Apparatus and method for the production of a cushion product from a single- or multi-layer continuous paper strip

Abstract

An apparatus for the production a cushion product from a single- or multi-layer continuous paper strip includes a feed unit for drawing the paper strip into the apparatus, a cutting unit for cutting the cushion product from the paper strip, and control electronics for the activation of the cutting unit according to a predetermined motion profile. A sensor captures a rotation angle position of the feed unit. The control electronics are configured to activate the feed unit continuously and to start an activation of the cutting unit for a discontinuous cutting operation during capturing a predetermined actual rotation angle position of the feed unit.

Claims

1. An apparatus for the production of a cushion product from a continuous paper strip, the apparatus comprising: a feed unit configured for drawing the paper strip into the apparatus; a cutting unit configured for cutting the cushion product from the paper strip, wherein the cutting unit comprises a rotation blade and a rotation cutting pad, the rotation cutting pad arranged opposing the rotation blade and configured to rotate adaptably to the rotation velocity of the rotation blade; and a control electronics for an activation of the cutting unit according to a predetermined motion profile, the control electronics further comprising a sensor configured for capturing a rotation angle position of the feed unit, wherein the control electronics is configured to activate the feed unit continuously and to start the activation of the cutting unit for a discontinuous cutting operation during the capturing of the predetermined actual rotation angle position of the feed unit.

2. The apparatus according to claim 1, wherein the control electronics is configured to determine a target feed rate for feeding the paper strip and to initialize the feed unit continuously according to the target feed rate, as well as to determine a target cushion length, and to adjust the cutting operation according to the target feed rate and the target cushion length, wherein the control electronics is configured to consider a feed diameter of the feed unit or a cutting diameter of a cutting unit.

3. The apparatus according to claim 2, wherein the control electronics is configured to define the predetermined current rotation angle position for the cutting operation for the production of cushion products in accordance with the target cushion length on the basis of the target feed rate and the feed diameter, wherein the control electronics is configured to: determine an incremental count threshold value, and in consideration of the feed diameter; and induce an initialization of the cutting unit when the sensor is capturing the incremental count threshold value.

4. The apparatus according to claim 1, wherein the sensor comprises a ferromagnetic incremental encoder and an electromagnetic incremental receiver, wherein the ferromagnetic incremental encoder has an incremental resolution between 20°-100° increments.

5. The apparatus according to claim 1, wherein the control electronics is configured to coordinately trigger the feed unit and a cutting rate of the cutting unit and a circumferential velocity of a rotation blade is 1% to 10% larger than a circumferential velocity of the feed unit.

6. The apparatus according to claim 5, wherein the cutting unit comprises a rotational blade and the control electronics comprises a second sensor assembly for capturing a rotation angle position of the rotation blade, wherein the sensor assembly comprising a second ferromagnetic incremental encoder and a second electromagnetic incremental receiver, wherein the second ferromagnetic incremental encoder has an incremental resolution between 10-100 increments.

7. The apparatus according to claim 6, wherein the sensor assembly is configured to monitor a cutting rotation angle position or a hold point rotation angle position of the rotation blade, with one or two position encoders, wherein the control electronics is configured to initiate a braking procedure for the cutting unit during the monitoring of the cutting rotation angle position.

8. The apparatus according to claim 1, wherein the predetermined motion profile comprises a velocity profile or a torque profile.

9. The apparatus according to claim 1, wherein the paper strip is drawn from a supply roll or supply stack and formed to a three-dimensional fill material strand upstream in a feed direction of the cutting unit.

10. The apparatus according to claim 1, wherein the central area is plastically deformed and the two hollow crumple spaces are formed by folding the edges towards the middle.

11. A method for the production of a cushion product from a continuous paper strip, the method comprising; feeding the paper strip into the apparatus continuously by a feed unit with a constant feed rate; cutting of the cushion product from the paper strip according to a predefined motion profile by a cutting unit being operated discontinuously, wherein the cutting unit comprises a rotation blade and a rotation cutting pad, the rotation cutting pad arranged opposing the rotation blade and configured to rotate adaptably to the rotation velocity of the rotation blade; capturing a rotation angle position of the feed unit; and inducing the discontinuous cutting when reaching a predetermined rotation angle position of the feed unit.

