Abstract: A label-like pull tab device releasably secures a leading end of a sheet stock material to a supply of stock material for a dunnage producing machine. The device has end portions with an adhesive on a back side, and a tab portion between the end portions. In use, one end portion is attached to the leading end of the stock material, the tab portion is placed across the leading edge of the stock material, and the other end portion, on the other side of the tab portion, is attached to the supply of stock material. The device also includes at least one tear line between the tab portion and at least one of the end portions. Pulling on the tab portion tears the device along the tear line, separating the tab portion from at least one end portion, and releasing the leading end of the stock material from the supply.

Abstract: A monitoring system for monitoring one or more packaging material conversion machines includes one or more sensors for monitoring one or more operating characteristics of the one or more conversion machines. The system also includes a controller in communication with the one or more sensors. The controller evaluates the one or more operating characteristics of the one or more conversion machines to thereby provide diagnostic, inventory and machine usage information. In addition, a method of monitoring one or more packaging material conversion machines includes sensing an operating characteristic of the one or more conversion machines and evaluating the operating characteristic of the one or more conversion machines. The sensed operating characteristics may be evaluated either local to the conversion machines or at a remote site, thereby providing a substantial amount of flexibility.

Abstract: A monitoring system for monitoring one or more packaging material conversion machines includes one or more sensors for monitoring one or more operating characteristics of the one or more conversion machines. The system also includes a controller in communication with the one or more sensors. The controller evaluates the one or more operating characteristics of the one or more conversion machines to thereby provide diagnostic, inventory and machine usage information. In addition, a method of monitoring one or more packaging material conversion machines includes sensing an operating characteristic of the one or more conversion machines and evaluating the operating characteristic of the one or more conversion machines. The sensed operating characteristics may be evaluated either local to the conversion machines or at a remote site, thereby providing a substantial amount of flexibility.

Abstract: A cushioning conversion machine and method for converting sheet stock material into a cushioning dunnage product and wherein the tension in the stock material is controlled to avoid problems associated with improper tension. A conversion assembly draws the stock material from a stock supply and converts the stock material into a strip of cushioning, and a controller controls the operation of the conversion assembly. The conversion assembly is powered by a motor and the controller controls the operation of the motor in response to a sensed parameter related to the tension in the paper. In another embodiment, a torque control is interposed between the feed motor and feed components that engage the stock material.

Abstract: A pad production (supply) and packaging system, and method, for automatically producing dunnage pads and inserting one or more of the produced dunnage pads into a container for packaging of an article in the container. The invention is characterized by a pad discharge assembly and/or pad insertion assembly to provide an automatic pad production and packaging system, and method, that afford advantages over existing pad production and packaging arrangements. The discharge assembly, which provides for controlled discharge of dunnage pads produced by a pad producing machine, includes a gating device for effecting passage of the pad out of the holding zone in a direction transverse to the pad length. A controller causes the discharge assembly to release a pad held in the holding zone for passage onto a working surface and preferably a conveyor in synchronous relation to movement of the conveyor for controlled deposition of pads onto the conveyor.

Abstract: A system that converts the stock material into a cushioning product has associated therewith a conversion assembly which converts the stock material into the cushioning product and a stock roll loading assembly. The stock roll loading assembly includes a frame, a stock roll transfer member, and a ramp. The stock roll transfer member is mounted to the frame for movement between a load position whereat a stock roll may be loaded thereon and a release position whereat the stock roll is released from the transfer member. The ramp receives the stock roll from the transfer member and conveys the stock roll to a position remote from the release position. In an embodiment, the stock roll transfer member is loaded from an end thereof. In another embodiment, the stock roll transfer member is loaded from the side thereof. A stock roll storage assembly stores one or more stock rolls and enables the stock rolls to be sequentially released from the ramp.

