U.S. patent application number 10/476820 was filed with the patent office on 2004-08-05 for paper set feeding apparatus.
Invention is credited to Amdahl, Samuel, Russo, James.
Application Number | 20040150152 10/476820 |
Document ID | / |
Family ID | 32772160 |
Filed Date | 2004-08-05 |
United States Patent
Application |
20040150152 |
Kind Code |
A1 |
Russo, James ; et
al. |
August 5, 2004 |
Paper set feeding apparatus
Abstract
A set feeding apparatus (10) separates an uppermost set of paper
sheets from a staggered stack of sets (36) with a platform (34)
that biases the stack toward a carriage (42) that is moveable with
respect to the stack. The carriage includes a cam-activated pic and
a knife head that combine to raise the uppermost set from the
stack. A plow then engages the raised portion of the uppermost set
to move the set off of the stack.
Inventors: |
Russo, James; (Chicago
Heights, IL) ; Amdahl, Samuel; (Arlington Heights,
IL) |
Correspondence
Address: |
LEYDIG VOIT & MAYER, LTD
TWO PRUDENTIAL PLAZA, SUITE 4900
180 NORTH STETSON AVENUE
CHICAGO
IL
60601-6780
US
|
Family ID: |
32772160 |
Appl. No.: |
10/476820 |
Filed: |
November 4, 2003 |
PCT Filed: |
May 3, 2002 |
PCT NO: |
PCT/US02/13919 |
Current U.S.
Class: |
271/18 |
Current CPC
Class: |
B65H 3/247 20130101;
B65H 2301/422 20130101; B65H 3/54 20130101; B65H 2301/4228
20130101; B65H 2701/18266 20130101 |
Class at
Publication: |
271/018 |
International
Class: |
B65H 003/00 |
Claims
I claim as my invention:
1. A sheet set feeding apparatus for separating and feeding
successive sheet sets from a stack of sheet sets, said successive
sheet sets being offset relative to adjacent sheet sets in said
stack, said sheet set feeding apparatus comprising: a set picker,
said set picker exerting a temporary downward force on said stack
of sheet sets during operation; and; a support surface adapted to
support said stack of sheet sets, said support surface having an
upper surface with a rest position, said upper surface being pliant
and resilient such that the upper surface deflects from the rest
position in response to said downward force exerted on the
supported stack of sheet sets and said upper surface returns to
substantially its rest position upon removal of the downward
force.
2. The sheet set feeding apparatus of claim 1 wherein the support
surface includes a pad.
3. The sheet set feeding apparatus of claim 2 wherein said pad
comprises foam.
4. The sheet set feeding apparatus of claim 1 further comprising a
platform disposed subjacent said support surface.
5. The sheet set feeding apparatus of claim 2 wherein the pad is at
least 1/2 inch thick.
6. The sheet set feeding apparatus of claim 5 wherein the pad is at
least 1 inch think.
7. The sheet set feeding apparatus of claim 1 wherein the support
surface deflects no more than 1/2 inch during operation of the set
picker.
8. A sheet set feeding apparatus for separating and feeding
successive sheet sets from a stack of sheet sets, said stack of
sheet sets including at least an uppermost set having a lower
surface, and a penultimate set disposed subjacent said lower
surface and having an upper surface, said penultimate set being
offset from said uppermost set to present an upper exposed portion,
said penultimate set being disposed offset from the sheet sets of
said stack of sheet sets disposed subjacent said penultimate set
such that the stack of sheet sets presents staggered sheet set
edges at opposed ends of the stack of sheet sets, said sheet set
feeding apparatus comprising: a support surface adapted to support
said stack of sheet sets; a set picker assembly, said set picker
assembly including a pic adapted to create a separation between the
uppermost set and the penultimate set, said pic comprising a
rotatable camming arrangement including a protrusion disposed to
engage said staggered sheet set edges and moveable through an arc
to exert a downward force on the exposed portion of the penultimate
set, continued rotation exerting a separation force on the lower
surface of the uppermost set to cause said separation between the
lower surface of the uppermost set and the upper surface of the
penultimate set, and a set removal device disposed to engage the
separated uppermost set and remove the uppermost set from the stack
of sheet sets.
