PILE PREPARATION UNIT

Abstract

A pile preparation unit for preparing a pile of sheets is provided. The pile of sheets has a first end, which first end is optionally standing on a pallet, and opposite a free second end, a front edge side and a side edge side. The PPU includes a rotation base configured for standing on a floor and for supporting a rotation unit, configured with an infeed side for receiving a pile of sheets in a feed direction. The pile of sheets may optionally be on a pallet. The rotation unit may have a rotation unit frame with a rotation unit frame cross section. The rotation unit may be configured with an edge side support unit, configured with an edge side support face to support an edge side of the pile of sheets when the pile of sheets is in a rotated position to lean on the edge side support face.

Claims

1. A pile preparation unit for preparing a pile of sheets having a first end standing on a pallet and opposite a free second end, a front edge side and a side edge side, the pile preparation unit comprising: a rotation base configured for standing on a floor and for supporting a rotation unit configured with an infeed side for receiving a pile of sheets in a feed direction, the rotation unit having a rotation unit frame with a rotation unit frame cross section the rotation unit configured to rotate about the feed direction: an edge side support unit configured with an edge side support face to support an edge side of the pile of sheets when the pile of sheets is in a rotated position to lean on the edge side support face; and a lift unit configured to engage a lift plate to the free second end of the pile of sheets in the pile preparation position and to lift a pile of sheets and wherein the edge side support unit further is configured with a pile support unit configured with a pile support face for engaging and supporting the front edge side of the pile of sheets.

2. The pile preparation unit according to claim 1, wherein the rotation unit frame comprises two guides shifted in the feed direction relatively to each other and each fixed to the rotation base and guiding a belt driven by a rotation unit drive system in the rotation base.

3. The pile preparation unit according to claim 1, wherein the edge side support unit is pivotally arranged to tilt the edge side support unit when rotated about 90 degrees.

4. The pile preparation unit according to claim 1, wherein the edge side support unit further is configured with a blower unit configured to blow into the edge side of the pile of sheets from the edge side support face.

5. The pile preparation unit according to claim 1, wherein the blower unit has air mouthpieces installed in blower conveyor belts configured for movements along a pile of sheets.

6. The pile preparation unit according to claim 1, wherein the edge side support unit further is configured with one or more vibration units configured to vibrate the edge side support face.

7. The pile preparation unit according to claim 1, wherein the rotation unit further comprising a conveyor configured to transport a pallet with a pile of sheets from the infeed side in the feed direction to a pile preparation position;

8. The pile preparation unit according to claim 7, wherein the belts encircles the conveyor.

9. A method of preparing a pile of sheets for processing, the pile of sheets having a first end standing on a pallet and opposite a free second end, a front edge side and a side edge side, the method comprising acts of: preparing a pile preparation unit for receiving a pile of sheets for free transport to a pile preparation position; placing the pile of sheets at the pile preparation position with the side edge side of the pile of sheets in the vicinity of an edge side support face of the edge support unit; engaging a pile support face of a pile support unit on the front edge side of the pile of sheets; rotating the pile of sheets to about 90 degrees for the edge side support face to support the side edge side of the pile of sheets; and repeatedly as required: tilting the pile of sheets against the pile support face; blowing and optionally vibrating the pile of sheets, where blowing is into the pile of sheets from the edge side support face.

10. The method according to claim 9, wherein the act of blowing is performed whilst moving air-mouthpieces in first end to second end and vice versa directions and/or top-to down and vice versa directions of the pile of sheets.

11. The method according to claim 9, wherein there is one or more acts of: storing any previously performed set of acts; editing any previously performed set of acts; retrieving any previously performed set of acts; and executing any previously performed set of acts.

