Rotary Die Axis Synchronization System and Adjustable Wedge Apparatus Therefor

An adjustable wedge apparatus is provided that includes a split wedge, a first block, a second block, a threaded adjustment screw, and an expandable and contractable biasing device. The split wedge is configured to be sandwiched between the first block and the second block. The first block and the second block are configured to be held together, with the split wedge between, by the expandable and contractable biasing device. The spilt wedge has a narrow end divided into two tines, and a threaded through-hole. The threaded adjustment screw has an external thread that is complementary to the internal thread of the through-hole. Tightening the threaded adjustment screw spreads apart the first block and the second block. An axle alignment system including the adjustable wedge apparatus is also provided, for example, a rotary die cutter alignment system. A method skew of adjustment is also provided.

FIELD OF THE INVENTION

The present invention relates to systems and processes for mounting and positioning rotating rolls in a rotary die. More specifically, the present invention relates to a roll mounting and positioning system.

BACKGROUND OF THE INVENTION

Rotary die cutters are well known for cutting apertures of various sizes and shapes in a running web, particularly a web operating in conjunction with a printing press. An exemplary application of such die cutters is to cut peel-off labels carried on a backing sheet. Known rotary die cutters utilize a pair of rolls rotating about two parallel axes that are rotatably mounted between a pair of side frames. The rolls are driven by a line shaft. One roll, designated as the die roll, or cylinder, carries flexible sheet metal dies on its outer surface, which include cutting and creasing lands. Each die is formed from a thin metal sheet and has raised lands formed in the shape of an aperture to be cut and crease lines to be formed. The die is wrapped around the die cylinder and secured to it, for example, by magnetic attraction produced by permanent magnets embedded in the die cylinder. Dies can also be secured by tapes, mechanical clamps, or other types of fasteners. The anvil cylinder is formed of a hardened material and is of such diameter that its surface speed is substantially equal to the web speed.

As the web passes between the rotating cylinders, the cutting and creasing lands of the die are pressed into the web backed up by the anvil cylinder to produce the desired aperture and creases in the web. Such rotary die cutters have end-mounted die rolls and anvil rolls, and side frames. Problems arise due to the deflection of the die roll caused by operating forces, machine distortions, vibrations, and thermal expansions. A traditional solution has been to utilize a roll having a sufficiently large diameter that it is able to resist any significant deflection. While this can work, the necessary roll diameter can be too large for many applications. Moreover, there is a disadvantage in that such a die cylinder can be large and costly to manufacture. This is particularly true where the outer surface of the die cylinder must be machined to extremely tight tolerances. In addition, the substantial rotational inertia of such a large diameter die roll is an impediment to achieving a fast stop in the case of an emergency stop.

Other disadvantages relate to the need to have the apertures extremely accurately located so that they are in registration with the pattern printed on a web. A vertical adjustment of the die, one affecting the spacing between the die and anvil rolls, is also important to adjust the spacing between the cutting and creasing lands of the die and the anvil cylinder. Axial adjustment is just as important so that the die achieves a reliable cut in the web, the cutting lands do not strike the anvil cylinder becoming dulled or damaged, and so that the correct spacing occurs across the full length of the die roll. In addition, as is well known to those skilled in the art, even when proper adjustments in the position of the dies are made, changes in factors such as the web material, wear of the die, and shifts in the relative position of components due to thermal expansion, can require periodic readjustments of the die positions in order to have reliable cuts and creases.

Another known technique for changing the axis to axis (vertical) spacing of the rolls is to mount at least one of the rolls on an eccentric so that its center line location can be varied between two extreme positions. Such adjustments cannot be made on the run, that is, while the rotary die is running, and a web or paperboard blanks are passed through the rotating die cutter cylinders. Axial and circumferential adjustments of the die also require that the rotary die be stopped while the die position is manually shifted on the die cylinder and reset. The adjustment process is manual, time-consuming, and cannot be made on the run. Also, eccentric adjustments do not provide the fine degree of adjustment often required to compensate for wear or the other factors listed above. When eccentrics have been used while the rotary die cutter is operating, they have been used most often to move the die roll a substantial distance to go “off impression”, that is, moving the die cylinder away from the web to allow operation but without operation of the die cutter.

