Separator sheet handling assembly

The present invention is embodied in a separator sheet handling assembly (10) that includes a lifting assembly (20) adapted to receive a pallet (12) containing a stack of separator sheets (14). The lifting assembly (20) positions the stack of separator sheets (14) into a predetermined location where a feed assembly (30) engages a separator sheet (16) positioned at the top of the stack of separator sheets (14). The feed assembly (30) removes the separator sheet (16) and transports it to a test assembly (50) where the separator sheet (16) is monitored for a particular characteristic such as cleanlines or structural integrity. The separator sheet (16) is delivered to a first storage assembly (60) if the separator sheet (16) has the particular characteristic, or a second storage assembly (70) if the separator sheet (16) does not include the particular characteristic.

FIELD OF THE INVENTION

The invention relates generally to an assembly for handling separator sheets, and particularly to an assembly that sorts a pile of separator sheets, which are used in stacking multiple layers of products onto pallets, into different piles depending on the characteristics of the individual separator sheets.

BACKGROUND OF THE INVENTION

Smaller products or articles of production (e.g., beverage containers) are commonly stacked on to pallets for shipping and handling. The products are arranged in horizontal tiers, or layers, on the pallet such that additional layers can be stacked on top of the lower layers. Separator sheets are placed between the layers of products to provide a uniform support surface for each layer of products. The uniform support surface makes adding and removing the top layer of products easier. As the top layers of products are unstacked from the pallet, the separator sheets between each layer are removed and set aside for reuse.

Depending on the types of products that are stacked onto the pallet, and the environment where the stacking process takes place, the separator sheets may become dirty and/or damaged. Using a dirty or damaged separator sheet in order to facilitate stacking products into layers on a pallet can result in (i) the products becoming damaged or dirty, (ii) the products being stacked on to the pallet unsafely, and (iii) damage to the palletizing machine that stacks the products on to the pallet.

SUMMARY OF THE INVENTION

The present invention provides a separator sheet handling assembly that is capable of (i) receiving a stack of separator sheets, (ii) testing the separator sheets, and (iii) sorting the separator sheets into various piles depending on whether each separator sheet is dirty, clean, damaged or undamaged (among other characteristics).

The separator sheet handling assembly includes a lifting assembly that is adapted to receive a pallet containing a stack of separator sheets. The lifting assembly positions the stack of separator sheets into a predetermined location where a feed assembly engages a separator sheet positioned at the top of the stack of separator sheets. The feed assembly delivers the top separator sheet to a test assembly where the separator sheet is monitored for a particular characteristic (e.g., cleanliness or structural integrity). The separator sheet is delivered to a first storage assembly if the separator sheet has a particular characteristic, or a second storage assembly if the separator sheet does not include a particular characteristic.

DETAILED DESCRIPTION

A separator sheet handling assembly10embodying the invention is illustrated inFIGS. 1 and 2. The illustrated separator sheet handling assembly10includes a lift assembly20, feed assembly30, alignment assembly40, test assembly50, first storage assembly60and second storage assembly70.

During operation of the separator sheet handling assembly10, a pallet12having a stack of separator sheets14thereon is supplied into the lift assembly20. The lift assembly20moves the pallet12upward until the feed assembly30grasps a separator sheet16positioned on lop of the stack of separator sheets14. The feed assembly30transports the separator sheet16into the alignment assembly40. As the separator sheet16passes through the alignment assembly40, the separator sheet16is maneuvered to a predetermined location for delivery to the test assembly50. The test assembly50is adapted to test the separator sheet16in order to determine if the separator sheet16is clean and free from holes, tears or any other damage. The separator sheet16is preferably tested (and analyzed) as it is transported through the test assembly50, although the movement of the separator sheet16might have to either be slowed, or stopped altogether, depending on types of tests that are performed.

Depending on the condition of the separator sheet16, it is either transported into the first storage assembly60or transported over the first storage assembly60into the second storage assembly70. It should be noted that additional storage assemblies could be added if the test assembly50has the capacity to analyze additional characteristics on the separator sheet16. As an example, clean and undamaged separator sheets16would be transported to the first storage assembly60, dirty but undamaged sheets would be transported into the second storage assembly70and damaged sheets would be transported into a third storage assembly (not shown).

