Abstract:
A stacking apparatus includes a base, a main conveyor pivotably supported on the base that is pivotable between a first, lowered, position and a second, raised, position, an accumulator section downstream of a discharge end of the main conveyor for receiving articles from the main conveyor, where the accumulator section includes a support for supporting a stack of items fed to the accumulator section by the main conveyor. Also, at least one optical sensor detecting the presence of an object in the main conveyor travel path and at least one controller operatively connected to the main conveyor and the optical sensor, the at least one controller receiving signals from the optical sensor and controlling the main conveyor based on the signals and on the direction of movement of the main conveyor.

Description:
[0001]    This non-provisional application claims the benefit of U.S. Provisional application No. 60/883,680, filed on Jan. 5, 2007, the entire contents of which are hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to an apparatus for stacking generally planar articles of material. More specifically, the present invention relates to an apparatus for stacking generally planar articles of material that includes at least one safety sensor and a safety controller for reducing the risk of injury to persons near the apparatus. 
         [0004]    2. Description of the Related Art 
         [0005]    Devices for stacking generally planar articles of material, such as sheets of corrugated material, are well known. One example of a commercially available device is the AGS2000 Rotary Die Cut Stacker made by the assignee of the present invention, A.G. Machine, Inc., Weyers Cave, Va. Further examples of such devices are disclosed in U.S. Pat. Nos. 3,321,202 to Geo. M. Martin and 3,419,266 to Geo. M. Martin, each of which is expressly incorporated herein by reference in its entirety. 
         [0006]      FIGS. 1 and 2  illustrate a conventional apparatus for stacking corrugated blanks. The stacking machine  100  generally comprises a layboy section  102  which receives conjugated blanks, such as those produced by a rotary die cut machine (not illustrated), and discharges the corrugated blanks onto a transfer conveyor  104 . The transfer conveyor  104  receives the blanks and transports them to a main conveyor  106 . The main conveyor  106  has an intake end  108  and a discharge end  110 . At intake end  108 , the main conveyor  106  is mounted to a base  112  at a pivot point  114  so that the conveyor may be pivoted to raise the discharge end  110  of the conveyor  106 . At the discharge end  110  of the conveyor  106 , an accumulator section  116  receives discharged blanks. 
         [0007]    In operation, the main conveyor  106  is pivoted about the pivot points to lower the discharge end  110  of the conveyor to an initial position. Sheets are fed onto the main conveyor  106  at its intake end  108 , transported along the distance of the conveyor to its discharge end  110 , and discharged from the conveyor over an accumulator faceplate  121  having a lower end  123 . The sheets are discharged and often strike a backstop  118 , having a lower end  119 , in the accumulator section  116  which stops the forward momentum of the sheets. The stopped sheets settle down, typically onto a discharge conveyor  132 , to form a stack of sheets. As additional sheets are placed on the stack, the main conveyor  106  is pivoted to raise the discharge end  110  vertically so that the discharged sheets are discharged above the top of the growing stack. 
         [0008]    Once a stack of sheets is completed, it must be removed to allow additional stacks of articles to be formed on the discharge conveyor. To allow the stack to be removed without stopping the main conveyor  106 , catcher elements  120  in accumulator section  116  are extended beyond and below the discharge end  110  of the main conveyor  106  so that sheets leaving the discharge end  110  of the main conveyor  106  fall onto the catcher elements  120 . A small pile of sheets is formed on the catcher elements  120  while the stack on the discharge conveyor  132  is removed, and when the stack is clear of the accumulator section  116 , main conveyor  106  is lowered, and the catcher elements  120  are withdrawn to deposit the pile of sheets from the catcher elements  120  onto the discharge conveyor  132  to form the beginning of a new stack of sheets onto which additional sheets from the discharge end of the main conveyor  106  are deposited. 
         [0009]    The main conveyor  106  is massive, moves relatively quickly from a raised to a lowered position, and can maim or kill a person who is present therebeneath when lowered. Of particular concern are the pinch point formed between the bottom  119  of the accumulator backstop  118  and the discharge conveyor  132  and the pinch point formed between the bottom  123  of the accumulator front plate  121  and the discharge conveyor  132 . Either of the pinch points could crush an object, including a user or user&#39;s body part, that is in the pinch point when the main conveyor descends. A person standing beneath the main conveyor  106 , upstream of the accumulator faceplate  121 , for example, could also be severely injured when the main conveyor  106  descends. 