Conventional rotary die cutters utilize only one die cylinder and the only practical way to adjust the axial or side to side position of a web is to shift the lateral position of the web as it passes through the cutter. This web shift has a significant disadvantage in that it requires that all of the other pieces of equipment in the line, such as gluers, perforators, numbering machines, plow stations, and combinations thereof also be adjusted with respect to the web to maintain registration. This multiple adjustment of a series of machines to the web shift is time-consuming and tedious. A need exists for a rotary die cutter capable of an axial adjustment of the cutter. A need also exists for an apparatus that enables a rotary die cutter to be axially adjustable, especially quickly and reliably.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a mounting and positioning system for a rotary die cutter.

It is another object of the present invention to provide a mounting and positioning system that provides extremely accurate positioning of the die with respect to a web and an anvil roll, including positioning vertically, axially, and circumferentially.

Yet another object of the present invention is to provide a rotary die cutter positioning and mounting system wherein adjustments can be made with extreme accuracy, independently of one another, and while the die cutter is operating.

It is yet another object of the present invention to provide a rotary die cutter mounting and positioning system that can be set up or adjusted within an extremely short make-ready time as compared to conventional systems currently in use.

Still another object of the present invention is to provide a mounting and positioning system for a rotary die cutter, which can mount two or more die rolls in an axially spaced relationship operating in cooperation with the same anvil where each die roll can be adjusted vertically and axially independently of the other yet exhibit all of the foregoing advantages.

Yet another object of the present invention is to provide a roll positioning and mounting system for a rotary die cutter that has a favorable cost of manufacture and that can be adapted to an existing system.

These and other objects and advantages of the present invention will become evident by the appended drawings and by the detailed description that follows, both of which are intended to illustrate, not limit, the present teachings.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides an adjustable wedge apparatus that can be tightened or loosened to increase or decrease the spacing it provides and adjust skew in a rotary die cutter. The adjustable wedge apparatus comprises a split wedge, a first block, a second block, a threaded adjustment screw, and an expandable and contractable biasing device. The split wedge is configured to be sandwiched between the first block and the second block. The first block and the second block are configured to be held together, with the split wedge there between, by the expandable and contractable biasing device. The threaded adjustment screw can be rotated to expand or contract the spread provided between the first block and the second block.

The split wedge has a blunt end, a narrow end, a recess, a through-hole, and a pair of through-slots. The recess has an opening at the narrow end, which extends toward the blunt end. The recess also has a recess bottom. The recess divides the narrow end into two tines, namely, an upper tine and a lower tine. The through-hole extends from the blunt end to the bottom of the recess and has an internal thread. The pair of through-slots at least partially straddle the recess and respectively extend along the tines.

The threaded adjustment screw has an external thread that is complementary to the internal thread of the through-hole. Each of the first block and the second block has a pair of projections configured to align respectively with the pair of through-slots, for catching the biasing device. The projections of each block can be formed by a split pin forced through the block in a height direction. Each through-slot of the pair of through-slots, and the biasing device, are configured such that the biasing device can pass through the through-slots and catch one of the projections of the first block and one of the projections of the second block.

Although the components can be packaged, disassembled, or packaged separately, the present invention also provides an assembled apparatus. The adjustable wedge apparatus can be assembled together such that the split wedge is sandwiched between the first block and the second block. When the adjustable wedge apparatus is assembled, the biasing device can be caught on a first projection of the first block and caught on a first projection of the second block. The biasing device can pass through a first through-slot of the pair of through-slots and can bias the first block and the second block such that they are urged toward one another. When the adjustable wedge apparatus is assembled, the threaded adjustment screw bears against the first block and the second block, extends through the recess, and is threaded into the through-hole.

