Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: ADJUSTABLE CONVEYOR APPARATUS AND METHOD FOR
BOOK BLOCK FINISHING MACHINE
FIELD
[0001] The described embodiments relate to an apparatus for
conveying a plurality of sheets that can be used in a book block finishing
machine.
INTRODUCTION
[0002] Digital printing presses are an alternative to traditional offset
printing presses and can be used to create multiple copies of a printed work.
In some examples of digital printing presses, the printed content is applied
to
a continuous length of web, and the web is then cut and sorted to form a
book. One method of converting the printed continuous web into a book
involves the individual pages of the printed content (i.e., the book being
printed) being cut, separated and stacked into book blocks. A portion of the
digital printing press known as the finishing machine or book block finishing
machine can perform at least some of these operations.
[0003] Finishing machines can take a considerable amount of time to
allow for a format change (i.e., to accept a different book block size and
shape), which requires the associated digital printing press to also stop for
a
period of time. This can reduce some of the "change-on-the-fly" advantage of
digital printing presses.
SUMMARY
[0004] This summary is intended to introduce the reader to the more
detailed description that follows and not to limit or define any claimed or as
yet
unclaimed invention. One or more inventions may reside in any combination
or sub-combination of the elements or process steps disclosed in any part of
this document including its claims and figures.
[0005] According to one broad aspect of the invention, an apparatus for
conveying a plurality of sheets into a receiving member includes receiving
member and a conveyor for conveying a plurality of sheets into the receiving
member so that the sheets are stacked one upon another to form a book
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block. The conveyor can have a downstream end that is moveable relative to
the stack of sheets in the receiving member. The apparatus can also include
an actuator connected to the conveyor that is operable to move the
downstream end of the conveyor relative to the stack of sheets in the
receiving member.
[0006] Optionally, the downstream end of the conveyor is moveable in
a generally vertical direction and the second position is at a higher
elevation
than the first position.
[0007] The apparatus can also include a controller communicably
linked to the actuator for automatically moving the downstream end of the
conveyor between the first and second positions.
[0008] Optionally, the controller is operable to move the downstream
end of the conveyor based on a height of the book block in the receiving
member.
[0009] Optionally, the conveyor is movable between the first and
second positions while conveying the plurality of sheets.
[0010] Optionally, in the first position the downstream end of the
conveyor is at a higher elevation than the book block.
[0011] Optionally, second position is always at a higher elevation than
the book block.
[0012] Optionally, the conveyor is displaceable in a lateral direction
relative to the frame and the receiving member.
[0013] According to another broad aspect of the invention, a method of
conveying a plurality of sheets into a receiving member includes a)
positioning a downstream end of an adjustable conveyor at a
first height; b) conveying the plurality of sheets toward a receiving member;
c)
depositing the plurality of sheets in the receiving member one upon another in
a stack to form a book block; and d) raising the downstream end of the
conveyor relative to the stack of sheets in the receiving member so that the
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downstream end of the conveyor is always at a higher elevation than the
stack of sheets in the receiving member.
[0014] Optionally, the method also includes adjusting the downstream
end as the receiving member is filled so that the downstream end of the
conveyor remains at generally a constant spacing above a top sheet in the
stack.
[0015] Optionally, the method also includes automatically adjusting the
position of the downstream end of the conveyor using an actuator controller
by a controller.
[0016] Optionally, the method also includes using the controller to
determine a desired rate of change of the elevation of the downstream end of
the conveyor based on a rate at which the plurality of sheets are conveyed
into the hopper.
[0017] Optionally, the method also includes removing the stack from
the receiving member and returning the downstream end to the first height to
begin stacking another plurality of sheets in the receiving member.
[0018] According to another broad aspect of the invention, an
apparatus for conveying a plurality of sheets in a book block finishing
machine
includes a frame and an upstream conveyor to convey a plurality of sheets in
a machine direction. The apparatus can also include a downstream conveyor
to receive a plurality of sheets from the upstream conveyor. The downstream
conveyor can be movably mounted on the frame and includes a conveyor
reference axis extending in the machine direction. The downstream conveyor
can be selectably displaceable relative to the upstream conveyor in a
transverse direction to align the conveyor reference axis with a reference
axis
defined by the plurality of sheets when the sheets are being conveyed in a
machine direction by the upstream conveyor.
[0019] Optionally, the conveyor reference axis is a lateral centerline of
the downstream conveyor.
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[0020] Optionally, the apparatus also includes a receiving member
downstream from the downstream conveyor for receiving the plurality of
sheets. The conveyor can be displaceable in the transverse direction relative
to the receiving member.
[0021] Optionally, the apparatus also includes at least one transverse
actuator drivingly connected to the downstream conveyor. The actuator can
be operable to translate the downstream conveyor in the transverse direction.
[0022] Optionally, the apparatus also includes a controller
communicably linked to the at least one transverse actuator to automatically
adjust the transverse position of the downstream conveyor based on the
location of the sheet reference axis.