In the assembly illustrated inFIGS. 1 and 2, the lift assembly20is adapted to receive a pallet12that is inserted by a lift truck or other pallet handling device including, but not limited to, a conveyor21. Although any conventional lift could be employed without departing from the scope of present invention, the lift assembly20is shown as a scissors lift which is powered by a hydraulic cylinder that indexes the pallet12upward at designated intervals so that the feed assembly30removes the separator sheets16one at a time from the top of the stack of separator sheets14.

Positioned above the lift assembly20is a top frame remover assembly17(shown inFIG. 1only). The top frame remover assembly17includes a gripper assembly18(shown in the raised position) that is lowered as needed to grab a top frame19positioned on top of the stack of separator sheets14. The gripper assembly18is suspended from, and travels along, horizontal rails15. During operation of the separator sheet handling assembly10, the gripper assembly18is positioned above the lift assembly20until a top frame19is detected on top of the stack of separator sheets14. Operation of the sheet feed assembly30is suspended and the gripper assembly18lowers until it engages the top frame19and grabs it with pneumatically powered grippers (not shown). The gripper assembly18then returns to the raised position and moves along guide rails15until it is over a frame collection bin13where the top frame19is released by the grippers to fall into the frame collection bin13. As shown inFIG. 2, the top frame collection bin13is positioned beside lift assembly20but it should be understood that it can be positioned in any available position that is adjacent to the lift assembly20.

The lift assembly20also includes an air chamber25positioned near the top of the stack of separator sheets14. The air chamber25moves air through the lift assembly20to facilitate removing only the top separator sheet16instead of multiple sheets. The sheets in the stack of separator sheets14often tend to adhere to the top sheet due to moisture, dirt and/or static among other reasons.

In a preferred form of the invention, the lift assembly20includes squaring fences (not shown). The squaring fences organize the stack of separator sheets14into a neat pile before the uppermost sheet is removed by the feed assembly30. The squaring fences can be any configuration commonly known in the art and may continuously, or periodically, square the stack of separator sheets14as the lift assembly20indexes the pallet upward toward the feed assembly30.

The feed assembly30is shown in detail inFIGS. 3-5. The feed assembly30is adapted for horizontal movement relative to the lift assembly20and the alignment assembly40. Horizontal motion is translated to a portion78of the feed assembly30by a drive80. The drive80maneuvers a chain79in an endless pattern as indicated by arrow A inFIG. 4. Abracket81is connected to a section of the chain79such that the bracket81moves along the path of the chain79. The bracket81is pivotally connected to one end82of a support arm83such that maneuvering the bracket81causes movement of the support arm83. An opposite end84of the support arm83is pivotally connected to a bracket85(seeFIG. 3) that is connected to a laterally extending support structure86of the feed assembly30. The pivotal connection between the ends82,84of the support arm83and the respective brackets81,85causes the nonlinear motion of the support arm83to be translated to horizontal linear motion of the laterally extending support structure86. A pair of support rods87A,87B extend longitudinally from opposite sides of the laterally extending support structure86. The support rods87A,87B are supported for horizontal movement by bearings32positioned on opposite sides of the separator sheet handling assembly10. The feed assembly30is maneuvered vertically by pneumatic cylinders34positioned on opposite sides of the separator sheet handling assembly10.

The feed assembly30includes vacuum fittings36that engage the top surface of the separator sheet16. A preferred form and arrangement of the vacuum fittings36are disclosed in PCT/US97/07520, which is incorporated herein by reference.

During operation of the separator sheet handling assembly10, the feed assembly30moves backward and downward to grasp the separator sheet16positioned on the top of the stack of separator sheets14. Once the vacuum fittings36engage the top surface of the separator sheet16, the feed assembly30moves upward and forward to position the separator sheet16between rotating drive rollers37,38. Drive roller38drives a first plurality of endless belts41and drive roller37drives a second plurality of endless belts39. The first and second plurality of belts39,41contact the upper and lower surface of the separator sheet16and deliver the separator sheet16into the alignment assembly40.

The feed assembly30includes a pair of brackets89A,89B that are pivotally connected to support members90A,90B that are part of separator sheet handling assembly10. This pivoted connected allows the feed assembly30to be rotated (i.e., raised up) by activating pneumatic cylinders34that are positioned on opposite sides of the feed assembly30. The ability to raise the feed assembly30in this manner permits easy inspection and/or maintenance of the area between the first and second plurality of belts39,41, especially when a separator sheet16becomes jammed in the feed assembly30.