The assembled adjustable wedge apparatus can further include a washer. The threaded adjustment screw can have a head and the washer can be positioned between the head and both the first block and the second block such that one side of the washer contacts the head and the other side of the washer contacts both the first block and the second block. When the adjustable wedge apparatus is assembled together, the projections of the first block have respective distal ends that are separated from one another in a height direction, by a first distance. The through-slots of the spilt wedge can be separated by a maximum spacing and the first distance can be greater than the maximum spacing.

The biasing device can comprise a flat, metal, split, planar ring that can expand and contract within a plane. The split ring can be rigid with respect to deforming out of the plane. The biasing device can comprise a spring steel material. The biasing device can comprise an internal retaining ring having internally protruding inner ring features on which the projections of the first block and the second block can catch. The biasing device can comprise a pair of biasing devices, for example, the biasing device can comprise a pair of retaining rings. An exemplary biasing device is a spring steel, internal retaining ring for bores, available as item number 38DN71 from Grainger Industrial Supply of Lake Forest, Ill.

The adjustable wedge apparatus can further comprise a mounting bracket in contact with, or integrally formed as part of, at least one of the first block and the second block. The mounting bracket can have a through-hole formed therethrough, through which a fastener can partially pass to mount the mounting bracket to a surface, for example, to a surface of a rotary tool bearing housing. The mounting bracket through hole can be threaded or can have an inner diameter that is larger than the outer diameter of a bolt or other fastener intended to pass through the through-hole. The mounting bracket can be formed integral with the first block, for example, part of the first block such that the mounting bracket and first block together form a solid monolithic structure. The mounting bracket can be made as a separate component, that is, not integral with either the first block or the second block. As a separate component, the mounting bracket can swing to the left side of the adjustable wedge apparatus, to the right side of the adjustable wedge apparatus, to the top of the adjustable wedge apparatus, to the bottom of the adjustable wedge apparatus, or to an angle with respect to the adjustable wedge apparatus.

The pair of projections on the first block can comprise opposite ends of a slotted spring pin extending through a first block through-hole. The block through-hole can be formed through the first block in a height direction. The pair of projections on the second block can comprise opposite ends of a second slotted spring pin extending through a second block through-hole. The second block through-hole can be formed through the second block in a height direction.

The first block can have a top surface, an opposite bottom surface, and an inner side surface configured to contact the spilt wedge. Each of the top surface and the bottom surface can have a block recess formed therein. The pair of projections of the first block can protrude from the top surface block recess and from the bottom surface block recess. The second block can also have a top surface, an opposite bottom surface, and an inner side surface configured to contact the spilt wedge. Each of the top surface and the bottom surface of the second block can have a block recess formed therein. The pair of projections of the second block can protrude from the top surface block recess of the second block and from the bottom surface block recess of the second block.

According to various embodiments of the present invention, an axis alignment or synchronization system is provided. The system can comprise an axle configured for rotation around an axis of rotation. An assembled adjustable wedge apparatus as described herein, or a pair or other set of such adjustable wedge apparatuses, can be positioned in contact with the axle or in contact with a first axle bearing housing. The first axle bearing housing can be configured to hold a first end of the axle for rotation of the axle. The axle can have a second end, opposite the first end. The system can include a second bearing housing that is also configured to enable rotation of the axle, and the second end of the axle can be housed in the second bearing housing. An assembled adjustable wedge apparatus as described herein, or a pair or other set of such adjustable wedge apparatuses, can be positioned in contact with the axle or in contact with a first axle bearing housing. Adjusting the assembled adjustable wedge apparatus or apparatuses by turning the respective threaded adjustment screw can enable an adjustment of the position of the axis of rotation. In an exemplary embodiment, four adjustable wedge apparatuses of the present invention are used at each end of the system to adjust the respective bearing housing at the respective end of the axle. The axle adjustment system can be used in a rotary die tool according to various embodiments of the present invention.

The present invention also provides a method of adjusting an axis of rotation of an axle. The method can comprise providing an axle alignment system as described herein and turning the threaded adjustment screw to change a position of the axis of rotation. The method is particularly useful in aligning an upper cutting cylinder of a rotary tool with a lower anvil cylinder of the rotary tool as will be even more apparent from the description that follows.

