Hopper loader

A hopper loader interfaced with a variety of hoppers/feeders having a horizontal infeed conveyor with a hand-feed belt section near the input end movable between an operative position for hand-feed operation and a lowered position to facilitate automatic feeding. A positioning actuator is coupled between the hopper loader and the hopper to provide for automatic fine-tuning adjustment of the jogger position as well as for machine make-ready to accommodate changing product size. A single controller is provided for simultaneously positioning a plurality of loaders. The controller has adjustable stops for accommodating frequently used product formats. Automatic air delay shut-off saves energy by shutting off the air blast system a predetermiend delay after the loader is halted. further automatic means saves energy and prevents "over jogging" and damage to the product by turning off the jogger a predetermined delay interval after the loader stops. One or a plurality of side guides adjustable by a single operating handle facilitate accurate and horizontal product alignment over the entire length of the loader. A feed rack having two swingable sections coupled through a center pivot enables removal of one section for attachment to a loader. The loader control panel is swingable mounted to a boom facilitating movement of the control panel to either side of a loader. A beaver-tail joggr has an easy-to-use manually operated fine-tuning adjustment assembly for facilitating rapid and precise adjustment thereof.

FIELD OF THE INVENTION 
The present invention relates to hopper loaders and more particularly, to a 
novel improved hopper loader having unique features which greatly 
facilitate both set-up and use thereof. 
BACKGROUND OF THE INVENTION 
Loaders are well known to the art and are used in a variety of different 
segments within the fields of printing and publishing. For example, 
feeders are utilized to feed signatures one at a time from a hopper onto a 
conveyor; are used to supply signatures to a hopper; and are used to 
supply signatures to a signature feed assembly which, in turn, delivers 
partially opened signatures one at a time to a saddle conveyor, to name 
just a few applications. In all of the above-identified applications, it 
is necessary to provide signature streams and/or signature stacks which 
are in proper alignment to facilitate trouble-free transfer to the 
utilization device receiving signatures from the feeder. 
In addition, when stacking signatures side-by-side preparatory to their 
transfer to an output utilization device, it is extremely important that 
the signatures be aligned so that they do not exert undue forces on the 
output utilization device thereby causing undesirable misfeeds. 
In addition to the above, it is also important to provide feeders which not 
only have the versatility enabling the feeder to accommodate a variety of 
different signature sizes but also have the ability to permit rapid 
adjustment of the feeder when changing from one feeder size to another or 
when changing the coupling of the feeder output from one output 
utilization device to another. 
The complicated nature and construction and the operating features of 
present day feeders increase the possibility of jams or other malfunctions 
during use and require complicated set-up operations, significantly 
increasing the cost of equipment as well as the cost of operating the 
equipment. 
BRIEF DESCRIPTION OF THE INVENTION 
An improved feeder which overcomes the above-mentioned disadvantages as 
well as providing other distinct advantages is characterized by comprising 
a horizontal conveyor section at the infeed for receiving signatures 
either manually or from an outfeed conveyor. The downstream end of the 
horizontal conveyor transfers signatures placed in a near-vertical 
orientation to an inclined ramp conveyor which typically operates at 
either the same or a greater linear speed than the horizontal conveyor, 
serving to separate the signatures and to arrange them in a shingled 
stream. The output end of the inclined ramp conveyor delivers the shingled 
stream to a short conveyor section which is typically aligned to advance 
the signatures delivered thereto either horizontally into a hopper or 
diagonally downward for insertion into any one of a variety of output 
utilization devices and typically oriented at an acute angle to the 
vertical. 
Side guides are provided along the opposite parallel sides of the feeder to 
maintain the alignment of signatures as they move from the input to the 
output end thereof. Adjustable side guides are utilized to accommodate 
signatures of different sizes and align them with an output utilization 
device. A novel side guide mechanism is provided on at least one side of 
the feeder for adjusting a one-piece side guide extending the entire 
length of the feeder through a single operating handle. Two such side 
guide cams may be provided, one along each side of the feeder for 
applications in which the product register is the centerline of the 
machine. Alternatively, a fixed guide may be used along one side of the 
feeder if the fixed side of the loader is employed for product registry. 
The side guide cam comprises an elongated threaded assembly ("worm") 
comprised of linear threaded sections for each of the horizontal, ramp and 
output conveyor sections the adjacent ends of which are joined end-to-end 
by universal joints. Links pivotally coupled to threaded nuts threadedly 
engaging the elongated worm member are caused to pivot about a point 
intermediate their ends by means of a second link fixedly secured at one 
end to said threaded member and pivotally coupled to a point intermediate 
the ends of said first-mentioned coupling link. A pair of such linkages 
are arranged respectively near the input and output ends of the feeder and 
by rotation of the elongated threaded member by rotation of a crank handle 
the side guide may be rapidly adjusted to accommodate signatures of any 
size within a predetermined range thus significantly reducing set-up time. 
The horizontal infeed conveyor section is provided with an adjustable 
hand-feed conveyor section provided at the input end thereof. The section 
is provided with an adjustable hand-feed frame assembly which may be 
adjusted to any desired angular position between horizontal alignment and 
one forming an acute angle to the horizontal alignment. The adjustable 
hand-feed frame section includes conveyor means driven by and in 
synchronism with the main conveyor section. The inclined section greatly 
simplifies the manual loading of signatures. An operator can place stacks 
of signatures which are hand-carried to the feeder in a rapid and simple 
manner without the exercise of careful, tedious attention to the stacking 
of signatures thereon since the inclination of the hand-feed frame 
assembly holds the signatures deposited thereon generally upright, greatly 
facilitating the operation of depositing signatures thereon by an 
operator. The adjustable frame assembly holds a substantial number of 
signatures providing a buffer storage enabling the person loading the 
feeder to fill another feeder thereby enabling a single operator to feed 
multiple loaders. In addition, the angle of inclination may be adjusted to 
accommodate the operator's height, thereby significantly reducing operator 
fatigue by reducing the amount of bending experienced by the operator 
during hand-feeding of the feeder. The hand-feed frame assembly is further 
capable of being collapsed to the horizontal position enabling the feeder 
to be interfaced with an outfeed conveyor for use in an automatic feeding 
application, which typically accepts bundled signatures. 
Alignment and precision adjustment of the feeder with a hopper is 
accomplished by means of an electrically powered positioning actuator 
mounted near the lower end of the downstream legs supporting the feeder 
and extending toward the supporting structure for the hopper which will 
receive signatures from the feeder upon connection therewith. The forward 
free-end of the positioning actuator extends into a clevis bracket having 
a manually releasable self-locking member for automatically and precisely 
positioning the forward free end of the positioning actuator relative to 
the hopper assembly. The positioning actuator is operated by a control 
panel which moves the free end of the positioning actuator either inward 
or outward relative to the feeder to adjust the output end of the feeder 
relative to the hopper enabling adjustment between a range of sizes 
between a maximum and minimum product size. This technique totally 
eliminates the need for the prior art coupling method which requires 
loosening of a manually operable locking handle and rolling the entire 
loader (which typically weighs approximately 1,000 pounds) into proper 
position and thereafter tightening the locking handle. 
Alignment in the horizontal direction is obtained by providing guide 
channels which are accurately positioned relative to the hopper and clevis 
bracket in order to automatically provide spatial alignment in the 
horizontal plane simply by rolling the feeder wheels into the guide 
channels. 