[0023] Optionally, the downstream conveyor can include an upstream
end for receiving the plurality of sheets and a downstream end. The
downstream end of the conveyor can be movable relative to the receiving
member between a first position and a second position, the second position
being at a higher elevation than the first position.
[0024] Optionally, the apparatus can also include an elevation actuator
drivingly connected to the downstream end for moving the downstream end
between the first and second positions. The elevation actuator can be
displaceable in the transverse direction relative to the frame with the
downstream conveyor.
[0025] Optionally, the apparatus can also include a nozzle apparatus
mounted on the downstream conveyor for blowing a fluid between sequential
ones of the plurality of sheets exiting the downstream conveyor. The nozzle
apparatus can movable in the transverse direction with the downstream
conveyor.
[0026] Optionally, the apparatus can also include a jogging apparatus
mounted on the downstream conveyor for jogging the plurality of sheets
exiting the conveyor in the machine direction. The jogging apparatus can be
moveable in the transverse direction with the downstream conveyor.
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[0027] According to another broad aspect of the invention, a method of
conveying a plurality of sheets in a book block finishing machine can include
a) conveying a plurality of sheets in a machine direction on an upstream
conveyor; b) displacing a downstream conveyor relative to the upstream
conveyor in a transverse direction to align a conveyor reference axis of the
downstream conveyor with a sheet reference axis defined by the plurality of
sheets when the sheets are being conveyed in a machine direction by the
upstream conveyor; and c) transferring the plurality of sheets from the
upstream conveyor to the downstream conveyor.
[0028] Optionally, the conveyor reference axis is a lateral centerline of
the downstream conveyor.
[0029] Optionally, the method also includes automatically adjusting the
transverse position of the downstream conveyor to align the conveyor
reference axis with the sheet reference axis using a transverse actuator
drivingly connected to the downstream conveyor and a controller
communicably linked to the transverse actuator.
[0030] Optionally, the method also includes transferring the plurality of
sheets from the downstream conveyor to a receiving member and stacking
the sheets in the receiving member to form a book block.
[0031] Optionally, the method also includes adjusting the vertical
elevation of a downstream end of the downstream conveyor to adjust a
vertical spacing between the downstream end of the downstream conveyor
and the book block.
[0032] Optionally, the method also includes injecting fluid between
sequential ones of the plurality of sheets entering the receiving member using
a nozzle apparatus, the nozzle apparatus being moveable in the transverse
direction in unison with the downstream conveyor.
[0033] Optionally, the method also includes jogging the plurality of
sheets in the receiving member in the machine direction using a jogging
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apparatus, the jogging apparatus moveable in the transverse direction in
unison with the downstream conveyor.
[0034] It is contemplated that any one or more of the aspects described
above can be combined in a plurality of combinations or sub-combinations to
provide a plurality of embodiments of the invention.
DRAWINGS
[0035] For a better understanding of the applicant's teachings
described herein and to show more clearly how they may be carried into
effect, reference will now be made, by way of example only, to the
accompanying drawings which show at least one exemplary embodiment, and
in which:
[0036] Figure 1 is a side view of an example of a transfer apparatus for
use in a book block finishing machine;
[0037] Figure 2 is a side view of the transfer apparatus of Figure 1 in a
lowered position;
[0038] Figure 3 is a side view of the transfer apparatus of Figure 1 in an
intermediate position;
[0039] Figure 4 is a side view of the transfer apparatus of Figure 1 in a
raised position;
[0040] Figure 5 is a side view of an example of a transfer apparatus
that includes a sensor;
[0041] Figure 6 is a top plan view of an example of a transfer apparatus
that is translatable in the lateral direction;
[0042] Figure 7 is a top plan view of the transfer apparatus of Figure 6
in a different lateral position;
[0043] Figure 8 is a side view of another example of a transfer
apparatus that is pivotable and translatable;
[0044] Figure 9 is a perspective view of the transfer apparatus of Figure
8 in a lowered position;
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i i
[0045] Figure 10 is a side view of the transfer apparatus of Figure 9;
[0046] Figure 11 is a perspective view of the transfer apparatus of
Figure 8 in an intermediate position;
[0047] Figure 12 is a side view of the transfer apparatus of Figure 11;
[0048] Figure 13 is a perspective view of the transfer apparatus of
Figure 8 in a raised position;
[0049] Figure 14 is a side view of the transfer apparatus of Figure 13;
[0050] Figure 15 is a perspective end view of the transfer apparatus of
Figure 8 in a first lateral position
[0051] Figure 16 is a top plan view of the transfer apparatus of Figure 8
in the first lateral position;
[0052] Figure 17 is a perspective end view of the transfer apparatus of
Figure 8 in a second lateral position;
[0053] Figure 18 is a top plan view of the transfer apparatus of Figure 8
in the second lateral position; and
[0054] Figure 19 is a perspective view of the underside of the transfer
apparatus of Figure 8.
