U.S. patent application number 12/769256 was filed with the patent office on 2010-11-04 for apparatus and method for detecting thickness of paper product.
This patent application is currently assigned to MULLER MARTINI MAILROOM SYSTEMS, INC.. Invention is credited to James BAIRD, Timothy GOSZKA, John MESSENGER, Harry NOLL, John SHAFFER.
Application Number | 20100276862 12/769256 |
Document ID | / |
Family ID | 43029785 |
Filed Date | 2010-11-04 |
United States Patent
Application |
20100276862 |
Kind Code |
A1 |
GOSZKA; Timothy ; et
al. |
November 4, 2010 |
APPARATUS AND METHOD FOR DETECTING THICKNESS OF PAPER PRODUCT
Abstract
A system detects the sheet quantity of sheet material such as
paper by use of a detection roller which deforms from concentric
when sheet material passes between the detection roller and another
roller, and using a detector to detect the degree of
de-concentricity and provide an output indicating the number of
sheets passing through. The system has particular application to
insert machines for detecting the number of sheets of insert
material being inserted into host material such as newspapers.
Inventors: |
GOSZKA; Timothy; (EMMAUS,
PA) ; BAIRD; James; (FOGELSVILLE, PA) ;
MESSENGER; John; (ALLENTOWN, PA) ; NOLL; Harry;
(MACUNGIE, PA) ; SHAFFER; John; (SCHNECKSVILLE,
PA) |
Correspondence
Address: |
LUCAS & MERCANTI, LLP
475 PARK AVENUE SOUTH, 15TH FLOOR
NEW YORK
NY
10016
US
|
Assignee: |
MULLER MARTINI MAILROOM SYSTEMS,
INC.
Allentown
PA
|
Family ID: |
43029785 |
Appl. No.: |
12/769256 |
Filed: |
April 28, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61173761 |
Apr 29, 2009 |
|
|
|
Current U.S.
Class: |
270/58.31 ;
271/263; 271/265.04 |
Current CPC
Class: |
B65H 2511/20 20130101;
B65H 2511/528 20130101; B65H 2553/24 20130101; B65H 2511/524
20130101; B65H 2511/524 20130101; B65H 2404/1431 20130101; B65H
2404/185 20130101; B65H 2511/13 20130101; B65H 2511/20 20130101;
B65H 2511/22 20130101; B65H 2801/66 20130101; B65H 2511/528
20130101; B65H 2553/61 20130101; B65H 2404/1411 20130101; B65H
2557/61 20130101; B65H 43/04 20130101; B65H 2511/13 20130101; B65H
2404/193 20130101; B65H 29/12 20130101; B65H 2404/191 20130101;
B65H 2511/22 20130101; B65H 2511/13 20130101; B65H 2220/01
20130101; B65H 2220/03 20130101; B65H 2220/03 20130101; B65H
2220/01 20130101; B65H 2220/03 20130101; B65H 2220/03 20130101;
B65H 2220/01 20130101; B65H 7/12 20130101; B65H 2404/1122 20130101;
B65H 2511/30 20130101; G01B 5/068 20130101; B65H 2511/30
20130101 |
Class at
Publication: |
270/58.31 ;
271/265.04; 271/263 |
International
Class: |
B65H 33/04 20060101
B65H033/04; B65H 7/02 20060101 B65H007/02; B65H 7/12 20060101
B65H007/12 |
Claims
1. A system for detecting the sheet quantity of moving sheet
product, comprising: a detection roller adapted for engagement with
a drive element for accepting sheet product between the detection
roller and drive element, the detection roller having a rotation
axis, and an outer ring component which becomes more de-concentric
relative to the rotation axis as the sheet quantity of sheet
product between the rollers increases; and a detector to detect the
amount of de-concentricity and for providing an output
corresponding to the sheet quantity of sheet product in dependence
on the degree of de-concentricity.
2. The system of claim 1, wherein the detection roller comprises a
central core and a web material between the central core and outer
ring component.
3. The system of claim 2, wherein the web material is more
resilient than the central hub and outer ring.
