Jogger Having a Floating Mount

This application is related to copending application Ser. No. 978,994, filed Nov. 19, 1992, now U.S. Pat. No. 5,310,172, and application Ser. No. 693,638, filed Apr. 30, 1991, now U.S. Pat. No. 5,197,590, issued Mar. 30, 1993, both of said documents being assigned to the assignee of the present invention.

The present invention relates to joggers and more particularly to a novel floating mount for devices such as joggers for regulating the force applied to the top edges of signatures being jogged into alignment and preventing signatures from being curled.

Vertical hopper loaders are well known in the art and are typically used in the printing and publishing field and are utilized to form neatly aligned stacks of signatures preparatory to being fed to saddle conveyors, bindery machines and the like. One typical hopper loader which may use the present invention to great advantage is described in copending application Ser. No. 978,994, filed Nov. 19, 1992 and assigned to the assignee of the present invention. For purposes of understanding the present invention, the vertical hopper loader of application Ser. No. 978,994, receives stacks of signatures typically manually placed upon a first, horizontal conveyor section. The signatures are tilted over so as to be substantially diagonally aligned and in a near-vertical position and are thereafter moved along a diagonally aligned conveyor path formed by a ramp conveyor section which causes the signatures to be fed in a shingle fashion at a speed which is the same as or faster than the speed of the horizontal conveyor with the folded edges extending upwardly and being spaced by an increased distance from the folded edge of adjacent signatures due to the diagonally upward movement. The conveyor path then changes whereupon the lower edges of the signatures are moved along a third, short conveyor path aligned so as to move the lower edges of the signatures either horizontally or diagonally downwardly toward a collection device typically inclined at an acute angle to the vertical.

As the signatures are advanced along the third, short conveyor path by virtue of a conveyor means engaging and driving the bottom edges of the signatures engaging the conveyor means to advance the signatures to the output utilization device, it is advantageous to provide a jogging means for jogging the top edges of the signatures to form a neat stack preparatory to delivery to the output utilization means to assure proper feeding.

Jogging is typically accomplished by employment of jogging means such as a beaver-tail jogger described in the aforementioned U.S. Pat. No. 5,197,590. Such beaver-tail joggers are adjustable, typically in at least two mutually perpendicular directions, to adjust the beaver-tail plate which undergoes oscillation to jog the stack of signatures therebeneath by repeated engagement with the upper folded edges of the signatures as they move along the third conveyor path.

Conventional beaver-tail joggers of the type described in U.S. Pat. No. 5,197,590 have the disadvantage of being substantially fixed in space, once adjusted, so that signatures may be damaged or unnecessarily curled and/or the beaver-tail jogger drive assembly may be overloaded and possibly damaged due to changes in the nominal position of the top folded edges of the signatures.

The present invention is characterized by comprising a novel four-bar parallelogram-type linkage assembly for floatingly mounting jogger assemblies and the like. The jogger assembly is swingably mounted upon a support post which serves as one "bar" of the four-bar assembly. First ends of a second "bar" and a third "bar" are swingably mounted to said post and a fourth "bar" has its ends pivotally coupled to the free ends of said second and third bars. A jogger assembly is coupled to the fourth bar by adjustable means for adjusting the position and angular orientation of the beaver-tail jogging plate relative to the top folded edges of a stack of forming signatures.

The aforementioned second bar is provided with an extension that extends away from the jogger assembly and which is provided with a mass which is movable along a slidable mount provided on the extension and includes releasable fastening means for maintaining the slidable mass in a predetermined position, said slidable mass at least partially counterbalancing the weight of the jogger assembly by an amount which is a function of weight of the mass and the position of the slidable mass along the extension rod.

Once the jogging plate is positioned at the desired orientation, the four-bar linkage assures that the jogging plate thereafter remains parallel to its original orientation regardless of any swinging movement up or down experienced by the linkage assembly. The weight or force of the jogging plate upon the top folded edges of the signatures is dynamically adjusted in the event that any changes occur in the position or positions of the top folded edges of signatures conveyed to the third and final conveying path of the hopper loader. This arrangement also operates as a safety feature which permits movement of the jogger assembly responsive to any impediment which may strike or be struck by the jogger plate and/or jogger.

