Abstract: An interfolder separator apparatus and method utilize a pair of count fingers that are movable longitudinally along and transversely to a stream of folded sheets, for temporarily supporting each successive pack formed by the separator and then releasing each successive pack when partly completed to alternating build fingers, so that the operation of separating successive packs from one another is performed separately from the operations of completing the build of each pack and transporting the completed packs to downstream operations. The count fingers may be mounted to pivot about axes that are movable longitudinally along and transversely to the stream of sheets. A first or last panel of the completed pack may also be folded back partly upon itself, after the partly completed pack is released by the count fingers. Some or all of the fingers may be spring loaded and automatically resettable for clearing jams.

Abstract: A method and apparatus are provided for facilitating folding of material fed through a nip between two folding rolls having a tucker on one roll and a corresponding gripper on the other roll, by using a resilient tucker element having a tip that is moveable from a neutral position thereof, through elastic deformation of at least a portion of a body of the tucker element, for directing a portion of the material into the gripper. The resilient tucker element may have a tucker body formed at least partially of elastically resilient material fixedly attached at a proximal end thereof to the other roll. A portion of a distal end of the resilient tucker element may be wedge-like and have vacuum ports extending at least partially into the wedge-like portion, for securing an end of a sheet of material being fed through the nip between the folding rolls.

Abstract: A flexographic printing apparatus and method utilize a support platform attached to a printer frame and four bearing support carriages attached to the support platform for operatively supporting opposite ends of a plate roll and an anilox roll. One plate roll carriage and one anilox roll carriage are operatively attached to the support platform along each opposite side of the support platform by a common linear guide arrangement. The plate roll carriages are positioned along the linear guide arrangements by two plate roll linear positioners operatively attached between the support plate. The anilox carriages are positioned along the linear guide arrangements with respect to the plate roll carriages by a pair of anilox roll linear positioners operatively attached between the plate roll and anilox roll carriages. The support platform is also transversely movable with respect to the printer frame for lateral registration.

Abstract: An apparatus and method for creating stacks of sheets. In some embodiments, the sheets separated are those in or issuing from a starwheel assembly. The present invention includes a first separator finger that is inserted between two adjacent sheets to separate first and second sheets. The first separator finger retains the first sheet upstream to begin a first stack upstream of the first separator finger and allows the second sheet to complete another stack downstream of the first separator finger. In some embodiments, the first separator finger is inserted between the two adjacent sheets in a closed position and, after the first separator finger is inserted, the first separator finger moves to an open position to create a gap between the first and second stacks.

Abstract: An apparatus and method for moving stacks of product discharged from a stacking device. The apparatus includes a first conveyor movable at a first speed and a second conveyor movable at a second speed. The first conveyor includes an upstream end adjacent to the stacking device. The first conveyor is positioned to receive product from the stacking device. The second conveyor includes an upstream end adjacent to the stacking device. The second conveyor is positioned to receive product from the stacking device. The running speed of the first conveyor is faster than the running speed of the second conveyor to move stacks of product on the first conveyor away from the stacking device at a faster speed than stacks of product on the second conveyor.

Abstract: A method and apparatus for wrapping stacks of web product with wrap web material supplied from a supply roll. The apparatus includes a conveyor for supporting and moving the stacks to be wrapped along a conveying path, a drive assembly operable to receive wrap material from the supply roll and positively feed the wrap material to the conveying path, and a wrapping assembly for manipulating the wrap material around the stack. The method includes supporting and moving the stacks to be wrapped along a conveying path, rotating a cutting roll, clean cutting the wrap material received from the supply roll to separate a wrap sheet from the wrap material, defining a trailing edge of the wrap sheet, delivering the trailing edge to the conveying path after the wrap sheet is separated from the wrap material, and manipulating the wrap sheet around the stack.

Abstract: A starwheel feed apparatus and method for feeding and guiding sheets of a web material into a starwheel assembly. In some embodiments, a feeding conveyor is movable to convey sheets at a first velocity toward the starwheel, and a guiding conveyor is located adjacent the starwheel and has a conveying surface movable at a velocity less than the first velocity. In other embodiments, other relative speeds of the guiding and feeding conveyors are employed. In some embodiments, a feeding conveyor feeds sheets into slots of a starwheel, and a guiding conveyor located adjacent the starwheel has a conveying surface to guide trailing edges of the sheets along a length of the conveying surface as the sheets enter the slots.

Abstract: A starwheel feed apparatus and method for feeding and guiding sheets of a web material into a starwheel assembly. In some embodiments, a feeding conveyor is movable to convey sheets at a first velocity toward the starwheel, and a guiding conveyor is located adjacent the starwheel and has a conveying surface movable at a velocity less than the first velocity. In other embodiments, other relative speeds of the guiding and feeding conveyors are employed. In some embodiments, a feeding conveyor feeds sheets into slots of a starwheel, and a guiding conveyor located adjacent the starwheel has a conveying surface to guide trailing edges of the sheets along a length of the conveying surface as the sheets enter the slots.

Abstract: An apparatus and method for discharging sheets from a starwheel assembly and creating stacks of a desired number of sheets without interrupting the rotation of the starwheel assembly. The present invention separates sheets such that one separated sheet completes a stack and the other separated sheet is supported by a separator to begin a new stack. The completed stack is preferably transported away from the starwheel assembly by a conveyor as the new stack supports additional sheets that are discharged from the starwheel assembly. The new stack will preferably move away from the starwheel assembly to provide clearance for the accumulation of additionally discharged sheets. The apparatus can allow for cyclical repetition of the separation of sheets, the stacking of sheets, and the transportation of stacks such that continual rotation of the starwheel assembly is not interrupted.

