High speed drum processing apparatus

An apparatus for processing sheet products includes a rotatable drum having a plurality of pockets adapted to receive individual sheet products. Plural rollers are disposed along the periphery of the drum between adjacent pocket openings. The rollers are rotated through a portion of the drum movement and locked against rotation through the remainder of the drum movement. Cam rollers are provided to lift the pockets radially outward, tilt the pockets, and open and close sidewalls of the pockets to facilitate ingress and egress of the sheet products.

BACKGROUND OF THE INVENTION 
This invention pertains to the art of processing sheet products and more 
particularly to processing a stack of sheet products to a conveyor system 
that handles each sheet product on an individual basis. 
The invention is particularly applicable to receiving a stack of sheet 
products whether they be newspapers, inserts, periodicals, magazines, etc. 
The term "sheet products" will be understood to refer to these and similar 
products. The subject new apparatus is adapted to handle a high volume of 
sheet products for a variety of different operations. 
By way of example, the sheet products may be a stack of newspapers received 
from a printing press. At printing press speeds approximating 60,000 to 
100,000 newspapers per hour, downstream equipment must keep up with the 
supply and prepare the newspapers for handling in various downstream 
stations such as stuffing or inserting, stacking and the like. Prior 
processing machinery has been unable to maintain pace with the increasing 
press speed resulting from advanced technological innovations in that 
area. To accommodate the high output of the printing machinery, it has 
heretofore been necessary to employ plural processing devices to handle 
large numbers of sheet products. Even then, maintenance of plural conveyor 
lines associated with plural processing devices adds to the increased cost 
of handling sheet products. An increased need has developed to provide an 
on-line processing apparatus that is able to handle large numbers of sheet 
products in an efficient manner. The apparatus has to effectively convey 
between a stack of sheet products on one side and a conveyor system on the 
other side that handles each sheet product individually. Therefore, the 
apparatus must accurately and quickly separate the sheet products from the 
stack, quickly move the sheet products to an outfeed location, and present 
individual sheet products for pickup by grippers spaced along a conveyor 
system. 
Further constraints are placed on the system because of the type of 
product; namely, sheet products which require special handling. The 
processing equipment must be able to adapt to various thicknesses of the 
sheet products as experienced in a newspaper processing system. Typically, 
the newspaper thickness will vary from day to day, or even in different 
printing runs on the same day. Also, the flexible nature of the sheet 
product requires special handling in transferring the product from a stack 
to the processing apparatus, as well as transferring this same product 
from the processing apparatus to the conveyor system. 
Nevertheless, the present invention is not restricted to receipt of papers 
from a printing press but is applicable to any general processing of sheet 
products. It will be appreciated that the invention has broader 
applications in all these fields and may be advantageously employed in 
still other sheet product environments and applications. 
The present invention contemplates a new and improved processing apparatus 
that overcomes all of the above referred to problems and others and 
provides an economical, efficient processing apparatus. 
SUMMARY OF THE INVENTION 
According to the subject invention, a processing apparatus includes a 
rotatable drum having plural, radially disposed pockets adapted to receive 
sheet products therein. Rollers are defined along the periphery of the 
drum between pocket openings and are adapted to engage an associated stack 
of sheet products and transfer the sheet products one-by-one into a 
respective pocket. The rollers are rotated relative to the drum through a 
preselected portion of the drum rotation. Thereafter, the rollers are 
locked against rotation for the remainder of the drum rotation. 
According to yet another aspect of the invention, means for selectively 
actuating movement of pocket sidewalls toward and away from one another to 
grip the associated sheet products is provided. 
According to yet another aspect of the invention, means for actuating 
radial movement of the pockets toward and away from the periphery of the 
drum is provided. 
According to still another aspect of the invention, means for tilting the 
pockets is provided. 
A primary advantage of the invention resides in the ability to process a 
large number of sheet products in an efficient manner. 
Another advantage of the invention resides in pockets that open and close 
to facilitate gripping of the sheet products. 
Yet another advantage of the invention is realized in the radial movement 
of the pockets to assist in removal of the sheet products from the 
rotating drum. 
Still another advantage is found in the tilting of the pockets to 
facilitate ingress/egress of sheet products to and from the pockets. 