4. The system of claim 2, wherein the outer ring comprises a
metallic ring.
5. The system of claim 3, wherein the outer ring comprises an outer
tire outside the metallic ring.
6. The system of claim 4, wherein the detector comprises a detector
which detects the position of the outer ring relative to the
rotation axis.
7. The system of claim 2, wherein the web material has a hardness
of about 65 durometer on Shore A scale.
8. The system of claim 6, wherein the detector comprises a detector
which outputs an electrical signal having a component which varies
linearly with the amount of de-concentricity.
9. The system of claim 1, wherein the detection roller and detector
are mounted on a bearing plate.
10. The system of claim 1, further including a drive element.
11. The system of claim 1, wherein the drive element is a
high-speed disk.
12. An insert machine having the system of claim 1.
13. A system for detecting the sheet quantity of moving sheet
product, comprising: a detection roller adapted for engagement with
a drive element for accepting sheet product between the detection
roller and drive element, the detection roller having a rotation
axis, and an outer ring component which becomes more de-concentric
relative to the rotation axis as the sheet quantity of sheet
product between the rollers increases; and a detector to detect the
amount of de-concentricity of the outer ring component relative to
the rotation axis and for providing an output corresponding to the
sheet quantity of sheet product in dependence on the degree of
de-concentricity, wherein the detection roller comprises a central
core and a web material between the central core and outer ring
component.
14. An insert machine having the system of claim 1.
15. A system for detecting the thickness of moving sheet product,
comprising: a detection roller adapted for engagement with a drive
element for accepting sheet product between the detection roller
and drive element, the detection roller having a rotation axis, and
an outer ring component which becomes more de-concentric relative
to the rotation axis as the sheet quantity of sheet product between
the detection roller and drive element increases; and a detector to
detect the amount of de-concentricity of the outer ring component
relative to the rotation axis and for providing an output
corresponding to the sheet quantity of sheet product in dependence
on the degree of de-concentricity, wherein the detection roller
comprises a central core and a web material between the central
core and outer ring component, and wherein the detector comprises a
detector which detects the position of the outer ring relative to
the rotation axis.
16. An insert machine having the system of claim 1.
17. A system for detecting the sheet quantity of moving sheet
product, comprising: a detection roller adapted for engagement with
a drive element for accepting sheet product between the detection
roller and drive element, the detection roller having a rotation
axis, and an outer ring component which becomes more de-concentric
relative to the rotation axis as the sheet quantity of sheet
product between the detection roller and drive element increases;
and a detector to detect the amount of de-concentricity and for
providing an output corresponding to the sheet quantity of sheet
product in dependence on the degree of de-concentricity, wherein
the detector comprises a detector which outputs an electrical
signal having a component which varies linearly with the amount of
de-concentricity.
18. An insert machine having a system for detecting the sheet
quantity of moving sheet product, comprising: a detection roller
adapted for engagement with a drive element for accepting sheet
product between the detection roller and drive element, the
detection roller having a rotation axis, and an outer ring
component which becomes more de-concentric relative to the rotation
axis as the sheet quantity of sheet product between the rollers
increases; and a detector to detect the amount of de-concentricity
and for providing an output corresponding to the sheet quantity of
sheet product in dependence on the degree of de-concentricity.
19. A method for detecting the sheet quantity of moving sheet
product in a sheet handling machine, comprising: providing a
detection roller adapted for engagement with a drive element for
accepting sheet product between the detection roller and drive
element, the detection roller having a rotation axis, and an outer
ring component which becomes more de-concentric relative to the
rotation axis as the sheet quantity of sheet product between the
rollers increases; detecting the amount of de-concentricity; and
providing an output corresponding to the sheet quantity of sheet
product in dependence on the degree of de-concentricity.
20. A method for detecting the sheet quantity of moving sheet
product in an insert machine, comprising: providing a detection
roller adapted for engagement with a drive element for accepting
sheet product between the detection roller and drive element, the
detection roller having a rotation axis, and an outer ring
component which becomes more de-concentric relative to the rotation
axis as the sheet quantity of sheet product between the rollers
increases; detecting the amount of de-concentricity; and providing
an output corresponding to the sheet quantity of sheet product in
dependence on the degree of de-concentricity.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority on U.S. Ser. No.