Description

BRIEF DESCRIPTION

[0088] Some of the embodiments will be described in detail, with references to the following Figures, wherein like designations denote like members, wherein:

[0089] FIG. 1 illustrates the pile preparation unit with a pile of sheets on a pallet;

[0090] FIG. 2A illustrates the rotation unit and a close up of the rotation unit drive system;

[0091] FIG. 2B illustrates a close up of one of the two rotation unit drive wheel sections;

[0092] FIG. 3 illustrates the rotation unit frame cross section;

[0093] FIG. 4 illustrates the pile preparation unit without a pile of sheets on a pallet;

[0094] FIG. 5A illustrates a pile preparation unit in a rotated position with a large pile of sheets on a pallet;

[0095] FIG. 5B illustrates how the front edge side of the pile of sheets connects with the pile support face;

[0096] FIG. 6A illustrates a pile preparation unit in a rotated position with a small pile of sheets on a pallet;

[0097] FIG. 6B illustrates how the front edge side of the pile of sheets connects with the pile support face;

[0098] FIG. 7A illustrates the lift unit and a close up of the lift unit safety lock;

[0099] FIG. 7B illustrates a close up of the lift safety lock;

[0100] FIG. 8 illustrates the pile support unit in home position;

[0101] FIG. 9A illustrates the pile preparation unit and a cross section of the blower unit and the pile support unit;

[0102] FIG. 9B illustrates a cross section of the blower unit;

[0103] FIG. 10 illustrates a method for preparing a pile of sheets;

[0104] FIG. 11 illustrates a top view of the pile preparation unit;

[0105] FIG. 12A illustrates the first part of the preparation of a pile of sheets;

[0106] FIG. 12B illustrates a top and side view of the PPU;

[0107] FIG. 12C illustrates a top and side view of the PPU;

[0108] FIG. 13A illustrates the second part of the preparation of a pile of sheets;

[0109] FIG. 13B illustrates a top and side view of the PPU;

[0110] FIG. 13C illustrates a top and side view of the PPU.

DETAILED DESCRIPTION

[0111] FIG. 1 shows a pile preparation unit (PPU) 100 on a floor 150. The PPU 100 comprises a plurality of parts. One part is a rotation base 200, which is the base for the rotation unit 300.

[0112] Another part is a conveyor 400 for transporting the pile of sheets 130 from a first end 131 and a second end 132.

[0113] Another part is a lift unit 500 for reading the height of the pile of sheets 130 when a new pile of sheets 130 arrives and to maintain the pile of sheets 130 during the preparation process.

[0114] Another part is the edge side support 600, which comprises a pile support unit 700 and a blower unit 800. The pile support unit 700 and the blower unit 800 creates an edge side support face 610 to support an edge side of the pile of sheets 130 when the pile of sheets 130 is in a rotated position to lean on the edge side support face 610.

[0115] In FIG. 1 a pallet 140 with a pile of sheets 130 is placed on the conveyor 400. The pile of sheets 130 has a first end 131 standing on the pallet 140 and opposite a free second end 132.

[0116] The rotation unit 300 is configured with an infeed side 120 for receiving a pallet 140 with a pile of sheets 130 in a feed direction 125. The rotation unit 300 has a rotation unit frame 302 with a rotation unit frame cross section 304. The rotation unit 300 is configured to rotate about the feed direction 125. The rotation may be around the rotation axis.

[0117] FIG. 2A illustrates the rotation unit 300 and FIG. 2B illustrates a close up of one of the two rotation unit drive wheel 340 sections.

[0118] The rotation unit 300 is the main unit for the preparation process. The main units/functions required for the preparation process is installed in the rotation unit 300.

[0119] The control system controls the rotation unit position. The rotation degree set in recipes is monitored and adjusted automatically. A home position reference sensor 370 detects the home position of the rotation unit 300. When the rotation unit motor 320 runs the rotation, travel distance information is transferred to the control system which enables stopping at predetermined degrees with accuracy.

[0120] The rotation unit drive system 350 is installed on the rotation unit frame 302 as shown in FIG. 2A.

[0121] The rotation unit drive system 350 rotates with the rotation unit 300 in turning degrees stated in recipes. To begin with the rotation unit 300 is turned close to 90, then at other degrees as stated in recipe steps, and finally back to 0 again.

[0122] The rotation is accomplished with a rotation unit motor 320 allowing controlled turning speed and precise positioning of the rotation unit 300 at the determined stop positions. The drive is accomplished by means of two rotation unit timing belts 310, driving the two rotation unit rings 308.

