Patent Description:
Exemplary embodiments of the invention relate to systems, methods, and devices for converting sheet materials. More specifically, exemplary embodiments relate to a converting machine for converting paperboard, corrugated board, cardboard, and similar sheet materials into templates for boxes and other packaging.

Shipping and packaging industries frequently use paperboard and other sheet material processing equipment that converts sheet materials into box templates. Such a converting machine is known e.g. from <CIT>.

One advantage of such equipment is that a shipper may prepare boxes of required sizes as needed in lieu of keeping a stock of standard, pre-made boxes of various sizes. Consequently, the shipper can eliminate the need to forecast its requirements for particular box sizes as well as to store pre-made boxes of standard sizes. Instead, the shipper may store one or more bales of fanfold material, which can be used to generate a variety of box sizes based on the specific box size requirements at the time of each shipment. This allows the shipper to reduce storage space normally required for periodically used shipping supplies as well as reduce the waste and costs associated with the inherently inaccurate process of forecasting box size requirements, as the items shipped and their respective dimensions vary from time to time.

In addition to reducing the inefficiencies associated with storing pre-made boxes of numerous sizes, creating custom sized boxes also reduces packaging and shipping costs. In the fulfillment industry it is estimated that shipped items are typically packaged in boxes that are about <NUM>% larger than the shipped items. Boxes that are too large for a particular item are more expensive than a box that is custom sized for the item due to the cost of the excess material used to make the larger box. When an item is packaged in an oversized box, filling material (e.g., Styrofoam, foam peanuts, paper, air pillows, etc.) is often placed in the box to prevent the item from moving inside the box and to prevent the box from caving in when pressure is applied (e.g., when boxes are taped closed or stacked). These filling materials further increase the cost associated with packing an item in an oversized box.

Customized sized boxes also reduce the shipping costs associated with shipping items compared to shipping the items in oversized boxes. A shipping vehicle filled with boxes that are <NUM>% larger than the packaged items is much less cost efficient to operate than a shipping vehicle filled with boxes that are custom sized to fit the packaged items. In other words, a shipping vehicle filled with custom sized packages can carry a significantly larger number of packages, which can reduce the number of shipping vehicles required to ship the same number of items. Accordingly, in addition or as an alternative to calculating shipping prices based on the weight of a package, shipping prices are often affected by the size of the shipped package. Thus, reducing the size of an item's package can reduce the price of shipping the item. Even when shipping prices are not calculated based on the size of the packages (e.g., only on the weight of the packages), using custom sized packages can reduce the shipping costs because the smaller, custom sized packages will weigh less than oversized packages due to using less packaging and filling material.

Although sheet material processing machines and related equipment can potentially alleviate the inconveniences associated with stocking standard sized shipping supplies and reduce the amount of space required for storing such shipping supplies, previously available machines and associated equipment have various drawbacks. For instance, previously available machines have had a significant footprint and have occupied a lot of floor space. The floor space occupied by these large machines and equipment could be better used, for example, for storage of goods to be shipped. In addition to the large footprint, the size of the previously available machines and related equipment makes manufacturing, transportation, installation, maintenance, repair, and replacement thereof time consuming and expensive. For example, some of the existing machines and related equipment have a length of about <NUM> feet and a height of <NUM> feet.

In addition to their size, previous converting machines have been quite complex and have required access to sources of high power and compressed air. More specifically, previous converting machines have included both electrically powered components as well as pneumatic components. Including both electric and pneumatic components increases the complexity of the machines and requires the machines to have access to both electrical power and compressed air, as well as increases the size of the machines.

Accordingly, it would be advantageous to have a relatively small and simple converting machine to conserve floor space, reduce electrical power consumption, eliminate the need for access to compressed air, and reduce maintenance costs and downtime associated with repair and/or replacement of the machine.

To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:.

The embodiments described herein generally relate to systems, methods, and devices for processing sheet materials and converting the same into packaging templates. More specifically, the described embodiments relate to a compact converting machine for converting sheet materials (e.g., paperboard, corrugated board, cardboard) into templates for boxes and other packaging.

While the present disclosure will be described in detail with reference to specific configurations, the descriptions are illustrative and are not to be construed as limiting the scope of the present invention as defined in the claims. Various modifications can be made to the illustrated configurations without departing from the scope of the invention as defined by the claims. For better understanding, like components have been designated by like reference numbers throughout the various accompanying figures.

As used herein, the term "bale" shall refer to a stock of sheet material that is generally rigid in at least one direction, and may be used to make a packaging template. For example, the bale may be formed of continuous sheet of material or a sheet of material of any specific length, such as corrugated cardboard and paperboard sheet materials. Additionally, the bale may have stock material that is substantially flat, folded, or wound onto a bobbin.

As used herein, the term "packaging template" shall refer to a substantially flat stock of material that can be folded into a box-like shape. A packaging template may have notches, cutouts, divides, and/or creases that allow the packaging template to be bent and/or folded into a box. Additionally, a packaging template may be made of any suitable material, generally known to those skilled in the art. For example, cardboard or corrugated paperboard may be used as the template material. A suitable material also may have any thickness and weight that would permit it to be bent and/or folded into a box-like shape.

As used herein, the term "crease" shall refer to a line along which the template may be folded. For example, a crease may be an indentation in the template material, which may aid in folding portions of the template separated by the crease, with respect to one another. A suitable indentation may be created by applying sufficient pressure to reduce the thickness of the material in the desired location and/or by removing some of the material along the desired location, such as by scoring.

The terms "notch," "cutout," and "cut" are used interchangeably herein and shall refer to a shape created by removing material from the template or by separating portions of the template, such that a cut through the template is created.

<FIG> illustrates a perspective view of a system <NUM> that may be used to create packaging templates. System <NUM> includes one or more bales <NUM> of sheet material <NUM>. System <NUM> also includes a converting machine <NUM> that performs one or more conversion functions on sheet material <NUM>, as described in further detail below, in order to create packaging templates <NUM>. Excess or waste sheet material <NUM> produced during the conversion process may be collected in a collection bin <NUM>. After being produced, packaging templates <NUM> may be formed into packaging containers, such as boxes.

With continued reference to <FIG>, attention is also directed to <FIG>, which generally illustrate various aspects of converting machine <NUM> is greater detail. As illustrated in <FIG>, converting machine <NUM> includes a support structure <NUM> and a converting assembly <NUM> mounted on support structure <NUM>. Support structure <NUM> includes base members <NUM> that rest upon a support surface, such as a floor. Extending generally upwardly from base members <NUM> are supports <NUM>. Supports <NUM> may be integrally formed with or coupled to base members <NUM>. Converting assembly <NUM> is mounted on or coupled to supports <NUM>.

As can be seen, converting assembly <NUM> is elevated above and spaced apart from a support surface when converting assembly <NUM> is mounted on supports <NUM>. For instance, as shown in <FIG>, converting assembly <NUM> may be elevated above the height of bale <NUM>. Additionally, or alternatively, converting assembly <NUM> may be elevated to a height that would allow relatively long packaging templates <NUM> to hang therefrom without hitting the support surface below. Since converting assembly <NUM> is elevated, a platform <NUM> may optionally be connected to support structure <NUM> so that an operator may stand thereon when loading sheet material <NUM> into or servicing converting assembly <NUM>.

As shown in <FIG> and <FIG>, connected to and extending from support structure <NUM> and/or platform <NUM> are bale guides <NUM>. Bale guides <NUM> are generally vertically oriented and spaced apart from one another along the width of converting machine <NUM>. Bale guides <NUM> may facilitate proper alignment of bales <NUM> with converting machine <NUM>.

In the illustrated embodiment, for instance, converting machine <NUM> is designed to receive sheet material <NUM> from two bales 102a, 102b. Each of bales 102a, 102b may be positioned between adjacent bale guides <NUM> in order to properly align bales 102a, 102b with converting assembly <NUM>. To assist with positioning of bales 102a, 102b between adjacent bales guides <NUM>, bale guides <NUM> may be angled or may include flared portions that act to funnel bales <NUM> into the proper positions relative to converting assembly <NUM>.

In some embodiments, bale guides <NUM> may be movably or slidably connected to structure <NUM> and/or platform <NUM>, such that one or more of bale guides <NUM> may be moved along the width of converting machine <NUM> to increase or decrease the distance between adjacent bale guides <NUM>. The movability of guides <NUM> may accommodate bales <NUM> of different widths.

As shown in <FIG> and <FIG>, bales <NUM> may be disposed proximate to the backside of converting machine <NUM>, and sheet material <NUM> may be fed into converting assembly <NUM>. Sheet material <NUM> may be arranged in bales <NUM> in multiple stacked layers. The layers of sheet material <NUM> in each bale <NUM> may have generally equal lengths and widths and may be folded one on top of the other in alternating directions. In other embodiments, sheet material <NUM> may be a rolled-up single-facer corrugate or similar semi-rigid paper or plastic products, or other forms and materials.

As best seen in <FIG> and <FIG>, converting machine <NUM> may also have one or more infeed guides <NUM>. Each infeed guide <NUM> may include a lower infeed wheel <NUM> and an upper infeed wheel <NUM>. In the illustrated embodiment, lower infeed wheels <NUM> are connected to support structure <NUM> and upper infeed wheels <NUM> are connected to converting assembly <NUM>. In some embodiments, lower infeed wheels <NUM> or upper infeed wheels <NUM> may be omitted.

