Shaft mounting and drive for carton blank processing machine

Abstract: A carton blank processing machine (10) is disclosed having rolls (25, 26, 30, 32) for printing, cutting, creasing and otherwise processing carton blanks. The processing rolls are driven by shafts (42, 48) extending into bearings (49) supported by spaced-apart frame members (12). At least one shaft extends through its associated bearing to the outboard side of the frame member and is surrounded by a motor (50), preferably of the frameless type, having a hollow rotor (62) in which the shaft is received and connected for direct drive by the rotor. Axial adjustment systems (80, 95) are provided for axially adjusting at least one shaft and roll, and such systems may be mounted on the outboard end of the frameless motor.

Description: This invention relates to a machine for processing a stream of individual carton blanks. Machines for printing, cutting, creasing and otherwise processing flat carton blanks, including those used for flexographic printing, commonly include a plurality of interacting rolls such as print rolls, impression rolls, die rolls and anvil rolls. In a typical machine, see e.g. US-A-4 878 407, the die roll is driven directly by a first, main motor while the anvil roll is driven through a variable speed gear system comprising several gears, a register and a trim motor; all of such motors and gearing being positioned at the end of the roll shafts extending outboard of the machine frame. While the foregoing multiple-motor and multiple-gear system is effective in driving the various rolls at the desired relative speeds, it is apparent that these systems are complex, and the requirement for four or more gears introduces an undesirable amount of backlash between the gears. Such unavoidable backlash prevents maintaining such precise angular relationship between the cooperating rolls as is desired. Also, such multiple gears require a substantial amount of costly assembly time, and subsequent maintenance time, as well as making trouble-shooting and diagnostic efforts much more difficult. Even though each gear of the complex, multiple gear system is manufactured to extremely high tolerances, a certain amount of backlash and inaccuracy cannot be avoided. Therefore, there has long been a need for a simpler and more accurate motor-drive system for driving large carton blank processing rolls. DE-U-93 06 369 discloses that certain of the rolls in an offset printing machine may be directly driven by separate and distinct frameless motors. According to the present invention there is provided a machine for processing a stream of individual carton blanks, comprising: a) a pair of spaced-apart and upright frame members; b) at least one bearing located in each frame member; c) a hollow processing roll extending horizontally between the frame members, the ends of the roll being positioned adjacent the frame members; d) drive shafts extending from opposite ends of the roll into respective ones of the bearings; characterised by at least one of the drive shafts being hollow, the hollow shaft extending through the bearing and projecting beyond the frame member; and e) a frameless motor encircling the hollow drive shaft outboard of the frame member, the motor including a stator and a hollow rotor, with the drive shaft extending into the rotor; f) means for connecting the drive shaft directly to the rotor for rotation therewith, and g) a suction pump mounted outboard of the motor for extracting air from the hollow interior of the processing roll, through the drive shaft and the rotor, to produce sub-atmospheric pressure therein. Further features are set out in Claim 2 et seq. Carton blanks are typically composed of such materials as paperboard, cardboard or corrugated stock. In the present invention the drive shaft is made hollow thus reducing the mass of metal contained within the motor. In addition, this construction enables air to be extracted from the hollow interior of the processing roll through the drive shaft and the motor allowing air to flow through the drive shaft and the motor which assists in keeping the shaft cool. For a better understanding of the present invention reference will now be made, by way of example, to the accompanying drawings, in which: Fig. 1 is a simplified, diagrammatic, side elevational view of a machine for processing a stream of individual carton blanks; Fig. 2 is a schematic side view of a first embodiment of a machine in accordance with the present invention; Fig. 3 is a schematic side view of a second embodiment of a machine in accordance with the present invention; Fig. 4 is a schematic, block diagram illustrating two frameless motors connected through a control system; and Fig. 5 is a simplified, partial side view showing one pair of die and anvil rolls with a frameless motor mounted on the outboard end of each roll drive shaft, and showing alternative axial adjustment systems mounted outboard of the frameless motors. As shown in Fig. 1 a machine 10 for processing a stream of individual carton blanks comprises a pair of spaced, vertically extending frame members (only