61/173,761, filed Apr. 29, 2009, which is incorporated by reference
herein.
STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT
[0002] None.
BACKGROUND OF THE INVENTION
[0003] 1. Technical Field
[0004] The present invention relates to detecting the sheet
quantity of paper products, and more particularly to detecting the
sheet quantity of insert material in an insert machine for
inserting the insert material into newspapers and other paper
products.
[0005] 2. Description of the Related Art
[0006] In paper handling systems, it is often necessary or
desirable to detect the sheet quantity of paper products to
determine whether the correct number of sheets of paper are being
handled or transported.
[0007] One particular system in which it is useful to detect the
thickness of paper products is in insert machines which insert
product such as advertisements, promotional materials, booklets, or
other material into host-product, such as magazines or newspapers,
particularly Sunday newspapers.
[0008] In many cases, the insert product has intrinsic value, such
as a promotional or discount coupon. In such a case, it is
important that the insert machine insert only one such insert into
the host-product. Even in cases where such insert product is not of
such intrinsic value, it is important to insert only one of such
product to each subscriber, because the quantity of insert product
supplied for an insert operation is typically only 1% over the
host-product, and it is important that the supply of insert product
not be depleted before the host-product is fully-inserted.
[0009] Insert machines and other paper-handling systems have used
sheet quantity detectors to detect the sheet quantity of the
inserts or other paper. The individual inserts may be single sheet
or multiple sheets. If more than the desired thickness (or number
of inserts) is detected, corrective action usually needs to be
taken to remove the excess inserts. Such corrective action is
usually done by hand and is time-consuming and costly, and holds up
an insert operation which has deadlines in getting the
fully-inserted product to its ultimate destination, such as a
subscriber's home or newsstand.
[0010] Attempts to detect sheet quantity of inserts have included
contact sensors, radiation sources and detectors, fiber optic light
sensors, Hall sensor devices, and measuring the capacitance of the
document. However, those attempts have met varying degrees of
success, and some of them are affected by the temperature and
humidity of the environment, as well as other process
variables.
SUMMARY OF THE INVENTION
[0011] The invention provides a system for detecting the sheet
quantity of moving sheet product, comprising a detection roller
adapted for engagement with a drive element for accepting sheet
product between the detection roller and drive element, the
detection roller having a rotation axis, and an outer ring
component which becomes more de-concentric relative to the rotation
axis as the sheet quantity of sheet product between the rollers
increases; and a detector to detect the amount of de-concentricity
and for providing an output corresponding to the sheet quantity of
sheet product in dependence on the degree of de-concentricity.
[0012] The invention provides a system for detecting the sheet
quantity of moving sheet product, comprising a detection roller
adapted for engagement with a drive element for accepting sheet
product between the detection roller and drive element, the
detection roller having a rotation axis, and an outer ring
component which becomes more de-concentric relative to the rotation
axis as the sheet quantity of sheet product between the rollers
increases; and a detector to detect the amount of de-concentricity
of the outer ring component relative to the rotation axis and for
providing an output corresponding to the sheet quantity of sheet
product in dependence on the degree of de-concentricity, wherein
the detection roller comprises a central core and a web material
between the central core and outer ring component.
[0013] The invention provides a system for detecting the sheet
quantity of moving sheet product, comprising a detection roller
adapted for engagement with a drive element for accepting sheet
product between the detection roller and drive element, the
detection roller having a rotation axis, and an outer ring
component which becomes more de-concentric relative to the rotation
axis as the sheet quantity of sheet product between the detection
roller and drive element increases; and a detector to detect the
amount of de-concentricity of the outer ring component relative to
the rotation axis and for providing an output corresponding to the
sheet quantity of sheet product in dependence on the degree of
de-concentricity, wherein the detection roller comprises a central
core and a web material between the central core and outer ring
component, and wherein the detector comprises a detector which
detects the position of the outer ring relative to the rotation
axis.
