U.S. patent application number 10/974308 was filed with the patent office on 2005-03-31 for paper jam detector for automatic food processing line.
This patent application is currently assigned to Packaging Progressions, Inc.. Invention is credited to Ely, Allen M..
Application Number | 20050067750 10/974308 |
Document ID | / |
Family ID | 26697352 |
Filed Date | 2005-03-31 |
United States Patent
Application |
20050067750 |
Kind Code |
A1 |
Ely, Allen M. |
March 31, 2005 |
Paper jam detector for automatic food processing line
Abstract
A paper jam detector for use in connection with a substrate
interleaver of an automated food processing line is provided. At
least one jam detector sensor is located along at least one of the
feed path from the substrate feed mechanism and a second conveyor
that receives product from a first conveyor, and is adapted to
detect when a substrate passes from the substrate feed mechanism
onto the second conveyor. A controller is connected to the at least
one jam detector sensor and to the substrate feed mechanism such
that upon detection of an unsuccessful substrate feed, the
controller turns off the substrate feed mechanism to prevent
feeding of more substrates into the jam area, which creates a hard
jam and longer down time for the production line for clearing the
jam. A method for detecting jams is also provided.
Inventors: |
Ely, Allen M.; (Downingtown,
PA) |
Correspondence
Address: |
VOLPE AND KOENIG, P.C.
UNITED PLAZA, SUITE 1600
30 SOUTH 17TH STREET
PHILADELPHIA
PA
19103
US
|
Assignee: |
Packaging Progressions,
Inc.
Collegeville
PA
|
Family ID: |
26697352 |
Appl. No.: |
10/974308 |
Filed: |
October 27, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10974308 |
Oct 27, 2004 |
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10023582 |
Dec 18, 2001 |
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60257560 |
Dec 22, 2000 |
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Current U.S.
Class: |
271/9.01 |
Current CPC
Class: |
B65B 57/04 20130101;
B65B 25/08 20130101 |
Class at
Publication: |
271/009.01 |
International
Class: |
B65H 003/44 |
Claims
What is claimed is:
1. An interleaver having a substrate jam detector comprising: first
and second conveyors, the first conveyor adapted to feed a product
onto the second conveyor; a substrate feed mechanism having a feed
path positioned to insert a predetermined length of substrate
between the first and second conveyors and onto the second conveyor
such that the substrate is adapted to be located under the product
as the product is transferred from the first conveyor to the second
conveyor; at least one jam detector sensor located along at least
one of the feed path from the substrate feed mechanism and the
second conveyor for sensing a substrate; and a controller,
connected to the at least one jam detector sensor and to the
substrate feed mechanism, which is adapted to determine an
unsuccessful substrate feed by at least one of a determination of
whether the jam detector sensor senses a substrate for greater than
a predetermined interval greater than zero and a determination of
whether the jam detector sensor fails to sense a substrate for
greater than a predetermined interval greater than zero, such that
upon a determination of an unsuccessful substrate feed, the
controller turns off the substrate feed mechanism.
2. The interleaver of claim 1, wherein the jam detector sensor
comprises a photo-eye.
3. The interleaver of claim 1, wherein the jam detector sensor
comprises a fiber optic cable connected to an optic sensor
connected to the controller, the fiber optic cable having an end
positioned adjacent to at least one of the feed path and the second
conveyor.
4. The interleaver of claim 3, wherein the fiber optic cable is
bendable.
5. The interleaver of claim 1, further comprising a product
detector located along the first conveyor to generate a signal to
activate the substrate feed mechanism.
6. The interleaver of claim 1, wherein the substrate feed mechanism
includes a perforator and at least one acceleration roller for
separating the substrate to be interleaved along a perforation
line, and the at least one jam detector sensor is located between
the perforator and the at least one acceleration roller.