         [0010]    Previous attempts to protect machine operators have often focused on perimeter protection, as disclosed, for example in U.S. Pat. No. 6,986,635 and U.S. Pat. No. 7,104,747, both issued to Talken et al. Such systems use a light curtain or one or more beams of light that are broken when a user approaches a dangerous area. However, when the light curtain is too close to an operating piece of machinery, it may not be possible to stop the machine in time to avoid user injury. When the light curtain is too far away from the operating machinery, however, it may frequently be tripped by accident and cause unnecessary shut downs of the machine being protected. Light curtains also do not address the scenario of a person being present between the light curtain and the area of danger when another operator resets the safety system leaving that person exposed to possible injury when the machine resumes operation. 
         [0011]    It would therefore be beneficial to provide an article stacking apparatus that is configured to reduce or eliminate human injuries. 
       SUMMARY OF THE INVENTION 
       [0012]    These and other difficulties are addressed by the present invention, a first aspect of which comprises a stacking apparatus for moving items from an upstream location to a downstream location. The stacking apparatus includes a base and a main conveyor pivotably supported on the base with an intake end and a discharge end that is pivotable between a first, lowered, position and a second, raised, position. These first and second positions define first and second ends of a main conveyor travel path. The stacking apparatus also includes an accumulator section downstream of the main conveyor discharge end for receiving items from the main conveyor, and the accumulator section includes a support for supporting a stack of items fed to the accumulator section by the main conveyor. The stacking apparatus further includes at least one optical sensor detecting the presence of an object in the main conveyor travel path and at least one controller operatively connected to the main conveyor and the optical sensor. The at least one controller receives signals from the optical sensor and controls the main conveyor based on the signals and on the direction of movement of the main conveyor. 
         [0013]    Another aspect of the invention comprises a method of operating a stacking apparatus that includes a base and a main conveyor pivotably supported on the base that has an intake end and a discharge end. The main conveyor discharge end is pivotable between a first, lowered, position and a second, raised, position, where the first and second positions define first and second ends of a main conveyor travel path. The method includes steps of providing at least one optical sensor detecting the presence of an object a first zone in and within a first distance of the main conveyor travel path and a second zone outside the first zone, allowing movement of the main conveyor between the lowered position and the raised position when the optical sensor detects an object in the first zone, and stopping the movement of the main conveyor between the raised position and the lowered position when the optical sensor detects an object in the first zone. 
         [0014]    A further aspect of the invention comprises a rotary die cut stacker that includes a base, a layboy receiving die cut blanks from a rotary die cutter, and a main conveyor pivotably supported on the base and having an intake end and a discharge end, the main conveyor discharge end being pivotable between a first, lowered, position and a second, raised, position, which first and second positions define first and second ends of a main conveyor travel path. The rotary die cut stacker further includes an accumulator section downstream of the main conveyor discharge end for receiving items from the main conveyor, and the accumulator section includes a support for supporting a stack of items fed to the accumulator section by the main conveyor. The rotary die cut stacker also includes at least one optical sensor detecting the presence of an object in the main conveyor travel path, and at least one controller operatively connected to the main conveyor and the optical sensor. The at least one controller receives signals from the optical sensor and controls the main conveyor based on the signals and on the direction of movement of the main conveyor. 