the front member being visible) which support nine large processing rolls such as, for example, first and second print rolls 25, 26 which cooperate with corresponding impression rolls 27, 28, as well as at least one die cutter roll 29 with associated anvil roll 30, and two or more creaser and/or slotter rolls 31 together with their respective backing rolls 32. The machine 10 also includes a large plurality of other types of rolls such as a stripper roll 35, multiple pairs of nip rolls 33 for advancing the carton blanks through the machine 10, and one or more ink or anilox rolls 34 and associated wiper rolls 36. As shown in Fig. 2, a vacuum producing pump or compressor 101 is mounted on the outboard end of a hollow drive shaft 102 which extends through a frameless motor 104. The drive shaft 102 extends through bearing 106 in machine frame member 108, and supports and drives a print roll 110. A subatmospheric pressure may be created within the print roll 110 by the vacuum producing compressor 101 drawing air through hollow drive shaft 102. On the opposite side of the machine, a second drive shaft 112 extends through a bearing 107 in frame member 109, and an encoder 114 is mounted on shaft 112 inboard of an axial adjustment system 116 as will hereinafter be described with reference to Fig. 5. An axial adjustment system may be mounted on one drive shaft. In some instances, such as with extra heavy or extra long rolls, it may not be desirable to apply all of the driving torque to only one drive shaft at one end of the print roll 110 as in the previous examples. In such cases, the present invention contemplates the use of two motors to drive the same roll. In such an embodiment, torque may be supplied to the roll through each of the drive shafts in a precisely controlled manner by the digital indexing of the two motors and problems caused by torsional twisting of the roll and/or shafts are eliminated. Numerous other arrangements are also possible with the present invention as illustrated, for example, with reference to Fig. 3 which illustrates a particularly preferred embodiment. In this embodiment, a die cylinder 138 is mounted on shafts 140, 142, while an anvil cylinder 144 is mounted on shafts 146 and 148; drive shafts 140, 142, 146 and 148 being journaled in bearings 141, 143, 147 and 149, respectively. A frameless motor 150, is mounted on shaft 142 to drive die cylinder 138, and a second frameless motor 152, is mounted on shaft 148 to drive anvil cylinder 144. Encoder units are mounted on the opposite corresponding shafts 140 and 146 as illustrated by encoders 154 and 156, and axial adjustment systems 158 and 160. This has the advantage of permitting the vacuum/compressor 162 to be mounted outboard of frameless motor 150 as previously described with respect to the Fig. 2 embodiment. Alternatively, if it is desired to have a minimum number of components on the left side of the machine as viewed in Fig. 3, which may be the front of the machine, then the Fig. 2 embodiment enables encoder 156 and axial adjustment system 158 to be mounted on shaft 148 outboard of frameless motor 152 thereby positioning all units, except encoder 154 and axial adjustment system 160, at the rear of the machine. Where additional units such as encoders, axial adjustment systems or vacuum pumps are not to be mounted on the outboard end of the motors, then only one axial end of the motor must be sufficiently open to receive the drive shaft. On the other hand, where additional units are to be mounted on the outboard end of the motor, as for example in the embodiments of Figs. 2 and 5, then both axial ends of the motor must be sufficiently open in order to receive the shaft at one end and the axial adjustment system or vacuum pump at the other end. Thus, frameless motors having only an axially extending sleeve or partial casing, and having both axial ends open as illustrated in Fig. 5 are preferred. Alternative axial adjustment systems will now be considered in relation to Fig. 5. Referring to Fig. 5, numeral 12 represents the left wall or frame member of a pair of horizontally spaced frame members. The left end of a die roll 29 is secured to an end plate 20 which is bolted by bolts 22 to a circular flange 40 of a drive shaft 42. Drive shaft 42 extends through a bearing 44 which is secured in a bearing housing 23; bearing housing 23 being retained in frame member 12 by bolts 24. In a similar manner, the left end of anvil roll 30 is secured to an end plate 45 which is bolted to circular flange 46 of a drive shaft 48. Drive shaft 48 extends through bearing 49 which is secured in an adjustable, eccentric bearing housing 47 supported in frame member 12. Each of drive shafts 42 and 48 extend through a respective electric motor 50, 52 in a similar manner such that it will be understood that a description of the relationship of drive shaft 42 and motor 50 also applies to drive shaft 48 and motor 52. Motor 50 is preferably of the frameless type and comprises an annular cooling jacket 54 including water or air cooling fluid passages 56 sealed by a cooling jacket sleeve 57. Alternatively, motor 50 may