Adjustably mounted sensing means is provided to activate the jogger assembly only in the presence of a signature stack to be jogged. Further sensing means are provided to deactivate the jogger assembly when the jogging assembly is lifted to a given position displaced from the nominal stack jogging position.

It is therefore one object of the present invention to provide a novel mounting assembly for floatingly mounting jogging assemblies and the like.

Still another object of the present invention is to provide a novel four-bar linkage for floatingly mounting jogger assemblies and the like.

Still another object of the present invention is to provide a novel mounting assembly for floatingly mounting beaver-tail joggers and the like.

Still another object of the present invention is to provide a novel assembly for floatingly mounting joggers, jogger assemblies and the like and incorporating a slidably mounted mass for adjusting the force exerted by the jogger assembly upon a stack of signatures being formed on an outfeed conveyor.

The above, as well as other objects of the present invention will become apparent when reading the accompanying description and drawings, in which:

FIG. 1 is a simplified elevational view of a vertical hopper loader incorporating the floating top jogger assembly of the present invention;

FIG. 1a shows a simplified, diagrammatical view of the jogger mounting assembly of FIG. 1 which is useful in explaining the manner in which the orientation of the jogger assembly jogger plate is maintained regardless of swinging movement of the mounting assembly;

FIG. 2a is a detailed exploded perspective view of the support assembly of FIG. 1;

FIG. 2b is a detailed assembled perspective view of the support assembly of FIG. 2a;

FIG. 2c is a perspective view of guard plates employed with the floating support assembly of FIG. 2a; and

FIGS. 3a and 3b are exploded perspective and assembled perspective views of the jogger assembly.

FIG. 1 shows a simplified view of a vertical hopper loader 10 which includes a wheeled support frame 12 having a first substantially horizontally aligned conveyor section 14 for conveying signatures S in the direction shown by arrow A. A hopper loader suitable for use with the present invention is described in detail in U.S. Pat. No. 5,197,590 and incorporated herein reference thereto.

Stacks of signatures are typically manually placed upon the first conveyor section with their folded edges up. The signatures are maintained in a substantially diagonal alignment and move in the direction of arrow A toward a second conveyor section 16 which moves the signatures diagonally upward and to the right as shown by directional arrow B. Movement of signatures S along conveyor path 16 serves to separate adjacent signatures from one another preparatory to their movement to the final output conveyor section 18 which supports and engages the folded edges of signatures S with the cut edges being substantially aligned along the top of the group G of signatures being formed upon the upper run of conveyor section 18. The signatures are advanced by conveyor section 18 so as to be moved either horizontally or in a slightly diagonally downward direction as shown by arrow C.

The signatures S in the signature group G are incrementally stepped toward a limit plate 20 by apparatus described in detail in U.S. Pat. No. 5,197,590. Signatures are typically extracted, one at a time, once they reach the limit plate, for example, by suction means shown in U.S. Pat. No. 5,197,590 (see FIG. 6) and are fed to an output utilization device such as, for example, a bindery or stitching saddle. It is extremely important that each signature be accurately aligned upon arrival at limit plate 20 in order to be assured that it will be accurately picked up and fed to the output utilization device. The vertical hopper loader serves this function together with the jogger assembly 30 of the present invention. Although the first, second and third conveyor sections 14, 16 and 18 respectively provide a substantially neat alignment of signatures in group G as they are advanced to limit plate 20, the desired precise alignment is further assured through the use of jogger assembly 30 which employs a jogging plate 40 reciprocated by a drive motor 42 to move in the direction shown by double-headed arrow D to jog the top folded edges of signatures in group G as they are advanced in the direction shown by arrow C along conveyor section 18, thus, assuring that the top folded edges are substantially in perfect alignment preparatory to reaching limit plate 20.

Heretofore, jogger assemblies employing a jogging plate utilized adjustment means for adjusting the jogging plate according to the angular orientation as well as the distance of the jogging plate above the surface of conveyor section 18, which is a function of the height of the signatures being collected. One such jogger assembly and the adjustment means therefor is described in the aforementioned U.S. Pat. No. 5,197,590.

