Patent Publication Number: US-11660834-B2

Title: Pleated filter preparation system

Description:
CROSS-REFERENCE 
     This application is a continuation of and claims benefit to U.S. patent application Ser. No. 16/270,522 filed on Feb. 7, 2019, issued as U.S. Pat. No. 11,123,946 on Sep. 21, 2021 and which applications are incorporated herein by reference in their entirety. 
    
    
     FIELD 
     Embodiments of the present disclosure generally relate to the field of manufacturing filtration devices. More specifically, embodiments of the disclosure relate to systems and methods for a pleated filter preparation system that accurately counts the number of pleats in a corrugated sheet of material to be used for the production of air filters. 
     BACKGROUND 
     An air filter designed to remove particulate matter from an airstream generally is a device comprising fibrous materials. These fibrous materials may remove solid particulates such as dust, pollen, mold, and bacteria from the airstream. Air filters are used in applications where air quality is important, notably in building ventilation systems and with engines. 
     Air filters may be used in automobiles, trucks, tractors, locomotives and other vehicles that use internal combustion engines. Air filters may be used with gasoline engines, diesel engines, or other engines that utilize fossil fuels or other combustible substances. Air filters may be used with engines in which combustion is intermittent, such as four-stroke and two-stroke piston engines, as well as other types of engines that take in air continuously so that a combustible substance may be burned. For example, air filters may be used with some gas turbines. Filters may also be used with air compressors or in other devices that take in air. 
     Filters may be made from pleated paper, foam, cotton, spun fiberglass, or other known filter materials. Generally, the air filters used with internal combustion engines and compressors tend to be comprised of either: paper, foam, or cotton filters. Air filters for internal combustion engines prevent abrasive particulate matter from entering the engine&#39;s cylinders, where it would cause mechanical wear and oil contamination. In many fuel injected engines, a flat panel pleated paper filter element may be used. 
     Air filters may be manufactured from a continuous roll of pleated material. It is essential that assembled air filters have a predetermined number of pleats. For example, suppose an air filter is to be tapered. A manufacturer may calculate the number of pleats needed by taking into consideration the size of the air filter and the height of the pleat. A piece of material that includes the desired number of pleats may be cut from the roll. Once cut, the piece of material may be joined at its ends to form a sleeve which is then formed into a filter medium of the air filter. 
     Along an assembly line, the desired number of pleats generally is counted manually and marked at each interval where the desired number repeats on the roll. The roll is then manually cut at the marked intervals to form filter media comprising the desired number of pleats. In the case of round air filters, for example, the ends of each piece of material are manually joined together and then crimped together to form a filter medium suitable for being formed into a round air filter. 
     As will be appreciated, manually counting pleats, marking intervals along the roll, and manually cutting the at the marked intervals not only is time consuming, but is also subject to error. The likelihood of such errors generally is increased by the tedious nature of the job. If the number of pleats is improperly counted, a faulty air filter will result. A need exists, therefore, for a pleat counter that accurately counts the number of pleats in a corrugated sheet of material to be used for the production of air filters. 
     SUMMARY 
     A pleated filter preparation system and methods are provided for accurately counting pleats along a continuous sheet of pleated filter material and cutting the sheet into filter strips to be formed into filters. The pleated filter preparation system comprises a pleat driver configured to move the pleated filter material through the system. The pleat driver includes one or more drive gears that are configured to engage with a pleat height comprising the pleated filter material so as to convey the pleated filter material through the system. The pleated filter preparation system includes a pleat counter configured to count peaks and valleys of each pleat comprising the pleated filter material so as to identify a target pleat to be cut. The pleat counter is configured to clamp the pleated filter material and stretch the target pleat to distinguish the target pleat among the other pleats. A punch cut station configured to located and cut the target pleat to form a filter strip having the desired number of pleats. A conveyor is configured to transport filter strips from the punch cut station to a pleat compressor. The pleat compressor is configured to compress filter strips to a predetermined size and then eject the compressed filter strips into a suitable container or bin. 
     In an exemplary embodiment, a pleated filter preparation system comprises: a pleat driver configured to move a pleated filter material through the system; a pleat counter configured to identify a target pleat to be cut; a punch cut station configured to cut the target pleat to form a filter strip; and a pleat compressor configured to compress the filter strip to a predetermined size. 
     In another exemplary embodiment, the pleated filter preparation system further includes a feed entrance configured to guide the pleated filter material from a pay-out into the pleat driver, the pay-out comprising one or more rolls of pleated filter material to be processed by the system. In another exemplary embodiment, the feed entrance includes side rails that are configured to move to optimally guide different widths of the pleated filter material into the pleat driver. 
     In another exemplary embodiment, the pleated filter preparation system further includes a conveyor disposed between the punch cut station and the pleat compressor, the conveyor being configured to transport filter strips from the punch cut station to the compressor. In another exemplary embodiment, the conveyor is configured to move each of the filter strips onto a filter support comprising the pleat compressor. In another exemplary embodiment, the conveyor is configured to transport the filter strips at a speeds that emulate feed rates of the pleat drive. 
