Patent Description:
Shipping and packaging industries frequently use paperboard and other sheet material processing equipment that converts sheet materials into box templates. One advantage of such equipment is that a shipper may prepare boxes of required sizes as needed in lieu of keeping on hand 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. Some of the drawbacks result from using fanfold sheet material to create box or packaging templates. Fanfold sheet material is sheet material (e.g., paperboard, corrugated board, cardboard) that has been folded back and forth on itself such that the material is stacked into layers. A crease or fold (also referred to herein as a "fanfold crease") is formed in the material between each layer to allow the material to be stacked in layers. When the material is unfolded so that it can be converted into box templates or other packaging, the fanfold creases may pose some difficulties in forming the box templates or packaging. For instance, the fanfold creases may cause the sheet material to fold or otherwise not lie flat, which can cause the sheet material to jam a converting machine that is being used to convert the sheet material to a box template or other packaging.

The fanfold creases may also pose some challenges to forming the box templates into strong, structurally sound boxes. For instance, if a box template is formed with a fanfold crease extending through a glue tab of the box template (or a portion of the template to which the glue tab is to be glued), the fanfold crease may cause the glue tab to curl or fold, making it difficult to securely attach the glue tab to another portion of the box template. Similarly, fanfold creases in other areas of a box template (e.g., in the flaps, panels, etc.) can also make it more difficult to erect a box from the box template or make the erected box less structurally sound.

Accordingly, there remains room for improvement in the area of sheet material processing machines.

<CIT> system that converts sheet material into packaging templates includes a converting assembly that performs conversion functions, such as cutting, creasing, and scoring, on the sheet material as the sheet material moves through the converting machine in a first direction. The converting assembly may be mounted on a frame such that the converting assembly is elevated above a support surface. One or more longhead converting tools performs conversion functions on the sheet material in a first direction and a crosshead converting tool performs conversion functions on the sheet material in a second direction in order to create packaging templates. <CIT> discloses a sensor arrangement for detecting creases on a moving web. Two sensors are offset, in some cases in feed direction, and can detect creases. The crease pattern is used as position reference for cutting; the technique for sensing the position of a longitudinal crease line can for example be used as a position reference at cutting.

Exemplary embodiments of the disclosure relate to systems, methods, and devices for converting sheet materials into boxes. More specifically, exemplary embodiments relate to box forming machines that convert paperboard, corrugated board, cardboard, and similar sheet materials into box templates and fold and glue the box templates to form un-erected boxes.

For instance, one embodiment is directed to a converting machine used to convert sheet material into packaging templates for assembly into boxes or other packaging according to claim <NUM>.

According to another embodiment, a method of converting sheet material into packaging templates for assembly into boxes or other packaging is provided, as per claim <NUM>.

These and other objects and features of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the disclosure as set forth hereinafter.

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 converting machine for converting sheet materials (e.g., paperboard, corrugated board, cardboard) into templates for boxes and other packaging.

While the present disclosure will describe details of embodiments with reference to specific configurations, the descriptions are illustrative and are not to be construed as limiting the scope of the present invention.

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 box or packaging template. For example, the bale may be formed of a continuous sheet of material or a sheet of material of any specific length, such as corrugated cardboard and paperboard sheet materials.

As used herein, the terms "box template" and "packaging template" shall refer to a substantially flat stock of material that can be folded into a box-like shape. A box or packaging template may have notches, cutouts, divides, and/or creases that allow the box or packaging template to be bent and/or folded into a box. Additionally, a box or 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 sheet material or box template may fold. For example, a crease may be an indentation in the sheet material. In the case of fanfold creases, the indentation may be made by folding the sheet material into layered stacks in a bale. Other creases may be formed in the sheet material to aid in folding portions of the sheet material separated by the crease, with respect to one another, to form a box.

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 divide 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> and <FIG>, converting machine <NUM> includes a support structure <NUM> and a converting assembly <NUM> mounted on support structure <NUM>.

As shown in <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.

As best seen in <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 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>. For instance, 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>.

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 that feeds sheet material <NUM> through converting assembly <NUM> and performs the conversion functions thereon.

<FIG> illustrate an example converting cartridge <NUM> separate from the rest of converting assembly <NUM> and converting machine <NUM>. As can be seen in <FIG>, converting cartridge <NUM> includes a guide channel <NUM>. Guide channel <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, guide channel <NUM> includes opposing upper and lower guide plates 132a, 132b 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 132a, 132b may be flared or spaced further apart at on opening end to facilitate insertion of sheet material <NUM> therebetween.