Each set of lower and upper infeed wheels <NUM>, <NUM> are designed and arranged to guide sheet material <NUM> into converting assembly <NUM> while creating few if any bends, folds, or creases in sheet material <NUM>. More specifically, lower infeed wheels <NUM> are positioned such that the axes of rotation of lower infeed wheels <NUM> are both vertically and horizontally offset from the axes of rotation of upper infeed wheels <NUM>. As shown, the axes of rotation of lower infeed wheels <NUM> are positioned vertically lower than the axes of rotation of upper infeed wheels <NUM>. Additionally, the axes of rotation of lower infeed wheels <NUM> are positioned horizontally further away from converting assembly <NUM> than the axes of rotation of upper infeed wheels <NUM>. Nevertheless, lower and upper infeed wheels <NUM>, <NUM> may intersect a common horizontal plane and/or a common vertical plane. In any case, lower and upper infeed wheels <NUM>, <NUM> are positioned relative to one another such that sheet material <NUM> may be fed therebetween and into converting assembly <NUM>.

Lower and upper infeed wheels <NUM>, <NUM> may rotate to facilitate smooth movement of sheet material <NUM> into converting assembly <NUM>. Additionally, lower infeed wheels <NUM> and/or upper infeed wheels <NUM> may be at least somewhat deformable so as to limit or prevent the formation of bends, folds, or creases in sheet material <NUM> as it is fed into converting assembly <NUM>. That is, lower infeed wheels <NUM> and/or upper infeed wheels <NUM> may be able to at least partially deform as sheet material <NUM> is fed therebetween. When lower infeed wheels <NUM> and/or upper infeed wheels <NUM> partially deform, lower infeed wheels <NUM> and/or upper infeed wheels <NUM> may more closely conform to the shape of sheet material <NUM>. For instance, when sheet material <NUM> is being fed into converting assembly <NUM>, sheet material <NUM> may be pulled around infeed wheels <NUM>, <NUM> (e.g., over lower infeed wheels <NUM> or under upper infeed wheels <NUM>). If infeed wheels <NUM>, <NUM> were not at least partially deformable, sheet material <NUM> may be bent or folded as it is pulled around infeed wheels. However, when infeed wheels <NUM>, <NUM> are at least partially deformable, infeed wheels <NUM>, <NUM> may deform so that the area of infeed wheels <NUM>, <NUM> that contacts sheet material <NUM> is flatter than the normal radius of infeed wheels <NUM>, <NUM>. As a result, less folds or creases will be formed in sheet material <NUM> as it is fed into converting machine <NUM>.

Lower infeed wheels <NUM> and/or upper infeed wheels <NUM> may include an outer surface formed of a deformable and/or elastic material (e.g., foam, rubber) or may include a low pressure tube/tire thereabout. The deformable/elastic material or low pressure tubes/tires may deform and/or absorb the forces applied to sheet material <NUM> in order to prevent or limit the formation of folds, bends, or creases in sheet material <NUM> during the feeding process. Additionally, the deformable/elastic material or low pressure tubes/tires may also limit noises associated with feeding sheet material <NUM> into converting assembly <NUM>.

As sheet material <NUM> is fed through converting assembly <NUM>, converting assembly <NUM> may perform one or more conversion functions (e.g., crease, bend, fold, perforate, cut, score) on sheet material <NUM> in order to create packaging templates <NUM>. Converting assembly <NUM> may include therein a converting cartridge <NUM> that feeds sheet material <NUM> through converting assembly <NUM> and performs the conversion functions thereon.

<FIG> illustrate converting cartridge <NUM> separate from the rest of converting assembly <NUM> and converting machine <NUM>. Converting cartridge <NUM> may be formed as a unit such that converting cartridge <NUM> may be selectively removed from converting assembly <NUM> as a single unit, such as for servicing or replacement. For instance, converting cartridge <NUM> may include a frame upon which the various components of converting cartridge <NUM> are assembled or to which they are connected. The converting cartridge frame may be connected to support structure <NUM> so that the converting cartridge frame does not bend or become twisted, which could adversely impact the performance of the components of converting cartridge <NUM>.

More specifically, the converting cartridge frame may be connected to support structure <NUM> at three connection points. By using three connection points, rather than four or more, the converting cartridge frame is less likely to bend during assembly or use. Optionally, each of the connection points may be flexible connections to allow converting cartridge frame to move slightly or "float" relative to support structure <NUM>. The flexible connections may be achieved using resilient materials (e.g., rubber washers) at the connection sites, for example. Additionally, the three connection points may be arranged so that two of the connection points control the longitudinal movement of the converting cartridge frame, but not the transverse movement of the converting cartridge frame. The third connection point may control the transverse movement of the converting cartridge frame, but not the longitudinal movement of the converting cartridge frame. In this way, converting cartridge <NUM> may remain straight and the functional aspects of converting cartridge <NUM> will not be adversely affected due to misalignment or other results of bending or twisting of the converting cartridge frame.

As can be seen in <FIG>, converting cartridge <NUM> may include one or more guide channels <NUM>. Guide channels <NUM> may be configured to flatten sheet material <NUM> so as to feed a substantially flat sheet thereof through converting assembly <NUM>. As shown, for instance, each guide channel <NUM> includes opposing upper and lower guide plates that are spaced apart sufficiently to allow sheet material <NUM> to pass therebetween, but also sufficiently close enough together to flatten sheet material <NUM>. In some embodiments, as shown in <FIG>, the upper and lower guide plates may be flared or spaced further apart at on opening end to facilitate insertion of sheet material <NUM> therebetween.

Some of guide channels <NUM> may be held or secured in a fixed position along the width of converting cartridge <NUM> while other guide channels <NUM> are able to move along at least a portion of the width of converting cartridge <NUM>. In the illustrated embodiment, converting cartridge <NUM> includes movable guide channels 132a and fixed guide channels 132b. More specifically, fixed guide channels 132b may be secured in place between the opposing sides of converting cartridge <NUM>. Movable guide channels 132a are disposed between left and right sides of converting cartridge <NUM> and fixed guide channels 132b such that movable guide channels 132a are able to move back and forth between the left and right sides of converting cartridge <NUM> and fixed guide channels 132b.

Movable guide channels 132a may be able to move so that guide channels 132a, 132b are able to accommodate sheet materials <NUM> of different widths. For instance, movable guide channels 132a may be able to move closer to fixed guide channels 132b when a narrower sheet material <NUM> is being converted than when a wider sheet material <NUM> is being converted. When a wider sheet material <NUM> is being converted, movable guide channels 132a may be moved away from fixed guide channels 132b so that the wider sheet material <NUM> may be passed between guide channels 132a, 132b. Movable guide channels 132a may be biased toward fixed guide channels 132b so that, regardless of how wide sheet material <NUM> is, movable and fixed guide channels 132ab, 132b will be properly spaced apart to guide sheet material <NUM> straight through converting assembly <NUM>. Movable guide channels 132a may be biased toward fixed guide channels 132b with a spring or other resilient mechanism.

Fixed guide channels 132b may act as "zero" or reference points for the positioning of converting tools, which will be discussed in greater detail below. More specifically, the converting tools may reference the positions of fixed guide channels 132b to determine the location of sheet material <NUM> or an edge thereof. When the converting tools have been properly positioned using fixed guide channels 132b as zero points, the converting tools can perform the desired conversion functions at the proper locations on sheet material <NUM>. In addition to providing an zero or reference point to the converting tools, the location of fixed guide channels 132b and/or the relative distance between guide channels 132a, 132b can also indicate to a control system the width of the sheet material <NUM> that is being used. Furthermore, allowing movable guide channel 132a to move relative to fixed guide channel 132b allows for small deviations in the width of sheet material <NUM>.

In the illustrated embodiment, converting cartridge <NUM> includes two sets of guide channels <NUM> (e.g., movable guide channel 132a and fixed guide channel 132b) that guide lengths of sheet material <NUM> through converting assembly <NUM>. It will be understood, however, that converting cartridge <NUM> may include one or multiple sets of guide channels for feeding one or multiple, side-by-side lengths of sheet material <NUM> (e.g., from multiple bales <NUM>) through converting assembly <NUM>. For instance, the illustrated guide channels 132a, 132b form a first (or left) track for feeding a first length of sheet material <NUM> from bale 102a (<FIG>) through converting assembly <NUM> and a second (or right) track for feeding a second length of sheet material <NUM> from bale 102b through converting assembly <NUM>.

As also illustrated in <FIG>, converting cartridge <NUM> also includes one or more sets of feed rollers <NUM> that pull sheet material <NUM> into converting assembly <NUM> and advance sheet material <NUM> therethrough. Each track formed by sets of guide channels <NUM> may include its own set of feed rollers <NUM>. Feed rollers <NUM> may be configured to pull sheet material <NUM> with limited or no slip and may be smooth, textured, dimpled, and/or teethed.