     In another exemplary embodiment, the pleat drive includes a pleat height index comprising a vertically oriented disc having one or more drive gears disposed around the periphery of the disc, the drive gears being free to rotate with respect to the pleat height index. In another exemplary embodiment, the drive gears each includes peripheral teeth configured to engage with a pleat height comprising the pleated filter material so as to convey the pleated filter material through the system. In another exemplary embodiment, the drive gears each include a pulley portion configured to receive a drive belt whereby a drive motor turns all of the drive gears simultaneously. In another exemplary embodiment, a tensioner is configured to maintain an optimal belt tension during operation of the drive gears. In another exemplary embodiment, the pleat height index includes a suitable engagement driver configured to move the pleat height index vertically to an indexing configuration. In another exemplary embodiment, the indexing configuration comprises the pleat height index being raised to disengage a bottom-most of the one or more drive gears from the pleated filter material. In another exemplary embodiment, the indexing configuration of the pleat height index is configured to facilitate switching to a different bottom-most of the one or more drive gears so as to engage with a differently-sized pleated filter material. 
     In another exemplary embodiment, the pleat counter includes a sensor disposed above the pleated filter material and a pleat detector disposed underneath the pleated filter material, the sensor and the pleat detector being configured to identify and count peaks and valleys comprising each of the pleats comprising the pleated filter material. In another exemplary embodiment, the sensor and the pleat detector are configured to identify the target pleat to be cut. In another exemplary embodiment, the pleat counter is configured to clamp the pleat filter material and stretch the target pleat so as to distinguish the target pleat among the other pleats. 
     In another exemplary embodiment, the punch cut station includes a stamping press configured to cut the pleated filter material at the midpoint of the target pleat. In another exemplary embodiment, the punch cut station is coupled with a sensor configured to detect the location of the target pleat. In another exemplary embodiment, the stamping press includes an elongate stamping die in mechanical communication with a hydraulic actuator, the stamping die being a single blade positioned parallel with the target pleat, the hydraulic actuator being configured to forcibly press the stamping die into the midpoint of the target pleat. 
     In another exemplary embodiment, the pleat compressor includes an ejector configured to push a compressed filter strip onto a fall arrestor adjacent to the pleat compressor, the fall arrestor being configured to support the compressed filter strip in a horizontal orientation. In another exemplary embodiment, the fall arrestor is configured to quickly retract such that the compressed filter strip maintains the horizontal orientation during dropping into a suitable container or bin. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings refer to embodiments of the present disclosure in which: 
         FIG.  1    illustrates a perspective view of an exemplary embodiment of a pleated filter preparation system according to the present disclosure; 
         FIG.  1 A  illustrates a table showing a multiplicity of filter property-ranges that may be accommodated by way of the pleated filter preparation system of  FIG.  1   ; 
         FIG.  2    illustrates an isometric view of an exemplary embodiment of a pay-out that may be used in conjunction with the pleated filter preparation system shown in  FIG.  1   ; 
         FIG.  3 A  illustrates an exemplary embodiment of a feed entrance that may be incorporated into the pleated filter preparation system of  FIG.  1   ; 
         FIG.  3 B  illustrates the feed entrance of  FIG.  3 A  with side rails moved adjacent to the sides of a filter material being drawn through the pleated filter preparation system of  FIG.  1   ; 
         FIG.  4 A  illustrates an exemplary embodiment of a pleat drive comprising the pleated filter preparation system of  FIG.  1   ; 
         FIG.  4 B  illustrates the pleat drive of  FIG.  4 A  in an exemplary engaged configuration wherein the pleat drive conveys a filter material through the pleated filter preparation system of  FIG.  1   ; 
         FIG.  4 C  illustrates the pleat drive of  FIG.  4 A  in an exemplary indexing configuration wherein the pleat drive is disengaged from the filter material; 
         FIG.  5    illustrates a side plan view of an exemplary embodiment of a pleat counter comprising the pleated filter preparation system of  FIG.  1   ; 
         FIG.  5 A  illustrates the pleat counter of  FIG.  5    in a pleat location configuration whereby pleats of a filter material are counted and a pleat to be cut is identified; 
         FIG.  5 B  illustrates the pleat counter of  FIG.  5    in a pleat clamping configuration wherein the filter material is clamped by way of teeth extending into pleats adjacent to the pleat to be cut; 
         FIG.  5 C  illustrates the pleat counter of  FIG.  5    in a pleat stretching configuration wherein the pleat to be cut is marked by way of stretching to distinguish the pleat to be cut from other pleats comprising the filter material; 
         FIG.  5 D  illustrates an exemplary pleat height index configuration of the pleat counter shown in  FIG.  5   , whereby the pleat counter may be adjusted to accommodate different pleat heights of the filter material; 
         FIG.  6 A  illustrates a first isometric view of an exemplary embodiment of a punch cut station that may be incorporated into the pleated filter preparation system of  FIG.  1   ; 
         FIG.  6 B  illustrates a second isometric view of an exemplary embodiment of a punch cut station that may be incorporated into the pleated filter preparation system of  FIG.  1   ; 
         FIG.  7 A  illustrates an exemplary embodiment of a pleat compressor that may be incorporated into the pleated filter preparation system of  FIG.  1   ; 
         FIG.  7 B  illustrates a filter receiving configuration of the pleat compressor shown in  FIG.  7 A , wherein the pleat compressor receive a filter strip to be compressed; 
         FIG.  7 C  illustrates a filter compression configuration of the pleat compressor shown in  FIG.  7 A , wherein the pleat compressor is beginning to compress the filter strip; 
         FIG.  8 A  illustrates a filter compression configuration of the pleat compressor of  FIG.  7 A  during compressing a filter strip; 
         FIG.  8 B  illustrates a carriage retract configuration of the pleat compressor of  FIG.  7 A , wherein a plate carriage comprising the pleat compressor is retracted after compressing the filter strip; 
         FIG.  9 A  illustrates an exemplary filter ejection configuration of the pleat compressor of  FIG.  7 A , wherein a compressed filter strip is pushed from the pleat compressor onto a fall arrestor; 
         FIG.  9 B  illustrates an exemplary embodiment of a fall arrestor being retracted to allow the compressed filter strip to drop controllably into a container; 
         FIG.  10    illustrates a schematic of an exemplary embodiment of a pleated filter manufacturing station comprising multiple pleated filter preparation stations operating in parallel; and 
         FIG.  11    is a block diagram illustrating an exemplary data processing system that may be used with an automated filter preparation system, in accordance with the present disclosure. 