[0123] The rotation unit 300 is driven by a rotation unit motor 320 allowing precise positioning. The rotation unit motor 320 communicates with the rotation unit drive wheels 340 through a rotation unit drive shaft 330. The rotation unit drive wheels 340 (one for each side) drives two rotation unit timing belts 310 attached to the rotation unit turning rings 308. Rotation unit support rollers 364, rotation unit side support bearings 368 and main idling support rollers 360 keep the rotation unit 300 in position. The tension of the rotation unit timing belts 310 is secured by the timing belt tensioner 312.

[0124] FIG. 2B illustrates a close up of one of the two rotation unit drive wheel 340 sections.

[0125] A rotation unit motor 320 communicates with a rotation unit drive wheel 340 through a rotation unit drive shaft 330. The rotation unit drive wheel 340 drives the rotation unit timing belts 310 attached to rotation unit turning rings 308. The tension of the rotation unit timing belts 310 is secured by the timing belt tensioner 312.

[0126] FIG. 2B also shows rotation unit side support bearings 368 and two adjuster screws 369.

[0127] FIG. 3 illustrates the rotation unit frame cross section 304. The rotation unit frame cross section 304 comprises a rotation unit timing belt 310 with a fix block 382. The rotation unit timing belt 310 is driven by the rotation unit drive wheel 340 and the tension in the rotation unit timing belt 310 is kept by the timing belt tensioner 312, which can be adjusted by the adjuster screw 369. The main idling support roller 360 keeps the rotation unit 300 in position.

[0128] FIG. 4 illustrates the PPU 100 without a pile of sheets 130 and a pallet 140. The PPU 100 comprises a rotation base 200, which is the base for the rotation unit 300, a conveyor 400, a lift unit 500, an edge side support 600, a pile support unit 700 and a blower unit 800.

[0129] FIG. 5A illustrates a PPU 100 in a rotated position with a large pile of sheets 130 on a pallet 140. FIG. 5A and FIG. 5B illustrate the same arrangement at different angles, but FIG. 5B does not show the conveyor 400.

[0130] In FIG. 5A the PPU 100 is rotated almost 90 degrees and tilted a few degrees, say 0 to 45 degrees. The tilt direction is perpendicular to the rotation direction. The tilt is to secure a proper connection between the pile of sheets 130 and the edge support face 610.

[0131] FIG. 5B illustrates how the front edge side 133 of the pile of sheets 130 connects with the pile support face 702, and how the side edge side 135 connects with the edge side support face 610.

[0132] FIG. 6A illustrates a PPU in a rotated position with a small pile of sheets on a pallet. FIG. 6A and FIG. 6B illustrate the same arrangement at different angles, but FIG. 6B does not show the conveyor 400.

[0133] In FIG. 6A the PPU 100 is rotated almost 90 degrees and tilted a few degrees. The tilt direction is perpendicular to the rotation direction. The tilt is to secure a proper connection between the pile of sheets 130 and the edge support face 610.

[0134] FIG. 6B illustrates how the front edge side 133 of the pile of sheets 130 connects with the pile support face 702, and how the side edge side 136 connects with the edge side support face 610.

[0135] FIG. 5A and FIG. 6A illustrate that the PPU 100 can handle different sizes of piles of sheets 130.

[0136] In other embodiments the pile of sheets 140 may have different geometric shapes.

[0137] FIG. 7A illustrates the lift unit 500. The two main functions for the lift unit 500 are to read the pile of sheets' 130 height when a new pile of sheets 130 arrives and to maintain the pile of sheets 130 during the preparation process.

[0138] When a new pile of sheets 130 arrives, the lift plate 540 moves downwards, until the second end 132 of the pile of sheets 130 is detected. The lift unit photocell 530 is installed in the lift plate 540 for this purpose. The lift plate 540 continues to move downwards and puts pressure on the pile of sheets 130 second end 132. The control system reads the position of the lift plate 540 (reported by the motor resolver) and stores the position as the height of the pile of sheets 130. This value is used for different purposed in the preparation process.

[0139] The pile of sheets 130 is supported by the lift plate 540 during the process. The pile of sheets 130 is turned at different degrees as defined in the used recipe. The lift plate 540 supports the pile of sheets. Lift positions is also defined in recipes and can increase/decrease space to the pile of sheets 130 in order to allow good aeration of the pile of sheets 130. The lifting plate movement is controlled by a lift unit motor 520 allowing precise positioning of the lift plate 540.