Feed rollers <NUM> may be positioned, angled, shaped (e.g., tapered), or adjusted so as to apply at least a slight side force on sheet material <NUM>. The side force applied to sheet material <NUM> by feed rollers <NUM> may be generally in the direction of fixed guide channel 132b. As a result, sheet material <NUM> will be at least slightly pushed toward/against fixed guide channel 132b as sheet material <NUM> is advanced through converting assembly <NUM>. One benefit of at least slightly pushing sheet material <NUM> toward/against fixed guide channel 132b is that the biasing force required to bias movable guide channel 132a toward fixed guide channel 132b (e.g., the zero point for the converting tools) is reduced.

In the illustrated embodiment, each set of feed rollers <NUM> includes an active roller 134a and a pressure roller 134b. As discussed below, active rollers 134a may be actively rolled by an actuator or motor in order to advance sheet material <NUM> through converting assembly <NUM>. Although pressure rollers 134b are not typically actively rolled by an actuator, pressure rollers 134b may nevertheless roll to assist with the advancement of sheet material <NUM> through converting assembly <NUM>.

Active rollers 134a are secured to converting cartridge <NUM> such that active rollers 134a are maintained in generally the same position. More specifically, active rollers 134a are mounted on shaft <NUM>. In contrast, pressure rollers 134b are able to be moved closer to and further away from active rollers 134a. When pressure rollers 134b are moved toward active rollers 134a, feed rollers 134a, 134b cooperate to advance sheet material <NUM> through converting assembly <NUM>. In contrast, when pressure rollers 134b are moved away from active rollers 134a, sheet material <NUM> is not advanced through converting assembly <NUM>. That is, when pressure rollers 134b are moved away from active rollers 134a, there is insufficient pressure applied to sheet material <NUM> to advance sheet material <NUM> through converting assembly <NUM>.

<FIG> illustrate one set of feed rollers <NUM> and a mechanism for moving pressure roller 134b closer to and further away from active roller 134a. As shown, pressure roller 134b is rotatably secured to pressure roller block <NUM>, which is pivotally connected to converting cartridge <NUM> via hinge <NUM>. When pressure roller block <NUM> is pivoted about hinge <NUM>, pressure roller 134b is moved toward (<FIG>) or away from (<FIG>) active roller 134a. When pressure roller 134b is moved toward active roller 134a, pressure roller 134b is activated or in an activated position. When pressure roller 134b is moved away from active roller 134a, pressure roller 134b is deactivated or in a deactivated position.

Pressure roller 134b may be selectively moved from the activated position to the deactivated position by engaging a pressure roller cam <NUM> on pressure roller block <NUM>. The engagement of pressure roller cam <NUM> will be discussed in greater detail below. Briefly, however, when sheet material <NUM> is not to be advanced through converting assembly <NUM>, pressure roller cam <NUM> may be engaged to cause pressure roller block <NUM> and pressure roller 134b to pivot about hinge <NUM> so that pressure roller 134b is moved to the deactivated position, as shown in <FIG>. Similarly, when sheet material <NUM> is to be advanced through converting assembly <NUM>, pressure roller cam <NUM> may be disengaged. Disengagement of pressure roller cam <NUM> allows pressure roller block <NUM> and pressure roller 134b to pivot about hinge <NUM> so that pressure roller 134b is moved to the activated position, as shown in <FIG>.

Pressure roller 134b may be biased toward either the activated position or the deactivated position. For instance, pressure roller 134b may be biased toward the activated position so that pressure roller 134b remains in the activated position unless actively moved to the deactivated position (e.g., by engagement of pressure roller cam <NUM>). Alternatively, pressure roller 134b may be biased toward the deactivated position so that pressure roller 134b remains in the deactivated position unless actively moved to the activated position.

In the illustrated embodiment, once pressure roller 134b has been moved to the deactivated position, pressure roller 134b may be selectively held in the deactivated position. For instance, when pressure roller 134b is moved to the deactivated position, a locking mechanism <NUM> may hold pressure roller 134b in the deactivated position until it is desired to move pressure roller 134b to the activated position. By way of example, locking mechanism <NUM> may be an electromagnet that holds pressure roller block <NUM> and pressure roller 134b in the deactivated position. When it is desired to move pressure roller 134b to the activated position, locking mechanism <NUM> may be released, such as by deactivating its magnetic force. The magnetic force may be deactivated by turning off the electromagnetic field of the electromagnet. Rather than using an electromagnet, a permanent magnet may be used to hold pressure roller block <NUM> and pressure roller 134b in the deactivated position, When it is desired to move pressure roller 134b to the activated position, the magnetic force of the permanent magnet may be deactivated by applying an electric field around the magnet that counteracts the magnet's magnetic field. Alternatively, locking mechanism <NUM> may be a mechanical mechanism, solenoid, or other device than can selectively hold pressure roller 134b in the deactivated position. Locking mechanism <NUM> enables pressure roller 134b to be held in the deactivated position without require the continuous engagement of pressure roller cam <NUM>.

When it is desired to advance sheet material <NUM> through converting assembly <NUM>, pressure roller 134b may be moved to the activated position as described above. One or both of feed rollers <NUM> may be actively rotated to advance sheet material <NUM>. For instance, in the illustrated embodiment, shaft <NUM> (on which active roller 134a is mounted) is connected to a stepper motor <NUM> (<FIG>) via belt <NUM>. Stepper motor <NUM> may rotate belt <NUM>, which causes shaft <NUM> and active roller 134a to rotate. When pressure roller 134b is in the activated position, pressure roller 134b presses sheet material <NUM> against active roller 134a, which causes sheet material <NUM> to advance through converting assembly <NUM>. In contrast, when pressure roller 134b is in the deactivated position, pressure roller 134b does not press sheet material <NUM> against active roller 134a. Without pressure roller 134b pressing sheet material <NUM> against active roller 134a, active roller 134a may rotate/spin underneath sheet material <NUM> without advancing sheet material <NUM> through converting assembly <NUM>.

Returning attention to <FIG>, it can be seen that converting cartridge <NUM> includes one or more converting tools, such as a crosshead <NUM> and longheads <NUM>, that perform the conversion functions (e.g., crease, bend, fold, perforate, cut, score) on sheet material <NUM> in order to create packaging templates <NUM>. Some of the conversion functions may be made on sheet material <NUM> in a direction substantially perpendicular to the direction of movement and/or the length of sheet material <NUM>. In other words, some conversion functions may be made across (e.g., between the sides) sheet material <NUM>. Such conversions may be considered "transverse conversions.

To perform the transverse conversions, crosshead <NUM> may move along at least a portion of the width of converting cartridge <NUM> in a direction generally perpendicular to the direction in which sheet material <NUM> is fed through converting assembly <NUM> and/or the length of sheet material <NUM>. In other words, crosshead <NUM> may move across sheet material <NUM> in order to perform transverse conversions on sheet material <NUM>. Crosshead <NUM> may be movably mounted on a track <NUM> to allow crosshead <NUM> to move along at least a portion of the width of converting cartridge <NUM>.

<FIG> illustrate perspective views of crosshead <NUM> and a portion of track <NUM> separate from the rest of converting cartridge <NUM>. Crosshead <NUM> includes a body <NUM> with a slider <NUM> and a sensor <NUM>. Slider <NUM> connects crosshead <NUM> to track <NUM> to allow crosshead <NUM> to move back and forth along track <NUM>. Crosshead <NUM> also includes one or more converting instruments, such as a cutting wheel <NUM> and creasing wheels <NUM>, which may perform one or more transverse conversions on sheet material <NUM>. More specifically, as crosshead <NUM> moves back and forth over sheet material <NUM>, cutting wheel <NUM> and creasing wheels <NUM> may create creases, bends, folds, perforations, cuts, and/or scores in sheet material <NUM>.

While creasing wheels <NUM> are able to rotate, creasing wheels <NUM> may remain in substantially the same vertical position relative to body <NUM>. In contrast, cutting wheel <NUM> may be selectively raised and lowered relative to body <NUM>. For instance, as shown in <FIG>, cutting wheel <NUM> may be raised so that cutting wheel <NUM> does not cut sheet material <NUM> as crosshead <NUM> moves over sheet material <NUM>. Alternatively, as shown in <FIG>, cutting wheel <NUM> may be lowered in order to cut sheet material <NUM> as crosshead <NUM> moves over sheet material <NUM>.

In the illustrated embodiment, cutting wheel <NUM> is rotatably mounted on a cutting wheel frame <NUM>. Cutting wheel frame <NUM> is movably connected to body <NUM>. In particular, cutting wheel frame <NUM> is slidably mounted on one or more shafts <NUM>. Cutting wheel frame <NUM> is held on shafts <NUM> and biased toward the raised position by one or more springs <NUM> that are connected between body <NUM> and cutting wheel frame <NUM>.

One or more solenoids <NUM> may be used to selectively move cutting wheel frame <NUM> and cutting wheel <NUM> from the raised position (<FIG>) to the lowered position (<FIG>). Solenoids <NUM> each include a solenoid plunger <NUM> that extends and retracts upon activation and deactivation of solenoids <NUM>. When solenoid plungers <NUM> are retracted, cutting wheel frame <NUM> and cutting wheel <NUM> are raised (via springs <NUM> and/or the normal forces from sheet material <NUM>) so that cutting wheel <NUM> does not cut sheet material <NUM>. In contrast, when solenoids <NUM> are activated, solenoid plungers <NUM> extend, thereby causing cutting wheel frame <NUM> and cutting wheel <NUM> to be lowered (<FIG>) so that cutting wheel <NUM> cuts sheet material <NUM>.