Abstract: An apparatus and method for creating stacks of sheets. In some embodiments, the sheets separated are those in or issuing from a starwheel assembly. The present invention includes a first separator finger that is inserted between two adjacent sheets to separate first and second sheets. The first separator finger retains the first sheet upstream to begin a first stack upstream of the first separator finger and allows the second sheet to complete another stack downstream of the first separator finger. In some embodiments, the first separator finger is inserted between the two adjacent sheets in a closed position and, after the first separator finger is inserted, the first separator finger moves to an open position to create a gap between the first and second stacks.

Abstract: An apparatus and method for discharging sheets from a starwheel assembly and creating stacks of a desired number of sheets without interrupting the rotation of the starwheel assembly. The present invention separates sheets such that one separated sheet completes a stack and the other separated sheet is supported by a separator to begin a new stack. The completed stack is preferably transported away from the starwheel assembly by a conveyor as the new stack supports additional sheets that are discharged from the starwheel assembly. The new stack will preferably move away from the starwheel assembly to provide clearance for the accumulation of additionally discharged sheets. The apparatus can allow for cyclical repetition of the separation of sheets, the stacking of sheets, and the transportation of stacks such that continual rotation of the starwheel assembly is not interrupted.

Abstract: In a preferred embodiment, the web product manipulation device of the present invention is a finger having a constrained layer damping assembly coupled thereto. The constrained layer damping assembly preferably has a damping layer located between a constraining layer and an elongated body at least partially defining the finger. The damping layer preferably includes viscoelastic damping material, and the constraining layer is preferably a resilient element such as a strip of metal on the damping layer. The application of the constrained layer damping assembly to the finger dampens vibrations induced in the finger during operation. This reduces deflection in the end of the finger caused by vibration, thereby allowing the machine in which the finger is installed to be operated at higher speeds.

Abstract: A rotary knife incorporates the use of an electronically controlled, active damping system to control vibrations of knife cylinders. The system preferably uses pairs of electromagnetic actuators to provide opposing pulling forces on a ferromagnetic portion of a lever arm that is mechanically coupled to the stationary support shaft for the knife cylinder. Vibration sensors, preferably accelerometers, are used to monitor vibrations of the respective knife cylinders. A digital signal processor implementing a state space control system controls the electromagnetic actuators to actively cancel vibration energy in the knife cylinders.

Abstract: Shingling of paperboard sheets cut from a web with a helical blade cutoff knife utilizes the downward deflection of the trailing edge of the cut sheet and simultaneous lifting of the leading edge of the web to position the sheets for shingling immediately downstream of the knife. A vacuum outfeed conveyor takes advantage of the initial downward deflection of the sheet caused by cutting to pull the trailing edge of the sheet onto the vacuum conveyor which is simultaneously slowed relative to the lead edge of the advancing web. In the preferred embodiment, vacuum is continuously applied and the conveyor is accelerated back to line speed as soon as the leading end of the web is pulled onto the vacuum conveyor.

Abstract: A rotary knife incorporates the use of an electronically controlled, tuned mass active damping system to control vibrations of the knife cylinder. The system preferably uses one or more electromagnetic actuators to provide force on a tuned mass which is mechanically coupled to the knife cylinder. Vibration sensors, preferably accelerometers, are used to monitor vibrations of the respective knife cylinders and tuned masses. A digital signal processor implementing a state space control system controls the electromagnetic actuators to remove vibration energy from the system. An active damping system in accordance with the invention is more effective in removing vibration energy than passive systems, especially in heavy-duty applications.

Abstract: An active vibration damping system (e.g. an active tuned mass damping system) uses phasor techniques for accommodating excessive phase shifts in system components (e.g. amplifier and actuators). Optimal control techniques are used to determine preliminary coefficient values for the controller model. These preliminary coefficients are scaled to account for differences in units and the scaled coefficients are then used to determine phase angle and relative phasor magnitudes. For each component of the control force on the tuned mass, the respective phasor is shifted to accommodate a known phase shift in the system while maintaining the same relative phasor magnitude for each component. The phase-shifted coefficient values are then scaled to return the coefficients to the original units, and these coefficients are used in the controller to generate the command signal to drive the actuator that provides the control force on the tuned mass.

Abstract: Apparatus for separating two rolls of paper which are interconnected end-to-end, is characterized by a pair of arms pivotally connected at their upper ends and carrying inwardly facing wedges at their lower ends. The arms are advantageously mounted on wheels to facilitate transport of the same, and a hydraulic cylinder extends between the arms intermediate the pivotal connection and wedges. To separate two interconnected paper rolls lying on a floor, the apparatus is positioned to straddle the rolls with inner edges of the wedges aligned on opposite sides of the rolls with the juncture therebetween, whereupon the hydraulic cylinder is actuated to pull the arms together and move the wedges into the juncture to forcefully separate the rolls one from the other.

Abstract: A starwheel feed apparatus and method for feeding and guiding sheets of a web material into a starwheel assembly. In some embodiments, a feeding conveyor is movable to convey sheets at a first velocity toward the starwheel, and a guiding conveyor is located adjacent the starwheel and has a conveying surface movable at a velocity less than the first velocity. In other embodiments, other relative speeds of the guiding and feeding conveyors are employed. In some embodiments, a feeding conveyor feeds sheets into slots of a starwheel, and a guiding conveyor located adjacent the starwheel has a conveying surface to guide trailing edges of the sheets along a length of the conveying surface as the sheets enter the slots.