[0055] Elements shown in the figures have not necessarily been drawn
to scale. For example, the dimensions of some of the elements may be
exaggerated relative to other elements. Further, where considered
appropriate, reference numerals may be repeated among the figures to
indicate corresponding or analogous elements.
DESCRIPTION OF VARIOUS EMBODIMENTS
[0056] Various apparatuses or processes will be described below to
provide an example of an embodiment of each claimed invention. No
embodiment described below limits any claimed invention and any claimed
invention may cover processes or apparatuses that are not described below.
The claimed inventions are not limited to apparatuses or processes having all
of the features of any one apparatus or process described below or to
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features common to multiple or all of the apparatuses described below. It is
possible that an apparatus or process described below is not an embodiment
of any claimed invention. Any invention disclosed in an apparatus or process
described below that is not claimed in this document may be the subject
matter of another protective instrument, for example, a continuing patent
application, and the applicants, inventors or owners do not intend to abandon,
disclaim or dedicate to the public any such invention by its disclosure in
this
document.
[0057] As described herein, a book block finishing machine is any
machine that is operable to receive an incoming, continuous printed paper
web and convert the web into one or more book blocks. Generally, the
incoming web is separated into a plurality of individual sheets of paper that
advance through the machine in a machine direction (i.e. the general direction
of travel of the web and/or sheets, for example as illustrated by arrow 100 in
Figure 1) and are collected and stacked in a receiving member, for example a
hopper, to form a book block. The direction generally orthogonal to the
machine direction can be referred to as the lateral or transverse direction.
[0058] For the purposes of this description, a book block comprises a
plurality of sheets of paper, stacked in order, generally taking the form of a
book without a cover or other permanent binding. Book blocks may be formed
having a variety of physical dimensions (length and width) based on the
requirements of the finished book (i.e.,. paper back, hardcover, coffee table
book, etc.) and may contain a variety of numbers of pages depending on the
length of the book being printed. Varying the number of pages in a book block
may vary the height of the book block. While the term book block is generally
used in this description to describe a plurality of pages arranged in order to
form the text of a book, it is understood that the term book block also refers
more generally to any collection of stacked sheets or pages, the contents of
which may be a book or any other type' of printed media, including flyers,
catalogues, directories and manuals.
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[0059] The incoming sheets that will form the book block can be initially
supplied to the book block finishing machine as individual sheets, or as a
generally continuous, moving web of paper (or other suitable material) upon
which desired text and/ or graphics is printed. Such an incoming web can
then be separated into a plurality of sheets, which can then be arranged into
one or more steams of sheets moving through the machine. Each stream of
sheets can be fed into a hopper, in which the sheets are stacked to form the
book block.
[0060] Optionally, the book block finishing machine may be configured
to operate in an "on-line" capacity, in which the incoming web is received
from
a printing engine (digital or offset) in real time (i.e. the printed web
exiting the
printing press is fed into the book block finishing machine). Alternatively,
the
book block finishing machine may be configured to operate in an "off-line"
capacity in which the incoming web is unwound from a spool or roll of pre-
printed material, as opposed to coming directly from the output of a printing
press. In either example, the web can be supplied to the book block finishing
machine at a given linear velocity or web speed that can be expressed in
absolute terms, for example the web can be traveling at ten linear feet per
second, or in relative terms, for example the web and/or sheets can be
traveling between about 400 and 800 sheets per minute (which may represent
a variety of different velocities depending on the length of each sheet), or
greater than 800 sheets per minute.
[0061] An example of such a book block finishing machine is the book
block finishing machine described in PCT/CA2010/000832 (Speller et al.),
filed June 1, 2010 and entitled "Book Block Finishing Machine", the entirety
of
which is incorporated herein by reference.
[0062] Referring to Figure 1 an example of an apparatus for conveying
a plurality of sheets that is suitable for use in a book block finishing
machine is
illustrated. In the illustrated examples the apparatus 102 can be provided as
a
discrete, or stand-alone unit that can co-operate with, or replace, other
discrete units or modules in the book block finishing machine. Alternatively,
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the apparatus 102 can be incorporated as a sub-unit or sub-assembly within
another unit in the book block finishing machine, including, for example, a
batcher unit and a shingle and interrupt unit. In this example, the apparatus
102 is adapted to convey a plurality of individual sheets of paper 104 from an
upstream portion of the book block finishing machine, for example an
upstream conveyor 106 that may form part of a shingle and interrupt unit, to a
downstream receiving member of the book block finishing machine, for
example the hopper 108 that may form part of a batcher unit.
[0063] In the illustrated example, the apparatus 102 comprises a
conveyor portion 110 that is moveably mounted on a supporting frame 112.
The frame 112 supporting the apparatus 102 can be a stand-alone frame, or,
as illustrated, can be integrated with the frame of the book block finishing
machine.
