U.S. patent application number 10/353564 was filed with the patent office on 2003-06-19 for packing material product and method and apparatus for making, monitoring and controlling the same.
Invention is credited to Harding, Joseph J., Ratzel, Richard O..
Application Number | 20030114288 10/353564 |
Document ID | / |
Family ID | 46279411 |
Filed Date | 2003-06-19 |
United States Patent
Application |
20030114288 |
Kind Code |
A1 |
Harding, Joseph J. ; et
al. |
June 19, 2003 |
Packing material product and method and apparatus for making,
monitoring and controlling the same
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.
Inventors: |
Harding, Joseph J.; (Mentor,
OH) ; Ratzel, Richard O.; (Westlake, OH) |
Correspondence
Address: |
Christopher B. Jacobs
Renner, Otto, Boisselle & Sklar, LLP
Nineteenth Floor
1621 Euclid Avenue
Cleveland
OH
44115-2191
US
|
Family ID: |
46279411 |
Appl. No.: |
10/353564 |
Filed: |
January 29, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10353564 |
Jan 29, 2003 |
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09160127 |
Sep 24, 1998 |
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6524230 |
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09160127 |
Sep 24, 1998 |
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08943037 |
Oct 2, 1997 |
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08943037 |
Oct 2, 1997 |
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08597127 |
Feb 6, 1996 |
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5864484 |
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08597127 |
Feb 6, 1996 |
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08482015 |
Jun 7, 1995 |
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5897478 |
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08482015 |
Jun 7, 1995 |
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08279149 |
Jul 22, 1994 |
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Current U.S.
Class: |
493/464 |
Current CPC
Class: |
B31D 2205/0088 20130101;
B31D 5/0047 20130101; B31D 2205/007 20130101; B31D 2205/0047
20130101; B31D 5/006 20130101; G05B 23/0264 20130101; B31D
2205/0058 20130101; Y10S 493/967 20130101; B31D 2205/0023
20130101 |
Class at
Publication: |
493/464 |
International
Class: |
B31B 001/00 |
Claims
What is claimed is:
1. A monitoring system for monitoring one or more packaging
material conversion machines, the system comprising: at least one
sensor, wherein the at least one sensor monitors an operating
characteristic of the one or more packaging material conversion
machines and provides one or more signals indicative of the
operating characteristic; and a controller in communication with
the at least one sensor, wherein the controller evaluates the one
or more signals of the one or more packaging material conversion
machines.
2. The system of claim 1, wherein one of the one or more packaging
material conversion machines comprises a crimped strip packaging
material conversion machine for converting a sheet material into
elongated, crimped strips.
3. The system of claim 1, wherein one of the one or more packaging
material conversion machines comprises a cushioning pad conversion
machine.
4. The system of claim 1, further comprising a display coupled to
the controller for providing visual indicia of the operating
characteristic of the one or more packaging material conversion
machines.
5. The system of claim 1, wherein the at least one sensor is
selected from the group consisting of a bar code reader, a color
sensor, a paper quantity sensor, a temperature sensor, a shredding
motor sensor, a vibration sensor, a pressure sensor, a timer, a
shear force sensor and a container sensor.
6. The system of claim 1, wherein the operating characteristic of
the packaging material conversion machines are selected from the
group consisting of inventory data relating to a roll of sheet
material being used, a color or quantity of sheet material being
used, a quantity of sheet material that has been converted, a
performance quality of a shredding device, a status of the
shredding device, a temperature of one or more portions of the
conversion machine, a pressure exerted on a barrier, a shear force
exerted by a transverse cutting element and container data for
dispensing of a converted product from the conversion machine.
7. The system of claim 1, further comprising: a remote processor
for monitoring the operating characteristic of the one or more
packaging material conversion machines based on information
retrieved from the one or more packaging material conversion
machines; and a communication device for facilitating communication
between the controller and the remote processor.
8. The system of claim 7, wherein the communication device
comprises at least two modems, wherein one modem is local to the
remote processor and the other modem is local to the
controller.
9. The system of claim 1, further comprising one or more
controllers, wherein a controller is dedicated to each of the one
or more packaging material conversion machines.
10. The system of claim 1, further comprising a memory associated
with the controller for storing a value indicative of the operating
characteristic of the one or more packaging material conversion
machines.
11. A method of monitoring one or more packaging material
conversion machines, comprising the steps of: sensing an operating
characteristic of the one or more packaging material conversion
machines; and evaluating the operating characteristic of the one or
more packaging material conversion machines.
12. The method of claim 11, wherein evaluating the operating
characteristic comprises: converting the operating characteristic
into a signal; and comparing the operating characteristic to a
predetermined threshold.
13. The method of claim 12, further comprising the step of
providing a warning if the operating characteristic exceeds the
predetermined threshold.
14. The method of claim 12, further comprising the step of
providing a warning if the operating characteristic falls below the
predetermined threshold.
15. The method of claim 11, further comprising the step of storing
a value indicative of the operating characteristic in a memory.
16. The method of claim 11, further comprising the step of
displaying the operating characteristic on a display.
17. The method of claim 11, further comprising the step of
transmitting the operating characteristic to a remote site for
evaluation.
18. The method of claim 17, wherein transmitting comprises the
steps of: transmitting the operating characteristic along a
communication link via a modem; and receiving the operating
characteristic via a modem.
19. The method of claim 18, further comprising downloading the
operating characteristic to a memory at the remote site.
20. The method of claim 18, further comprising downloading the
operating characteristic to a display at the remote site.
21. The method of claim 11, wherein the step of sensing comprises
measuring an operating parameter.
22. The method of claim 11, wherein the step of sensing comprises
reading a code on packaging material being converted by the one or
more packaging material conversion machines.
23. A diagnostic system for performing real time diagnostics on a
crimping machine, the system comprising: a machine resident
monitoring system for controlling and monitoring operation of the
crimping machine; a remote processor for performing diagnostic
functions based on information retrieved from a crimping machine;
and a communication device for facilitating real time communication
between the monitoring system and the remote processor.
24. The diagnostic system of claim 23, wherein the monitoring
system comprises: a machine resident controller; and one or more
sensors for monitoring an operating characteristic of the crimping
machine and communicating one or more signals indicative of the
operating characteristic to the machine resident controller.
25. The diagnostic system of claim 24, further comprising memory
directly accessible by the machine resident controller.
26. The diagnostic system of claim 25, wherein the memory is
accessible by the remote processor through the machine resident
controller.
27. A crimping machine, comprising: a conversion assembly,
including a shredder, a feeder assembly and a crimping means; a
resident controller for controlling and evaluating operation of the
conversion assembly; a diagnostic device which monitors an
operating characteristic of the conversion assembly, and
communicates a signal indicative of the operating characteristic of
the machine to the resident controller.
28. A method of making crimped, elongate strip segments, said
method comprising the steps of: supplying a stock material;
providing a conversion machine including a shredder, a feeder
assembly and a crimping barrier for converting the stock material
into the crimped, elongate strip segments; using the conversion
machine to convert the stock material into the crimped, elongate
strip segments; monitoring the operational status of the machine;
generating signals in accordance with such status; and
communicating the generated signals in real time to a remote
processor.
29. A method as set forth in claim 28, wherein the communicating
step comprises transmitting the generated signals to a personal
computer.
30. A method as set forth in claim 28, wherein said communicating
step comprises automatically transmitting the generated signals to
the remote processor.
31. A method as set forth in claim 28, wherein the communicating
step is performed while the shredder, feeder assembly and crimping
barrier are active.
32. A method as set forth in claim 28, wherein the supplying step
comprises supplying stock material that is biodegradable,
recyclable and reusable.
33. A diagnostic system for performing real time diagnostics at a
remote service station on a conversion machine at a packaging site,
the system comprising: a machine resident controller, resident in
the conversion machine, for controlling and monitoring operation of
the machine; a remote processor, at the remote service station, for
performing diagnostic functions based on information retrieved from
the machine resident controller; and a communication device for
facilitating real time communication between the machine resident
controller and the remote processor, whereby skilled personnel at
the remote service station may perform real time diagnosis on the
conversion machine at the packaging site.
34. In combination, a conversion machine at a packaging site and a
diagnostic system for performing real time diagnostics on the
conversion machine at a remote service station, the combination
comprising: a conversion assembly which converts a stock material
into crimped, elongate strip segments; a controller, resident near
the conversion machine, for controlling and monitoring operation of
the conversion assembly, determining a status of the conversion
assembly, and generating signals in accordance with such status; a
remote processor at a remote service station; and a communication
device for communicating the status of the conversion assembly to
the remote processor, whereby a skilled personnel at the remote
service station may perform real time diagnostics on the conversion
machine.
35. A combination as set forth in claim 34, wherein the
communication device communicates the status of the conversion
assembly in real time.
36. A combination as set forth in claim 34, wherein the conversion
assembly comprises a shredder, a feeder assembly and a crimping
barrier.
37. A method of making crimped, elongate strip segments, said
method comprising the steps of: providing a conversion machine
including a conversion assembly for converting stock material into
the crimped, elongate strip segments at a packaging site;
activating the conversion assembly to convert the stock material
into the crimped, elongate strip segments at the packaging site;
monitoring the operational status of the conversion assembly at the
packaging site; generating signals in accordance with such status
at the packaging site; and communicating the generated signals to a
remote processor at a remote service station, whereby a skilled
personnel at the remote service station may perform diagnostics on
the conversion machine.
38. A method as set forth in claim 37, wherein the step of
communicating the generated signals to the remote processor is
performed in real time, thereby allowing the skilled personnel at
the remote site to perform diagnostics in real time.
39. A method as set forth in claim 37, wherein the communicating
step comprises transmitting the generated signals to a personal
computer at the remote service station.
40. A method as set forth in claim 37, wherein said communicating
step comprises automatically transmitting the generated signals to
the remote processor at the remote service station.
41. A method as set forth in claim 37, wherein the communicating
step is performed while the conversion assembly is active.
42. A method as set forth in claim 37, further comprising the step
of supplying stock material to the conversion assembly that is
biodegradable, recyclable and reusable.
43. A monitoring system, comprising: one or more packaging material
conversion machines; and a controller in communication with the one
or more packaging material conversion machines for evaluating one
or more operating characteristics of the packaging material
conversion machines.
44. The monitoring system of claim 43, wherein the one or more
operating characteristics is selected from the group consisting of
an on/off/idle status of a shredder motor, an on/off/idle status of
a sheet material feeder motor, an accumulated run time of one or
more components, an electric safety interlock status and a status
of one or more safety circuits.
45. The monitoring system of claim 43, further comprising one or
more sensors for monitoring the one or more operating
characteristics of the one or more packaging material conversion
machines.
46. The monitoring system of claim 43, further comprising: a remote
processor for monitoring the one or more operating characteristics
of the one or more packaging material conversion machines based on
information received from the one or more packaging material
conversion machines; and a communication device for facilitating
communication between the controller and the remote processor.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-owned U.S.
patent application Serial Nos. 08/482,015 and 08/279,149, filed
Jun. 7, 1995 and Jul. 22, 1994, respectively, both entitled,
"Cushioning Conversion Machine" and incorporated herein by this
reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a resilient packing
material or the like and to the method and apparatus for making the
same. More particularly, this invention relates to an apparatus and
method having a controller which can be used to monitor a number of
different machines and to record and perform machine
diagnostics.
BACKGROUND OF THE INVENTION
[0003] Styrofoam pellets or peanuts are commonly used within the
wholesale and retail industries as bulk packaging material. The
peanuts are used to position a product away from the interior sides
of a container and fill the empty space located therebetween. The
peanuts are intended to protect the packaged product against the
impact of a blow or other mistreatment.
[0004] Dispensing styrofoam peanuts does not require a great degree
of sophistication. The peanuts are simply gravity fed from large
retainer bins into the empty spaces within a packaging container.