The present invention provides a novel floating assembly 30 which is of a four-bar linkage type and is comprised of a support post 34 having its lower end secured to the hopper loader support structure by suitable support means 35. A pair of "bars" 36 and 37 are swingably mounted to post 34 by pivots at their ends 36a, 37a. A fourth "bar" 38 has its upper end 38a pivotally coupled by suitable coupling means 36f, 46 to the free end 36b of bar 36 (see FIG. 2a). The lower end 38b of bar 38 is pivotally coupled by coupling means 38f, 46 to the right-hand, free end 37b of bar 37 (see FIG. 2a).

Bar 36 is provided with an extension 39 extending to the left of support post 34 and provided with a mass 41 which is mounted to slide in either of the two directions shown by arrows E, F. Releasable fastening means (to be more fully described) serve to maintain mass 41 at any desired position along the permissible length of travel provided by means to be more fully described.

Adjustment means, to be more fully described, permit adjustment of the jogging plate shown by double-headed arrows H, I and J in FIG. 1a.

Assuming the orientation of the plate 40 to be as shown in FIG. 1a, the novel operation of the four-bar linkage is as follows:

Omitting the description of extension bar 39 and slidable mass 41 for the moment, the pivotal mounts MP.sub.1 through MP.sub.4 provided to swingably mount each of the bars to at least two associated adjacent bars cause the assembly to swing clockwise about the pivotal mounts MP.sub.1, MP.sub.4 coupling bars 36 and 37 to post 34 due to the weight of the linkage assembly as well as the weight of the jogger assembly mounted thereto.

Any irregularities or differences along the top edges of the signatures within group G (see FIG. 1) will exert an upward force against jogging plate 40 causing the plate to move upwardly. The pivotal mounts MP.sub.1 through MP.sub.4 freely permit this movement, further preventing the signatures from either being damaged or unduly curled.

The movement of arms 36 and 37 in either the clockwise or the counterclockwise direction has no effect whatsoever upon the angular orientation of bar 38 which remains parallel to vertically aligned post 34 regardless of the amount or direction of angular movement experienced by bars 36 and 37 within the normal range of movement. As a result, the surface of jogging plate 40 likewise always remains parallel to its nominal position, shown in solid line fashion in FIG. 1a.

Force exerted upon the top edges of signatures in the group G is a function of the weight of bars 36, 37 and 38 as well as the jogger assembly 30. This force may be counterbalanced and/or reduced by adjustment of slidable mass 41 with the counterbalancing force being a function of the weight of mass 41 and the distance of mass 41 from the upward pivotal mount MP.sub.1 joining extension 39 and bar 36 to post 34. This arrangement permits the force exerted by the jogger assembly 30 upon the top folded edges of the signatures to be adjusted within predetermined limits. For example, in one preferred embodiment, the force exerted by plate 40 upon the top edges of the signatures in group G may be altered from a range of from one ounce to five pounds.

FIG. 2a shows a detailed exploded view of the support assembly 30 and FIG. 2b shows a detailed assembled view, both in perspective, of the jogger assembly floating support in which like numerals as between FIGS. 1 and la and FIGS. 3a and 3b designate like elements.

The lower end of support post 34 is swingably mounted in a cup-shaped support 35 having a flat surface 35a joined to the hopper loader frame 14 as shown in FIG. 1. U-shaped member 33 is secured to frame 12 (see FIG. 1) to further support post 34 and prevent rotation about its longitudinal axis. The side walls 37c, 37d of arm 37 are pivotally mounted to block 45 arranged at a predetermined position along post 34. Fasteners F retain block 45 at the desired position. Fasteners such as 36a-1, which include a collar 46, swingably mount the right-hand end of arm 37 to block 45. The side walls 36c, 36d of arm 36 are mounted to a similar block 48 secured at a predetermined height along post 34 by fasteners F.sub.1. "Bar" 38 is a channel-shaped member having sides 38c, 38d arranged on opposite sides of bars 36 and 37. Fasteners 36f, 38f couple the channel side 38d to bars 36 and 37. Side 38c is secured to the opposite sides of bars 36 and 37 in a similar manner and utilizing similar fasteners (not shown for purposes of simplicity). Collars 46 provide the desired pivotal motion of bars 36, 37 and 38. Spacers 49 are arranged to span between the vertical sides 36c, 36d of channel-shaped bar 36 and 37c, 37d of channel-shaped bar 37.