be externally cooled, and conventional fluid seals have been omitted for clarity. Jacket 54 surrounds a stator 58 having field windings 60 shown an opposite ends of the motor. Stator 58 surrounds a hollow rotor 62 which is secured, as by bonding, shrink-fitting or hydraulic coupling, to a hollow rotor sleeve 64. It will be noted that drive shaft 42 extends through the entire axial length of sleeve 64 of hollow rotor 62. Sleeve 64 may be connected to drive shaft 42 in a number of ways. As illustrated, for purposes of example only, a pair of annular rings 66 are positioned around each end of sleeve 64, and a pair of tapered wedge rings 68 are force-fitted between annular rings 66 and the exterior surface of reduced diameter portions 70 of sleeve 64. Wedge rings 68 may be forced into secure engagement between annular rings 66 and sleeve portions 70 by a plurality of bolts 72 extending into annular rings 66 so that sleeve portions 70 are forced radially inwardly in releasable, frictional locking engagement with the external surface of drive shaft 42. Thus, drive shaft 42 is directly and positively locked to hollow rotor 62 so as to rotate with the rotor, and shaft 42 may be angularly positioned by direct digital indexing of the motor. While additional bearings are not necessary, it is preferred to provide one outboard shaft bearing, such as bearing 74, between the outboard end of drive shaft 42 and the outboard end of motor 50. For example, bearing 74 may be retained in an end plate 76 secured to cooling jacket 54 and/or to sleeve 57. It will be understood that, since bearing 44 supports substantially the full weight of roll 29, drive shaft 42 and frameless motor 50, the conventional motor support structure is eliminated, and the only requirement is to provide a means for preventing the motor jacket and stator structure from rotating with the rotor structure. This is easily and simply accomplished by providing a plurality of machine bolts 78, for example, which secure cooling jacket sleeve 57 to bearing housing 23. Alternatively, motor 50 may be secured directly to frame 12 such that, in either mounting arrangement, cooling jacket 54 and stator 58 remain stationary as rotor 62 rotates the directly coupled shaft 42. As previously stated, shaft 48 is directly coupled to frameless motor 52 in the same manner as just described, and the principal elements are indicated by the same numerals primed. However, it will be noted that eccentric bearing housing 47 is journaled in frame member 12 so as to be able to rotate about off-center axis A and thereby permit adjustment of the spacing between rolls 29 and 30. For this reason, motor sleeve 57' is preferably bolted by bolts 53 to eccentric bearing housing 47 such that the motor rotates with the eccentric bearing housing 47 when the latter is adjusted. Means such as gear teeth 55 are provided over a portion of the outer surface of eccentric housing 47 in order to rotate the latter about axis A; axis B being the rotational axis of the rotor. With respect to the axial adjustment requirements previously mentioned, the use of frameless motors with the roll drive shafts extending through the rotors as just described enables manual, hydraulic or other types of adjustment systems to be positioned in direct coupling relationship with the shafts. For purposes of example, a manual system 80 is illustrated in connection with die roll 29 and frameless motor 50, while a hydraulic system 95 is illustrated with respect to anvil roll 30 and frameless motor 52. Manual system 80 comprises a bell-shaped housing 81 which may be solid or formed as a web having 3 or 4 legs 82. Housing 81 or legs 82 are connected to end plate 76 and include a threaded bushing 83 through which a threaded shaft 84 extends. Shaft 84 is rotated by a handwheel 85 and is connected to an inner, bell-shaped housing or web 86 by a ball bearing connector 87. The opposite end of inner housing 86 is connected to the outboard end of shaft 42 through an annular bearing 88 and annular ring 89, the latter of which is secured to the shaft. Inner housing or web 86 is preferably made hollow in order to support an encoder 90 which is coupled to and driven by shaft 42 through a coupling 91. Inner housing 86 is prevented from rotating by a plurality of radially extending guides 92 which slide in slots in the inner housing. Rotation of threaded shaft 84 by rotating handwheel 85 moves threaded shaft 84 axially within stationary, threaded bushing 83. Axial movement of threaded shaft 84 axially moves inner bell-shaped housing 86 which, in turn, axially moves and adjusts shaft 42 and roll 29 to the desired axial position. As shaft 42 is adjusted in axial position, the shaft carries with it sleeve 64, rotor 62 and inner bearing races 44a and 74a such that the rotor assembly is axially displaced with respect to the stator. It has been found that the rotor may be axially moved relative to the stator by as much as 2.5cm (an inch) without significantly decreasing the torque or other performance characteristics of the motor. The hand-adjustment system just described is well-suited to those instances