9. The sheet set feeding apparatus of claim 8 wherein the camming
arrangement includes an eccentric, said protrusion extending toward
said sheet set stack from said eccentric, rotation of said
eccentric resulting in rotation of said protrusion through said
arc.
10. The sheet set feeding apparatus of claim 8 wherein said pic is
moveably mounted to be disposed at the opposed ends of the stack of
sheet sets, and said protrusion is rotatable in either direction
dependent upon the location of the pic at either of the opposed
ends of the stack of sheet sets.
11. The sheet set feeding apparatus of claim 10 wherein the set
removal device is disposed at a first end of the opposed ends of
the stack of sheet sets, and the pic is moveably mounted to cause
said separation at the opposed end opposite the first end, said pic
mounted to continue to exert the separation force on the lower
surface of the uppermost set while traversing the stack of sheet
sets to dispose said separation along said first end.
12. The sheet set feeding apparatus of claim 11 wherein the pic
does not traverse the stack of sheet sets when causing said
separation at the first end of the opposed ends of the stack of
sheet sets.
13. The sheet set feeding apparatus of claim 11 further comprising
a separation enhancer, said separation enhancer being disposed at
the first end of the opposed ends of the stack of sheet sets to
enter the separation between the uppermost and penultimate sets to
enhance the separation.
14. The sheet set feeding apparatus of claim 8 further comprising a
separation enhancer, said separation enhancer being disposed to
enter the separation between the uppermost and penultimate sets to
enhance the separation,
15. The sheet set feeding apparatus of claim 8 wherein the set
removal device is a plow which exerts a pushing force on the
uppermost set.
16. The sheet set feeding apparatus of claim 8 wherein the set
removal device is a grasping device which grasps and exerts a
pulling force on the uppermost set.
17. The sheet set feeding apparatus of claim 8 further comprising a
stabilizer disposed to selectively exert a downward force on stack
of sheet sets.
18. The sheet set feeding apparatus of claim 11 further comprising
a stabilizer disposed to exert a downward force on the stack of
sheet sets during at least traversing of the pic.
19. The sheet set feeding apparatus of claim 8 wherein the support
surface has an upper surface with a rest position, said upper
surface being pliant and resilient such that said upper surface
deflects fro said rest position in response to said downward force
and said upper surface substantially returns to its rest position
upon removal of the downward force.
20. A sheet set feeding apparatus for separating and feeding
successive sheet sets from a stack of sheet sets, said stack of
sheet sets including at least an uppermost set having a lower
surface, and a penultimate set disposed subjacent said lower
surface and having an upper surface, said penultimate set being
offset from said uppermost set to present an upper exposed portion,
said penultimate set being disposed offset from the sheet sets of
said stack of sheet sets disposed subjacent said penultimate set
such that the stack of sheet sets presents staggered sheet set
edges at opposed ends of the stack of sheet sets, said sheet set
feeding apparatus comprising: a support surface adapted to support
said stack of sheet sets; a set picker assembly, said set picker
assembly including a pic adapted to create a separation between the
uppermost set and the penultimate set, said pic being mounted to be
substantially linearly moveable to traverse the stack of sheet
sets, said pic being operable to create said separation at either
of the opposed ends of the stack depending upon the location of the
exposed portion of the penultimate set, said pic further being
adapted to maintain said separation while traversing the stack of
sheet sets, a separation enhancer disposed at a first end of said
opposed ends of the stack of sheet sets, and a set removal device
disposed to engage the separated uppermost set and remove the
uppermost set from the stack of sheet sets.
21. The sheet set feeding apparatus of claim 20 further comprising
a stabilizer disposed to exert a downward force on the stack of
sheet sets during at least traversing of the pic.
Description
FIELD OF THE INVENTION
[0001] The invention generally pertains to devices for handling
sets of paper sheets. More specifically, the invention relates to a
device that will separate and remove individual sets of sheets from
a stack of sets arranged in a staggered, or offset, manner.
BACKGROUND OF THE INVENTION
[0002] Publishing, photocopying, and otherwise processing large
quantities of printed materials such as books, loose-leaf
collections, and other assemblages of individual sheets is often a
multi-step process. Typically, printing or photocopying of
individual copies, also known as sets, of the subject materials is
followed by various other operations such as punching, binding,
counting, sorting, and the like. Often, after each individual set
comprising a copy of particular work passes through a process, it
is stacked with other copies of the same work in preparation for
feeding into subsequent process devices. Additional processing may
occur "on-line" or "off-line." In on-line processing, a single set
of sheets is typically forwarded directly to the next process. In
off-line processing arrangements, a stacked arrangement of
identical, or differentiated, individual sets facilitates efficient
bulk transfer of the sets between sequential processing stations
that may or may not be located in physical proximity to each other.