Cut-out portions 36e and 37e in the top surface of channel-shaped bars 36 and 37 provide adequate clearance for mounting blocks 45 and 48 to permit the linkage assembly to move along its normal swing path between position 30 and 30' (see FIG. 1a) without interference.

Extension 39 of bar 36 is integral with bar 36 and is a channel-shaped member provided with elongated slots 39a, 39b along side surface 39c. Similar slots (not shown) may be provided along side surface 39d. An elongated slot 39e is provided in the top surface 39f of channel-shaped extension 39. Mass 41 is slidably mounted between the sides 39c and 39d of channel-shaped extension 39 and is adjustable over a predetermined distance which is equal to the length of the slots 39a, 39b, 39e, the length of these slots being equal to one another.

A permanent magnet member 52 is secured to bracket 50 which in turn is positioned to span between sides 39c and 39d of extension 39. Suitable fastening means (not shown) secure bracket 50 to extension 39. Fastening means F.sub.2 secure permanent magnet 52 to mounting bracket 50.

A switch PS is mounted upon mounting block 44 (see FIG. 2b) and is activated by permanent magnet 52 when the four-bar linkage is pivoted counterclockwise in order to lift the jogger assembly upward and away from the signature stack being formed (see dotted line position 30' in FIG. 1a), the lifting of bars 36, 37, and 38 causing the lowering of extension 39 to position the permanent magnet 52 in close proximity to switch PS which automatically turns off the jogging assembly. The proximity switch PS activates to turn off motor M (see FIG. 3a) when the extension forms an angle of the order of 15.degree. with vertical post 34.

Channel-shaped "bar" 38 is provided with mounting openings 38e in side wall 38c for adjustably mounting the jogger assembly to be more fully described in connection with FIGS. 3a and 3b.

FIGS. 3a and 3b show a jogging assembly 42 which is comprised of an L-shaped mounting bracket 60 having elongated slots 60c provided in arm 60a. Adjustable fasteners F.sub.3 threadedly engage tapped openings 38e in side 38c of channel 38 shown in FIG. 2a to adjustably mount bracket 60 to channel-shaped bar 38. Motor M is mounted upon a pair of mounting blocks 62, 62 which are in turn secured to the arm 60b of bracket 60.

A bracket 64 is slidably mounted on the surface of bracket arm 60b opposite the surface facing motor M and is provided with elongated slots 64a for receiving adjustable fasteners F.sub.4 for adjusting the vertical position of bracket 64 along bracket arm 60b to thereby adjust the angular orientation of jogging plate 92 as will be more fully described. A solid block 66 is integrally joined to bracket 64 and is provided with a substantially horizontally aligned elongated opening for slidably receiving rod 68 which is held between a pair of blocks 70, 70.

Blocks 70, 70 are secured by suitable fasteners (not shown) to the right-hand end of jogging plate 92, the fasteners extending through mounting openings 92c in plate 92. Plate 92 and blocks 70, 70 are swingable about the longitudinal axis of rod 68 which freely rotates relative to block 66. The position of bracket 64 relative to the motor output shaft MS determines the angular orientation of jogging plate 92.