While the present disclosure references the use of solenoids to move various components, such reference is made merely by way of example. Other types of actuators may be used to perform the functions described herein. For instance, other linear or nonlinear actuators may be used, including voice coils, linear motors, rotational motor, lead screws, and the like. Accordingly, reference to solenoids is not intended to limit the scope of the present invention. Rather, the present invention may employ solenoids or any other actuator capable of performing the functions described herein in connection with solenoids.

As shown in <FIG>, converting cartridge <NUM> includes a support plate <NUM> positioned below crosshead <NUM>. Support plate <NUM> supports sheet material <NUM> as cutting wheel <NUM> and creasing wheels <NUM> perform the transverse conversions on sheet material <NUM>. Additionally, support plate <NUM> includes a channel <NUM> that is aligned with and able to receive at least a portion of cutting wheel <NUM>. When cutting wheel <NUM> is lowered to cut through sheet material <NUM>, cutting wheel <NUM> may extend through sheet material <NUM> and at least partially into channel <NUM>. As a result, cutting wheel <NUM> may extend entirely through sheet material <NUM> without engaging support plate <NUM>, which could result in undue wear.

In order to reduce the amount of force required of solenoids <NUM> (and thus the power required to activate solenoids <NUM>) to cut through sheet material <NUM>, the kinetic energy of the moving components of crosshead <NUM> may be used to assist in cutting through sheet material <NUM>. More specifically, the activation of solenoids <NUM> causes solenoid plungers <NUM> to move as they extend out of solenoids <NUM>. The movement of solenoid plungers <NUM> causes cutting wheel frame <NUM> and cutting wheel <NUM> to move as well. As solenoid plungers <NUM>, cutting wheel frame <NUM>, and cutting wheel <NUM> begin to move, they build up momentum, and thus kinetic energy, until cutting wheel <NUM> engages sheet material <NUM>. When cutting wheel <NUM> engages sheet material <NUM>, the built-up kinetic energy of solenoid plungers <NUM>, cutting wheel frame <NUM>, and cutting wheel <NUM> works with the force provided by solenoids <NUM> to cut through sheet material <NUM>. Thus, utilizing the kinetic energy of the components of crosshead <NUM> in this way reduces the forces required of solenoids <NUM>.

In some converting machines, a cut is made in a material by moving a cutting tool over the material to a location where the cut needs to begin. Prior to initiating the cut, the cross movement of the cutting tool is stopped. Then the cutting tool is lowered to penetrate the material and the cross movement of the cutting tool is resumed. In such a situation, a relatively significant amount of force may be required to lower the cutting tool and penetrate the material. This is partially due to the fact that some of the force used to lower the cutting tool will be used to compress the material before the cutting tool actually penetrates through the material. The compression of the material is at least partially due to a relatively large chord of the cutting tool trying to cut through the material at the same time.

In contrast, converting machine <NUM> may include an "on-the-fly" mode where the movement of crosshead <NUM> over sheet material <NUM> and the lowering of cutting wheel <NUM> are combined to initiate a cut through sheet material <NUM>. In an on-the-fly mode, crosshead <NUM> may begin moving across sheet material <NUM> toward the location where a cut needs to be made in sheet material <NUM>. Rather than stopping the cross movement of crosshead <NUM> before beginning to lower cutting wheel <NUM>, cutting wheel <NUM> is lowered while crosshead <NUM> continues to move across sheet material <NUM>. The cross movement of crosshead <NUM> and the lowering of cut wheel <NUM> may be timed so that cutting wheel <NUM> engages and initiates a cut in sheet material <NUM> at the desired location.

In an on-the-fly mode, less force is required of solenoids <NUM> to lower cutting wheel <NUM> in order to initiate a cut through sheet material <NUM>. The decreased force is at least partially due to a smaller chord of cutting wheel <NUM> being used to initiate the cut in sheet material <NUM>. More specifically, as crosshead <NUM> moves across sheet material <NUM> and cutting wheel <NUM> is lowered into engagement with sheet material <NUM>, only a leading edge of cutting wheel <NUM> will be used to initiate the cut. As a result, less of the force used to lower cutting wheel <NUM> will be expended in compressing sheet material <NUM> before cutting wheel <NUM> is able to penetrate sheet material <NUM>.

Furthermore, a pulse-width modulation (PWM) circuit board or other voltage adjusting electric components may generate sufficiently high currents within solenoids <NUM> so that solenoids <NUM> are able to generate enough force to cut through sheet material <NUM>. Once cutting wheel <NUM> has initiated a cut through sheet material, the PWM circuit board or other voltage adjusting electric components may reduce the current in solenoids <NUM>, while still enabling solenoids <NUM> to maintain cutting wheel <NUM> in the lowered position. In other words, a relatively high current may be generated in solenoids <NUM> to provide enough force to enable cutting wheel <NUM> to penetrate sheet material <NUM>. Once cutting wheel <NUM> has penetrated sheet material <NUM>, the current in solenoids <NUM> may be reduced, while still enabling solenoids <NUM> to continue cutting through sheet material <NUM>.

The ability to use varying voltages/currents to initiate and continue making a cut in sheet material <NUM> is made possible, at least in part, by the characteristics of solenoids <NUM>. Solenoids have unique force-to-stroke curve profiles. In the beginning of a solenoid's stroke, the solenoid has a relatively limited force. Further into the solenoid's stroke, the force increases dramatically. Accordingly, a relatively high voltage/current can be used during the solenoid's stroke in order to generate the relative large force at the end of the stroke so that the cutting wheel may penetrate the sheet material. At the end of the solenoid's stroke (e.g., when the plunger is fully extended), the voltage/current can be reduced while still maintaining a relative high holding force. That is, even with the reduced voltage/current, the solenoid may have enough force to hold the cutting wheel in place so that the cutting wheel continues cutting sheet material <NUM>.

Being able to adjust to the voltage level supplied to solenoids <NUM> (and thus the current in solenoids <NUM>) can also be beneficial for various reasons. For instance, less power can be used to achieve the desired results. For example, high voltage can be used for a short time in order to initiate a cut, while lower voltage can be used to continue making the cut. Not only does this reduce the overall amount of power required, but it can improve the performance of certain components. For instance, limiting high voltage supplies to relatively short durations can prevent the temperature of solenoids <NUM> from increasing or overheating due to high currents in solenoids <NUM>. Higher temperatures or overheating of solenoids <NUM> can cause damage thereto and/or reduce their activation force. The ability to adjust the voltage can also be beneficial when activating solenoids <NUM> when no sheet material <NUM> is below cutting wheel <NUM> ("dry-firing"). For instance, if solenoids <NUM> were dry-fired with a high voltage, cutting wheel <NUM> may be lowered too far or too rapidly, potentially resulting in damage and/or excessive mechanical wear.

When crosshead <NUM> has finished performing the transverse conversions on sheet material <NUM>, crosshead <NUM> may be used to move pressure roller 134b from the activated position to the deactivated position. More specifically, when it is desired to stop advancing sheet material <NUM>, crosshead <NUM> may be moved adjacent to pressure roller block <NUM> such that a portion of crosshead <NUM> engages pressure roller cam <NUM>. As noted above, engagement of pressure roller cam <NUM> causes pressure roller block <NUM> and pressure roller <NUM> to pivot about hinge <NUM> to the deactivated position. As shown in <FIG>, crosshead <NUM> includes a horizontally oriented wheel <NUM> that can engage pressure roller cam <NUM> to move pressure roller 134b to the deactivated position.

In addition to being able to create transverse conversions with crosshead <NUM>, conversion functions may also be made on sheet material <NUM> in a direction substantially parallel to the direction of movement and/or the length of sheet material <NUM>. Conversions made along the length of and/or generally parallel to the direction of movement of sheet material <NUM> may be considered "longitudinal conversions.

Longheads <NUM> may be used to create the longitudinal conversions on sheet material <NUM>. More specifically, longheads <NUM> may be selectively repositioned along the width of converting cartridge <NUM> (e.g., back and forth in a direction that is perpendicular to the length of sheet material <NUM>) in order to properly position longheads <NUM> relative to the sides of sheet material <NUM>. By way of example, if a longitudinal crease or cut needs to be made <NUM>,<NUM> (two inches) from one edge of sheet material <NUM> (e.g., to trim excess material off of the edge of sheet material <NUM>), one of longheads <NUM> may be moved perpendicularly across sheet material <NUM> to properly position longhead <NUM> so as to be able to make the cut or crease at the desired location. In other words, longheads <NUM> may be moved transversely across sheet material <NUM> to position longheads <NUM> at the proper location to make the longitudinal conversions on sheet material <NUM>.

<FIG> illustrates a close up view of a portion of converting cartridge <NUM>, including one of longheads <NUM>. As can be seen, longhead <NUM> includes a body <NUM> with a slider <NUM>. Slider <NUM> connects longhead <NUM> to a track <NUM> to allow longhead <NUM> to move back and forth along at least a portion of the width of converting cartridge <NUM>. Longhead <NUM> may include one or more converting instruments, such as cutting wheel <NUM> and creasing wheel <NUM>, which may perform the longitudinal conversions on sheet material <NUM>. More specifically, as sheet material <NUM> moves underneath longhead <NUM>, cutting wheel <NUM> and creasing wheel <NUM> may create creases, bends, folds, perforations, cuts, and/or scores in sheet material <NUM>.