[0014] The invention provides a system for detecting the sheet
quantity of moving sheet product, comprising a detection roller
adapted for engagement with a drive element for accepting sheet
product between the detection roller and drive element, the
detection roller having a rotation axis, and an outer ring
component which becomes more de-concentric relative to the rotation
axis as the sheet quantity of sheet product between the detection
roller and drive element increases; and a detector to detect the
amount of de-concentricity and for providing an output
corresponding to the sheet quantity of sheet product in dependence
on the degree of de-concentricity, wherein the detector comprises a
detector which outputs an electrical signal having a component
which varies linearly with the amount of de-concentricity.
[0015] The invention provides an insert machine having a system for
detecting the sheet quantity of moving sheet product, comprising a
detection roller adapted for engagement with a drive element for
accepting sheet product between the detection roller and drive
element, the detection roller having a rotation axis, and an outer
ring component which becomes more de-concentric relative to the
rotation axis as the sheet quantity of sheet product between the
rollers increases; and a detector to detect the amount of
de-concentricity and for providing an output corresponding to the
thickness of sheet product in dependence on the degree of
de-concentricity.
[0016] The invention provides a method for detecting the sheet
quantity of moving sheet product in a sheet handling machine,
comprising providing a detection roller adapted for engagement with
a drive element for accepting sheet product between the detection
roller and drive element, the detection roller having a rotation
axis, and an outer ring component which becomes more de-concentric
relative to the rotation axis as the sheet quantity of sheet
product between the rollers increases, detecting the amount of
de-concentricity, and providing an output corresponding to the
sheet quantity of sheet product in dependence on the degree of
de-concentricity.
[0017] The invention provides a method for detecting the sheet
quantity of moving sheet product in an insert machine, comprising
providing a detection roller adapted for engagement with a drive
element for accepting sheet product between the detection roller
and drive element, the detection roller having a rotation axis, and
an outer ring component which becomes more de-concentric relative
to the rotation axis as the sheet quantity of sheet product between
the rollers increases, detecting the amount of de-concentricity,
and providing an output corresponding to the sheet quantity of
sheet product in dependence on the degree of de-concentricity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a plan view of a system for detecting the sheet
quantity of moving sheet product according to the invention,
showing the case where the system is in a no-load condition with
the detection roller out of engagement with the high-speed driving
disk, with a close-up view of the detection roller;
[0019] FIG. 2 is a plan view similar to FIG. 1, but showing a
pre-load condition where the detection roller is engaged with the
high-speed driving disk and no sheet product there between, with a
close-up view of the detection roller;
[0020] FIG. 3 is a plan view similar to FIGS. 1 and 2, but showing
a load condition of a single sheet product between the detection
roller and high-speed driving disk, with a close-up view of the
detection roller;
[0021] FIG. 4 is a plan view similar to FIGS. 1, 2, and 3, but
showing a load condition of two sheets of product between the
detection roller and high-speed driving disk, with a close-up view
of the detection roller; and
[0022] FIG. 5 is a perspective view of the system according to
FIGS. 1-4, mounted in an assembly in an insert machine, and with a
tire outside the detection roller.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0023] A preferred embodiment of the invention will now be
described with reference to use in an insert machine, but the
invention is not limited to use in insert machines or the preferred
embodiment.
[0024] FIG. 1 shows an assembly 10 used to detect the sheet
quantity of paper product. The assembly comprises a detection
roller 12 (sometimes called roller ring 12 or simply roller 12) and
a high-speed driven disk 14. The detection roller 12 comprises a
central core 16 having a central rotation axis, an outer metallic
ring component 18, and a hub 20 formed of a resilient web material.
The assembly also includes a bearing plate 30 on which the
detection roller 12 is mounted for rotation, and on which a
detector 32 is mounted.