[0064] The conveyor portion 110 includes a conveyor belt 114 that is
movingly supported by an upstream pulley 116 and a downstream pulley 118,
located at an upstream end 120 and a downstream end 122 of the conveyor
portion 110, respectively. At least one of the pulleys can be driven by a
motor,
or other suitable drive mechanism (not shown), to drive the conveyor belt 114.
The conveyor belt 114 can be formed from, for example, but not limited to,
any suitably flexible material.
[0065] The conveyor portion 110 can also include a supporting table
126, about which the conveyor belt 114 travels. The supporting table 126 can
provide structural stiffness for the conveyor portion 110, and can be formed
as
any suitable structure. Portions of the conveyor belt 114 can be in sliding
contact with the supporting table 126 during operation.
[0066] When the plurality of sheets 104 reach the downstream end 122
of the conveyor portion, they are ejected or discharged from the conveyor
portion 110 and, in the illustrated example, are deposited into a receiving
member, which in the example illustrated is hopper 108. In this description,
the distance between the vertical elevation of downstream end 122 of the
conveyor portion 110 and the top surface of the contents of the hopper 108 is
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referred to as the conveyor spacing 130. This spacing 130 can represent the
distance that a sheet will fall when it is transferred from the downstream end
122 of the conveyor portion 110 into the hopper 108. When the hopper 108 is
empty (Figure 2) the conveyor spacing 130 can be measured between the
upper surface of the conveyor portion 110 (the point at which the sheets 104
exit the conveyor portion 110) and the floor 132 of the hopper 108. When the
hopper 108 contains one or more sheets 104 (Figures 3 and 4), the spacing
130 can be measured between the upper surface of the conveyor portion 110
and the top sheet 128 in the stack of sheets 104 in the hopper 108.
[0067] If the distance 130 between the downstream end 122 of the
conveyor 110 and the floor 132 of the hopper is large relative to the size of
the
sheets 104 on the conveyor, when the hopper 108 is empty the sheets 104
may tend to flutter, drift or deflect in the air as they are falling from the
conveyor portion 110 into the hopper 108. Such motion may cause
misalignment between sequential sheets 104 and/or between the sheets 104
and the walls of the hopper 108. Decreasing the distance 130 between the
downstream end 122 of the conveyor 110 and the floor 132 of the hopper 108
may reduce such misalignment.
[0068] As the sheets 104 accumulate in the hopper 108, the thickness
or height 134 of the resultant book block 136 (Figure 4) will increase.
Depending on the number of sheets 104 in the book block, the height 134 of
the book block 136 may approach or exceed the initial spacing between the
downstream end 122 of the conveyor 110 and the floor 132 of the hopper 108,
which may cause binding or jamming as new sheets 104 are introduced into
the hopper 108. Maintaining a desired vertical distance 130 between the
downstream end 122 of the conveyor portion 110 and the top sheet 128 of the
hopper 108 (i.e. the top sheet in the stack in Figures 3 and 4) may help
reduce the occurrence of jamming and other similar problems. For clarity of
illustration, the distance 130 has been exaggerated in the schematic drawings
in Figures 1-4. In any given book block finishing machine, the distance 130
can be relatively smaller than the spacing illustrated in the figures, and can
be
generally the same as the diameter of the downstream conveyor pulley (for
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example pulley 118 in Figure 1), or optionally can be set to be generally the
same as the combined thickness of a few sheets at the top of the stack. For
example, the spacing distance 130 can be selected so that it is generally
equal to the thickness of 15-50 sheets in the stack. In other examples the
spacing 130 can be less than the thickness of 15 sheets, or more than the
thickness of 50 sheets in the stack.
[0069] In the illustrated example, the conveyor spacing 130 can be
adjusted by moving the position of the downstream end 122 of the conveyor
portion 110 relative to the top sheet 128 of the hopper 108 as the sheets 104
accumulate in the hopper 108. Providing a vertically adjustable downstream
end 122 on the conveyor portion 110 enables the downstream end 122 of the
conveyor portion 110 to be positioned in a lowered position when the hopper
108 is empty (Figures 1 and 2) and to be moved to a raised position (Figure 4)
as the hopper 108 fills. Optionally, the downstream end 122 of the conveyor
110 can be moved while the sheets 104 are being deposited into the hopper
108 so that the conveyor spacing 130 remains generally constant throughout
the filling process (see Figures 2-4).
[0070] In this example the upstream pulley 116 of conveyor portion 110
is pivotally connected to the frame 112 and the downstream end 122 of the
conveyor portion, including the downstream pulley 118, is free to move
vertically relative to the frame 112. The downstream end 122 of the conveyor
portion 110 is supported by a conveyor elevation actuator 138 that is operable
to change the vertical position of the downstream end 122 of the conveyor
portion 110, between the lowered position and the raised position. The
elevation actuator 138 can be drivingly connected to the supporting table 126,
the axel or rod supporting the downstream pulley 118, or any other suitable
portion of the conveyor 110.