12. The method according to claim 11, wherein the predetermined motion profile comprises: an acceleration phase, in which a rotation blade of the cutting unit is accelerated to a nominal velocity; an operation phase in which the rotation blade is moved constantly with nominal velocity, wherein the nominal velocity is 1% to 10% larger than the constant feed rate; a cutting process, during which the cutting unit separating the cushion product from the paper strip, wherein the cutting rate of the rotation blade is 1% to 10% larger than the constant feed rate; a braking phase, in which the velocity of the cutting unit is reduced; and a hold phase, in which the rotation blade is held fixedly in an initial position.

13. The method according to claim 11, wherein the predetermined motion profile comprises a velocity profile or a torque profile.

14. The method according to claim 11, wherein the central area is plastically deformed and the two hollow crumple spaces are formed by folding the edges towards the middle.

15. The method according to claim 11, further comprising: determining a target feed rate for feeding the paper strip; initializing the feed unit continuously according to the target feed rate; determining a target cushion length; and to adjusting the cutting operation according to the target feed rate and the target cushion length, wherein the adjusting considers a feed diameter of the feed unit or a cutting diameter of the cutting unit.

16. The method according to claim 15, further comprising: defining the predetermined current rotation angle position for the cutting operation for the production of cushion products in accordance with the target cushion length on the basis of the target feed rate and the feed diameter by: determining an incremental count threshold value, and in consideration of the feed diameter; and inducing an initialization of the cutting unit when the incremental count threshold value is captured by a sensor.

17. The method according to claim 16, wherein the sensor comprises a ferromagnetic incremental encoder and an electromagnetic incremental receiver, wherein the ferromagnetic incremental encoder has an incremental resolution between 20°-100° increments.

18. The method according to claim 15, further comprising: coordinately trigger the feed unit and a cutting rate of the cutting unit and a circumferential velocity of the rotation blade is 1% to 10% larger than a circumferential velocity of the feed unit.

19. An apparatus for the production of a cushion product from a continuous paper strip, the apparatus comprising: a feed unit configured for drawing the paper strip into the apparatus; a cutting unit configured for cutting the cushion product from the paper strip; and a control electronics for an activation of the cutting unit according to a predetermined motion profile, the control electronics further comprising a sensor configured for capturing a rotation angle position of the feed unit, wherein the control electronics is configured to activate the feed unit continuously and to start the activation of the cutting unit for a discontinuous cutting operation during the capturing of the predetermined actual rotation angle position of the feed unit, wherein the control electronics is configured to coordinately trigger the feed unit, and a cutting rate of the cutting unit and a circumferential velocity of a rotation blade is 1% to 10% larger than a circumferential velocity of the feed unit.

20. An apparatus for the production of a cushion product from a continuous paper strip, the apparatus comprising: a feed unit configured for drawing the paper strip into the apparatus; a cutting unit configured for cutting the cushion product from the paper strip; and a control electronics for an activation of the cutting unit according to a predetermined motion profile, the control electronics further comprising a sensor configured for capturing a rotation angle position of the feed unit, wherein the sensor comprises a ferromagnetic incremental encoder and an electromagnetic incremental receiver, wherein the ferromagnetic incremental encoder has an incremental resolution between 20 and 100 increments/360°; further wherein the control electronics is configured to activate the feed unit continuously and to start the activation of the cutting unit for a discontinuous cutting operation during the capturing of the predetermined actual rotation angle position of the feed unit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The system and method may be better understood with reference to the following drawings and description. Non-limiting and non-exhaustive embodiments are described with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the drawings, like referenced numerals designate corresponding parts throughout the different views.

(2) FIGS. 1A-1F are a perspective, partly sectioned view of an apparatus according to one embodiment for the production of a cushion product, wherein the cutting unit is in different rotation angle positions;

(3) FIGS. 2A and 2E are lateral cross section views of the apparatus according to one embodiment according FIGS. 1A and 1E;

(4) FIG. 3 is a perspective view of an apparatus according to one embodiment according to FIG. 1;

(5) FIG. 4 is a detail view according to the detail IV of FIG. 3;

(6) FIG. 5 is a different perspective view of the cushion product production apparatus according to FIG. 1;

(7) FIG. 6 is a detail view according to the detail VI according to FIG. 5;

(8) FIG. 7 is a perspective depiction of a cushion product production apparatus according to one embodiment according to FIGS. 1A-1F;

(9) FIG. 8 is a schematic depiction of the production method according to one embodiment; and

(10) FIG. 9 is a depiction of a predefined velocity and a predefined torque profile for the operation of the cutting unit.