Use of styrofoam peanuts, however, has many drawbacks. For example,
if styrofoam peanuts are used to protect a heavy object placed
within a container, and such package is jostled or shaken, the
object usually gravitates toward the bottom of the container and
the peanuts float upward. Eventually the object comes to rest
against the base or side of the container and damage to the object
may occur. The light weight of the styrofoam peanuts also allows
them to be easily blown by the wind and scattered. The styrofoam
peanuts also create static electricity, causing the peanuts to
cling to the protected articles after the articles are removed from
their containers. Further, the peanuts may create an electrostatic
discharge (ESD) which can cause damage to sensitive electronic
components.
[0005] Of particular concern, styrofoam peanuts are extemely
difficult to dispose of and destroy after use. In fact, because of
the extensive use of this nonbiodegradable product, which emits
toxic gases if burned, styrofoam peanuts present a major threat to
the environment and are being banned from an increasing number of
communities. Styrofoam peanuts are also dangerous to children and
to wildlife who often mistake them as food and consequently ingest
them. Styrofoam peanuts are not digestible and are a major source
of tracheal blockage in children.
[0006] Other packaging filler materials, such as shredded paper,
have also been used. Shredded paper, however, usually lays flat
within the container and a large amount of paper is required to
provide the bulk needed to fill the voids and to protect the
contained object. To provide such a large amount of shredded paper
is often cost prohibitive and, following its use, such voluminous
amounts of paper must be disposed. In addition, the shock
absorbency of flat, shredded paper is minimal.
[0007] U.S. Pat. No. 5,403,259, which is hereby incorporated by
reference, is directed toward an apparatus and method for rapidly
producing large quantities of bulk packaging material comprising
folded and crimped, interlocking strips of sheet material which may
be used as resilient padding to cushion and prevent heavier objects
from gravitating toward the bottom or sides of a container. The
apparatus and method provides for the production of selectable
lengths, the smaller lengths capable of being gravity fed into
containers to fill voids and larger lengths capable of being
wrapped around a product to provide a secure, protective cushion.
The method and apparatus is also operable to produce such folded
and crimped, interlocking strips of sheet material in selectable
colors and/or controlled color combinations for decorative and
aesthetic purposes. Furthermore the apparatus and method allows for
the manufacture of such strips from biodegradable material, such as
pulp material (i.e., paper, cardboard, or the like).
[0008] Due to the increased popularity of paper protective
packaging material, additional, automated control mechanisms to
operate and/or monitor such packaging material construction, would
be desirable. Consequently, it would be desirable to provide a
single controller which could monitor a variety of machine types
without substantial adjustments or modifications to the controller.
It would also be desirable for a controller to collect and to store
diagnostic information and to perform enhanced and automated
packaging functions.
SUMMARY OF THE INVENTION
[0009] The present invention provides a packing product and method
and apparatus for making the same having a monitoring system
including a controller suitable for use in monitoring and providing
diagnostics for one or more conversion machines with little or no
change required of the controller. The controller associated with
the one or more conversion machines communicates with various
sensors and measuring devices to greatly increase the information
available to a user or technician either local to or remote from
the one or more conversion machines for recording machine and stock
material usage and aiding in diagnostic evaluation and other
functions.
[0010] The controller monitors one or more operating
characteristics of the one or more conversion machines. Exemplary
operating characteristics include inventory data relating to a roll
of sheet material being used, data relating to a treatment of the
sheet material, a color of the sheet material being used and a
quantity of sheet material that has been converted. Additional,
exemplary operating characteristics that may be monitored by the
monitoring system include a performance quality of a shredding
device, a status of the shredding device, a temperature of one or
more portions of the conversion machine, a pressure exerted within
a restricting region, a shear force exerted by a transverse cutting
element and container data for dispensing of a converted product
from the conversion machine into a container.
[0011] According to one aspect of the present invention, a
cushioning conversion machine having a controller for monitoring
the cushioning conversion machine is disclosed. The controller is
suitable for use in a variety of different configurations of the
cushioning conversion machine with little or no change required of
the controller. The controller includes a number of output ports
for controlling the function of the cushioning conversion machine
regardless of the cutting assembly employed or the operation mode
selected for the controller. The cushioning conversion machine
preferably includes a controller which communicates with various
sensors and measuring devices to greatly increase the information
available to the controller for recording and aiding in diagnostic
and other functions.
[0012] In accordance with another aspect of the present invention,
an apparatus and method for rapidly producing and monitoring large
quantities of bulk packaging material comprising folded and
crimped, interlocking strips of sheet material is disclosed. In
this particular embodiment of the present invention, sheet material
is cut into a plurality of longitudinal strips. The advancement of
the strips is restricted to cause the strips to fold against
themselves in a relatively controlled manner, thereby repetitively
folding, crimping or creasing each strip. The monitoring system of
the present invention is operable to monitor one or more of the
operating characteristics of the apparatus and method and provide
diagnostic information to a user either local to or remote from
manufacturing site.
[0013] The monitoring system, via the controller, is operable to
monitor each of the above discussed features of one or more
conversion machines as well as other conversion machine operating
characteristics. For example, the controller is operable to monitor
the pressure exerted by the accumulated body of strips to ensure
that the shredding device does not become jammed. In addition, the
controller monitors the status of the shredding blades to ensure
that the blades are properly aligned and maintained. Further, the
controller may monitor the shearing force exerted by a shearing
device used to cut the elongated strips into strip segments, (if
employed). Further still, the controller is operable to monitor the
amount of total paper and/or the various amounts of different
colored paper used for inventory control and/or marketing purposes.
Lastly, the controller is operable to monitor the timing of machine
operation and the stability or vibrational modes of the conversion
machine to ensure that any wear or failure mechanisms are
pro-actively addressed before a machine failure occurs. The
controller is operable to monitor one or more of the above
conversion machine characteristics and provide visual and/or
audible indications of such characteristics via a display.
[0014] The controller may be utilized local to one or more
conversion machines by a user or alternatively they may be
monitored remotely via a data communication port and a
communication apparatus such as a modem. With remote monitoring,
multiple conversion machines at various locations can be easily and
efficiently monitored.
[0015] To the accomplishment of the foregoing and related ends, the
invention comprises the features hereinafter fully described and
particularly pointed out in the claims. The following description
and the annexed drawings set forth in detail certain illustrative
embodiments of the invention. Theses embodiments are indicative,
however, of but a few of the various ways in which the principles
of the invention may be employed. Other objects, advantages and
novel features of the invention will become apparent from the
following detailed description of the invention when considered in
conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] In the annexed drawings:
[0017] FIG. 1 is an illustration of a cushioning conversion
machine;
[0018] FIG. 2 is a block diagram of a universal controller for a
cushioning conversion machine;
[0019] FIGS. 3 through 8 are electrical schematic diagrams of an
embodiment of the universal controller;
[0020] FIG. 9 is a block diagram of a controller for a cushioning
conversion machine with enhanced diagnostic capabilities;
[0021] FIG. 10 is a front view of a length measuring device and
other relevant portions of the cushioning conversion machine;
[0022] FIG. 11 is a side view of the length measuring device;
[0023] FIG. 12 is a block diagram of a controller including a code
reader for reading information from stock paper and a container
probe for determining packaging information from a container to
which packaging is to be added;
[0024] FIG. 13 is a block diagram of a fault tolerant cushioning
producing network;
[0025] FIG. 14 is an illustration of two cushion producing machines
positioned at either end of a conveyor and communicating via a
network;
[0026] FIG. 15 is a simplified, isometric view of strips of
shredded paper as found in the prior art;
[0027] FIG. 16 is a simplified, isometric view of a plurality of
folded, crimped, interlocking strips of shredded sheet material as
produced by the present invention;
[0028] FIG. 17 is a simplified, isometric view of a plurality of
folded, crimped, interlocking strip segments of shredded sheet
material which is a product of the present invention;
[0029] FIG. 18 is a partial, cross-sectional, side elevational view
of one embodiment of the present invention, wherein a conversion
machine is monitored by a universal controller and a plurality of
sensors;
[0030] FIG. 19 is a partial, cross-sectional, side elevational view
of the apparatus shown in FIG. 18, wherein the gate of the
conversion machine is urged away from its closed position;
[0031] FIG. 20 is a fragmentary, sectional side elevational view of
a controllable feeder apparatus according to one embodiment of the
present invention;
[0032] FIG. 21 is a side fragmentary, sectional side view of a
controllable feeder apparatus that is integrated with the
conversion machine;
[0033] FIG. 22 is a block diagram of the controller according to an
embodiment of the present invention; and
[0034] FIG. 23 is a block diagram of the controller coupled to a
remote processor according to another embodiment of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The present invention provides a packing product and method
and apparatus for making the same having a monitoring system
including a controller suitable for use in monitoring and providing
diagnostics for one or more conversion machines with little or no
change required of the controller. The controller associated with
the one or more conversion machines also communicates with various
sensors and measuring devices to greatly increase the information
available to a user or technician either local to or remote from
the one or more conversion machines for recording machine and stock
material usage and aiding in diagnostic evaluation and other
functions.
[0036] The controller monitors one or more operating
characteristics of the one or more conversion machines. Exemplary
operating characteristics include inventory data relating to a roll
of sheet material being used, data relating to a treatment of the
sheet material, a color of the sheet material being used and a
quantity of sheet material that has been converted. Additional,
exemplary operating characteristics that may be monitored by the
monitoring system include a performance quality of a shredding
device, a status of the shredding device, a temperature of one or
more portions of the conversion machine, a pressure exerted within
a restricting region, a shear force exerted by a transverse cutting
element and container data for dispensing of a converted product
from the conversion machine into a container. Further, the
controller may store machine information such as a serial number,
software revision number and date, physical site location, customer
data and a conversion machine number or identifier. Other,
additional information, as needed or desired, may also be
evaluated, monitored and/or stored.
[0037] The present invention is applicable to many types of
packaging material conversion machines. For example, with reference
to the drawings and initially to FIG. 1, there is shown a
cushioning conversion machine 10 including a frame 12 upon which
the various components of a conversion assembly 14 are mounted and
a controller 16 (illustrated schematically) for controlling the
machine including the components of the cushioning assembly. The
frame 12 includes a stock supply assembly 18 which holds a roll of
stock for conversion by the conversion assembly 14 into a
cushioning material. The conversion assembly 14 preferably includes
a feed assembly 19 which includes a forming assembly 20 and a gear
assembly 22 powered by a feed motor 24, a cutting assembly 26
powered by, for example, a cut motor 28 selectively engaged with
the cutting assembly by an AC solenoid driven clutch 30 and a post
cutting constraining assembly 32.
[0038] During the conversion process, the forming assembly 20
causes the lateral edges of the stock material to roll inwardly to
form a continuous strip having two lateral pillow-like portions and
a central band therebetween. The gear assembly 22 performs a
"pulling" function by drawing the continuous strip through the nip
of two cooperating and opposed gears of the gear assembly thereby
drawing stock material through the forming assembly 20 for a
duration determined by the length of time that the feed motor 24
rotates the opposed gears. The gear assembly 22 additionally
performs a "coining" or "connecting" function as the two opposed
gears coin the central band of the continuous strip as it passes
therethrough to form a coined strip. As the coined strip travels
downstream from the gear assembly 22, the cutting assembly 26 cuts
the strip into sections of a desired length. These cut sections
then travel through the post-cutting constraining assembly 32.
[0039] The controller 16 is preferably "universal" or capable of
use in a number of differently configured cushioning conversion
machines without requiring substantial change to the controller.
Accordingly, one configuration of a universal controller 16 can
thus be manufactured for a variety of different cushioning
conversion machines. The assembly technician then need not adapt
the controller 16 to a specific configuration of the cushioning
machine, such as when one of the particular cushioning machines is
adapted to use an air powered cutting assembly, a direct current
powered solenoid cutting assembly, or a motor driven cutting
assembly. The capability of the universal controller to control
differently configured machines reduces assembly time, reduces
assembly cost since the labor cost in specifically configuring a
controller often outweighs the cost of assembling unused electrical
components in the controller and reduces the possibility of
assembly error. Moreover, repair of the machine is facilitated
since training of the repair technician is minimized and since an
inventory of universal controllers for use in a variety of
cushioning machines can be maintained.
[0040] An exemplary universal controller 16 is illustrated in FIG.