Thus, stacking individual sets of documents in a staggered or
offset fashion eliminates the need for costly set separators and is
the most efficient way to feed sets into processing equipment that
only accepts sets fed one-by-one, rather than as an entire stack of
sets.
[0003] Although a staggered arrangement of individual sets in a
stack creates efficiencies in the selection and feeding of
individual sets, feeding individual sets from a staggered stack can
still be a time-consuming and labor-intensive undertaking. This is
true of any paper-handling situation where individual sets are
separately selected and removed from a stack. Each set must be
carefully gathered, engaged, and handled without losing or
separating individual sheets from a set, and without mixing sets.
Further, many processing operations, even ordinary photocopying,
require the individual page edges of a set to be in precise
alignment. Sheets or edges, such as tabs, which extend beyond the
general edge of the set may hamper reliably feeding large numbers
of sets into processing equipment. Automated devices have been
proposed to handle the task of separating and removing complete
sets of sheets from a stack of identical or differentiated sets for
feeding the individual sets into processing equipment.
[0004] A device for mechanically feeding a set of sheets for
further processing is disclosed, for example, in U.S. Pat. Nos.
6,126,384, 5,820,334, and 5,556,254 to Darcy et al. In the set
feeder disclosed in the Darcy patents, the sets are disposed in a
hopper and fed from the lowermost end by a driven shutter
mechanism. The force exerted by the stack of sets in such
bottom-feeding apparatus, however, can effect the accuracy of the
set feeding, particularly when the stack is relatively have or
large.
OBJECTS AND BRIEF SUMMARY OF TEE INVENTION
[0005] It is a primary object of the invention to provide an
automated device that reliably selects, gathers, and removes a set
of sheets from a staggered stack of identical or differentiated
sets. It is a related object of the invention to provide a set
feeding apparatus which eliminates the effect of stack weight.
[0006] It is a further object of this invention to provide an
automated means of feeding individual sets of sheets from a stack
of substantially identical sets into processing equipment used in
on-line applications or in off-line applications, including
multi-stage printing or photocopying operations.
[0007] Another object of the invention is to provide a set feeding
apparatus that can accommodate different sizes of sheets and
protrusion from the edge of the set, such as tabs.
[0008] The present invention is directed to a set feeder apparatus
for separating an uppermost set of paper sheets from a previously
staggered stack of similar sets and individually feeding the
uppermost set into a subsequent processing station. The invention
provides a vertically movable platform which has a pliable,
resilient upper surface or a foam pad or the like disposed along
its upper surface. Thus, the stack of sheet sets resting on the
platform can deflect downward when a pressure or force is applied
to the upper sets.
[0009] A frame supports a movable carriage, a stabilizing unit for
stabilizing the stack of sets during an initial separation
operation, and a plow assembly which pushes the uppermost set from
the apparatus. The movable carriage supports the elements which
provide an initial separation of one edge of the uppermost set from
the remainder of the stack so that the plow can engage the
uppermost set for removal. Thus, the movable carriage supports a
pair of sensors for detecting the exact positions of the sets of
the stack, a pic for providing an initial separation between the
top two sets, and profiled knife for enhancing the separation
between the top two sets for removal by the plow.
[0010] Once the platform is loaded, and the operator has input the
paper dimensions, the platform raises the stack towards the
moveable carriage. As the stack moves upward, the exposed edge
portion of the set immediately below the uppermost set contacts one
of the sensors disposed on the carriage, thus initializing the
invention to begin the process of selecting and removing the
uppermost set from the stack. The carriage sensors are disposed at
opposite ends of the carriage to facilitate sensing at either end
of the stack. Thus, each time the uppermost set is removed, the
carriage can shift to detect the newly exposed edge portion at the
opposite end of the stack.