Still other advantages and benefits of the invention will become apparent 
to those skilled in the art upon a reading and understanding of the 
following detailed description.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring now to the drawings wherein the showings are for purposes of 
illustrating the preferred embodiment of the invention only and not for 
purposes of limiting same, the FIGURES show a processing apparatus or high 
speed drum type feeder A interposed between an infeed mechanism B and a 
gripper conveyor C. 
More particularly and with reference to FIGS. 1 and 2, a printing press or 
other processing station (not shown) provides a stack D of sheet products 
SP, such as newspapers, to the infeed mechanism B for processing by the 
high speed drum type feeder A. The infeed mechanism includes opposed, 
first and second sidewalls 10, 12 and a third or bottom wall 14 for 
supporting the stack of sheet products along three sides. According to the 
preferred embodiment, the second sidewall 12 is selectively movable toward 
and away from the first sidewall 10 by shifting the second sidewall along 
a horizontally disposed shaft 16. Any conventional adjustable clamping 
arrangement can be utilized to secure the second sidewall and shaft 16 
together. The shaft 16 is driven by an associated drive means such as a 
direct drive motor, drive belt, or other drive transmission arrangement 
(not shown). Generally vertically extending shafts 24, 26 are 
interconnected with the shaft 16 through a right angle gear box or similar 
horizontal-to-vertical drive arrangement. The specific details of the 
right angle gear box do not form a part of the invention and further 
discussion thereof is deemed unnecessary. 
Vertically extending idler shafts 28, 30 are associated with the shafts 24, 
26, respectively. The shaft pair 24, 28 receives a pair of belts 32 
therearound to define the first sidewall 10. Likewise, the shaft pair 26, 
30 receives a pair of spaced belts 34 therearound to define the second 
sidewall 12. Still further, a pair of belts 36 are received around the 
shaft 16 and a corresponding idler shaft 38 to define the bottom wall 14. 
Each of the belts 32, 34, 36 includes discrete teeth or coat 46 adapted to 
drivingly engage the sheet products and advance the stack toward the drum 
processing apparatus A. Since the shafts 16, 24, 26 are synchronously 
driven, the belt pairs 32, 34, 36 advance the sheet product stack toward 
the drum processing apparatus at the same rate. 
The bottom wall 14 includes a vibrating plate 48 disposed between belt pair 
36 and driven by a vibrating means such as an eccentric motor or 
reciprocating piston device 50. Preferably, the vibrating plate is a rigid 
structure. The plate has a generally smooth, planar upper surface that 
permits the sheet product stack to slide easily thereover. The vibrating 
plate assists in orienting the sheet products for individual receipt into 
the drum processing apparatus as will be fully described hereinbelow. 
An auxiliary infeed mechanism 52 is provided between the shafts 16, 24, 26 
and the drum processing apparatus A. The auxiliary infeed mechanism 
includes three shafts 54, 55, 58 that synchronously rotate with the 
remainder of the infeed mechanism B. These shafts can be driven by a 
separate drive means (not shown) from that of the remainder of the infeed 
mechanism or commonly driven if so desired. A toothed belt 60 extends 
around the shafts 54, 56, 58 to bridge the gap between the belts 32, 34, 
36 of the main infeed mechanism and the drum processing apparatus. 
Specifically, shafts 56, 58 are disposed below the horizontal plane 
defined by the top surface of the vibrating plate 48 and axially behind a 
vertical plane defined by shafts 24, 26. In this manner, the portion of 
the belt 60 that extends between shafts 54, 58 is disposed down and away 
from the rotational path of the drum processing apparatus A so that the 
sheet products are advanced as close as possible to the drum processing 
apparatus without interfering with rotation thereof. The belt 60 of the 
auxiliary infeed mechanism provides a driving engagement to the sheet 
product stack to a point immediately adjacent the periphery of the drum 
processing apparatus. 
First and second gate pins 70, 72 are located adjacent the inner end of the 
vibrating plate 48. The pins are pneumatically actuated to selectively 
extend above and below the horizontal plane defined by the upper surface 
of the vibrating plate. A signal provided by sensor 74 actuates the gate 
pins to reciprocate above and below the horizontal plane of the vibrating 
plate to prevent and permit advancement of the individual sheet products 
of the stack into the processing apparatus. Since the thickness of the 
sheet products can change from one operating run to the next, the 
reciprocating or cycling action of the gate pins 70, 72 can likewise be 
altered to accommodate these variations in thickness. 