2 and includes a number of different output ports 36, 38, 40, 42,
44 and 46 devoted to providing a control signal from a
microprocessor 48 to a DC shear solenoid, an AC control solenoid, a
cut motor, a feed motor, a counter and a spare port, respectively,
in accordance with a number of inputs 50. While the microprocessor
48 is illustrated and described herein as a single device, it is
noted that microprocessor 48 may be embodied as a number of
microprocessors or control units of the same type or as different
microprocessors adapted for performing certain functions. The DC
shear solenoid, controlled by the microprocessor 48 through DC
shear solenoid port 36, powers a cutting blade positioned at the
output of a cushioning conversion machine. When the DC shear
solenoid is provided power by a control signal sent through the
port 36, the solenoid actuates a cutting blade to force the blade
through the dunnage to make a cut. One machine employing a cutting
assembly powered by a DC solenoid is marketed by Ranpak Corp. under
the name PadPak.RTM. and is disclosed in U.S. Pat. No. 4,968,291
which is incorporated herein by this reference.
[0041] The AC control solenoid port 38 controls an external AC
solenoid which is typically used in conjunction with either an
air-powered cutting assembly or a motor powered cutting assembly.
When a cushioning conversion machine including the universal
controller 16 employs an air-powered cutting assembly, the cutting
assembly uses the AC solenoid to control the supply of pressurized
air to an air cylinder which drives a cutting blade to shear off a
section of dunnage fed through the machine. A cushioning conversion
machine employing an air-powered cutting assembly is marketed under
the name PadPak.RTM. by Ranpak Corp. and disclosed in U.S. Pat. No.
4,968,291 which has been incorporated herein above. The AC control
solenoid port 38 may also be used to control an AC solenoid which
acts to couple the direct drive cut motor 28 to the cutting
assembly 26 via the clutch 30 to drive a cutting blade through a
cutting stroke to cut a section of dunnage material fed through the
machine. One such machine is marketed by Ranpak Corp. under the
name AutoPad.RTM. and is disclosed in U.S. Pat. No. 5,123,889 which
is also incorporated herein by this reference. In this embodiment
of a cushioning conversion machine, the cut motor port 40 is used
to supply a signal to the cut motor 28 to ensure that the cut motor
is running when a cut is desired.
[0042] In any of the embodiments of a cushioning conversion machine
described above, there is employed some means for moving the paper
material through the machine to create the dunnage material. The
PadPak.RTM. and AutoPad.RTM. machines referenced above employ the
feed motor 24 which turns the enmeshed gears 22 that grip the paper
stock and feed it through the machine where the appropriate
conversion of the sheet-like stock to a dunnage product and the
cutting of the dunnage product into appropriate lengths takes
place. The universal controller 16 controls the feed motor 24
through the feed motor port 42. When it is desired that an
appropriate length of paper be fed through the cushioning
conversion machine by the feed motor 24, the microprocessor 48
sends a signal through the feed motor port 42 which causes power to
be supplied to the feed motor for as long as the signal is present.
When the microprocessor 48 has determined that the desired length
of paper stock has been fed through the machine 10, the signal is
disabled causing the feed motor 24 to stop and the supply of paper
through the machine to stop. At this time the microprocessor 48
will determine, based on the position of the mode selection switch
52 and the condition of the input signals 50, whether to initiate a
cut of the dunnage material fed through the machine 10, as is
described more fully below.
[0043] Depending upon the embodiment of the cushioning conversion
machine 10, the universal controller 16 may also use the counter
port 44 to control a counter which keeps track of the machine usage
or a spare port 46 which can be used to provide command signals to
some other device.
[0044] While the universal controller 16 includes the output ports
36 through 46 for the control of the feed motor 24 and a variety of
cutting assemblies, in most applications less than all of the ports
will be used. For example, when the universal controller 16 is used
to control a cushioning conversion machine having a DC shear
solenoid powered cutting assembly, such as the PadPak.RTM. machine
mentioned above, the DC shear solenoid port 36 is used while the AC
control solenoid port 40 and the cut motor port 16 will not be
used. When the universal controller 16 is used to control a machine
10 having an air powered cutting assembly, the AC control port 38
is employed to control the AC control solenoid, and the DC shear
solenoid port 36 and the cut motor port 40 may be unused.
Similarly, when the universal controller 16 is used in conjunction
with a cushioning conversion machine using the cut motor 28 to
actuate the cutting assembly 26, such as the AutoPad.RTM. machine
mentioned above, the AC control solenoid port 38 and cut motor port
40 will be used to control and power the cutting assembly 26 while
the DC shear solenoid port 36 will be unused. Preferably, the
microprocessor 48 will more or less simultaneously cause
appropriate signals to be sent to each of the respective output
ports 36, 38, 40 regardless of the actual cutting assembly employed
with a machine. In this way the microprocessor 48 does not need to
be informed of this aspect of the configuration of the machine and
the cutting assembly 26 connected to a port will thus be the one
that responds to a signal sent from the microprocessor without the
microprocessor having to distinguish which type of cutting assembly
is employed.
[0045] Control of the various devices, such as the DC shear
solenoid and the cut and feed motors, is performed by the
microprocessor 48 in accordance with certain inputs 50 which are
indicative of the operating condition of the cushioning conversion
machine 10 and certain events which may have been sensed. The
inputs 50 also include an indication of the operating mode for the
cushioning conversion machine selected through the mode selection
switch 52, such as a rotary switch. The mode selection switch 52
includes a number of settings corresponding to different operating
modes, for example, keypad mode, electronic dispensing system mode,
automatic cut mode, feed cut foot switch mode, and automatic feed
mode. The mode setting of the controller 16 as well as a number of
error signals may be displayed as alphanumeric codes on the display
54. For example, a display code of `1` may indicate to an operator
that the machine 10 is operating in the automatic feed mode, while
a display of "A" may indicate that an error has occurred in the
buttons used to manually command a cut.
[0046] The keypad mode is for cushioning conversion machines which
are equipped with a keypad through which an operator may input the
length of each pad which she desires the machine to produce by
depressing the appropriate key on the keypad. In this mode,
regardless of the cutting assembly employed, the microprocessor 48
provides a signal to the feed motor through the feed motor port 42
to feed material through the machine for the appropriate length of
time to provide dunnage of the length which the operator selected
through the keypad. The keypad buttons are preferably
pre-programmed so that each button corresponds to a particular cut
length. For example, if an operator pushes button 12 on the keypad,
and this button was preprogrammed to correspond to a length of 12
inches, the microprocessor 48 will signal the feed motor 24 and
turn the feed motor on for a length of time that equates to 12
inches of dunnage material being fed out, and then the
microprocessor will disable the feed motor. Upon completion of the
dunnage material of the selected length being fed through the
machine, the microprocessor 48 automatically commands the cutting
assembly 26 employed, through the output ports 36, 38, and 40, to
perform a cut. The microprocessor 48 then waits for the next key on
the keypad to be depressed and repeats the process to produce a
length of dunnage corresponding to the key depressed.
[0047] When the electronic dispensing system (EDS) mode setting is
selected on the mode selection switch 52, an external electronic
dispensing sensor is employed to detect the presence or absence of
a dispensed length of dunnage material. The information as to the
presence or absence of dunnage material is provided to the
microprocessor 48 through one of the inputs 50. If the sensor
detects that there is no dunnage material left at the cutting area
of the machine, this information is passed to the microprocessor 48
which will send a signal to the feed motor 24 through the feed
motor port 42 to feed out a certain length of material. The length
of material to be fed through the machine 10 is determined by the
setting of a thumb wheel, which is described below, as reported to
the microprocessor 48 over one of the inputs 50. Once material is
fed through the machine 10 and emerges at the cutting exit, the
electronic dispensing sensor will report to the microprocessor 48
the presence of the dunnage material at the cutting exit of the
machine. After the complete length of material has been fed through
the machine 10 by the feed motor 24, the microprocessor 48 will
wait a short period of time to allow the feed motor to stop and
will then send a signal over the necessary output ports to command
a cut to be performed by the attached cutting assembly 26. The
electronic dispensing assembly will continue to report to the
microprocessor 48 the presence of the dunnage material at the exit
of the machine until the material is removed. Upon removal of the
material, the sensor will report the removal to the microprocessor
48 through the inputs 50 whereupon the microprocessor will send a
signal to the feed motor 24 again to feed another length of dunnage
material through the machine and once the feed is complete the
microprocessor will send a signal over the required output ports to
cause the cutting assembly 26 to cut the material. This process
will continue as long as the operator continues to remove the cut
dunnage from the exit area of the machine.
[0048] The automatic cut mode selection on the selector switch 52
causes the microprocessor 48 to perform basically the same process
set forth above for the EDS mode with the exception that an
operator need not remove a length of dunnage material from the
machine in order for the next length to be fed through the machine
and cut. In this mode the microprocessor 48 commands the feed motor
24 through the feed motor port 42 to feed material through the
machine for a length of time determined by the setting of the thumb
wheel. Once the desired length of material has been fed through the
machine, the microprocessor 48 will disable to signal to the feed
motor 24, will wait a short period of time to allow the feed motor
to stop and then will send the appropriate signals to the output
ports 36, 38, 40 controlling the respective cut assemblies 26. The
microprocessor 48 will cause predetermined lengths of material to
be fed and cut by the machine continuously in this mode unless a
predetermined number of lengths has been selected by the
operator.
[0049] When the feed cut foot switch mode is selected on the mode
selection switch 52, the control of the machine by the
microprocessor 48 will be as instructed by an operator actuated
foot switch. When an operator depresses the foot switch, an input
indicating the fact is sent to the microprocessor 48 through one of
the inputs 50. In response, the microprocessor 48 will send a
signal to the feed motor 24 through the feed motor port 42 to feed
material through the machine. The signal sent to the feed motor 24
by the microprocessor 48 will continue until the operator lets the
pressure off of the foot switch at which time the microprocessor
will disable the signal to the feed motor, will wait a short period
of time to allow the feed motor to stop and then will send a signal
to the output ports 36, 38, 40 operating the cutting assemblies 26
to cut the material fed through the machine.
[0050] The fifth mode of the mode selection switch 52 is the auto
feed mode. In the auto feed mode the microprocessor 48 signals the
feed motor 24 through the feed motor port 42 to feed a length of
paper through the machine as determined by the position of the
thumb wheel. After the appropriate length of dunnage material has
been fed through the machine, the microprocessor will pause until a
cut is manually requested. In this mode the operator must then
instruct the microprocessor to signal the cut assembly to perform a
cut. The operator preferably causes a cut to occur by manually
depressing two cut buttons simultaneously. When the buttons have
been depressed, both inputs are sent to the microprocessor 48 over
the input lines 50 and, provided the buttons have been pushed near
simultaneously, the microprocessor will send a signal through the
appropriate outputs to the cutting assembly 26 employed on the
machine to cut the material. After a cut has been completed, the
microprocessor 48 will again send a signal to the feed motor 24 to
cause the selected length of material to be fed through the machine
and will then wait for the operator to instruct that a cut be
made.
[0051] An embodiment of the universal controller 16 described above
is shown in the schematic circuit diagram of FIGS. 3 through 8.
Turning first to FIGS. 3 through 5, the interaction between the
microprocessor 48 and output ports 36 through 46 is shown. The
microprocessor 48 may be any one of a number of commercially
available general purpose processing chips and preferably one
suitable for convenient interface with the output ports 36 through
46 and the inputs 50 through a storage memory 60, such as a
programmable peripheral device that may include ROM, RAM and I/O
ports. The microprocessor 48 is also provided with keypad inputs 62
to which a keypad may be attached when the universal processor 16
is desired to operate in the keypad mode. To control the various
output ports the microprocessor stores the appropriate signal value
in a location in the memory 60 accessible to the appropriate output
port. For example, to send a signal to the feed motor 24 through
the feed motor port 42, the microprocessor 48 will place the
desired signal value in a location in the memory 60 accessible by
the line 62, to send a signal to the cut motor 28 through the cut
motor port 40 the signal value will be placed in a location
accessible by the line 66, and to send a signal to the DC shear
solenoid through the DC shear solenoid port 36 or to the AC control
solenoid through the AC control solenoid port 38 the signal value
is placed in a memory location accessible by the line 64. When a
control signal is sent to the feed motor port 42 to cause the feed
motor 24 to run, an hour meter 68 may also be activated which keeps
track of the run time of the cushioning conversion machine. To
control the spare output port 46 or the counter port 44 (see FIG.