[0011] The cam-activated pic on the movable carriage is configured
to rotate to lift and separate an edge portion of the uppermost set
from the stack. In operation, after the exposed edge portion of the
set immediately below the uppermost set contacts the sensor, the
pic moves into position at the exposed edge. The stabilizer unit is
always preferably exerting a downward force on the stack during the
operation of the pic and the knife. The eccentric, cam-driven
rotation of the pic initially moves the pic downwardly, into
contact with the exposed edge portion. After passing the lowest
point of its travel, the pic rotates upwardly into contact with the
bottom of the uppermost stack, lifting an edge portion thereof, and
creating a gap between the two uppermost sets. A profiled knife,
likewise disposed on the carriage, is advanced into the gap created
by the pic between the two uppermost sets, so as to further lift
and separate a portion of the uppermost set from the stack, while
simultaneously exerting a downward force on the stack. When the pic
is disposed at the end of the stack proximal to the plow, the knife
is advanced into the gap immediately after the "pick" is performed.
If the pic is operating at the end of the stack distal to the plow,
the carriage moves the pic engaged between the top two sets to the
end proximal the plow before the knife is advanced into the gap.
Thus, the more significant separation due to the profiled knife is
always ultimately disposed at the end proximal the plow.
[0012] Once an edge portion of the uppermost set of sheets is
lifted above the remaining stack by the knife, the stabilizer unit
releases the downward pressure on the stack, and a plow is deployed
to engage the edge of the uppermost set raised by the knife. The
plow travels in a horizontal path above the level of the unlifted
stack, so that it only engages the uppermost set when the uppermost
set is raised by the knife. Once the plow has engaged the uppermost
set, the plow pushes this set off of the stack. The plow thus
removes the uppermost set from the top of the stack without
interfering with the rest of the stack. Significantly, neither the
pic, the blade, nor the plow interfere with the use of tabs or the
like which protrude from the front edge of the sets.
[0013] The knife and plow then return to their predetermined
operating positions, the carriage positions itself to detect the
next exposed edge portion, and the entire process will continue
repeating itself, until all of the sets have been moved off of the
platform.
[0014] The operation of the set feeding apparatus is thus an
improvement over the prior art. These and other advantages of the
present invention, as well as additional inventive features, will
be apparent from the description of the invention provided
herein.
BRIEF DESCRIPTION OF THEE DRAWINGS
[0015] FIG. 1 is a perspective view of a preferred embodiment of
paper set feeding apparatus constructed according to teaching of
the present invention.
[0016] FIG. 2 is a front elevational view of the apparatus shown in
FIG. 1.
[0017] FIG. 3 is a top plan view of the embodiment of the invention
shown in FIG. 1.
[0018] FIG. 4 is a side elevational view of the embodiment of the
invention shown in FIG. 1.
[0019] FIG. 5 is a perspective view of the stabilizer component of
the present invention.
[0020] FIG. 6 is a perspective view of the carriage portion of the
present invention.
[0021] FIG. 7 is an exploded perspective view of the carriage
portion of the present invention shown in FIG. 6.
[0022] FIG. 8 is a perspective view of the plow portion of the
present invention.
[0023] FIG. 9 is a side elevational view of the plow portion of the
present invention.
[0024] FIG. 10 is a perspective view of the pic and associated cam
of FIGS. 6 and 7.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Turning now to the drawings, FIGS. 1-4 show a set feeder
apparatus 10 constructed according to the present invention. The
apparatus 10 has a rear 110 and a front 112. The apparatus 10
consists of a base 12 that carries a support surface or platform
34, which supports a stack of offset or staggered sheet sets 36,
and a frame 11 which supports other powered elements of the set
feeding apparatus 10. The frame 11 preferably includes upfront
supports and horizontal elements connecting the upfront supports.
In the preferred embodiment illustrated, front support 14 and a
rear support 16, secured to the base 12, and extending generally
upward therefrom. As best seen in FIGS. 1 and 2, the front support
14 is disposed and constructed such that it does not interfere with
the movement of the individual sets of the stack of sheets 36
through the front end of the apparatus 10. In order to support
mechanized components of the apparatus 10, the top 18 of the front
support 14 is coupled to the top 20 of the rear support 16 by
carriage rods 22, 24 and bracket 26 is coupled to support 14. It
will be appreciated that the carriage rods 22, 24 also serve to
further enhance the rigidity of the skeleton.