DETAILED DESCRIPTION

(11) The apparatus according to one embodiment for the production of a cushion product from a single- or multi-layer continuous paper strip is attributed in the figures with the reference numeral 1. The continuous paper strip has the reference numeral 13 and the cut-off cushion product has the reference numeral 11. The apparatus 1 exhibits main components of a feed unit 3 for drawing in the paper strip 13, a cutting unit 5 for cutting off the cushion product 11 from the paper strip 13 and control electronics 21 for initializing the cutting unit.

(12) The feed unit 3 comprises a pair of feed and embossing rollers 31, 33. The embossing rollers 31, 33 of the feed unit 3 each exhibit a teeth profile and comb each other. The lower embossing roller 31 is stationarily mounted to the feed roller shaft 32. The feed roller shaft 32 is driven by an electromotor 41, which is preferably realized as direct current motor. The drive rotation speed of the motor 41 is reduced by a reduction gear 43 into a lower rotation velocity of the feed roller shaft (32). The upper feed roller 33 is held stationarily at the feed roller shaft 34 and rotates with it by the combing engagement with the first, driven, feed roller 31. The feed roller 33 is connected rotationably with a side plate 35, whose plate diameter essentially equals the outer teeth diameter. The imprint of the feed and forming rollers 31, 33 is wave-shaped. The side plates 35 stabilize the wave-shaped imprint in transverse direction. The combing engagement of the lower feed roller 31 in the upper feed roller 33 defines a feed diameter D3 which equals the identical pitch circle diameter of the feed rollers 31, 33, of the defected preferred embodiment (FIG. 2A, FIG. 2E).

(13) As shown in FIGS. 3 and 4, an incremental encoder 23a is aligned at the lower feed roller shaft 32 non-rotatably. The incremental encoder 23a comprises 40 increments, which narrow and are distributed evenly over the perimeter of the incremental encoder 23a. An incremental receiver 23b for capturing the increments or the incremental encoder 23a or the rotation angle position of the lower feed roller shaft 32 or the initial shaft of the gear 43, respectively, is aligned stationarily at a frame 2 of the apparatus 1. The incremental encoder 23 can be milled or cut, particularly laser cut, from a ferromagnetic sheet metal.

(14) The preferred embodiment of a cutting unit 5 depicted in the figures is realized as rotation cutter. The rotation cutter comprises a rotation blade 51 as well as a cutting pad 53 cooperating with the blade 51. The rotation blade 51 is held non-rotatably at the cutting shaft. The cutting pad 53 is held non-rotatably at a cutting pad shaft 54. The rotation movement of the cutting shaft 52 and the pad shaft 54 is synchronized by a pair of teeth wheels 55a, 55b.

(15) The cutting unit 5 of the preferred embodiment of a paper pillow production apparatus 1 shown in FIGS. 5 and 6 exhibits an electric drive motor 61, preferably a direct current motor, as well as a reduction gear 63 for providing a reduced cutting shaft rotation speed, compared to the rotation velocity of the electromotor 61. The electromotor 61 of the cutting unit 5 and the electro motor 41 of the feed unit 3 can be constructed identically. The gear 63 of the cutting unit 5 and the gear 43 of the feed unit 3 can be constructed identically. The incremental encoder 25a of the sensor assembly 55 of the cushion product production apparatus according to one embodiment shown in FIG. 6 is arranged at the cutting pad shaft 54 non-rotatably. The incremental receiver 25b, which cooperates with the incremental encoder 25a, is aligned at the frame 2 of the apparatus 1 stationarily. The increments of the incremental encoder 25a have a rectangular-shaped cross section shape and their number is 20. The sensor assembly 25 also has a position encoder 25c, which is provided according to a cutting blade initial position A or initial position, wherein the arrival of this initial position A can be captured by the position receiver 25d, which is mounted at the frame 2 stationarily.