In the illustrated embodiment, converting cartridge <NUM> includes a single guide channel <NUM> that guides lengths of sheet material <NUM> through converting assembly <NUM>. It will be understood, however, that converting cartridge <NUM> may include multiple guide channels for feeding one or multiple lengths of sheet material <NUM> (e.g., from multiple bales <NUM>) through converting assembly <NUM>. When multiple guide channels are included, the guide channels may be horizontally and/or vertically offset from one another.

As also illustrated in <FIG>, converting cartridge <NUM> also includes at least one feed roller <NUM> that pulls sheet material <NUM> into converting assembly <NUM> and advances sheet material <NUM> therethrough. Feed roller(s) <NUM> may be configured to pull sheet material <NUM> with limited or no slip and may be smooth, textured, dimpled, and/or teethed. Each feed roller <NUM> may be actively rolled by an actuator or motor in order to advance sheet material <NUM> through converting assembly <NUM>.

As best seen in <FIG>, 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 of) 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 to allow crosshead <NUM> to move along at least a portion of the width of converting cartridge <NUM>.

Crosshead <NUM> may include one or more converting instruments, such as a cutting wheel and/or a creasing wheel, 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>, a cutting wheel and/or a creasing wheel may create creases, bends, folds, perforations, cuts, and/or scores in sheet material <NUM>.

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 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 locations to make the longitudinal conversions on sheet material <NUM>.

Longheads <NUM> may include one or more converting instruments, such as a cutting wheel and/or a creasing wheel, which may perform the longitudinal conversions on sheet material <NUM>. More specifically, as sheet material <NUM> moves underneath longhead <NUM>, the cutting wheel and/or creasing wheel may create creases, bends, folds, perforations, cuts, and/or scores in sheet material <NUM>.

A control system can control the operation of the converting machine <NUM>. More specifically, the control system can control the movement and/or placement of the various components of the converting machine <NUM>. For instance, the control system can control the rotational speed and/or direction of the feed rollers <NUM> in order to govern the direction (i.e., forward or backward) the sheet material <NUM> is fed and/or the speed at which the sheet material <NUM> is fed through the converting machine <NUM>. The control system can also govern the positioning and/or movement of the converting tools <NUM>, <NUM> so that the converting tools <NUM>, <NUM> perform the conversion functions on the desired locations of the sheet material <NUM>.

The control system may be incorporated into converting machine <NUM>. In other embodiments, converting machine <NUM> may be connected to and in communication with a separate control system, such as a computer, that controls the operation of converting machine <NUM>. In still other embodiments, portions of the control system may be incorporated into converting machine <NUM> while other portions of the control system are separate from converting machine <NUM>. Regardless of the specific configuration of the control system, the control system can control the operations of converting machine <NUM> that form box templates <NUM> out of sheet material <NUM>.

As illustrated in <FIG> and discussed in greater detail below, converting machine <NUM> can include a fanfold crease sensing mechanism <NUM> (also referred to as sensing mechanism <NUM>) that is configured to detect fanfold creases in sheet material <NUM> as sheet material <NUM> is fed into converting machine <NUM>. After the sensing mechanism <NUM> detects the fanfold creases in sheet material <NUM>, the control system can cause converting machine <NUM> to alter the portion of sheet material <NUM> used to create box template <NUM>. For instance, in some embodiments, the control system can cause converting machine <NUM> to cut off the portions of sheet material <NUM> that include the fanfold creases so the fanfold creases do not end up in specific portions of the box template <NUM>. According to the invention the control system can cause the converting machine <NUM> to cut off a leading edge of sheet material <NUM> so as to shift the location of the fanfold creases within the box template <NUM>.

With continued attention to <FIG>, attention is also now directed to <FIG>, which illustrate an example embodiment of fanfold crease sensing mechanism <NUM>. In the illustrated embodiment, sensing mechanism <NUM> is mounted adjacent to guide channel <NUM> and is configured to monitor sheet material <NUM> as sheet material <NUM> is fed into converting machine <NUM> through guide channel <NUM>. To enable sensing mechanism <NUM> to monitor sheet material <NUM> as sheet material passes through guide channel <NUM>, guide plate 132a and/or 132b may include one or more openings <NUM> therethrough. Sensing mechanism <NUM> may interact with sheet material <NUM> through openings <NUM> to detect fanfold creases in sheet material <NUM>.