[0026] In accordance with the invention, the apparatus 10 includes
powered elements which act on the stack of sets 36 supported on an
upwardly biased platform 34 to separate the uppermost stack and
advance it out of the front of the apparatus 10. The structure and
each of these powered elements, as well as the platform 34, will be
described in turn. In short, the apparatus 10 includes a movable
support platform 34 which advances the stack of sets 36 upward
until the uppermost set 37 is positioned adjacent a set picker
assembly 69, which separates and slightly lifts the top set 37 from
the second set 38, a stabilizer unit 49, which stabilizes the stack
of sets 36 during the picking operation, and a plow assembly 88,
which functions to push the uppermost set 37 from the stack of sets
36.
[0027] The platform 34 preferably includes not only a horizontal
plate portion which supports the stack of sets 36, but at least one
vertical element 34a against which an edge of the stack 36 may be
disposed to ensure proper positioning. In the preferred embodiment
illustrated, two such vertical elements 34a along the side and back
of the apparatus 10 may be seen in FIGS. 2-4. Significantly, the
vertical elements 34a are disposed such that they will not
interfere with the operation of the powered elements of the
apparatus 10.
[0028] To ensure that the sets always feed to the same position as
they are fed out of the front 112 of the apparatus 10, the platform
34 is biased or powered to advance the stack of sets 36 upward to
position the uppermost set 37 at the desired feed level, adjacent
the set picker assembly 69 and plow assembly 88. In order to
support the platform 34, platform rods 28, 30,32 are provided which
extend upwardly from the base 12. Coupling brackets 35 slidably
mounted on the platform rods 28, 30, 32 and secured to the platform
34 facilitate the vertical motion of the platform 34 along the
platform rods 28, 30, 32 to vertically move a previously staggered
stack 36 of sheet sets. The interface of the coupling bracket 35
with the platform rods 28, 30, 32 may consist of a reversible drive
apparatus such as a motor which engages with one or more of the
platform rods 28, 30, 32, via gears, frictionally, or via some
other reversible means of facilitating vertical motion along the
platform rods 28, 30, 32. Alternately, the platform 34 may be
biased into the desired uppermost position by adjustable springs of
the like. Thus, it will be appreciated by those of skill in the art
that any appropriate mechanism may be utilized, so long as the
uppermost set 37 is ultimately disposed at the desired
location.
[0029] According to an important feature of the invention, the
platform 34 preferably incorporates a pliant, resilient pad (not
pictured) or has a resilient upper surface. In this way, the stack
36 of sheets may locally deflect in response to downward pressure,
the significance of which will be apparent upon an explanation of
the set picking device below. This pad may be made of foam or other
suitable material, which is sufficiently pliable to allow
deflection, yet resilient enough to return to its original state
when the downward force is removed. In the currently preferred
embodiment, a urethane foam having a minimum thickness of
apparently one inch (1") or 25 mm is utilized. It has been
determined that such a foam pad permits a deflection on the order
of 3/8 inch. It will be appreciated that the required deflection
will be dependent upon the dimensions of the set picker, as will be
described below.
[0030] In order to properly position the stack of sets 36 so that
the set picker assembly 69 and plow assembly 88 may separate and
advance the uppermost set 37 from the stack 36, the apparatus 10 is
preferably provided with one or more sensors 44, 46. The sensor(s)
44, 46 arranged so that they sense when the stack 36 is disposed
with the uppermost and second sets 37, 38 in the desired position.
In a stack of sets 36, the uppermost set 37 and the second set 38
are offset from one another such that a portion 39 of the second
set 38 is exposed at one end of the uppermost set 37. In the
preferred embodiment of the invention, two sensors 44, 46 are
provided and are disposed to sense this exposed portion 39 at the
front and the back, respectively, of the stack of sets 36. During
operation, when the sensor 44,46 is just in from the edge of the
stack of sets 36 (typically on the order of 1/4" to 3/4", depending
upon the degree of offset in the staggering), the platform 34 will
move upward until the sensor 44, 46 is activated or closed, at
which time the platform 34 stops. In this way, the uppermost set 37
is appropriately positioned to be "picked," and the set feeding
sequence is initialized.