5), the microprocessor 48 places a signal value in a location in
the memory 60 accessible by these ports or devices.
[0052] It is noted that since the cushioning conversion machine 10
in which the universal controller 16 is employed will be used with
only one cutting assembly 26, the output ports which control a
cutting assembly may be shared by different types of cutting
assemblies, for example the AC control solenoid port 38 may control
an air powered cutting assembly or the engagement clutch 30 of the
cut motor 28 powered cutting assembly 26, or a single control line
may control more than one output port as the control line 64 is
shown to control both the DC shear solenoid port 38 and the AC
control solenoid port 14. Further, while only a single cutting
assembly 26 is employed by a machine 10 at a time, more than one
control line may be used to control a single cutting assembly or to
provide other control over the machine. In the instance where the
cushioning conversion machine 10 is employed with a cut motor 28,
both the control lines 64 and 66 are used to actuate a cut. The
control line 66 instructs the cut motor 28 through the cut motor
port 40 to run while the control line 64 instructs the AC control
solenoid through the AC control solenoid port 38 to engage the
clutch 30 coupling the cut motor 28 and the cutting blade assembly
26. The control lines 62 and 64 are also used cooperatively to
ensure that the feed motor 24 is not operating when a cut has been
initiated as this may cause the dunnage material to become jammed
in the machine. A pair of transistors 70 and 72 are interconnected
with the control lines 62 and 64 so that the feed motor 24 and a
cutting assembly 26 cannot both be actuated simultaneously as the
presence of a signal on one control line disables the other control
line.
[0053] The inputs 50 to the microprocessor 48 are generated through
a variety of circuits as shown in FIGS. 6 through 8. FIG. 6
illustrates the thumb wheel circuit 76 discussed above. A two-digit
thumb wheel 78 is coupled to the input bus 50 via the bus interface
80 and control line 82 and allows the operator to select the time
during which the microprocessor 48 will command the feed motor 24
via control line 62 and feed motor port 42 to run, and thus the
length of dunnage material to be fed through the machine, during
the EDS mode, automatic cut mode and the automatic feed mode. The
selected feed length is sent to the microprocessor 24 over the
input bus 50. Shown in FIGS. 6 through 8 are a number of current
sensing circuits which provide additional inputs over the input bus
50 that inform the microprocessor 48, through the memory 60, of
various, operating events of the cushioning conversion machine,
e.g. whether a cut has been completed, whether the foot switch is
depressed or whether a cut button has been depressed, etc, as well
as the selected mode of operation for the universal controller
16.
[0054] The current sensing circuits are each of a similar
construction but sense unique occurrences. An exemplary current
sensing circuit generally includes a contact 84 which receives
current when a particular event specific to that sensing circuit
occurs. When such an event occurs, current passes through the
contact 84 to a capacitor 86 connected in electrical parallel to a
pair of diodes 88 of an opto-coupler 90 arranged in reverse
parallel. When current is detected across the diodes 88, indicating
that the event which the particular sensing circuit is designed to
sense, light from the diodes turns on the phototransistor 92 which
causes the transistor to input 98 to the bus interface 100. The bus
interface 100 provides the appropriate input to the memory 60 over
the input bus 50 as controlled by control line 102.
[0055] Turning then to the specific sensing circuits, the sensing
circuit 104 (RELAYS ON) detects whether the cushioning conversion
machine has been reset and whether all safety switches are closed
indicating that the cover, etc., of the machine is closed. The
status of the detection is then sent to the microprocessor 48 via
the memory 60 as an input on the input bus 50.
[0056] The circuit 106 (FEED REV) senses when an operator has
pressed a reverse push button which allows the operator to reverse
the rotation direction of the feed motor 24. The purpose of the
feed reverse function is to provide a means for clearing a dunnage
material jam. Oftentimes, the jammed dunnage can be cleared by
simply reversing the feed motor and pulling the dunnage material
away from the cutting assembly where jams most often occur. The
status of this sensing circuit 106 is also reported to the
microprocessor 48 over the input bus 50 through the memory 60.
[0057] The circuit 108 (CUT COMP) senses the status of a cut
complete switch. Cutting assemblies using a DC solenoid to drive a
cutting blade have an attribute of heating up quickly as power is
continually applied to the solenoid. When such a solenoid heats up
too much, it loses power and cannot cut as effectively as it can
when in a cooler state. The cut complete switch detects whether a
cut of the dunnage material has been completed. The sensing circuit
108 senses the status of the cut complete switch and reports the
status to the microprocessor 48 so that the microprocessor can
immediately discontinue the supply of power to the DC shear
solenoid by sending an appropriate signal to the DC shear solenoid
port 36 over the control line 64.
[0058] The position of the foot switch used when the universal
controller 16 has been set to the feed cut foot switch mode is
sensed by the sensing circuit 110 (FEED FS). The sensing circuit
110 senses the position of the foot switch and reports the position
to the microprocessor 48. As discussed above, when in the foot
switch mode, if the foot switch is depressed, the microprocessor 48
will signal the feed motor 24 through the feed motor port 42 and
control line 62 to continually feed paper through the machine 10
while the foot switch is depressed. Upon the pressure on the foot
switch being released, the sensing circuit will report to the
microprocessor 48 that the foot switch has been released and the
microprocessor will discontinue the signal to the feed motor
causing the feed motor to stop and then the microprocessor will
send out a signal to the output ports 36, 38 and 40 over the
control line 64 and 66 prompting the attached cutting assembly 26
to perform a cut.
[0059] The circuit 112 (BLADE) senses the status of a blade switch.
The blade switch detects whether the knife blade is in its normal
at rest position or if the knife blade is at some other point, such
as partially through a cut. If the knife blade is at its rest
position, it is safe to feed paper through the machine 10,
otherwise if the knife blade was partially through a cut and paper
was fed, the paper could feed into the blade and jam the machine.
The position of the knife blade as sensed by the circuit 112 is
reported to the microprocessor 48 which will disable signals to the
feed motor 24 until the circuit 112 has sensed that the knife blade
has returned to its rest position.
[0060] The circuit 114 (EDS SEN) senses the presence or absence of
dunnage material at the cutting assembly 26 area of the cushioning
conversion machine 10 and reports the information to the
microprocessor 48. When the universal controller 16 is in the EDS
mode, the microprocessor 48 will automatically signal the feed
motor 24 to feed a length of dunnage material determined by the
thumb wheel circuit 76 (FIG. 6) through the machine 10 and signal
the attached cutting assembly 26 to cut the material after the
appropriate length has been fed whenever the circuit 114 senses
that the last length of dunnage material fed has been removed from
the exit area.
[0061] Continuing the description of the sensing circuits with
reference to FIG. 8, the sensing circuits 116 (L-CUT), 118 (R-CUT)
and 120 (COM-CUT) correspond to three push buttons located on the
cushioning conversion machine 10 which allow for the operator to
manually cause the cutting assembly 26 to cut the dunnage material
fed through the machine 10. These circuits are recognized by the
microprocessor 48 when the universal controller 16 is in the auto
feed mode of operation. As a safety measure it is preferable that
the microprocessor 48 detect an input from one of the circuits 116,
118 near simultaneously with the detection of an input from the
circuit 120 indicating that the COM-CUT button and one of the L-CUT
or R-CUT buttons have been pressed near simultaneously before the
microprocessor signals the cutting assembly 26 attached to one of
the output ports 36, 38 or 40 to perform a cut. The pressing of one
of the push buttons by the operator causes the corresponding
circuit 116, 118, 120 to provide an input over the input bus to the
memory 60 via the bus interface 122, input line 124 and control
line 126.
[0062] The sensing circuits 128, 130, 132 and 134 sense the
position of the mode selection switch 52 and indicate whether the
mode selector switch is set to the keypad mode (KEYPAD), the EDS
mode (EDS SEL), the automatic cut mode (A/M CUT), or the feed cut
foot switch mode (F/C COMB), respectively, and report such
information to the microprocessor 48 over the input bus 50 to the
memory 60. In the event that the mode selection switch 52 is not
set to either the keypad mode, the EDS mode, the automatic cut
mode, or the feed cut foot switch mode, the microprocessor 48 will
default to operation in accordance with the automatic feed mode
described above.
[0063] The sensing circuit 136 (COUNTER) senses when a
predetermined number of lengths of dunnage material have been
generated. When the machine is in the automatic feed mode, the
operator sets the counter to the desired number of pads. When this
number is reached, a contact closing in the counter is sensed and
the circuit 136 informs the microprocessor 48 that the number of
dunnage lengths has been reached and the microprocessor disables
the automatic feed operation.
[0064] A number of spare sensing circuits 138 (SPAREl), 140
(SPARE2) as seen in FIG. 7, are also provided to enable the
microprocessor 48 to perform expanded control functions based on
additional inputs.
[0065] As noted above, the operational status of the machine may be
indicated to the operator through an alphanumeric display 54 (See
FIGS. 2 and 5). The alphanumeric display may be any of a variety of
commercially available displays capable of interfacing with the
microprocessor 48. The microprocessor 48 supplies the display 54
with information for display in accordance with information
received over the input bus 50 or through other inputs which
indicate to the microprocessor 48 the mode of operation of the
machine as well as whether any errors have been detected in
operation. Preferably, error codes displayed on the display 54
flash or blink to enhance the noticeability of the detected
error.
[0066] Examples of errors which may be detected by the
microprocessor 48 are jams in the feed or cutting assemblies 19,
26. To facilitate detection of such errors it is preferable that an
encoder 144, such as an inductive proximity switch, be positioned
proximate the coining gears of the gear assembly 22 to sense
rotation and rotational speed of the gears and feed motor 24 (See
FIG. 1), although other forms of detection means could be employed
to sense the rotational speed of the various components of the feed
assembly 19. If the microprocessor 48 determines that the
rotational speed of the feed motor 24 has dropped below a certain
threshold which is indicative of a paper jam in the feed assembly
19, such as in the gear assembly 22 or forming assembly 20, the
microprocessor stops the feed motor 24 and displays an appropriate
error code on the display 54 so the operator can attend to
correction of the error.
[0067] To detect a jam in the cutting assembly 26, the
microprocessor 48 may similarly monitor the position of the cutting
blade as determined by the blade position detecting circuit 112
(See FIG. 7). If the blade is not in its rest position after a cut
or does not return to its rest position after a period of time from
the initiation of a cut cycle, the microprocessor 48 will disable
the cutting operation of the machine and send an appropriate error
code to the display 54 to inform the operator of the jam in the
cutting assembly 26.
[0068] With reference to FIG. 9 there is shown a controller 216 for
communication with a remote processor 218, such as a remote
terminal or personal computer, through a pair of modems 220, 222,
respectively, over a transmission line 224. (The remote processor
218 and corresponding modem 222 are designated as separate from the
controller 216 by the dashed box 226 indicating a remote location,
such as a service center.) The controller 216 is generally
equivalent to the controller 16 described above relative to FIGS. 1
through 8. As is discussed above, the microprocessor 48 receives a
number of inputs 50 corresponding, for example, to events detected
by the current sensing circuits shown in FIGS. 6 through 8. The
information sensed by the current sensing circuits includes the
operational status of the machine, such as whether the machine is
in the key pad mode, the electric dispensing mode, the automatic
cut mode, etc., and further includes detection of machine errors,
such as jams in the feed or cutting assemblies 19, 26, as well as
the number of cuts that have been completed by the machine, the
number of pads that have been produced by the machine and various
other information.
[0069] The controller 216 may also be provided with a real-time
clock 228 to permit the microprocessor 48 to record a number of
timed events, for example the total time the machine is on, the
total time the machine is active as opposed to the time devoted to
maintenance, the time spent in each of the operational modes, the
total time the feed motor or cut motor is running and the total
time the feed motor is operating in reverse. The real-time clock
228 can also be used to time and date stamp occurrences of faults
detected by the microprocessor 48.