[0071] Once a first book block 136 is completed, it can be removed
from the hopper 108 to make room for a subsequent plurality of sheets 104 to
be stacked in the hopper 108 to form a second book block. Once all of the
sheets in the first book block have exited the conveyor portion 110 and,
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optionally, when the book block 136 is still partially within the hopper and
is
just starting to move downstream out of the hopper, the downstream end 122
of the conveyor 110 can be returned to its lowered position (or any desired
starting position), from its raised position in order to begin stacking the
second
plurality of sheets in an empty hopper 108. Optionally, the downstream end
122 of the conveyor portion 110 can be moved while the first book block is
being removed from the hopper 108.
[0072] Optionally, the movement of the downstream end 122 of the
conveyor portion 110 can be manually controlled, for example by a machine
operator operating the book block binding machine, or at least partially
automatically controlled by a controller 140 that is communicably linked to
the
conveyor actuator 138. The controller 140 can be a stand-alone controller (as
illustrated) or, optionally, the controller 140 can be integrated with, or
incorporated into, a book block machine controller or control system.
[0073] The controller 140 can determine the appropriate vertical
position of the downstream end 122 of the conveyor portion 110 using any
suitable method. In one example, the controller 140 may determine the
appropriate position of the conveyor portion 110 based on machine or sheet
104 material properties. For example, the controller 140 may raise the
downstream end 122 of the conveyor 110 based on the expected thickness of
the book block 136 (e.g., by counting the sheets 104 entering the hopper 108
and summing the thicknesses), or by the amount of time elapsed during a
particular filling operation (e.g., the conveyor is gradually moved from the
lowered position to the raised position every second). The controller 140 can
also be connected to one or more sensors or other input devices that can
provide data about the operation of the transfer apparatus 102 and/or other
portions of the book block binding machine.
[0074] Referring to Figure 5, one example of a sensor is an ultra sonic
sensor 142 that is positioned above the hopper 108 and can be used to sense
the height of the stack of sheets 104 in accumulated in the hopper 108. In
this
example, the sensor 142 can determine the height 144 of the top sheet 128 of
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the hopper 108 relative to the sensor 142, and the controller 140 can then
determine the position of the downstream end 122 of the conveyor 110
relative to the top sheet 128 in any suitable manner, including, for example
by
summing the distance 144 between the sensor 140 and the top sheet 128 and
the distance 146 between the sensor 140 and the downstream end 122 of the
conveyor 110. Based on this determination, the controller 140 can
automatically trigger the actuator 138 to raise or lower the downstream end
122 of the conveyor 110 in order to achieve a desired conveyor spacing 130.
[0075] The conveyor actuator 138 can be one or more of any suitable
type of actuator, including, for example, a pneumatic cylinder, a hydraulic
cylinder and a ball screw. Optionally, the conveyor portion 110 can be biased
to return to either of the raised or lowered positions when the actuator 138
is
disengage, for example by using a spring or other resilient member.
Alternatively, the actuator 138 can be configured to drive the conveyor
portion
110 in both directions. Optionally, the conveyor actuator 138 can be
continuously variable to move the downstream end 122 smoothly between the
lowered and raised positions. Alternatively, the conveyor actuator 138 can be
configured to move the downstream end 122 between a plurality of indexed
positions intermediate the raised and lowered positions (e.g. 25% raised, 50%
raised, etc.).
[0076] Optionally, to inhibit binding or jamming between sheets in the
hopper 108 and sheets exiting the conveyor portion 110, the downstream end
122 of the conveyor portion 110 can be maintained at an elevation that is
always higher than the elevation of the top sheet 128 in the hopper 108, so
that the conveyor spacing 130 is always greater than the thickness of the
sheets 104.
[0077] The rate at which the elevation of the downstream end 122 of
the conveyor portion 110 is changed can be selected based on a plurality of
machine conditions and/or the traits of the sheets 104 being stacked,
including, for example, machine speed (e.g., 400 sheets per minute), sheet
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thickness, sheet stiffness and total number of sheets expected to be stacked
in the hopper 108 per book block 136.
[0078] Optionally, the downstream end 122 of the conveyor portion can
also include a plurality of other elements, including, for example, air
nozzles,
forming rollers and jogging mechanisms. Some or all of these additional
elements can be configured to engage the plurality of sheets 104 as they are
ejected from the downstream end of the conveyor portion, and/or while the
sheets are stacked in the hopper. Optionally, these additional elements can
be mounted to the conveyor portion such that the additional elements can
move in unison with the conveyor portion when the conveyor portion is
pivoted. This may enable the additional elements to remain in a fixed vertical
position relative to the sheets 104 being ejected from the conveyor portion
110 regardless of the vertical position of the conveyor portion 110.