[0031] Due to the alternating staggered arrangement of the stack
36, each time the uppermost set is removed, the successive exposed
portion 39 of the new second set 38 is located at an opposite end
of the stack than was the previous exposed portion. Accordingly,
the set picker assembly 69 as well as the sensors 44, 46 are
preferably disposed on a movable carriage unit 42. The carriage
unit 42 is attached to carriage rods 22, 24 by a carriage bracket
43. It will be appreciated that the interface of the carriage
bracket 43 with the carriage rods 22, 24 may consist of any
appropriate reversible drive apparatus such as a motor which
engages with one or more of the carriage rods 22, 24 via gears,
frictionally, or via some other reversible means of facilitating
motion along the carriage rods 22, 24.
[0032] In use, as the platform 34 raises, the sensor 46 senses the
exposed portion 39 of the second set 38 at the rear 110 of the
stacked sets 36 (as may be seen in FIG. 4) to arrest the movement
of the platform 34. The set picker assembly 69 is then moved into
position to begin the picking operation, as will be explained in
greater detail below. It will be appreciated that when the
uppermost set 37, as shown in FIG. 4 is removed, the exposed
portion 39a of the new second set will be disposed at the opposite
or front end 112 of the stack of sets 36. When the exposed portion
39a is so disposed at the front end, the opposite sensor 44 is
moved to a position at the front of the stack of sets 36 such that
the platform 34 moves upward to raise the stack 36 to a position
where the exposed surface 39a actuates or closes the sensor 44, at
which point the platform 34 stops. The set picker assembly 69 is
then moved into position to begin the picking operation at the
front end of the stack 36. Thus, the positioning of the sensors 44,
46 to the front or rear of the set picking assembly 69 allows the
sensors 44, 46 to perform the sensing function on opposite ends of
the stack 36 as the uppermost set is removed, and the stack 36
continues to move upwardly toward the carriage 42. By utilizing two
sensors 44, 46, to detect an exposed portion 39, 39a on either end
of the stack 36, the range of motion of the carriage unit 42 can be
minimized, thus reducing the overall size of the set feeding
apparatus 10.
[0033] In order to stabilize the stack of sets 36 and prevent
shifting of individual sheets or sets while the set picker assembly
69 lifts the uppermost set 37, a stabilizer unit 49 is provided.
The stabilizer unit 49 is disposed such that it may be actuated to
apply a downward force on the stack of sets 36 to sandwich the
stack 36 between the stabilizer unit 49 and the platform 34. While
the stabilizer unit 49 may be actuated before or after the set
picker assembly 69 is moved into position, the stabilizer unit 49
is preferably actuated to apply a downward force immediately after
the sensor 44, 46 is closed by exposed portion 39, 39a of the stack
of sets 36.
[0034] As shown in FIGS. 1-3, channel 54 of the stabilizer unit 49
is secured to bracket 26 by bolts or the like. The detail of the
stabilizer unit 49 itself is best depicted in FIG. 5, a perspective
view. The stabilizer unit 49 includes a stabilizer pad 50 to which
rods 58, 60,62 are mounted. The rods 58, 60,62 are slidably mounted
to the channel 54 with bearings or the like such that sliding the
rods 58, 60, 62 relative to the channel 54 moves the pad 50
downward or upward to move the pad 50 into or out of contact with
the stack of sets 36. The stabilizer unit 49 further includes
stabilizer motor or actuator 52 which provides such vertical
movement to the pad 50 and rods 58, 60, 62. The actuator 52 is
preferably coupled to the pad 50 by a rack and pinion gear
arrangement 56, 57. The shaft of the pinion gear 57 extends through
the bracket 54 and meshes with the rack 56 disposed along one of
the rods 60. In this way, as the actuator 52 imparts a rotating
motion to the pinion gear 57, the pad 50 is moved upward or
downward with the rod 60. In operation, the stabilizer pad 50
contacts the uppermost set 37 and applies a downward force thereto
in order to hold the uppermost set 37 of sheets in place and
together as a group while an edge is lifted from the remaining
stack 36.
[0035] Once the stabilizer unit 49 has applied a downward force to
the uppermost set 37, the uppermost set 37 is ready for lifting for
eventual separation from the remaining stack 36. As previously
mentioned, the carriage 42 may be shifted so that the set picker
assembly 69 is appropriately positioned to lift the uppermost set
37 either before or after the stabilizer unit 49 has established
the stabilizing downward force on the stack 36, so long as the set
picker assembly 69 is not actuated until after the force has been
applied.