where it is desired to set the axial position of the roll once, and then allow that setting to continue for a significant period of time, such as in the case of the print and die rolls. However, where more frequent axial adjustment is desired, such as the continuous adjustment of the anvil roll, a hydraulic system such as that illustrated at 95 may be employed. Numeral 96 represents the housing of a hydraulic motor which may be entirely conventional, and hence, is not illustrated in detail. Housing 96 may be secured to end plate 76' in any convenient manner, such as for example, by bolting the flange of the housing to end plate 76'. It will be understood that hydraulic motor 96 contains a hydraulically driven piston (not shown) which is connected to the end 98 of shaft 48, and that such piston is controlled in its axial position by a conventional hydraulic controller 99. Thus, shaft 48 is axially adjusted by the hydraulic motor and the shaft, along with its associated rotor 62' and sleeve 64', are moved axially relative to stator 58' in the same manner as previously described with reference to shaft 42 and motor 50 except that controller 99 may be operated to continuously change the position of the hydraulic piston, and hence, continuously change the axial position of anvil roll 30. Frameless motors suitable for use in the above described invention are commercially available and may be digitally controlled such that their angular or rotational position can be precisely determined. For example, as illustrated in Fig. 4 frameless motor 52 may be slaved to frameless motor 50 through digital control unit 100 such that the precise angular position and speed of each motor is maintained in the desired relationship without the need for any of the complex and costly gearing previously required. While Fig. 2 illustrates one preferred arrangement with the axial adjustment system and the encoder mounted on the outboard end of the frameless motor, other arrangements are also possible with the present invention. For example, many carton blank processing machines utilize a vacuum system to hold the printing plate on the cylinder of the print roll.

Claims: A machine for processing a stream of individual carton blanks, comprising: a) a pair of spaced-apart and upright frame members (108, 109); b) at least one bearing (106, 107) located in each frame member; c) a hollow processing roll (110) extending horizontally between the frame members, the ends of the roll being positioned adjacent the frame members; d) drive shafts (102, 112) extending from opposite ends of the roll into respective ones of the bearings, at least one of the drive shafts being hollows; characterised by the hollow shaft extending through the bearing and projecting beyond the frame member; and e) a frameless motor (104) encircling the hollow drive shaft (102) outboard of the frame member, the motor including a stator (58, 58') and a hollow rotor (62, 62'), with the drive shaft extending into the rotor; f) means (66, 68, 70) for connecting the drive shaft directly to the rotor for rotation therewith, and g) a suction pump (101) mounted outboard of the motor for extracting air from the hollow interior of the processing roll, through the drive shaft and the rotor, to produce sub-atmospheric pressure therein. A machine as claimed in Claim 1, in which the other drive shaft (112) extends through and beyond its respective bearing; in which an axial position adjustment system (116) is mounted on the projecting end of the said other shaft, and in which the other drive shaft is coupled to the position adjustment system whereby the axial position of the drive shaft and the rotor may be adjusted relative to the stator, thereby to adjust the axial position of the roll relative to its frame members. A machine as claimed in any preceding claim, in which both the drive shafts (118, 120) of at least one roll extend outboard of the frame members, and in which a frameless motor (130, 132) is mounted on each drive shaft to rotate the intervening roll in unison. A machine as claimed in any preceding claim, including a second processing roll (144) mounted in parallel with, and closely-spaced from, the first roll (138) for operating on carton blanks passing through the nip of the pair of rolls; in which the second roll has drive shafts (146, 148) extending through and beyond the frame members; in which one of the shafts has a frameless motor (152) mounted thereon outboard of the respective frame member, and in which the other shaft of the second roll has an axial position adjustment system (158) mounted thereon outboard of the respective frame member. A machine as claimed in Claim 4, in which the first roll is a print roll, and in which the second roll is an impression roll. A machine as claimed in Claim 4, in which the first roll is a die-cut roll (138), and in which the second roll (144) is an anvil roll.

Inventors: KAPLAN SOLOMON D, KOWALEWSKI JAMES M, KAPLAN, SOLOMON D., KOWALEWSKI, JAMES M.
Applicants: WARD HOLDING CO, WARD HOLDING COMPANY, INC.
Application year: 1995
Main classification: B41F13
IPC codes: B31B1, H02K7, B41F13