With reference now to the drawings,FIGS. 1A-1Gshow an adjustable wedge apparatus10according to an exemplary embodiment of the present invention.FIG. 1Ais a top, right, front perspective view,FIG. 1Bis a top view,FIG. 1Cis a front end view andFIG. 1Dis a right-side view of adjustable wedge apparatus10.FIGS. 1E-1Gcorrespond toFIGS. 1B-1D, respectively, and show exemplary dimensions that can be used for forming adjustable wedge apparatus10and its individual components. As can be seen,FIGS. 1A-1Gshow that adjustable wedge apparatus10comprises a split wedge20, a first block30, a second block40, a threaded adjustment screw50, and two expandable and contractable biasing devices90and92. Split wedge20is configured to be sandwiched between first block30and second block40. First block30and second block40are configured to be held together, with split wedge20there between, by expandable and contractable biasing devices90and92.

As best seen inFIG. 1D, second block40has a split pin80extending therethrough, through a through-hole. A through-hole for this purpose can be seen inFIG. 3Cas through-hole330. Split pin80projects from second block40in a recess42at the top of second block40. Split pin80also projects from second block40in a recess44at the bottom of second block40. As such, split pin80forms a pair of projections configured to align respectively with a pair of through-slots in split wedge20, as shown inFIGS. 2A, 2C, and 2Fthat are described in greater detail below. In the embodiment shown, first block30is identical to second block40and each is exemplified by block30shown inFIGS. 3A-3G. Accordingly, split pin70extends through a through-hole in first block30, projects from first block30in a recess42at the top of first block30, and also projects from first block30in a recess44at the bottom of first block30. As such, split pin70forms a pair of projections configured to align respectively with the through-slots in split wedge20.

FIGS. 1B and 1Ealso shows a biasing device90in the form of a first, flat, metal, internal retaining ring. Biasing device90is captured on the top projections of split pins70and80, biasing first block30and second block40toward each other. A second biasing device92, also in the form of a flat, metal, internal retaining ring, is shown inFIGS. 1D and 1Gcaptured on the bottom projections of split pins70and80. Biasing device92also biases first block30and second block40toward each other. Each of biasing devices90and92can comprise a flat, metal, split, planar ring that can expand and contract within a plane but that is rigid with respect to deforming out of the plane. Each biasing device90and92can comprise a spring steel material. Biasing devices90and92can be internal retaining rings for bores and can have interiorly protruding catch holes.

As seen inFIGS. 1A and 1D, the projections formed by split pin80have respective distal ends and the distal ends are separated in a height direction by a first distance. Through-slots214and216of spilt wedge20are separated by a maximum spacing, and, as can be seen, the first distance between the distal ends of the split pin is greater than the maximum spacing separating the through-slots. As such, once the biasing devices are caught on the split pin projections, they are captured in place.

Also shown inFIGS. 1A-1Gis a bracket60for mounting adjustable wedge apparatus10to a bearing housing or other frame or housing, and bracket60has a through-hole62for such purpose. Bracket60is connected to the remainder of adjustable wedge apparatus10via threaded adjustment screw50passing through another through-hole56formed in bracket60. A washer52is provided so that threaded adjustment screw50can rotate in a threaded through-hole218formed in split wedge20, without becoming hung-up on bracket60. Although bracket60is depicted as separate component, it is to be understood that, in place of bracket60, a mounting bracket can be formed integral with at least one of the first block and the second block and can have a through-hole formed therethrough, through which a fastener can pass to mount the mounting bracket to a surface.

With the arrangement exemplified inFIGS. 1A-1G, threaded adjustment screw50can be tightened to spread apart first block30and second block40as split wedge20is moved closer and closer to bracket60and toward the head of threaded adjustment screw50. While first block30and second block40are spread apart, the outer surfaces (306inFIGS. 3A-3D) of first block30and second block40remain parallel to one another due to the wedge shape of split wedge20and the less-pronounced wedge shape of each of first block30and second block40. With such an arrangement, the opposing, parallel, flat surfaces of adjustable wedge apparatus10can provide uniform pressure across a large area to secure, for example, a bearing housing within a frame as depicted inFIGS. 6A and 6Bdescribed below.