         [0015]    Still another aspect of the present invention comprises a safety system for a stacking apparatus that moves items from an upstream location to a downstream location. The safety system includes at least one optical sensor detecting the presence of an object in a main conveyor travel path, and the main conveyor is pivotably supported on a base and has an intake end and a discharge end. The main conveyor discharge end is pivotable between a first, lowered, position and a second, raised, position, which first and second positions define first and second ends of a main conveyor travel path. The system also includes at least one controller operatively connected to the main conveyor and the optical sensor, the at least one controller receiving signals from the optical sensor and controlling the main conveyor based on the signals and based on a direction of movement of the main conveyor. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The above and other aspects of exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings, in which: 
           [0017]      FIG. 1  is a top plan view of a conventional apparatus for stacking generally planar articles such as corrugated blanks; 
           [0018]      FIG. 2  is a side elevational view of the apparatus of  FIG. 1 ; 
           [0019]      FIG. 3  is a side elevational view of an apparatus for stacking generally planar articles of material according to an embodiment of the present invention with a main conveyor in a raised position; 
           [0020]      FIG. 4  is a side elevational view of the apparatus of  FIG. 3  with the main conveyor in a lowered position; 
           [0021]      FIG. 5  is a side elevational detail view of a discharge end of the main conveyor of the apparatus of  FIG. 3 ; 
           [0022]      FIG. 6  is a front elevational view of an accumulator backstop taken in the direction of arrows VI-VI in  FIG. 5 ; 
           [0023]      FIG. 7  is a front elevational view of an accumulator face plate taken in the direction of arrows VII-VII in  FIG. 5 ; 
           [0024]      FIG. 8  is a plan view of the apparatus of  FIG. 3  schematically showing several defined safety zones; and 
           [0025]      FIG. 9  is an elevational view of the apparatus of  FIG. 8  illustrating an operator standing at a control panel of the apparatus. 
       
    
    
     DETAILED DESCRIPTION 
       [0026]    The matters defined in the description such as a detailed construction and elements are provided to assist in a comprehensive understanding of the embodiments of the invention and are merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes to and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. Also, descriptions of well-known functions and constructions are omitted for clarity and conciseness. 
         [0027]    Referring now to the drawings, wherein the showings are for the purpose of illustrating preferred embodiments of the invention only and not for the purpose of limiting same,  FIG. 3  illustrates a stacking apparatus  200  for stacking generally planar articles of material, such as die-cut blanks formed by a rotary die-cutting machine. One use of the present invention is the stacking of die cut corrugated blanks of cardboard material, and the material being processed may be described herein as sheets or boards or blanks. The same reference numerals will be used to identify elements of stacking apparatus  200  that are common to the conventional apparatus  100  illustrated in  FIGS. 1 and 2 . 
         [0028]    With reference to  FIGS. 3 and 4 , operation stacking apparatus  200  is controlled by a main controller  202  housed in control panel  204 . Touch screen  206  forms an interface for controller  202  and is mounted on a pivotable pendant arm  208  so that an operator  210  can control the stacking apparatus from a location away from the moving parts of the machine. Also mounted in control panel  204  is a safety controller  212  for controlling various safety sensors described hereinafter. A suitable safety controller is available from SICK, Inc. of Minneapolis, Minn. under the model designation UE410 Flexi. 
         [0029]    Safety controller  212  receives input from various safety sensors on apparatus  200  including a first optical transmitter  214  and optical receiver  216  mounted on accumulator backstop  118  illustrated in  FIG. 6  and a second optical transmitter  218  and a second optical receiver  220  mounted on accumulator face place  121  illustrated in  FIG. 7 . Safety controller  212  also receives input from a contact sensing strip  222 , illustrated in  FIG. 7 , and a non-contact optical area scanner  224  illustrated, for example, in  FIG. 5 . The optical transmitters and receivers may comprise, for example, safety photoelectric switch system L4000 from SICK, Inc., the safety contact strip may be obtained, for example, from Omron Scientific Technologies, Inc., of Fremont, Calif., and the optical scanner may comprise a Leuze Lumiflex ROTOSCAN RS4-4 available from Leuze Electronic GmbH +Co. KG, of Owen, Germany. Each of these elements and their mutual interaction to protect persons working near stacking apparatus  200  is discussed below. It is further noted that, as used herein, “optical” refers to visible or other electromagnetic radiation—radiation having infrared wavelengths often being used. However, electromagnetic radiation having different wavelengths, or other non-contact sensors, such as ultrasonic sensors, could potentially also be used. 