In the illustrated embodiment, sensing mechanism <NUM> includes a first sensor <NUM> and a second sensor <NUM>. As best seen in <FIG>, sensors <NUM>, <NUM> are mounted within converting machine <NUM> so that first sensor <NUM> and second sensor <NUM> are offset from one another in the direction that sheet material <NUM> is feed through converting machine <NUM> (indicated by arrow A in <FIG>). This offset of the sensors <NUM>, <NUM> may be referred to as a longitudinal offset or feed direction offset. The sensors <NUM>, <NUM> may be longitudinally offset from one another such that only one of the sensors <NUM>, <NUM> is disposed above a fanfold crease at a given time. In some embodiments, it can be desirable to position the sensors <NUM>, <NUM> as close together as possible while only one of the sensors <NUM>, <NUM> is disposed above the fanfold crease at a time. In some embodiments, the closer the sensors <NUM>, <NUM> are to each other (e.g., the shorter the longitudinal offset), the more tolerant the sensors <NUM>, <NUM> become. In other words, by positioning the sensors <NUM>, <NUM> closer together (while still being spaced apart far enough that only one of the sensors <NUM>, <NUM> is above a fanfold crease at a time), there is less of a chance that movement of the sheet material <NUM> (e.g., up and down, closer to or further from the sensors <NUM>, <NUM>) will prevent accurate detection of the fanfold creases. In some embodiments, the sensors <NUM>, <NUM> have a longitudinal offset of about <NUM>, about <NUM>, about <NUM>, or more, or any value therebetween.

The sensors <NUM>, <NUM> communicate with the control system. Each of the sensors <NUM>, <NUM> communicates signals to the control system that indicate whether the sensors <NUM>, <NUM> detect the potential presence of a fanfold crease. The control system may include a filter or algorithm that compares the signals from the sensors <NUM>, <NUM>, and optionally other system data (e.g., the rotational speed and/or direction of the feed rollers <NUM>, the speed the sheet material <NUM> is being fed through the converting machine <NUM>, etc.) to determine whether a fanfold crease is present or has been detected.

By way of example, the filter or algorithm of the control system may determine whether both sensors <NUM>, <NUM> have detected the potential presence of a fanfold crease. If both sensors <NUM>, <NUM> have detected the potential presence of a fanfold crease, the filter or algorithm may determine whether each sensor <NUM>, <NUM> has detected the presence of the same potential fanfold crease. For instance, the filter or algorithm of may determine a temporal displacement (e.g., a time differential) between the signals from each of the sensors <NUM>, <NUM> that indicated the potential presence of a fanfold crease.

The filter or algorithm may use the temporal displacement and other system data to determine whether the sensors <NUM>, <NUM> have detected the same potential fanfold crease. For instance, the filter or algorithm may use the temporal displacement and the speed at which the sheet material <NUM> is being fed through the converting machine <NUM> to determine whether the sensors <NUM>, <NUM> have detected the same potential fanfold crease. If filter or algorithm determines that the sensors <NUM>, <NUM> have detected the same potential fanfold crease within a predetermined distance, the filter or algorithm will determine that the sensors <NUM>, <NUM> have detected an actual fanfold crease. The predetermined distance can vary between embodiments. For instance, the predetermined distance may be about <NUM>, about <NUM>, about <NUM>, about <NUM>, about <NUM>, or more, or any value therebetween. In some embodiments, the predetermined distance may be adjustable (e.g., by a user, based on the thickness of the sheet material, etc.).

As illustrated in <FIG>, sensors <NUM>, <NUM> may optionally be offset from one another in a direction generally perpendicular or transverse to the feed direction. In other embodiments, sensors <NUM>, <NUM> may not be offset from one another in a direction perpendicular or transverse to the feed direction. For example, sensor <NUM> may be positioned directly behind sensor <NUM> (in the feed direction).

The sensors <NUM>, <NUM> may detect the presence or absence of sheet material <NUM> within the converting machine <NUM>, and more particularly within guide channel <NUM>. The sensors <NUM>, <NUM> may communicate to the control system the presence or absence of sheet material <NUM>. If the sensors <NUM>, <NUM> do not detect the presence of sheet material <NUM>, the control system can provide an alert that sheet material <NUM> needs to be loaded into converting machine <NUM>. In some embodiments, the system may include a feed changer that selectively feeds different sheet materials into the converting machine <NUM>. The sensors <NUM>, <NUM> may also detect whether the sheet material from the feed changer is loaded or unloaded correctly and the control system may provide alerts regarding the same.