[0140] The lift unit motor 520 drives the two parallel lift unit timing belts 512 attached to the linear guide system 550 (one at each side). Each lift unit timing belt 512 is joined with a clamp unit 514. Tensioning is carried out by means of the tension screw 516 on top of the timing belt system 510.

[0141] The drive motor gear 522 is attached to the lift unit drive shaft 524 by means of one triple drive chain 526. The lift plate 540 is attached to the linear guide system 550 on both sides. Four lift plate cylinders 542 are installed on the lift plate 540 to enable preparation of pallets 140 between 850 mm and 650 mm. The pile preparation range height is between 650 mm and up to 1650 mm.

[0142] FIG. 7B illustrates a close up of the lift safety lock 560.

[0143] The lift safety lock 560 is a safety device that will lock the lift unit 500 if power and/or air pressure change or even disappear. The lift safety lock 560 is designed as one disk 562 with stop holes and two lift safety lock cylinders 564.

[0144] Each lift safety lock cylinder 564 is equipped with a spring loaded piston 566. The distance between the spring loaded pistons 566 corresponds to 1, 5 stop holes.

[0145] This means that only one of the lift safety lock cylinders 564 can be in locking position at a time. When the position is to be locked (secured) both lift safety lock cylinders 564 are deactivated, and the springs forces the two spring loaded pistons 566 towards to the surface of the lift safety lock disk 562. One of the spring loaded pistons 566 enters a hole as it comes into position.

[0146] FIG. 8 illustrates the pile support unit 700 in home position.

[0147] In home position, the pile support unit 700 is in the innermost position so that the pile support bar 740 is in line with the blower unit 800. The pile support motor 720 runs the pile support units' positioning function. The pile support bar 740 can move in an in/out direction 750 and a sideways direction 760.

[0148] The pile support rod 730 is activated by the pile support air cylinder 710 installed inside the pile support bar 740. The purpose of the pile support rod 730 is to move the support rod 730 down onto the pallet 140 and put a light pressure on the pallet 140. The support rod 730 moves in a rod direction 770.

[0149] Pressure can be adjusted by means of the pressure regulator installed on the upper rear side of the blower unit 800.

[0150] FIG. 9A illustrates the PPU 100 when it is turned in a turn direction and tilted 8 degrees in a tilt direction.

[0151] The blower unit 800 is used when the pile of sheets is turned. The purpose is to minimize friction between sheets and line up the sheets in the pile of sheets 130 nicely. The side channel blowers 810 supply air for the blower unit 800, the air is transported through the blower hoses 880.

[0152] When the blower unit 800 is turned it becomes a base for the pile of sheets 130 when preparing the sheets in the pile of sheets 130.

[0153] FIG. 9B illustrates a cross section of the blower unit 800 and the pile support unit 700.

[0154] The air flow 850 blows out from air mouthpieces 820 installed in the blower unit 800. Air mouthpieces 820 move along the blower plate 832 during the vibration process.

[0155] The moveable air mouthpieces 820 are installed in blower conveyor belts 830, driven by an air mouthpiece conveyor drive motor 840. The air mouthpieces 820 have a blower conveyor belt movement 834 as indicated in FIG. 9B. The speed of the air mouthpiece conveyor drive motor 840 is altered automatically, based on the material of the pile of sheets 130.

[0156] The blowing unit 800 is installed on rubber brackets to reduce vibration in other parts than the blow/vibration section. Vibration is accomplished by means of two vibration units, one of which is disclosed in FIG. 9B. Thus the vibration may be performed fully automatically.

[0157] The blower unit 800 consists of three powerful standard side channel blowers 810. The side channel blowers 810 supply air for the blower unit 800 when the pile of sheets 130 is turned as defined in recipes. The amount of air flow 850 is also defined in recipes based on the material of the pile of sheets 130. The air flow 850 control is achieved by a frequency converter controlling the speed of the side channel blower motors.

[0158] The blower unit 800 is tilted 8 (say between 0 to 45 degrees), so the pallet 140 can slide towards the edge side support unit 600 and the pile of sheets 130 can slide towards the pile support unit 700, before the blow and vibration process is started.

[0159] FIG. 10 illustrates a method 1000 of preparing a pile of sheets 130 for processing, which may comprise one or more of the following acts. The acts may be performed by using structural features previously disclosed.