(16) The sensor 23 and the sensor assembly 25 are connected with the control electronics signal transmission correspondingly. The incremental receiver 23b and 25b are preferably constructed identically. The position receiver 25 and the incremental receiver 25b and/or 23b can also be realized constructively identically. By the disposition of similar components, cost reductions can be achieved.

(17) FIGS. 1A (and 2A), 1B, 1C, 1D, 1E (and 2E) as well as 1F show different rotation angle positions of the cutting unit 5 and of the feed unit 3. The perspective rotation angle positions A-F are shown in the diagram of a motion profile, that is a velocity profile v5 or, respectively, a torque profile T5, shown in FIG. 9.

(18) FIGS. 1A and 2A show the production apparatus 1 in perspective or in side view, respectively, in a state, in which the rotation cutter largely clears a feed channel 4 for letting pass a formed paper strip 13 so that the paper strip 13 can pass the cutting unit 5 basically unhindered.

(19) The initial position A shown in FIGS. 1A and 2A of the rotation cutter can be captured by the sensor assembly 25.

(20) FIGS. 1E and 2E show the cutting unit 5 and the cutting position E. The rotation plate 51 with the cutting pad 53 cuts a cushion product 11 from the paper strip 13 in the cutting position E (FIG. 1E). The rotation blade 51 crosses the feed path F′ of the paper strip 13, along which the paper strip 13 is fed at a rate preferably equaling with the target feed rate f, at the moment of the cutting position E.

(21) Starting from the initial position A or initial position, the rotation blade 51 moves around the rotation shaft 52 with the rotation blade circumferential velocity v5, as exemplarily shown for the respective rotation blade intermediate position B, C, D in FIGS. 1B, 1C and 1D. The path of the predefined motion profile of the rotation cutter is shown for the initial position A, the intermediate positions B, C and D and the cutting position E qualitatively in the diagram of FIG. 9. During the movement from the initial position A in the direction of the cutting position E, the rotation blade first experiences an acceleration until the rotation blade 51 reaches a nominal velocity, present during the passing of the intermediate position D. For accelerating the rotation blade 51 from the initial position A, the motor 61 first, for example during passing the initial positions B and C, provides a high torque, which decreases when reaching the nominal velocity.

(22) The cutting unit 5 has an embossing or punch tool, respectively, 56a, 56b, both, preceding and following the blade 51 relatively to the direction of rotation. As shown in FIG. 1D, the preceding embossing tool 56a of the cutting assembly 5 is coming into contact engagement with the paper strip 13 first. The embossing tool 56 effectuates a stabilization of the cushion shape by the feed pad following the cutting (not further described; compare [DE 10 2012 018 867 A1]). From the moment on which the preceding embossing tool 56a is in contact with the paper strip 13, a revolution resistance against the rotation cutting movement is present, so that the rotation movement of the rotation blade 51 is decelerated. Along with that, the torque T5 increases rapidly. The torque T5 reaches its maximum when reaching the cutting position E. After passing the cutting position E, the torque T5 drops. The passing of the cutting position E can be captured with the sensor assembly 25 in order to initiate a subsequent deceleration of the rotation blade 51 so that same stops completely when reaching the initial position A again.

(23) During the cutting of the cushion product 11 from the paper strip 13, the embossing tools 56a, 56b are executing an embossing at the following end of the cushion product 13 and at the preceding end of the paper strip 13, which becomes a preceding cushion product at the next, following cutting process. In the intermediate position of the cutting unit 5 shown in FIG. 1F, the following embossing tool 56b is just in touch contact with the preceding end of the formed paper strip 13.

(24) One embodiment of the production method is shown schematically in FIG. 8. A desired target paper cushion length L and a target feed rate f are predefined to the control electronics 21, for example by a not further depicted user console. The control electronics can have a digital storage for applying one or several cushion length values or feed rate values. When or as long as cushion products are to be produced, the electronic control unit 21 receives an operation signal or start signal T0, respectively. When an initialization signal T0 is present, the control electronics 21 triggers the feed unit 2 to feed the paper strip 13 into the production apparatus. In doing so, the rotation angle opposition of the feed unit 3 is supervised by a sensor 23. The sensor 23 is preferably realized as incremental sensor and comprises impulse-like incremental steps ml. The sensor 23 transmits the rotation angle positions or incremental steps n1, respectively, of the feed unit 3 to the control unit 21. Device-specific variable or constant values, for example regarding the motor 41 or 61, the feed roller 31, 33, for example their feed diameter D3, etc., can be provided in the control unit 21. The control electronics 21 can set and store an incremental threshold value on the basis of the target cushion length L, the target feed rate f, according to which the feed unit 3 is initiated, on whose incidence the cutting unit 4 is triggered to cut off a cushion product 11 approximately corresponding to the target cushion length L.