[0079] Referring to Figures 6 and 7, another example of apparatus 202
is illustrated. In this example, apparatus can include a conveyor portion 210
that is translatable in the transverse direction relative to other portions of
the
book block finishing machine. Aspects of the apparatus 202 are similar to
those of the apparatus 102 described above, and will be marked using like
reference characters indexed by 100. In these Figures, a plurality of sheets
204 being transferred by the upstream conveyor 206 are illustrated in a
shingled (i.e., partially overlapped configuration) in which only a portion of
each sheet 204 is visible from above. When the apparatus 202 is in use, the
sheets 204 can continue in the shingled arrangement until they are deposited
into the hopper 208. However, for clarity and to better illustrate the
underlying
features of the conveyor portion 210, only a single representative stream of
sheets is illustrated on the conveyor 214 in Figures 5 and 6.
[0080] The apparatus 202 comprises a conveyor portion 210 that
includes a conveyor belt 214 and a supporting table 226. The conveyor
portion 210 is movably mounted to the underlying frame 212 so that the
conveyor portion 210 can translate in the lateral direction relative to the
hopper 206 and the upstream conveyor 206. In the illustrated example, the
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conveyor portion 210 is slidably supported by a pair of spaced apart rails 250
that extend laterally across the frame 212. A translation actuator 252 is
drivingly connected between the conveyor portion 210 and the frame 212 to
laterally shift the conveyor portion 210. The conveyor actuator 252 is
illustrated as being a ball screw (with a corresponding nut affixed to the
conveyor portion 210), but any suitable actuator can be used.
[0081] In some instances, such as, for example, if the downstream end
222 of the conveyor portion 210 includes a variety of additional elements (air
nozzles, joggers, as described above), it may be desirable to align a
reference
axis 254 of the conveyor portion 210 with the lateral centre line 256 of the
sheets 204 that are being conveyed into the hopper 206. Aligning the
reference axis 254 of the conveyor portion 210 with the centre line 256 of the
sheets 204, can help ensure that the additional elements affixed to the
conveyor portion 210 are properly aligned with the sheets 204 as they enter
the hopper 206.
[0082] In the illustrated example, the reference axis 254 of the
conveyor portion 210 coincides with the lateral centerline of the conveyor
portion 210. Optionally, in other examples, the reference axis 254 may not be
coincident with the lateral centerline, but may be aligned with another
feature
on the conveyor portion 210.
[0083] Referring to Figure 6, in some examples the sheets 204 being
processed by the book block finishing machine can have a relatively large
lateral width 258 that is close to the lateral width 260 of the hopper 208. In
such examples, lateral centerline 256 of the sheets 204 can be approximately
coincident with the lateral centerline 262 of the hopper 208 and the
centerline
264 of the upstream conveyor 206. Optionally, a hopper reference position
can be defined for the book block finishing machine, and may serve as a
guide for depositing the sheets 204 into the hopper 208. In the illustrated
example, the plurality of sheets 204 are edge justified relative to the hopper
208, so that one edge 205 of the sheets 204 abuts a side wall 209 of the
hopper 206 when the sheets 204 are stacked in the hopper 208. This may
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help align and justify the stacked sheets 204 within the hopper 208. In this
example, the hopper reference position is the position to which the centerline
256 of the sheets 204 should be aligned when the sheets 204 are properly
justified, and is represented by hopper reference axis 266. In Figure 6, the
hopper reference axis 266 is coincident with the hopper centerline 262.
[0084] In this configuration, the conveyor portion 210 can be laterally
centered so that the reference axis 254 is coincident with the sheet, hopper
and upstream conveyor centerlines 256, 262, 264 and the hopper reference
axis 266.
[0085] Referring to Figure 7, in some examples the lateral width 258 of
the sheets 204 being processed by the book block finishing machine can be
relatively narrower than the sheets in Figure 6. In this example, the hopper
reference axis 268 and the centerline 256 of the sheets 204 may not be
coincident with the lateral centerlines 262, 264 of the hopper 208 and
upstream conveyor 206.
[0086] To align the conveyor portion reference axis 254 with the lateral
centerline 256 of the narrower sheets 204 in this example, the conveyor
portion 210 is laterally shifted (downward as viewed in Figure 7), so that the
conveyor reference axis 254 is laterally aligned with the centerline 256 of
the
sheets 204 as they exit the upstream conveyor 206. The sheets 204 are then
conveyed along the conveyor portion 210 and deposited into the hopper 208
so that the lateral centerline 256 of the sheets 204 is aligned with the
hopper
reference axis 266.
[0087] In this configuration, at least a portion of the conveyor portion
210, for example a first side portion 268, can protrude laterally beyond the
sidewalls, for example sidewall 209, of the hopper 208.
