Methods and systems for producing pressware
A system for scoring a web of a roll of material comprises a plate, a scoring punch, a scoring station actuator, and a controller. The plate has a slot extending about a shape representing an outline of a pressware product. The scoring punch has a protruding blade operable to enter the slot of the plate. The scoring station actuator is configured to shift the scoring punch or the plate to press the blade against the web to form a slot in the web. The controller is configured to direct the scoring station actuator to press the blade to a first predetermined scoring depth within the web.
1 . A system for scoring a web of a roll of material, the system comprising:
a plate having one or more slot extending about and defining a shape representing an outline of a pressware product;
a scoring punch having one or more protruding blade corresponding to the one or more slot of the plate;
a platen that supports the scoring punch;
one or more toggle bearing block supporting the platen;
a scoring station actuator configured to shift at least one of the one or more toggle bearing block or the plate from a retracted position in which the scoring punch and the plate are separated and an extended position in which the protruding blade of the scoring punch is located in the one or more slot of the plate at a scoring depth relative to the one or more slot;
one or more wedge set positioned between the one or more toggle bearing block and the platen;
a height adjust actuator operable to shift the one or more wedge set relative to the one or more toggle bearing block to vary a distance between the one or more toggle bearing block and the platen to adjust the scoring depth; and
a controller configured to receive a signal representative of a desired scoring depth, direct the height adjust actuator to adjust the scoring depth to the desired scoring depth, and direct the scoring station actuator to shift at least one of the scoring punch or the plate so that the one or more protruding blade is positioned at the desired scoring depth.
2 . The system of claim 1 , wherein the plate and the scoring punch are formed of metal.
3 . The system of claim 1 , wherein the one or more toggle bearing block is operatively associated with the scoring station actuator.
4 . The system of claim 1 , further comprising one or more biasing elements configured to bias the one or more toggle bearing block toward the platen to sandwich the one or more wedge set.
5 . The system of claim 4 , further comprising:
one or more additional toggle bearing block operatively associated with the scoring station actuator;
one or more additional wedge set positioned between the one or more additional toggle bearing block and the platen; and
a wedge drive plate in operative association with the height adjust actuator and the one or more wedge set and the one or more additional wedge set so that actuation by the height adjust actuator shifts both the one or more wedge set and the one or more additional wedge set relative to their respective one or more toggle bearing blocks.
6 . The system of claim 5 , wherein the height adjust actuator comprises a servo motor.
7 . The system of claim 6 , further comprising a lead screw operatively associated with the servo motor and the wedge drive plate so that actuation of the servo motor extends or retracts the lead screw to shift the wedge drive plate.
8 . A system for scoring a web of a roll of material, the system comprising:
a plate having one or more slot extending about and defining a shape representing an outline of a pressware product;
a scoring punch having one or more protruding blade corresponding to the one or more slot of the plate;
a platen having a first side connected to the scoring punch and a second side opposing the first side;
a plurality of toggle bearing blocks indirectly connected to the second side of the platen;
a scoring station actuator configured to shift the plurality of toggle bearing blocks from a retracted position in which the scoring punch and the plate are separated and an extended position in which the protruding blade of the scoring punch is located in the one or more slot of the plate at a scoring depth relative to the one or more slot;
a plurality of wedge sets positioned between the platen and the plurality of toggle bearing blocks;
a plurality of biasing elements configured to bias the plurality of toggle bearing blocks toward the platen to sandwich the plurality of wedge sets;
a height adjust actuator operable to shift the plurality of wedge sets relative to the plurality of toggle bearing blocks and the platen to adjust the scoring depth; and
a controller configured to receive a signal representative of a desired scoring depth, direct the height adjust actuator to shift the scoring punch to adjust the scoring depth to the desired scoring depth, and direct the scoring station actuator to shift the scoring punch so that the one or more protruding blade is positioned at the desired scoring depth when the scoring punch is at the extended position.
9 . The system of claim 8 , further comprising one or more wedge drive plate in operative association with the height adjust actuator and two or more of the plurality of wedge sets so that actuation by the height adjust actuator shifts the one or more wedge drive plate, thereby shifting the two or more of the plurality of wedge sets relative to their respective toggle bearing blocks.
10 . The system of claim 9 , wherein the height adjust actuator comprises a servo motor.
11 . The system of claim 10 , further comprising a lead screw operatively associated with the servo motor and the one or more wedge drive plate so that actuation of the servo motor extends or retracts the lead screw to shift the one or more wedge drive plate.