Although the adjustable wedge apparatus10is shown assembled inFIGS. 1A-1G, it is to be understood that the individual components of adjustable wedge apparatus10can be packaged and sold separately, or packaging, unassembled, as a kit.

With particular reference toFIGS. 2A-2G, split wedge20has a narrow end202, a blunt end204, a recess206, a through-hole218, and a pair of through-slots214and216. Recess206has an opening at narrow end202and extends toward blunt end204. Recess206has a recess bottom208and divides narrow end202into two tines210and212. Through-slots214and216at least partially straddle recess206and respectively extend along tines210and212. In the embodiment shown, split wedge20is symmetrically shaped from top to bottom and from side to side such that it could be turned upside down and still look the same. In the views shown, split wedge20has a top surface220. Through-hole218extends from blunt end204to recess bottom208and has an internal thread. Threaded adjustment screw50(FIGS. 1A-1G) has an external thread that is complementary to the internal thread of the through-hole218.

Through-slot214, and the ring-shaped biasing device90(FIGS. 1B and 1D), are configured such that top biasing device90can pass through through-slot214and catch the top projections of split pins70and80. Similarly, through-slot216, and biasing device92(FIG. 1D), are configured such that biasing device92can pass through through-slot216and catch the bottom projections of split pins70and80. Exemplary dimensions for split wedge20are shown inFIGS. 2E-2G.

As mentioned above, first block30and second block40are identical. As such, the features of each are described with reference to just first block30. Exemplary dimensions for first block30and for second block40are shown inFIGS. 3E-3G.

With particular reference toFIGS. 3A-3G, first block30has a blunt end302, a chamfered, narrow end304, an outer surface306, an inner surface308, a top310, a bottom312, a top recess42, and a bottom recess44. In addition, a conical recess320is formed recessed into inner surface308. Conical recess320has a wide end322that intersects with blunt end302of first block30, and a narrow end324that terminates at inner surface308. Conical recess320is provided along inner surface308to accommodate threaded adjustment screw50as threaded adjustment screw50passes between first block30and second block40and engages with threaded through-hole218of split wedge20to form the assembly shown inFIGS. 1A-1G. Like first block30, second block40has a conical recess along its inner surface to likewise accommodate threaded adjustment screw50as threaded adjustment screw50passes between first block30and second block40and engages with threaded through-hole218of split wedge20.

As mentioned above, through-hole330through first block30is provided to accommodate split pin70(FIGS. 1A, 1B, and 1D). Through-hole330begins at top recess42, extends completely through first block30, and terminates at bottom recess44. Similarly, second block40has a through-hole identical to through-hole330shown inFIGS. 3A-3Dbut for accommodating split pin80shown inFIGS. 1A and 1B.

The adjustable wedge apparatus shown inFIGS. 1A-3Gcan be used to make skew adjustments in a rotary die tool. Initially, skew adjustments related to the axial parallelism between an upper cylinder and a lower cylinder can be factory set. Additional skew adjustments are sometimes required, however, to make the blades of an upper cylinder parallel to the blades of a lower cylinder such that the cut is uniform across the entire tool surface. Thermal expansion and contraction, vibrations over time, and wear can all contribute to the need for additional skew adjustment. According to various embodiments of the present invention wherein one or both of the rotary tools are heated, thermal expansion can noticeably affect skew. When the cutting is skewed, a skew adjustment is required.

Skew is the degree of straightness or parallelism between the upper and lower cylinders, i.e., between the axes of the rotary tools. To test check for a skew, an imaginary line can be drawn through the center of each of the rotary tools, axially. Looking at the two center lines or axes from above, a skew can be determined by determining the parallelism of the lines relative to each other in a horizontal plane. Skew is not the variation up and down, of the lines as this instead is known as the gap. Examples of when a skew adjustment is needed are illustrated in the top views shown inFIGS. 4A-4C. InFIG. 4A, an upper cylinder400is shown skewed at its left end with respect to a lower cylinder410. As can be seen, axis of rotation402of upper cylinder400is not lined-up with, or on the same horizontal plane as, axis of rotation412of lower cylinder410. To align axes of rotation402and412of cylinders400and410, respectively, a skew adjustment can be made to one or both of the bearing units holding upper cylinder400. Adjustment to such a bearing unit would translate into an adjustment of axis of rotation402. The adjustment can be made in the direction shown by the directional arrow. Lower cylinder410can remain locked in place.

