Abstract:
A sheet material conveying apparatus includes a plurality of pockets, each pocket including a setting device for adjusting a height of the pocket when the pocket is stationary so as to define a set height. A sheet delivery section delivers sheet material into the pockets and a release station for releases the sheet material from the pockets. A reset station automatically resets the pockets to the set height. A method and a sheet material pocket are also provided.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to a sheet conveying apparatus, for example, for conveying newspapers, and more particularly to a sheet conveying apparatus having pockets moving on a track. The present invention also relates to such pockets and to a method for conveying such pockets. 
     2. Background Information 
     U.S. Pat. No. 5,911,416 describes a sheet material conveying apparatus with a plurality of pockets moveable around a track to accept sheet material from sheet material feeders. These pockets permit for example a first outer section of a newspaper to first be fed into the pockets by a first sheet material feeder, and then an inner newspaper section to be inserted between the folds of the first outer newspaper section. 
     The apparatus of the &#39;416 patent uses a lift cam 20 to move a semicircular actuator gear 150 to rotate a drive shaft 110 so as to set a height for pocket feet 90 arranged on racks 80. A pawl and rachet mechanism prevents the pocket from opening. The sheet material can then be accepted and inserted into the pockets. 
     To deliver the sheet material, the pawl and ratchet mechanism can then be released by a trip cam 22. Tracks 80 move to a lower position through a biasing spring, so that feet 90 release through operation of a driver cam 130. The sheet material in the pocket can thus move out of the pocket from the bottom to be further conveyed or to be stacked. 
     U.S. Pat. No. 5,251,888 purports to describe pockets moveable along an endless path. Each pocket is provided with two vertically adjustable stops mounted displaceably in a pocket carrier. A guide member purportedly can be set to vertically adjust the stops as the pockets are moved along the endless path. 
     These patents do not provide setting devices directly on the pockets for setting when the pockets are stationary. 
     BRIEF SUMMARY OF THE INVENTION 
     An object of the present invention is to permit the pockets to be set to a desired height while stationary. 
     The present invention provides a sheet material conveying apparatus comprising a plurality of pockets, each pocket including a setting device for adjusting a height of the pocket when the pocket is stationary so as to define a set height, a sheet delivery section for delivering sheet material into the pockets, a release station for releasing the sheet material from the pockets, and a reset station for resetting the pockets to the set height. 
     The present invention permits the pockets to be set while stationary to the set height and to operate continuously at the set height. To change a pocket height, the apparatus is stopped and the setting devices for each pocket are changed to a new height. The reset station may include a movable resent incline ramp which is then also set for the new height, and may also include a lock engagement device. 
     Each pocket includes a lock device for the setting device, the lock device including a lock ring with a single point ratchet and a pawl for interacting with the lock ring. 
     The setting device preferably includes a height indicator fastened to a semicircular or reset gear, which is attached to a reset cam follower. A knob gear has an outer gear section geared to the semi-circular gear and rotatably fixed to a shaft which can set the height of the pockets. The lock ring fits around the shaft, and the knob gear is selectively engageable with the lock ring, by sliding of the knob gear axially with respect to the shaft. When the lock ring engages the knob gear, both elements rotate together. When the knob gear is disengaged from the lock ring by sliding the knob gear, for example, manually, the lock ring is free to rotate about the shaft, while the knob gear remains rotationally fixed with respect to the shaft. 
     The semicircular gear preferably is spring-loaded in a direction which causes the fingers to drop to a bottom of the pocket and release. The unlocking of the lock mechanism at the release station thus causes the fingers to release and to release any sheet material in the pocket. 
     The present invention also provides a sheet material pocket comprising a first wall, a second wall spaced apart from the first wall so as to define a sheet receiving area, at least one finger movable with respect to the first wall for defining a pocket bottom, the at least one finger releasable so that the pocket bottom opens, a shaft connected to the at least one finger for moving the at least one finger, a knob gear rotationally fixed with respect to the shaft and slidable with respect to the shaft, and a lock ring selectively engageable with the knob gear. 
