Paper jam detector for automatic food processing line

Abstract

A paper jam detector for use in connection with a substrate interleaver of an automated food processing line is provided. At least one jam detector sensor is located along at least one of the feed path from the substrate feed mechanism and a second conveyor that receives product from a first conveyor, and is adapted to detect when a substrate passes from the substrate feed mechanism onto the second conveyor. A controller is connected to the at least one jam detector sensor and to the substrate feed mechanism such that upon detection of an unsuccessful substrate feed, the controller turns off the substrate feed mechanism to prevent feeding of more substrates into the jam area, which creates a hard jam and longer down time for the production line for clearing the jam. A method for detecting jams is also provided.

1 . An interleaver having a substrate jam detector comprising: 
 first and second conveyors, the first conveyor adapted to feed a product onto the second conveyor;    a substrate feed mechanism having a feed path positioned to insert a predetermined length of substrate between the first and second conveyors and onto the second conveyor such that the substrate is adapted to be located under the product as the product is transferred from the first conveyor to the second conveyor;    at least one jam detector sensor located along at least one of the feed path from the substrate feed mechanism and the second conveyor for sensing a substrate; and    a controller, connected to the at least one jam detector sensor and to the substrate feed mechanism, which is adapted to determine an unsuccessful substrate feed by at least one of a determination of whether the jam detector sensor senses a substrate for greater than a predetermined interval greater than zero and a determination of whether the jam detector sensor fails to sense a substrate for greater than a predetermined interval greater than zero, such that upon a determination of an unsuccessful substrate feed, the controller turns off the substrate feed mechanism.    
   
   
       2 . The interleaver of  claim 1 , wherein the jam detector sensor comprises a photo-eye.  
   
   
       3 . The interleaver of  claim 1 , wherein the jam detector sensor comprises a fiber optic cable connected to an optic sensor connected to the controller, the fiber optic cable having an end positioned adjacent to at least one of the feed path and the second conveyor.  
   
   
       4 . The interleaver of  claim 3 , wherein the fiber optic cable is bendable.  
   
   
       5 . The interleaver of  claim 1 , further comprising a product detector located along the first conveyor to generate a signal to activate the substrate feed mechanism.  
   
   
       6 . The interleaver of  claim 1 , wherein the substrate feed mechanism includes a perforator and at least one acceleration roller for separating the substrate to be interleaved along a perforation line, and the at least one jam detector sensor is located between the perforator and the at least one acceleration roller.  
   
   
       7 . Method of detecting a jam in a substrate interleaver for products traveling along a conveyor path, comprising: 
 (a) providing first and second conveyors, the first conveyor adapted to feed a product onto the second conveyor;    (b) positioning a jam detector sensor along at least one of a substrate feed path of a substrate feed mechanism positioned to insert substrates under product being conveyed by the first conveyor to the second conveyor and the second conveyor;    (c) detecting a product traveling along the first conveyor and initiating a substrate feed sequence from the substrate feed mechanism;    (d) sensing at least one of a substrate and a blockage of the jam detector sensor;    (e) determining an unsuccessful substrate feed by at least one of determining whether the jam detector sensor senses at least one of a substrate and a blockage for greater than a predetermined interval greater than zero, and determining whether the jam detector sensor fails to sense a substrate for greater than a predetermined interval greater than zero; and    (f) turning off the substrate feed mechanism in the event that an unsuccessful substrate feed is determined.    
   
   
       8 . The method of  claim 7 , wherein the substrate feed mechanism is turned off prior to feeding a next substrate.  
   
   
       9 . The method of  claim 7 , further comprising sounding an alarm when the unsuccessful substrate feed is detected.  
   
   
       10 . The method of  claim 9 , further comprising clearing a jam and resetting the jam detector.  
   
   
       11 . The method of  claim 7 , wherein the jam detector sensor includes a fiber optic cable, the method further comprising positioning a sensing end of the fiber optic cable along the substrate feed path.  
   
   
       12 . The method of  claim 7 , further comprising generating a signal to turn off upstream equipment when the unsuccessful substrate feed is detected.  
   
   
       13 . The method of  claim 7 , wherein the sensing of the substrate includes sensing at least one of a leading and a trailing edge of the substrate.  
   
   
       14 . An interleaver having a substrate jam detector comprising: 
 first and second conveyors, the first conveyor adapted to feed a product onto the second conveyor;    a substrate feed mechanism, which includes cutting rollers and acceleration rollers positioned to convey a predetermined length of substrate along a feed path which flows downstream from the cutting rollers to the acceleration rollers, and from the acceleration rollers between the first and second conveyors onto the second conveyor, such that the substrate is adapted to be located under the product as the product is transferred from the first conveyor to the second conveyor;    at least one jam detector sensor, positioned to sense the substrate at a location downstream from the cutting rollers of the substrate feed mechanism; and    a controller connected to the at least one jam detector sensor and to the substrate feed mechanism which is adapted to determine an unsuccessful substrate feed by at least one of a determination of whether the jam detector sensor senses a substrate for greater than a predetermined interval and a determination of whether the jam detector sensor fails to sense a substrate for greater than a predetermined interval, such that upon a determination of an unsuccessful substrate feed, the controller turns off the substrate feed mechanism.    
   
   
       15 . A method of detecting a jam in a substrate interleaver comprising: 
 providing first and second conveyors, the first conveyor positioned to feed a product onto the second conveyor;    providing a substrate feed mechanism having a feed path positioned to insert a predetermined length of substrate between the first and second conveyors and onto the second conveyor to locate the substrate under the product as the product is transferred from the first conveyor to the second conveyor, the substrate feed mechanism including a perforator and at least one acceleration roller for separating the substrate to be interleaved along a perforation line, the feed path flowing downstream from the perforator to the at least one acceleration roller;    detecting a product traveling along the first conveyor and initiating a substrate feed sequence from the substrate feed mechanism;    sensing a substrate along the feed path in an area downstream from the perforator;    determining an unsuccessful substrate feed by at least one of determining whether the jam detector sensor senses a substrate for a predetermined interval greater than zero and determining whether the jam detector sensor fails to sense a substrate for a predetermined interval greater than zero; and    turning off the substrate feed mechanism in the event that an unsuccessful substrate feed is determined.    
   
   
       16 . The method according to  claim 15 , further comprising sensing the substrate along the feed path in an area between the at least one acceleration roller and the perforator.  
   
   
       17 . The method according to  claim 15 , further comprising turning off upstream equipment in the event that an unsuccessful substrate feed is determined.