As can be seen in <FIG> and <FIG>, converting assembly <NUM> may also include a converting roller <NUM> positioned below longheads <NUM> so that sheet material <NUM> passes between converting roller <NUM> and cutting wheel <NUM> and creasing wheel <NUM>. Converting roller <NUM> may support sheet material <NUM> while the longitudinal conversions are performed on sheet material <NUM>. Additionally, converting roller <NUM> may advance packaging templates <NUM> out of converting assembly <NUM> after the conversion functions are completed. Additional detail regarding converting roller <NUM> will be provided below.

Cutting wheel <NUM> and creasing wheel <NUM> are rotatably connected to body <NUM> and oriented to be able to make the longitudinal conversions. In some embodiments, cutting wheel <NUM> and creasing wheel <NUM> may be pivotally connected to body <NUM> and/or longhead <NUM> may be pivotally connected to slider <NUM>. As sheet material <NUM> advances through converting assembly <NUM>, sheet material <NUM> may not advance in a perfectly straight line. By allowing longhead <NUM>, cutting wheel <NUM>, and/or creasing wheel <NUM> to pivot, the orientation of cutting wheel <NUM> and creasing wheel <NUM> may change to more closely follow the feeding direction of sheet material <NUM>. Additionally, the braking force (discussed below) required to maintain longhead <NUM> in place may be reduced because sheet material <NUM> will apply less side force to cutting wheel <NUM> and creasing wheel <NUM>. Similarly, the biasing force required to bias movable guide channels 132a toward fixed channels 132b may likewise be reduced.

When longhead <NUM> has been repositioned at the desired location along the width of converting cartridge <NUM>, longhead <NUM> may be secured in place. More specifically, once positioned as desired, longhead <NUM> may be secured to a brake belt <NUM>, other another portion of converting cartridge <NUM>. <FIG> and <FIG> illustrate cross-sectional views of longhead <NUM> and one exemplary mechanism for securing longhead <NUM> to brake belt <NUM>. As can be seen, longhead <NUM> includes a brake pivot arm <NUM> that is pivotally connected to body <NUM>. A spring <NUM> is connected between brake pivot arm <NUM> and body <NUM> to bias brake pivot arm <NUM> to the locked position, shown in <FIG>. When brake pivot arm <NUM> is in the locked position, an engagement member <NUM> is held against or pressed into brake belt <NUM>. Spring <NUM> may bias brake pivot arm <NUM> toward the locked position with sufficient force that engagement member <NUM> is held against or pressed into brake belt <NUM> with sufficient force to prevent longhead <NUM> from moving along the length of track <NUM>.

When it is desired to reposition longhead <NUM> along the length of track <NUM>, brake pivot arm <NUM> may be pivoted to disengage engagement member <NUM> from brake belt <NUM>, as shown in <FIG>. The pivoting of brake pivot arm <NUM> may be accomplished using a solenoid <NUM> that is mounted on crosshead <NUM> (<FIG>, <FIG>, <FIG>). In order to pivot brake pivot arm <NUM> with solenoid <NUM>, crosshead <NUM> is first moved into alignment with longhead <NUM>. Solenoid <NUM> is then activated, which causes a solenoid plunger <NUM> to extend and engage brake pivot arm <NUM>, as shown in <FIG>. As solenoid plunger <NUM> engages brake pivot arm <NUM>, brake pivot arm <NUM> pivots, which causes engagement member <NUM> to disengagement brake belt <NUM>.

Notably, spring <NUM> is connected between body <NUM> and brake pivot arm <NUM> in such a way that the force required of solenoid <NUM> to pivot brake pivot arm <NUM> remains substantially constant. As brake pivot arm <NUM> is pivoted from the locked position (<FIG>) to the unlocked position (<FIG>), spring <NUM> is stretched. As spring <NUM> stretches, the force that would normally be required to continue pivoting pivot brake arm <NUM> would continue to increase. However, as brake pivot arm <NUM> pivots, the connection location between spring <NUM> and brake pivot arm <NUM> begins to move over the pivot location of brake pivot arm <NUM> and the connection location between spring <NUM> and body <NUM> so that spring <NUM> is oriented more vertically. The more vertical orientation of spring <NUM> reduces the horizontal force that spring <NUM> applies to brake pivot arm <NUM>. Thus, the increased force normally required to stretch spring <NUM> is generally offset by the reduced horizontal force applied to brake pivot arm <NUM> by spring <NUM>.

With engagement member <NUM> disengages from brake belt <NUM>, longhead <NUM> may be repositioned along the length of track <NUM>. Rather than equipping longhead <NUM> with an actuator dedicated to repositioning longhead <NUM>, crosshead <NUM> may be used to reposition longhead <NUM>. More specifically, crosshead <NUM> and longhead <NUM> may be connected together or otherwise engaged such that movement of crosshead <NUM> results in movement of longhead <NUM>. This arrangement, therefore, only requires the ability to actively control crosshead <NUM>, while longhead <NUM> may be passively moved by crosshead <NUM>. Furthermore, longheads <NUM> do not require electric sensors and electric or pneumatic actuators. As a result, longheads <NUM> do not need to be connected to electrical power or compressed air, such as with electrical cables/wires and hoses in a cable chain. This enables a much more cost effective design of longheads <NUM>, as well as enables a more cost effective manufacturing and maintenance friendly design of the whole converting assembly <NUM> and converting machine <NUM>.

One exemplary manner for selectively connecting longhead <NUM> to crosshead <NUM> is shown in <FIG>. When crosshead <NUM> is aligned with longhead <NUM> and brake pivot arm <NUM> is pivoted (e.g., to disengage engagement member <NUM> from brake belt <NUM>), a portion of brake pivot arm <NUM> may engage crosshead <NUM> so as to connect longhead <NUM> to crosshead <NUM>. More specifically, an extension <NUM> on brake pivot arm <NUM> may pivot into a notch <NUM> on body <NUM> of crosshead <NUM>. As long as extension <NUM> is positioned within notch <NUM>, the movements of crosshead <NUM> and longhead <NUM> will be linked together. That is, when extension <NUM> is positioned within notch <NUM> and crosshead <NUM> is moved, longhead <NUM> will move with crosshead <NUM>.

<FIG> show notch <NUM> formed on the side of body <NUM> of crosshead <NUM>. As can be seen, notch <NUM> can include a flared opening that can assist with guiding extension <NUM> into notch <NUM>. For instance, if longhead <NUM> has moved slightly since last being positioned, the flared opening can guide extension <NUM> in notch <NUM> and thereby correct minor position errors of longhead <NUM>. Once crosshead <NUM> has repositioned longhead <NUM>, extension <NUM> is released from notch <NUM> and longhead <NUM> is locked into place. Notably, longhead <NUM> will be locked into place at the correct location since any positioning errors of longhead <NUM> will have been corrected when extension <NUM> was pivoted into notch <NUM>. As a result, converting machine <NUM> can be operating without requiring frequent resetting or manual adjustments to longheads <NUM>.

Notch <NUM> can also include substantially vertical interior walls. The vertical interior walls of notch <NUM> apply the forces to extension <NUM> that result in the movement of longhead <NUM>. Notably, the vertically walls of notch <NUM> only apply horizontal forces on extension <NUM>. Since notch <NUM> does not apply any downward forces on extension <NUM>, the force required of solenoid <NUM> to maintain brake pivot arm <NUM> in the unlocked position is reduced. In connection therewith, a relatively low amount of power is required by solenoid <NUM> to maintain brake pivot arm <NUM> in the unlocked position while longhead <NUM> is moved.

Like solenoids <NUM>, the kinetic energy of solenoid plunger <NUM> may be used to reduce the amount of force required of solenoid <NUM> (and thus the power required to activate solenoid <NUM>). More specifically, the activation of solenoid <NUM> causes solenoid plunger <NUM> to move as it extends out of solenoid <NUM>. As solenoid plunger <NUM> begins to move, it builds up momentum, and thus kinetic energy. When plunger <NUM> engages brake pivot arm <NUM>, the built-up kinetic energy of plunger <NUM> works with the force provided by solenoid <NUM> to pivot brake pivot arm <NUM> so as to disengage engagement member <NUM> from brake belt <NUM>. In addition to disengaging engagement member <NUM>, pivoting of brake pivot arm <NUM> causes brake pivot arm <NUM> to build up kinetic energy. The combined kinetic energy of plunger <NUM> and brake pivot arm <NUM> similarly reduces the force required of solenoid to correct minor position errors of longhead <NUM> and to connect crosshead <NUM> to longhead <NUM>. Specifically, the kinetic energy of plunger <NUM> and brake pivot arm <NUM> facilitates insertion of extension <NUM> into notch <NUM>, which both corrects position errors of longhead <NUM> and connects crosshead <NUM> and longhead <NUM> together.