[0160] There may be an act of preparing 1100 a PPU 100 for receiving a pile of sheets 130 for free transport to a pile preparation position 127.

[0161] There may be an act of placing 1200 the pile of sheets 130 at the pile preparation position 127 with the side edge side 135 of the pile of sheets 130 in the vicinity of an edge side support face 610 of the edge support unit 600.

[0162] There may be an act of engaging 1300 a pile support face 702 of a pile support unit 700 on the front edge side 133 of the pile of sheets 130.

[0163] There may be an act of rotating 1400 the pile of sheets 130 to about 90 degrees for the edge side support face 610 to support the side edge side 135 of the pile of sheets 130.

[0164] There may be acts that are repeated as required and as follows.

[0165] There may be an act of tilting 1500 the pile of sheets 130 towards the pile support face 702.

[0166] There may be an act of blowing 1600 the pile of sheets 130, where blowing 1600 is into the pile of sheets 130 from the edge side support face 610.

[0167] There may be an act of vibrating 1700 the edge side support face 610 and then the pile of sheets 130.

[0168] The act of blowing 1600 may be performed whilst moving air mouthpieces 820 in the first end 131-second end 132 directions top-down-direction of the pile of sheets 130.

[0169] FIG. 11 illustrates a top view of the PPU 100 before a pile of sheets is 130 fed in the infeed side 120. The pile of sheets 130 is moving in the feed direction 125.

[0170] The dotted line represents a photocell beam, which is used to measure the length of pile of sheets 130 as it moves into the PPU 100.

[0171] The large dot in the center of the conveyor 400 is a photocell that checks if a material is present.

[0172] FIG. 11 illustrates the edge side support unit 600 comprising the side support rod 700 and the blower unit 800.

[0173] FIGS. 12A, 12B and 12C illustrate the first part of the preparation of a pile of sheets. The FIGS. 12A, 12B and 12C illustrate a side view and a top view of the pile preparation unit 100 during operation.

[0174] The right side of FIG. 12A illustrates a top view of the PPU 100 before a pile of sheets 130 is fed in the infeed side 120. The pile of sheets 130 is moving in the feed direction 125.

[0175] The dotted line represents a photocell beam, which is used to measure the length of pile of sheets 130 as it moves into the PPU 100. The length measurement is used to calculate pile preparation position 127.

[0176] The large dot in the center of the conveyor 400 is a photocell that checks if a material is present.

[0177] The left side of FIG. 12A illustrates a side view of the PPU 100 with the pile of sheets 130 placed at the pile preparation position 127. In this Figure, the lift unit 500 has clamped down onto the second end 132 of the pile of sheets 130.

[0178] The right side of FIG. 12B illustrates a top view of the PPU 100 at the moment when the pile of sheets is 130 is stopped at the pile preparation position 127. The Figure discloses that the side edge side 135 of the pile of sheets 130 is placed in the vicinity of an edge side support face 610 of the edge support 620. In this embodiment the blower unit 800 is the edge side support 620.

[0179] The left side of FIG. 12B illustrates a side view of the PPU 100 with the pile of sheets 130 placed at the pile preparation position 127. In the Figure the lift unit 500 has clamped down onto the second end 132 of the pile of sheets 130.

[0180] The right side of FIG. 12C illustrates a top view of the PPU 100 where the pile of sheets is 130 at the pile preparation position 127. The Figure discloses part of the act of engaging 1300 a pile support face 702 of a pile support unit 700 on the front edge side 133 of the pile of sheets 130. In this Figure the pile support unit 700 is moved in the in-/outward direction 750.

[0181] The left side of FIG. 12C illustrates a side view of the PPU 100 with the pile of sheets 130 placed at the pile preparation position 127. In the Figure the lift unit 500 has clamped down onto the second end 132 of the pile of sheets 130.

[0182] FIGS. 13A, 13B and 13C illustrate the second part of the preparation of a pile of sheets. The FIGS. 13A, 13B and 13C illustrate a side view and a top view of the PPU 100 during operation.