     The present invention also provides a method for setting a height of a plurality of pockets comprising the steps of: 
     individually setting the height of each of the plurality of pockets using a setting device on each of the plurality of pockets so as to define a common set height; 
     locking the setting device on each of the plurality of pockets using a single point ratchet; and 
     moving the pockets in an loop. 
     The method preferably includes providing a first set of sheet material to the pockets while the pockets are moving, and then providing a second set of sheet material to the pockets. 
     The method also advantageously may include the step of releasing the pockets so that the sheet material may be delivered, for example, to a delivery station. 
     The setting device preferably is spring-loaded to force a downward movement and release of the fingers, so that a setting which causes the pocket bottom to move upwardly operates against the spring-loading. 
     The method further may include setting a height of a reset ramp to correspond to the common set height, and that a reset cam follower of the setting device interacts with the reset ramp to return the fingers to the common set height. A lock engagement device can then lock the fingers in place. The step of setting the reset ramp height to correspond to the common set height is highly advantageous, otherwise the locking device may bang or damage the single point ratchet, or even reset the pockets to an improper height. 
     The present invention provides a simple method and device for resetting pocket height and permits for manual resetting of a pocket height. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A preferred embodiment of the present invention is described below by reference to the following drawings, in which: 
     FIG. 1 shows a schematic view of a sheet material conveying apparatus according to the present invention; 
     FIG. 2 shows a partial side view of a pocket according to the present invention, with certain elements omitted for clarity purposes; 
     FIG. 3 shows a partial perspective view of a pocket according to the present invention with certain elements omitted for clarity purposes; 
     FIG. 4 shows another partial perspective view of a pocket according to the present invention with certain elements omitted for clarity purposes; 
     FIGS. 5 and 6 show more detail of the setting device for setting a finger height according to the present invention; 
     FIG. 7 shows more detail of the lock mechanism of FIG. 1; 
     FIG. 8 shows more detail of the release station of FIG. 1; and 
     FIG. 9 show more detail of the reset station of FIG.  1 . 
    
    
     DETAILED DESCRIPTION 
     FIG. 1 shows a schematic view of a sheet material conveying apparatus  100  having an endless track  101  for transporting a plurality of pockets  10  in direction  17 . Each pocket  10  includes fingers  90  for defining a pocket height, an individual height setting mechanism  8  and a releasable lock mechanism  9  for the height setting mechanism  8 . 
     At a setting area  1 , each pocket  10  can be set, for example manually, by the setting mechanism  8  to move the fingers  90  to a desired height, for example for receiving 10½ inch folded products. The pockets  10  are stationary during setting, and the setting can occur outside the setting area as well, for example by an operator moving about track  101 . Alternatively the pockets could be moved to the setting area, the apparatus stopped, and each pocket set. 
     After a pocket is set to a desired height, the setting mechanism  8  is then locked in place by the lock mechanism  9  so that the pocket height is set. After all the pockets are set, the pockets  10  are moved to pass beneath a first sheet material feed station  2  where, for example, a folded cover section  6  of a newspaper or other printed product is delivered into the pocket  10 . At a second and optional sheet material feed station  3 , a second section may be inserted between the cover section  6  to form a final printed product  7 . 
     The pockets  10  can then pass a release station  4  which releases lock mechanism  9 . Setting mechanism  8 , which is spring-loaded, then releases the fingers  90  so that the bottom of pocket  10  opens, and the products  7  are delivered, for example to a conveyor belt  11 . 
     As pockets  10  continue past release station  4 , pockets  10  pass through a reset station  5  which includes a movable incline reset ramp  25  for interacting with a reset cam follower  156  of setting mechanism  8  and a lock engagement device  35  for locking lock mechanism  9 . The pockets  10 , which are preferably all set to a common height, are then reset to the common height by the reset ramp  25 , and locked into place by lock engagement device  35  engaging lock mechanism  9 . 