In the situation shown inFIG. 4B, axis402of upper cylinder400is skewed at both ends of upper cylinder400, with respect to axis412of lower cylinder410. To align axis402with axis412, adjustments can be made to both ends of upper cylinder400, that is, to the position of both the left and right bearing units holding upper cylinder400. The adjustment can be made at the two ends in the respective directions shown by the directional arrows. Meanwhile, lower cylinder410can remain locked in place.

In the situation shown inFIG. 4C, axis402of upper cylinder400is skewed in a first direction, at the left end of the cylinder, and in a second, opposite direction at the right end of the cylinder. The skew is with respect to axis of rotation412of lower cylinder410. As such, an adjustment can be made to the bearing unit holding the left end of upper cylinder400in the direction shown by the directional arrow shown adjacent to the left end. An adjustment can also be made to the bearing unit holding the right end of upper cylinder400but in the opposite direction as shown by the directional arrow adjacent to the right end. Again, lower cylinder410can remain locked in place.

It is also within the realm of the present invention to instead adjust, or additionally adjust, one or both ends of lower cylinder410.

Skew adjustment is important so that the dies properly cut and form material passing between the two cylinders, whether the material is a web or sheet. The web or sheet should be uniformly cut or formed across the tools. The following skew adjustment steps can be used to orient the rotary tools so that the center lines of the tools are directly in line with each other along a horizontal plane, i.e., so that the axes are aligned along the same horizontal plane.

First, a pair of cross-web cutting or creasing blades are located at each side of the rotary tools. Strips of paper 1 inch wide by 3 inches long, for example, can be cut and taped to the upper tool. One strip can be placed on each of the ends of the upper tool.

Second, the upper tool can be retreated until the tools stop cutting. This can be done by using a phase hub on the gear side of the upper tool.

Third, using a dial indicator, the upper tool can be advanced in 0.001-inch increments until the tools just starts to cut. Skew is considered adjusted if both ends of the tools start cutting at the same time. If the blade on one end begins to cut first, the tools are out of skew.

Fourth, the upper tool can continue to be advanced in 0.001-inch increments until the blade that was not cutting begins to cut or crease the paper.

Fifth, to determine the skew, the difference between the dial indicator readings is determined. The resulting difference indicates the necessary skewing adjustment that is to be made.

An Example is shown inFIGS. 5A-5C. InFIG. 5A, it can be seen that the gear side is cutting and the operator side is not. After making a phase adjustment of 0.002 inch into the cut direction, cutting is improved and extends further toward the operator side, as shown inFIG. 5B. After making an additional phase adjustment of 0.001 inch into the cut direction, to result in a total adjustment of 0.003 inch, cutting is further improved and extends from the gear side all the way to the operator side, as shown inFIG. 5C.

A total adjustment of 0.003 inch was made to the upper tool so that the tools uniformly cut across the cylinders. This amount indicates the necessary skewing adjustment. Using the axis synchronization system of the present invention, the adjustable wedge screw can be adjusted 0.003 inch into the cut direction on the operator side. To do so, the adjustable wedge screw on the opposite side of the bearing housing can first be adjusted to reduce the spacing it provides, by 0.003 inches. After the skew adjustment is made, the gap can be checked, and the rotational phasing and side-to-side alignment can be double-checked. One side or both sides of the upper tool or lower tool can be used for the skewing adjustment. The skew should not have to be changed by more than 0.015 inch or 0.381 mm on each side. For large skew adjustments, each cylinder can be adjusted by half the required amount to collectively make the adjustment. The object of the skew adjustment is to shift the tools into parallel alignment in order to be able to cut or crease the material properly.