         [0030]    Safety controller  212  is also operatively connected to apparatus controller  202  and can cause apparatus controller  202  to either stop or slow the movement of main conveyor  106 . In addition, safety controller  212  is connected to an indicator display  236  that includes green, yellow and red lights to provide visible warning information to users of stacking apparatus  212  and persons working near the machine and optionally, a speaker for generating one or more warning tones as well. 
         [0031]    Stacking apparatus  200  is configured so that power is required to lower main conveyor  106 ; therefore, main conveyor  106  cannot descend when power is disconnected from stacking apparatus  200 , and the stacking apparatus is placed into a safe state in the event of power loss. This is accomplished through the use of multiple hydraulic cylinders (not illustrated) with counterbalance valves that as a hydraulic pressure control safety subsystem by providing back pressure in the actuators to eliminate the natural gravitational tendencies of the main conveyor  106  to fall. A pilot operated check valve, which is another hydro-mechanical component, (not illustrated) may be provided to prevent the hydraulic cylinders from retracting in the absence of a command signal from the directional control valve. The pilot operated check valve prevents the deck from falling if one or both of the counterbalance valves fail. A normally closed safety down valve which is held open during normal stacker operation may be provided. Upon a safety system fault, the valve closes thus preventing the deck from descending. During normal operation, this simple safety valve device allows the stacker main conveyor to ascend or descend. 
         [0032]    First optical transmitter  216  and first optical receiver  218  are mounted on opposite sides of backstop  118  and spaced from the lower end  119  of backstop  118  and aligned so that an optical beam passes between the transmitter  216  and receiver  218 . When this beam is interrupted, a signal is sent to safety controller  212 . These sensors are mounted on slide supports  226  so that they will slide out of the way if one of the sensors contacts an object as the accumulator backstop  118  moves. Such contact will move the transmitter  216  and receiver  218  out of alignment and break the beam therebetween so that the transmitter and receiver themselves to not cause injury while the accumulator backstop moves. Second optical transmitter  218  and second optical receiver  220  are mounted on opposite sides of accumulator faceplate  121  and operate in a similar manner, sending a signal to safety controller  212  when an optical beam therebetween is interrupted. Sensing strip  222  also outputs a signal to safety controller  212  when an object contacts that safety strip  222  with a predetermined force. 
         [0033]    Non-contact optical scanner  224  is mounted near the base  112  of stacking apparatus  200  and scans an arc of about 190 degrees out to a distance of approximately meters from the scanner. The scanner is programmed to recognize fixed objects within its scanning field and to output various signals when other objects move into the scanning field. Furthermore, the scanning field has multiple zones, and different signals are sent to safety controller  212  depending on the zone in which an object has been detected. The area scanner  224  is generally positioned so that the scanning field is about centimeters from the floor on which the stacking apparatus  200  rests and so that the scanning field extends beneath the main conveyor  106  and out from the opposite, or drive side, of the stacking apparatus. 
         [0034]      FIG. 8  illustrates three safety zones recognized by the area scanner  224 , a first or safe zone  230 , a second or caution zone  232 , and a third or danger zone  234 . These zones will generally correspond to an industry defined detectable scanning zone, detection zone, and warning zones, respectively, but can be set as desired by the machine owner and/or as required by applicable laws. When safety controller  212  receives a signal indicative of a person or object in the safety zone  230 , a green light on indicator  236  is illuminated; when safety controller  212  receives a signal indicative of an object in caution zone  232 , a yellow light is illuminated and a warning chime or tone may be sounded. This draws the attention of the operator or other person to the fact that they are in a potentially dangerous situation. When safety controller  212  receives a signal indicative of an object in the danger zone  234 , a red light is illuminated and a warning buzzer or siren is sounded. What additional actions are taken with respect to the operation of the stacking apparatus depends on the operating state of the stacking apparatus whether the main conveyor  106  is moving up or down. Various scenarios are discussed below. 