7. Method of detecting a jam in a substrate interleaver for
products traveling along a conveyor path, comprising: (a) providing
first and second conveyors, the first conveyor adapted to feed a
product onto the second conveyor; (b) positioning a jam detector
sensor along at least one of a substrate feed path of a substrate
feed mechanism positioned to insert substrates under product being
conveyed by the first conveyor to the second conveyor and the
second conveyor; (c) detecting a product traveling along the first
conveyor and initiating a substrate feed sequence from the
substrate feed mechanism; (d) sensing at least one of a substrate
and a blockage of the jam detector sensor; (e) determining an
unsuccessful substrate feed by at least one of determining whether
the jam detector sensor senses at least one of a substrate and a
blockage for greater than a predetermined interval greater than
zero, and determining whether the jam detector sensor fails to
sense a substrate for greater than a predetermined interval greater
than zero; and (f) turning off the substrate feed mechanism in the
event that an unsuccessful substrate feed is determined.
8. The method of claim 7, wherein the substrate feed mechanism is
turned off prior to feeding a next substrate.
9. The method of claim 7, further comprising sounding an alarm when
the unsuccessful substrate feed is detected.
10. The method of claim 9, further comprising clearing a jam and
resetting the jam detector.
11. The method of claim 7, wherein the jam detector sensor includes
a fiber optic cable, the method further comprising positioning a
sensing end of the fiber optic cable along the substrate feed
path.
12. The method of claim 7, further comprising generating a signal
to turn off upstream equipment when the unsuccessful substrate feed
is detected.
13. The method of claim 7, wherein the sensing of the substrate
includes sensing at least one of a leading and a trailing edge of
the substrate.
14. An interleaver having a substrate jam detector comprising:
first and second conveyors, the first conveyor adapted to feed a
product onto the second conveyor; a substrate feed mechanism, which
includes cutting rollers and acceleration rollers positioned to
convey a predetermined length of substrate along a feed path which
flows downstream from the cutting rollers to the acceleration
rollers, and from the acceleration rollers between the first and
second conveyors onto the second conveyor, such that the substrate
is adapted to be located under the product as the product is
transferred from the first conveyor to the second conveyor; at
least one jam detector sensor, positioned to sense the substrate at
a location downstream from the cutting rollers of the substrate
feed mechanism; and a controller connected to the at least one jam
detector sensor and to the substrate feed mechanism which is
adapted to determine an unsuccessful substrate feed by at least one
of a determination of whether the jam detector sensor senses a
substrate for greater than a predetermined interval and a
determination of whether the jam detector sensor fails to sense a
substrate for greater than a predetermined interval, such that upon
a determination of an unsuccessful substrate feed, the controller
turns off the substrate feed mechanism.
15. A method of detecting a jam in a substrate interleaver
comprising: providing first and second conveyors, the first
conveyor positioned to feed a product onto the second conveyor;
providing a substrate feed mechanism having a feed path positioned
to insert a predetermined length of substrate between the first and
second conveyors and onto the second conveyor to locate the
substrate under the product as the product is transferred from the
first conveyor to the second conveyor, the substrate feed mechanism
including a perforator and at least one acceleration roller for
separating the substrate to be interleaved along a perforation
line, the feed path flowing downstream from the perforator to the
at least one acceleration roller; detecting a product traveling
along the first conveyor and initiating a substrate feed sequence
from the substrate feed mechanism; sensing a substrate along the
feed path in an area downstream from the perforator; determining an
unsuccessful substrate feed by at least one of determining whether
the jam detector sensor senses a substrate for a predetermined
interval greater than zero and determining whether the jam detector
sensor fails to sense a substrate for a predetermined interval
greater than zero; and turning off the substrate feed mechanism in
the event that an unsuccessful substrate feed is determined.
16. The method according to claim 15, further comprising sensing
the substrate along the feed path in an area between the at least
one acceleration roller and the perforator.
17. The method according to claim 15, further comprising turning
off upstream equipment in the event that an unsuccessful substrate
feed is determined.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 10/023,582, filed Dec. 18, 2001, which claims
the benefit of U.S. Provisional Patent Application No. 60/257,560,
filed Dec. 22, 2000.
