Abstract: An apparatus for stacking sheet material that may include a trim section and a stacking section, the stacking section being downstream the trim section for receiving the blanks of sheet material, forming bundles each having a plurality of blanks, and transferring the bundles downstream. The apparatus may further include a plurality of longitudinal positioning systems for independently longitudinally positioning a plurality of components in at least one of upstream or downstream directions so as to create an operator access space. In some embodiments, the apparatus may further include an incline conveyor section downstream the trim section and upstream the stacking section, and the trim section may have a takeaway conveyor for conveying the plurality of blanks of sheet material to the incline conveyor. In certain embodiments, the plurality of longitudinal positioning systems can individually longitudinally position at least two of the takeaway conveyor, the incline conveyor, or the stacking apparatus.

Abstract: The present disclosure relates to a bundle orienting device in-line with a conveyor configured for transporting bundles in a conveying direction. The bundle orienting device can include a plurality of selectively actuatable orientation elements that, collectively, laterally and/or angularly displace a bundle as it travels in the conveying direction through the bundle orienting device. In addition, the present disclosure relates to a method for rotating bundles traveling in a conveying direction along a conveyor system. The method includes conveying a bundle along a conveyor to pass through a bundle orienting device, thus described.

Abstract: Sheet deceleration apparatus and methods for decelerating a sheet of material for use in a sheet stacking or other application. The deceleration apparatus includes a rotatable cam nip, rotatable about a first axis and provided on one side of the travel path, such that the sheet of material can pass by the cam nip. The cam nip includes a lobe end, such that when the lobe end is away from the travel path, the sheet of material can pass substantially unimpeded past the cam nip, and when the lobe end is near the travel path, the sheet of material is nipped by the cam nip decelerating the sheet of material from the first speed to a second speed.

Abstract: A method of forming layered stacks of bundles includes providing a gripping appliance comprising a first gripping assembly and a second gripping assembly. The first gripping assembly is configured for grasping one or more first bundles and the second gripping assembly is configured for grasping one or more second bundles. The first and second gripping assemblies are configured such that first and second bundles grasped thereby may be reoriented relative to one another. The method further includes retrieving from a first location one or more first bundles with the first gripping assembly and one or more second bundles with the second gripping assembly and transporting the first and second bundles to a second location, During transport of the first and second bundles, the bundles are reoriented relative to one another. The bundles are deposited at a selected position in the second location to form at least a partial layer of a layered stack of bundles.

Abstract: Apparatus for separating a stack of sheets from a pile of sheet material that is arranged so that tear paths of a plurality of sheets form a tear surface includes a first clamp for clamping the pile at a first side of the tear surface and a second clamp for clamping the pile at a second side of the tear surface. At least the first clamp includes a sustaining member having at least one sustaining point for supporting the pile, and an upper member having at least one contact point for contacting the pile. Rotation of the first clamp relative to the second clamp brings about the separation of a stack of sheets from the pile of sheet material by breaking the tear paths present in the tear surface.

Abstract: Sheet deceleration apparatus and methods for decelerating a sheet of material for use in a sheet stacking or other application. The deceleration apparatus includes a rotatable cam nip, rotatable about a first axis and provided on one side of the travel path, such that the sheet of material can pass by the cam nip. The cam nip includes a lobe end, such that when the lobe end is away from the travel path, the sheet of material can pass substantially unimpeded past the cam nip, and when the lobe end is near the travel path, the sheet of material is nipped by the cam nip decelerating the sheet of material from the first speed to a second speed.

Abstract: One embodiment of the present disclosure relates to a stacking device including a conveyor belt configured to move one or more items towards a receiving storage hopper configured to receive the one or more items from the conveyor belt. The one or more items may form a stack of items in the receiving storage hopper. The stacking device may further include a sensing device configured to determine a level of the stack of items in the receiving storage hopper. The stacking device may be configured to adjust a height of the conveyor belt relative to the storage hopper based on the level of the stack of items in the receiving storage hopper.

Abstract: A method and apparatus are disclosed that allow items to be placed on a stack of items in a manner that minimizes interference with the existing stack. Further, a method and apparatus are disclosed for stacking items such that marking of the items is minimized while the item is stacked. In some embodiments, the method and apparatus may include employing a plurality of forks, where a first fork in the plurality includes a belt that rotates at least partially within a tapered housing of the fork. In some embodiments, the plurality of forks is vertically movable, and the method and apparatus may include a squaring mechanism that is separate from the plurality of forks. The overall throughput of the method and apparatus may be increased by employing this independent squaring mechanism.

Abstract: Sheet deceleration apparatus and methods for decelerating a sheet of material for use in a sheet stacking or other application. The deceleration apparatus includes a rotatable cam nip, rotatable about a first axis and provided on one side of the travel path, such that the sheet of material can pass by the cam nip. The cam nip includes a lobe end, such that when the lobe end is away from the travel path, the sheet of material can pass substantially unimpeded past the cam nip, and when the lobe end is near the travel path, the sheet of material is nipped by the cam nip decelerating the sheet of material from the first speed to a second speed.

Abstract: A safety system for detecting the presence of an undesired object in a safety area may include a first pair of distance measuring sensors disposed on opposed sides of the conveying path, the pair of distance measuring sensors defining a sensor field between said pair of distance measuring sensors, and an electronic control device operatively coupled to the sensors. The electronic control device may be configured to initiate a machine-stopping sequence based at least in part on signals received from the distance measuring sensors.

