A System for a Paper Folding Machinery

The present invention provides a system 100 for a paper folding machinery 200. The paper folding machinery 200 includes a roller folding unit, a strip directing The strip directing unit 220 directs a strip 300 received from the roller folding unit 210 in a predefined direction and at least one folding unit 230 folds the strip 300 received from the strip directing 200 unit 220. The system 100 includes a detecting unit 20 and mounting units 30a & 30b. The detecting unit 20 detects misalignment of the strip 300 on the strip directing unit 220 and at least one folding unit 230. Each of the mounting unit 30a and 30b enables movements in at least one direction of the strip directing unit 220 and the folding unit 230 respectively mounted thereon for correcting the misalignment of the strip 300 thereon.

FIELD OF THE INVENTION

The present invention relates to a system for a paper folding machinery. More specifically, the present invention relates to a system for a paper folding machinery that produces pharmaceutical inserts & outserts or any such informational items.

BACKGROUND OF THE INVENTION

Pharmaceutical inserts & outserts are folded paper items having information related to medicines printed thereon (in). Generally, these inserts and outserts are first made as zigzag strips in a one direction and further folded to configure folded paper articles. Referring now toFIG.1, a block diagram of an existing a paper folding machinery200for producing inserts & outserts is illustrated. The paper folding machinery200includes a roller folding unit (ZF)210, strip delivering unit215, a strip directing unit (SDU)220, a first folding unit F1230and a second folding unit F2240. These units are fixed to a ground surface.

A paper sheet305(FIG.2a) having printed information thereon is fed to the roller folding unit210. The roller folding unit210makes a paper strip300(referFIG.2c) with a zigzag pattern310(referFIG.2b) therein. The roller folding unit210is having a set of rollers for making the zigzag pattern310in the paper sheet305. The paper strip300is received at the strip directing unit220. The strip directing unit220directs the paper strip300to a set of units (230&240) arranged in a machine line (production line)400. In the shown embodiment, the units (220,230&240) are arranged horizontally inline or in any shape as desired. In other/existing machineries, the units (220,230&240) in an “L” shape or “U shape” or such shapes according to the available of space for carrying out folding operations.

The first folding unit230folds the received paper strip300from the strip directing unit220to in a first fold direction to make a first folded article320(referFIG.2d). Further, the second folding unit240folds the first folded article320in a fold direction to make a second folded article340(add figure). Similarly, a plurality of folding units can be arranged in the paper folding machinery200for making different types of folded article. Generally, these folding units,230&240can be “knife folding machines” or “roller folding machines” or “ press folding machine” which are commonly referred as so.

Generally for obtaining efficient folding of the paper strip300, a centre line302of the paper strip300must be in line with a centre line of a unit. More specifically, the centre line302of the paper strip300must be in line with centre lines222,232,242of each machinery units200such as the strip directing unit220, the first folding unit230and the second folding unit240. The efficient folding here refers to folding of the articles without any folding errors. Generally, when a width “w” or a length “l” of the fed paper305or number of zigzag folds in the zigzag pattern310is alignment of the centre line302of the strip300with the centre lines222,232of the units220,230&240varies, thereby causing misalignments.

In order to obtain to overcome misalignments, each unit of the machinery200such as the strip directing unit220, the first folding unit230and the second folding unit240are unfixed from the ground surface and moved in relevant direction (direction along X, Y Or Z axis) for aligning the centre lines of these units220,230,240with the centre line302of the strip300. Shifting of these units is time consuming. Shifting of these units and for carrying further folding operations is tedious and increases a set-up time of the units folding operation.

Further, folding unit230generally includes a shaft having an elastic rings wrapped there around if the units are “roller folding machine”. These elastic rings wear out over due to the folding operations. Generally, the shaft from the folding unit is replaced for carrying next folding operations. Removing and replacing the shaft from the folding units F1 or F2 and replacing the shaft is tedious and increases the set up time of the folding operations.

Therefore, there is a need for a system in the paper folding machinery200to overcome problems of the prior art.

OBJECTS OF THE INVENTION

An object of the present invention is to provide a system for a paper folding machinery; more specifically, a system for a paper folding machinery that produces inserts and outserts or any informational items.