[0036] Turning to FIGS. 6 and 7, the set picker assembly preferably
includes a protrusion or pic 70, which provides an initial lifting
of the uppermost set 37 from the stack 36, and a separation
enhancer or knife 76, which is subsequently advanced to a position
between the uppermost and second sets 37, 38 to enhance the
separation for the final removal of the uppermost set 37 from the
stack 36. The pic 70 itself has an elongated structure and is
preferably formed of a relatively low friction material so that it
does not shift the papers of the second set during the "pick"
operation. In order to actually lift the corner edge of the
uppermost set 37 from the second set 38, the pic 70 is mounted on
an eccentric, rotatable cam arrangement 71 to the pic actuator 72
(shown in more detail in FIG. 10). Significantly, the pic 70 may be
rotated in either a clockwise or counterclockwise direction, the
significance of which will become apparent upon further
explanation.
[0037] When the carriage 42 shifts to position the set picker
assembly 69, the pic 70 is positioned above the exposed portion 39,
39a of the second set 38. Specifically, the carriage 42 will shift
such that the pic 70 is located at substantially the same position
relative to the stack 30 that the sensor 44, 46 was previously
located. Once the carriage 42 has shifted (and the stack 36 is
stabilized by the downward pressure of the stabilizer pad 50), pic
actuator 72 eccentrically rotates the pic 70 downward and toward
the centerline of the stack 36 from a predetermined position above
the lowest point of the rotational path of pic 70. As the eccentric
motion of the actuator 72 rotates the pic 70, initially in a
downward arc, the pic 70 depresses the exposed portion 39 of the
second set 38. Inasmuch as the platform 34 includes a pliant,
resilient pad along its upper surface, the stack 36 below the pic
70 deflects downward as the pic 70 continues to rotate downward. As
the pic 70 passes the lowest point of its rotation, the continuing
eccentric motion of the pic actuator 72 will cause the pic 70 to
move in an upward circular motion. The upward circular motion of
the pic 70 will thus bring the pic 70 into contact with the bottom
of the uppermost set 37. The continued upward motion of the pic 70
raises the uppermost set 37 to a predetermined level, creating a
space between the uppermost set 37 and the second set 38. Upon
reaching a predetermined, uppermost position, the rotation of the
pic 70 ceases, thus maintaining the space between the sets.
[0038] It will be appreciated by those of skill in the art that the
pic 70 always moves down and inward toward the stack 36 during the
"pick" operation. Thus, when exposed portion 39 is disposed at the
rear 110 of the apparatus 10 (i.e., to the left as shown in FIG.
4), the pic 70 is moved in a counterclockwise direction.
Conversely, when the exposed portion 39 is disposed at the front
112 of the apparatus 10 (i.e., to the right as shown in FIG. 4),
the pic 70 moves in a clockwise direction.
[0039] In order to provide a more significant separation between
the uppermost and second sets 37, 38, the set picker assembly 42
further includes a separation enhancer, in this case a profiled
knife 76. The knife 76 is rotatably coupled to a knife rod 80 which
is further coupled to a powered knife actuator 74. The extending
and retracting motion of the knife 76 is facilitated by a knife cam
78 driven by the knife actuator 74. The eccentric motion of the
knife cam 78 imparts a longitudinal reciprocating motion to the
knife rod, between the horizontal extreme portions of the knife cam
78 rotational path. To provide the knife 76 some vertical and
lateral flexibility so that the knife 76 can engage the stack 36
over a wide positional tolerance range, a knife spring 82 disposed
adjacent the knife 76. Although the knife 76 is biased to the
illustrated position, the knife spring 82 permits some rotational
movement of the knife 76 about the axis of the knife rod 80.
[0040] In operation at the rear end 110 of the apparatus 10, after
the pic 70 has stopped, the knife actuator 74 fires, pushing the
profiled knife 76 into the space created between the uppermost set
37 and the next set 38 by the pic 70. Significantly, the knife 76
is advanced into the stack 36 at a point further from the edge of
the uppermost set 37 than where the pic 70 is engaged. In this way,
the knife 76 increases the spacing between the uppermost set 37 and
the second set 38 not only as a result of its higher profile, but
also as a result of its more distal disposal. The knife 76 then
remains in this position, maintaining the space between the
uppermost set 37 and the second set 38, in preparation for the
uppermost set 37 removal operation. Thus, when the carriage sensor
44 detects the exposed edge surface 39 at the rear end 110 of the
stack 36, the entire lifting and separating operation will occur at
the rear end 110 of the stack.