Abstract: A system for conveying sheets of corrugated paperboard material or other materials. The system includes a processing module configured for transferring the material in a conveying direction, the processing module having a first nip point. A conveyor is positioned downstream of the processing module and also configured for transferring the material in the conveying direction. The conveyor includes a first support roller and second support roller having a first conveyor belt wound therearound, with the belt defining a deflector section extending from the first support roller to the second support roller. Similar to the processing module, the conveyor includes a second nip point. An adjustment drive can be operatively associated with either or both of the first and second support rollers and configured to adjust the position of the second nip point in or counter to the delivery direction.

Abstract: A folding system for folding leading and/or trailing flaps of container blanks is provided. The system may include a conveyor having a conveying surface configured for conveying the blank along a predetermined path to a first folding position and a second folding position, a folding apparatus, and a control system. The folding apparatus may include a drive assembly and a folding tool. The control system may be operatively coupled to the folding apparatus and operable to control movement of the folding tool between a first rotational position and a second rotational position. Rotation of the folding tool to the first rotational position may cause the leading flap of the container blank positioned in the first folding position to fold about a leading flap fold line. Rotation of the folding tool from the first rotational position to the second rotational position may cause the trailing flap of the container blank positioned in the second folding position to fold about a trailing flap fold line.

Abstract: The present disclosure includes an apparatus for feeding a stack of sheet stock in blocks. The apparatus includes a backstop, a block pusher plate, and at least one sensor for determining a height differential between the stack at generally near a lead edge of the stack and the stack at generally near a trail edge of the stack. The apparatus automatically adjusts for warp in the sheet stock. The present disclosure further includes a method comprising obtaining a first measurement at generally near a lead edge side of the stack, obtaining a second measurement at generally near a trail edge side of the stack, comparing the first and second measurements, and pushing the portion of sheet stock from the stack with a block pusher plate when the second measurement is within a predetermined tolerance of the first measurement.

Abstract: In one aspect, a programmable load forming system is programmed to perform the method of downloading a calculated path from the computer to the robot controller, moving one or more bundles along the calculated path to position the one or more bundles in a predetermined stacking position of a stacking pattern using the robot, and determining if the robot has completed moving along the calculated path. The calculated path is defined, in part, by the stacking pattern and other parameters such as, for example, bundle geometry, bundle levelness, bundle compressibility, among other parameters. In another aspect, the system is programmed to perform a method of sensing the top of a bundle and controllably placing a bundle. Additional aspects are directed to systems and methods of safely operating the robot and an inventive hopper design for holding bottom/tie sheets.

Abstract: A sheet deceleration apparatus includes a pair of rotatable rollers, being rotatable about first and second axes, the rollers positioned on opposite sides of the travel path. At least one of the rollers is moveable relative to the other to nip the sheet between the rollers to reduce the travel speed of the sheet. A vacuum conveyor is further provided along the travel path subsequent the pair of rollers to control delivery of the sheet to a stacking hopper. A third rotatable roller, or similar apparatus, may be included in some embodiments, for pushing the sheet of material away from the vacuum conveyor at the appropriate time.

Abstract: A product orienting apparatus for orienting a product according to the present invention comprises a table comprising a rotatable device. The table has a table surface comprising at least a first surface area being provided by the rotatable device. The device is rotatable about an axis substantially perpendicular to the table surface. The table also has an array of substantially identical spherical rollers, each spherical roller being suitable for contacting the product at a first contacting point of the spherical roller and for contacting the table surface with a second contacting point of the spherical roller. The array of spherical rollers comprises a first group of spherical rollers contacting the surface area of the device with their second contacting point thereby enabling to convert a rotation of the device into rotation of a product contacting the spherical rollers of the first group of spherical rollers. The table furthermore has a plate having an aperture encompassing the rotatable device.

Abstract: A system and method for transferring blanks of material passing from a feeder line to a production line along differing conveyor segments. The production line moves at a higher velocity that the feeder line. Just as a blank is about to transfer from the feeder line to the production line, the feeder line is rapidly accelerated to substantially match the velocity of the production line. This assures a smooth, even, and accurate transfer. Near the end of the transfer, the feeder line is decelerated. Thus, the transferred blank is now moving at a higher velocity than the next adjacent blank.

Abstract: An apparatus and method for removing waste sheets from a sheet feed apparatus, removes waste sheets in a ergonomic manner. The bottom sheet or sheets from a stack of sheets is moved from an input hopper to a waste hopper. An accumulation of sheets in the waste hopper are rotated to an on-end orientation for convenient removal from the sheet feed apparatus. A conveyor may be provided to convey the on-end waste sheet out of the sheet feed apparatus. Sensors and alarms may be provided to modify a user when the waste sheet hopper is full. An interlock mechanism may be provided to prevent waste sheets from being added to the waste sheet hopper when it is full or tilted for sheet removal.

Abstract: The present invention relates to a method and apparatus for a two-piece box construction which is a continuous, in-line process in which a pair of panels or blanks are fed simultaneously from one end of the apparatus and move along a substantially linear path through the apparatus where they are joined together so that upon exit from such apparatus the joined blanks can be fed directly, in line, into a conventional folder/gluer apparatus for final folding, gluing and other processing.