[0070] All information received by the microprocessor 48 may be
stored in a nonvolatile memory 230 for later retrieval. When
desired, the information stored in the non-volatile memory 230 may
be accessed from a remote location 226 through communication
between the remote processor 218 and the microprocessor 48 over the
modems 220 and 222. The modems 220 and 222 may be conventional
commercially available modems communicating over a telephone link
224 through conventional communications protocols as would be
appreciated by those skilled in the art.
[0071] The information stored in the non-volatile memory 230 of the
controller 216 may be automatically downloaded to the remote
processor 218 at pre-planned timed intervals, for example, at the
end of a day, or the end of a week. Alternatively, a service person
at the remote location 226 can instruct the microprocessor 48
through the connection with the remote processor 218 via the modems
220 and 222 to download the information stored in the non-volatile
memory 230 to the remote processor 218 as desired. Further, the
connection between the remote processor 218 and the microprocessor
48 allows a service person to view in near real-time the status of
all of the machine inputs 50, corresponding to the sensors and
other inputs described above, while the machine is running. This
enables the service person to diagnose effectively errors in the
machine 10 since the service person is able to look at the inputs
50 as an error is occurring. The information downloaded to the
remote processor 218 from the non-volatile memory 230 can also be
used to schedule maintenance for the machine and to perform billing
functions in instances where a customer is charged for use of the
machine 10 based on its operating time, on the amount of paper fed
through the machine, or on the length or number of pads produced by
the machine.
[0072] In instances where a service person is at the site of the
cushion conversion machine 10 it is also possible to access the
non-volatile memory 230 through the same port provided for
communication with the remote processor 218. In such a case instead
of the modem 220 being connected to the microprocessor 48, a
personal computer or other terminal may be connected to the
microprocessor 48 for access to the information stored in the
non-volatile memory 230. This allows a service person more access
to the informational inputs 50 to the microprocessor 48 during
servicing of the machine.
[0073] The microprocessor 48 resident in the cushioning conversion
machine and the remote processor 218 can also function as a real
time diagnostics system for the cushioning conversion machine by
utilizing the modems 220 and 222 and the transmission line 224 to
provide real time or near real time communication between the
microprocessor and the remote processor. Near real time
communication permits an operator at a central location, such as a
servicing or manufacturing location 226, to obtain operational
information on the performance of a cushioning conversion machine
as the machine is operating. The machine information may be used as
a preventative measure to determine if the machine is functioning
properly or is in need of preventive maintenance. For example, if
the remote processor 218 determines based on information received
from the microprocessor 48 in real time that a motor runs
excessively long or draws excessive current following a certain
command from the microprocessor, the remote processor can infer
that the motor is excessively worn and schedule a replacement
before the motor fails. The machine information may also be used to
diagnose or correct machine problems, as well as to determine if
the machine is being operated correctly by an operator.
[0074] Some types of information which the remote processor 218 can
receive from the machine microprocessor 48 include the status of
any machine input, such as the operation mode of the machine, any
keypad inputs, cut complete signals, operation of the footswitch or
cut buttons, as well as other inputs received by the microprocessor
indicating the machine operation. The microprocessor 48 may also
provide information to the remote processor 218 relating to control
commands or instructions produced by the microprocessor, including
outputs to any of the ports, such as the feed motor port 42, the
cut motor port 40 or the solenoid ports 38, 40. The remote
processor 218 can also access, through the microprocessor 48, any
of the machine RAM locations or the non-volatile memory 230 to
provide an in depth view of the functioning of the machine and to
analyze whether the microprocessor is receiving and processing data
correctly.
[0075] Aside from requesting information from the microprocessor
48, the remote processor 218 can also provide inputs to the
microprocessor to instruct the microprocessor to execute a
predetermined test or the remote processor may change values in the
microprocessor accessible RAM to monitor the functioning of the
cushioning conversion machine in accordance with desired
inputs.
[0076] Consequently, a skilled servicing technician at a central
location can follow the operation of a remote cushioning conversion
machine in real time or near real time as the machine is operating
to allow the servicing technician to readily ascertain the
functioning of the machine and to correct errors remotely, to
recommend different operating guidelines to an operator or to aid a
technician actually working with the machine in diagnosing and
correcting problems in the machine.
[0077] In instances where a customer is charged for usage of the
machine based on the amount of paper used it may be desirable to
provide a paper usage meter 232 in communication with the
microprocessor 48. While it is possible for the microprocessor 48
to keep a running total of paper used by the machine in the
non-volatile memory 230 by indirectly measuring the time that the
feed motor is running as determined by the real time clock 228 and
by multiplying that time by the paper speed, provided that the
speed of the feed motor is known and constant, in some instances
the paper usage may be more accurately determined by use of the
paper usage meter 232. Such a meter may include a contact roller
which rolls along the paper fed into the machine to directly
measure the length of paper used or may be embodied through some
other conventional means of measuring length. The paper usage, as
well as other information stored in the non-volatile memory 230 may
be made available for display when desirable on the display 54 as
well as through the remote processor 218 as is described above.
[0078] Where it is desired to accurately determine the amount of
dunnage product or padding produced by a machine, such as for
billing purposes or when the length of the pad to be produced must
closely fit within a container, the machine 10 may be provided with
a length measuring device 234. An embodiment of a length measuring
device is shown in FIGS. 10 and 11 and more fully described in
co-owned U.S. patent application Serial No. 08/155,116, which is
incorporated in its entirety by this reference. The illustrated
length measuring device 234 is positioned to monitor the angular
movement of the gear assembly 22. The length measuring device 234
includes a rotating member 280 which is attached to the gear shaft
281 and a monitor 282 which monitors the angular motion of the
member 280, and thus the gear shaft 281. Preferably, the rotating
member 280 is a disk with a series of openings 284 arranged in
equal circumferential increments. More preferably, the rotating
member 280 is a black, nonreflective, aluminum disk with twelve
openings. In this manner, each opening 284 will correspond to a
30.degree. angular movement and, in the preferred embodiment, one
inch of pad length.
[0079] The monitor 282 comprises a photo-optic transmitter/receiver
286 which transmits and receives light beams and a reflector 288
which reflects the transmitted light beams. The
transmitter/receiver 286 is mounted on the machine frame and is
positioned so that, as the rotating member 280 turns, transmitted
light beams will travel through the openings 284. The photo-optic
transmitter/receiver 286 preferably includes electrical circuitry
capable of relaying interruptions in the receipt of light beams.
The reflector 288 is mounted on the machine frame and is positioned
to receive transmitted light beams which travel through the
openings 284.
[0080] As the rotating member 280 turns, light beams transmitted by
the transmitter/receiver 286 will pass through a first opening 284,
contact the reflector 288, and reflect back to the
transmitter/receiver 286. Once this opening 284 rotates out of
alignment with the transmitter/receiver 286 (and the reflector
288), the receipt of reflected light beams by the
transmitter/receiver 286 will be interrupted until the next opening
284 moves into alignment. Thus, with the preferred rotating member
280, twelve interruptions would occur for every revolution of the
member 280, and thus for every revolution of the drive gear shaft
281.
[0081] The transmitter/receiver 286 relays the occurrence of an
interruption to the processor 48 (FIG. 9) in the form of a pulse.
The processor 48 uses this information to control the gear assembly
22 (i.e., to send activation/deactivation signals to the feed motor
over the feed motor port 42) and thus uses this information to
control pad lengths as well as to determine and store in the
non-volatile memory 230 the total length of pad produced.
[0082] Referring to FIG. 12, there is shown a controller 216'
substantially the same as the controller 216 described above and
including a paper code reader 300 and a container probe 302. While
the controller 216' is illustrated with only the code reader 300
and container probe 302 and the non-volatile memory 230, the
controller may also include the modem 220 for communication with a
remote processor 218, the real-time clock 228, the paper usage
meter 232 and the length measuring device 234 described with
reference to FIG. 9. The paper code reader 300 and the container
probe 302 may also be used separately or together.
[0083] The paper code reader 300 reads information encoded on the
stock paper 304 as the paper is fed through the machine prior to
the paper entering the conversion assembly 20 in order to identify
or to verify the stock paper type, source or lot. Such information
may aid the service person in diagnosing machine problems, such as
problems which have occurred among machines using a particular
paper lot, or may be used to determine information regarding the
cushioning properties of a pad formed from such paper as may vary
between, for example, single or multi-ply paper stock. The latter
type of information may be of particular value where the machine 10
automatically determines and produces the amount of pad to
adequately cushion a given container. The controller 216' may in
some instances be adapted to produce pads only upon the
verification of certain types of stock paper by the paper code
reader 300, such as to as an example prevent damage to the machine
10 from the use of inappropriate stock paper material.
[0084] The paper code reader 300 is preferably a conventional bar
code reader with the stock paper bearing an appropriate bar code
encoded with the desired information. The paper code reader 300 can
also be used to supply paper length information to the processor 48
when the bar codes are printed on the stock paper 302 at known
spatial intervals or are encoded with length information. The paper
code reader 300 may also be another type of information retrieval
system including, for example, an optical code reader other than a
bar code reader or a reader adapted to read or to detect the
presence of encoded information using ultraviolet light.
[0085] Information detected from the paper stock 304 by the paper
code reader 300 is transferred to the processor 48 where it may be
acted upon and/or, as desired, stored for latter retrieval from the
non-volatile memory 230. The number of rolls or amount of stock
paper used from a particular source or the number of rolls or
amount of stock paper used of a certain grade, thickness or ply are
examples of useful information for storage in the non-volatile
memory 230.
[0086] The container probe 302 may be embodied as a code reader
such as a bar code reader which reads information from a container
306 for determining the amount of pad and the lengths of pads to
produce to adequately cushion the container. In such an instance a
bar code would be printed on or otherwise affixed to the container
306 or to a packaging invoice supplied with the container and the
bar code reader would be positioned to read the bar code as the
container is conveyed to or the bar code is placed at a known
position relative to the machine 10. Upon reading the information
from the bar code, the container probe 302 will transfer the
information to the processor 48 which may use the information to
instruct the machine 10 to produce the required number and lengths
of pads as determined by a look-up table or as directly encoded
into the bar code. The operator would then take the pads
automatically produced by the machine 10 and place them in the
container 306 without further interaction between the operator and
the machine.
[0087] The container probe 302 may also be in the form of probe
which actually measures the void volume of the container. Such a
probe may include a mechanical probe such as a plunger, an air
cylinder or other low pressure probe which probes the container 306
to determine the volume of padding necessary to fill the container.
A mechanical probe may probe the container 306 in one or in
multiple locations to determine the amount of pad needed. The
mechanical probe may also be used in conjunction with a bar code
reader or used in conjunction with or supplanted with sensors which
sense the dimensions or degree of fill of the container 306
including optical and ultrasonic sensors and sensor using other
forms of machine vision or pattern recognition.
[0088] A fault tolerant cushioning producing network 400 is
illustrated schematically in FIG. 13. Such a network 400 would
typically include a number of cushioning conversion machines 10
each preferably having a controller 402 such as the controllers 16,
216 and 216' described above for controlling the pad producing and
diagnostic functions of the machine. The individual machines 10
would also be controlled by a supervisory controller 404 which may
be a devoted supervisory controller implemented in a personal
computer or similar processor or may be resident in a cushioning
conversion machine in which case it would control its host machine
as well as provide supervisory control functions to its host
machine and the other machines in the network 400. The supervisory
controller 404 may communicate with controllers 402 of each machine
10 in a conventional "master-slave" mode or the controllers may
communicate with each other in a conventional "peer-to-peer" mode
depending on the level of intercommunication between the machines
10 that is desired and whether it is desired to employ a master
supervisory controller.
[0089] When the network 400 is operating in the master-slave mode,
individual or plural machines 10 are instructed by the supervisory
controller 404 to produce pads of the desired number and lengths.