The feeder operating panel is provided with a toggle switch having a normal 
center position and being selectively movable in either opposing direction 
from the center position to respectively control movement of the feeder 
either closer to or further away from the hopper. The operating motor 
advances the positioning actuator in 1/16 inch increments enabling the 
feeder jogger to be accurately positioned within the hopper to produce a 
neat pile as well as permitting utilization of the actuator for a set-up 
in which the product format is changed. 
The feeder control panel is mounted at the free end of a rotatable control 
arm or "boom" which is rotatably mounted through coupling means to one 
side of the feeder frame. The control panel is rotatably mounted to the 
free end of the boom to enable the control panel to be readily and simply 
positioned on either side of the feeder with the face of the control panel 
along which the displays and manually operable control members are mounted 
facing away from the feeder thereby greatly facilitating control of the 
feeder by an operator. For example, assuming that equipment or other 
obstacles are in close proximity to one side of the feeder, the control 
panel may be simply swung to the other side of the feeder and the control 
panel itself rotated so that the control panel face containing displays 
and control knobs may be readily accessed by the operator. 
When setting the positioning actuator, the fine-tuning of the feeder 
relative to the hopper may be accomplished as the hopper is being operated 
thus assuring that the positioning alignment directly results in smooth, 
uniform feeding of signatures from the hopper. 
The positioning actuators of a plurality of feeders may be simultaneously 
operated from a single, main control unit which is utilized during the 
make-ready phase to move all of the loaders at one time. This is 
accomplished by coupling all of the positioning actuators to a single 
control unit. In one embodiment, the main controller may move each feeder 
in the same direction through small (i.e. 1/16 inch increments). However, 
in order to accurately position all of the feeders relative to their 
associated hoppers (for example) and wherein the individual feeders may be 
located at differing distances from their associated hoppers, adjustable 
stops may be provided whereupon movement of each feeder controlled by its 
positioning actuator is continued until a sensor, such as a limit switch 
strikes the desired stop. This technique is extremely advantageous when 
multiple adjustments of a plurality of feeders are desired in a system in 
which two product sizes are run more predominately or exclusively as 
compared with other product sizes. 
In applications where it is desired to adjust a plurality of feeders to any 
one of an infinite number of positions within the range of maximum to 
minimum product size, a value representative of product size is dialed 
into the control unit and to generate a voltage proportional to product 
size which is compared against an analog value generated by a linear 
proximity switch (which measures the distance between feeder and hopper) 
to determine the difference and direction between the present setting of 
each linear actuator and the dialed-in product size whereupon the linear 
actuator is moved to the desired position. The comparison operations and 
energization of the linear actuators may be performed either 
simultaneously or sequentially, the latter being performed in a high speed 
manner. 
Sensor means are provided to determine when the hopper receiving signatures 
from the feeder is loaded to a proper height. In order to prevent misfeeds 
or jams, the sensor automatically turns off the feeder when the pile of 
signatures reaches a desired maximum height. The feeder is not turned on 
again until the height of the signature stack has lowered to a 
predetermined point. As signatures make the transition from the horizontal 
conveyor to the ramp conveyor, pressurized air is directed toward the 
signatures to separate the signatures and assure the formation of a neat 
shingled stream along the ramp conveyor. In order to conserve energy, the 
signal automatically turning off the feeder is utilized to set a timer to 
control a shut-off valve decoupling the air blast system after the timer 
is timed out in order to save energy. 
Product joggers which jog the product as it is being collected in the 
hopper are likewise automatically shut off by control means which turns 
off the joggers a predetermined time delay after the feeder has stopped 
running in order to save operating energy and to further prevent "over 
jogging" of the product during turn-off periods of the feeder which can 
damage the signature. 
When it is desired to couple the feeder to a saddle hopper feedrack, 
existing feeders necessitate the removal of the feedrack from the saddle 
stitcher which operation is a labor, intensive, time-consuming procedure. 
The present invention provides a sectional feedrack assembly which pivots 
in the center allowing for a very simple installation of the feeder. The 
feedrack is formed in two sections, one section pivoting relative to the 
other for alignment therewith when used in the manual feed mode and 
swingable downwardly and out of the way of a feeder when the feedrack is 
to be coupled to a feeder for automatic feeding. The feedrack length is 
thus reduced which is advantageous since a loader interfaced to an 
existing ("long") rack presents a product pile which is too large, 
producing excessive pressure on the hopper, thereby significantly reducing 
the ability of the hopper to operate smoothly and properly. 
The feeder is provided with a jogger mechanism referred to as a beaver-tail 
jogger to form a neat pile of signatures in the hopper. In order to 
facilitate adjustment of the jogger paddle to prevent excessive pressure 
on the jogger which can damage the signatures, overload the jogger and 
lead to destruction thereof, the beaver-tail jogger mechanism is provided 
with a "micro" adjustment system wherein the jogger paddle is raised or 
lowered by means of a threaded rod operable by a hand wheel which, when 
rotated, moves a block threadedly engaging said threaded rod either 
downwardly or upwardly through a fine adjustment to thereby locate the 
beaver-tail jogger paddle at the desired location thereby "fine-tuning" 
the jogger to obtain a neat pile within the hopper. 
All the above features cooperate to provide a feeder which is easier to set 
up and operate, which provides significantly improved operating 
performance all of which features are obtained at a significantly reduced 
operating cost. 
OBJECTS OF THE INVENTION 
It is, therefore, one object of the present invention to provide a feeder 
which is easy to set up and may be set up preparatory to a run in a fast 
and simple manner. 
Still another object of the present invention is to provide a novel feeder 
having a positioning actuator which provides for high speed set-up and 
accurate positioning of a feeder relative to a hopper receiving signatures 
from the feeder. 
Still another object of the present invention is to provide novel automatic 
positioning means for simultaneously adjusting a plurality of feeders 
relative to their associated output hoppers through the use of single 
control means. 
Still another object of the present invention is to provide a novel control 
means for adjusting a feeder relative to an output utilization device and 
employing a positioning actuator controlled by automatic positioning 
means. 
Still another object of the present invention is to provide a novel control 
means for adjusting a feeder relative to an output utilization device and 
employing a positioning actuator controlled by automatic positioning means 
including adjustable positioning devices which may be preset according to 
the predominant product sizes being run. 
Still another object of the present invention is to provide novel means for 
automatically shutting off the feeder air blast system at a predetermined 
time delay after the feeder is turned off to conserve energy. 
Still another object of the present invention is to provide a novel feeder 
assembly having means for automatically shutting off the feeder jogging 
means a predetermined time interval after the feeder has turned off to 
save energy and prevent "over jogging" of the product, as well as 
preventing damage to the jogger. 
Still another object of the present invention is to provide a feeder having 
novel adjustable side guides to facilitate simple, rapid adjustment 
thereof to accommodate different product sizes. 
Still another object of the present invention is to provide a feeder having 
novel adjustable side guides to facilitate simple, rapid adjustment 
thereof to accommodate different product sizes and wherein said adjustment 
means utilizes a single operating handle. 
Still another object of the present invention is to provide a feeder 
assembly provided with a novel hand-feed section which is adjustably 
movable between horizontal position to accommodate automatic feeding of 
signatures to the feeder and an inclined position to facilitate 
hand-feeding. 
Still another object of the present invention is to provide a feeder 
assembly provided with a novel hand-feed section which is adjustably 
movable between a horizontal position to accommodate automatic feeding of 
signatures to the feeder and an inclined position to facilitate 
hand-feeding and wherein the inclined angle of the hand-feeder frame 
assembly may be adjusted to accommodate operators of different sizes.