The sensors <NUM>, <NUM> can also detect the presence and/or location of fanfold creases in sheet material <NUM>. When sheet material <NUM> is unfolded from a bale <NUM>, the unfolded fanfold creases may take the form of depressions or projections on or in the surface of the sheet material <NUM>. As sheet material <NUM> is fed into converting machine <NUM>, and particularly through guide channel <NUM>, sensor <NUM>, <NUM> may detect the depressions or projections on or in the surface of the sheet material <NUM>. Detection of such depressions or projections provides an indication of the presence and location of fanfold creases in sheet material <NUM>.

The control system can use the detected locations of the fanfold creases to predict the locations of upcoming fanfold creases. Typical sheet material bales <NUM> have relatively consistent layer dimensions (e.g., distances between fanfold creases on opposing ends of a layer). As a result, the fanfold creases are relatively evenly spaced apart. For instance, some bales <NUM> have fanfold creases that are spaced apart by about <NUM> inches.

Using the detected and/or predicted locations of the fanfold creases, the control system can cause the converting machine <NUM> to cut off portions of sheet material <NUM> and/or adjust which portions of sheet material <NUM> are used to form box templates <NUM>. For instance, if the sensors <NUM>, <NUM> detect a fanfold crease close to the leading end of sheet material <NUM>, the control system can cause the converting machine <NUM> to cut off the leading portion of sheet material <NUM> that includes the fanfold crease. By cutting off the leading portion of sheet material <NUM> that includes the fanfold crease, the risk of the leading edge of the sheet material <NUM> curling or folding and jamming the converting machine <NUM> are greatly reduced.

In some cases, the leading end of the sheet material <NUM> is used to form a glue tab portion of a box template <NUM>. If a fanfold crease extends through the glue tab, the glue tab may curl or fold or have reduced strength, making it difficult to securely attach the glue tab to a panel of the box template <NUM>. For instance, a glue tab with a fanfold crease may not lie flat, which can make it difficult to securely attach the glue tab to another portion of the box template <NUM> because the glue tab will try to curl or fold away from the other portion of the box template. As a result, a glue joint formed with a glue tab having a fanfold crease may prematurely fail. Similarly, the leading end of the sheet material <NUM> may be used to form a panel of the box template to which a glue tab is to be attached. If a fanfold crease is located near an edge of the panel to which the glue tab is to be secured, the edge of the panel may curl or fold or have reduced strength, making it difficult to securely attach the glue tab to the panel. To avoid such issues, the control system can cause the converting machine <NUM> to cut off the leading portion of the sheet material <NUM> in which the sensors <NUM>, <NUM> detected the fanfold crease.

According to the invention , if the sensors <NUM>, <NUM> detect the presence of a fanfold crease within a predetermined or user configurable range of the leading edge of sheet material <NUM>, the control system can cause the converting machine <NUM> to cut off the predetermined or user configurable amount of the leading edge of the sheet material <NUM>, including the fanfold crease therein. For instance, in some embodiments, the predetermined range may be the first <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> of the sheet material <NUM>. In such cases, the control system can cause the converting machine <NUM> to cut off the first <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> of the leading edge of the sheet material <NUM>, including the fanfold crease therein. The box template <NUM> may then be formed with the following sheet material <NUM> that does not include a fanfold crease within the predetermined or user configurable range of the leading edge of sheet material <NUM>.

As noted above, fanfold creases are typically relatively evenly spaced apart from one another. As a result, once sensors <NUM>, <NUM> detect the location of a fanfold crease in sheet material <NUM>, the control system can predict the locations of upcoming fanfold creases. Continually detecting the location of fanfold creases (via sensors <NUM>, <NUM>) and predicting the locations of upcoming fanfold creases can allow for the avoidance of fanfold creases in areas of box template <NUM> other than just near the leading end thereof.