     FIGS. 2,  3  and  4  show more details of pocket  10 . Pocket  10  has an upper rear wall  54  and an upper front wall  52 , in between which is an opening  56  for accepting sheet material, as well as a side wall  44 . Pocket  10  also may have a lower rear wall  64  and a lower front wall  62 . Slidable with respect to wall  52  is a rack  80 , on which fingers  90  are supported. The fingers  90  are supported on rack  80  by a pivot  96  attached to a first section  92  of finger  90 . A second section  94  of finger  90  can define a pocket bottom when fingers  90  are in a closed position. Rack  80  includes teeth  82  (FIG. 4) which interact with a gear  122  of a pinion  120  (FIGS.  3  and  4 ), which also includes a release cam  130 . Pinions  120  are located on a shaft  110  rotatably supported in walls  44  and  46 . At the wall  46  (FIG. 4, not fully shown to improve clarity), an end  111  of shaft  110  connects to a setting knob gear  140 . Knob gear  140  has an interior surface which ensures that knob gear  140  rotates in a fixed relationship with shaft  110 . However, knob gear  140  can slide axially with respect to shaft  110  for selective interlocking with a lock ring  160  (interior to gear  140  and visible only in FIG.  4 ), which forms part of lock mechanism  9 . Lock mechanism  9  also includes a pawl  209  for interacting with a single ratchet on the exterior of ring  160 . Knob gear  140  is shown in FIGS. 2,  3  and  4  only in part, with a knob for manually pulling and turning the gear not being shown. The details of knob gear  140  and its interaction with lock ring  160  will be described in more detail with respect to FIGS. 5 and 6. 
     FIG. 3 shows how fingers  90  extend through the front wall. Release cam  130  can interact with a release surface  100  (FIG. 4) of finger  90  located in an opening  86  between teeth  82  when fingers  90  are fully lowered, so that the fingers rotate away from the rear wall and release any products in the pocket  10 . Release of the fingers  90  is similar to the release of the feet in U.S. Pat. No. 5,911,416, the entire disclosure of which is hereby incorporated by reference herein. 
     FIG. 2 shows knob gear  140  interacting with a semicircular setting gear  150  having a pocket height indicator  19 , which may include numbers or other identification data next to the shown markings. On one side of semicircular gear  150  is a reset cam follower  156  held rotationally at an axis  154 . 
     A marking  18  on wall  46  provides a stationary reference point for indicator  19 . The FIG. 2 setting shows a highest possible pocket setting. By rotating knob  140  in FIG. 2 counterclockwise when lock mechanism  9  is disengaged, an operator can lower the pocket fingers  90  since shaft  110  is likewise rotated. Semicircular gear  150  and indicator  19  thus likewise rotate about axis  152  so as to indicate the height of the fingers and thus the setting of the pockets. 
     As shown in FIG. 4, semicircular gear  150  is attached to a spring  158  to spring-load gear  150  in a direction  151 , as also shown in FIG.  2 . 
     An operator selects a proper setting by pulling the knob gear  140  outwardly so as to disengage from lock ring  160  and rotating knob gear  140 , which is rotationally fixed with respect to shaft  110 . The lock ring  160  remains held in place by pawl  209 , and shaft  110  is free to rotate with respect to lock ring  160 . Pawl  209  is in a locked upward position and interacts with a single ratchet on a lock ring  160 . Once the rotation of knob gear  140 , while disengaged from the lock ring  160 , moves the fingers to the desired location, the operator releases knob gear  140  so that knob gear  140  again is rotationally fixed to lock ring  160 , for example through star gearing. The pocket is thus set to a new height. 
     FIG. 5 shows an exploded view of the details of knob gear  140 . End  111  of shaft  110  fits in interiorly toothed hole  147  of knob gear  140 . End  111  is fixed to a screw  145  which abuts knob gear  140  through a spring  146 . Knob gear  140  thus can be pulled against the force of spring  146  in the direction of arrow  240  so as to slide axially with respect to shaft  110 , however always remaining rotationally fixed with shaft  110 . 
     Interior to knob gear  140  with respect to shaft end  111  is lock ring  160 , which interacts fixedly through an interior star gear  163  with an exterior star gearing  143  of knob gear  140  when knob gear  140  is not pulled axially against the spring force of spring  146 . When pulled axially against the spring force (i.e. to the left in FIG.  5 ), knob gear  140  releases from lock ring  160 , which then is freely rotatable about shaft  110  due to a smooth inner surface section  162  which rests on shaft  110 . 