DETAILED DESCRIPTION OF THE INVENTION 
FIG. 1 shows a feeder 10 supported on four legs 12 (only two of which are 
shown in the Figure), each leg being provided with a caster assembly 14 
for rollingly supporting feeder 10 to facilitate easy movement. The legs 
12 support a frame 16 which houses the motor drives and related mechanisms 
for driving the horizontal conveyor section 18, the ramp conveyor section 
20 and an outfeed conveyor section 22. Legs 12 are provided with manual 
handwheels for adjusting the height of the conveyor sections relative to 
hopper 30, for example. Signatures S are delivered to the horizontal 
conveyor section either automatically by means of an outfeed conveyor (not 
shown) arranged immediately adjacent the left-hand end of the conveyor 
section 18, or manually. As signatures are delivered to the ramp conveyor 
they rest against the ramp conveyor belts (only belt B being shown in FIG. 
1 for purposes of simplicity) and move upwardly therealong, forming a 
shingled stream. The shingled stream of signatures reach and thereafter 
move along the conveyor belts of the outfeed conveyor section 22. Each 
signature moves off of the outfeed conveyor section 22 and falls into a 
hopper 30 coupled to feeder 10. The hopper 30 is provided with a support 
32 mounted upon the floor and preferably precisely located thereon by a 
positioning pin (or pins) 34 (FIG. 1c), such as a lag bolt, which 
facilitates accurate positioning of the hopper and the feeder coupled 
thereto in a manner to be more fully described. 
The signatures fall into hopper 30 oriented in a substantially horizontal 
plane. The hopper delivers signatures in a one-at-a-time fashion into an 
output utilization device (not shown). In order to assure proper signature 
feeding from hopper 30 it is important to form a neat signature stack 
therein. The alignment of signatures within the feeder and the adjustment 
of the feeder relative to the hopper significantly contribute to accurate, 
error-free operation and it is important to provide apparatus which 
assures the desired alignment and positioning of components as well as 
guidance of the signatures throughout the feeding and stacking operation. 
For example, the feeder 10 is provided with side guides including side 
guide sections 24, 26, 28 and 29 which are provided along opposite 
longitudinal sides of the feeder, the side guides of only one side of the 
feeder being visible in FIG. 1, the side guides assuring proper alignment 
of the signatures in the horizontal plane and within hopper 30. Adjustable 
side guides are provided as will be described more fully hereinbelow in 
order to accurately align the signatures in the feeder relative to the 
output hopper as well as greatly facilitating set-up of the feeder when 
changing to a different product size. 
The feeder is provided with a control panel 40 having a variety of control 
buttons and displays. The control panel is easily accessible from one side 
of the feeder as shown in FIG. 1 as well as the top plan view shown in 
FIG. 1a. The control panel 40 is mounted to the free or right-hand end 42a 
of a rotating control arm or boom 42 having an inverted J-shape which has 
its lower left-hand end 42b rotatably mounted within a cup assembly 44. A 
pivot coupling 45 rotatably mounts an upper portion of section 42b. 
Control panel 40 is rotatably coupled to the end 42a of boom 42 by means 
of a bearing assembly 43 (not shown in detail) arranged within the upper 
portion of the control panel housing. 
Summarizing, the lower end of boom 42 fits within a pivot cup 44 having a 
suitable bearing for rotatably mounting boom 42 therein. A pivot block 45 
is mounted along the machine frame a spaced distance above pivot cup 44. 
The lower end of boom 42b pivots within suitable bearing means in pivot 
cup 44. A pivot block 45 arranged a spaced distance above pivot cup 44 
provides a similar bearing assembly and cooperates with pivot cup 44 to 
prevent any movement by boom 42 other than about its longitudinal vertical 
axis. 
In the event that feeder 10 is positioned in close proximity to adjacent 
equipment or other objects which serve as an obstacle preventing an 
operator from gaining access to the control panel when positioned in the 
manner shown in solid line fashion in FIG. 1a, the boom may be rotated 
about couplings 44-45 from the solid line position 42 to the dotted line 
position 42' shown in FIG. 1a. Control panel 40 may then be rotated 
through approximately 180 degrees causing the control panel knobs and 
display to be facing away from the feeder 10 and hopper 30 to facilitate 
access to and operation of the control panel. The height of the boom is 
sufficient to permit the boom and control panel to be rotated either 
clockwise or counterclockwise through 360 degrees without interfering with 
or colliding with any of the feeder or hopper assembly components. FIG. 1a 
shows further orientations which the boom and control panel may assume 
during operation of the feeder. Note positions 40"-42" and 40'"-42'". 
As was described hereinabove, it is extremely important to properly align 
the feeder relative to the hopper since this automatically aligns the 
jogger assembly 46 provided at the downstream end of the feeder and 
including a jogger paddle 46a which reciprocates at high speed in the 
manner shown by the double-headed arrow A serving to jog and thereby 
properly align the signatures S within hopper 30 to form a neat pile. 
Alignment is obtained by means of a positioning actuator assembly 48 
including a motor 48a mounted beneath a channel 15 forming part of the 
machine frame. The positioning actuator is secured to the underside of 
channel 15 and extends toward the right. The free, right-hand end of 
actuator 48 extends into a clevis bracket 32a integrally joined to hopper 
support 32 having a hollow interior conforming to the cross-section of the 
right-hand end of position actuator 48. The position actuator is provided 
with a pin 48b extending outwardly from opposite sides of the actuator 
with each projecting side of the pin (only one being shown in FIGS. 1 and 
1c) being guided into the clevis bracket 32a by a pair of V-shaped slots 
32b (only one being shown in FIGS. 1 and 1c). A spring-loaded locking or 
latch arm is swingably mounted to bracket 32a by pin 32c and is 
spring-loaded by bias means (not shown) to be urged in the 
counterclockwise direction about pin 32c. A stop pin 32d limits the 
counterclockwise travel of lever 32 e. A nose portion of lever 32e is 
slanted at 32e-1 so that, when engaged by pin 48b, the latch lever 32e is 
urged clockwise against the force of the bias spring to move out of the 
way of pin 48b. When pin 48b rests against the base of the V-shaped groove 
32b, latch lever 32e springs back to the solid-line position shown in FIG. 
1c causing its shoulder 32e-2 to collectively embrace pin 48b together 
with the base of V-shaped slot 32b to retain the position actuator 48 in 
the proper position relative to the hopper support 32 and hence hopper 30. 
When it is desired to remove the feeder from the hopper assembly, this may 
be done simply by lifting latch lever 32e (i.e. moving it clockwise) 
through an angle sufficient to displace the latch from pin 48b whereupon 
the feeder may be pulled to the left and out of the locking mechanism. 
The positioning actuator is comprised of a mechanism which moves the end of 
the actuator either further away from or closer to the left-hand end 
thereof which is secured to the frame of feeder 10. A suitable 
mechanically operated feeder which is comprised of a motor driving a spur 
gear and operating a worm gear to extend or retract the right-hand end of 
the assembly is the Model 5703551 Actuator produced by the Thomson-Saginaw 
Company. The position actuator is electrically operated by means of a 
toggle arm such as, for example, the toggle arm 40a mounted upon control 
panel 40 as shown in FIG. 1a. Toggle arm 40a has a neutral position as 
shown and may be pushed to either the left or the right as shown by arrows 
B1 and B2 respectively. When moving the toggle from the neutral position 
in the direction of arrow B1, the motor is turned on and operates the 
position actuator in a direction which causes the feeder to move closer to 
the hopper assembly 30, i.e. to move toward the minimum product size. The 
loader control is such that the position actuator moves in 1/16 inch 
increments and at a rate which is slow enough to enable operation of the 
toggle arm 40a to be moved to the left and returned to the neutral 
position to limit movement to just one incremental step. 
