Stack loading apparatus and method

A stack loading apparatus for receiving and aligning stacks of similarly shaped sheet-like objects, said stack loading apparatus comprising:

• a base plate adapted to rotatably fix aligner actuator ends;
• a plurality of elongate aligner actuators each having a first end, a second end, and an outer surface, said aligner actuator first end being rotatably fixed to said base plate to permit rotation of said aligner actuator about its longitudinal axis which is positioned perpendicular to said base plate, said plurality of aligner actuators arranged on said base plate about a polygon perimeter corresponding to said sheet-like object perimeter, and said aligner actuators each having an aligner actuator track disposed on its outer surface;
• a movable guide plate, positioned substantially parallel to said base plate, having a plurality of aligner actuator-receiving apertures which apertures are defined by an inner perimeter sized for receiving said aligner actuators, said aligner actuator-receiving apertures having a ball bearing rotatably mounted on said inner perimeter for engaging said aligner actuator tracks;
• a plurality of elongate aligners, each aligner fastened at one end to said aligner actuator second end, each elongate aligner corresponding to an aligner actuator;
• means, disposed on said guide plate substantially at the center of said aligner actuator polygon, for supporting an unaligned stack of similarly shaped sheet-like objects in an orientation substantially parallel to said guide plate;
• and
• means for moving said guide plate relative to said base plate along said aligner actuator longitudinal axis while maintaining said plates in substantially parallel relationship;
• wherein, said moving means causes said guide plate to move relative to said base plate which causes said aligner actuators to rotate about their longitudinal axes which causes said aligners to contact and to act upon said unaligned stack to obtain an aligned stack of similarly shaped sheet-like objects.

A stack loading device for receiving, aligning, and delivering stacks of similarly shaped sheet-like objects to containers, said stack loading device comprising:

• an elongate rotation shaft;
• frame means for rotatably fixing the ends of said rotation shaft;
• and
• at least two gripper assemblies that each have a plurality of reciprocatingly rotating elongate aligners that rotate about axes parallel to their longitudinal axes for receiving and aligning stacks of similarly shaped sheet-like objects, said gripper assemblies supported on said rotation shaft;
• wherein pairs of said gripper assemblies are disposed from each other approximately 180 degrees around said rotation shaft;
• and
• wherein, during operation of said device, while one member of said gripper assembly pair receives an unaligned stack of similarly shaped sheet-like objects, the other member of said gripper assembly pair delivers an aligned stack of similarly shaped sheet-like objects to said container.

A method of receiving, aligning, and delivering stacks of similarly shaped sheet-like objects to containers, said method comprising the steps of:

• a) providing a stack loading apparatus with accept and deliver positions and an alignment and deliver cycle having (i) a grasp and constrain step, (ii) a shuffle step, (iii) a wrist rotation step, and (iv) a press to container step, said stack-loading apparatus having a gripper assembly coupled to an elongate rotation shaft which shaft is supported at each end by a frame member, said gripper assembly having a plurality of selectively extendable fingers for assisting in encaging an unaligned stack of similarly shaped sheet-like objects and a plurality of aligners for aligning and encaging said unaligned stack, said gripper assembly having means for reciprocatingly rotating said fingers and said aligners about axes parallel to their longitudinal axes, whereby said aligners contact and align said unaligned stack into an aligned stack of similarly shaped sheet-like objects;
• b) providing a packaging station having means for loading said unaligned stack into said gripper assembly and having means for positioning a container to receive said aligned stack from said gripper assembly;
• c) delivering said unaligned stack to said gripper assembly at said packaging station while said stack loading apparatus is in its accept position;
• d) operating said stack loading apparatus through said grasp and constrain step wherein said gripper assembly fingers and aligners encage said unaligned stack;
• e) operating said stack loading apparatus through said shuffle step wherein said aligners reciprocatingly rotate causing said aligners to contact and to align said unaligned stack into said aligned stack;
• f) operating said stack loading apparatus through said wrist rotation step wherein said rotation shaft rotates approximately 180 degrees causing said gripper assembly to rotate approximately 180 degrees from the accept position;
• and
• g) operating said stack loading apparatus through said press to container step wherein said gripper assembly delivers said aligned stack to said container without disrupting alignment of said aligned stack.