Field of the invention

The present invention relates to a converting machine for producing paper and cardboard containers, such as folding boxes. In particular, it relates to blank joining module configured to join two blanks before folding the blanks in unison.

Background

Converting machines such as folder-gluers are used in the production of packaging items such as paperboard and cardboard boxes. These machines comprise a plurality of workstations which may fold and glue blanks to form boxes and then count, stack and condition the boxes into batches.

Folder-gluer machines can be configured to produce many different types of packaging containers and folding boxes. One type of boxes which is composed from two blanks joined together is often referred to as a “shelf-ready” box. The shelf-ready box comprises an outer carton and an inner carton glued together. The inner carton may serve as a container for the item to be stored, while the outer carton may serve as protection during transportation. This type of box is frequently used in supermarkets and shops, where the inner carton is placed on a shelf with the items left inside.

When producing boxes from several blanks joined together, a blank joining module with a double feeder is needed. Specifically, a first and a second blanks each need a dedicated feeder.

An example of a blank joining module is described in document EP2072241. As the composed boxes is an assembly of two different blanks, there is a need to ensure that the blanks are correctly aligned before they are joined together.

To control the alignment, the blank joining module in EP2072241 comprises upper and lower cleat belts provided with abutments to control the positions of both the first and the second blanks. US2002077236 discloses an alignment device configured to align insert sheets and blanks in relation to each other. The insert sheets are transported along a separate transportation path until the insert sheets and blanks are joined together.

An alignment is achieved by detecting the positions of each blank and insert sheet. A displacement to the insert sheet is then provided to either advance or delay the arrival of the insert sheet such that it is aligned with the blank. The displacement is provided by a conveyor belt which is configured to perform an acceleration or deceleration to each insert sheet, depending on if each particular insert sheet arrives to the sensor with an advance or a delay.

Summary

In view of the prior art, it is an object of the present invention to provide a register control system configured to provide an accurate register correction while maintaining a high production speed.

This object is solved by a blank joining module according to claim 1.

According to a first aspect of the present invention, there is provided a blank joining module comprising an upper feeder device configured to feed an upper blank, a lower feeder device configured to feed a lower blank, and an upper conveyor system configured to transport the upper blank from the upper feeder device, and a lower conveyor system configured to transport the lower blank from the lower feeder device, the upper and lower conveyor systems being configured to transport the upper and lower blanks towards a junction point where the upper blank is positioned onto the lower blank,

The blank joining module comprising a register control arrangement comprising a sensing system and a position correction device. The sensing system comprises an upper transfer sensor configured to detect the passage of the upper blank and a lower transfer sensor configured to detect the passage of the lower blank,

The register control arrangement further comprises a control unit and a memory, the control unit being configured to receive detection signals from the upper and lower transfer sensors and calculate a total relative total displacement between the upper blank and the lower blank, the control unit being further configured to activate the position correction device to provide a correction displacement in the direction of transportation to the upper blank such that the upper blank is displaced to be aligned to the lower blank.

The invention is based on a realization that by only correcting the position of the upper blank, the production speed as defined by the lower blank can be maintained. In a preferred embodiment, only the position of the upper blank is corrected. Consequently, the position of the lower blank is not corrected.

The total relative displacement is the displacement of the upper blank in relation to the actual position of the lower blank and in relation to the predefined assembly position of the upper and lower blanks in the direction of transportation. The total relative displacement is determined by the detection times at the passage of the leading edges of the upper and lower blank at each respective transfer sensor.

The actual position of the lower blank may thus be taken as a reference position for the upper blank and the position correction device is configured to provide a correction displacement such that the upper blank is aligned with the lower blank in the junction point.

The direction of transportation can be defined as a horizontal direction extending from the upper and lower feeder devices to the junction point. The direction of transportation preferably coincides with the longitudinal direction of the converting machine. The direction of transportation extends between an inlet and an outlet of the converting machine. The direction of transportation may thus extend all the way from the upper and lower feeder devices to a folding and gluing module of the converting machine, and further downstream to a delivery module of the converting machine.