By moving the toggle arm 40a from the neutral position toward the right as 
shown by arrow B2, the motor is operated in the direction which causes the 
feeder 10 to move further away from the hopper, i.e. in the direction 
toward maximum product size. By maintaining the toggle arm activated in 
either the left or right-hand position, the feeder will move through a 
number of incremental steps where alternatively by operating the toggle 
arm just once to the left and right and then rapidly releasing it, 
incremental (1/16 inch) steps may be obtained. This control enables the 
feeder positioning relative to the hopper to be "fine-tuned" assuring the 
production of neat piles within the hopper and especially preventing 
overloading of the jogger assembly 46. The control arrangement may also be 
utilized when setting up the feeder to accommodate a change in product 
size. Holding the lever arm in the active position for a longer time 
allows the actuator to advance through a plurality of 1/16 inch 
increments. 
The alignment of the feeder 10 in the horizontal plane relative to the 
hopper 30 is obtained through the utilization of a pair of channel-shaped 
guides 50, only one of which is shown in FIG. 1, a guide being provided 
for each of the right-hand casters 14 of the feeder. The channel guides 
are preferably formed in a unitary manner having an intermediary or 
cross-piece member (not shown) joined between the guides to maintain them 
in spaced parallel fashion. The guides and joining member are then placed 
upon the floor and provided with positioning means for positioning the 
guides relative to the floor pin(s) 34 thereby properly aligning the 
channel guides relative to the hopper assembly. The guides may be provided 
with a member 51 coupled between guides 50 and pin(s) 34 to accurately 
position the guides relative to the pin(s). Proper alignment is thus 
assured by rolling the feeder assembly 10 toward the right so that each of 
the forward casters 14 enter one of the channel guides. The feeder is then 
pushed forward by an amount sufficient to cause the pin 48b to be locked 
within the clevis bracket in the manner previously described thereby 
assuring proper alignment. If desired, the channel guides 50 may be of a 
length sufficient to receive both the forward and rearward casters 14 of 
the feeder. 
FIG. 2 shows a plan view of a plurality of hopper loaders 10 each arranged 
to deliver signatures to an associated inserter hopper 30. Each feeder is 
provided with an associated position actuator 48 coupled to an associated 
clevis bracket (not shown) provided for each hopper assembly 30. A central 
control panel 40' is utilized to gang position all of the actuators 48 
thus significantly simplifying the positioning operations for the 
plurality of feeders. Considering FIGS. 1c and 2, each hopper assembly 
support frame is provided with an elongated rod 52 integrally joined 
thereto and extending in a direction toward the feeder. Rod 52 is provided 
with a pair of adjustable stops 54, 56 slidably arranged along rod 52. For 
example, rod 52 may be circular or rectangular in cross-section and stops 
54 and 56 provided with openings conforming to the cross-section of rod 
52. Set screws 54a, 56a threadedly engage threaded openings within stops 
54 and 56 to secure the adjustable stops at desired positions along the 
length of rod 52. A limit switch 58 is mounted to the channel 15 of each 
feeder 10 and is provided with a swingably mounted switch arm 58a having a 
roller 59 at its free end. Switch arm 58a is biased by suitable bias means 
(not shown) so as to be normally vertically oriented. When moved either 
clockwise or counterclockwise from the vertical orientation represented by 
the dotted centerline C, limit switch 58 automatically turns off actuator 
motor 48a. The manner in which the ganged operation of the feeders is 
accomplished as follows: 
Control panel 40' is preferably provided with a toggle arm 40a of the type 
shown in FIG. 1a. By moving the toggle arm of the control panel toward the 
maximum product direction, the motors 48a of all of the feeders 10 are 
simultaneously energized and moved in a direction causing the feeders to 
move away from their associated hoppers, i.e. toward the maximum product 
size direction. Limit switch arm 58a is maintained in the vertical 
position. As soon as the roller 59 of each switch arm engages stop 54, the 
switch arm is caused to rotate clockwise against the bias force of the 
internal spring provided within limit switch 58 causing the limit switch 
to turn off actuator motor 48a. Each actuator motor will be turned off as 
soon as its associated limit switch hits the maximum product stop 54. The 
reverse operation may be obtained by operating the toggle arm to cause the 
actuators of each feeder 10 to move closer toward its associated hopper, 
i.e. toward the minimum product size, whereupon when switch arm 58a 
engages stop 56, it is urged away from the normal vertical position and 
moves in the counterclockwise direction against the force of the internal 
bias spring whereupon the limit switch causes its associated actuator 
motor to be turned off. Even assuming that the feeders 10 are aligned at 
different positions relative to the desired end position, only a single 
operation of the control panel toggle arm is required since the limit 
switch provided on each feeder automatically stops the feeder at the 
desired product size regardless of the distance travelled by each actuator 
in reading the desired position. The embodiment of FIG. 1c is extremely 
advantageous for use when only two product sizes are being run or 
alternatively when two product sizes are run more frequently than other 
product sizes. 
If desired, the rod 52 may be mounted upon feeder 10 and the limit switch 
may be mounted upon the hopper supporting structure. The same is also true 
of actuator 48, i.e. clevis bracket 32a may be mounted upon feeder 10 and 
actuator 48 upon hopper support 32. 
In applications wherein it is desired to obtain any one of an infinite 
number of positions between maximum and minimum product sizes, the limit 
switch 58 and rod 52 and cooperating adjustable stops 54 and 56 may be 
eliminated and replaced by a linear proximity switch 60 as shown in FIG. 
1d. The linear proximity switch is mounted upon feeder 10, for example, in 
the position occupied by limit switch 58 shown in FIG. 1c and detects 
surface 32, for example, or alternatively, an element provided on surface 
32, to generate a voltage whose amplitude is representative of the 
distance between a feeder 10 and a hopper 30. In an arrangement in which 
only one feeder is being controlled, the control panel 40' is provided 
with an off/on switch and a control knob 40b" for developing a code 
representative of the desired product size which is shown in display 40a". 
The output, which may be digital, is applied to a digital-to-analog 
converter 62. The signal from proximity switch 60 is applied to a pair of 
comparators 64a, 64b. One of the comparators determines when the signal is 
greater than the output of the proximity switch 60 while the other 
comparator determines when the control signal is less than the output of 
the proximity switch. The output signal from proximity switch 60 is also 
converted in A-to-D converter 68 where it is compared against the digital 
output of the control signal. The difference signal developed by circuit 
70 is applied to actuator controller 66 which provides appropriate signals 
for the direction and distance through which the linear actuator 48 is to 
be moved. Actuator 48 may be provided with a potentiometer for generating 
an output signal whose value is representative of the position of the 
actuator. This is compared with the output signal of the actuator 
controller by a difference circuit 70 to turn off the actuator controller 
66. 
Circuitry of the type shown in dotted rectangle 72 may be provided within 
each feeder Thus, by adjusting the control knob 40b", all of the feeders 
coupled thereto may be simultaneously adjusted to any one of an infinite 
number of positions between the minimum and maximum product size limits. 