BACKGROUND
[0002] The present invention relates generally to interleaving
devices used in food preparation lines. More particularly, the
invention relates to a method for detecting paper jams on automated
food processing lines and allowing rapid service without the need
for shutting down the entire line.
[0003] Automated food processing machines have become prevalent in
the art for interleaving and stacking food products. Food
processing machines may produce sliced meat hamburger patties or
other types of food which can then be arranged in a designated
pattern on a substrate which is then stacked and packaged. Products
handled in this manner include sandwich meats, cheese, steak meat,
hamburger, pizza, pasta, dough products, as well as other food
which can then be easily accessed in a predetermined quantity by a
food preparer who can simply unload the set-up during the food
preparation process. Typically, interleaved products have
particular weights of a food serving located on a substrate.
Automated equipment for preparing interleaved products is known,
and may include different food slicing, extruding or other handling
equipment which creates the predetermined quantity of food. The
food is then carried to an interleaver where it is placed upon the
predetermined length of a substrate, such as a separating paper, to
form the interleaved product. From there, further equipment takes
the interleaved product on the predetermined length of paper to a
stacking machine for stacking and packaging. Such equipment may run
at speeds of 50-250 set-ups per minute, depending upon the food
being packaged. For example, hamburger patties are typically run at
approximately 80 to 320 interleaved products per minute in a single
lane or multi lane operation. Minute steaks can be processed at a
speed of 240 interleaved products per minute, depending upon the
particular equipment being utilized. Typically the processing
equipment is fully automated such that only one operator may be
able to monitor the production of several food lines at the same
time.
[0004] A known problem with the existing interleavers for placing
the predetermined length of separating paper under the food product
is that sometimes the automatic paper feeding mechanism jams. Since
the food processing line operates at high speed, in the time it
takes to detect that food product is being dispensed from the
product line without the required separating paper, the paper feed
may have already attempted to insert 15-20 additional sheets of
paper creating a hard jam in the interleaver equipment feed. The
entire product line must then be shut down for 10-15 minutes while
an operator clears the multiple sheets of paper jammed in the
interleaver feed path. Additionally, this can result in damage to
the interleaver feed rolls as the paper jam is cleared, since
operators typically use a screw driver or other blunt instrument to
pry the paper out. An additional problem caused by the delay is
that the batch of food being processed may have to be discarded,
depending on the delay time. It would therefore be desirable to
have a faster and easier way to detect paper jams in the
interleaver and clear the paper jams once they are detected.
SUMMARY
[0005] The present invention provides an interleaver having a
susbtrate jam detector. The interleaver includes first and second
conveyors, with the first conveyor feeding a product onto the
second conveyor. A substrate feed mechanism is provided having a
feed path positioned to insert a predetermined length of substrate
between the first and second conveyors and onto the second conveyor
such that the substrate is located under the product as the product
is transferred from the first conveyor to the second conveyor. At
least one jam detector sensor is located along at least one of the
feed path from the substrate feed mechanism and the second
conveyor, and is adapted to detect when a substrate passes from the
substrate feed mechanism onto the second conveyor. A controller is
connected to the at least one jam detector sensor and to the
substrate feed mechanism such that upon detection of an
unsuccessful substrate feed, the controller turns off the substrate
feed mechanism. Because the jam detector shuts down the substrate
feed mechanism as soon as a jam is detected, an operator can easily
clear a one to two sheet jam from the interleaver feed mechanism at
a much faster rate than in the prior known equipment where the
substrate feeder continued to jam additional sheets of substrate
into the feed opening. This prevents damage to the feed rolls,
paper wire guides, and other machine components.