The supervisory controller 404 can divide up the work load among
the different machines according to work schedules and maintenance
schedules of the machines and can bypass or reallocate work from a
machine which has informed the supervisory controller of a fault
condition, such as a paper jam, or that the machine has run out of
paper stock. The machines may also communicate information and
fault conditions with each other. While it is preferable that each
machine 10 is provided with a separate controller 402, a machine
may be controlled through the supervisory controller 404 without
the need of an individual controller for each machine.
[0090] When the network 400 is operating in the peer-to-peer mode,
a primary or first machine is active producing pads while the
remaining machine or machines are inactive. If the first machine
fails, the remaining machine or machines can automatically take
over for the first machine. Such a network could be implemented
between two machines 10a and 10b at either end of a reversible
conveyor system 410, as shown in FIG. 14. In this case, in normal
operation one machine is active while the other machine is idle.
The active machine, say machine 10a, produces pads of the desired
length and deposits the pads onto the conveyor system 410 which
carries the pad away from the active machine 10a and to an
operator. If the machine 10a becomes inoperable, such as due to a
jam or lack of paper for instance, or a switch is desired at a
scheduled intervals, the machine 10a becomes inactive and the
machine 10b takes over the pad producing functions. At this time
the direction of the conveyor system 410 would also reverse
direction to carry pads produced by the machine 10b away from that
machine and to an operator.
[0091] While a number of controllers have been described above
relative to a number of specific cushioning conversion machines, it
will be readily apparent that the controllers of the present
invention have a wide range of applications in controlling the
operation of many types or configurations of cushioning conversion
machines. The versatility and structure of the controllers as well
as the provision of spare controller ports also permits
customization of controller functions for different machine
applications and control of accessory devices.
[0092] For example, referring now to FIGS. 15-23, a different type
of packaging material conversion machine is disclosed, a conversion
machine for converting sheet material into a plurality of
elongated, crimped strips. Referring to the drawings and
particularly to FIG. 15, wherein like reference numerals indicate
like parts throughout, the prior art generally teaches that sheets
of paper may be cut into elongated strips 520. The strips 520,
however, do not provide a substantial amount of resiliency or
forgiveness when subjected to a force or other mistreatment.
Consequently, a large number of strips 520 are undesirably required
to fill a given empty space.
[0093] Referring now to FIG. 16, there is illustrated a plurality
of shredded, elongated, interconnecting strips 522 which have been
folded and crimped using the apparatus and methods as taught
herein. The folds within the crimped strips 522 interlock with one
another to form a resilient mass of intertwined and interconnected
strips of decorative or bulk packaging material. The folds also
form a variety of differently angled flanges and/or webbing which,
when used as a packing material, distribute a blow or impact
received in a disbursed manner throughout each interconnect fold of
the interlocked crimped strips 522 to prevent damage to the packed
item. The folds also cause the crimped strips 522 to occupy a
greater volume of space, using a smaller amount of sheet material
than would otherwise be required.
[0094] Turning now to FIG. 17, a plurality of shredded, elongated,
interconnecting strips 522 which have been folded, crimped, and
sheared into strip segments 523 are shown. The strips 522 may also
have been bonded together at a forward terminal end 524 and a
rearward terminal end 526 thereof to form the strip segment 523.
The formation of the interlocked crimped strips 522 of FIG. 16 and
the sheared strip segments 523 of FIG. 17 will now be described in
conjunction with FIGS. 18-23.
[0095] FIG. 18 illustrates one embodiment of the present invention,
that is, a conversion machine 530 which includes a shredding device
532. Although various shredding devices 532 are well known in the
prior art and each are contemplated by the present invention, the
shredding device 532 receives sheet material 534 and feeds the
sheet material 534 into a plurality of parallel cutting blades 536
and 538 which rotate to longitudinally cut the sheet material 534
into a plurality of strips 520 (FIG. 15). A conveyor belt 540 may
be used to support and urge the sheet material 534 into the cutting
blades 536 and 538. The conveyor belt 540 may be free rolling, but
preferably is powered by a motor or belt assembly as will be
discussed in greater detail infra with respect to FIG. 20. The
cutting blades 536 and 538 may be smooth or serrated cutting blades
to facilitate the longitudinal cutting of the sheet material
534.
[0096] When passed between the cutting blades 536 and 538, the
sheet material 534 is cut into the elongated strips 520 (FIG. 15)
which are then directed toward, and expelled outwardly from, an
exit opening 542 of the shredding device 532. The elongated strips
520 are generally expelled through the exit opening 542 at a very
rapid rate, for example, a rate of about 125-450 feet per
minute.
[0097] The conversion machine 530 may include a durable and
inexpensive discharge chute attachment 543 which is either local to
or in physical attachment with the shredding device 532. As the
sheet material 534 is converted into the elongated strips 520 as it
exits the parallel cutting blades 536 and 538, the elongated strips
520 (FIG. 15) are initially impacted or impelled against a barrier
560. The barrier 560 causes the shredded strips 520 (FIG. 15) to
assume a partially jammed state within a compression chamber or
confined area 562 located between the barrier 560 and the cutting
blades 536 and 538.
[0098] Continued shredding of additional sheet material 534 by the
shredding device 532 forces additional elongated strips 520 (FIG.
15) into the confined area 562, forming a dam of temporarily jammed
strips 520 (FIG. 15). Once a dam of shredded strips 520 is formed,
the front of the dam, which is located most closely to the cutting
blades 536 and 538, serve as an additional barrier mechanism. As
additional amounts of the sheet material 534 are fed or pulled into
the shredding device 532, the expelling force exerted by the
cutting blades 536 and 538 forces the strips 520 (FIG. 15) into the
confined area 562. As the strips 520 (FIG. 15) are forced against
the barrier 560, the strips 520 (FIG. 15) are confined within the
confined area 562 and are forced to fold against themselves in a
relatively controlled manner. Such folding and further insertion of
strips 520 (FIG. 15) into the confined area 562, causes the folded
strips to become compacted against themselves in relatively
uniformly generated folds, thereby resulting in the
accordion-shaped mass of crimped strips 522 as illustrated in FIG.
16.
[0099] The function of the discharge chute attachment 543 is to
serve as a pressure sensitive barrier 560 for temporarily damming a
passage of the strips, 520 (FIG. 15) which are expelled from the
shredding device 532. Consequently, the conversion machine 530 has
a means for urging the barrier 560 toward a closed position.
Preferably, the barrier 560 is a compression door or gate 570
having a closed position located within a generally vertical plane,
and an open position, located within a generally horizontal plane.
FIG. 18 illustrates the gate 570 in a closed position, while FIG.
19 illustrates the gate 570 in an open position with the crimped
strips 522 traveling through a guide portion 604.
[0100] Initially the gate 570 is urged toward its closed position
by an urging means 572. The urging means 572 may include a spring,
a weight, or a pneumatically or hydraulically controlled piston 574
which is connected to the gate 570 by a linkage assembly 576. The
force exerted by the urging means 572 upon the gate 570 may be
controlled by either the type of the characteristics of the spring
used, or by a valve mechanism attached to the piston 574, depending
upon the urging means utilized. If, for example, a piston assembly
is utilized, a fluid or air pressure reservoir 580 may be provided
and appropriately connected to the piston 574 via a hose assembly
582, as illustrated in FIG. 18. Electronic pressure sensors may
also be used to determine the amount of pressure which is being
exerted upon the gate 570 and to activate and/or release the urging
means 572 when needed.
[0101] In the preferred embodiment, the confined area 562 is
defined by the gate 570, its sidewalls (not shown), the guide
portion 604 and by the cutting blades 536 and 538. Once a dam,
however, of partially jammed crimped strips 522 are within the
confined area 562, the frictional resistance between the crimped
strips 522 and the interior surfaces of the guide portion 604
provides sufficient retaining force to eliminate the need for the
gate 570. At this point the gate 570 may be automatically or
incrementally raised to its open position as illustrated in FIG.
19. In this manner the remaining dam of the crimped strips 522
serve the same function as the gate 570 by providing a barrier by
which the strips fold against themselves in a relatively controlled
manner thereby creating the crimped strips 522. In an alternative
embodiment, a barrier-less paper restriction mechanism may be
employed such as, for example, a narrowing passageway in which the
strips 520 experience increased restriction as it travels along the
passageway. Consequently, the folded, crimped strips 522 may be
generated without use of the gate 570 or other mechanism as the
barrier 560.
[0102] The length of the crimped strips 522 may also be adjusted. A
cutting, chopping, or shearing device 620 may be engaged at
preselected intervals to cut the compressed strips 522 into the
strip segments 523 as illustrated in FIG. 17. The shearing device
620 may be a cutting blade 622 to cut the compressed crimped
strips. The length of the crimped strips 522 may be controlled by
regulating the rate of passage of the strips 522 through the
conversion machine 530 and/or by regulating the rate or time
interval between which the blade 622 cuts the strips 522. Therefore
the conversion machine 530 may produce variable lengths of crimped
strips 522. After the crimped strips 522 have been formed they exit
the confined area 562 and guide portion 604, and are deposited in a
receiving bin 616 via a chute or ramp 618, as illustrated in FIG.
19.
[0103] FIGS. 18 and 19 illustrate an embodiment in which the sheet
material 534 is advanced through the shredding device 532 and the
length of the various crimped strips 522 is then determined by the
shearing device 620. If, however, it is desired to provide pre-cut
sheets of the sheet material 534 rather than transversely cutting
the packaging material after it is formed, a feeder section 702
having a transverse cutting component 722 may be provided upstream
from the shredding device 532 as illustrated in FIG. 20.
[0104] The feeder section 702 of FIG. 20 contains a transverse
cutting component 722 which includes four rotating cutting blades
724 which are mounted for rotation on a shaft 725. A cylinder
roller 726 is in alignment with the shaft 725 and preferably
includes elastomeric material sections 728 for specific alignment
in cooperation with the blades 724. Each of the blades 724
preferably includes a generally serrated edge but also includes
several gaps along its transverse length in order to provide only a
partial cut of the sheet material 534 as it transfers thereunder in
direction "A". With the sheet material 534 being transversely cut,
it is advanced to a second pair of drive rollers 730 and 731 for
further direction to the shredding device 532 to maintain the sheet
material 534 in a position for advancement to the cutting component
722. A first biased roller means 721 is biased toward and in
alignment with the first drive roller 720, wherein a second biased
roller means 731 is biased toward and in alignment with the second
drive roller 730. In such a manner, the sheet material 534 is
advanced to the shredding device 532 with the sheet material 534
cut in predetermined lengths.
[0105] The first pair of drive rollers 720 and 721, the backing
cylinder 726 and the second pair of drive rollers 730 and 731 all
rotate at approximately the same circumferential speed. Each of the
components in the feeder section 702 are preferably greater than
15" wide in order to provide the sheet material 534 to the
shredding device 532, thereby making the conversion machine 530
capable of accommodating a sheet material 534 that is 15" wide. The
first pair of drive rollers 720 and 721 are preferably knurled or
roughed to provide sufficient friction for advancing the sheet
material 534 therethrough while the second pair of drive rollers
730 and 731 preferably have a lower coefficient of friction than
the first pair of driver rollers 720 and 721. Additionally, the
second pair of drive rollers 730 and 731 have a slightly larger
diameter or rotate faster which yields a faster circumferential
speed than the first pair of drive rollers 720 and 721 in order to
the keep the material 534 tight for proper partial cutting by the
transverse cutting component 722. Because of the lower friction
surface of the rollers 730 and 731, the additional tension created
by the slightly faster circumferential speed of the second pair of
drive rollers is not sufficient to tear or separate the resulting
sheets 738 of the sheet material 534 simply by the action of the
drive rollers 720 and 730. The separated sheet material 534 is then
fed into the shredding device 532 for shredding and formation of
the crimped strips 522 as discussed in conjunction with FIGS. 18
and 19. Although FIGS. 18-20 illustrate the conversion machine 530
as separate components, the feed assembly, shredding devise, and
restriction mechanism may be integrated into a single unit as
illustrated in FIG. 21. The operation of the integrated conversion
machine of FIG. 21 operates in substantially the same manner as the
machine of FIGS. 18-20, consequently a detailed description of FIG.