Another object of the present invention is to provide system for a paper folding machinery for reducing the set up time for making a folded paper article by folding operations.

Still another object of the present invention is to provide a system for a paper folding machinery for facilitating easy adaptation of the units of the paper folding machinery with a change in dimension of the paper strip.

Further, an object of the present invention is to provide a system for a paper folding machinery which is simple in construction and easy in operation.

Furthermore, an object of the present invention is to provide a system for a paper folding machinery for reducing the events of effort in removing a shaft from a folding unit for and replacing the shafts with worn rings wrapped there-around.

SUMMARY OF THE INVENTION

According to the present invention, there is provided a system for a paper folding machinery. The paper folding machinery includes a roller folding unit, a strip delivering unit, a strip directing unit and at least one folding unit. The roller folding unit is capable of folding a paper sheet into a strip. The Strip delivering unit is arranged at the end of to the strip folding unit. Strip directing unit is connected to the roller folding unit with a strip delivering unit there between. The strip directing unit directs the received strip from the roller folding unit in a predefined direction. The at least one folding unit folds the strip received from the strip directing unit.

The system includes a detecting unit and mounting units. The detecting unit detect a misalignment of the strip on the strip directing unit and also on the at least one folding unit. In an embodiment, the detecting unit includes a first scale, a second scale and a third scale and a display. The first scale measures a first distance between a centre line of the strip on the strip directing unit and a reference along the at least one direction. The second scale measures a second distance between a centre line of the strip directing unit and the reference. The third scale measures a third distance between a centre line of the at least one folding unit and the reference. The difference between the second distance and the first distance; the third distance and the first distance is displayed as the misalignments of the strip directing unit and the folding unit respectively though a display of the detecting unit.

In an alternative embodiment, the detecting unit detects the misalignments electronically or optically. The mounting units are configured for mounting the strip directing unit and the at least one folding unit thereover. The each of the mounting unit enables movements in at least one direction of the strip directing unit and the at least one folding unit respectively for correcting the misalignment of the strip thereon.

More specifically, each of the mounting unit includes a fixed base, a movement facilitator and a movable frame. The fixed base is rigidly arranged to the ground surface. The movement facilitator is arranged on the fixed base. The movement facilitator is a rack and a pinion arrangement or a lead screw arrangement or a hydraulic or a pneumatic drive or a worm drive or and the like. Further, the movement facilitator is connected to an operating member.

The movable frame is connected to the movement facilitator. The strip directing unit or the at least one folding unit is mounted on the respective movable frame of the respective mounting unit. Upon operating the operating member to a predefined operation position, the movement facilitator moves the movable frame up to a predefined distance in an at least one direction, thereby moving the strip directing unit or the at least one folding unit up to the predefined distance in the at least one direction. The at least one direction is a length direction or a width direction or a height direction. The operating member is operated mechanically or electrically for moving the strip directing unit or the at least one folding unit for correcting the misalignment of the strip thereon.

Further, the system includes a locking arrangement for locking the movements of the moving units in other directions except in the one direction. In an alternative embodiment, the strip delivering unit or strip delivering unit includes an adjustable delivery end. The delivery end can be adjusted to change a delivery location of the strip on the strip directing unit, in at-least one direction.

DETAILED DESCRIPTION OF THE INVENTION

The disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms.

Referring now toFIG.3, a schematic view of a system100configured in a paper folding machinery200in accordance with the present invention is illustrated. The paper folding machinery200includes a roller folding unit210, a strip delivering unit215, a strip directing unit220and at least one folding unit230. The roller folding unit210is capable of folding a paper sheet305into a strip300. The strip directing unit220is connected to the roller folding unit210with the strip delivering unit215therebetween. The strip directing unit220directs the received strip300from the roller folding unit210in a predefined direction. In the present embodiment, the predefined direction is along an X direction602as shown inFIG.1. The strip directing unit220and the at least one folding unit230are arranged horizontally. In an alternative embodiment, the units220and230can be arranged in shape of “L” or “U” or in a circle or any such shapes as per the availability of space to the paper machinery200. The X direction602is a length direction of the units220and230.