For instance, detection of fanfold creases (via sensors <NUM>, <NUM>) and prediction of future fanfold crease locations can allow the control system to determine if a fanfold crease would be located within a predetermined range (e.g., <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>) or user configurable range of the end of a box template <NUM>. Having a fanfold crease near the trailing edge (e.g., within the last <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>) of a box template <NUM> may pose similar problems to those discussed above when a fanfold crease is near a leading end of the box template <NUM>. If the control system determines that a fanfold crease would be located within a predetermined range (<NUM>, <NUM>, <NUM>, <NUM>, or <NUM>) or user configurable range of the last or trailing edge of a box template <NUM>, the control system can cause the converting machine <NUM> to cut the predetermined range (e.g., <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>) or user configurable range off of the leading end of the sheet material <NUM> and use the following sheet material <NUM> to make the box template <NUM>. Cutting the predetermined range (e.g., first <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> ) or user configuration range off of the leading end of the sheet material <NUM> will shift where in the box template <NUM> the fanfold crease is located.

By way of example, if the control system determines that an upcoming fanfold crease would be located within <NUM> of the trailing end of a box template <NUM>, the control system can cause the converting machine <NUM> to cut <NUM> off of the leading end of the sheet material <NUM>. By cutting <NUM> off of the leading end of the sheet material <NUM> and using the subsequent sheet material <NUM> to form the box template <NUM>, the location of the upcoming fanfold crease is shifted further into the box template (e.g., more than <NUM> away from the trailing end thereof). When the fanfold crease is shifted away from the trailing end, the likelihood that the fanfold crease will pose a problem decreases. This can be due to the fanfold crease not being located where a glue joint is to be made or attached. Furthermore, when a fanfold crease is located further away from an edge, the sheet material <NUM> is less likely to curl or fold in an undesirable manner.

Detecting and predicting the locations of fanfold creases can also enable the system <NUM> to avoid fanfold creases being located in box templates at other potentially problematic areas. For instance, the control system may cause the converting assembly <NUM> to cut a length of sheet material <NUM> off of the leading end thereof so as to shift the location of an upcoming fanfold crease away from a crease between box template panels, flaps, or the like.

Detecting and predicting the locations of fanfold creases can also enable the system <NUM> to create box templates <NUM> is different orders to avoid fanfold creases being located in undesirable locations in the box templates <NUM>. For instance, if the control system determines that an upcoming fanfold crease would be located in an undesirable location in a first box template but not would not be in an undesirable location in a second box template (e.g., due to the second box template having different dimensions), the control system can have the converting machine <NUM> make the second box template before the first box template.

As noted above, the sensing mechanism <NUM> includes two sensors (i.e., first and second sensors <NUM>, <NUM>) that are offset from one another in the feeding or longitudinal direction. The longitudinal offset between the sensors <NUM>, <NUM> allows for the readings of the sensors <NUM>, <NUM> to be compared to one another to determine the presence and location of a fanfold crease.

More specifically, as the sheet material <NUM> advances past the sensing mechanism <NUM>, each of the sensors <NUM>, <NUM> will obtain a reading regarding the surface of the sheet material <NUM>. For instance, the readings may indicate the distance between the sensors <NUM>, <NUM> and the surface of the sheet material <NUM>. When substantially flat portions of the sheet material <NUM> (e.g., portions without fanfold creases) advance past the sensors <NUM>, <NUM>, as illustrated in <FIG>, the sensors <NUM>, <NUM> provide readings that are the same or within a predetermined tolerance.

In contrast, when a fanfold crease advances past the sensors <NUM>, <NUM>, the sensors <NUM>, <NUM> will detect a change in the surface of the sheet material <NUM>. For instance, as illustrated in <FIG>, as the fanfold crease advances under sensor <NUM>, sensor <NUM> will provide a first reading and sensor <NUM> will provide a second reading that is different than the first reading. The different readings indicate the presence of the fanfold crease.

As the sheet material <NUM> continues to advance, as illustrated in <FIG>, the sensor <NUM> will provide a reading that is different than the reading of the first sensor. In some embodiments, this can provide a verification of the location of the fanfold crease. In other embodiments, the readings from the two sensors can allow for vertical movement of the sheet material <NUM>. As the sheet material <NUM> advances through the guide channel <NUM>, the sheet material <NUM> may move up and down slightly because the upper and lower guide plates 132a, 132b are spaced apart by a distance greater than the thickness of the sheet material <NUM>. Using two offset sensors <NUM>, <NUM> allows for fanfold creases to be detected even if the sheet material <NUM> moves vertically.