[0088] Like the conveyor elevation actuator 138 described above, the
translation actuator 252 can be manually controlled by a machine operator, or
automatically controlled by a controller 240 linked to the actuator 252
(Figure
7). The controller 240 can be configured to control the lateral position of
the
conveyor portion 210 based on user input information, such as the width of
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CA 02754497 2011-10-07
the sheets being stacked, or sensed information collected from one or more
sensors monitoring the stream of sheets 204.
[0089] Optionally, at least one sidewall of the hopper 208 (for example
the upper sidewall as viewed in Figures 6 and 7) can be moveable in the
lateral direction so that the geometric lateral centre line 262 of the hopper
208
can be aligned with the hopper reference axis 266 regardless of the width 258
of the sheets 204 being stacked.
[0090] Optionally, at least one of the sidewalls of the hopper 208, for
example side wall 209a, can be moveable in the transverse direction and can
be configured to oscillate or vibrate in the lateral direction. In such
examples,
when sheets are flowing into the hopper 208 the sidewall 209a can set to be
wider (for example between one and two millimeters) than the sheets so as to
not pinch them or impede their motion into the hopper 208. Once all the
sheets are in the hopper 208, the sidewall 209a moves to a position equal to
or slightly less than the width of the sheets (for example, approximately 0.5
millimeters narrower than the sheets). The laterally squeezed sheets can then
be removed from the hopper 208, for example by using a movable shuttle
apparatus. Laterally squeezing the stacked sheets in this manner may help
improve the alignment of the sheets in the lateral direction.
[0091] The lateral translation aspects of the transfer apparatus 202 can
be used as an alternative to vertical pivoting aspects of transfer apparatus
102 to provide a transfer apparatus that can either pivot or translate if
desired.
Optionally, aspects of the transfer apparatus 202 can be used in combination
with aspects of the transfer apparatus 102 to provide a transfer apparatus
that
can both pivot and translate relative to the other portions of the book block
finishing machine. Nothing in this description limits a transfer apparatus
including only one of, or both of, the pivoting and translating functions, or
any
features thereof, as described herein.
[0092] Referring to Figures 8-16, another example of an apparatus 302
is provided. Apparatus 302 can include a conveyor portion 310 that is both
pivotable in the vertical direction (like apparatus 102) and translatable in
the
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transverse direction (like apparatus 202) relative to other portions of the
book
block finishing machine. Aspects of the transfer apparatus 302 are similar to
those of the transfer apparatus 102 described above, and will be marked
using like reference characters in the 300 series. In the illustrated example,
the transfer apparatus 302 is configured as a multi-stream transfer apparatus
that is capable of handling four parallel streams of sheets 304, on four
parallel
conveyor belts 314. While only a single stream will be described in detail
herein, each stream can have some or all of the same features. Further, in the
illustrated example, the conveyor belt 314 comprises three separate conveyor
belts 314a, 314b, 314c (Figures 9, 16 and 18) that are spaced apart across
each stream. However, any suitable conveying mechanism can be used.
[0093] The downstream end 322 of the conveyor portion 310 also
includes some additional elements that are mounted on the conveyor portion
310 and movable in unison therewith. For example, referring to Figures 16
and 17 the apparatus 302 comprises a jogging mechanism 370 that can
oscillate in the machine direction to jog sheets 304 entering the hopper 308.
The apparatus 302 also includes a pair of air nozzles 372 that are operable to
inject pulses (or streams) of air between sequential ones of the sheets 304
entering the hopper 308. In the illustrated example, both jogging apparatus
370 and air nozzles 372 are symmetrical about the reference axis 354. In this
configuration, if the reference axis 354 is aligned with the centerline 356 of
the
sheets 304 on the conveyor 310, the jogging apparatus 370 and air nozzles
372 will be symmetrically aligned with the sheets 304 as they fall into the
hopper 308. In the illustrated example the jogging mechanism 370 is a
generally U-shaped, oscillating plate. Optionally, as illustrated, the jogging
mechanism can be configured so that portions of the jogging mechanism, for
example jogging arms 370a (Figure 15), extend into the space between
adjacent ones of the downstream pulleys 318 of the conveyors 314a-c.
Providing jogging arms 370a that are disposed between the conveyors 314a-c
may help inhibit sheets exiting the conveyors from getting caught between the
conveyors 314a-c as the sheets flow into the hopper 308.
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CA 02754497 2011-10-07
[0094] In these Figures, a plurality of sheets 304 being transferred by
the apparatus 302 is illustrated in a shingled stream (see Figures 9, 16 and
18, for example) in which only a portion of each sheet 304 is visible from
above. When the transfer apparatus 302 is in use, the sheets 304 can
continue in the shingled arrangement until they are deposited into the hopper
308. For clarity, the hopper 308 sidewall 309 (see Figure 15) located toward
the front of the illustrations has been removed from the drawing to enable the
book blocks 336 and downstream end 322 of the conveyor portion 310 to be
seen more clearly. In the assembled apparatus, the side wall 309 and other
apparatuses (glue heads, clamps, etc.) would be installed in the appropriate
locations.
