Am International Incorporated

Thomas A Rowe

Stephen M Ent

Andrew D Bruce

A method and apparatus are disclosed for establishing a random fault limit for hoppers in a collating machine. A plurality of hoppers are arranged in an array, each adapted to feed signatures, one at a time, to a conveyor. A miss feed base number and a double feed base number is established in a microcomputer for each of the hoppers equal to either (i) a predetermined number of signature feeds by that hopper, (ii) a predetermined number of books assembled, or (iii) a predetermined number of collator machine cycles. A miss feed fault number and a double feed number is established in the microcomputer for each of the hoppers. Each hopper has an associated miss feed detector and a double feed detector electrically connected to the microcomputer. The microcomputer (i) monitors each of the detectors, (ii) counts the number of miss feeds or double feeds for each hopper, (iii) compares the number of miss feeds and double feeds for each hopper against its associated base number, (iv) determines whether the number of detected miss feeds or double feeds exceed their associated base number, and (v) warns an operator if it is determined that the detected number of miss feeds or double feeds does exceed their respective established base number for any of the hoppers.

Method and apparatus for controlling a collator

A method and apparatus are disclosed for providing a collator having a variable raceway jam fault detection arrangement. A plurality of hoppers are arranged in an array, each adapted to feed signatures onto a raceway having a moving chain. The chain has spaced apart chain pins, the distance therebetween defining signature feed locations. A plurality of jam detector switches are located along the raceway and are adapted to detect a signature jam, e.g., a signature overlying a chain pin. A controller monitors each of the jam switches. The operator enters into the controller a desired rejection pattern for each of the jam switches separately. When a jam switch is tripped, the controller (i) identifies which jam switch was tripped, (ii) recalls the reject pattern for that jam switch, (iii) marks and tracks the assemblages in the recalled reject pattern as they proceed down the raceway, and (iv) enables a reject gate to reject the assemblages commensurate with the reject pattern recalled as the marked assemblages reach the reject gate. The hoppers downstream of the location of the tripped jam switch are disabled from feeding signatures to assemblages marked for rejection.

A method and apparatus are disclosed for controlling a collator. A microcomputer learns hopper insertion points, jam switch insertion points, and hopper miss and double feed service angles relative to a reject gate. Based on the learn collator configuration, the controller controls collator operation. When a hopper phase adjustment is made by an operator, the controller automatically re-learns the hopper service angles during a ripple start of the collator and adjusts its reject data in response thereto. A miss verify sensor arrangement permits the controller to monitor for phase adjustments after a ripple start and to warn the operator upon such occurence.

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North Ridgeville, OH, United States of America

Thomas A Rowe