         [0035]    With continued reference to  FIG. 8 , an operator  210  stands at touch screen  206  to operate stacking apparatus  200  when main conveyor  106  is in the down position illustrated in  FIG. 3 . At this time, blanks are exiting the discharge end  110  of the main conveyor  106  and forming a stack on discharge conveyor  132 , and main conveyor  106  is slowly rising to keep discharge end  110  above the top of the growing stack of objects on the discharge conveyor. If the operator steps into the caution zone  232  at this time, the light on the indicator display  236  changes color to yellow and an audible signal may be generated, but the operation of the stacker does not stop. If the operator moves into the danger zone  234 , the indicator light changes to red, and safety controller causes the main controller to shut off a control valve (not illustrated) that will prevent the main conveyor  106  from descending. However, operation of the stacking operation still does not stop because, as long as the main conveyor  106  is still rising, it presents a relatively minor threat to the safety of the operator. If the operator thereafter moves back through the caution zone  232  to the safety zone  230 , main controller opens the control valve so that the main conveyor  106  can descend when such movement becomes necessary in the operation cycle. In this manner, an automatic reset occurs, and it is not necessary for the operator  210  to manually reset the system after an incursion into the danger zone as was often the case with conventional systems, using light curtain technology, for example. 
         [0036]    In a second scenario, operator  210  steps into the caution zone  232  from safety zone  230  when main conveyor  106  is descending. Safety controller  212  then illuminates the yellow light on indicator display  236  and sounds a tone or other warning signal to warn the operator that he is moving into a dangerous position. In addition, the downward movement of the main conveyor  106  is slowed but not stopped. Slowing the main conveyor  106  will make the descent of the main conveyor  106  easier to stop if the operator thereafter moves into the danger zone  234 . As in the conventional stacking apparatus discussed above in connection with  FIGS. 1 and 2 , as the main conveyor  106  descends, articles of material are being caught on catcher elements  120  prior to being deposited on the discharge conveyor  132 . The slowing of the descent of the main conveyor therefore does not adversely affect the total output of the stacking apparatus  200 . When the operator  210  moves back into the safety zone  230 , the green light on the indicator display comes on and the main conveyor  106  resumes descending at its normal speed. If, however, the operator does not return to the safety zone  230  from the caution zone  232  but instead steps into the danger zone  234 , safety controller  212  illuminates the red light on display indicator  236 , sounds a warning siren or alarm, and stops the downward travel of the main conveyor  106 . Because the downward motion of the main conveyor  106  has already slowed, the motion can be stopped completely relatively quickly. Downward movement of the main conveyor continues only after the safety controller  212  senses an object moving from the danger zone  234  to the caution zone  232  and out to the safety zone  230 . This sequence of signals, indicating that the operator has left the danger zone, allows the operation of the stacking apparatus to resume without any further action on the part of the operator  210 . 
         [0037]    As will be appreciated from the drawing figures, area scanner  224  does not scan an area above discharge conveyor  132 . This is because the growing stack of objects on the discharge conveyor and the movement of the lower end  119  of backstop  118  and the lower end  123  of accumulator faceplate  121  would appear to the scanner as objects impermissibly in the danger zone  234 . By positioning the area scanner  224  at about 20 centimeters off the floor supporting the operator  210  and the stacking apparatus  200 , the fixed objects, such as the supports of discharge conveyor  132  can be noted and distinguished from any object that moves into the sensing fields. However, this inability of the area scanner  224  to sense objects on the discharge conveyor leaves open the possibility that an operator or other object on the discharge conveyor  132  could be crushed by either backstop  118  or accumulator faceplate  123 . These possibilities are addressed as follows. 
         [0038]    If operator  210  steps onto discharge conveyor  132  from danger zone  234 , area scanner  224  will no longer see an object in the sensing zones. However, safety controller  212  is programmed to detect a fault condition when an object entering the danger zone  234  via caution zone  232  does not thereafter exit the danger zone  234  through caution zone  232 . This fault condition must be manually cleared by an operator before the main conveyor  106  will be allowed to descend. The main conveyor  106  therefore will not descend if an operator is standing on the discharge conveyor  132 . 