[0025] The detector 32 detects the relative position of the roller
ring 12, which is metallic, and outputs an electrical signal
generally proportional to the distance between the detector 32 and
roller 12, even if the roller 12 is rotating and regardless of
whether there is paper product between roller 12 and high-speed
disk 14. As sheets of paper stock are fed between roller 12 and
disk 14, the hub will deform and become de-concentric relative to
the central axis of the roller. The amount of deformation and
de-concentricity can be detected by the position of the roller ring
18 relative to the detector, even as the roller rotates. The
detector output signal will indicate the amount of material (e.g.,
zero sheets, one sheet, two sheets, etc.) between the roller 12 and
disk 14, thereby indicating whether no sheet, one sheet, two
sheets, etc., have passed through the roller 12 and disk 14.
[0026] FIG. 1 shows the detection roller 12 in a no-load condition,
with no deflection or de-concentricity in the roller. In other
words, the outer ring component 18 is generally concentric with the
central axis of rotation of the roller. The right side of FIG. 1
shows a close-up of the roller in this no-load position.
[0027] FIG. 2 shows the detection roller 12 in a pre-load
condition, wherein the roller 12 is engaged with the high-speed
disk 14, but wherein no sheet material is between the roller 12 and
high-speed disk 14. In this condition, as shown in more detail on
the close-up in the right of FIG. 2, the roller ring is slightly
non-concentric or de-concentric with the central rotation axis. The
hub is compressed slightly due to biased engagement of the roller
with the high-speed disk 14. The amount of deflection or
de-concentricity is about 0.5 mm. The detector signal output
correlates this with a pre-load but no-paper or no-insert material
condition.
[0028] FIG. 3 shows a loaded condition with a single sheet of paper
or insert material condition of 3 mm thickness of paper. The amount
of deflection is about 3.0 mm, indicating a single insert. There is
no motion in the bearing plate 30. The close-up on the right of
FIG. 3 shows the roller ring shifted de-concentrically to the left
relative to the central rotation axis of the roller 12, due to the
compression of the hub on the right side only of the roller 12,
from engagement of the roller 12 with the disk 14 and one sheet or
insert there-between.
[0029] FIG. 4 shows an overloaded or double-loaded condition, where
maximum deflection of the roller ring 12 is achieved and bearing
plate 30 pivots away from the high-speed disk 14. In this
condition, the sensor detects a double-loaded condition of about 6
mm thickness of paper, or two inserts of 3 mm each. In this
condition, maximum deflection of the roller ring 12 is achieved
(with this design of roller) and bearing plate pivots away from the
high-speed disk. In this case, the sensor does not detect
additional changes in thickness because the sensor is mounted on
the bearing plate 30 which is moving. This condition can be seen in
the roller close-up on the right of FIG. 4.
[0030] According to the invention, rollers can be arranged to
detect more than two sheets of inserts, if desired. In the
preferred embodiment in connection with an insert machine,
detection of a single insert and double-insert is usually
sufficient, as there is very little, if any, possibility of more
than two inserts passing through. Even so, the system will detect
whether more than one (and thus, two or more) passes through, which
indicates excess insert material feeding, whether it is one extra
insert or more than one extra insert. In an insert machine
operation, the number of extra inserts may not be as important as
simply detecting whether there is an excess insert condition.
[0031] FIG. 5 shows the assembly of FIGS. 1-4 in part of an insert
machine. The roller 12 can be seen having a hub or web with a
finned-design with cutouts or less material between the webs,
contributing to the resiliency of the hub or web. In FIG. 5, an
outer tire is shown surrounding the metallic ring 18.
[0032] It has been found that the hardness of a hub or web material
of about 65-70 durometer on Shore A scale works well, giving
sufficient durability through large numbers of cycles while still
providing reliable deflection characteristics.
[0033] In insert applications, an acceptable extra insert rate is
about 1%, because inserts are normally supplied at a 101% rate of a
host material. Above 101%, the insert material would run out before
the host material, in addition to a disadvantage of having some
customers or subscribers receiving extra promotional material or
coupons, which for some promotions is not desired.
[0034] Although, in the described embodiment the high-speed disk is
not fully-round, it could be fully-round throughout its entire
circumference. Also, the detection roller 12 could be a driven
roller.