21 is omitted.
[0106] Referring to FIG. 22, the conversion machine 530 of FIGS.
18-21 further includes a monitoring system 650 including a
controller 652 for monitoring the operation and status of the
conversion machine 530 through a plurality of sensors 654a-654i and
a display 656 for providing a visual indicia of machine operation
to a user and/or a service technician. The monitoring system 650 is
operable to monitor and display the machine operation in real time
or alternatively may take sample data at prescribed time intervals
and save the data in an internal or external memory for subsequent
analysis purposes. In yet another alternative embodiment, the
monitoring system 650 may monitor machine operation in real time
(or at sampled intervals) and communicate the data to a remote
processor via a data transmission line or communications link to
provide for monitoring and diagnostic evaluation of multiple
conversion machines at various site locations as will be discussed
in greater detail infra in conjunction with FIG. 23.
[0107] The plurality of sensors 654a-654i monitor various, diverse
operational indicia of the conversion machine 530. Each of the
sensors 654a-654i monitor a particular operating characteristic or
machine parameter and report the characteristic or parameter to the
controller 652 via a wire or cable connection. Alternatively,
however, each sensor 654a-654i may use wireless technology such as
radio-frequency (RF) communication or infrared (IR) linking or
other communication methodologies such as, for example, use of
fiber-optic cable or coaxial cable to communicate its data to the
controller 652. Various types of sensors may be utilized. For
example, a bar code reader 654a may be positioned upstream from the
shredding device 532 near the feeder assembly 702 of FIG. 20 to
read any bar code data that may exist on a bar code label on the
roll of sheet material 534. Such data may include an inventory
control number, color data and perhaps even control data to be
utilized for the particular roll of sheet material 534. In
addition, such data may further include the paper characteristics
for use in machine control operations like feed rate, moisture or
chemical application or gate pressure as well as other types of
control operations. Consequently, inventory control can be
effectuated by identifying which colors and particular rolls of
sheet material 534 are being utilized. Re-stocking inventory in
response in such data may therefore be easily and efficiently
accomplished.
[0108] Other sensors may also be employed with the conversion
machine 530. A color sensor 654b may alternatively be used instead
of, or in addition to, the bar code reader 654a. The color sensor
654b, which is commonly known in the art, is preferably located
upstream of the shredding device 532 near the feeder assembly 702
of FIG. 20 and senses the color of the sheet material 534 to ensure
that the desired color of sheet material 534 is, in fact, being
utilized to form the crimped strips 522.
[0109] A paper quantity sensor 654c is also preferably located
upstream of the shredding device 532 to monitor the accumulated
amount of paper (sheet material 534) which has been converted by
the conversion machine 530. The paper quantity sensor 654c may be,
for example, a feeder monitor which counts the number of rotations
of the drive roller 720 which the controller then preferably
converts the rotation count data into a paper quantity.
Alternatively, if the conversion machine 530 operates at only a
single speed, the paper quantity sensor 654c may constitute a timer
which monitors the on-time of the conversion machine 530 and the
controller estimates the amount of paper used based upon the
machine run time. Any sensing methodology by which the amount of
sheet material 534 used by the conversion machine 530 is monitored
is contemplated by the present invention. The information regarding
the amount of paper used may then be utilized to easily and
efficiently calculate use charges, etc. if the conversion machine
530 is being leased or charged based on the paper amount used.
Further, the information may also be used to schedule preventative
maintenance for the conversion machine 530.
[0110] Shredding device sensors 654d and 654e may also be employed
within the conversion machine 530, as illustrated in FIGS. 18 and
19. The shredding motor sensor 654d monitors one or more motors
which drives the transverse cutting component 722 and the cutting
blades 536 and 538 to evaluate the status of the motors (not shown)
and thus the status of the transverse cutting component 722 and the
cutting blades 536 and 538. For example, the shredding motor sensor
654d may be one or more current sensors which monitor the load
current of the shredding motors of the cutting blades 536 and 538.
Any load current that rises above a predetermined current threshold
(I.sub.TH) may be indicative of a dulling or misalignment of the
cutting blade 536 and 538, since an excessive amount of power is
being expended by the motors.
[0111] A temperature sensor 654e also may be utilized instead of,
or addition to, the shredding motor sensor 654d to monitor various
aspects of the shredding device 532. The temperature sensor 654e
may be a single sensor (such as, for example, a thermocouple and an
A/D converter) or may include multiple sensors strategically
located about the shredding device 532 (or even about the entire
conversion machine 530). Thermal data may then be utilized by the
controller 652 to monitor motor degradation (of either the
shredding motors or feed motors), cutting blade dulling or
misalignment, or variation in speed, etc. Consequently, the status
and operational characteristics of the shredding device 532 can be
easily and efficiently monitored by a user and/or service
technician, allowing for any potential problems to be detected
before a machine failure occurs. Although a shredding motor sensor
654d and temperature sensor 654e are utilized to monitor the
shredding device 532, other type sensing mechanisms may also be
utilized and are contemplated by the present invention.
[0112] A vibration sensor 654f is preferably utilized to monitor
the vibrational characteristics or modes of the conversion machine
530. The vibration sensor 654f monitors the shredding device 532 to
insure that vibrations due to machine operation do not exceed a
predetermined vibration threshold or other criteria. As is well
known by those skilled in the art, the vibration characteristics of
various components within an operational system may provide
functional or diagnostic information to a technician. For example,
excessive vibration of the shredding device 532 may be indicative
of a jam in the shredding device 532 or an operational problem with
the cutting blades 536 and 538. Furthermore, excessive vibrations
may also be indicative of an operational problem with the barrier
560 which forms the crimped strips 522. The vibration sensor 654f
may be, for example, one or more accelerometers and may be
positioned strategically about the shredding device 532 or at other
portions of the conversion machine 530 to monitor the operation of
the conversion machine 530.
[0113] A pressure sensor 654g may also be utilized within the
conversion machine 530. In a preferred embodiment, the pressure
sensor 654g monitors the status of the gate 570 which constitutes
the barrier 560 by which the crimped strips 522 are initially
formed. Once a particular pressure threshold is reached, the gate
570 is forced into a partial or complete open position to thereby
allow the crimped strips 522 to travel toward the receiving bin
616. Failure of the gate 570 to open at the prescribed pressure
level may result in the crimped strips 522 within the confined
areas 562 causing a jam at the shredding device 532. Consequently,
the pressure sensor 654g may monitor the force being exerted
against the gate 570. If the pressure needed to raise the gate 570
exceeds a predetermined threshold, the pressure sensor 654g may
communicate such a status to the controller 652. The pressure
sensor 654g may measure the force exerted against the gate 570 by,
for example, measuring the force being exerted at the hinge of the
gate 570, such a measurement being, for example, a torque
measurement. Other methods by which the pressure sensor 654g may
monitor the status of the gate or the pressure at the cutting
blades 536 and 538 are also contemplated by the present invention.
For example, a position sensor in conjunction with a potentiometer
or a linear variable differential transducer (LVDT) may be
utilized.
[0114] Another sensor that may be employed in the monitoring system
650 is a shear force sensor 654h which senses or measures the shear
force being exerted by the transverse cutting blade 622 before the
crimped strips 522 exit the conversion machine 530 and enter the
receiving bin 616. As stated earlier, the transverse cutting blade
622 is operable to cut the crimped strips 522 into selectable
lengths, thereby resulting in sheared fragments or segments as
illustrated in FIG. 17. It is desirable, therefore, for the
transverse cutting blade 622 to cut the crimped strips 522 with a
minimal amount of force so as to ensure cutting of the front
portion 524 and back portion 526 of the crimped strips 522 to
thereby form the segments 523. Consequently, the shear force sensor
654h is operable to monitor the shear force being exerted by the
transverse cutting blade 622 against the crimped strips 522. If the
shear force exerted by the transverse cutting blade 522 does not
meet or exceed a predetermined force threshold, the shear force
sensor 654h provides an indication of such a operation
characteristic to the controller 652. Alternatively, the sensor
654h may additionally communicate the shear force data to the
controller 652 for continuous monitoring.
[0115] Lastly, the monitoring system 650 may include a container
sensor 654i. The container sensor 654i may entail a bar code reader
to thereby read a bar code label on the container 616. The bar code
label may contain information regarding the customer identity
and/or the container volume. Consequently, the container sensor
654i can relay such information to the controller 652 for use in
recording the usage of various customers for marketing and/or
control purposes. In addition, the container volume data may be
utilized to evaluate whether sufficient amounts of the crimped
strips 522 are being used to fill the container bin 616 having a
known volume for quality control purposes. The container sensor
654i may also include a weight sensor to correlate the volume of
the strips 522 placed in the bin 616 with other data collected from
other sensors 654a-654h to ensure that the sensors are accurately
measuring their respective operation characteristics or
parameters.
[0116] Preferably, the controller 652 illustrated in FIGS. 18, 19,
22 and 23 is a universal type programmable controller such as a
programmable logic controller (PLC), the configuration and
programmability of which is well known to those skilled in the art.
The universal type controller is preferred because it allows for a
single type of controller configuration to be adaptable to various
machine variations. Further, a universal controller allows for
reduced set-up time, reduces assembly cost, and makes maintenance
easier and less expensive. Lastly, universal controllers are
beneficial since training of the repair technician is minimized and
since an inventory of universal controllers may be easily
maintained. Although a universal controller is preferred, any
custom-type controller may also be utilized and is contemplated as
falling within the scope of the present invention. For example, any
8-bit, 16-bit or 32-bit custom, programmable I/O controller may be
utilized on conjunction with the present invention.
[0117] An exemplary universal controller 652 is illustrated in FIG.
22 and includes a plurality of input ports 658a-658i devoted to
receiving data from the various sensors 654a-654i. Preferably, the
data received from each of the sensors 654a-654i is digital, single
or multi-bit digital data. Alternatively, however, the controller
652 may incorporate an A/D converter internally or external to the
input ports 658a-658i to convert received analog signals into
single or multi-bit digital data. In addition, while the controller
652 is illustrated as a single, integrated device, it is noted that
the controller 652 may be embodied as a plurality of controllers
that may each be adapted for a particular function.
[0118] The controller 652 also includes a plurality of output ports
659a-659j (wherein j=1, 2 . . . n) to provide control functions for
the conversion machine 530. For example, the controller 652, via
the output ports 659a-659j, is operable to control the main power,
interlocks, operator panel switches and indicators, etc.
Consequently, the controller 652 is operable to restrict the order
of start up (by, for example, ensuring that the shredding device is
running before the sheet rollers are activated). Since the
controller 652 provides machine control functionality, the
controller 652 has a substantial amount of monitoring-type
information without data from the sensors 654a-654i. For example,
the controller 652 has machine status information that may be
evaluated for diagnostic purposes such as the on/off/idle status of
the sheet motors and shredder motors, the accumulated run time of
each component, the electric safety interlocks on the operator
access panels and the status of safety circuits such as, for
example, the emergency stop circuit.
[0119] The controller 652 provides such control functions via its
internal programming. For example, since many of the control
functions are on/off type control functions, a 1-bit digital signal
may comprise the control output signal. For variable type output
control functionality, one or more multi-bit control signals may be
utilized (for example, to provide variable feed roller
circumferential control speed) as will be appreciated by those
skilled in the art.
[0120] The universal controller 652 receives the data from the
sensors 654a-654i at the sensor input ports 658a-658i and stores,
processes and/or displays the data and its internal control data on
the display 656 which is preferably local to the monitored
conversion machine 530. The controller 652, in response to the data
at the input ports 658a-658i and its internal programming,
generates a display output via a display driver (not shown) to
provide a visual indicia of the machine status on the display 656.
Alternatively, or in addition to the display, the controller 652
stores the input data in an internal memory 660 and/or in an
external memory 662. For example, if the bar code reader 654a reads
a bar code on a roll of sheet material 534 and determines that a
roll #10 of gray paper is being used, the controller 652 receives
that data as a multi-bit piece of digital data, wherein, for
example, the first three bits are a color code and the next three
bits constitute the particular roll number for that particular
color. The controller 652 receives the multi-bit data, determines
the color and roll number (via its internal programming, as is well
known by those skilled in the art) and displays the data on the
display 656 and/or stores the data in the memory 660 or 662 for
later inventory analysis.