As shown in <FIG>, the illustrated embodiment includes two longheads <NUM>. It will be appreciated, however, the converting cartridge <NUM> may include one or more longheads <NUM>. Regardless of how many longheads <NUM> are included, crosshead <NUM> may be used to selectively move each longhead <NUM> individually. A normal setup for creating regular slotted box (RSC) packaging templates requires at least three longheads, of which two are equipped with crease tools, and one with a side-trim knife. In order to enable side-trimming on the outer side of each track of the sheet material, a forth longhead with a knife is added on the opposite side of the first knife longhead. Furthermore, in order to avoid having to move the longheads long distances from one track to the other, two additional crease tools may be added in the middle. Thereby a set of two crease longheads and one cut longhead are mainly used for one track, and another identical - but mirrored - setup is used mainly for the other track. This also enables conversion to more complicated packaging template designs, where the four creasing longheads can each create a longitudinal crease, while either of the cut longheads may be used for side-trimming. A seventh longhead equipped with a knife may be added in the middle, thereby enabling two packaging templates to be created in parallel, side-by-side.

As noted above, crosshead <NUM> includes a sensor <NUM>. Sensor <NUM> may be used to detect the presence of longheads <NUM> adjacent to crosshead <NUM>. For instance, when it is desired to reposition a longhead <NUM>, crosshead <NUM> may move across converting cartridge <NUM> to the location where a longhead <NUM> is supposed to be (according to a control system). Once crosshead <NUM> is so positioned, sensor <NUM> may be used to confirm that longhead <NUM> is at the proper position. Upon detection of the longhead <NUM> by sensor <NUM>, solenoid <NUM> may be activated so as to release the braking mechanism of the longhead <NUM> and connect the longhead <NUM> to crosshead <NUM>. Once crosshead <NUM> has moved the longhead <NUM> to the desired location, sensor <NUM> may be used to confirm the proper positioning of the longhead <NUM> at the desired location (either before or after disengagement between crosshead <NUM> and longhead <NUM>).

Sensor may also be used to count the number of longheads <NUM> and determine the current position of each longhead <NUM>. Converting machine <NUM> may include control circuitry or be connected to a computer that monitors the positions of longheads <NUM> and controls crosshead <NUM>. In the event that sensor <NUM> does not detect a longhead <NUM> at the last known position, the control circuitry can direct crosshead <NUM> to move across converting cartridge <NUM> so that sensor <NUM> may detect the location of the missing longhead <NUM>. If sensor <NUM> is unable to locate each of the longheads <NUM> after a predetermined number of attempts, an error message may be generated to direct an operator to manually locate the longheads <NUM> or call for maintenance or service.

In addition to detecting and monitoring the location of longheads <NUM>, crosshead <NUM> may include a sensor <NUM> (<FIG>) that detects the position of guide channels <NUM>. For instance, as crosshead <NUM> move back and forth across converting cartridge <NUM>, sensor <NUM> may detect the current location of each guide channel <NUM>. Based on the detected locations, the control circuitry may determine if each guide channel <NUM> is in the proper location. For example, if the detected location of fixed guide channel 132b does not match the previously set location, it may be that fixed guide channel 132b has slipped or an operator adjusted fixed guide channel 132b without updating the control circuitry. In such a case, the control circuitry may generate an error message indicating that fixed guide channel 132b needs to be repositioned. Alternatively, the control circuitry may simply update the stored location of fixed guide channel 132b to the detected location and thereby determine the width of the sheet material <NUM> is being used.

Sensor <NUM> may similarly detect the current location of movable guide channel 132a so that the control circuitry may determine if movable guide channel 132a is in the proper position. As noted above, movable guide channel 132a is able to move to accommodate sheet material <NUM> of different widths. As a result, movable guide channel 132a may not be in the proper location if sheet material <NUM> has run out, if sheet material <NUM> is damaged, or converting machine <NUM> is loaded with sheet material <NUM> that is wider or narrower than what control circuitry is set for. In such cases, the control circuitry may generate an error message indicating that fixed guide channel 132b needs to be repositioned, new sheet material <NUM> needs to be loaded, or the like.

As noted above, converting roller <NUM> supports sheet material <NUM> as longheads <NUM> perform the longitudinal conversions on sheet material <NUM>. Longheads <NUM> and converting roller <NUM> may be positioned relative to one another such that the conversion functions are performed on sheet material <NUM> as sheet material <NUM> passes between longheads <NUM> and converting roller <NUM>. For instance, as shown in <FIG>, cutting wheel <NUM> may extend into converting roller <NUM> so that there is no clearance between cutting wheel <NUM> and converting roller <NUM>. As a result, sheet material <NUM> will be cut as it passes cutting wheel <NUM>. Since creasing wheel <NUM> does not need to penetrate through sheet material <NUM>, creasing wheel <NUM> may be positioned such that there is some clearance between creasing wheel <NUM> and converting roller <NUM>.

Other arrangements of converting roller <NUM>, cutting wheel <NUM>, and creasing wheel <NUM> are also possible. For instance, in order to reduce or eliminate contact between cutting wheel <NUM> and converting roller <NUM>, the rotational axis of cutting wheel <NUM> may be horizontally offset from the rotational axis of converting roller <NUM> such that cutting wheel <NUM> is positioned slightly behind converting roller <NUM>. By horizontally offsetting cutting wheel <NUM> from converting roller <NUM>, cutting wheel <NUM> may be positioned lower without extending further (or at all) into converting roller <NUM>. The lower positioning of cutting wheel <NUM> may also ensure that cutting wheel <NUM> cuts through the entire thickness of sheet material <NUM>.

In the case where cutting wheel <NUM> and/or creasing wheel <NUM> contact or extend into converting roller <NUM>, it may be necessary to separate or otherwise disengage converting roller <NUM> and cutting wheel <NUM> and/or creasing wheel <NUM> before repositioning longheads <NUM>. With attention to <FIG> and <FIG>, one exemplary mechanism is illustrated that may be used to selectively separate converting roller <NUM> and cutting wheel <NUM> and/or creasing wheel <NUM>. In the illustrated embodiment, converting roller <NUM> is selectively raised and lowered to engage or disengage converting roller <NUM> from cutting wheel <NUM> and/or creasing wheel <NUM>. Thus, rather than raising each longhead <NUM> to enable movement of each longhead <NUM>, converting roller <NUM> may be lowered as shown in <FIG> to disengage all of longheads <NUM> at once and allow longheads <NUM> to be repositioned as desired. Lowering converting roller <NUM> to disengage longheads <NUM> eliminates any need to have sensors, actuators, or cables chains (for electrical power, compressed air) connected to longheads <NUM>, giving the advantages noted above. This is especially important in an all-electric machine that does not include pneumatic actuators or that does not have access to compressed air.

As shown in <FIG>, converting roller <NUM> is mounted on shaft <NUM>. Like feed roller 134a, converting roller <NUM> is rotated by stepper motor <NUM> via belt <NUM>. When stepper motor <NUM> rotates belt <NUM> in a first direction (e.g., clockwise as shown in <FIG>), converting roller <NUM> is likewise rotated in the first direction, which advances sheet material <NUM> under longheads <NUM> and/or advances packaging templates <NUM> out of converting assembly <NUM>. In contrast, when stepper motor <NUM> rotates belt <NUM> in a second direction (e.g., counterclockwise as shown in <FIG>), converting roller <NUM> is lowered to the position shown in <FIG>.

<FIG> illustrate (separate from the rest of converting cartridge <NUM>) converting roller <NUM> and the mechanism used to lower converting roller <NUM>. As noted, converting roller <NUM> is mounted on shaft <NUM>. A first end of shaft <NUM> extends through a bearing block <NUM> and has a gear <NUM> mounted thereon. As shown in <FIG>, belt <NUM> engages gear <NUM> in order to rotate shaft <NUM> and converting roller <NUM>. A second end of shaft <NUM> extends into a bearing block <NUM>.

<FIG> illustrate an eccentric bearing assembly <NUM> that enables converting roller <NUM> to rotate in the first direction and be lowered when rotated in the second direction. <FIG> illustrate bearing block <NUM> and eccentric bearing assembly <NUM> mounted on the first end of shaft <NUM>. More specifically, <FIG> illustrates a side view of eccentric bearing assembly <NUM> disposed in bearing block <NUM>, <FIG> illustrates a cross sectional view of eccentric bearing assembly <NUM> and bearing block <NUM>, and <FIG> illustrate exploded views of eccentric bearing assembly <NUM> and bearing block <NUM>. As shown in <FIG>, the second end of shaft <NUM> also has an eccentric bearing assembly <NUM> that is substantially similar to eccentric bearing assembly <NUM>.

As shown in <FIG>, bearing block <NUM> includes a generally square recess <NUM> in which eccentric bearing assembly <NUM> is positioned and is able to rotate. Bearing block <NUM> also includes a generally rectangular recess <NUM> formed therein. Shaft <NUM> extends through recesses <NUM>, <NUM> and has eccentric bearing assembly <NUM> and a bearing <NUM> mounted thereon, as shown in <FIG>. Bearing <NUM> is mounted on shaft <NUM> and positioned within recess <NUM> to enable shaft <NUM> to move within recess <NUM> (e.g., when converting roller <NUM> is raised or lowered) in a low friction and long lasting manner.

Eccentric bearing assembly <NUM> includes a one-way bearing <NUM>, an eccentric bearing block <NUM>, and a two-way bearing <NUM>. As shown, eccentric bearing block <NUM> includes a recess <NUM> in which one-way bearing <NUM> is disposed. Eccentric bearing block <NUM> also includes a projection <NUM> on which bearing <NUM> is mounted. Bearing <NUM> enables eccentric bearing block <NUM> to rotate within and relative to recess <NUM> (e.g., when converting roller <NUM> is raised or lowered) in a low friction and long lasting manner. Furthermore, eccentric bearing block <NUM> includes an aperture <NUM> through which shaft <NUM> extends.