An elongated rod 72 has its upper end joined to the right-hand surface of block 66 and extends downwardly and through an opening 74a in adjustable block 74 which is provided with a fastener 76 having a butterfly-shaped adjustment head to adjust the position of block 74 along vertically oriented rod 72. Block 78 is integrally joined to one face of block 74 and is provided with an opening 78a for receiving the right-hand end of an elongated rod 80 whose left-hand end extends into an opening 82a in disk-shaped member 82. Plate 84 secures disk-shaped member 82 to a sensing means 86 which projects a signal toward the stack of signatures building on conveyor section 18 (see FIG. 1) and is provided with a sensor for detecting a signal reflected off the surface of a signature to maintain the jogging assembly energized. When the signatures are greater than a predetermined distance from the sensor, the sensor deenergizes the jogger assembly to thereby provide operation of the jogging plate only when signatures are in the region of influence of the jogging plate. Adjustable blocks 74 and 78 permit adjustable movement of the sensing means 86 in mutually perpendicular directions in order to adjust the sensor according to the size of signatures being collected and jogged.

Motor shaft MS of motor M has mounted thereto an eccentric 88 which extends through the center 90a of ring-shaped member 90. Flange 89 at the free end of eccentric 88 retains the ring-shaped member 90 on eccentric 88.

The jogging plate 92, referred to as a "beaver-tail" due to its shape, is mounted to the underside of block 94 by suitable fasteners cooperating with openings 92b. A plate 96 is secured by suitable fasteners to the upper surface of block 94 and engages the periphery of ring-shaped member 90. An elongated rod 98 extends through a horizontally aligned opening 94a in block 94. A pair of tension springs 100 each have their lower ends 100a secured to opposite ends 98a, 98b of elongated rod 98 which rod ends extend beyond the adjacent vertical sides of block 94. The upper ends 100b of tension springs 100 are secured to a mounting plate 102 at the right-hand end of motor M. Thus, block 94 and hence the jogging plate are resiliently urged toward the ring-shaped member by springs 100.

Energization of motor M rotates eccentric 88 causing the bifurcated ends 92a of beaver-tail plate 92 to rotate in a reciprocating manner about pivot rod 68 to repeatedly strike the top edges of the jogger signatures as shown in FIG. 1 and thereby bring the signatures into precise alignment in readiness for take away of each signature as it reaches the limit plate 20.

The force exerted upon the top edges of the signatures by jogging plate 92 is a function of the weight of the jogger assembly and four-bar linkage.

This force is at least partially counterbalanced by adjustment of the slidable mass 41 along extension arm 39 whereby movement of mass 41 further away from post 34 increases the moment arm defined by mass 41 and extension arm 39 to counterbalance at least a portion of the force exerted by the jogging plate 92 (FIG. 3a) upon the signatures.

A safety shield 104 shown in FIG. 2c is secured to bracket 60b and acts as a safety shield to protect operators from injury by preventing operators from inserting a finger, hand or arm into the open region surrounded by the members 36, 37 and 38 of the linkage assembly which collapse when the support assembly moves to the upper, displaced position, reducing the size of the opening region.

The jogging plate 92 (FIG. 3a) may be adjusted to accommodate signature runs of different sizes. Once the jogging plate is adjusted, the jogging plate is maintained parallel to its initial adjustment position regardless of the swinging motion experienced by the linkage about pivot blocks 45 and 48. The freewheeling mounting assembly enables the jogging assembly to be freely lifted up in the event of any blockage or obstruction in the path of the jogging plate.

The sensing means 86 permits motor M to be energized only in the presence of signatures on conveyor section 18 and in the absence of signatures automatically turns motor M off. The jogging assembly may be easily lifted upward for inspection, maintenance or any other purpose whereupon movement of extension arm 39 to form an angle of the order of fifteen degrees (15.degree.) with post 34 causes permanent magnet 52 to activate the proximity switch PS to automatically deenergize motor M when the jogging assembly is lifted upward and away from the jogging region.

A pair of guards 54, 56 are mounted on opposite sides of the four-bar linkage and have mounting members 55 and 57 which snap onto the heads of shoulder bolts 36f, 37f on opposite sides of the four-bar linkage in order to protect operating personnel.

The floating assembly 30 may be employed in any application where it is desired to maintain orientation of an element or device throughout a range of swingable movement as well as at least partially counter-balancing the weight of such element or device. For example, the element may be a feeler arm for sensing the top, side or bottom edges of a stack, a collector or a dispenser for a liquid, etc.

A latitude of modification, change and substitution is intended in the foregoing disclosure, and in some instances, some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein described.