The at least one folding unit230folds the strip300received from the strip directing unit220to configure a folded strip320. In the present embodiment, the system100includes one folding unit230. In an alternative embodiment, the system100may include two or three or four (more than one) folding units for carrying out series of folding operations for configuring inserts and outserts. In the present embodiment, there are different types of folding units230employed in the paper folding machinery200. By way of non-limiting example, some of the types are knife fold type, roller fold type or press type and the like.

The system100includes a detecting unit20(referFIG.4) and mounting units30aand30b. The detecting unit20detects a misalignment of the strip300on the strip directing unit220and on the at least one folding unit230. As the units are arranged horizontally in the shown embodiment, for making an efficient folding operations, a centre line302of the strip300needs to be in line with centre lines222and232of the strip directing unit220and the folding unit230respectively.

The detecting unit20includes a first scale22, a second scale24and a third scale26and a display28. The first scale measures a first distance (d1) between the centre line302of the strip300on the strip directing unit220at a position224and a reference40along an at least one direction. In this embodiment, the one direction can be along Y direction604as shown inFIG.1. The reference40can be a fixed point or a position. The second scale24measures a second distance (d2) between the centre line222of the strip directing unit220and the reference40. The third scale26measures a third distance (d3) between a centre line232of the at least one folding unit230and the reference40. The difference between the second distance (d2) and the first distance (d1) is displayed as a misalignment of the strip directing unit220through the display28of the detecting unit20. Similarly, the difference between the third distance (d3) and the first distance (d1) is displayed as a misalignment of the at least one folding unit230though the display28of the detecting unit20.

In an alternative embodiment, the detecting unit20detects the misalignment electronically or optically and displays misalignments through an electronic or optical displays. It may be obvious to person skilled in the art to configure structural components of the detecting unit20for detecting misalignments of the units220and230with the strip300. In the shown embodiment, the units are arranged in the line, the misalignments are displayed as magnitude of a distance along Y direction604. In case the units are arranged in a “U” shape or the “L” shape or angular elevation or depressions, the misalignments are displayed as magnitude of distance in X. Y or Z direction or magnitude of angle or any such measurable factors which are obvious to a person skilled in the art.

Referring now toFIGS.5and6, a top and front schematic view of units220and230mounted on mounting units30aand30bof the system100in accordance with the present invention are illustrated. The mounting units30aand30bare configured for mounting the strip directing unit220and the folding unit230thereover. The each of the mounting unit30aor30benables movements in an at least one direction of the strip directing unit220and the folding unit230respectively for correcting the misalignment of the strip300thereon.

More specifically, each of the mounting unit30aand30bincludes a fixed base, a movement facilitator and a movable frame. The mounting unit30aincludes a fixed base36a, a movement facilitator34aand a movable frame32a. Similarly, the mounting unit30bincludes a fixed base36b, a movement facilitator34band a movable frame32b. The fixed base36ais rigidly arranged to the ground surface500. The movement facilitator34ais arranged on the fixed base36a. The movement facilitator34ais connected to an operating member38a. In the present embodiment, the movement facilitator34ais a rack and a pinion arrangement. In an alternative embodiment, the movement facilitator34acan be a lead screw drive or a hydraulic or a pneumatic drive or a worm drive or any such arrangement facilitates relative movements therewith which is obvious to a person skilled in the art.

Further, the movable frame32ais connected to the movement facilitator34a. The strip directing unit220is mounted on the movable frame32a. Similarly, the folding unit230is mounted on the movable frame32b. It may be obvious to a person skilled in the art to configure the system100with mounting units30a,30b,30c. . .30naccording to number of units needed to be mounted thereover.

Furthermore, Upon operating the operating member38ato a predefined operation position, the movement facilitator34amoves the movable frame32aup to a predefined distance in an at least one direction (referFIGS.7band7c). For example, if the operating member38ais to be operated to a predefined operation position, the strip directing unit220is moved to a predefined distance in the at least one direction. The at least one direction can be along width direction of the strip directing unit220. The width direction can be “Y” direction604. In an alternative embodiment, the at least one direction is a length direction (X) (referFIGS.7dand7e)602direction or a height direction (Z) direction606(referFIGS.7fand7g). The movement facilitator34ais configured to facilitate the movements of the strip directing unit220along X, Y and Z directions to various positions as shown inFIGS.7a,7b,7c,7d,7e,7fand7g.