[0006] In another aspect, the invention provides a method of
detecting a jam in a substrate interleaver for products traveling
along a conveyor path. The method includes:
[0007] (a) providing first and second conveyors, the first conveyor
adapted to feed a product onto the second conveyor; (b) positioning
a jam detector sensor along at least one of a substrate feed path
of a substrate feed mechanism positioned to insert substrates under
product being conveyed by the first conveyor to the second conveyor
and the second conveyor; (c) detecting a product traveling along
the first conveyor and initiating a substrate feed sequence from
the substrate feed mechanism; (d) sensing at least one of a
substrate leading edge passing the jam detector sensor within a
predetermined time, a continuous blockage of the jam detector
sensor, and a substrate trailing edge passing the jam detector
sensor within a second predetermined time; and (e) turning off the
substrate feed mechanism in the event that a jam is detected.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The following detailed description of the preferred
embodiments of the present invention will be better understood when
read in conjunction with the appended drawings. For the purposes of
illustrating the invention, there is shown in the drawings
embodiments which are presently preferred. It is understood,
however, that the invention is not limited to the precise
arrangements and instrumentalities shown.
[0009] FIG. 1 is an elevational view of an interleaver having a jam
detector in accordance with the present invention.
[0010] FIG. 2 is a top plan view of the interleaver in accordance
with FIG. 1.
[0011] FIG. 3 is a right side elevational view of the interleaver
in accordance with FIG. 1.
[0012] FIG. 4 is a greatly enlarged detail of a portion of the
interleaver indicated in FIG. 1, showing the jam detector
sensors.
[0013] FIG. 5 is a cross-sectional view of the conveyor taking
along lines 5-5 in FIG. 3.
[0014] FIG. 6 is a top plan view of the conveyor shown in FIG.
5.
[0015] FIG. 7 is a right side elevational view of the conveyor
shown in FIG. 5.
[0016] FIGS. 8A through 8C are a flow diagram of the logic for the
paper jam detector utilized with the interleaver in accordance with
a first preferred embodiment of the present invention.
[0017] FIG. 9 is an elevational view similar to FIG. 4, showing a
jam detector sensor in accordance with a second preferred
embodiment of the present invention.
[0018] FIGS. 10A through 10C are a flow diagram of the logic for
the paper jam detector utilized with the interleaver in accordance
with a second preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Referring now to FIGS. 1-3, an interleaver 10 for use in
connection with an automated food production line in which a food
product is placed upon a separating paper substrate is shown. The
interleaver 10 includes a first product conveyor 12 and a second
product conveyor 14 which are supported on a frame 16. As shown in
FIG. 1, preferably the first conveyor 12 is located at a slightly
higher elevation than the second conveyor 14. A substrate feed
mechanism 20 is located between the first and second conveyors 12,
14. A paper jam detector 40 in accordance with a first embodiment
of the present invention is mounted below the second conveyor 14.
Product is carried in the product flow direction, indicated by
arrow 18 in FIG. 1, on the first conveyor 12. As each product
passes from the first conveyor 12 to the second conveyor 14, a
substrate 13, such as a piece of wax paper or any other suitable
material, is introduced onto the surface of the second conveyor 14
underneath the product such that the product is located on the
substrate 13. The product/substrate food set-up is then carried
from the second conveyor 14 for further processing, stacking or
packaging.
[0020] Referring now to FIG. 4, the paper feed path 22 of the
substrate feed mechanism 20 is shown in detail. The paper feed path
is defined by a plurality of feed rollers and includes a first
roller pair 24 which pulls the substrate, such as paper, from a
continuous roll (not shown) into the paper feeder 20. The paper
then passes between a pair of cutter rolls 25, 26 which cut a line
of perforations through the continuous roll of feed stock to allow
separation of a paper substrate 13 of a desired length for each
food product being conveyed to form the food set-up. The substrate
13 then passes between a pair of acceleration rolls 27 which rotate
at a higher speed than the cutter rolls 25, 26 and the feed rolls
24. The high speed rolls 27 accelerate the portion of the paper
substrate 13 above the perforation line, parting the desired length
of paper substrate 13 at the separation line such that the paper
substrate 13 of the desired length is advanced through the space
between the first conveyor 12 and the second conveyor 14.