To adjust the position of, for example, the gear side of the upper cylinder, the adjustable wedge screws at the gear side are adjusted. Looking at the upper cylinder from the gear side, if the upper cylinder needs to be adjusted to the left, the left-side adjustable wedge screw is loosened. If the ratio of (1) rotation of the adjustable wedge screw set screw to (2) adjustable wedge screw spread, is 0.001 inch per rotation, then the left-side adjustable wedge screw can be loosened by two full rotations to reduce the spread by 0.002 inch. The resulting 0.002-inch gap would not likely result in a 0.002-inch movement of the upper cylinder to the left but would provide room for a movement of 0.002 inch. Rotation of the right-side adjustable wedge screw, for tightening by two rotations, would result in 0.002-inch movement of the upper cylinder, to the left. Loosening of the adjustable wedge screw on the side toward which movement is desired can be followed by tightening to expand the adjustable wedge screw spread on the opposite side.

FIG. 6Ais an end view of a rotary die cutter system comprising an upper rotary tool601and a lower rotary tool651stacked together. Upper rotary tool601includes a rotary cutting cylinder (not shown) that rotates about an axis of rotation602and is held by and configured for rotation within an upper bearing housing612. Similarly, lower rotary tool651includes an anvil cylinder (not shown) that rotates about an axis of rotation622and is rotatably held at a proximal end by a lower bearing housing662. Similar bearing housings are provided in a similar stacked configuration at opposite, distal ends of the upper cutting cylinder and the lower anvil cylinder. Upper rotary tool601and lower rotary tool651are stacked together in such a manner that cutting blades or lands on the upper cutting cylinder cooperate with cutting blades or lands, or other counter features, on the lower anvil cylinder such that the upper cutting cylinder and the lower anvil cylinder work together to cut and form material passing through a nip formed between the cylinders. One or more shims640can be placed between upper rotary tool601and lower rotary tool651to perfectly space the upper cutting cylinder and the lower anvil cylinder apart from one another. A pressure block634is pressed down by a pressure screw (not shown) to maintain upper rotary tool601in contact with lower rotary tool651.

Although the upper cutting cylinder cannot be seen inFIG. 6A, an end cap630for upper bearing housing612is shown nested in a pilot recess632. Similarly, an end cap680for the lower anvil cylinder (not shown) is shown nested in a pilot recess682of lower bearing housing662.

As can be seen inFIG. 6A, upper bearing housing612is mounted to a bow tie plate620by eight socket head cap screws616. Each socket head cap screw can be of any suitable size, for example, from 3/16 inch to 13/16 inch or, for example, ⅜ inch, 7/16 inch, ½ inch, or 9/16 inch. The socket head cap screws can be made of steel, steel alloy, stainless steel, or the like. Hex bolts or other fasteners can instead be used. Bow tie plate620is mounted to upper bearing housing612. A second, i.e., backing bow tie plate (not shown) that is a mirror image of bow tie plate620, is mounted to the backside of upper bearing housing612, for example, by eight socket head cap screws. The set of bow tie plate620and the backing bow tie plate (not shown), straddle a left side plate604and a right-side plate608. Left side plate604presents a vertical surface614and right-side plate608presents a vertical surface618. As can be seen, bow tie plate620is clamped to side plates604and608by four set screws636. The backing bow tie plate can be, but is not necessarily, similarly clamped to side plates604and608by four set screws. In a similar fashion, lower bearing housing662is mounted to a bow tie plate670by eight socket head cap screws616and a second, backing bow tie plate (not shown), that is a mirror image of bow tie plate670, is mounted to the backside of lower bearing housing662, for example, by eight socket head cap screws. The set of bow tie plate670and the mirror image backing bow tie plate (not shown), straddle left side plate604and right side plate608. Like bow tie plate620, bow tie plate670is clamped to side plates604and608by four set screws636. The backing bow tie plate that backs bow tie plate670can be, but is not necessarily, similarly clamped to side plates604and608by four set screws.