[0121] The paper quantity sensor 654c monitors the total amount of
paper used by the machine 530 or alternatively the amount of paper
used on the present roll of sheet material 534 or both.
Alternatively, the sensor 654c may monitor both pieces of data or
separate sensors may be utilized for such a function. Preferably,
the sensor 654c monitors the number of rotations of a feed roller
and calculates the amount of paper by multiplying the rotation
count by the known circumference of the drive roller. This data is
then fed to the controller 652 (or alternatively merely the
rotation count is sent to the controller 652 and the controller
makes the calculation via its internal programming) and the amount
of paper used is then displayed on the display 656 and/or
downloaded into the memory 660 or 662, preferably at predetermined
time intervals. These time intervals may be, for example, every
five minutes, every thirty minutes, each hour, or each day. The
controller 652 may also provide a sheet material roll status
indication to the user via the display 656 by generating a warning
indication or low paper indication on the display 656 when the
controller 652 determines that the amount of the sheet material 534
on the roll is almost finished.
[0122] Various other diagnostic functions are performed by the
controller 652 in conjunction with the sensors 654a-654i. In each
of these monitoring functions, the sensors 654a-654i either convert
the sensed condition into digital data internally or send the raw
data to the controller 652 for subsequent processing. Preferably,
each sensor 654a-654i converts its data to digital data to prevent
errors due to line loss (via, for example, analog-to-digital
converters), and the controller 652 performs any subsequent
processing to minimize the complexity and cost of each sensor
654a-654i. Alternatively, however, the controller 652 may include
A/D conversion capability as discussed earlier to further simplify
each of the sensors 654a-654i.
[0123] With several of the monitoring functions such as those
provided by, for example, the vibration sensor 654f and shear force
sensor 654h, a warning is preferably provided to the user visually
via the display and/or audibly via an alarm when the monitored
characteristic(s) exceeds or falls below a predetermined parameter
threshold. For example, the vibration sensor 654f senses the
vibration modes of the conversion machine 530 at one or more
locations. If the conversion machine 530 exceeds a predetermined
vibration level at one or more locations, the controller 652
records the vibration level data in its memory 660 (or the external
memory 662) and also compares the vibration data to a predetermined
programmed threshold. If the vibration data exceeds the threshold,
the controller 652 generates an error or warning signal to the user
so that maintenance of the machine 530 may be performed before a
machine failure occurs. Preferably, the controller 652 generates a
visual warning via the display 656 coupled with an audible warning
to focus the user's attention on the system condition.
[0124] The controller 652 preferably provides such functionality in
the following manner. The controller 652 receives the vibration
data (or, alternatively, shear force data, thermal data, etc.) and
compares it to the predetermined threshold. Preferably, the
threshold is simply subtracted from the vibration data and if the
result is positive, a warning is generated (indicating the
vibration data exceeds the threshold). Alternatively, the vibration
data can be converted to a corresponding voltage via a look-up
table and compared to a voltage corresponding to the threshold via
a comparator circuit as is well known by those skilled in the art.
The controller 652 preferably maintains its status if no warning is
needed and may, if desired, display the present vibration data on
the display 656. Alternatively, the vibration data may be stored in
the memory 660 and displayed on the display 656 only when prompted
by the user via an I/O peripheral (such as a keypad 664).
[0125] In the preferred embodiment of the present invention, the
monitoring system 650 of the conversion machine 530 simply displays
the status of the various system characteristics as measured by the
sensors 654a-654i. Alternatively, however, the controller 652 may
also control the operation of the conversion machine 530 via a
machine disable output 666 coupled to a machine power control 668.
If, for example, the controller 652 received data from one of the
sensors 654a-654i that the controller 652 determined (via its
internal programming) constitutes a dangerous condition that could
cause machine damage, etc., the controller 652 may trigger the
machine disable output 666 to turn off the conversion machine 530
via the machine power control 668 and relay the condition to the
user via the display 656. In this manner the monitoring system 650
collectively provides machine conversion control to prevent machine
damage or failure.
[0126] In the previous embodiment of the present invention, the
monitoring system 650 monitored the status and operating
characteristics of the conversion machine 530 and stored and
displayed the results locally in the memory 660 or 662 and the
display 656. According to another embodiment of the present
invention, a monitoring system 716 is operable to monitor the
status and operating characteristics of the conversion machine 530
of FIGS. 18-22 and transmit the data to another location for remote
monitoring and diagnostic analysis, as illustrated in FIG. 23.
[0127] With reference to FIG. 23, there is shown a monitoring
system 816 having a controller 817 local to one or more conversion
machines 530 for communication with a remote processor 818, such as
a remote terminal or personal computer, through a pair of modems
820, 822, respectively, over a transmission line or communication
link 824. (The remote processor 818 and corresponding modem 822 are
designated as separate from the controller 817 by the dashed box
826 indicating a remote location, such as a service center.) The
controller 817 is generally equivalent to the controller 652
described above relative to FIGS. 18 through 22. As is discussed
above, the controller 817 receives a number of inputs 827a-827i
corresponding to events detected by the sensors 654a-654i shown in
the FIGS. 18 though 22. The characteristics and status sensed by
the sensors 654a-654i include the type and. quantity of paper being
used, the container being filled, etc. and further includes
detection of machine errors, such as jams in the feeder or cutting
assemblies 702 and 532, excessive vibrational modes due to
misalignments, etc., the shear force exerted by the cutting
mechanism 622 and various other types of information. In addition,
the controller 817 has one or more output ports 859a-859i to
provide machine control functionality.
[0128] The controller 817 may also be provided with a real-time
clock 829 to report a number of time events, for example, the total
time the machine is on, the total time the machine is active as
opposed to the time devoted to maintenance and the total time the
feed motor or cut motor is running. The real-time clock 829 can
also be used to time and date stamp occurrences of faults or
warning conditions detected by the controller 817. Although the
clock 829 is only illustrated in conjunction with FIG. 23, the
clock 829 is also equally applicable to the monitoring system 650
of FIG. 22.
[0129] All information received by the controller 817 may be stored
in an internal memory 829 or an external, non-volatile memory 830
for later retrieval. When desired, the information stored in the
memory 829 or 830 may be accessed from the remote location 826
through communication between the remote processor 818 and the
controller 817 over the modems 820 and 822. The modems 820 and 822
may be conventional, commercially available modems communicating
over a telephone link 824 through conventional communications
protocols as would be appreciated by those skilled in the art.
[0130] The information stored in the memory 829 or 830 of the
controller 817 may be automatically downloaded to the remote
processor 818 at pre-planned time intervals, for example, at the
end of a day, or the end of a week. Alternatively, a service person
at the remote location 826 can instruct the controller 817 through
the connection with the remote processor 818 via the modems 820 and
822 to download the information stored in the memory 829 or 830 to
the remote processor 818 as desired. Further, the connection
between the remote processor 818 and the controller 817 allows a
service person to view in real-time or near real-time the status of
machine 530 corresponding to the sensors 654a-654i and other inputs
described above, while the machine 530 is running. This enables the
service person to remotely diagnose errors in the conversion
machine 530 since the service person is able to look at sensor
information from the machine 530 as an error is occurring in
real-time. The information downloaded to the remote processor 818
from the memory 820 or 830 can also be used to schedule maintenance
for the machine 530 and to perform billing functions in instances
where a customer is charged for use of the machine 530 based on its
operating time, on the amount of paper fed through the machine 530,
or on the number of sheared strips 523 produced by the machine 530.
The information downloaded to the remote processor 818 can further
be used to effectuate inventory control by identifying what types
and quantities of paper are being used so that paper inventories
can be automatically replenished in a timely manner.
[0131] In instances where a service person is at the site of the
conversion machine 530, it is also possible to access the memory
820 or 830 through the same port provided for communication with
the remote processor 818. In such a case, instead of the modem 820
being connected to the controller 817, a personal computer or other
terminal may be connected to the controller 817 for access and
downloading of the information stored in the memory 829 or 830.
Alternatively, the service person may view the operational status
of the machine 530 via the display 656 and the key pad 664.
[0132] The controller 817, which is resident in the conversion
machine 530 or local to the conversion machine 530, and the remote
processor 818 can also function as a real-time diagnostics system
for the conversion machine 530 by utilizing the modems 820 and 822
and the transmission line 824 to provide real-time or near
real-time communication between the controller 817 and the remote
processor 818. Near real-time communication allows an operator at a
central location, such as a servicing or distribution location 826,
to obtain operational information on the performance of one or more
conversion machines 530 as the machines are operating. The machine
information may be used as a diagnostic measure to determine if the
machine 530 is functioning properly or is in need of preventive
maintenance. For example, if the remote processor 818 determines,
based on information received from the controller 817 in real-time,
that a motor runs excessively long or drawn excessive current, the
remote processor 818 can infer that the motor is excessively worn
and schedule a replacement before the motor fails. The machine
information may also be used to diagnose or correct machine
problems, as well as to determine that the machine 530 is being
operated correctly by an operator.
[0133] Some types of information which the remote processor 818 can
receive from the machine controller 817 includes the status of any
machine sensor 654a-654i. The controller 817 may also provide
information to the remote processor 817 relating to control
commands or instructions produced by the controller 817, including
the machine output disable port 660. The remote processor 818 can
also access, through the controller 817, any of the internal or
external memory locations 829 or 830 to provide an in depth view of
the functioning of the machine 530 and to analyze whether the
controller 817 is receiving and processing data correctly.
[0134] Aside from requesting information from the controller 817,
the remote processor 818 can also provide input to the controller
817 to instruct the controller 817 to execute a predetermined test
(as dictated by the internal programming of the controller 817) or
the remote processor 818 may change threshold values in the memory
829 or 830 of the controller 817 to monitor the function of the
conversion machine 530 in accordance with desired inputs. Further,
the internal programming control routines may be modified from the
remote site 826, thereby allowing software monitoring, control and
diagnostic upgrades to be easily implemented globally to multiple
machines 530 from one central location.
[0135] Consequently, a skilled servicing technician at a central
location can follow the operation of a remote conversion machine
530 in real-time or near real-time as the machine 530 is operating
to allow the service technician to readily ascertain the
functioning of the machine 530 and to correct errors. In addition,
the servicing technician can recommend different operating
guidelines to an operator or a technician working with the machine
530 in diagnosing and correcting problems in the machine 530.
Furthermore, the technician at the central location can monitor the
inventories at the remote site to ensure that sufficient quantities
of the various colors of paper are available before they are
actually required.
[0136] Although the monitoring systems 650 and 816 of the present
invention have been disclosed in conjunction with the conversion
machine 530 of FIGS. 18-23, it should be understood that the
present invention is equally applicable to various, diverse types
of packaging material conversion machine and packaging material
dispensing machines. For example, the monitoring systems 650 and
816 are equally applicable to a packaging material conversion
machine that produces various types of dunnage such as cushion
pads, styrofoam peanuts, plastic wrapping materials, etc. In
addition to being applicable to machines that produce such dunnage,
the present invention is also contemplated as applying to various
types of apparatus that dispense such dunnage into containers
and/or apply such dunnage to various objects for packing.
[0137] Although the invention has been shown and described with
respect to certain preferred embodiments, it is obvious that
equivalent alterations and modifications will occur to others
skilled in the art upon the reading and understanding of this
specification and the annexed drawings. In particular regard to the
various functions performed by the above described components
(assemblies, devices, sensors, circuits, etc), the terms (including
a reference to a "means") used to describe such components are
intended to correspond, unless otherwise indicated, to any
component which performs the specified function of the described
component (i.e., that is functionally equivalent), even though not
structurally equivalent to the disclosed structure which performs
the function in the herein illustrated exemplary embodiments of the
invention. In addition, while a particular feature of the invention
may have been disclosed with respect to only one of several
embodiments, such feature may be combined with one or more other
features of the other embodiments as may be desired and
advantageous for any given or particular application.
* * * * *