[0183] The right side of FIG. 13A illustrates a top view of the PPU 100 where the pile of sheets is 130 at the pile preparation position 127. The Figure discloses part of the act of engaging 1300 a pile support face 702 of a pile support unit 700 on the front edge side 133 of the pile of sheets 130. The engagement between the pile support face 702 of the pile support unit 700 and the front edge side 133 of the pile of sheets 130 is met by moving the pile support bar 740 in a sideways direction 760.

[0184] The left side of FIG. 13A illustrates a side view of the PPU 100 with the pile of sheets 130 placed at the pile preparation position 127. In this Figure the lift unit 500 has clamped down onto the second end 132 of the pile of sheets 130.

[0185] The right side of FIG. 13B illustrates a top view of the PPU 100 where the pile of sheets is 130 at the pile preparation position 127.

[0186] The left side of FIG. 13B illustrates a side view of the PPU 100 with the pile of sheets 130 placed at the pile preparation position 127. In this Figure the PPU 100 has rotated about 90 degrees.

[0187] The right side of FIG. 13C illustrates a top view of the PPU 100 where the pile of sheets is 130 at the pile preparation position 127. The edge side support unit 600 has tilting means or a tilter and the act of tilting 1500 the pile of sheets 130 towards the pile support face 702 is shown in the Figure.

[0188] The tilting angle may be a few degrees. In one embodiment the tilting angle is about 8 degrees or say between 0 and 45 degrees.

[0189] At this point in preparation of the pile of sheets, there may be an act of blowing 1600 the pile of sheets 130, where blowing 1600 is into the pile of sheets 130 from the edge side support face 610. Blowing may be performed by applying airflow. There may be an act of vibrating 1700 the edge side support face 610 and then the pile of sheets 130. The act of blowing 1600 may be performed whilst moving air mouthpieces 820 in the first end 131-second end 132 directions top-down-direction of the pile of sheets 130.

[0190] The left side of FIG. 13C illustrates a side view of the PPU 100 with the pile of sheets 130 placed at the pile preparation position 127. In the Figure the PPU 100 has rotated approximately 90 degrees.

[0191] Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.

[0192] For the sake of clarity, it is to be understood that the use of a or an throughout this application does not exclude a plurality, and comprising does not exclude other steps or elements. The mention of a unit or a module does not preclude the use of more than one unit or module.

TABLE-US-00001 Item Reference Number Pile preparation unit (PPU) 100 Infeed side 120 Feed direction 125 Pile preparation position 127 Pile of sheets 130 First end 131 Second end 132 Front edge side 133 Side edge side 135 Pallet 140 Floor 150 Rotation base 200 Rotation unit 300 Rotation unit frame 302 Rotation unit frame cross section 304 Guides 306 Rotation unit turning ring 308 Rotation unit timing belt 310 Timing belt tensioner 312 Rotation unit motor 320 Rotation unit drive shaft 330 Rotation unit drive wheel 340 Rotation unit drive system 350 Main idling support roller 360 Lift unit support roller 362 Rotation unit support roller 364 Rotation unit support roller adjuster 366 Rotation unit side support bearings 368 Adjuster screw 369 Home position reference sensor 370 Metal block 380 Fix block 382 Conveyor 400 Lift Unit 500 Lift unit timing belt system 510 Lift unit timing belt 512 Clamp unit 514 Tension screw 516 Lift unit motor 520 Drive motor gear 522 Lift unit drive shaft 524 Triple drive chain 526 Lift unit photocell 530 Lift plate 540 Lift plate cylinders 542 Linear guide system 550 Lift safety lock 560 Lift safety lock disk 562 Lift safety lock cylinders 564 Spring loaded piston 566 Edge side support unit 600 Edge side support face 610 Edge side support 620 Pile Support Unit 700 Pile Support face 702 Pile Support air cylinder 710 Pile Support motor 720 Pile Support rod 730 Pile Support bar 740 In-/outward direction 750 Sideways direction 760 Rod direction 770 Blower Unit 800 Side Channel Blower 810 Air mouthpiece 820 Blower conveyor belt 830 Blower plate 832 Blower conveyor belt movement 834 Air blow mouth piece conveyor drive motor 840 Air flow 850 Tilt cylinder 860 Vibration unit 870 Blower hose 880 Vibration unit 890 Method 1000 Preparing 1310 Placing 1200 Engaging 1300 Rotating 1400 Tilting 1500 Blowing 1600 Vibrating 1700