Upstream of the junction point, the transportation path of the upper blank is downwardly sloping. For the lower blank, the transportation path upstream of the junction point may be horizontal, or with a deviation of about 15°.

The term “upstream in the direction of transportation” means in a direction from the junction point J to the upper feeder device. The term “downstream in the direction of transportation” means in a direction from the upper feeder device to the junction point J. The correction displacement corresponds to the relative total displacement. The displacement is provided by an acceleration or deceleration of the upper blank.

The memory preferably contains instructions for performing the calculation and a transitional memory for storing the total relative total displacement of each blank present between the feeder unit and the junction point.

The upper conveyor system may comprise an alignment conveyor and a register conveyor.

Preferably, the upper blank is conveyed with a selected displacement distance, such that each upper blank is displaced in relation to a predefined register position of the upper blank.

In a preferred embodiment, the selected displacement distance is selected such that each upper blank always arrive at the location of the upper transfer sensor with a total relative displacement, in relation to the lower blank and wherein the position of each upper blank is corrected with the position correction device.

In an embodiment, the selected displacement distance is selected such that each upper blank needs a correction in the same direction in the upper transportation path. The same direction means that each upper blank is corrected such that it is provided with a displacement in a direction upstream or downstream in the upper transportation path and in relation to the direction of transportation.

In an embodiment, the lower transfer sensor is configured to detect the actual position of the lower blank before the upper transfer sensor detects the actual position of the upper blank.

This allows the control unit to first determine the reference position from the position of the lower blank.

Preferably, only the position of the upper blank is corrected.

In an embodiment, the lower transfer sensor is configured to detect the actual position of the lower blank before the upper transfer sensor detects the actual position of the upper blank.

In an embodiment, the position correction device comprises a housing shroud provided with an extension which extends further upstream in the direction of transportation than the cleat belt, and wherein the upper transfer sensor is located on said protruding extension.

In an embodiment, the actual speed of the upper blank is different from the actual speed of the lower blank.

In another embodiment, the release timing of the upper blank or the actual transportation speed of the upper blank is selected such that the upper blanks are provided with a selected displacement in relation to the register position of the upper blank.

In an embodiment, the position correction device comprises a cleat belt provided with at least one abutment, and wherein the control unit is configured to either position the abutment to abut against the front edge or the rear edge of the upper blank such as to modify the position of the upper blank in the direction of transportation.

The memory preferably comprises a first set of operating instructions for a first operating mode, in which the position correction device is configured to abut against the rear edge of the upper blank such that each upper blank is accelerated by the position correction device, and a second set of instructions for a second operating mode in which the position correction device is configured to abut against the front edge of the upper blank, such that each blank is decelerated by the position correction device to reach the desired position. The acceleration or deceleration allows the upper blank to reach its desired position.

In an embodiment, the position correction device is connected to a displacement mechanism attached to a structural frame of the blank joining module, and wherein the position correction device is displaceable in the direction of transportation such that the position correction device can be moved to a first operating position in the first operating mode and to a second operating position in the second operating mode.

The displacement mechanism comprises a motor and a slide mechanism, and wherein the control unit is configured to actuate to motor to displace the position correction device according to the longitudinal length of the upper blank and the type of correction mode selected. The slide mechanism may comprise a slide rail and a slider. In an embodiment, the register control arrangement further comprises an upper feed sensor and a lower feed sensor configured to detect the respective passage of the upper blank and the lower blank, and wherein the control unit is configured to determine an initial relative feeder displacement from the difference in detection times, and wherein the control unit is configured to issue a warning signal if the initial relative feeder displacement is higher than a correction threshold.

In an embodiment, the upper conveyor system comprises an alignment conveyor and a register conveyor, and wherein the upper alignment conveyor is connected to the register conveyor and an upper feeder, wherein the upper feeder is movable in the longitudinal direction and wherein the upper alignment conveyor is provided with a variable length.