[0041] When the carriage sensor 44 detects the stack 36 and
initializes the lifting operation from the front end 112 of the
stack, however, the pic 70 will engage and lift the uppermost set
from the front end 112. In order to position the knife 76 for
firing, the carriage unit 42 then moves toward the rear end 110 of
the stack 36 with the pic 70 still engaged in the stack 36,
stopping before the pic 70 clears the end of the uppermost set 38.
It will be appreciated that the pic 70 and knife 76 are now
disposed in the same position at the rear 110 of the apparatus 10
as if the pic 70 had originally performed the separation operation
entirely at the rear 110, as explained above. With the pic 70 still
engaged with the uppermost set 38, now at the rear end 110 of the
stack 36, the profiled knife 76 is advanced into the pic-created
opening in the stack 36, increasing the separation between the
uppermost sets.
[0042] Thus, the set picker assembly 69 presents a gap between the
uppermost and second set 37, 38 at the rear 110 of the stack 36,
whether initial separation by the pic 70 occurred at the front 112
or rear 110 of the stack 36. Once the knife 70 is advanced to so
separate the sets 37, 38, the stabilizer unit 49 is actuated to
retract the stabilizer pad 50 and discontinue the downward
stabilizing force on the stack 36.
[0043] In order to remove the spaced, uppermost set 37 from the
remaining stack 36, a set removal device, here, a plow assembly 88
is provided, as shown in detail in FIGS. 8 and 9. It will be
appreciated by those of skill in the art, however, that an
alternate removal device, such as a grasping device, may be
provided. The plow assembly 88 includes a plow blade 90, which is
mounted for linear movement to engage the separated, uppermost set
37, and push it from the stack 36, and an actuator or motor 108 for
driving the blade 90. The motor 108 is coupled to the rear bracket
16 by a cradle 100. As best seen in FIG. 8, plow guide rods 92, 94,
104, in this case, three such guide rods, are secured to the plow
blade 90 at one end and slidably mounted in bores 96, 98 in the
cradle 100. Axial motion is imparted to the plow guide rods 92, 94,
104 from the motor 108 by a rack and pinion system. More
specifically, a rotatably driven gear 106 is mounted to engage a
rack 105 disposed along one of the guide rods 104. Thus, as the
motor 108 rotates the gear 106, the rack 105 moves the guide rod
104 in an axial direction to drive the plow blade 90 either forward
to push the set 37 from the apparatus 10, or rearward to retract
the plow blade 90.
[0044] Thus, during operation while the edge of the uppermost set
37 is lifted off of the stack 36 by the knife 76, a plow blade 90
moves forward and engages the uppermost set 37. The plow blade 90
continues forward to a predetermined point, at which the uppermost
stack 37 has been completely removed from the stack 36. As shown in
FIGS. 8 and 9, the plow blade 90 includes a protruding lower edge
91 which prevents the uppermost set 37 from falling back onto the
stack 36 during this step.
[0045] After this final operation, the plow blade 90 and the knife
76 retract to their predetermined starting positions. The carriage
unit 42 is then shifted to the opposite staggered side of the stack
36, and the entire lift, separate, and push sequence is repeated to
remove a newly uncovered set from the stack 36.
[0046] It will be appreciated by those of skill in the art that the
motors or actuators 52, 72, 74, 108 may be of any appropriate type
or design. Further, the motors or actuators 5, 72, 74, 108 may be
coupled together by any appropriate means so that signals may be
conveyed between them as necessary to initiate operation.
[0047] While this invention has been described with an emphasis
upon preferred embodiments, variations of the preferred embodiments
can be used, and it is intended that the invention can be practiced
otherwise than as specifically described herein. Accordingly, this
invention includes all modifications encompassed within the spirit
and scope of the invention as defined by the following claims.
[0048] All of the references cited herein, including patents,
patent applications, and publications, are hereby incorporated in
their entireties by reference.
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