In the preferred operation of the infeed mechanism the sheet products of 
the stack are disposed so that the folded edges of the sheet products SP 
are disposed along the bottom wall 14. In other words, the open or free 
ends of the sheet products are disposed upwardly to define the only 
unsupported surface of the sheet products. The toothed belts engage the 
folded edges of the sheet products for advancement toward the drum 
processing apparatus. 
The second sidewall 12 has a reduced axial length relative to the first 
sidewall 10. This arrangement allows the sheet products to be fed to the 
infeed mechanism from a direction generally perpendicular to the path of 
belts 32, 34, 36. The sheet products are loaded from the side of the 
infeed mechanism adjacent the second sidewall, across the bottom wall 14, 
and in abutting engagement with the first sidewall. Thereafter, the sheet 
products are advanced by the belts toward the drum processing apparatus. 
It will be understood that the first sidewall could alternatively be 
shorter than the second sidewall to receive products from the other side 
of the infeed mechanism if desired. 
The drum processing apparatus A includes an external frame or housing 
defined by opposed side plates 76, 78. The side plates are typically 
secured to further exterior framework (not shown). The frame side plates 
support a drum 80 for rotation about a horizontal central axis 82. Motor 
84 drives the drum 80 through any conventional manner such as a drive 
sprocket and toothed wheel arrangement. The particulars of the drive 
arrangement form no part of the subject invention so that further 
discussion thereof is deemed unnecessary. The drum has a generally 
cylindrical configuration defined by a circular outer periphery 86. Plural 
pockets 90 of substantially identical construction are defined in the drum 
so that description of one pocket is applicable to the other pockets. The 
pockets are generally radially disposed for selective receipt of 
individual sheet products. Each pocket includes radially extending 
sidewalls 92, 94 interconnected along a bottom wall 96 (FIG. 3). The 
radially outer portions of the sidewalls are spaced apart defining a 
pocket opening 98 adapted to receive the sheet products therein. 
A plurality of rollers 104 are circumferentially disposed along the 
periphery of the drum. A roller is disposod between contiguous pockets, 
that is between a sidewall 92 of one pocket and a sidewall 94 of an 
adjacent pocket. In this manner, each pocket 90 has a roller 104 
associated therewith. 
To distinguish between the adjacent rollers and pockets, a small 
alphabetical suffix will delineate between the different pockets and 
rollers. Nevertheless, it will be understood that each roller and pocket 
configuration is substantially identical to its counterparts. Likewise, 
each sheet product SP will be identified by a corresponding letter set 
apart in quotations, to facilitate an understanding of the infeed and 
operation of the drum processing apparatus. 
Specifically, roller 104c is rotated by the drum assembly to a position 
adjacent the lower, inner folded edge of the stack of sheet products. A 
sucker or vacuum region 106c is defined on the roller and faces outwardly 
from the drum apparatus for engagement with the lower edge of sheet 
product "c". Through suitable means for supplying a vacuum to the sucker 
region to be described hereinbelow, secure engagement between the roller 
and lower edge of sheet product "c" is completed. As shown in FIG. 3, the 
drum apparatus is rotating in a counterclockwise direction and the 
rollers, rotating along their own respective axes in a clockwise 
direction, engage the sheet products and urge one sheet product at a time 
into a pocket disposed directly below the roller. Thus, roller 104c urges 
sheet product "c" through pocket opening 98c. 
Roller 104b has advanced through approximately 10.degree. of drum rotation 
in a counterclockwise direction and approximate1y 90.degree.. of clockwise 
rotation around its own axis so that a greater portion of sheet product 
"b" has been urged into pocket 90b. After the approximately 90.degree.. 
rotation of each roller, the vacuum source is terminated and the 
frictional engagement between the roller and associated sheet product 
continues to urge the sheet product into a selected pocket. As shown with 
roller 104a, the vacuum source has been terminated but continued 
engagement between the rotating roller and associated sheet product "a" 
further urges the sheet product into the pocket 90a. 