As best seen in <FIG>, shaft <NUM> has a central rotational axis A about which converting roller <NUM> rotates when belt <NUM> rotates shaft <NUM> in the first direction. One-way bearing <NUM>, bearing <NUM>, recess <NUM>, and aperture <NUM> are mounted on or disposed around shaft <NUM> so as to have central axes that are coaxial with axis A. In contrast, eccentric bearing block <NUM>, projection <NUM>, and bearing <NUM> share a common rotational axis B that is offset from axis A.

When belt <NUM> rotates shaft <NUM> in the first direction, one-way bearing <NUM> allows shaft <NUM> to rotate in the first direction, relative to eccentric bearing block <NUM>, and about axis A. In contrast, when belt <NUM> rotates shaft <NUM> in the second direction, one-way bearing <NUM> locks together with eccentric bearing block <NUM> to prevent relative movement between shaft <NUM> and eccentric bearing block <NUM>. Thus, when shaft <NUM> is rotated in the second direction, eccentric bearing block <NUM> also rotates in the second direction.

When eccentric bearing block <NUM> is rotated in the second direction, eccentric bearing block <NUM> rotates about axis B. Rotation of eccentric bearing block <NUM> about axis B causes shaft <NUM> to revolve around axis B. As shown in <FIG>, when eccentric bearing block <NUM> is rotated in the second direction about axis B, shaft <NUM> revolves around axis B so that shaft <NUM> is lowered from the position shown in <FIG>. As a result, converting roller <NUM> is lowered when rotated in the second (e.g., reverse) direction.

As shown in <FIG>, a spring loaded tensioner <NUM> creates tension in belt <NUM>. The tension in belt <NUM> applies a force on gear <NUM> that has both an upward vertical component and a horizontal component. As discussed in greater detail below, a spring mechanism applies a similar force on eccentric bearing assembly <NUM>. As a result of the forces applied to gear <NUM> and eccentric bearing assembly <NUM>, eccentric bearing assembly <NUM> and eccentric bearing assembly <NUM> automatically rotate back to the raised position shown in <FIG> when belt <NUM> begins rotating shaft <NUM> in the first direction again. In this way, eccentric bearing assembly <NUM> and eccentric bearing assembly <NUM> are synchronized (both raised or both lowered).

More specifically, in order to lower converting roller <NUM>, belt <NUM> rotates shaft <NUM> in the second direction, which causes the eccentric bearing blocks in eccentric bearing assemblies <NUM>, <NUM> to rotate about axis B. If the eccentric bearing blocks are rotated in the second direction more or less than <NUM> degrees, then the upward forces on eccentric bearing assemblies <NUM>, <NUM> will have enough of a mechanical advantage to automatically rotate eccentric bearing assemblies <NUM>, <NUM> back to the raised position when belt <NUM> begins to rotate shaft <NUM> in the first direction. This is due to the fact that the upward forces will not be acting directly under axis B. However, if the eccentric bearing blocks are rotated <NUM> degrees in the second direction (e.g., so the upward forces are acting directly under axis B), then the upward forces on eccentric bearing assemblies <NUM>, <NUM> may not have enough of a mechanical advantage to automatically rotate eccentric bearing assemblies <NUM>, <NUM> back to the raised position. In such a case, belt <NUM> may be rotated further in the second direction so that the upward forces will have enough of a mechanical advantage to automatically rotate eccentric bearing assemblies <NUM>, <NUM> back to the raised position.

In order to ensure that eccentric bearing assemblies <NUM>, <NUM> are synchronized or to correct any lack of synchronization therebetween, belt <NUM> may be rotated in the second direction and then in the first direction to reset eccentric bearing assemblies <NUM>, <NUM>. For instance, belt <NUM> may be rotated <NUM> degrees in the second direction and then <NUM> degrees in the first direction. By rotating in the second direction less than <NUM> degrees, it is assured that the upward forces are not acting directly under axis B. As a result, when belt <NUM> is rotated in the first direction, the upward forces will have a sufficient mechanical advantage to cause eccentric bearing assemblies <NUM>, <NUM> to automatically rotate to the raised position.

The forces provided by tensioner <NUM> also counter most downward forces applied to converting roller <NUM> by sheet material <NUM> and longheads <NUM>, thereby preventing eccentric bearing assembly <NUM> from rotating and lowering converting roller <NUM> when belt <NUM> is not rotating in the second direction. However, recess <NUM>, eccentric bearing block <NUM>, and bearing <NUM> are sized and arranged to prevent eccentric bearing assembly <NUM> from unintentionally rotating and lowering converting roller <NUM> in the event that a downward force is applied to converting roller <NUM> that would overcome the upward force provided by tensioner <NUM>.

During normal operation (e.g., when sufficient downward forces are not applied to converting roller <NUM> to overcome the upward forces provided by tensioner <NUM>), bearing <NUM> allows for eccentric bearing assembly <NUM> to operate as described above. More specifically, as can best be seen in <FIG>, bearing <NUM> has a slightly smaller outer diameter than eccentric bearing block <NUM> and recess <NUM> includes a notch <NUM> directly above eccentric bearing block <NUM>. As a result, the upward forces provided by tensioner <NUM> cause bearing <NUM> to engage the upper interior surface of recess <NUM>. At the same time, however, eccentric bearing block <NUM> does not engage the upper surface of recess <NUM>. Rather, the upper surface of eccentric bearing block <NUM> extends into notch <NUM>. This arrangement allows for eccentric bearing block <NUM> to rotate about axis B when belt <NUM> rotates shaft <NUM> in the second direction.

In the event that a sufficiently large downward force is applied to converting roller <NUM> to overcome the upward force provided by tensioner <NUM>, converting roller <NUM> is lowered slightly until eccentric bearing block <NUM> engages the lower surface of recess <NUM>. As can be seen in <FIG>, the larger outer diameter of eccentric bearing block <NUM> causes eccentric bearing block <NUM> to engage the lower surface of recess <NUM> while still providing clearance between bearing <NUM> and the lower surface of recess <NUM>. As a result, friction is created between eccentric bearing block <NUM> and the lower surface of recess <NUM>. The friction created therebetween can be sufficient to prevent eccentric bearing block <NUM> from rotating about axis B, and thereby preventing the unintentional lowering of converting roller <NUM>.

Tensioner <NUM>, and particularly the location of tensioner <NUM>, allows for converting roller <NUM> to be lowered and raised as well as providing a relatively consistent rotational force to active roller 134a. Tensioner <NUM> is connected to belt <NUM> between stepper motor <NUM> and converting roller <NUM>, as opposed to being connected to belt <NUM> between stepper motor <NUM> and active roller 134a. Not having tensioner <NUM> connected to belt <NUM> between stepper motor <NUM> and active roller 134a ensures that belt <NUM> provides a relatively consistent force to active roller 134a, which allows for relatively consistent feeding of sheet material <NUM> through converting assembly <NUM>. In contrast, connecting tensioner <NUM> between stepper motor <NUM> and converting roller <NUM> allows for the force applied by belt <NUM> to converting roller <NUM> to vary. For instance, when belt rotates converting roller <NUM> in the first direction, belt <NUM> provides a given force on converting roller <NUM>. When belt <NUM> rotates converting roller <NUM> in the second direction, tensioner <NUM> reduces the upward force applied to converting roller <NUM>, thereby allowing converting roller <NUM> to be lowered as described above.

Eccentric bearing assembly <NUM> on the second end of shaft <NUM> provides the same functionality as eccentric bearing assembly <NUM>. Specifically, when shaft <NUM> is rotated in the first direction, eccentric bearing assembly <NUM> allows shaft <NUM> and converting roller <NUM> to rotate to advance sheet material <NUM>. When shaft <NUM> is rotated in the second direction, eccentric bearing assembly <NUM> causes shaft <NUM> and converting roller <NUM> to be lowered.

Since the second end of shaft <NUM> is not connected to a belt like belt <NUM> that provide an upward force, bearing block <NUM> includes a biasing mechanism to return eccentric bearing assembly <NUM> to the raised position. As shown in <FIG>, the biasing mechanism includes a pivot arm <NUM> pivotally connected to bearing block <NUM>. A spring <NUM> is disposed between bearing block <NUM> and a first end of pivot arm <NUM>. Spring <NUM> causes a second end of pivot arm <NUM> to rotate up against eccentric bearing assembly <NUM>, thereby biasing eccentric bearing assembly <NUM> toward the raised position. Optionally, the second end of pivot arm <NUM> can include a bearing <NUM> that can reduce wear between pivot arm <NUM> and eccentric bearing assembly <NUM>.

The arrangement of belt <NUM>, feed rollers 134a, 134b, and converting roller <NUM> enables converting assembly <NUM> to utilize a single motor (e.g., stepper motor <NUM>) to perform multiple functions. Specifically, stepper motor <NUM> may be used to advance sheet material <NUM> through converting assembly <NUM> by rotating active roller 134a. Stepper motor <NUM> may also be used to advance packaging templates <NUM> out of converting assembly <NUM> by rotating converting roller <NUM> in a first direction. Still further, stepper motor <NUM> may disengage longheads <NUM> for repositioning by rotating converting roller <NUM> in a second direction in order to lower converting roller <NUM>.