     
    
    
     While the present disclosure is subject to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. The invention should be understood to not be limited to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure. 
     DETAILED DESCRIPTION 
     In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one of ordinary skill in the art that the invention disclosed herein may be practiced without these specific details. In other instances, specific numeric references such as “first pleat,” may be made. However, the specific numeric reference should not be interpreted as a literal sequential order but rather interpreted that the “first pleat” is different than a “second pleat.” Thus, the specific details set forth are merely exemplary. The specific details may be varied from and still be contemplated to be within the spirit and scope of the present disclosure. The term “coupled” is defined as meaning connected either directly to the component or indirectly to the component through another component. Further, as used herein, the terms “about,” “approximately,” or “substantially” for any numerical values or ranges indicate a suitable dimensional tolerance that allows the part or collection of components to function for its intended purpose as described herein. 
     Air filters may be manufactured from a continuous roll of pleated material. It is essential that assembled air filters have a predetermined number of pleats. Along an assembly line, the desired number of pleats may be counted and marked at each interval where the desired number of pleats repeats along the roll. Manually counting pleats is time consuming prone to error. If the number of pleats is improperly counted, a faulty air filter will result. Embodiments presented herein below provide a pleat counter capable of accurately counting a desired number of pleats in a corrugated sheet of filter material. 
       FIG.  1    illustrates a perspective view of an exemplary embodiment of a pleated filter preparation system  100  (hereinafter, “system  100 ”), according to the present disclosure. The system  100  is configured to automate counting pleats along a continuous roll of pleated material, cutting the roll into desired length strips of pleated material based on the number of counted pleats, compressing the strips of pleated material, and packing the strips in preparation for being formed into air filters. As shown in  FIG.  1   , the system  100  includes a pay-out  104 , feed entrance  108 , a pleat drive  112 , a pleat counter  116 , a punch cut station  120 , a conveyor  124 , a pleat compressor  128 , and a fall arrestor  132 . In general, the system  100  is configured to produce a desired spectrum of filter configurations without requiring manual intervention. It is envisioned, however, that an operator  136  may manually configure portions of the system  100 , such as, for example, changing a stamping die comprising the punch cut station  120 . 
     As stated, the system  100  is configured to advantageously produce a desired spectrum of filter configurations.  FIG.  1 A  illustrates a table  140  showing a multiplicity of filter property-ranges that may be accommodated by way of the system  100 . For example, the system  100  may produce filters having pleat widths ranging between about 1¼″ to about 21⅝″. Desired pleat counts generally range between about 18 pleats and 153 pleats. Table  140  further shows desired pleat sizes, or pleat heights, that may be accommodated by the system  100 , such as 7/16″, ⅝″, ⅞″, and 1¼″. It should be understood, however, that the system  100  is not limited to producing filters strictly in accordance with the filter properties shown in table  140 , but rather the system  100  is capable of producing filters having properties other than those shown in  FIG.  1 A . For example, in some embodiments, the system  100  is configured to produce filters having a pleat height that is less than 7/16″, such as, by way of non-limiting example, a pleat height of 5/16″. Further, in some embodiments, the system  100  is configured to produce filters having a pleat height that is greater than 1¼″, such as, by way of non-limiting example, a pleat height of 1⅜″. Moreover, in some embodiments, the system  100  may be configured to operate with filter materials having metric properties, without limitation. 
       FIG.  2    illustrates an isometric view of an exemplary embodiment of a pay-out  104  that may be used in conjunction with the system  100  shown in  FIG.  1   . In general, the pay-out  104  comprises one or more rolls of filter material to be processed by the system  100  to form filters. In the embodiment of  FIG.  2   , the pay-out  104  includes a first spool  144  and a second spool  148  of rolled filter materials that are supported vertically with respect to one another on a stand  152 . The spools  144 ,  148  are each supported by way of a support post  156  extending horizontally through a hole  160  disposed in the center of the spool. The support posts  156  are fixed to opposite ends of a pay-out arm  164  that is rotatably attached to the stand  152  by way of a pivot  168 . As will be appreciated, the pivot  168  enables the pay-out arm  164  to be rotated with respect to the stand  152 , as desired. 
     In some embodiments, the upper of the spools  144 ,  148  feeds the system  100  while the lower of the spools  144 ,  148  remains on standby. Once the upper of the spools  144 ,  148  is finished being used, or is no longer desired to be used, the pay-out arm  164  may be rotated about the pivot  164  to position the lower of the spools  144 ,  148  in the upper position. It is contemplated, that the pivot  168  may be operated either by way of an electric motor or manually to switch the respective positions of the spools  144 ,  148 , as desired. It is contemplated that, in some embodiments, the spools  144 ,  148  may be comprised of distinctly different filter materials. For example, the first spool  144  may be comprised of filter material having a 7/16″ pleat height while the second spool  148  includes a filter material having ⅞″ pleat height. As such, the spools  144 ,  148  may be switched according to the desired pleat height of the filters produced by the system  100 . 