[0035] The detector may be an inductive proximity (linear scale)
sensor which provides an electrical output generally
linearly-related to the amount of deflection (de-concentricity) of
the roller ring, and thus, product sheet quantity or thickness.
[0036] One way to process the output of the detector is to first
process the output signal during a load condition with no sheet
material passing there through. A photo detector can be used to
confirm that no sheet material is passing there through to get a
calibration or baseline reference for an empty or "no paper"
condition. The reference signal can be obtained by obtaining a
plurality of sample points (e.g., 20) throughout one revolution of
the roller and averaged to get a single output value. This process
may be repeated a plurality of times (e.g., nine) to get more
output values. The values are then averaged, and the average value
is taken to be the "empty reference" value, to which a reference of
"0" is assigned to indicate zero sheets of paper product.
[0037] The next step is to feed single sheets of paper product
through the rollers, taking the same samples and values as above.
The average value is then taken to be the "product reference" value
indicating a single insert. It should be understood that the single
insert could be a plurality of sheets which comprise the single
insert, comprising a unit sheet quantity, or unit thickness. That
average value may be assigned a "product reference" value of
100.
[0038] The system is ready to detect sheet quantity. When the
detected value is about 100, the product being fed is determined to
be a single unit of sheet quantity. When the detected value is
about 200, the product being fed is determined to be a double unit
of sheet quantity, and so on. A value of about 140-150, is a useful
threshold value, below which it is determined to be a single unit
of sheet quantity, and above which, a double-sheet quantity, (or
more). Higher threshold values for higher numbers of multiple
sheets could be 250, 350, etc. Accordingly, any reading between 50
and 150 will be determined to be a single-sheet quantity, and
between 150 and 250, a double-sheet quantity, and so on.
[0039] A drift compensation can be employed so that the values of
100, 200, 300, etc., and the threshold values of 150, 250, 350,
etc., will be adjusted upward or downward, depending on the average
values detected within each category of single, double, etc., drift
from 100, 200, etc. For example, if after running the machine for
awhile, the average value for a single insert is about 102, the
threshold values may be adjusted upward by 2% to 153, 255, 357,
etc.
[0040] When obtaining detector output values, it is desirable to
sample the detector output signal during the period of time when
sheet product (if there is any) actually would be between the
rollers, not taking any samples for the time points when the sheet
product enters the rollers or exits the rollers, because at these
time points, the rollers jump up at the front edge of the sheet
product and jump down at the trailing edge of the street
product.
[0041] Because the roller may be slightly de-concentric to start,
it is advantageous to obtain a plurality of sample points and
sample values during a wide, circumferential extent of the roller,
to thereby "average out" de-concentricities.
[0042] A typical high-speed disk would be about 7 inches in
diameter, or about 22 inches in circumference. This disk rotates
360.degree. per revolution. Since a typical roller diameter would
be 2.75 inches, or about 8 inches in circumference, the roller
would rotate over 3 times per complete revolution of the high speed
disk. Since it is expected to have some de-concentricity's in both
the roller and high speed disk due to manufacturing tolerances,
this could affect the accuracy of the detection system. The
sampling of values is controlled to begin at the same point in the
cycle (therefore at a specific angle on the high speed disk), it is
advantageous to use a sampling window of 1 revolution of the roller
so that de-concentricity's will be averaged. For the diameters of
the high speed disk and roller mentioned above, this window would
be approximately 150.degree.. Handling the sampling window this way
allows for less tolerances but still has the ability to be very
accurate. Of course, other arrangements can be used. Other
detectors, such as a laser, could be used.
[0043] Once excess insert material is detected, excess inserts
could be removed downstream at the insert operation, if desired.
The excess-inserted host material could be tagged and associated
with the detector output, so that the excess-inserted host material
could be located downstream and corrected by removing the excess
insert material.
[0044] It should be understood that the present invention has
application to different types of machines, and can be located at
different locations within a certain type of machine.
[0045] One preferred embodiment of the invention is described, but
the invention is not limited to this preferred embodiment. The
scope of the invention is defined only by way of the following
claims.
* * * * *