Considering FIG. 1, the signatures delivered to hopper 30 are preferably 
controlled to prevent the quantity of signatures delivered thereto from 
exceeding a predetermined limit. This is accomplished by utilizing a 
photoelectric device 76 which senses a reflective element 78 provided near 
the upper end of the right-hand wall 30a of hopper 30. When the signatures 
collected in hopper 30 reach a predetermined height, they cover reflective 
element 78 causing a change in the output of sensor 76 which condition is 
detected to automatically turn off the conveyors belts in each of the 
sections 18, 20 and 22 of feeder 10. The conveyor belts are not turned on 
until the level of signatures in hopper 30 falls sufficiently to expose 
reflective element 78. This condition is sensed by sensor 76 causing the 
conveyor belt motors to be reenergized. 
Feeder 10 is further provided with an air blast device 80 which directs a 
blast of air toward the top of the signatures S as they make the 
transition from the horizontal conveyor section 18 to the inclined or ramp 
conveyor section 20. The air blast serves to urge the signatures 
downwardly against the ramp conveyor belt and further serves to separate 
the signatures from one another. FIG. 3 shows an electrical circuit 
provided within the feeder 10 for automatically turning off air blast 
device 80 after a predetermined delay. 
FIG. 3 shows an electrical circuit in which an AC input 82 is applied to a 
power supply 84 coupled between AC lines 87a, 87b for converting 115 volt 
AC to a 24 volt DC power supply. Fuse F1 protects the power supply. The 24 
volt DC output is coupled across lines 86a, 86b. A run switch PB2 is 
closed when the feeder is turned on energizing relay CR1 and closing its 
normally-open contacts CR1-1 and CR1-2 and CR1-3. Contacts CR1-1 maintain 
relay CR1 energized so long as the stop button PB1 is not operated. 
Contact CR1-2 enables an electrical circuit for energization of relay CR2 
when contact arm 88 engages stationary contact 88b. 
A toggle switch having a switch arm 88 and stationary contacts 88a and 88b 
is switchable between a test or bypass state and a run state being 
respectively coupled to stationary contacts 88a and 88b for these 
operating states. During a test or bypass operation, switch arm 88 engages 
contact 88a completing an electrical circuit for relay CR2 which closes 
contacts CR2-1 thereby energizing relay CR3. The closure of relay CR3 
opens normally-closed contacts CR3-1 turning off time delay relay TD1 
which substantially immediately causes contacts TD1-1 to close and remain 
closed. The time delay relay TD1 is a settable time delay relay having a 
plurality of DIP switches (not shown) for adjusting the time delay to any 
suitable time interval, for example, one second. Upon energization of time 
delay relay TD1, normally-closed contacts TD1-1 open one second after 
energization of TD1 to turn off solenoid-controlled air valve 90. This 
test or bypass mode may be utilized for testing relay TD1 as well as 
confirming its proper operation. 
In the run mode, switch arm 88 engages stationary contact 88b providing 
electrical power to microswitch 76 which is identified as the light 
sensing element 76 shown in FIG. 1. So long as the reflective element 78 
(see FIG. 1) is not covered by signatures, microswitch 76 establishes a 
closed circuit in series with relay contact CR1-2 causing relay CR2 to be 
energized and closing its contacts CR2-1 which energizes relay CR3 to open 
normally-closed contact CR3-1 thereby deenergizing time delay relay TD1 
and maintaining its normally-closed contacts TD1-1 closed. Since contacts 
CR1-3 are closed, solenoid-controlled air valve 90 is maintained energized 
during normal operation. 
When reflective element 78 is covered with signatures, microswitch 76 
establishes an open circuit which, even though relay contacts CR1-2 are 
closed, causes deenergization of relay CR2 which causes contacts CR2-1 to 
open deenergizing relay CR3. The deenergization of relay CR3 closes 
contacts CR3-1 energizing relay TD1. The energization of relay TD1 opens 
its normally-closed contacts TD1-1 one second after deenergization (for 
example) thus turning off the solenoid-controlled air valve 90 to save 
energy as well as preventing the generation of an air blast when 
signatures are not moving along the conveyor. One of the relays CR2 or 
CR3, not shown for purposes of simplicity, may cause immediate turn off of 
the conveyor belts in the conveyor sections 18, 20 and 22. 
In a similar manner the circuit of FIG. 3a operates nose jogger motor 
control circuit 46b as follows: 
During the test mode, switch arm 88 engages stationary contact 88a 
energizing relay CR2 which closes contact CR2-1 thereby energizing relay 
CR3. The energization of relay CR3 opens its normally-closed contacts 
CR3-1 deenergizing time delay relay TD1 causing its normally-closed 
contacts TD1-1 to close rapidly and remain closed. The closure of contacts 
CR1-3 upon energization of relay CR1 provides AC power to the nose jogger 
motor control 46b. 
In the run state, switch arm 88 engages contact 88b energizing microswitch 
76. When the reflector element 78 is uncovered (FIG. 1), an electrical 
path is completed through microswitch 76 and relay contact CR1-2, 
energizing relay CR2 and closing its contact CR2-1 thereby energizing 
relay CR3 to open its normally closed contact CR3-1 thus maintaining time 
delay relay TD1 deenergized. The normally-closed contacts TD1-1 of time 
delay relay TD1 remain closed and cooperate with the previous closure of 
relay contact CR1-3 to provide electrical energy to motor control 46b. 
When the reflector element 78 is covered, sensor 76 opens the electrical 
circuit previously completed with contacts CR1-2 thereby deenergizing 
relay CR2 and opening its contacts CR2-1 which deenergizes relay CR3 
returning its contacts CR3-1 to the closed condition. This closure 
energizes time delay relay TD1 which, after a predetermined delay 
(settable by DIP switches provided as part of relay TD1--not shown) 
contacts TD1-1 open after the predetermined time delay, for example, one 
second, turning off nose jogger motor control 46b. One of the relays CR2 
or CR3 may be used to immediately turn off the conveyor sections 18, 20 
and 22. 
The circuits of FIGS. 3 and 3a continually switch from one state to the 
next (i.e. "on" to "off" to "on") as the hopper 30 alternates its 
condition between being filled to capacity with signatures and having the 
signature level fall below reflector 78. In each case the deenergization 
of the time delay relays in FIGS. 3 and 3a cause substantially immediate 
closure of the normally-closed contacts for respectively energizing the 
solenoid 90 and the motor control 46b while providing a presettable time 
delay for turn off of solenoid 90 and jogger motor control circuit 46b. 
The circuits of FIGS. 3 and 3a are both used in systems incorporating a 
jogger and an air blast device. 
FIGS. 4a, 4b and 4c respectively show the side elevation, top plan view and 
end view of the novel side guide assembly utilized in the feeder 10. 
The preferred embodiment of the side guide assembly 100 is comprised of a 
one-piece side guide 102 of a shape conforming to the shape of the 
sections 18, 20 and 22. A pair of supporting blocks 104 and 106 are 
directly secured to side guide 102 by suitable fastening means F. A 
linkage arm 108, 110 is pivotally coupled to an associated one of the 
mounting blocks 104, 106 by a fastener F1 which threadedly engages each of 
the arms 108, 110 while extending through a clearance opening in each 
block 104 and 106. The clearance opening 104a is shown for block 104 in 
FIG. 4c. 
The opposite end of each of the arms 108, 110 is pivotally coupled to 
threaded nuts 112, 114 by pin means 112a, 114a. 