To assist in separation of the individual sheet products from one another 
and the remainder of the stack D, stripper or divider bars 108 (FIGS. 8-9) 
are disposed adjacent each roller along the periphery of the drum 80. When 
a sheet product is substantially received in an associated pocket, the 
outer, free edge of the sheet product will engage a stripper bar adjacent 
the radially outer end of pocket sidewall 94. This prevents the free end 
of each sheet product from interfering with the next sheet product being 
fed by an adjacent roller as the drum continues to rotate in a 
counterclockwise direction. 
In FIGS. 4 and 5, means for selectively rotating the rollers in a clockwise 
direction about their own axes relative to the counterclockwise rotation 
of the drum 80 is more particularly illustrated. The right-hand end of 
each roller includes a sprocket 120 fixed to the roller. A rack assembly 
122 is comprised of a series of pins and the rack assembly mounted to 
frame side plate 78. As the drum rotates in a counterclockwise direction, 
the sprockets engage the individual pins of the rack assembly to actuate 
clockwise rotation of the rollers around their own axes. The rollers will 
rotate at the same speed as the drum under this arrangement. 
Rotation of the rollers takes place through approximately 40.degree. of the 
drum rotation. Through the remaining approximately 320.degree. of drum 
rotation, the rollers are lockedagainst further rotation by a cam 
arrangement. As shown in FIG. 5, the right-hand end of each roller 
includes a depending arm 124 that secures a first cam wheel or cam roller 
126 to the roller 104. The cam roller 126 is received in an associated cam 
track 128 defined in a cam plate 130. The cam plate has a reinforcing 
plate 132 secured to an outer face that, in turn, is secured to frame side 
plate 78. The first cam track 128 is generally continuous through 
320.degree. (FIG. 12) so that the cam roller 126 locks the individual 
rollers 104 against rotation through a major portion of the drum movement. 
Only through the approximately 40.degree. gap defined between 128a and 
128b in the first cam track are the rollers free to rotate as a result of 
the sprocket and rack assembly arrangement. 
As each roller exits the first cam track at location 128a, the sucker 
region is disposed radially outwardly for engagement adjacent the lower 
folded edge of a sheet product in the stack. A source of vacuum is then 
provided to the roller through approximately 90.degree. of the roller 
rotation to grasp the sheet product and urge it toward a selected pocket. 
Next the source of vacuum is terminated and continued rotation of the 
roller urges the paper into the pockets. By the time the drum has 
completed rotation through approximately 40.degree., i.e., through the 
arcuate path of the sprocket and rack assembly engagement, the sheet 
product is completely received in a selected pocket and cam roller 126 
reenters the cam track at 128b. 
With continued reference to FIG. 5, and additional reference to FIG. 6, the 
means for supplying a source of vacuum to the individual rollers will be 
set forth in greater detail. Particularly, the rollers have an opening or 
bore 136 extending axially therethrough. The sucker region 106 
communicates with the bore 136 through a sidewall opening 138. The 
left-hand end of the rollers selectively communicate with a port 140 
defined through frame side plate 76. A ring or collar 142 is disposed on 
the roller and receives a seal member such as 0-ring 144 that seals with 
bushing member 146 disposed on the roller. The collar sealingly engages a 
port block 148 that has a plastic seal face 150 secured thereto for 
smooth, sliding engagement with the collar. A biasing means such as spring 
152 urges the port block toward the collar. 
As represented in FIG. 6, the drum rotates the rollers relative to the 
frame side plate 76 and the bore 136 of each roller communicates through 
the port 140 with an external source of vacuum (not shown). 
Simultaneously, the rollers are rotating about their own axes due to the 
sprocket/rack assembly arrangement. The combined rotation of the drum and 
rollers connects the rollers to the source of vacuum through an 
approximate 90.degree. rotation of the respective rollers. Therefore, port 
140 has an elongated arcuate length, preferably defined in seal face 150, 
as illustrated in phantom in FIG. 6. The elongated length of the port is 
preselected to correspond to the circumferential dimension of drum 
rotation in which the rollers rotate 90.degree. about their own axes. 
A means for adjusting the location at which a roller is connected to the 
vacuum source is also provided. According to the preferred embodiment, the 
adjusting means includes a threaded member 152 pivotally secured to the 
frame side plate 76 at one end and follower mechanism 154 at the other 
end. The follower mechanism is, in turn, secured to port block 148. 