     Moreover, it is contemplated that the pay-out  104  may be comprised of more than the two spools  144 ,  148  shown in  FIG.  2   . In some embodiments, for example, the pay-out  104  may include three, four, five or more spools of distinctly different filter materials, without limitation. Each of the spools may include a filter material having a unique combination of the properties show in table  140 . Thus, the system  100  may produce a wide variety of differently-sized filters due, in part, to switching among spools of different filter material that are loaded into the pay-out  104 , without limitation. 
       FIG.  3 A  illustrates an exemplary embodiment of a feed entrance  108  that may be incorporated into the system  100  of  FIG.  1   . The feed entrance  108  includes a smooth sheet configured to guide continuous filter material from the spool  144  into the system  100 . The smooth sheet includes a rounded portion  172  near the spool  144  and comprises a flattened portion  176  within the feed entrance  108 . The flattened portion  176  transitions to a curved portion  180  upon exiting the feed entrance  108  and entering the pleat drive  112 . The portions  172 ,  176 ,  180  comprising the smooth sheet are configured to optimally guide the filter material into the system  100  with as little resistance as possible. 
     As shown in  FIG.  3 A , side rails  184  are disposed along opposite sides of the flattened portion  176  and are configured to move to optimally guide different widths of filter material through the system  100 . As shown in  FIG.  3 B , for example, the side rails  184  may be moved closer together to be adjacent to the sides of a filter material  188  being drawn through the system  100 . In the illustrated embodiment, each of the side rails  184  is moveable by way of a servo  192  in mechanical communication with a threaded shaft  196 . Each of the side rails  184  is threadably engaged with the shaft  196 , such that turning the threaded shaft  196  causes the side rail  184  to move accordingly. In the illustrated embodiment, the servos  192  are configured to move the side rails  184  from a separation distance of about 1.5″ to about 22″, without limitation. Further, opposite ends of each side rail  184  slidably rides on a guiderail  200 . As will be recognized, the guiderails  200  are configured to keep the side rails  184  parallel to one another during width adjustments. 
       FIG.  4 A  illustrates an exemplary embodiment of a pleat drive  112  comprising the system  100  of  FIG.  1   . During operation of the system  100 , the pleat drive  112  is configured to be automatically indexed to a correct pleat drive gear for engaging with the filter material  188 . As shown in  FIG.  4 A , the pleat drive  112  includes a pleat height index  204  generally comprising a vertically oriented disc having one or more drive gears  208  disposed around the periphery of the disc. The drive gears  208  may be coupled with the pleat height index  204  by way of bearings, and thus each of the drive gears  208  is free to rotate with respect to the pleat height index  204 . As best shown in  FIGS.  4 B and  4 C , a drive motor  212  is configured to rotate the drive gears  208 . In the illustrated embodiment, the drive gears  208  each include a pulley portion  216  configured to receive a drive belt (not shown) whereby the drive motor  212  can turn all of the drive gears  208  simultaneously. A tensioner  220  may be utilized, as shown in  FIG.  4 A , to maintain an optimal belt tension during operation of the drive gears  208 . 
     Each drive gear  208  includes peripheral teeth configured to engage with a specific pleat height comprising the filter material  188  so as to convey the filter material through the system  100 . As such, in the illustrated embodiment, a first drive gear  208  includes teeth configured to engage with a filter material  188  comprising pleats having a pleat height of 7/16″, while a second drive gear  208  includes teeth for engaging with pleats having a pleat height of ⅝″. Further, a third drive gear  208  has teeth configured for engaging pleats having a pleat height of ⅞″, and a fourth drive gear  208  is configured to engage with the pleats of a filter material  188  comprising a pleat height of 1¼″. It is contemplated, however, that the drive gears  208  may be configured to engage with pleat heights other than those shown in  FIG.  1 A . For example, a drive gear  208  configured to engage with a 5/16″ pleat height, or other specific dimension, may be installed onto the pleat height index  204 , without limitation. It is further contemplated that the drive gears  208  may be configured to engage with metric pleat heights, without limitation. 
     In general, the pleat height index  204  is configured to be moved vertically between an engaged configuration  224 , shown in  FIG.  4 B , and an indexing configuration  228  shown in  FIG.  4 C . The pleat height index  204  may be moved vertically by way of a suitable engagement driver  232 , such as a linear servo or an electric motor. In the engaged configuration  224  of  FIG.  4 B , the pleat height index  204  is lowered to advantageously couple the bottom-most drive gear  208  with the filter material  188 . In the indexing configuration  228 , however, the pleat height index  204  is raised to disengage the bottom-most drive gear  208  from the filter material  188 . It is contemplated that the indexing configuration  228  facilitates moving a different drive gear  208  to the bottom-most position so as to engage with a differently-sized filter material  188 . An index motor  236  in mechanical communication with an axle  240  of the pleat height index  204  is configured to rotate the pleat height index  204  so as to change the vertical positions of the drive gears  208  with respect to the filter material  188 . Once the desired drive gear  208  is in the bottom-most position, the engagement driver  232  may be used to lower the pleat height index  204  to the engaged configuration  224 , as shown in  FIG.  4 B . The drive motor  212  may then be actuated to draw the filter material  188  through the system  100 , as described herein. 
