. If the control system determines that the fan fold crease will be located within a predetermined range (25mm, 50mm, 75mm, 100mm, or 150mm) or user-defined range of the last or trailing edge of box template 108, the control system may cause converting machine 106 to cut a predetermined range (e.g., 25mm, 50mm, 75mm, 100mm, or 150mm) or user-defined range of the leading end of sheet material 108 and form box template 108 using the next sheet material 104. Cutting a predetermined range (e.g., the first 25mm, 50mm, 75mm, 100mm, or 150mm) or user-defined range from the front end of sheet material 108 changes where the fan-fold crease is located in box template 108.

For example, if the control system determines that the upcoming fan fold crease will be within 50mm of the trailing end of box template 108, the control system may cause converting machine 106 to cut 50mm from the leading end of sheet material 104. By cutting 50mm from the leading end of sheet material 104 and using the subsequent sheet material 104 to form box template 108, the location of the upcoming fan fold crease is moved further into the box template (e.g., more than 50mm from its trailing end). The likelihood of the fan fold crease causing problems decreases as the fan fold crease moves away from the tail end. This may be due to the fan fold crease not being located where the glue joint is to be formed or attached. Further, when the fan fold crease is positioned further from the edge, the sheet material 104 is less likely to curl or fold in an undesirable manner.

Detecting and predicting the location of the fan fold creases also enables the system 100 to avoid fan fold creases from being located in other potentially problematic areas of the box template. For example, the control system may cause the converting assembly 106 to cut a length of sheet material 104 from its front end in order to move the location of the upcoming fan-folded crease away from the crease between the box mold panels, flaps, or the like.

Detecting and predicting the location of the fan fold creases may also enable system 100 to form box template 108 in a different order to avoid fan fold creases from being located in undesired locations in box template 108. For example, if the control system determines that an upcoming fan fold crease will be in an undesired location in a first box template but will not be in an undesired location in a second box template (e.g., because the second box template has a different size), the control system may cause the converting machine 106 to form the second box template before the first box template.

As described above, the sensing mechanism 200 includes two sensors (i.e., the first sensor 204 and the second sensor 206) that are offset from each other in the feed or longitudinal direction. The longitudinal offset between the sensors 204, 206 allows the readings of the sensors 204, 206 to be compared to each other to determine the presence and location of the fan fold crease.

More specifically, as the sheet material 104 advances through the sensing mechanism 200, each of the sensors 204, 206 will obtain a reading regarding the surface of the sheet material 104. For example, the readings may indicate the distance between the sensors 204, 206 and the surface of the sheet material 104. As the substantially flat portion (e.g., the portion without the fan fold crease) of the sheet material 104 advances past the sensors 204, 206, the sensors 204, 206 provide readings that are the same or within a predetermined tolerance, as shown in fig. 7.

Conversely, as the fan fold crease progresses past the sensors 204, 206, the sensors 204, 206 will detect changes in the surface of the sheet material 104. For example, as shown in FIG. 8, as the fan fold crease progresses under sensor 204, sensor 204 will provide a first reading and sensor 206 will provide a second reading that is different from the first reading. Different readings indicate the presence of a fan fold crease.

As the sheet material 104 continues to advance, as shown in FIG. 9, the sensor 206 will provide a reading that is different from the reading of the first sensor. In some embodiments, this may provide verification of the location of the fan fold crease. In other embodiments, readings from both sensors may allow for vertical movement of the sheet material 104. As the sheet material 104 advances through the guide channel 132, the sheet material 104 may move up and down slightly because the upper and lower guide plates 132a, 132b are spaced apart a distance greater than the thickness of the sheet material 104. The use of two offset sensors 204, 206 allows the fan fold crease to be detected even if the sheet material 104 is moved vertically.

More specifically, rather than holding the sheet material 104 in a vertical position and using that position as a baseline for taking readings, one of the sensors 204, 206 would provide a baseline reading reflecting the flat surface of the sheet material 104 while the other of the sensors 204, 206 would provide a reading relating to the fan fold crease. For example, as shown in fig. 8, the sensor 206 provides a reading for the flat surface of the sheet material 104 regardless of the vertical position of the sheet material 104. As shown in fig. 8, sensor 204 provides a reading for the fan fold crease. The difference in the two readings indicates the presence of a fan fold crease.

In addition, an encoder or similar device may be used to track the feed position of the sheet material 108 to determine the position of the fan fold crease. When the sensors 204, 206 detect the presence of a fan fold crease, the control system may use the current feed position (determined by the encoder) to determine the position of the fan fold crease.

As the sheet material 104 continues to advance to the position shown in fig. 9, the sensor 204 will provide a baseline reading based on the flat surface of the sheet material (again regardless of the vertical position of the sheet material 104). Sensor 206 will now provide a reading for the fan fold crease. Likewise, the difference in the two readings indicates the presence and location of the fan fold crease.

The sensors 204, 206 may take various forms. For example, in some embodiments, the sensors 204, 206 take the form of lasers (lasers) capable of detecting a distance to the surface of the sheet material 104. In other embodiments, the sensors 204, 206 may take the form of mechanical devices capable of detecting changes in the surface of the sheet material 104. For example, a mechanical sensor may contact the surface of the sheet material 104 and detect a change in the surface of the sheet material 104 (e.g., a depression/protrusion of a fan fold crease) by an increase or decrease in the position of the mechanical sensor. In still other embodiments, the sensors 204, 206 may take the form of optical sensors or vision (camera) systems.

Although the illustrated embodiment has shown both sensors 204, 206 being located above the sheet of material 104, this is merely exemplary. In other embodiments, the sensing mechanism may include two sensors located below the sheet of material 104. In still other embodiments, the sensing mechanism may include one sensor located above the sheet of material 104 and a second sensor located below the sheet of material 104.

Regardless of the particular type of sensor used or the location of the sensor, the sensor is capable of providing readings with a predetermined accuracy. For example, fan folded creases typically have a depth of between about 0.5mm to about 4 mm. To accurately detect a fan fold crease, the degree of accuracy of the sensor may be reduced by about two or three times the depth of the fan fold crease. Thus, for example, the sensor may provide a reading with an accuracy of about 0.2mm, 0.5mm, 1mm, 1.25mm, 1.5mm or 2 mm. In other words, the sensor is capable of detecting a 0.5mm, 1mm, 1.25mm, 1.5mm, 2mm or 4mm deep or high depression or protrusion on the surface of the sheet material 104.

In addition, the sensor is able to detect the fan-fold crease even when the sheet material 104 is advanced into the converter 106 and past the sensor at a relatively fast rate. For example, the sensor can detect a fan fold crease when the sheet material 104 is advanced at a rate of 0.25m/s, 0.5m/s, 0.75m/s, 1m/s, 1.25m/s, or 1.5 m/s.

Although the sensing mechanism 200 has been shown and described in connection with a particular converting machine (i.e., converting machine 106), it should be understood that the sensing mechanism 200 may be incorporated into a variety of different converting machines or other sheet material processing apparatuses.

It should be understood that relative terms such as "horizontal," "vertical," "up," "down," "over," "under," and the like are used herein only in a convenient manner. These relative terms are not intended to limit the scope of the present invention. Rather, it should be understood that the conversion component 114 can be configured and arranged such that these relative terms require adjustment.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are, therefore, to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.