Alternatively, the feed rolls 24 can be stopped to cause the paper
substrate 13 to part along the perforation line, parting the
desired length of substrate. The paper feed mechanism 20 is
controlled by a controller such that a paper substrate 13 is
introduced onto the surface of the second conveyor 14 as the food
product is delivered from the first conveyor 12 to the second
conveyor 14, such that the food product is placed on the substrate
13.
[0021] Referring now to FIGS. 4-7, the jam detector 40 in
accordance with the first embodiment of the invention preferably
includes four photo-eye detectors 42a, 42b, 42c, 42d which are
located beneath the surface of the second conveyor 14, preferably
by approximately 0.5 inches, as shown in FIG. 5. In the illustrated
embodiment, the interleaver 10 is arranged such that four adjacent
paper substrates 13 are interleaved at the same time beneath four
adjacent food products being carried along the first conveyor 12.
Each food product is placed upon one of the substrates 13 as the
food products are transferred from the first conveyor 12 to the
second conveyor 14. One photo-eye detector 42a-42d is provided for
each lane of food products traveling along the interleaver 10. The
photo-eye detectors 42a-42d are connected via wires, fiber optic
cables or any other suitable connections 44a-44d to a controller
48. The detectors are preferably a Banner Photo-eye Mini-beam
Sensor, such as Model No. SM312FVG. However, it will be recognized
by those skilled in the art from the present disclosure that other
types of sensors may be utilized. Additionally, the number of
sensors may vary, depending upon the number of lanes of food
product being carried by the conveyors 12, 14. The photo-eye
42a-42d is positioned such that it can detect whether a paper
substrate 13 is present at a given time based upon the time that a
paper substrate 13 is fed from the feed mechanism 20. In the event
that the paper substrate 13 is not detected within a predetermined
time period or count, the controller 48 signals the feed mechanism
20 to stop feeding additional paper substrates 13 to the second
conveyor 14. The conveyors 12 and 14 are allowed to continue to
run, and food product which passes through the interleaver 10
without a substrate 13 is removed from the automated food line in a
down stream quality control area. Because the interleaver 10
detects whether each substrate 13 has been received on the second
conveyor 14 within a predetermined time period, in the event that a
paper substrate 13 becomes jammed in the feed mechanism 20 in the
space between the conveyors 12, 14, no additional substrates 13 are
forced into the jam area. Once a jam is detected by one of the
photo-eye detectors 42a-42d, an alarm signal is also triggered so
that an operator can clear the jam and reset the paper feed
mechanism 20 such that the interleaving of paper substrates 13
under a food product can be continued with a minimum interruption
of the automated food processing line. Additionally, the jam detect
signal can be used to shut-off upstream equipment, if desired.
[0022] It will be recognized by those skilled in the art from the
present disclosure that more or less photo-eye detectors 42a-42d
may be provided depending upon the number of lanes of food product
being carried by the interleaver 10. It will be similarly
recognized by those skilled in the art that the photo-eye detectors
42a-42d could also be placed above the acceleration rollers 27 in
the area where jams occur to directly detect a jam, as described in
detail below in connection with the second preferred embodiment of
the invention, instead of detecting the absence of a paper
substrate 13 on the second conveyor 14, as in the first preferred
embodiment described above.
[0023] Referring now to FIGS. 8a-8c, a logic flow diagram for the
jam detector 40 in accordance with a first embodiment of the
present invention is shown. As shown in box 50, the jam detector
may be turned on or bypassed. If the jam detector 40 is off, the
interleaver 10 may be started as shown in box 52, and product flow
can begin as shown in box 54. The product detection photo-eye is
activated, as shown in box 56. The product detection photo-eye is
used as a timing trigger for the paper feed sequence, as shown in
box 58. Running the interleaver 10 without the jam detector 40
turned on allows for operation in the prior known manner, with the
product photo-eye signal, shown in box 56, activating the paper
feed sequence, as shown in box 58, such that a substrate 13 is
placed under each food product as it is conveyed from the first
conveyor 12 to the second conveyor 14.