In an embodiment, the control unit is configured to modify the release time and/or the transportation speed of the upper blank based on the length of the upper alignment conveyor.

Brief description of the drawings

The invention will now be described with reference to the appended drawings, in which like features are denoted with the same reference numbers and in which:

Figure 1 is a schematic view of a converting machine in the configuration of a folder gluer;

Figure 2a is schematic perspective view of a folding box in the configuration of a shelf-ready box;

Figure 2b is a planar view of composed blank for producing the folding box of figure 2a;

Figure 3 is a schematic perspective view of a blank-joining module according to an embodiment of the present invention;

Figure 4 is a cross-sectional view of the blank-joining module of figure 3;

Figure 5 is a schematic cross-sectional view of a feeder unit according to an embodiment of the present invention; Figure 6a is a schematic cross-sectional view of a position correction device according to an embodiment of the present invention;

Figure 6b is a detailed view of the position correction device;

Figure 7 is a schematic cross-sectional view of a lower alignment device according to an embodiment of the present invention;

Figures 8a and 8b are schematic cross-sectional side views of an upper alignment device according to an embodiment of the present invention;

Figure 8c is a schematic perspective view of the upper alignment device of figures 8a and 8b; and

Figure 8d is a top view of the upper alignment device of figures 8a to 8c.

Detailed description

Referring to the figures and in particular to figure 1 which illustrates a converting machine 1 in the form of a folder-gluer machine 1. The folder-gluer machine 1 is configured to receive a first stack S1 and a second stack S2 of blanks 2, join them and then fold and glue them together to form folding boxes 2’ or other composed packaging containers.

There are several types of boxes 2” and packaging containers and boxes which can be produced in a folder-gluer machine 1. One type of such a box 2” is illustrated in figures 2a and 2b and is often referred to as a “shelf-ready” boxes 2”. This type of box 2” is composed from two blanks 2b, 2a joined together. One blank 2a may form an inner container and the other blank 2b may form the outer container. In use, the outer container can be manually removed while the inner container is holding the items to be stored.

This type of composed boxes 2” is produced by first forming a composed blank 2’ from a first blank 2a and a second blank 2b in the folder-gluer machine 1. Subsequently, the composed blank 2 undergoes a folding and gluing operation.

As illustrated in figure 1 , the present folder-gluer machine 1 comprises a series of different workstations in the form of modules. The modules may include, from an inlet A to an outlet B: a blank joining module 10, a fold pre-breaking module 12, a gluing module 14 and a folding module 16. The folder-gluer machine 1 may further comprise a main user interface 11 and a quality control system 18. After the gluing and folding modules, a delivery module and conditioning section 20 can be provided in order to count and separate a shingled stream of folding boxes 2” into separate batches. The converting machine 1 further comprises a conveyance system 19 comprising conveyors such as endless belts and rollers configured to transport the first and second blanks 2a, 2b in a direction of transportation T. The converting machine 1 also comprises a control circuitry 80 configured to control the operation of the blank-joining module 10.

The blank joining module 10 enables the folder-gluer 1 to produce the composed blank 2’. As illustrated in figures 3 and 4, the blank joining module 10 comprises a feeder unit 32, an alignment unit 34, a gluing device 100, a register control arrangement 36, and a joining transfer 38.

As best seen in figures 3 and 4, the feeder unit 32 comprises a lower feeder device 32a and an upper feeder device 32b. The upper and lower feeder devices 32b, 32a are configured to respectively feed the blanks 2a, 2b one by one in the direction of transportation T.

The upper feeder device 32b is configured to feed a first blank 2b, also referred to as an “upper blank” 2b, from a stack positioned on an upper loading surface 33b. The lower feeder device 32a is configured to feed a second blank 2a, also referred to as a “lower blank” 2a from a stack positioned on a lower loading surface 33a in the lower feeder device 32a.