Rotation of the threaded member moves the follower mechanism along an 
elongated slot 156 formed in the side plate 76. Since the follower 
mechanism is fixed to the port block 148, the location at which a roller 
bore 136 communicates with the vacuum source may be altered. 
Due to the flexible nature of sheet products such as newspapers, the 
pockets must be specially accommodated to facilitate receipt of the 
individual sheet products from the stack and orient them for pick-up by a 
gripper conveyor arrangement C. The subject invention incorporates 
structural features that result in three primary movements of the pockets 
as the drum rotates to facilitate ingress and egress of the sheet 
products. Specifically, each pocket will (i) tilt, (ii) move radially 
relative to the drum, and (iii) open and close to grip and receive the 
sheet products. Each of these actions must be accomplished at a high rate 
of speed to permit processing of approximately 40,000 sheet products per 
hour. 
The means for actuating radial movement of each pocket includes a pair of 
lift rod members 164, 166 (FIGS. 7-9). Rod member 164 is pivotally secured 
to drum sidewalls 168, 170 and is generally cylindrical in conformation 
except along a notched face 172. The notched face abuttingly engages the 
associated pocket sidewall 92. The rod member 164, though, is not secured 
to the sidewall 92 but allows sliding movement therewith. On the other 
hand, the lift rod member 166 is also notched along one face 174 but is 
secured through a known fastening arrangement such as bolts 176 to the 
sidewall 94 of the pocket. A pivot or link arm 178 extends between the 
lift rod members 164, 166, preferably one link arm at each end of the 
pocket (FIG. 7). Further, a second cam roller 180 is disposed on a 
right-hand end of lift rod member 166. The second cam roller is received 
in a second cam track 182 defined in cam plate 130. As the drum rotates 
relative to the cam plate 130, the second cam roller rides in the second 
cam track and radially shifts as a result of the predetermined cam track 
configuration (FIG. 12). 
As illustrated in FIGS. 7 and 8, the pocket is in a radially recessed 
position. In the recessed position lift rod member 166 is disposed closer 
to the central axis of the drum than lift rod member 164. As the second 
cam track 182 increases its diameter along the track region 182a to 182b 
the second cam roller 180, and likewise lift rod member 166, move to a 
radially outer position that lifts the pockets to a radially outer 
position as shown in FIG. 9. Since lift rod member 164 is secured to the 
drum sidewalls, the lift rod member 166 pivots thereabout and lifts the 
pocket relative to the drum sidewalls. 
Of course the radial outward or lifting movement of the pocket is defined 
by the second cam roller movement in track 182. To accommodate this 
movement, the drum sidewalls 168, 170 have a scalloped configuration. The 
scalloped configuration is akin to a sinusoidal curve. Lift rod member 164 
is secured at the low points of the curve and the high points of the curve 
define a recess in which lift rod member 166 extends in its radially 
outermost position (FIG. 9). 
As the pocket is lifted radially outward, it also undergoes a closing 
action as the sidewalls 92, 94 move toward one another. To effect this 
closing relationship, a cam block 190 is disposed along an interior face 
of each drum sidewall 168, 170. The cam blocks are of substantially 
identical construction, the right-hand cam block being a mirror image of 
the left-hand cam block. Each cam block has third and fourth cam tracks 
192, 194 defined therein for opening and closing the pockets. First and 
second opening/closing rod members 196, 198 are associated with each 
pocket. Each of the rod members 196, 198 extends over the entire width of 
the pocket, and is secured to respective sidewalls 92, 94 of the pocket by 
fastening means 176. Each of the rod members 196, 198 has a notched face 
200, 202, respectively, that defines a planar surface to conform to the 
pocket sidewalls. 