Set screws636can bear against flat front vertical surfaces of side plates604and608. According to various embodiments, set screws636can be omitted such that bow tie plates620and670are not clamped to side plates604and608using set screws, in which case pressure block634is primarily what is used to force upper rotary tool601into contact with lower rotary tool651. In some cases, the upper and lower rotary tools can be held between side plates604and608solely by adjustable wedge screws according to the present invention.

As shown inFIG. 6A, bow tie plates620and670are clamped to side plates604and608and can be horizontally adjusted between side plates604and608by eight adjustable wedge screws601,603,605,607,609,611,613, and615. The adjustable wedge screws can be, for example, as shown inFIGS. 1A-3G.

As mentioned above, bow tie plate620is bolted to upper bearing housing612by eight socket head cap screws616. In this regard, it can be seen that upper bearing housing612flares-out at its left and right sides as shown by the phantom lines. Similarly, lower bearing housing622flares-out at its left and right sides as also shown by phantom lines. The phantom lines are shown because upper bearing housing612is behind bow tie plate620and lower bearing housing662is behind bow tie plate670, in the view shown.

FIG. 6Aalso shows a grease fitting628for lubricating upper rotary tool601and, more particularly, upper bearing housing612. Similarly, a grease fitting678is provided for lubricating lower bearing housing662of lower rotary tool651.

As shown inFIG. 6A, upper rotary tool601is held between side plates604and608, and can be adjusted for skew, by four adjustable wedge screws601,603,605, and607. Each adjustable wedge screw can be as described herein. Greater details of each adjustable wedge screw can be seen inFIG. 6B.FIG. 6Bis an enlarged view of section6B shown inFIG. 6A. With reference toFIG. 6B, adjustable wedge screw601is mounted by a bracket60to upper bearing housing612. A washer68and hex bolt66are used to mount bracket60to upper bearing housing612. Upper bearing housing612has a tapped, threaded hole for receiving hex bolt66. As can be seen, adjustable wedge screw601is urged against vertical side wall614of side plate604. Similar to the adjustable wedge screw depicted inFIGS. 1A-3G, adjustable wedge screw601comprises a spilt wedge20, a first block40, a second block30, bracket60, and a threaded adjustment screw50. A washer52is provided to space the head of threaded adjustment screw50from the facing surface of bracket60. Tightening threaded adjustment screw50pulls spilt wedge20closer to the head of threaded adjustment screw50and spreads first block40and second block30further apart from each other. Thus, the effect of tightening threaded adjustment screw50is the movement of upper bearing housing612, and the upper cutting cylinder that it supports, to the right. Loosening threaded adjustment screw50forces spilt wedge20away from the head of the threaded adjustment screw50such that first block40and second block30come closer together by virtue of a biasing device such as a spring steel internal retaining ring as described and shown in connection withFIGS. 1A-1G. Moving first block40and second block30closer together enables upper bearing housing612to move to the left, particularly, when adjustable wedge screw603(FIG. 6A) is correspondingly tightened. Tightening or loosening each of the eight adjustable wedge screws shown inFIG. 6Acan be used to adjust skew of the upper cutting cylinder and the lower anvil cylinder of the rotary die. A similar set of upper and lower bearing housings and adjustable wedge screws can be provided at the opposite ends of the upper cutting cylinder and the lower anvil cylinder.

Although not shown, one, two, or more adjustable wedge screws can also be provided between an upper rotary tool and a lower rotary tool to adjust the gap between the tools. In this regard, while the adjustable wedge screws shown and described herein might not fit in a space between, for example, upper rotary tool601and lower rotary tool651shown inFIG. 6A, one or more brackets can be used. For example, two L-shaped brackets, one mounted to the end of each rotary tool, can be provided such that an adjustable wedge screw as shown and described herein can be positioned between extending arms of the two brackets. A similar set of brackets can be used to house there between an adjustable wedge screw at the opposite ends of the upper and lower rotary tools. As such, one or more adjustable wedge screws as shown and described herein can be used to adjust the gap between upper and lower rotary tools without the need to position the one or more adjustable wedge screws physically between the rotary tools.

All patents, patent applications, and publications mentioned herein are incorporated herein in their entireties, by reference, unless indicated otherwise.