More specifically, rather than maintaining the sheet material <NUM> in a vertical position and using that position as a baseline for taking readings, one of the sensors <NUM>, <NUM> will provide a baseline reading that reflects the flat surface of the sheet material <NUM> while the other sensor <NUM>, <NUM> will provide a reading related to the fanfold crease. For instance, as shown in <FIG>, the sensor <NUM> provides a reading for the flat surface of sheet material <NUM> regardless of the vertical position of the sheet material <NUM>. The sensor <NUM>, as shown in <FIG>, provides a reading for the fanfold crease. The difference in the two readings indicates the presence of the fanfold crease.

Additionally, the location of the fanfold crease may be determined using an encoder or similar device to track the feed position of the sheet material <NUM>. When the sensors <NUM>, <NUM> detect the presence of a fanfold crease, the control system may use the current feed position (determined with the encoder) to determine the location of the fanfold crease.

As the sheet material <NUM> continues to advance to the position shown in <FIG>, the sensor <NUM> will provide the baseline reading based on the flat surface of the sheet material (again regardless of the vertical position of the sheet material <NUM>). The sensor <NUM> will now provide a reading for the fanfold crease. Again, the difference in the two readings indicates the presence and location of the fanfold crease.

The sensors <NUM>, <NUM> may take various forms. For instance, in some embodiments the sensors <NUM>, <NUM> take the form of lasers that are able to detect the distance to the surface of the sheet material <NUM>. In other embodiments, the sensors <NUM>, <NUM> may take the form of mechanical devices that can detect changes in the surface of the sheet material <NUM>. For instance, a mechanical sensor may contact the surface of the sheet material <NUM> and detect changes in the surface of the sheet material <NUM> (e.g., depressions/projections of a fanfold crease) by increases or decreases in the position of the mechanical sensor, etc. In still other embodiments, the sensors <NUM>, <NUM> may take the form of optical sensors or vision (camera) systems.

Although the illustrated embodiment has shown both of sensors <NUM>, <NUM> being positioned above the sheet material <NUM>, this is merely exemplary. In other embodiments, a sensing mechanism may include two sensors positioned below the sheet material <NUM>. In still other embodiments, a sensing mechanism may include one sensor positioned above the sheet material <NUM> and a second sensor positioned below the sheet material <NUM>.

Regardless of the specific type of sensors used or the location of the sensors, the sensors may be able to provide readings with a predetermined accuracy. For example, fanfold creases typically have depths of between about <NUM> and about <NUM>. In order to accurately detect the fanfold creases, the sensors may have an accuracy level of about two or three times less than the depth of the fanfold creases. Thus, for instance, the sensors may provide readings with an accuracy of about <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. In other words, the sensors may be able to detect depressions or projections on the surface of the sheet material <NUM> that are <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> deep or tall.

Additionally, the sensors may be able to detect the fanfold creases even when the sheet material <NUM> is being advanced into the converting machine <NUM> and past the sensors at a relatively fast rate. For instance, the sensors may be able to detect the fanfold creases when the sheet material <NUM> is being advanced at a rate of <NUM>/s, <NUM>/s, <NUM>/s, <NUM>/s. <NUM>/s, or <NUM>/s.

While the sensing mechanism <NUM> has been shown and described in connection with a particular converting machine (i.e., converting machine <NUM>), it will be appreciated that sensing mechanism <NUM> may be incorporated into a variety of different converting machines or other sheet material processing equipment. However, the sensing mechanism is not claimed alone.

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 (<NUM>) 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 (<NUM>) as the sheet material (<NUM>) moves through the converting machine (<NUM>) in a feed direction, 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;
a fanfold crease sensing mechanism (<NUM>) configured to detect the presence and location of fanfold creases in the sheet material (<NUM>), the fanfold crease sensing mechanism (<NUM>) comprising:
a first sensor (<NUM>) and a second sensor (<NUM>) that are offset from one another in the feed direction; and
a control system configured to:
cause the converting assembly (<NUM>) to cut off a leading end of the sheet material (<NUM>) if the fanfold crease sensing mechanism (<NUM>) detects the presence of a fanfold crease within a predetermined or user configurable range of a leading edge of the packaging template (<NUM>); or
cause the converting assembly (<NUM>) to cut off a leading end of the sheet material (<NUM>) if the control system predicts that a fanfold crease will be within a predetermined or user configurable range of a trailing edge of a packaging template (<NUM>) formed from the sheet material (<NUM>); and
compare a reading from the first sensor (<NUM>) to a reading from the second sensor (<NUM>) to determine the presence and location of a fanfold crease in the sheet material (<NUM>).