     It will be appreciated that a critical part of separating the filter material  188  into strips suitable for being formed into filters is counting the number of pleats comprising each of the strips and then stretching the pleats where the strips are to be cut from the filter material  188 . To this end,  FIG.  5    illustrates a side plan view of an exemplary embodiment of a pleat counter  116  comprising the system  100  of  FIG.  1   . The pleat counter  116  is shown clamping a portion of the filter material  188 . A first sensor  244  is disposed above the filter material  188 , and a pleat detector  248  is disposed underneath the filter material  188 . The first sensor  244  and the pleat detector  248  are configured to identify and count peaks  252  and valleys  256  comprising each of the pleats comprising the filter material  188 . It is contemplated that the first sensor  244  and the pleat detector  248  may include any of various detectors suitable for distinguishing between the peaks  252  and the valleys  256 , such as, by way of non-limiting example, reflective digital laser sensors and the like. In the embodiment of  FIG.  5   , for example, a laser  260  and the first sensor  244  are disposed substantially in the center of the pleat counter  116  and configured to detect the pleats that are to be cut. 
     It should be understood that the various sensors and detectors disclosed herein, such as the first sensor  244  and the pleat detector  248 , generally are an I/O variety of sensor that facilitates a bi-directional flow of information to and from each sensor. As will be appreciated, I/O sensors advantageously enable troubleshooting of problem areas, while allowing for easy configuration of the sensors without requiring physical changes based on estimation. As such, the I/O sensors enable an authorized operator  136  to control and calibrate sensor values without having to physically calibrate the sensors during maintenance or optimization. All calibrations can be done either in person or remotely, thereby giving other authorized users multiple ways to address any issues. 
       FIGS.  5 A through  5 C  illustrate exemplary configurations of the pleat counter  116  during pleat counting, pleat clamping, and pleat stretching.  FIG.  5 A  illustrates the pleat counter  116  in a pleat location configuration  264  whereby the pleats of the filter material  188  may be counted and the pleat to be cut may be identified. In the pleat location configuration  264 , the first sensor  244  and the pleat detector  248  are separated away from the filter material  188  to allow free movement of the filter material  188  therethrough during counting the pleats. Servo cylinders  268  are configured to move the first sensor  244  above the filter material  188 , and servo cylinders  272  are configured to lower the pleat detector  248  below the filter material  188 . As further shown in  FIG.  5 A , the first sensor  244  and the pleat detector  248  include teeth  276  configured to extend into adjacent pleats during clamping the filter material  188 . 
       FIG.  5 B  illustrates the pleat counter  116  in a pleat clamping configuration  280  wherein the servo cylinders  268 ,  272  have moved the first sensor  244  and the pleat detector  248  together so as to extend the teeth  276  into adjacent pleats. The pleat counter  116  is moved into the pleat clamping configuration  280  once the desired number of pleats have been counted and the pleat to be cut has been located. In the illustrated embodiment, the teeth  276  engage the filter material  188  such that the pleat to be cut is located in the center of the first sensor  244 . In some embodiments, however, the pleat counter  116  may further include a secondary, “after counter” (not shown) that is configured to verify that the desired number of pleats has been correctly counted. As such, it is contemplated that the teeth  276  engage the filter material  188  only once the after counter has confirmed that the correct number of pleats has been counted. 
       FIG.  5 C  illustrates the pleat counter  116  in a pleat stretching configuration  284  wherein the pleat to be cut is marked by way of stretching to distinguish the pleat to be cut from other pleats comprising the filter material  188 . In the embodiment illustrated in  FIG.  5 C , the teeth  276  remain extended into the pleats adjacent to the pleat to be cut while the first sensor  244  and the pleat detector  248  are each separated into halves that are pulled apart by way of a servo cylinder  288 . As will be appreciated, separating the halves of the first sensor  244  and the pleat detector  248  while the teeth  276  remain engaged with the pleats operates to stretch the pleat to be cut without alternating the pleats adjacent to the stretched pleat. It is contemplated that the stretched pleat may be later detected by a second sensor and then cut by way of the punch cut station  120 , as shown in  FIG.  1   . 
       FIG.  5 D  illustrates an exemplary pleat height index configuration  292  of the pleat counter  116  whereby the separation between the first sensor  244  and the pleat detector  248  may be adjusted to accommodate different pleat heights of the filter material  188 . As shown, the first sensor  244  and the pleat detector  248  are mounted onto cross members  296  that may be moved vertically along posts  300  under the action of respective servo cylinders  268 ,  272 , as described herein. Further, it is contemplated that the first sensor  244  and the pleat detector  248  may be moved horizontally along the cross members  296  by way of electric motors  304 . It should be understood, therefore, that the pleat counter  116  is configured to process all desired pleat heights comprising the filter material  188 , without limitation. 
       FIGS.  6 A and  6 B  illustrate isometric view of an exemplary embodiment of a punch cut station  120  that may be incorporated into the system  100  of  FIG.  1   . The punch cut station  120  generally is configured to cut the filter material  188  into filter strips having a desired number of pleats, as described herein. In some embodiments, a second sensor (not shown) that is similar to the first sensor  244  may be coupled with the punch cut station  120  and configured to detect the stretched pleat to be cut. It is contemplated that the second sensor may be configured to detect pleat peaks  252  disposed at the beginning and end of the stretched pleat. As will be appreciated, an exact location to cut the stretched pleat may be identified by dividing the detected stretch length in half relative to the known pleat height and current feed rate. 