The upper loading surface 33b is located vertically above the lower loading surface 33a. To facilitate the access to the upper loading surface 33b, the upper feeder device 32b can be displaceable in a longitudinal direction L and in the direction of transportation T1. In such a way, the upper loading surface 33b can be displaced into a horizontally offset position in relation to the lower loading surface 33a. The upper loading surface 33b can thus be moved closer to a machine operator.

As best seen in figures 3 to 5, the upper feeder device 32b is slidably mounted to a structural frame 40 of the blank joining module 10. The connection between the upper feeder device 32b and the structural frame 40 may be achieved with a sliding connection. The sliding connection may comprise a slide rail 42 and a slider 41. The upper feeder device 32b can be displaced along the slide rail 42 by a motor 44. The motor 44 may perform an automatic displacement of the upper loading surface 33b. The control circuitry 80 of the blank joining module 10 may automatically operate the motor 44 to displace the upper feeder device 32b to a predetermined operating position calculated from the longitudinal length La of the lower blank 2a in the lower feeder device 32a. The longitudinal length La is the length of the lower blank 2a in the direction of transportation T.

To further facilitate the access to the upper feeder device 32b, the blank joining module 10 may further comprise a modular podium 50. As best seen in figure 3, the podium 50 comprises at least one stepping surface 52a. Preferably the podium 50 comprises a second stepping surface 52b movably arranged on top of the first stepping surface 52a.

As illustrated in figure 4, the alignment unit 34 is arranged downstream (in the direction of transportation T) of the feeder unit 32 and is configured to laterally align the upper blank 2b and the lower blank 2a to their respective predefined lateral positions. In such a way, the upper blank 2b and the lower blank 2a are in the correct lateral positions when the blanks 2a, 2b are brought into contact with each other in a junction point J.

The alignment unit 34 comprises an upper alignment device 34b configured to align the upper blank 2b and a lower alignment device 34a configured to align the lower blank 2a. The upper and lower alignment devices 34b, 34a are provided with a respective distal upstream connection end 35b, 35a which is preferably fixedly connected to the upper and lower feeder devices 32b, 32a.

The lower alignment device 34a is configured to transport the lower blank 2a along a substantially horizontal transportation path Pa. As best seen in figure 7, the lower alignment device 34a comprises an upper pressing member 60a, a lower conveyor 61a and a guide (not shown). The lower conveyor 61a comprises an endless conveyor belt 62a having a contact length Lea configured to be in contact and drive the lower blank 2a forward in the direction of transportation T.

As best seen in figures 8a to 8d, the upper alignment device 34b comprises an upper pressing member 60b, and an upper conveyor 61 b. A guide 63 is arranged such that it is straight in the direction of transportation T. The upper pressing member 60b and the upper conveyor 61b are arranged at an angle in the direction of transportation T such as to direct a lateral edge of the lower blanks 2a against the guide 63. The upper conveyor 61b comprises an endless conveyor belt 62b having a contact length Lcb configured to be in contact and drive the upper blank 2b forward in the direction of transportation T.

The upper alignment device 34b is thus configured similarly to the lower alignment device 34a. However, the upper alignment device 34b is provided with a variable contact length Lcb in the direction of transportation T. The upper alignment device 34b further comprises a mobile distal end 35a connected to the upper feeder device 32b and a fixed distal end 37b connected to the structural frame 40 of the blank joining module 10. This allows the displacement of the upper feeder device 32b in the longitudinal direction L while maintaining a fixed connection to the upper alignment device 34b.

As best seen in figures 8b and 8c, the upper conveyor 61 b of the upper alignment device 34b further comprises a support structure 69 configured to support the conveyor belt 62b. The support structure 69 comprises a plurality of rollers 67 (see fig. 8a) onto which the conveyor belt 62b is mounted. The rollers 67 are attached to frame members 70 and a connection mechanism 68 is connecting adjacent frame members 70 to each other. The connection mechanism 68 is expandable such that the distance between the frame members 70 can be modified. The frame members 70 are displaceable in the direction of transportation T. Each roller 67 is attached to a frame member 70 and arranged in a line.