[0024] When the jam detector 40 is turned on, a jam reset count is
set, as shown in box 60. The jam reset count is a count signal
which times when a substrate 13 is detected by the jam detector
photo-eyes 42a-42d after a substrate 13 has been fed by the sheet
feeder 20. It is also possible to enter the number of jam detect
photo-eyes 42a-42d which are to be activated, as shown in box 62.
All jam detect photo-eyes 42a-42d may be activated, as shown in box
64. However, if selected jam eyes 42a-42d are not activated, they
are disabled by the control logic, as shown in the box 66. It is
also necessary to position the eyes 42a-42d for the number of
product lanes, as shown in box 68, and to load paper into the
interleaver paper feed mechanism 20, as shown in box 70. The
interleaver 10 is then started, as shown in box 72, and product
flow begins, as shown in box 74. Product traveling down the first
conveyor 12 activates the product photo-eye, as shown in box 76.
The controller then automatically runs a self diagnostic on the jam
detect photo-eyes 42a-42d to determine if they have been blocked by
product for more than two seconds, as shown in box 78. While two
seconds has been selected here, it is merely exemplary. If the jam
detect photo-eyes 42a-42d are blocked, for example by food products
which has fallen through the conveyor and onto the jam detect
photo-eyes 42a-42d, the program turns off the paper feed as
indicated in box 80, while the conveyors 12, 14 continue to run. An
alarm is activated, as indicated in box 82, and an operator is
required to manually clear the photo-eye 42a-42d, as indicated in
the box 84. The jam detect signal could also be used to turn off
upstream equipment, if desired. The jam detector is then reset as
indicated in box 86. If it is determined that the jam detect
photo-eyes 42a-42d are not blocked during the self diagnostic shown
in box 78, the paper feed sequence is initiated, as shown in box
88, based upon the signal received from the product activated paper
feed photo-eye, as shown in box 76. At that point, the jam detect
photo-eyes 42a-42d scan for the substrate fed by the paper feed
mechanism 20, as shown in box 90. As shown in box 92, if all of the
jam detect photo-eyes 42a-42d that are active sense the paper
substrate, the jam detector counter is reset as shown in box 94 and
the process is repeated. If all of the jam detect photo-eyes
42a-42d do not sense a substrate at the same time for each of the
lanes of food product, the jam reset counter determines if the
predetermined count has been exceeded, as shown in box 96. If the
count has not been exceeded and a substrate is detected by each jam
detect photo-eye 42a-42d within a given count, the jam detector
counter is reset and the process is repeated for the next product
or products in the product lanes which reach the product detection
photo-eyes. In the event that the jam reset counter is exceeded,
the controller 48 turns off the paper feed mechanism 20, as shown
in box 80, and activates an alarm, as shown in box 82, such that an
operator can clear the paper jam, as shown in box 84, before
resetting the jam detector, as shown in box 86. The logic is
carried out in the jam detector controller 48, which can be a PLC
or any other suitable programmable controller.
[0025] Referring now to FIG. 9, a second embodiment of a jam
detector 140 for use in an interleaver 10 in accordance with the
present invention is shown. The second embodiment of the jam
detector 140 is similar to the first embodiment 40, except that the
jam detect sensor 142 is formed by the end of a fiber optic cable
143 which can be positioned along the paper path to place the jam
detector sensor 142 between the perforating rolls 25, 26 and the
acceleration rolls 27. The fiber optic cable 143 is mounted on a
bracket 145, and the paper is remotely sensed via the fiber optic
cable 143, which is connected to the controller 148. This allows
greater flexibility to place a sensor in almost any location,
regardless of the small spaces available. While only a single jam
detect sensor 142 is shown, multiple jam detect sensors 142 and
associated fiber optic cables 143 could be utilized, depending on
the number of product lines being run. The fiber optic cable 143
can be a single optic fiber, or multiple optic fibers.