The separator sheet16is carried through the alignment assembly40by the first plurality of belts41which are positioned across the width of the separator sheet handling assembly10. As the separator sheet16travels through the alignment assembly40, the separator sheet16is maneuvered by guides42into a predetermined position. The separator sheet16needs to be maneuvered into this predetermined position so that the separator sheet16is properly positioned as it enters the test assembly50.

The plurality of belts41also transports the separator sheet16through the test assembly50. The test assembly50uses conventional monitoring devices in order to collect data regarding certain characteristics of each separator sheet16. In a preferred form, the test assembly50includes a light emitting system51that projects light upward toward the separator sheet16as the separator sheet16passes through the test assembly40. The test assembly50further includes a sensor52that checks to see if any light passes through the separator sheet due to tears or holes in the separator sheet16. The test assembly50could also perform other tests on the separator sheet16that are commonly known in the art, including, but not limited to, checking for load tags and surface contamination (e.g., oil or syrup spots, and footprints).

The collected data is supplied to a computer (not shown) or some other decisionmaking entity. The computer then instructs the separator sheet handling assembly10to direct the separator sheet16into either the first storage assembly60or the second storage assembly70.

The delivery of the separator sheet16into either the first storage assembly60or the second storage assembly70is illustrated inFIGS. 6 and 7. Depending on the characteristics of the separator sheet16, the computer sends out a signal that directs an actuator61to either expand or contract. The actuator61is connected to a directing guide62that moves up and down as the actuator61expands and contracts. In the assembly illustrated inFIG. 6, the actuator61is contracted such that the directing guide62is in a lowered position. When the directing guide62is in the lowered position, the separator sheet16passes over the directing guide62and moves from the plurality of laterally spaced belts41onto a separate set of laterally spaced belts65that transport the separator sheet16to the second storage assembly70.

If the computer directs the actuator61to expand, the directing guide62moves into a raised position (see phantom lines inFIG. 6) such that the separator sheet16enters the directing guide62between an upper bracket63and a lower bracket64. The separator sheet16continues through the directing guide62into the first storage assembly60.

The first storage assembly60includes a lifting frame69that is capable of supporting a pallet66in a predetermined location. The separator sheet16enters the first storage assembly60and is positioned on top of a pile67of previously sorted separator sheets by guides68. The lifting frame69is maneuvered up and down using chains100that are driven by sprockets positioned on opposite sides of a support structure105. As the separator sheets16continue to stack up on the pallet66, the lifting frame69is indexed downwardly until a desired number of separator sheets16have been stacked on to the pallet66. The full pallet66may be directed from the first storage assembly60via a conveyor (not shown).

The situation illustrated inFIG. 7occurs when the actuator61is retracted and the separator sheet16is transported over the directing guide62onto the plurality of laterally spaced belts65. The plurality of belts65transport the separator sheet16between an upper bracket74and a lower bracket75on a receiving guide71. The separator sheet16passes through the receiving guide71and is directed onto a pile of separator sheets76by guides77. The second storage assembly70includes a lifting frame72that is adapted to support a pallet73. Chains101move the lifting frame72up and down. Sprockets positioned on opposite sides of a support structure106support the chains101. The lifting frame72indexes downwardly as the separator sheets16are stacked onto the pallet73. Once the pallet73is stacked full of separator sheets, the pallet73can either be removed directly or transported via a conveyor (not shown) to another location.

The receiving guide71is different from the directing guide62in that the receiving guide71is not adjustable. As stated previously, the separate sheet handling assembly10can include additional storage assemblies (not shown). It should be apparent that the separator sheets need to be directed into one of the storage assemblies. The separator sheets will be directed into the storage assembly located on the end of the separator sheet handling assembly10if the separator sheet16has not been previously directed into another storage assembly. Therefore, a nonadjustable receiving guide71should be located before the final storage assembly.

In one form of the invention, the storage assemblies60,70each include squaring fences (not shown). The squaring fences organize the stack of separator sheets14into a neat pile as the sheets16are inserted into the respective storage assemblies60,70. The squaring fences can be any configuration commonly known in the art and may continuously or periodically square the stacks of separator sheets as the respective lifting frames69,72index the pallets66,73downward.

In another embodiment of present invention the second storage assembly70does not include a lifting frame72. Instead, the second storage assembly is located adjacent to the frame of separator sheet handling assembly10such that sheets16which are not delivered to the first storage assembly60are delivered off of an end99of the separator sheet handling assembly20into a receptacle (e.g., a trash bin).