     In the embodiment illustrated in  FIGS.  6 A and  6 B , the punch cut station  120  includes a stamping press  308  configured to cut the filter material  188 . A waste catch  312  located below the stamping press  308  is configured to capture scraps of the filter material  188  that may be produced during cutting. The stamping press  308  includes an elongate stamping die  316  in mechanical communication with a hydraulic actuator  320 . The stamping die  316  generally includes a single blade positioned parallel with the pleats and preferably is capable of cutting all pleat widths comprising the filter material  188 . The hydraulic actuator  320  is configured to forcibly press the stamping die  316  into the midpoint of the stretched pleat, as detected by the second sensor described herein. As further shown in  FIGS.  6 A and  6 B , the punch cut station  120  is coupled with a support structure  324  suitable for supporting the weight of the punch cut station  120  and incorporating the punch cut station  120  within the system  100 , as shown in  FIG.  1   . 
     Once the filter material  188  has been cut into strips, the resulting filter strips  328  are transported from the punch cut station  120  to a pleat compressor  128 , shown in  FIG.  7 A , by way of the conveyor  124  shown in  FIG.  1   . The conveyor  124  is configured to move each filter strip  328  onto a filter support  332  comprising the pleat compressor  128 . It is contemplated that the conveyor  124  is configured to transport the filter strips  328  at a speed, including acceleration and deceleration, that emulates the feed rate of the pleat drive  112 , such that the filter material  188  and the filter strips  328  move through the system  100  with a substantially constant velocity. 
     As shown in  FIG.  7 A , the pleat compressor  128  generally is an elongate assembly configured to compress filter strips  328  to a desired size and then eject the compressed filter strips  328  into a suitable container or bin. As will be appreciated, the filter support  332  has a width capable of supporting all desired pleat widths of the filter material  188 , as discussed with respect to table  140 . A compression plate  336  is disposed at a first end of the filter support  332 , near the conveyor  124 . The compression plate  336  is configured to slide an arriving filter strip  328  along the filter support  332  towards a fixed plate  340  disposed at a second end of the filter support  332 . Preferably, therefore, the filter support  332  includes a relatively smooth surface suitable for sliding the filter strips  328  thereon. Upon contacting the fixed plate  340 , the compression plate  336  compresses the filter strip  328  against the fixed plate  340  until the filter strip  328  assumes a predetermined size. An ejector  372  comprising the pleat compressor  128  is configured to move the compressed filter strip  328  off the filter support  332  into a suitable container or bin. 
     In the illustrated embodiment of  FIG.  7 A , the compression plate  336  is coupled with a plate carriage  344  that is configured to roll along a support rail  348  disposed above the filter support  332 . The plate carriage  344  is fixed to a belt  352  that is looped around a pulley  356  and a drive motor  360 . Thus, upon actuation of the drive motor  360 , movement of the belt  352  carries the plate carriage  344  along the support rail  348 . It is contemplated that one or more sensors may be mounted onto various locations of the pleat compressor  128  and configured to advantageously limit the travel of the plate carriage  344  along the support rail  348 , as desired. 
       FIGS.  7 B and  7 C  illustrate exemplary configurations of the pleat compressor  128  during receiving a filter strip  328  that is to be advantageously compressed, as described herein.  FIG.  7 B  illustrates a filter receiving configuration  364  of the pleat compressor  128  wherein the conveyor  124  pushes the filter strip  328  onto the filter support  332 . While in the filter receiving configuration  364 , at least one sensor (not shown) coupled with the pleat compressor  128  is used to detect a trailing edge of the filter strip  328 . Once the trailing edge of the filter strip  328  is detected, the pleat compressor  128  changes to a filter compression configuration  368  as shown in  FIG.  7 C . Once in the filter compression configuration  368 , the compression plate  336  is lowered behind the trailing edge of the filter strip  328 . The pleat compressor  128  then proceeds to compress the filter strip  328 , as described herein. 
       FIG.  8 A  illustrates a filter compression configuration  368  of the pleat compressor  128  during compressing the filter strip  328 . As shown in  FIG.  8 A , during compressing the filter strip  328  the plate carriage  344  moves along the support rail  348  in a direction  376  toward the fixed plate  340 . Once the filter strip  328  contacts the fixed plate  340 , the plate carriage  344  pushes the compression plate  336  against the filter strip  328  to compress the filter strip  328 . Once the filter strip  328  is compressed to a predetermined size, the pleat compressor  128  changes to a carriage retract configuration  380 . As shown in  FIG.  8 B , during the carriage retract configuration  380  the plate carriage  344  moves along the support rail  348  in a direction  384  away from the fixed plate  340 . After being compressed, the filter strip  328  remains on the filter support  332  near the fixed plate  340  before being ejected from the system  100 . 