(25) The control electronics 21 can command one or several predefined motion profiles, particularly on the basis of experience values, preferably relating to device specific specifications. A predefined motion profile can for example be the inertia of the cutting unit 5 taking into account the target pillow length L, the cutting diameter D5, rotation resistances due to embossing tools 56a, 56b, etc. The motion profile can also take into account the type of material, thickness, number of layers, etc. of the paper strip 13 to be formed, from which the cushion products 11 are cut off. The rotation blade and the rotation tools are preferably provided according to DE 10 2012 018 867 A1, DE 10 2012 018 941 A and/or DE 10 2013 015 875 A1, whose content is included to full extent by reference.

(26) For one time, the cutting unit 5 runs a cyclic motion profile for a cutting process, for example for a single revolution by 360° of the rotation blade 51. The cutting process starts at the moment t1 and ends at the moment t3 at the initial position A. The sensor assembly 25 of the cutting unit 5 can capture the initial position A and/or the cutting position E and/or single incremental steps of the incremental encoder 25a and can transmit them as rotation position values n2 of the control electronics 21. Incremental values of the incremental encoder 25a and incremental receiver 25b of the sensor assembly 25 can be of advantage during the initialization of the production apparatus 1 or when attaining the experience value with regard to one or different predefined motion profiles. According to one embodiment of the apparatus, the sensor assembly 25b can be set up to solely capture the initial position A and/or the cutting position E. The rotation angle positions captured by the sensor assembly 25 can be stored in the control electronics 21 in order to generate iteratively improved motion profiles. The rotation position values n of the feed unit with three or the n2 of the cutting unit 5 captured by the control unit can also be used for a device diagnostic.

(27) The attributes disclosed in the preceding description, the figures and the claims can be used in both, separately and in arbitrary combination for the realization of the invention in the different embodiments.

(28) The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other embodiments may be apparent to those of skill in the art upon reviewing the disclosure. Other embodiments may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. Additionally, the illustrations are merely representational and may not be drawn to scale. Certain proportions within the illustrations may be exaggerated, while other proportions may be minimized. Accordingly, the disclosure and the figures are to be regarded as illustrative rather than restrictive.

(29) One or more embodiments of the disclosure may be referred to herein, individually and/or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the description.

(30) The above disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true spirit and scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description. While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.

LIST OF REFERENCE NUMERALS

(31) 1 Apparatus

(32) 2 Frame

(33) 3 Feed unit

(34) 4 Feed channel

(35) 5 Cutting unit

(36) 11 Cushion product

(37) 13 Paper strip

(38) 21 Control electronics

(39) 23, 25 Sensor

(40) 23a, 25a Incremental encoder

(41) 23b, 25b Incremental receiver

(42) 25c, 25d Position encoder

(43) 31, 33 Embossing rollers

(44) 32 Feed roller shaft

(45) 35 Side plate

(46) 41 Electric motor

(47) 43 Transmission gear

(48) 51 Rotation blade

(49) 52 Cutting shaft

(50) 53 Cutting pad

(51) 54 Cutting pad shaft

(52) 55a, 55b Teeth wheels

(53) 56a, 56b Punching tool

(54) 61 Drive motor

(55) 63 Reduction gear

(56) A-F Rotation angle position

(57) D.sub.3 Feed diameter

(58) D.sub.5 Cutting diameter

(59) F Feed path

(60) f Target feed rate

(61) L Target cushion length

(62) n.sub.1 Incremental count threshold value

(63) p.sub.3 Feed diameter

(64) T.sub.0 Initialization signal

(65) T.sub.5 Torque profile

(66) v.sub.5 Circumferential speed