Smart die output lane assembly

A die output lane assembly for receiving a plurality of blanks from a cutting die of a die-cutter machine, the die output lane assembly comprising:

• a frame for positioning adjacent to the die-cutter machine, the frame comprising:
• two or more spaced apart frame members, at least one of the two or more frame members being configured to removably attach to the cutting die of the die- cutter machine and defining a portion of a plurality of lanes,
• a plurality of spaced apart support structures extending between and supported by the two or more frame members to define a portion of the plurality of lanes, wherein the two or more frame members span the plurality of support structures,
• one or more first pressure plate movable along one or more of the plurality of support structures and having a first shape corresponding to blanks of the plurality of blanks that exit the cutting die at a first orientation, and
• one or more second pressure plate movable along one or more of the plurality of support structures and having a second shape corresponding to blanks of the plurality of blanks that exit the cutting die at a second orientation that is different than the first orientation;
• and
• one or more memory device in a fixed relationship with the frame and storing data associated with the die output lane assembly thereon, the data including each of the following:
• a dimension of the die output lane assembly, a dimension of the cutting die of the die-cutter machine, a dimension of the plurality of blanks, pick positions for removing the plurality of blanks by a robot arm, retraction paths for removing the plurality of blanks by the robot arm, a speed of the robot arm for part handling, and a placement position for storing the plurality of blanks by the robot arm.

A system for producing sidewalls of paper cups from a web, the system comprising:

• a die-cutter machine comprising—
• a cutting die with a plurality of openings for forming the sidewalls, and
• a punch configured to press the web against the cutting die and push the sidewalls formed therein out of the openings;
• a die output lane assembly temporarily attached to the cutting die, the die output lane assembly comprising—
• a plurality of support structures that define a plurality of lanes, the support structures operable to receive the sidewalls from the openings of the cutting die,
• a frame comprising:
• a first frame member configured to be temporarily attached to the cutting die and spanning the plurality of support structures to support first ends of the plurality of support structures,
• a second frame member spaced apart from the first frame member so that the second frame member is in a spaced relationship with the cutting die when the first frame member is connected to the cutting die, the second frame member spanning the plurality of support structures to support second ends of the plurality of support structures,
• sensors attached to the frame and configured to generate data representative of capacities of the plurality of lanes, and
• a memory device secured to the frame and storing data associated with the die output lane assembly thereon, the data including each of the following:
• a dimension of the die output lane assembly, a dimension of the cutting die of the die-cutter machine, a dimension of the one or more blank, a pick position for removing the one or more blank by a robot arm, a retraction path for removing the one or more blank by the robot arm, a speed of the robot arm for part handling, and a placement position for storing the one or more blank by the robot arm;
• a robot arm operable to remove the sidewalls from the die output lane assembly;
• and
• a controller remote from the die output lane assembly and in communication with the robot arm, the controller being configured to:
• connect to the memory device,
• receive the data associated with the die output lane assembly,
• direct the robot arm to remove the sidewalls from the die output lane assembly,
• receive the data representative of capacities of the plurality of lanes, and
• transmit a signal representative of at least one of an instruction to the robot arm to adjust a speed of operation of the robot arm or an instruction to the die-cutter machine to adjust an operation rate based at least in part on the data representative of the capacities of the plurality of lanes.