       FIG.  9 A  illustrates an exemplary filter ejection configuration  388  of the pleat compressor  128 . In the filter ejection configuration  388 , the plate carriage  344  returns to the beginning of the filter support  332  and an ejector  372  pushes the compressed filter strip  328  off of the filter support  332  in preparation for compressing the next filter strip delivered by the conveyor  104 . In the embodiment illustrated in  FIG.  9 A , the ejector  372  includes an elongate bar  392  configured to slide the filter strip  328  onto a fall arrestor  396  adjacent to the filter support  332 . The bar  392  moves under the operation of a suitable actuator  400  and rides on parallel guiderails  404 . Once the compressed filter strip  328  clears the filter support  332  and is entirely supported by the fall arrestor  396 , the bar  392  is retracted away from the filter strip  328 , leaving the filter strip supported entirely by the fall arrestor  396 . As shown in  FIG.  9 A , the fall arrestor  396  generally includes multiple legs  408  that are separated so as to support the filter strip  328  in a horizontal orientation. Upon the legs  408  being retracted quickly, as shown in  FIG.  9 B , the filter strip  328  maintains the horizontal orientation during dropping into a suitable container or bin for storing compressed filter strips produced by the system  100 . It is contemplated that the number of legs  408  and their separation may be adjusted so as to accommodate a spectrum of desired filter sizes, without limitation. 
       FIG.  10    illustrates a schematic of an exemplary embodiment of a pleated filter manufacturing station  420  that may be implemented to manufacture a multiplicity of filter strips comprising various pleat properties and sizes, as described hereinabove. In the embodiment of  FIG.  10   , the pleated filter manufacturing station  420  includes three systems  100  operating in parallel under the oversight of multiple operators  136 . It should be understood, however, that the station  420  is not limited comprising three systems  100 , but rather the station  420  may be comprised of any number of systems  100 , without limitation. Each system  100  receives pleated filter material  188  to be processed by way of a pay-out  104 , and deposits compressed filter strips  328  into a filter tote  424 . Once the filter tote  424  is filled with compressed filter strips  328 , the operator  136  may replace the filled filter tote  424  with an empty tote to continue capturing compressed filter strips  328 . Further, the operator  136  may move the filled filter tote  424  to a downstream station  428 , wherein the compressed filter strips  328  are formed into filters, as desired. 
     As shown in  FIG.  10   , each system  100  is coupled to a central data cabinet  432  by way of a junction box  436 . The central data cabinet  432  generally comprises a programmable logic controller (PLC), or an automated PLC system, that is configured to process stored instructions and operate the systems  100  accordingly by way of the junction boxes  436 . As such, the PLC incorporated into the central data cabinet  432  processes the stored instructions to cause the systems  100  to perform operations, discussed hereinabove, to form compressed filter strips  328  and deposit the strips into the filter totes  424 . Further, it is contemplated that the PLC incorporated into the central data cabinet  432  is configured to allow for human interaction, such that the systems  100  may be switched into a manual operational mode. For example, in some embodiments, the central data cabinet  432  includes a Human Machine Interface (HMI), that advantageously enables an authorized operator  136  to control each of the systems  100  based on information flow to and from the above-described I/O sensors. The HMI generally includes a touch screen that visually represents operational functions and status information pertaining to the systems  100  based on data provided by the various I/O sensors coupled with the systems  100 , as described herein. As will be appreciated, therefore, the touch screen comprising the HMI enables the authorized operator  136  to operate the systems  100  according to the data provided by the I/O sensors. 
     It is contemplated that the pleated filter manufacturing station  420  preferably is to be protected from unrestricted access by way of a safety enclosure. Such a safety enclosure may be configured to protect personnel from entering or reaching into the station  420  during operation of the systems  100 . The safety enclosure may include a curtain that surrounds the station  420  or be comprised of rigid walls that include transparent panels and designated openings. In some embodiments, the safety enclosure may be configured to detect an unauthorized entry into the station  420  and may be configured to cease operation upon detecting a breach. It is envisioned that the safety enclosure may include lockable entry ways that provide safe access to the station  420  by way of any of various means for secured access, such as entry codes, keys, key cards, and the like. 
       FIG.  11    is a block diagram illustrating an exemplary data processing system  440  that may be used with an automated filter preparation system, such as the systems  100 , to perform any of the processes or methods described herein. System  440  may represent a desktop, a tablet, a server, a mobile phone, a media player, a personal digital assistant (PDA), a personal communicator, a network router or hub, a wireless access point (AP) or repeater, a set-top box, or a combination thereof. 
     In an embodiment, illustrated in  FIG.  11   , system  440  includes a processor  444  and a peripheral interface  448 , also referred to as a chipset, to couple various components to the processor  444 , including a memory  452  and devices  460 - 472  by way of a bus or an interconnect. Processor  444  may represent a single processor or multiple processors with a single processor core or multiple processor cores included therein. Processor  444  may represent one or more general-purpose processors such as a microprocessor, a central processing unit (CPU), and the like. More particularly, processor  444  may be a complex instruction set computing (CISC) microprocessor, reduced instruction set computing (RISC) microprocessor, very long instruction word (VLIW) microprocessor, or processor implementing other instruction sets, or processors implementing a combination of instruction sets. Processor  444  may also be one or more special-purpose processors such as an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), a network processor, a graphics processor, a network processor, a communications processor, a cryptographic processor, a co-processor, an embedded processor, or any other type of logic capable of processing instructions. Processor  444  is configured to execute instructions for performing the operations and steps discussed herein. 
     Peripheral interface  448  may include a memory control hub (MCH) and an input output control hub (ICH). Peripheral interface  448  may include a memory controller (not shown) that communicates with a memory  452 . The peripheral interface  448  may also include a graphics interface that communicates with graphics subsystem  456 , which may include a display controller and/or a display device. The peripheral interface  448  may communicate with the graphics device  456  by way of an accelerated graphics port (AGP), a peripheral component interconnect (PCI) express bus, or any other type of interconnects. 