[0095] The downstream end 322 of the transfer apparatus 302 is
pivotable in the vertical direction between a lowered position (Figures 9 and
10), one or more intermediate positions (or a continuously variable range of
positions, Figures 11 and 12) and a raised position (Figures 13 and 14). The
conveyor portion 310 is controllable (either manually or automatically) to be
moveable so that the conveyor spacing 330 remains generally constant,
despite the fact that the elevation of the top sheet 328 in the hopper 308
increases as sheets 304 accumulate in the hopper 308 to form the book block
336. Vertical movement of the downstream end 322 of the conveyor portion
310 can be controlled by a ball screw actuator 338.
[0096] The apparatus 302 is also translatable or shiftable in the lateral
direction. Referring to Figures 15 and 16, the downstream end 322 of
apparatus 302 is shown in a first lateral position to accommodate sheets 304
of a first width (in the transverse direction). In this example, the hopper
308 is
laterally sized to accommodate the sheets 304 such that the centerline 356 of
the sheets 304 is aligned with the hopper reference axis 366 (which is also
aligned with the hopper centerline). In this configuration, the conveyor
portion
310 is aligned so that the reference axis 354 of the conveyor portion 310 is
aligned with the lateral centerline 356 of the sheets 304 when the sheets 304
transferred from the upstream conveyor 306.
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[0097] Referring to Figures 17 and 18, the apparatus 302 is shown in a
second lateral position to accommodate relatively narrower sheets 304. When
handling narrower sheets (as explained in reference to Figure 7), the
centerline 356 of the sheets 304 can be closer to the near sidewall 309 of the
hopper 308, as illustrated (toward the left/bottom of Figures 17 and 18). To
align the reference axis 354 with the centerline 356 of the sheets 304, the
conveyor portion 310 has been shifted laterally, to the right as viewed in
Figures 15 and 17, or downward as viewed in Figures 16 and 18. In this
configuration, a side portion 368 of the conveyor portion 310, including a
portion of conveyor belt 314a, protrudes laterally beyond the side wall 309 of
the hopper 308.
[0098] Referring to Figure 12 and 19, to facilitate the pivoting motion,
the conveyor portion 310 is pivotally connected to longitudinally extending
side beams 382, using brackets 384 at the upstream pulley 316 and can pivot
about this point. In the illustrated example, the supporting table 326
includes a
transverse stiffening member 374 that is non-pivotally connected to the frame.
The stiffening member 374 can function as a fulcrum, or break, over which the
upper surface 376 (see Figure 18) of the table 326 can bend or flex (forming a
living hinge-like structure) to enable vertical movement of the downstream end
322. The downstream end 322 of the conveyor portion 310 is slidably
connected to and supported by a vertical rail 380.
[0099] To enable the lateral translation of the conveyor portion 310, in
combination with the vertical pivoting, the ends of side beams 382 supporting
the upstream end of the conveyor portion are slidably mounted on the
upstream horizontal rail 350a, and the downstream ends of the side beams
382 are slidably supported on the downstream horizontal rail 350b. This
enables the entire table 326 of the conveyor portion 310 to shift laterally.
In
addition, the vertical movement apparatus for supporting and driving the
downstream end 322 of the conveyor portion 310 is slidably mounted on the
downstream horizontal rail 350b. In the illustrated example, the vertical rail
380 is slidably mounted on the downstream horizontal rail 350b, so that the
vertical rail 380, related actuator 338, jogging mechanism 370 and air nozzles
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372 are all slidabie in the lateral direction, as well as being movable in the
vertical direction.
[00100] In the examples described herein the apparatus has been
illustrated as being configured to convey a single stream of sheets toward a
single hopper. Optionally, the apparatus can be configured to convey multiple,
parallel streams of sheets toward multiple hoppers in order to simultaneously
form multiple book blocks. Such multi-stream apparatuses can comprise
multiples of the features described herein where appropriate (e.g., multiple
conveyor belts to correspond to multiple streams, multiple actuators to move a
larger mass, etc.) but need not include multiples of all features (i.e., a
single
controller can be configured to operate a multi-stream transfer apparatus).
Any references made in the singular (i.e., a conveyor portion) are intended to
include the plural (i.e., a plurality of conveyor portions) where appropriate.
The
number of streams the apparatus is design to handle may be based on the
number of parallel streams of sheets that the book block binding machine is
configured to cut and stack. In multi-stream examples of the apparatus, the
apparatus may be operated as a single unit (i.e., all streams are
simultaneously pivoted or shifted), or each stream may be operated
independently (i.e., each conveyor portion can pivot and/or translate
independently of the other conveyor portions).
[00101] What has been described above has been intended to be
illustrative of the invention and non-limiting and it will be understood by
persons skilled in the art that other variants and modifications may be made
without departing from the scope of the invention as defined in the claims
appended hereto.
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