The intermediate portion of each arm 108, 110 is pivotally coupled to a 
short arm 116, 118 by means of a fastener F2 extending through a clearance 
opening in each arm 108 and 110 and threadedly engaging a tapped aperture 
in each of the arms 116 and 118. FIG. 4c shows fastener F2 extending 
through a clearance opening 108b in arm 108 and threadedly engaging an 
opening in arm 116. The opposite ends of each of the arms 116, 118 is 
pivotally coupled to a block 120, 122 by suitable pin means 120a, 122a 
respectively. Blocks 120 and 122 are fixedly secured to support frame 140. 
An elongated threaded assembly is comprised of a first elongated threaded 
member 124, a second shorter threaded member 126 coupled to member 124 by 
universal joint 128, and a final threaded member 130 coupled to the end of 
threaded member 126 by universal joint 132. Threaded member 124 is 
rotatably mounted, i.e. is mounted to rotate about its longitudinal axis 
represented by dotted line 124a by means of clamps 134, 136 and 138 
fixedly secured to side wall 140 of the feeder 10 by fasteners F4 (see 
FIG. 4c). The threaded sections 124 and 130 also extend through clearance 
openings in blocks 120 and 122. 
Members 112 and 114 are provided with tapped openings which threadedly 
engage threaded members 124 and 130, respectively. 
An operating handle comprised of hand crank 140 is fixedly secured to the 
left-hand end of threaded member 124 and a rotatable handle portion 140a 
is utilized to rotate threaded members 124, 126 and 130. The operation of 
adjustable side guide is as follows: 
By rotating operating handle 140 in a first direction, threaded blocks 112 
and 114 are caused to move in the direction shown by arrow A causing 
members 108 and 110 to rotate counterclockwise about fasteners F2 thereby 
moving one-piece adjustable side guide 102 in a direction shown by arrow 
A1. Rotating the hand crank in the opposite direction causes threaded 
members 112 and 114 to move in the directions shown by arrows A2 causing 
arms 108 and 110 to rotate clockwise about pivots F2 thereby moving side 
guide 102 in a direction shown by arrow A3. 
In applications wherein the centerline of the machine represented by dotted 
line CL is utilized for product registry of the feeder and cooperating 
hopper, a similar side guide assembly may be utilized along the opposite 
side 140' of the feeder 10. However, if side 140' of the feeder 10 serves 
as the product registry, a fixed guide may be employed along side 140'. It 
can thus be seen that the side guide (or guides) may be adjusted through 
operation of a single operating handle to both fine-tune the alignment of 
the signatures relative to the receiving hopper as well as adjusting the 
side guides when undertaking a product run requiring a change in product 
size. 
Returning again to FIG. 1, there is shown therein an adjustable angle 
hand-feed frame assembly 150 comprised of a driven hand-feed belt assembly 
152 having pulleys 154, 156 arranged at opposite ends thereof on a 
suitable supporting frame enabling the belt assembly to be moved between a 
horizontal dotted line position 152' to an inclined angular position 152 
shown in solid line fashion with the angle of the inclination being 
adjustable by means of an adjustable assembly also shown in FIGS. 1e and 
1f. 
The horizontal orientation 152' of the feed belt assembly is used when 
automatic feeding is utilized, i.e. when signatures are delivered to 
feeder 10 by a conveyor placed against the left-hand end thereof. Conveyor 
section 152 is coupled to the next adjacent conveyor section by suitable 
coupling means to operate at the desired linear speed. 
When signatures are to be delivered to feeder 10 by hand, the left hand or 
input end of the hand-feed belt section 152 is elevated as shown in solid 
line fashion. A large number of products, typically of a linear length of 
two feet or so, may be loaded upon the hand-feed belt section. This large 
buffer storage of signatures enables the operator to feed multiple 
loaders. The angle of incline enables the products to stand up without the 
need for exerting extreme care in the hand-delivery of signatures thereto. 
Because the signatures are driven down along the hand-feed belt section, 
the operator does not have to worry about achieving an extremely neat pile 
in the hand-feed section. The storage of approximately two feet of 
signatures enables the operator to walk away from the feeder and feed 
other adjacent feeders. In addition, the adjustability of the angle of 
inclination of the adjustable feed assembly 150 enables the section to be 
accommodated to the height of the particular operator resulting in a 
significant reduction in operator fatigue. 
FIGS. 1e and 1f show detailed views of the adjustment assembly forming part 
of the adjustable angle hand-feed frame assembly 150, the adjustment 
assembly comprising a rod 160 freely rotatable within a pair of end blocks 
162a, 162b forming a part of the feeder frame assembly supporting the 
horizontal conveyor. A block 164 is secured to rod 160 at a point 
intermediate the ends thereof and has an elongated threaded rod 166 
extending upwardly therefrom. Rod 166 has an adjuster knob 168 with a 
threaded opening which threadedly engages threaded rod 166. A locking knob 
170 also threadedly engages rod 166. Rod 166 extends through a central 
opening 172a in a bar 172 coupled at its opposite ends to a pair of frame 
members 174a, 174b forming part of the driven hand-feed belt assembly 152. 
Opening 172a is a clearance opening having an ID which is greater than the 
OD of threaded member 166. 
The manner in which the assembly 150 is adjusted for hand-feed operation is 
as follows: 
In order to convert from automatic feed to manual feed, belt assembly 152 
is lifted at its left-hand end causing it to rotate clockwise about the 
centerline for pulley 156. Adjuster knob 168 is rotated in a direction 
causing it to move upwardly toward bar 172 as shown by arrow 176. When the 
proper height is obtained, tightening knob 170 is rotated to firmly engage 
adjuster knob 168 in order to prevent the adjuster knob 168 from 
loosening. The weight of assembly 152 bears upon adjuster knob 168 by way 
of bar 172 maintaining the hand-feed belt assembly 150 in the proper 
position. 
In order to reduce the angle of inclination, or alternatively, to return 
the driven hand-feed belt assembly 152 to horizontal orientation, locking 
knob 170 and adjuster knob 168 are successively rotated in a direction 
opposite that shown by arrow 176 to lower these knobs downwardly toward 
rod 160 to a point which either reduces the angle of inclination of 
assembly 152 or returns the assembly to the horizontal orientation. 
Although the rod or shaft 160 is shown as being rotatable within members 
162a and 162b with block 164 fixedly secured to rod 160, rod 160 may be 
fixedly secured to mounting blocks 162a and 162b and block 164 may be 
rotatably mounted upon shaft 160. To prevent block 164 from sliding along 
rod 160, collars 178a, 178b are provided along rod 160, which collars are 
provided, for example, with set screws to fixedly secure the collars to 
rod 160 and thereby act as stops preventing member 164 from moving 
linearly along the direction of the longitudinal axis of rod 160. 
FIG. 5 shows another alternative feeder embodiment 200, a portion of which 
has been shown in schematic (i.e. simplified) fashion. The feeder shown 
therein is comprised of a horizontal conveyor section 18, a ramp conveyor 
section 20, and a generally downwardly inclined feeder section 22 which 
feeds signatures S so that their orientation is as shown at conveyor 
section 22 with the major faces thereof being aligned at an angle of about 
30 degrees with the vertical, the right-handmost signature resting against 
a back plate 202. In order that the signatures be uniformly fed in an 
error free manner from the conveyor section 22, it is important that the 
signatures collected on conveyor section 22 be neatly arranged. To 
facilitate this a beaver-tail jogger assembly 210 is provided. The 
beaver-tail jogger assembly includes a paddle 212 which is reciprocated at 
a high rate of speed by a motor 242 operating in a manner to be more fully 
described. The beaver-tail assembly is adjustable in two mutually 
perpendicular linear directions as shown by arrows D1 and D2 and is 
angularly adjustable as shown by arrows D3 in order to orient the jogger 
paddle 212 at the proper angle as well as adjusting the jogger paddle at 
the proper height relative to the signatures being collected upon conveyor 
section 22. 
