Methods and systems for transferring stacked sheet material

Abstract

Systems and methods for handling sheet material, for example, signatures or inserts, are provided. Individual systems and methods for loading and jogging stacks of sheet material are combined with systems and methods for transferring sheet material whereby the mishandling or misfeeding of sheet material is minimized or reduced. The loading and jogging aspects are characterized by pivotally mounted receptacles or bins that facilitate introducing sheet material to a conveyor. The transferring aspects include automated transfer devices adapted to grip and position stacks of sheet material, for example, into a hopper feeding a disk feeder. These automated systems and their combination minimizes or prevents the mishandling of sheet material whereby the processing of sheet material is enhanced compared to conventional systems and methods.

1 . A method for transferring stacked sheet material to an individual sheet material conveyor, the method comprising:
 positioning a stack of sheet material in a first position, the first position having a first surface at a first elevation;   gripping the stack of sheet material in the first position with a translatable gripping device;   transferring the gripping device and gripped stack of sheet material from the first position to a second position laterally disposed from the first position, the second position having a second surface at a second elevation, lower than the first elevation; and   introducing individual sheet material from the stack of sheet material to the individual sheet material conveyor.   
   
   
       2 . The method as recited in  claim 1 , further comprising conveying the stack of sheet material to the first position. 
   
   
       3 . The method as recited in  claim 1 , wherein gripping the stack of sheet material comprises compressing the stack of sheeting material between two opposing surfaces. 
   
   
       4 . The method as recited in  claim 3 , wherein gripping the stack of sheet material further comprises translating at least one of the two opposing surfaces toward the stack of sheet material. 
   
   
       5 . The method as recited in  claim 1 , wherein transferring the gripping device and gripped stack of sheet material comprises transferring the translatable gripping device. 
   
   
       6 . The method as recited in  claim 1 , wherein introducing individual sheet material from the stack of sheet material to the individual sheet material conveyor comprises positioning the stack of sheet material whereby individual sheet material is engagable by a rotatable disk conveyor. 
   
   
       7 . The method as recited in  claim 1 , wherein the individual sheet material conveyor comprises a rotatable drum conveyor. 
   
   
       8 . A system for transferring stacked sheet material to an individual sheet material conveyor, the system comprising:
 a first position having a first surface at a first elevation adapted to receive a stack of sheet material;   a second position laterally disposed from the first position and having a second surface at a second elevation, the second position located to introduce individual sheet material to the individual sheet material conveyor;   a transfer device comprising:
 means for grasping the stack of sheet material in the first position; and 
 means for transferring the stack of sheet material from the first position to the second position whereby the individual sheets in the stack of sheet material can be introduced to the individual sheet material conveyor. 
   
   
   
       9 . The system as recited in  claim 8 , wherein the means for grasping the stack of sheet material comprises two opposing surfaces adapted to engage the stack of sheet material. 
   
   
       10 . The system as recited in  claim 9 , wherein the means for grasping the stack of sheet material further comprises at least one fluid cylinder assembly adapted to translate at least one of the two opposing surfaces. 
   
   
       11 . The system as recited in  claim 10 , wherein the at least one fluid cylinder assembly comprises at least one of a hydraulic cylinder assembly and a pneumatic cylinder assembly. 
   
   
       12 . The system as recited in  claim 8 , wherein the means for transferring the stack of sheet material comprises a translatable support structure adapted to support the means for grasping the stack of sheet material, the translatable support structuring comprising a plurality of wheels adapted to engage a wheel rail. 
   
   
       13 . The system as recited in  claim 12 , wherein the means for transferring comprises means for translating the translatable support structure. 
   
   
       14 . The system as recited in  claim 13 , wherein the means for translating the translatable support structure comprises a chain conveyor adapted to engage the support structure. 
   
   
       15 . A system for transferring individual sheet material to a rotatable drum conveyor, the drum conveyor having a rotatable disk feeder, the system comprising:
 a conveyor adapted to transfer stacked sheet material to a first position having a first surface at a first elevation;   a transfer device comprising:
 two opposing surfaces adapted to engage the stack of sheet material in the first position; 
 means for translating at least one of the two opposing surfaces whereby the stack of sheet material is grasped by the two opposing surfaces; and 
 a translatable assembly supporting the two opposing surfaces; and 
   means for transferring the transfer device whereby the stack of sheet material is transferred from the first position to a second position laterally disposed from the first position wherein the individual sheets in the stack of sheet material can be introduced to the drum conveyor by the disk feeder.   
   
   
       16 . The system as recited in  claim 15 , wherein the second position comprises a second elevation lower than the first elevation. 
   
   
       17 . The system as recited in  claim 16 , wherein the transfer device is aspated to lower the stack of sheet material onto the second position. 
   
   
       18 . The system as recited in  claim 15 , wherein the translatable assembly comprises a plurality of wheels adapted to support the translatable assembly. 
   
   
       19 . The system as recited in  claim 15 , wherein the means for translating at least one of the two opposing surfaces comprises at least one fluid-driven cylinder. 
   
   
       20 . The system as recited in  claim 15 , wherein the means for transferring the transfer device comprises one of a drive belt and a drive chain. 
   
   
       21 . A system for handling sheet material comprising:
 a receptacle adapted to receive a plurality of pieces of sheet material, the receptacle pivotally mounted above a conveyor;   an agitating device mounted to the receptacle, the agitating device adapted to agitate the receptacle whereby at least some of the pieces of sheet material become aligned along an inside surface of the receptacle; and   means for pivoting the receptacle from a first position where the pieces of sheet material can be received to a second position where the pieces of sheet material can be displaced from the receptacle by the conveyor.   
   