     Knob gear  140  has a knob portion  142  for permitting an operator to firmly grip the knob gear  140  and pull and turn the gear  140 . External gear teeth  141  interact with semicircular gear  150  (FIG.  2 ). Thus rotating knob gear  140  causes semicircular gear  150  to rotate. 
     Lock ring  160  has a single ratchet  164  on an external surface, which can interact with a pawl  209 , as shown in FIG.  7 . An extension  210  extends outwardly from pawl  209 , for permitting pawl  209  to move between an upward and a downward position. The pawl may be spring-loaded to favor one position, or to click into both positions. 
     FIG. 8 shows the release station  4 , which moves pawl  209  of lock mechanism  9  downwardly to a released position as a pocket passes station  4  in direction  17 . Pawl  209  thus moves away from ratchet  164 , by the interaction of a sloped surface  304  of station  4  forcing extension  210  downwardly. Once pawl  209  moves downwardly, lock ring  160  moves counterclockwise (FIG.  7 ). This counterclockwise movement occurs because of the spring loading of semicircular gear  150  in direction  151  (FIG.  2 ), which rotates knob gear  140  counterclockwise (FIG.  2 ). Since shaft lock ring  160 , knob gear  140  and shaft  111  are all rotationally fixed at the release station, they all rotate together. Shaft  111  thus moves fingers  90  downwardly through gear  122  and rack  80  until cams  130  cause the fingers to open and release the sheet material in pocket  10 . 
     Once released, the pockets  10  are in a position A as shown in FIG. 9, with the reset cam follower  156  at a top position. As pocket  10  moves past reset station  5 , reset cam follower  156  is forced downwardly by incline ramp  25  to original set position B. Because the reset ramp  25  is set to the proper height, the single ratchet  164  of lock ring  160  is in the proper position at the bottom of ramp  25  for a lock engagement device  35  to move the extension  210  of pawl  209  upwardly and engage ratchet  164 . The pockets  10  thus are properly reset for continuous operation around track  101  without any stopping or cessation necessary. 
     The reset ramp  25  preferably should be set to a height corresponding to a common pocket height of all pockets. Reset ramp  25  can be moved incrementally in direction  225 . Thus if the pockets  10  are all reset for a different pocket height, reset ramp  25  should be moved to a position corresponding to the different pocket height. Dotted lines in FIG. 9 show a midway reset ramp position for a different pocket height. In this case, the cam follower  156  is not moved as far downwardly, so that the fingers are not moved upwardly as much and the pocket height (depth) is greater; for example, resetting the height for 12 inch folded products instead of 10½ inch folded products. 
     If the ramp is not set for a proper reset height, the pawl  209  will not engage directly at the single ratchet and thus the ring will rotate until the pawl contacts the single ratchet. This rotation may cause damage to lock ring  160  (if the ramp is set too low). 
     Operation of the apparatus  100  may be summarized as follows: 
     With the apparatus in a stationary position, for each pocket  10 , knob gear  140  is pulled out and disengaged from lock ring  160  and then turned to set indicator  19  to the desired pocket height for fingers  90  with pawl  209  in an engaged position. The height should be the same for each pocket  10 . The knob gear  140  is then released, so that the lock ring  160  is again rotationally fixed with respect to knob gear  140  and shaft  110 . All of the pockets  10  thus are locked at their desired set height. The incline ramp  25  is then set to correspond to the common height for the pockets. 
     The pockets  10  then receive sheet material from delivery stations  2  and  3 . When ready for release, the pockets pass by release station  4 , which causes the pawl  209  to release and the pocket fingers to move downwardly and release the indexed or collated sheet material  7 . 
     The pockets are then reset at reset station  5 , by cam follower  156  moving downwardly along ramp  25  to move the fingers  90  up to the proper height. Lock engagement device  35  moves pawl  209  back to lock lock ring  160  and the fingers  90  in the proper height. 
     The apparatus can thus continue operating at the set height. If a new set height is desired, the machine is stopped and each pocket  10  and the incline ramp  25  reset to a new height. 
     “Ramp” as defined herein can include any cam shaped for moving a cam follower in a desired direction. “Ratchet” as defined herein can include any stop for a pawl or similar device to a pawl.