The feeder 200 is turned on and off under the control of a sensor 76' 
similar to the sensor 76 in that it selectively controls the turn on and 
turn off of conveyor sections 18, 20 and 22 but differing from sensor 76 
in that sensor 76' is a proximity or distance measuring sensor which is 
adjusted to control the amount of signatures collected upon conveyor 
section 22. For example, when the position of the signature S' shown in 
FIG. 5 moves closer to proximity sensor 76', the sensor will turn off 
conveyor sections 18, 20 and 22. However, as soon as the signatures 
collected upon conveyor section 22 are fed to an output utilization device 
such as a saddle feeder (not shown for purposes of simplicity), then the 
distance between sensor 76' and signature S' increases whereupon conveyor 
sections 18, 20 and 22 are turned on. Similar to the beaver-tail jogger 
assembly 210, photosensor 76' may be adjusted in two mutually 
perpendicular directions as shown by arrows D4 and D5 and in an angular 
direction as shown by arrows D6. The first adjustment in the horizontal 
direction moves the sensor away from the feedrack for an increased depth 
of paper in the feedrack or moves toward the feedrack for a decrease in 
paper depth. The second adjustment raises and lowers the sensor for 
varying signature widths. The third adjustment changes the angular 
position of the sensor. 
FIGS. 5a, 5b and 5c show top, side and end elevational views respectively 
of beaver-tail jogger assembly 210. FIG. 5a shows the assembly 210 with 
the operating handle 218 removed. 
Frame member 216, mounted to support 215, is preferably a hollow tube of 
substantially rectangular cross-section and is provided with a pair of 
elongated slots 216a, 216b. A horizontal adjustment block 220 is slidably 
mounted within rectangular-shaped tube 216. A pair of threaded bolts 222a, 
222b threadedly engage top openings 220a and 220b within slidable block 
220. 
An elongated, hollow tube 224 of substantially rectangular cross-section is 
secured to tube 216 in a manner to be more fully described and supports 
jogger paddle 212 and motor 242. An elongated rectangular-shaped block 226 
is mounted within tube 224. Fastening member 220a is secured to block 224 
and extends into opening 220a in block 220. Threaded member 222b extends 
through a clearance opening 226b in block 226 and has its left-hand end 
coupled to an operating handle 228. By turning the handle 228 in a first 
direction, the threaded right-hand end of fastener 222b threadedly engages 
the tapped opening 220b pressing and clamping block 226 and tube 224 
firmly against tube 216 to retain the tube 224 in any position within the 
range of the slots 216a and 216b to thereby move the beaver-tail jogger 
assembly either closer to or further away from the end wall 202. 
An end cap block 230 is fixedly secured within the upper end of tube 224 to 
provide a bearing bushing for the stub shaft portion 218a of handle 
assembly 218 which comprises a substantially circular-shaped member 218b 
joined to the upper end of stub shaft 218a (relative to FIG. 5b) as well 
as a hand wheel 218c. 
The lower end of stub shaft 218a is integrally joined to an elongated 
threaded shaft 232 which threadedly engages and extends through and beyond 
the tapped opening 234a in a vertical adjustment block 234. The hand wheel 
assembly 218 is rotatably mounted within a suitable bearing bushing in end 
cap 230 so that threaded shaft 232, although rotatable about its 
longitudinal axis, experiences no linear movement relative to tube 224. 
Side 224a of tube 224 is provided with an elongated slot 224b. A 
rectangular-shaped plate 236 is secured to vertical adjustment block 234 
by a pair of threaded fasteners 238a, 238b which extend through suitable 
openings in plate 236 and threadedly engage tapped aperatures 234b, 234c 
in vertical adjustment block 234 to firmly secure plate 236 to block 234, 
while permitting block 234 and plate 236 to slide relative to tube 224. An 
adjustment handle 240 having an integral threaded portion 240a threadedly 
engages a tapped aperature 234d in vertical adjustment block 234 for 
clamping tube 224 between block 234 and plate 236 for securing a desired 
vertical position in a manner to be more fully described. 
Motor 242 is secured to a motor mount 244 which in turn is secured to 
vertical adjustment block 234 by means of a pair of fasteners 246a, 246b 
extending through an elongated slot 224d provided in side surface 224e of 
tube 224 which is parallel to side surface 224a, the elongated slot 224d 
being slightly greater in length than the slot 224b. 
The motor 242 is provided with an eccentric bushing 248. A linkage arm 250 
is rotatably mounted to the eccentric bushing by thrust bearing 252. The 
eccentric bushing 248 converts the rotation of motor output shaft 242a to 
a substantially linear reciprocating motion which is imparted to jogger 
paddle 212 whose left-hand end relative to FIG. 5a is secured to the 
jogger paddle mounting bracket 212a by suitable fastening means 212b. 
The manner of operation of the beaver-tail jogger assembly and the 
adjustment thereof is as follows: 
In order to adjust the position of tube 224 relative to tube 216, operating 
handle 228 is rotated counterclockwise, for example, to loosen tube 224 
relative to tube 216. Tube 224 may then be moved either toward the right 
or toward the left within the end limits of slots 216a, 216b. Upon 
appropriate positioning thereof, handle 228a is rotated clockwise, for 
example, to rigidly secure tube 224 to tube 216 by clamping blocks 226 and 
220 and hence tubes 216 and 222. 
A fine-tuned vertical adjustment is obtained by loosening operating handle 
240 and then operating hand wheel assembly 218 causing block 234 to move 
either upwardly or downwardly within tube 224 depending upon the direction 
of rotation of hand wheel assembly 218. When the proper position is 
obtained, handle 240 is tightened to maintain the fine-tuned position. The 
block 234 is drawn toward plate 236 which clamps side 224a of tube 224 
therebetween rigidly securing the motor 242 and jogger paddle 212 at the 
desired orientation relative to the stack of signatures collected on 
conveyor section 22. The rotational output of motor 242 is converted to 
reciprocating motion, which is imparted to paddle 212, by means of the 
eccentric bushing and link arm 248 and 250, respectively. The fine-tuning 
of the jogger paddle 212 due to the "micro" adjustment system produces a 
neater pile in the hopper feedrack. The tendency for the operator to 
overadjustment the jogger such that too great a pressure is imposed on the 
jogger is also reduced. In addition, overloading the jogger can damage the 
signatures and can also cause permanent damage to the jogger assembly. The 
simplicity of the adjustment assembly facilitates jogger fine-tuning. The 
pitch of the threaded rod is also selected to facilitate the "micro" 
adjustment capability. 
The feeder of the present invention may be utilized with a variety of 
different output utilization devices such as, for example, a saddle hopper 
feedrack. FIG. 6 shows a saddle hopper feedrack 260 designed in accordance 
with the principles of the present invention, which comprises a chain 
drive assembly for advancing signatures as they are removed from the 
feedrack for delivery to a saddle stitcher (not shown for purposes of 
simplicity). The feedrack comprises a pair of drive chains 262, only one 
of which is shown in FIG. 6 for purposes of simplicity, it being 
understood that each drive chain is similar in design and function. Chain 
262 is entrained about a drive sprocket 265 and guide edges of link 266 
and plate 272 as will be more fully described. When operated in the manual 
loading mode, signatures are loaded onto the drive chains 262 by hand and 
are arranged in the manner shown. The signatures are diagonally aligned in 
the manner shown and the right-handmost signature S' rests against a stop 
268. A take-off assembly 270 comprising a rotatably mounted arm 271 
carrying a suction member 274 draws the right-handmost signature S' away 
from the stack. As each signature is drawn from the stack, a feed pawl, to 
be more fully described in connection with FIGS. 6a-6c, operates to move 
the chains 262 through a distance substantially exactly equal to the 
thickness of one signature, i.e. the signature removed from the stack. 