Preferably, the connection mechanism 68 comprises a plurality of pivotable links 74a, 74b which allow an equidistant displacement of the frame members 70. The pivotable connection links 74a, 74b can be provided by two linear elements. The pivotable connection links 74a, 74b are connected to each frame member 70 in a central pivot 75. The pivotable connection links 74a, 74b are also connected to each other in an upper pivot 76 and a lower pivot 77. The upper pivot 76 and the lower pivot 77 are movable in the longitudinal direction L.

By connecting the frame members 70 to the central pivot 66, the horizontal position of the central pivot 75 is kept constant. The support structure has a first distal end 35b connected to the upper feeder device 32b and a second distal end 37b connected to the frame 40 of the blank joining module 10. The frame members 70 are connected to the central pivot 75 of the connection mechanism 68. The frame members 70 comprise a first cantilevered extension 70a and a second cantilevered extension 70b which are connected to a frame member bracket 70c.

The guiding rollers 67 of the conveyor belt 62b are attached to the first cantilevered extension 70a, and the pressing rollers 66 are attached to the second cantilevered extension 70b. The first and second cantilevered extensions 70a, 70b extend horizontally and parallel in relation to each other. The second cantilevered extension 70b is arranged vertically above the first cantilevered extension 70a.

The second cantilevered extension 70b may be supported by an upper guide rail 71b and the second cantilevered extension 70b may be supported by a lower guide rail 71a. The guide rails 71a, 71 b may be in the form of longitudinal bars arranged underneath the first and second cantilevered extensions 70a, 70b, respectively.

The distal inlet end 35b of the upper alignment device 34b may comprise an attachment bracket 79 configured to be attached to the upper feeder device 32b. The attachment bracket 79 may further provide a fixed structure to form an inlet section I for the upper pressing rollers 66 and supporting rollers 67 of the conveyor belt 62b. The attachment bracket 79provides a fixed connection to the cantilevered extensions 70b, 70c such that the inlet section I has a constant length, regardless of the extension or retraction of the connection mechanism 68. A distal central pivot 79a is attached to the attachment bracket 79. A second distal central pivot 79b is attached to a frame member 77 of the upper alignment module 34b.

The guide 63 is not present in this inlet section I defined by the length of the attachment bracket 79. In such a way, the upper blanks 2b are not guided in the inlet section I. This allows the upper blanks 2b to be transported out of the upper feeder device 32b before being urged sideways.

The register control arrangement 36 is configured to compensate for longitudinal register displacement shifts in the direction of transportation T and align the upper and lower blanks 2b, 2a to each other in the direction of transportation T. The longitudinal register displacement shifts are undesired displacements of the blanks 2a, 2b in relation to their predefined longitudinal register positions Pa_reg, Pb_reg at a certain moment in time. Both the upper and lower blanks 2b, 2a are subject to register displacement shifts du to variations in the blank transportation. Such variations may include variations in the feeder discharge time which results in a feeder displacement Adb_feeder, Ada_feeder at the respective upper and lower feeder devices 32b, 32a. The discharge time of the upper and lower feeder devices 32b, 32a may either be in advance or a delay in relation to their predefined discharge times. Another variation is transportation displacements Adb_transport, Ada_transport, of the upper and lower blanks 2b, 2a and are due to local wear on conveyor belts and associated support components.

As illustrated in figures 4 and 6, the register control arrangement 36 comprises a sensing system 83, a position correction device 86, and a control circuitry 84. The control circuitry comprises a control unit 91 and a memory 93.

As best seen in figures 6a and 6b, the position correction device 86 comprises a cleat belt 88 mounted on a belt driving mechanism 104. The belt driving mechanism 104 is attached to a frame member 105. The cleat belt 88 is configured to be driven with a variable acceleration and speed. The cleat belt 88 is provided with one or a plurality of abutments 90. Preferably, two abutments 90 are provided. The position correction device 86 further comprises a motor 92 configured to drive the cleat belt 88.