Abstract: A supply of sheet stock material for use in a cushioning conversion machine is disclosed. The supply of stock material includes at least one ply of sheet stock material rolled or folded into a compact configuration such as a roll of wound stock material or a stack of fan-folded stock material. The ply has disposed on a leading or trailing end thereof, a pressure sensitive adhesive layer and a removable release liner covering the pressure sensitive adhesive layer. When a supply of sheet stock material is almost spent, a succeeding supply of stock material may be spliced to the almost spent supply by removing the release liner to expose the adhesive and then applying the leading or trailing end, having the adhesive thereon, to a trailing end of the almost spent supply of stock material or leading end of the succeeding supply of stock material.

Abstract: A pad production (supply) and packaging system, and method, for automatically producing dunnage pads and inserting one or more of the produced dunnage pads into a container for packaging of an article in the container. The invention is characterized by a pad discharge assembly and/or pad insertion assembly to provide an automatic pad production and packaging system, and method, that afford advantages over existing pad production and packaging arrangements. The discharge assembly, which provides for controlled discharge of dunnage pads produced by a pad producing machine, includes a gating device for effecting passage of the pad out of the holding zone in a direction transverse to the pad length. A controller causes the discharge assembly to release a pad held in the holding zone for passage onto a working surface and preferably a conveyor in synchronous relation to movement of the conveyor for controlled deposition of pads onto the conveyor.

Abstract: A safety output chute for a cushioning conversion machine includes a chute having an input end and an output end, the input end including an opening for receiving a flexible cushioning product from an outlet of the cushioning conversion machine; and a plurality of rollers situated inside the chute, the rollers being oriented such that the flexible cushioning product must follow a non-linear path from the input end of the chute to the output end of the chute. Other embodiments of a safety output chute are also disclosed.

Abstract: A cushioning conversion system for converting a sheet-like stock material into a section of dunnage. The system has a feed motor operatively connected to advance the stock material under the control of a motor control signal, the motor control signal having a series of sequential values corresponding to either a motor power on state or a motor power off state; and a controller, the controller generating the motor control signal by executing a motor control logic routine.

Abstract: A cushioning conversion machine (20) including a conversion assembly (30) which converts a continuous sheet of multi-ply stock material (22) into a three dimensional cushioning product (32) and a stock supply assembly (550) which supplies the multi-ply stock material (22) to the conversion assembly (30). The conversion assembly (30) includes a forming assembly (52) which inwardly turns lateral portions of the stock material (22) as the stock material (22) travels therethrough in a downstream direction. The stock supply assembly (550) includes a separating device (574) and/or constant-entry device (580) designed to minimize tearing due to excessive tension in the lateral regions of the stock material (22). Additionally or alternatively, the forming assembly (52) includes a shaping member (590) having protrusions in its turning perimeter and/or holding surface to modify the shape of the cushioning product.

Abstract: A cushioning conversion machine and method for converting sheet stock material into a cushioning dunnage product and wherein the tension in the stock material is controlled to avoid problems associated with improper tension. A conversion assembly draws the stock material from a stock supply and converts the stock material into a strip of cushioning, and a controller controls the operation of the conversion assembly. The conversion assembly is powered by a motor and the controller controls the operation of the motor in response to a sensed parameter related to the tension in the paper. In another embodiment, a torque control is interposed between the feed motor and feed components that engage the stock material.

Abstract: An improved cushioning conversion machine and related methodology characterized by one or more features including, inter alia, a feeding/connecting assembly which enables an operator to easily vary a characteristic, for example, the density, of the cushioning product; a feeding/connecting assembly wherein input and/or output wheels or rollers thereof are made at least in part of an elastomeric or other friction enhancing material, which reduces the cost and complexity of the input and output rollers; a manual reversing mechanism that is useful, for example, for clearing paper jams; a modular arrangement of a forming assembly and feeding/connecting assembly in separate units that may be positioned remotely from one another, as may be desired for more efficient utilization of floor space; a turner bar which enables alternative positioning of a stock supply roll; and a volume expanding arrangement cooperative with the feeding/connecting assembly for adjusting the density of the cushioning product and changing pr

Abstract: A safety output chute for a cushioning conversion machine includes a chute having an input end and an output end, the input end including an opening for receiving a flexible cushioning product from an outlet of the cushioning conversion machine; and a plurality of rollers situated inside the chute, the rollers being oriented such that the flexible cushioning product must follow a non-linear path from the input end of the chute to the output end of the chute. Other embodiments of a safety output chute are also disclosed.