In applications wherein it is desirable to provide automatic feeding of 
signatures to the assembly 260, present day technology necessitates that 
the feedrack, including the drive chain 262 and its drive sprockets be 
removed from the saddle stitcher for installation of a feeder of the type 
shown, for example, in FIG. 5. This has proven to be a significant problem 
when the feeder is installed. The feedrack assembly shown in FIG. 6 
requires readjustment for proper hopper performance which is a 
labor-intensive, time-consuming procedure requiring a high degree of 
expertise. 
The design of the present invention provides a novel feedrack which is 
capable of pivoting in the center to allow a very simple installation of 
the feeder thereto. The conventional hopper feedrack cannot be used with 
the feeder for the reason that when the loader is interfaced with a 
conventional rack, the signature pile which is presented to the hopper is 
too large, i.e. contains too many signatures, causing too much pressure to 
be applied to the hopper which significantly degrades the desirable 
error-free operation. 
The novel hopper feedrack 260 of the present invention comprises a pair of 
link assemblies each assembly in turn comprised of first and second links 
264, 266 which are pivotally connected to one another. Noting, for 
example, FIGS. 6 and 6a-6c, the novel linkage assembly of the present 
invention is comprised of first and second linkage assemblies 261, 263 
which can be seen in FIG. 6b to be mirror images of one another. The like 
elements of assemblies 263 are designated by primes. The assembly 261 is 
shown in FIGS. 6b and 6c as comprising links 264 and 266 pivotally joined 
to one another by means of shaft 268. Link 266 is a substantially flat 
plate of uniform thickness and is maintained secured to link 264 by means 
of clamp 270. Link 264 has a uniform thickness T which extends from its 
right-hand end relative to FIG. 6b to substantially three-quarters of its 
entire length whereupon it has a reduced thickness T1 which is 
substantially uniform over the remaining one-quarter of its length forming 
a cut-out portion 264a which provides clearance for one of the feeder 
rollers R of the feeder, when the feedrack is aligned with a feeder 10 as 
will be more fully described in connection with FIGS. 6a and 6c. A chain 
guide plate 272 having curved left and right-hand ends 272a, 272b 
respectively is fixedly secured by suitable fastening members to link 264. 
Curved portion 272b provides clearance for sprocket 265 and curved portion 
272a provides clearance for the rounded end 266b of link 266. The guide 
edge 272c is aligned with sprocket 265 and the guide edges of link 266. 
Chain 262 slides along and is guided by the upper edge 272c of chain guide 
plate 272 and further slides along the top guide edge 266a of link 266 and 
the rounded left-hand end 266c, as shown best in FIGS. 6 and 6c. 
Considering FIG. 6, it can be seen that the chain 262 is not maintained 
taut about sprocket 265 and the guide plates 272, 266 but droops 
downwardly somewhat as shown by its lower run 262a. 
Sprockets 265 and 265' are rotatably mounted to links 264 and 264' (see 
FIG. 6b) and a shaft 276 common to sprockets 265, 265' mounts a feed pawl 
278 which is advanced by a conventional mechanism to rotate sprockets 265, 
265' through an angle sufficient to advance the upper runs of the chains 
entrained thereabout through a linear distance sufficient to advance the 
signatures remaining on the hopper feedrack through a distance equivalent 
to one signature thickness. 
A bracket 282 is fixedly secured to chain guide member 272' and has an 
axially adjustable pin 283 whose right-hand end is coupled to one end of a 
bias spring 284, the opposite end of which is coupled to feed pawl 278. 
In the embodiments shown in FIGS. 6a-6c to mount a feeder 10 to the 
feedrack clamps 270 and 270' are loosened, causing links 266, 266' swing 
downwardly and out of the way so as not to interfere with the operation of 
either the feedrack or the feeder. In order to take up some of the slack 
in chain 262, a semicircular guide member 286 is provided to cause chain 
262 to assume a substantially right angle shape beneath links 264, 266, as 
shown in FIG. 6c. 
As shown in FIG. 6a, the feeder downstream end is provided with a support 
surface T. Conveyor belts B are each entrained about a plurality of 
rollers R1 through R5. Rollers R1 and R2 are mounted upon a common shaft 
288. Rollers R4 and R5 are mounted upon a shaft 290. Roller R3 is mounted 
upon a shaft 292. Sufficient clearance is provided between rollers R2 and 
R3 and between rollers R3 and R4 in which to insert the left-hand end of 
the links 264 of the feedrack. 
In order to assemble the feeder to the feedrack, after the links 266 are 
loosened, the feeder is moved toward the feedrack and is aligned so that 
the assemblies 261 and 263 are positioned to enter into the gap regions 
between rollers R4-R3 and R3-R2, respectively. When the feeder 10 and 
feedrack assembly 260 are substantially in alignment, which can be 
accomplished by means of a conventional floor mount (not shown), any 
height adjustments are provided for by hand crank assemblies 12a provided 
on each of the leg assemblies of feeder 10 (see FIG. 1) so as to bring the 
axes of rotation of rollers R1 through R5 into colinearity with the 
longitudinal axis of shaft 268. 
The notched portions 264a and 264a' of links 264 and 264' provide clearance 
for rollers R4 and R2 as shown in FIG. 6b. The bracket 294 supporting the 
shaft 292 for rotatably mounting roller R3 is likewise notched as shown at 
294a to provide clearance for collar 270. 
It should further be noted that the brackets 296 and 298 further cooperate 
to rotatably support shafts 288 and 290, respectively. 
It can thus be seen that the novel split section feedrack of the present 
invention enables the feeder and the feedrack to be coupled together in a 
simple, rapid and yet highly accurate manner as compared with prior art 
techniques which require an extremely tedious and time-consuming 
procedure. 
As another alternative to pivoting down the sections 266 and 266', it is 
fairly obvious that rather than pivoting down the section 266 in the 
manner shown in FIGS. 6b and 6c, sections 266 and 266' may be removed from 
their associated sections 264 and 264' when attaching the feedrack to a 
feeder 10. 
When it is desired to operate the feedrack in the manual mode, the feeder 
10 is simply moved away from the feedrack, the links 266 and 266' are 
moved from the position shown in FIG. 6c to the position shown in FIG. 6 
and the clamps 270 and 270' are locked to retain the links 264, 266 and 
264', 266' in the straightline arrangement shown in FIG. 6. 
It can thus be seen that the novel saddle hopper feedrack assembly of the 
present invention greatly simplifies the coupling of the saddle stitcher 
to a feeder for automatic operation which set up is significantly easier 
and faster than the feedracks of conventional design and which further 
permits simple and rapid set-up of the feedrack for manual loading. 
A latitude of modification, change and substitution is intended in the 
foregoing disclosure, and in some instances, some features of the 
invention will be employed without a corresponding use of other features. 
Accordingly, it is appropriate that the appended claims be construed 
broadly and in a manner consistent with the spirit and scope of the 
invention herein described.