     An MCH is sometimes referred to as a Northbridge, and an ICH is sometimes referred to as a Southbridge. As used herein, the terms MCH, ICH, Northbridge and Southbridge are intended to be interpreted broadly to cover various chips that perform functions including passing interrupt signals toward a processor. In some embodiments, the MCH may be integrated with the processor  444 . In such a configuration, the peripheral interface  448  operates as an interface chip performing some functions of the MCH and ICH. Furthermore, a graphics accelerator may be integrated within the MCH or the processor  444 . 
     Memory  452  may include one or more volatile storage (or memory) devices, such as random access memory (RAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), static RAM (SRAM), or other types of storage devices. Memory  452  may store information including sequences of instructions that are executed by the processor  444 , or any other device. For example, executable code and/or data of a variety of operating systems, device drivers, firmware (e.g., input output basic system or BIOS), and/or applications can be loaded in memory  452  and executed by the processor  444 . An operating system can be any kind of operating systems, such as, for example, Windows® operating system from Microsoft®, Mac OS®/iOS® from Apple, Android® from Google®, Linux®, Unix®, or other real-time or embedded operating systems such as VxWorks. 
     Peripheral interface  448  may provide an interface to I/O devices, such as the devices  460 - 472 , including wireless transceiver(s)  460 , input device(s)  464 , audio I/O device(s)  468 , and other I/O devices  472 . Wireless transceiver  460  may be a WiFi transceiver, an infrared transceiver, a Bluetooth transceiver, a WiMax transceiver, a wireless cellular telephony transceiver, a satellite transceiver (e.g., a global positioning system (GPS) transceiver) or a combination thereof. Input device(s)  464  may include a mouse, a touch pad, a touch sensitive screen (which may be integrated with display device  456 ), a pointer device such as a stylus, and/or a keyboard (e.g., physical keyboard or a virtual keyboard displayed as part of a touch sensitive screen). For example, the input device  464  may include a touch screen controller coupled with a touch screen. The touch screen and touch screen controller can, for example, detect contact and movement or break thereof using any of a plurality of touch sensitivity technologies, including but not limited to capacitive, resistive, infrared, and surface acoustic wave technologies, as well as other proximity sensor arrays or other elements for determining one or more points of contact with the touch screen. 
     Audio I/O  468  may include a speaker and/or a microphone to facilitate voice-enabled functions, such as voice recognition, voice replication, digital recording, and/or telephony functions. Other optional devices  472  may include a storage device (e.g., a hard drive, a flash memory device), universal serial bus (USB) port(s), parallel port(s), serial port(s), a printer, a network interface, a bus bridge (e.g., a PCI-PCI bridge), sensor(s) (e.g., a motion sensor, a light sensor, a proximity sensor, etc.), or a combination thereof. Optional devices  472  may further include an imaging processing subsystem (e.g., a camera), which may include an optical sensor, such as a charged coupled device (CCD) or a complementary metal-oxide semiconductor (CMOS) optical sensor, utilized to facilitate camera functions, such as recording photographs and video clips. 
     Note that while  FIG.  11    illustrates various components of a data processing system, it is not intended to represent any particular architecture or manner of interconnecting the components; as such details are not germane to embodiments of the present disclosure. It should also be appreciated that network computers, handheld computers, mobile phones, and other data processing systems, which have fewer components or perhaps more components, may also be used with embodiments of the invention disclosed hereinabove. 
     Some portions of the preceding detailed descriptions have been presented in terms of algorithms and symbolic representations of operations on data bits within a computer memory. These algorithmic descriptions and representations are the ways used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. An algorithm is here, and generally, conceived to be a self-consistent sequence of operations leading to a desired result. The operations are those requiring physical manipulations of physical quantities. 
     It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the above discussion, it should be appreciated that throughout the description, discussions utilizing terms such as those set forth in the claims below, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system&#39;s registers and memories into other data similarly represented as physical quantities within the computer system&#39;s memories or registers or other such information storage, transmission or display devices. 
     The techniques shown in the figures can be implemented using code and data stored and executed on one or more electronic devices. Such electronic devices store and communicate (internally and/or with other electronic devices over a network) code and data using computer-readable media, such as non-transitory computer-readable storage media (e.g., magnetic disks; optical disks; random access memory; read only memory; flash memory devices; phase-change memory) and transitory computer-readable transmission media (e.g., electrical, optical, acoustical or other form of propagated signals—such as carrier waves, infrared signals, digital signals). 
     The processes or methods depicted in the preceding figures may be performed by processing logic that comprises hardware (e.g. circuitry, dedicated logic, etc.), firmware, software (e.g., embodied on a non-transitory computer readable medium), or a combination of both. Although the processes or methods are described above in terms of some sequential operations, it should be appreciated that some of the operations described may be performed in a different order. Moreover, some operations may be performed in parallel rather than sequentially. 
     While the invention has been described in terms of particular variations and illustrative figures, those of ordinary skill in the art will recognize that the invention is not limited to the variations or figures described. In addition, where methods and steps described above indicate certain events occurring in certain order, those of ordinary skill in the art will recognize that the ordering of certain steps may be modified and that such modifications are in accordance with the variations of the invention. Additionally, certain of the steps may be performed concurrently in a parallel process when possible, as well as performed sequentially as described above. To the extent there are variations of the invention, which are within the spirit of the disclosure or equivalent to the inventions found in the claims, it is the intent that this patent will cover those variations as well. Therefore, the present disclosure is to be understood as not limited by the specific embodiments described herein, but only by scope of the appended claims.