Alternatively, a combination of electrical and optic cables or
other signal transmission means could be utilized, or other types
of optic sensors could be used that provide an electrical signal
that is transmitted to the controller 148.
[0026] Referring now to FIGS. 10a-10c, a logic flow diagram for the
jam detector 140 in accordance with a second embodiment of the
present invention is shown. As shown in box 150, the jam detector
may be turned on or bypassed. If the jam detector 140 is off, the
interleaver 10 may be started as shown in box 152, and product flow
can begin as shown in box 154. The product detection photo-eye is
activated, as shown in box 156. The product detection photo-eye is
used as a timing trigger for the paper feed sequence, as shown in
box 158. Running the interleaver 10 without the jam detector 140
turned on allows for operation in the prior known manner, as
discussed above in connection with the first embodiment.
[0027] When the jam detector 140 is turned on, the interleaver 10
is started, as shown in box 160. The jam detector 140 then senses
whether the jam detector eye remains blocked for a predetermined
interval, for example 2 seconds, as shown in box 162. If it remains
blocked, the program turns off the paper feed as indicated in box
180 in FIG. 10C, while the conveyors 12, 14 continue to run. An
alarm is activated, as indicated in box 182, and an operator is
required to manually clear the jam, as indicated in the box 184.
The jam detector is then reset as indicated in box 186. Optionally,
the jam detect signal can be used to turn off upstream equipment
feeding the interleaver.
[0028] If it is determined that the jam detect eye 142 is not
blocked, product flow is initiated, as shown in box 164 in FIG.
10A. Product traveling down the first conveyor 12 activates the
product photo-eye, as shown in box 166, and initiates the paper
feed sequence, as shown in box 168. As shown in box 170, when the
product photo-eye is activated and the paper feed sequence is
initiated, an internal PLC latch is set, and a timer starts timing
a predetermined time delay, as shown in box 172 in FIG. 10B. If the
leading edge of the paper substrate 13 is not detected within this
predetermined time by the jam detect eye 142, as shown in box 174,
this is considered a jam, and the sequence in boxes 182, 184, 186
and 188 is initiated. If the leading edge of the substrate 13 is
detected, then the internal PLC latch is unlatched, as shown in box
176. At the conclusion of the paper feed sequence, as shown in box
177, an internal PLC latch is set, as shown in box 178, and an
internal timer starts timing a predetermined time delay, as shown
in box 179. If the trailing edge of the paper substrate 13 is not
detected within this predetermined time delay period, as shown in
box 180, this is again considered a jam, and the jam sequence is
initiated. If the passing of the trailing edge of the substrate 13
is detected, the sequence is reinitiated, as indicated, when the
next product activates the paper photo-eye 166.
[0029] By detecting jams in three ways: a continual blockage of the
jam detect eye 142, a leading edge detection failure, or a trailing
edge detection failure for each substrate, the jam detector 140
provides the ability to detect a jam after only a single piece of
substrate is fed (or mis-fed) to create a jam. This allows for less
down time to clear the jam, and a swift return to normal
operation.
[0030] By utilizing the present invention, down time and lost
product are avoided since the product in the automated food
processing line is allowed to continue to flow and an alarm is
immediately activated upon detection of a substrate jam in the
paper feed mechanism 20. This allows an operator to quickly and
easily clear a paper jam and restart the paper feed in a short time
period such that the batch of food product being processed and
placed on the paper substrates 13 does not have to be scrapped due
to excessive down time to clear large paper jams in the paper feed
mechanism 20, which was common in the prior art interleavers.
Products which continue through the food processing line without a
paper substrate 13 are handled in the normal manner for
rejects.
[0031] While the preferred embodiments of the invention have been
described in detail, the invention is not limited to the specific
embodiments described above, which should be considered as merely
exemplary. Further modifications and extensions of the present
invention may be developed, and all such modifications are deemed
to be within the scope of the present invention.
* * * * *