Abstract: A cushioning conversion machine for converting a sheet-like stock material into a dunnage product includes a frame having an upstream end and a downstream end, conversion assemblies, mounted on the frame, which convert the sheet-like stock material into a continuous strip of a dunnage product, a feeding assembly, mounted on the frame, for feeding the stock material through the conversion assemblies, a cutting assembly, mounted on the frame downstream of the conversion assemblies, which cuts the continuous strip of dunnage into a section of a desired length, a probe for determining the packaging requirements of a particular container, and a controller which controls the feeding and cutting assemblies to produce the required sections of dunnage product for the container as determined by the probe.

Abstract: An automated cushioning producing and filling system includes a cushioning conversion machine which converts stock paper into cut pads of a selected length and transports the pads to a staging location, a pad sensor for sensing the presence of a pad in the staging location, a box transporting system for transporting a box from a remote location to a filling location, a box sensor for sensing the presence of a box in the filling location, a bar code reader for reading a bar code from the box indicative of the packaging requirements of the box when the box sensor has sensed the presence of a box in the filling location, a pad transferring apparatus for transferring a pad from the staging location to the box when the pad sensor has sensed the presence of a pad in the staging area, and a system controller for determining the box packaging requirements from the code read by the bar code reader and instructing the cushioning conversion machine to produce pads in accordance with the packaging requirements for the bo

Abstract: An apparatus controllably moves the forks of a material handling vehicle in traverse directions relative to a carriage assembly. The carriage assembly includes fork position sensors which detect the transverse location of each fork. A controller receives signals from the position sensors and moves the forks to locations a preselected or calculated distance apart. Forktip sensors detect the opening in a load during movement of the forks. The controller receives signals from the forktip sensors and positions the forks such that they are disposable within the load opening. The apparatus is especially suitable for use on an Automatic Guided Vehicle (AGV).

Abstract: Industrial vehicles incorporating obstacle detection systems are commonly employed in commercial applications. Advantageously, such collision avoidance systems should incorporate failure detection systems sufficient to make such systems fail-safe. The subject obstacle detection system includes one or more transducers 24,24' adapted to produce article detected signals in response to sensing an obstacle in front of the vehicle 12. Preferably the transducers 24,24' are pivotally mounted to the vehicle 12. The transducers 24,24' are adapted to produce the article detected signals at regular predetermined intervals, and a sensor failed signal is produced in response to the transducers 24,24' ceasing to produce the article detected signal at such regular intervals.

Abstract: A self guided vehicle has a roller deck controllably powered by an electric motor to accept and deliver loads on both the left and right side of the vehicle. An infrared communication system is employed to coordinate the overall transfer of these loads between the vehicle and a docking station. The communication system performs the multiple functions of locating the docking station relative to the left and right side of the vehicle, determining the direction the load is to be transferred, and controlling the direction of motor rotation to effect such a transfer.

Abstract: In the field of automated guided vehicles it is particularly important that speed and steering angle feedbacks be accurate and reliable. Any deviations in these feedback signals should be promptly detected and used to alter operation of the vehicle. An apparatus constantly monitors the time varying output signals of a pair of resolvers respectively associated with wheel rotation and steering angle. The loss of either of the resolver signals for more than a preselected duration of time related to the excitation frequency and vehicle speed results in the power delivered to an electric drive motor being discontinued and the vehicle brakes being applied.