Referring now toFIGS.8aand8b, schematic views of the strip directing unit220of the system100at a misaligned position220aand at an aligned position220bwith the strip300in accordance with the present invention are illustrated. The operating member38acan be operated mechanically or electrically for moving the strip directing unit220for correcting the misalignment of the strip300thereon. For example, the detecting unit20detects the misalignment of “20 mm” in a Y direction604and displays the same through the display28. The operating member38ais operated mechanically or electrically to move the strip directing unit220by a “20 mm” on the mounting unit30ain the Y direction604from the misaligned position220ato the aligned position220bas shown inFIGS.8aand8brespectively, thereby aligning the centre line222of the strip directing unit220with the centre line302of the strip300.

Similarly, the operating member38bcan be operated mechanically or electrically for moving the folding unit230for correcting the misalignment of the strip300thereon by aligning the centre line232of the folding unit230and the centre line of the strip300. Similarly, by operating respective the operating members38aor38bof the units, the units can be moved in direction X602, Y604, Z606directions or combinations of these or in an arcade locus or angular deviation as shown inFIGS.9a,9b, and9c. It may be obvious to person skilled in the art to configure the locus paths in the respective the movement facilitator34aor34bfor moving the respective units220and230in moving paths (directions) as shown in9a,9band9c.

Further, the system100includes a locking arrangement (not shown) for locking the movements of the moving units220and230in other directions except in the at least one direction. For example, the strip directing unit220is moving the Y direction604, the movements of the strip directing unit220are locked in X602and Z606direction. The locking arrangement can include a mechanical lock such as plunger or pin or hook or such locking elements which are obvious to a person skilled in the art.

Referring now toFIGS.10a&10b, schematic views of the strip delivering unit215of an alternative embodiment of a system100for the paper folding machinery200at various positions (215aand215b) in accordance with the present invention are illustrated. In this embodiment, the strip delivering unit215includes an adjustable delivery end217. The delivery end217can be adjusted in at least one direction to change a delivery location of the strip300on the strip directing unit220. For example, if there is difference of 20 mm between the centre line302of the strip300and the centre line222of the strip directing unit220at a first buffer position215a, the delivery end217can be adjusted by moving the delivery end217in Y direction604by 20 mm to a second delivery position215bfor aligning the centre line302of the strip300and the centre line222of the strip directing unit220. Similarly, the strip delivering unit215can be configured to facilitate movements of the adjustable delivery end217in X602, Y604, Z606or angular directions for delivering the strip300at required locations for aligning the centre lines for correcting the misalignments.

Therefore, the present invention has an advantage of providing the system100in the paper folding machinery200. More specifically the system100for system in the paper folding machinery200that produces inserts and outserts or any informational items. As there is no need to shift a location of the3the folding unit240by unfixing from the ground500for aligning the centre lines of the units with centre line302of the strip300(if changed), the a set-up time for folding operations is reduced, therefore, the system100is reducing cycle time for making a folded paper article by the folding operations. The system100facilitates easy adaptation of the units220&230in the paper folding machinery200with a change in dimension of the paper strip300by moving the strip directing unit220and the folding unit230according to misalignment detected by the detecting unit20for correcting the same. Further, the system100is simple in construction and easy in operation.

Referring now toFIGS.11aand11b, schematic views of the roller folding unit230of the system100at various positions in accordance with the present invention are illustrated. The folding unit230includes a shaft60having an elastic ring50cfor performing the folding operations of the strap300. In the system100, the shaft60can be wrapped with a plurality of elastic rings50a,50b,50cand50d. Upon wear out of a ring50c(referFIG.11a), the folding unit230can be moved along Y direction604for aligning the ring50bwith the centre line302of the strip300. The folding operations are continued until the ring50bgets wear out. Similarly, the folding unit230can be moved along the Y direction604for aligning all rings50a,50b,50c&50dsequentially upon wearing out of each ring of the all rings50a,50b,50c&50d. Therefore, the system100reduces efforts for removing the shaft60from the folding unit230for replacing the same frequently, thereby decreasing or eliminating a down time and a re-set-up time, thereby reducing the set up time of the machinery.