Converting machine with fold sensing mechanism

1. A converting machine used to convert sheet material into packaging templates for assembly into boxes or other packaging, the converting machine comprising:

a converting assembly configured to perform one or more transverse conversion functions and one or more longitudinal conversion functions on the sheet material as the sheet material moves through the converting machine in a feed direction, the one or more transverse conversion functions and the one or more longitudinal conversion functions being selected from the group consisting of creasing, bending, folding, perforating, cutting, and scoring, to create the packaging templates; and

a fanfold crease sensing mechanism configured to detect the presence and location of fanfold creases that exist in the sheet material, the fanfold crease sensing mechanism comprising one or more sensors, the one or more sensors being configured to detect the presence and location of the fanfold creases and distinguish between the presence and location of a fanfold crease and movement of the sheet material closer to or further away from the one or more sensors.

2. The converting machine of claim 1 , wherein the one or more sensors comprise lasers, mechanical, optical, or vision sensors.

3. The converting machine of claim 1 , further comprising a control system, the control system being configured to receive readings from the one or more sensors to determine the presence and location of a fanfold crease in the sheet material.

4. The converting machine of claim 3 , wherein the control system is configured to cause the converting assembly to cut off a leading end of the sheet material if the sensing mechanism detects the presence of a fanfold crease within a predetermined or user configurable range of a leading edge of the sheet material.

5. The converting machine of claim 3 , wherein the control system is configured to cause the converting assembly to cut off a leading end of the sheet material if the control system predicts that a fanfold crease will be within a predetermined or user configurable range of a trailing edge of a packaging template.

6. The converting machine of claim 1 , wherein the one or more sensors comprises a first sensor and a second sensor, the first and second sensors being offset from one another in the feed direction such that only one of the first sensor and the second sensor is positioned above a fanfold crease at a given time and such that the first and second sensors are spaced apart by at least one of the following:

a distance of about half of a width of a fanfold crease; or about 7 mm.

7. The converting machine of claim 6 , wherein the first and second sensors are mounted on the converting assembly.

8. The converting machine of claim 6 , wherein both the first and second sensors are positioned either above the sheet material or below the sheet material.

9. The converting machine of claim 6 , wherein one of the first and second sensors is positioned above the sheet material and the other of the first and second sensors is positioned below the sheet material.

10. A method of converting sheet material into packaging templates for assembly into boxes or other packaging, the method comprising:

detecting with one or more sensors the presence and location of a fanfold crease in the sheet material,

distinguishing between the presence and location of a fanfold crease and movement of the sheet material closer to or further away from the one or more sensors;

determining that the fanfold crease is within a predetermined or user configurable distance of a leading edge of the sheet material;

cutting off a predetermined or user configurable length from a leading end of the sheet material to remove the fanfold crease; and

performing one or more conversion functions on remaining sheet material to form the packaging template.

11. The method of claim 10 , wherein the predetermined or user configurable distance comprises 25 mm, 50 mm, 75 mm, 100 mm, or 150 mm.

12. The method of claim 10 , wherein the predetermined or user configurable length comprises 25 mm, 50 mm, 75 mm, 100 mm, or 150 mm.

13. The method of claim 10 , wherein detecting the presence and location of a fanfold crease in the sheet material comprises comparing readings from multiple sensors of the one or more sensors.

14. A method of converting sheet material into packaging templates for assembly into boxes or other packaging, the method comprising:

detecting the presence and location of a fanfold crease in the sheet material;

predicting the location of a subsequent fanfold crease in the sheet material;

determining that the subsequent fanfold crease would be within a predetermined distance of a trailing edge of a packaging template formed from the sheet material;

cutting off a predetermined length from a leading end of the sheet material to move the subsequent fanfold crease further from the trailing edge than the predetermined distance; and

performing one or more conversion functions on remaining sheet material to form the packaging template.

15. The method of claim 14 , wherein the predetermined distance comprises 25 mm, 50 mm, 75 mm, 100 mm, or 150 mm.

16. The method of claim 14 , wherein the predetermined length comprises 25 mm, 50 mm, 75 mm, 100 mm, or 150 mm.

17. The method of claim 14 , wherein detecting the presence and location of a fanfold crease in the sheet material comprises comparing readings from multiple sensors.

18. A converting machine used to convert sheet material into packaging templates for assembly into boxes or other packaging, the converting machine comprising:

a converting assembly configured to perform one or more transverse conversion functions and one or more longitudinal conversion functions on the sheet material as the sheet material moves through the converting machine in a feed direction, the one or more transverse conversion functions and the one or more longitudinal conversion functions being selected from the group consisting of creasing, bending, folding, perforating, cutting, and scoring, to create the packaging templates;

a fanfold crease sensing mechanism configured to detect the presence and location of fanfold creases that exist in the sheet material, the fanfold crease sensing mechanism comprising one or more sensors, the one or more sensors being configured to detect the presence and location of the fanfold creases and distinguish between the presence and location of a fanfold crease and movement of the sheet material closer to or further away from the one or more sensors; and

a control system configured to receive readings from the one or more sensors and cause the converting assembly to cut off a leading end of the sheet material if:

the sensing mechanism detects the presence of a fanfold crease within a predetermined or user configurable range of a leading edge of the sheet material; or

the control system predicts that a fanfold crease will be within a predetermined or user configurable range of a trailing edge of a packaging template.

19. The converting machine of claim 18 , wherein the one or more sensors comprise first and second sensors that are offset from one another in the feed direction such that only one of the first sensor and the second sensor is positioned above a fanfold crease at a given time and such that the first and second sensors are spaced apart by at least one of the following:

a distance of about half of a width of a fanfold crease; or about 7 mm.

20. The converting machine of claim 18 , wherein the predetermined or user configurable range comprises 25 mm, 50 mm, 75 mm, 100 mm, or 150 mm.