Using a stepper motor in converting cartridge <NUM> (as opposed to a servo motor, for example) may provide various benefits. Stepper motors are more cost effective and accommodate a more favorable torque-curve, which enables a slimmer mechanical design. One common short-coming of stepper motors is that they lose much of their torque at higher speeds. In the present context, however, this property is advantageous because it requires a less rigid support structure to handle the higher torque of other motors. The lower torque at high speeds prevents moving components (e.g., crosshead <NUM>, longheads <NUM>, converting roller <NUM>, etc.) from being damaged as a result of high energy collisions. Furthermore, stepper motors immediately stall when speeds are too high, thereby reducing the likelihood of a damaging collision, increasing reliability of components, as well as personal safety.

Once converting assembly <NUM> has converted fanfold material <NUM> into packaging templates <NUM>, packaging templates <NUM> may be fed out of converting assembly <NUM> through an outfeed guide <NUM> as shown in in <FIG> and <FIG>. Outfeed guide <NUM> may be configured to deflect and/or redirect packaging templates <NUM> from moving in one direction to another. For example, outfeed guide <NUM> may be configured to redirect packaging templates <NUM> from a first direction, which may be in a substantially horizontal plane (e.g., as sheet material <NUM> moves through converting assembly <NUM>), to a second direction. The second direction may be angled relative to the first direction. For example, the first direction may be substantially horizontal, while the second direction may be at about a <NUM> degree angle relative to the first direction. Alternatively, the first direction and the second direction may form an acute or obtuse angle with respect to one another.

As shown, outfeed guide <NUM> includes a lower guide plate <NUM> and one or more upper guide teeth <NUM>. Packaging templates <NUM> may be fed between lower guide plate <NUM> and one or more upper guide teeth <NUM>. As can be seen, lower guide plate <NUM> and the one or more upper guide teeth <NUM> are curved and taper towards one another. As a result, lower guide plate <NUM> and the one or more upper guide teeth <NUM> cooperate to consistently guide packaging templates <NUM> out of converting assembly <NUM> at a predetermined and predictable location.

More specifically, lower guide plate <NUM> may support packaging templates <NUM> as they are fed out of converting assembly <NUM> so that packaging templates <NUM> consistently exit converting assembly at the same location. Similarly, the one or more upper guide teeth <NUM> may be configured to deflect and/or redirect packaging templates <NUM> from moving in the first direction to the second direction. The one or more upper guide teeth <NUM> may also be configured to maintain packaging templates <NUM> at a predetermined maximum distance from support structure <NUM>. As illustrated, the one or more upper guide teeth <NUM> may have a generally arcuate surface that deflect and/or redirect packaging templates <NUM> toward the second direction so that packaging templates <NUM> do not extend significantly out of converting assembly <NUM> in a horizontal direction.

In the illustrated embodiment, a cover <NUM> is positioned over the one or more upper guide teeth <NUM>. Cover <NUM> may prevent excess sheet material <NUM> from exiting converting assembly <NUM> without being deflected downward by the one or more upper guide teeth <NUM>. Cover <NUM> may optionally be clear to allow for inspection of outfeed guide <NUM> as well as the interior of converting assembly <NUM>.

In addition to lower guide plate <NUM> and the one or more upper guide teeth <NUM>, outfeed guide <NUM> may also include outfeed extensions <NUM>, <NUM>. Extensions <NUM> extend from lower guide plate <NUM> so as to form an angle (e.g., between about <NUM> degrees and about <NUM> degree; about <NUM> degrees, etc.) with the first direction of movement of sheet material <NUM>. Extensions <NUM> are generally rigid so as to be able to guide packaging templates <NUM> horizontally away from support structure <NUM> and support at least a portion of packaging templates <NUM> after packaging templates <NUM> exit converting assembly <NUM>. For instance, extensions <NUM> may guide and support packaging templates <NUM> so that packaging templates <NUM> hang from converting assembly <NUM> outside of collection bin <NUM>, as shown in <FIG>.

Extensions <NUM> extend from cover <NUM> near opposing sides of converting assembly <NUM>. Extensions <NUM> may be flexible or rigid. In any case, extensions <NUM> may extend generally straight down from cover <NUM>. Extensions <NUM> may be configured to deflect and/or direct excess sheet material <NUM> (such as side material cut off when forming packaging templates <NUM>) into collection bin <NUM>.

Converting assembly <NUM> may be connected to support structure <NUM> such that sheet material <NUM> is fed through converting assembly <NUM> in a first direction that is not in a horizontal plane. For instance, converting assembly <NUM> may be connected to support structure <NUM> such that sheet material <NUM> is fed through converting assembly <NUM> at an angle relative to a support surface on which converting machine <NUM> is positioned. The angle between the first direction and the support surface may be anywhere between <NUM> degrees to <NUM> degrees. Furthermore, converting assembly <NUM> may be movably connected to support structure <NUM> such that the angle between the first direction and the support surface may be selectively changed.

In a case where converting assembly <NUM> is connected to support structure <NUM> at an angle, the angle at which outfeed guide <NUM> feeds packaging templates <NUM> out converting assembly <NUM> may be changed. For instance, converting assembly <NUM> is angled so that sheet material <NUM> advances therethrough at an angle of <NUM> degrees relative to the support surface, outfeed guide <NUM> may feed packaging templates <NUM> out of converting assembly <NUM> in the same direction (e.g., so as to form a <NUM> degree angle with the support surface). Alternatively, outfeed guide <NUM> may feed packaging templates <NUM> out of converting assembly <NUM> at an angle relative to sheet material <NUM>'s direction of movement through converting assembly <NUM> (e.g., between about <NUM> degrees and about <NUM> degree; about <NUM> degrees, etc.).

It will be appreciated that relative terms such as "horizontal," "vertical," "upper," "lower," "raised," "lowered," and the like, are used herein simply by way of convenience. Such relative terms are not intended to limit the scope of the present invention. Rather, it will be appreciated that converting assembly <NUM> may be configured and arranged such that these relative terms require adjustment. For instance, if converting assembly <NUM> is mounted on support structure <NUM> at an angle, converting roller <NUM> may move between a "forward position" and a "backward position" rather than between a "raised position" and a "lowered position.

Converting assembly <NUM> may include a cover assembly having one or more covers or doors that allow for ready access to converting cartridge <NUM>. For instance, converting assembly <NUM> may include covers on one or both sides and/or one or more front and rear covers. The one or more covers may provide ready and convenient access to various portions of converting cartridge <NUM>.

For instance, as shown in Figures <NUM> and <NUM>, converting assembly <NUM> includes a cover assembly having a front cover <NUM>, a rear cover <NUM>, and opposing side covers <NUM>, <NUM>. Front cover <NUM> and rear cover <NUM> may be opened individually or together as shown in Figure <NUM> in order to gain access to the interior of converting assembly <NUM>, including converting cartridge <NUM>. As shown, front cover <NUM> and rear cover <NUM> are pivotally connected to and between opposing side covers <NUM>, <NUM>.

The cover assembly (e.g., covers <NUM>, <NUM>, <NUM>, <NUM>) may also be opened as a unit as shown in Figure <NUM> in order to provide greater access to or replacement of converting cartridge <NUM>. For instance, rear cover <NUM> may be opened (as shown in Figure <NUM>) after which side covers <NUM>, <NUM> may be pivoted back as shown in Figure <NUM>. Since front and rear covers <NUM>, <NUM> are connected between side covers <NUM>, <NUM>, front and rear covers <NUM>, <NUM> also rotate back when side covers <NUM>, <NUM> are rotated back. Once covers <NUM>, <NUM>, <NUM>, <NUM> are all rotated back, converting cartridge <NUM> may be serviced or replaced.

Claim 1:
A converting machine (<NUM>) used to convert sheet material (<NUM>) into packaging templates (<NUM>) for assembly into boxes or other packaging, the converting machine comprising:
a converting assembly (<NUM>) configured to perform one or more transverse conversion functions and one or more longitudinal conversion functions on the sheet material, the one or more transverse conversion functions and the one or more longitudinal conversion functions being selected from the group consisting of creasing, bending, folding, perforating, cutting, and scoring, to create the packaging templates, the converting assembly comprising:
one or more longheads (<NUM>) comprising one or more cutting wheels (<NUM>) or one or more creasing wheels (<NUM>) that perform the one or more longitudinal conversion functions on the sheet material, wherein at least one of the one or more longheads is adapted to be selectively repositioned along a width of the converting assembly to make the one or more longitudinal conversion functions at different positions along a width of the sheet material; and
a crosshead (<NUM>) comprising a body (<NUM>) and one or more cutting wheels (<NUM>) and one or more creasing wheels (<NUM>) that perform the one or more transverse conversion functions on the sheet material, the one or more creasing wheels being configured to remain in substantially the same vertical position relative to the body, wherein the crosshead is selectively movable relative to the sheet material and along at least a portion of the width of the converting assembly to perform the one or more transverse conversion functions on the sheet material, wherein the crosshead is adapted to selectively engage and reposition the at least one of the one or more longheads along the width of the converting assembly.