Moreover, the radially outer end of sidewall 92 has a hinged upper portion 
210 that pivots around pivot bar 212 secured to the exterior face of 
pocket sidewall 94. An arm 214 extends from the pivot bar to permit 
articulated movement of the upper portion 210 secured at the outer end of 
the arm. A spring 215 biases the upper sidewall portion 210 toward a 
closed position with sidewall 94. In the preferred embodiment the spring 
215 is a torsion spring received around pivot bar 212. On the other hand, 
means for opening the pocket against the spring bias is defined by cam 
rollers 216 on opposed ends of rod member 196 and cam rollers 218 disposed 
on opposite ends of rod member 198. The cam rollers 216 are received in 
the cam tracks 192 (FIG. 10) while cam rollers 218 are received in the cam 
tracks 194. The predetermined configuration of the cam tracks 192, 194 is 
adapted to hold the pockets in an open position when the pocket is 
radially recessed, move the first and second sidewalls 92, 94 toward one 
another during an intermediate range of radial outward movement of the 
pockets, and close the sidewall 94 toward sidewall 92 in the radially 
outermost movement of the pocket. 
As particularly illustrated in FIG. 10, those portions of each cam track 
192, 194 denoted by suffix "a" represent the position of cam rollers 206, 
208 when the pocket is in a recessed and open position corresponding to 
FIG. 8. The region denoted by suffix "b" indicates intermediate radial 
outward movement of the pocket toward a closing position. Lastly, suffix 
"c" illustrates the closed and outermost radial position of the pocket as 
illustrated in FIG. 9. 
As indicated above, tilting of the pocket is also effected to facilitate 
ingress and egress of the sheet products into the pockets. The tilting of 
the pockets results from the pivotal arrangement of the lift rod members 
164, 166 cooperating with the opening/closing rod members 196, 198. That 
is, as the second cam roller 180 travels in cam track 182 through the path 
182a to 182b the pocket is lifted radially outward. Simultaneously, the 
constraint imposed on the upper portion of each pocket in cam tracks 192, 
194 results in the lower or bottom portion of the pocket pivoting around 
rod member 161 to effect a tilting of the pocket. 
Tilting also occurs as the pockets are radially recessed from their FIG. 9 
position, i.e., as the cam roller 180 travels through the cam track path 
182b to 182c (FIG. 12). The tilting of the pockets is designed to 
facilitate ingress of the papers as the rollers urge the individual sheet 
products therein. Alternatively, the pockets are tilted in the opposite 
direction to facilitate egress of the papers as individual grippers 220 on 
the gripper conveyor mechanism C grasp and remove the sheet products from 
the pockets. 
In summary, a stack D of sheet products SP are urged toward drum 80 by a 
series of toothed belts. The vibrating plant 48 orients and aligns the 
sheet products as they travel through the infeed mechanism. Gate pins 70, 
72 assist in separation and advancement of the sheet products. The drum 80 
rotates and positions peripherally arranged rollers 104 for engagement of 
the lower fold edge of the sheet products. The rollers are freed for 
rotation relative to the drum, selectively connected to a source of vacuum 
to assist in gripping the sheet products, and rotated to urge the 
individual sheet products into selective pockets. Drum rotation continues 
through approximately 150.degree. from the sheet product infeed mechanism. 
At that point, the second cam roller 180 has advanced into the second cam 
track portion 182a to 182b and begins to tilt and lift the pockets 
radially outward. As the pockets move radially outward, cam tracks 192, 
191 cooperate with cam rollers 216, 218 to close the pocket sidewalls 92, 
94 and grip the looseleaf or free end of the sheet product. As shown in 
FIG. 9, the pocket is closed and located at its radially outermost 
position where a selected gripper 220 can grasp the free end of the sheet 
product and remove sheet product from the pocket against the bias of 
spring 198. The gripper conveyor mechanism then transports the sheet 
products individually for further processing downstream. Thereafter, cam 
roller 180 follows the path from 182b to 182c to radially recess and open 
the pockets. 
As particularly illustrated in FIG. 13, the tilting and radial disposition 
of the pockets is shown in a freeze-frame condition where the effect of 
the cam rollers and cam tracks have lifted, tilted, and closed the pockets 
from the infeed mechanism toward the outfeed area adjacent the conveyor 
mechanism. The remainder of the drum movement back toward the infeed 
mechanism, again, radially recedes the pockets and opens them for receipt 
to individual sheet products as the cycle continues. 
The invention has been described with reference to the preferred 
embodiment. Obviously modifications and alterations will occur to others 
upon a reading and understanding of this specification. It is intended to 
include all such modifications and alterations insofar as they come within 
the scope of the appended claims or equivalents thereof.