   
       22 . The system as recited in  claim 21 , wherein the means for pivoting the receptacle comprises at least one fluid driven cylinder having a first end mounted to a rigid support and a second end mounted to the receptacle. 
   
   
       23 . The system as recited in  claim 21 , wherein the conveyor comprises a plurality of translating guides adapted to contact and transfer the pieces of sheet material, and wherein the receptacle comprises at least one slot adapted to receive the plurality of translating guides. 
   
   
       24 . The system as recited in  claim 21 , wherein the conveyor comprises a plurality of translating guides adapted to contact and displace the pieces of sheet material, and wherein the second position comprises a position where at least one of the plurality of translating guides contacts and displaces the pieces of sheet material from the receptacle. 
   
   
       25 . The system as recited in  claim 21 , wherein the receptacle comprises a rectangular receptacle having an open top for receiving pieces of sheet material and a closed bottom. 
   
   
       26 . The system as recited in  claim 25 , wherein the system further comprises a plurality of bars mounted to the receptacle, the bars having a distal end pivotally mounted to a rigid structure. 
   
   
       27 . The system as recited in  claim 25 , wherein the inside surface of the receptacle comprises an inside lateral surface of the rectangular receptacle. 
   
   
       28 . The system as recited in  claim 21 , wherein the agitating device comprises an electric motor. 
   
   
       29 . The system as recited in  claim 21 , wherein the system comprises a plurality of receptacles adapted to receive a plurality of pieces of sheet material, each of the plurality of receptacles pivotally mounted above the conveyor. 
   
   
       30 . The system as recited in  claim 21 , wherein the agitating device comprises a first agitating device, and wherein the system further comprises a second agitating device, different from the first agitating device, the second agitating device adapted to agitate the receptacle. 
   
   
       31 . A method for handling sheet material comprising:
 introducing a plurality of pieces of sheet material to a receptacle, the receptacle pivotally mounted above a conveyor;   agitating the receptacle whereby at least some of the pieces of sheet material become aligned along an inside surface of the receptacle; and   pivoting the receptacle from a first position, where the pieces of sheet material can be introduced, to a second position, where the pieces of sheet material can be removed from the receptacle by the conveyor.   
   
   
       32 . The method as recited in  claim 31 , pivoting the receptacle comprises actuating at least one fluid driven cylinder having a first end mounted to a rigid support and a second end mounted to the receptacle. 
   
   
       33 . The method as recited in  claim 31 , wherein the conveyor comprises a plurality of translating guides adapted to contact and translate the pieces of sheet material, and wherein the method further comprises removing the pieces of material from the receptacle by contacting the pieces of material with the translating guides. 
   
   
       34 . The method as recited in  claim 31 , wherein the receptacle comprises a rectangular receptacle having an open top, and wherein introducing the plurality of pieces of sheet material to the receptacle comprises introducing the plurality of pieces of sheet material to the open top of the rectangular receptacle. 
   
   
       35 . The method as recited in  claim 34 , wherein the rectangular receptacle comprises at least one inside lateral surface, and wherein agitating the receptacle comprises agitating the rectangular receptacle wherein at least some of the pieces of sheet material become aligned along the inside lateral surface of the rectangular receptacle. 
   
   
       36 . The method as recited in  claim 31 , wherein agitating the receptacle comprises agitating the receptacle with an electric motor mounted to the receptacle. 
   
   
       37 . The method as recited in  claim 31 , wherein
 introducing the plurality of pieces of sheet material to a receptacle comprises introducing the plurality of pieces of sheet material to a plurality of receptacles, each pivotally mounted above the conveyor;   wherein agitating the receptacle comprises agitating the plurality of receptacles; and   wherein pivoting the receptacle comprises pivoting a plurality of the receptacles from a first position to a second position.   
   
   
       38 . The method as recited in  claim 31 , wherein agitating the receptacle comprises agitating the receptacle with an electric motor mounted to the receptacle, and wherein the method further comprises agitating the receptacle with a fluid-driven cylinder. 
   
   
       39 . A hopper loader system adapted to load individual sheet material to a rotatable drum conveyor, the drum conveyor having a rotatable disk feeder, the system comprising:
 a pivotally mounted receptacle adapted to receive a stack of sheet material;   an agitating device mounted to the receptacle, the agitating device adapted to agitate the receptacle whereby at least some of the pieces of sheet material in the stack of sheet material become aligned along an inside surface of the receptacle;   means for pivoting the receptacle from a first position where the stack of sheet material can be received to a second position where the stack of sheet material can be displaced from the receptacle;   a conveyor adapted to displace the stack of sheet material from the receptacle and transfer the stack of sheet material to a third position; and   a transfer device adapted to transfer the stack of sheet material from the third position to a fourth position laterally disposed from the first position wherein the pieces of the stack of sheet material can be introduced to the drum conveyor by the disk feeder.   
   
   
       40 . A method of introducing sheet material to a disk feeder, the method comprising:
 introducing a stack of pieces of sheet material to a pivotally mounted receptacle;   agitating the receptacle whereby at least some of the piece of sheet material in the stack of sheet material become aligned along an inside surface of the receptacle;   pivoting the receptacle from a first position, where the stack of sheet material can be introduced, to a second position, where the stack of sheet material can be removed from the receptacle;   transferring the stack of sheet material from the receptacle to a third position;   gripping the stack of sheet material in the third position with a translatable gripping device;   transferring the gripping device and gripped stack of sheet material from the first position to a second position laterally disposed from the first position, the second position; and   introducing individual sheet material from the stack of sheet material to the disk feeder.