         [0039]    There is a small chance that an object may remain on discharge conveyor  132  in a position below either the accumulator backstop  118  or the accumulator faceplate  121  even after operator  210  exits the danger zone  234  through the caution zone  232 . For example, the operator could enter the danger zone  234 , place an object (not illustrated) on the discharge conveyor  132 , and then exit the danger zone  234  via the caution zone  232 . Detecting this proper passage of the operator through the various zones, the main conveyor  106  would be allowed to descend, potentially crushing any object left on the discharge conveyor. Alternately, two operators could enter the danger zone, one operator could step onto the discharge conveyor and the other operator could leave the danger zone  234  via the caution zone  232  thereby potentially resetting the safety controller (which might not adequately distinguish between the two operators). Neither of these scenarios is highly likely, but the significant risk of severe bodily injury or death makes it beneficial to address them. These situations are addressed by the previously discussed first optical transmitter  214  and first optical receiver  216  mounted at the lower end  119  of the accumulator backstop  218  which will detect any object between the sensors (and thus in the path of the moving backstop  118 ) and send a signal to the safety controller to cause the downward movement of the main conveyor to be halted. After such an emergency stop, an operator would need to reset the safety controller because it would likely require human action to determine the cause of the fault and to correct the fault. During normal operation of the stacking apparatus  200 , the discharge conveyor  132  may come between the first optical transmitter  214  and the first optical receiver  216 . Controller  202  monitors the position of the main conveyor  106 , and safety controller  212  does not trigger a fault condition when the object sensed by the first optical transmitter  214  and first optical receiver  216  is determined to be the discharge conveyor. 
         [0040]    The second optical transmitter  218  and the second optical receiver  220  function in a similar manner and cause the downward motion of main conveyor  106  to stop when an object breaks the beam therebetween. Additional protection is provided by contact sensor  222  which also stops the downward movement of the main conveyor when contacted by an object. 
         [0041]    It should be understood that the particular configuration of the safety zones is dependent upon the particular device and particular application, and is configured appropriately. The system is freely configurable so that the safety zones can be adjusted according to customer product, machine size, plant layout, and any other relevant factors. Furthermore, it should be understood that the particular zone pair described above is configured with the recognition that the main conveyor presents less potential bodily harm to the operator while it is moving upward. 
         [0042]    As mentioned above, the scanning zones are configured depending on the operational state of the stacker. In addition to the main conveyor moving up, the various states include the main conveyor moving down, the main conveyor being stationary. Other operational states, such as the main conveyor being in maintenance mode, may also be recognized. 
         [0043]    Another mode of stacker operation is lock-out mode or maintenance mode. In this mode, a stacker may be placed in the full upward position,  FIG. 3 , and lock-out pins (not illustrated) may be placed in the stacker to engage the main conveyor and mechanically prevent the main conveyor  106  from descending. This is considered a safe maintenance or zero energy state. At this point, the main conveyor presents negligible bodily harm to the operator if the machine is at rest and not under power. Thus, the detectable scanner area and the warning scanner area are configured appropriately, and the safety system sounds appropriate warnings. 
         [0044]    Dual channel safety rated e-stop circuits that are two channel safety rated with multiple operators may be strategically and ergonomically located on the machine and connected to the safety controller  212 . The safety rated e-stop controls, which are commercially available, are designed to be control reliable in accord with EN954-1. In addition, each of the safety sensors discussed herein, namely, the first and second optical transmitters,  214 ,  218 , the first and second optical receivers  216 ,  220 , the safety contact strip  222 , the scanner  223  and the safety controller  224  are control reliable. Control reliability refers to the capability of the machine control system, the safeguarding, other control components and related interfacing to achieve a safe state in the event of a single failure within their safety related functions. In this manner, a high degree of safety can be provided to operators of stacking apparatus  200  and persons and objects in the vicinity of the apparatus. Redundancy is enhanced by the use of a control reliable safety controller separate from the less reliable machine controller, further reducing the possibility of injury. The safety system does not prevent the use of more traditional warning and safety mechanisms, such as appropriate signage and perimeter protection using hard guarding such as gates and/or fences. However, multiple safety sensors provide redundancy and greatly decrease the possibility of injury to persons working near an operating machine. 
         [0045]    While the present invention has been shown and described with reference to certain exemplary embodiments thereof, it will be understood by those skilled in the art that various additions and/or changes in form and details may be made therein without departing from the spirit and scope of the invention. It is intended that all such additions and changes form a part of the present invention to the extent they fall within the scope of the several claims appended hereto.