The position correction device 86 may comprise an inductive sensor 89 configured to detect the position of the cleat belt 88 such that the position of the abutments 90 can be determined. The inductive sensor 89 may be configured to sense the abutments 90. The abutments 90 may comprise a metallic material which can be sensed by the inductive sensor 89.

The position of the upper blank 2b can be corrected by contacting an abutment 90 against the front edge E1 b or the rear edge E2b of the upper blank 2b and either accelerating or decelerating the upper blank 2b in the direction of transportation T. Hence, two different operating modes 01 , 02 can be provided. In the first operating mode 01 , an abutment 90 of the position correction device 86 is contacting the rear edge E2b of each upper blank 2b and providing an acceleration. In the second operating mode 02, an abutment 90 of the position correction device is contacting the front edge E1b of each upper blank 2b and providing a deceleration. The location of the position correction device 86 may be different for the two operating modes 01 and 02. The position correction device 86 is preferably positioned closer to the junction point J in the second correction mode 02 than in the first correction mode 01.

The position correction device 86 may be mounted to a slide rail 95. This allows positioning the position correction device 86 according to the type of operating mode 01 , 02 and according to the longitudinal length Lb of the upper blank 2b in the direction of transportation T. This allows the abutments 90 to be positioned to abut against either of the rear edge E2b or the front edge E1 b of the upper blanks 2b.

As illustrated in figure 4, the sensing system 83 comprises an upper transfer sensor 81b configured to detect the passage of the front leading edge E1b of the upper blank 2b and a lower transfer sensor 81a configured to detect the passage of the front leading edge E1 a of the lower blank 2a. The upper and lower transfer sensors 81b, 81a are located at a distance upstream from the junction point J.

As best seen in figure 6, the upper transfer sensor 81 b is preferably mounted on a protruding extension 87 of the position correction device 86. The protruding extension 87 may be connected to the frame member 105 of the position correction device 86. The protruding extension 87 positions the upper transfer sensor 81b upstream on the cleat belt 88.

The control unit 91 is configured to receive the detection signals from the upper transfer sensor 81 b and the lower transfer sensor 81a and determine the actual positions Pb_act2, Pa_act2 of the upper and lower blanks 2b, 2a, at each respective transfer sensor 81a, 81b. The actual positions Pa_act2, Pb_act2 of the upper and lower blanks 2a, 2b are positions in the direction of transportation T at a predetermined moment in time. The predetermined moment in time can be defined in relation to the time duration elapsed from the issue of a lower feeder discharge signal.

The register control arrangement 36 further comprises an upper register conveyor 78 configured to transport the upper blank 2b. A lower transfer conveyor 79 is configured to transport the lower blank 2a. The upper register conveyor 78 and the lower transfer conveyor 79 respectively convey the upper blank 2b and the lower blank 2a towards the junction point J. The upper blank 2b has a transportation path Pb extending from the upper feeder device 32b to the junction point J. The lower blank 2a has a transportation path Pa extending from the lower feeder device 32a to the junction point J.

The upper transportation path Pb has an upper conveyor system 31b which comprises the upper alignment device 34b and the upper register conveyor 78. The lower transportation path Pa has a lower conveyor system 31a which comprises the lower alignment device 34a and the lower transfer conveyor 79.

The register control arrangement 36 is preferably configured to only correct the position of the upper blank 2b. As the lower blank 2a is also subject to register displacement shifts, the actual position Pa_act2 of each lower blank 2a at the lower transfer sensor 81a is selected as a reference position for each associated upper blank 2b. The position of each upper blank 2b is modified with the position correction device 86 before the upper blank 2b reaches the junction point J.

The detection time from the respective transfer sensors 81a, 81 b define the actual position Pb_act2 and Pa_act2 of the upper and lower blanks 2b, 2a. The lower transfer sensor 81a is located at a distance upstream from the junction point J. As the upper transfer sensor 81 b is preferably mounted on a protruding extension 87 connected to the position correction device 86, the passage of the upper blank 2b can be detected before the upper blank 2b is contacted by the cleat belt 88.

The control circuitry 84 is configured to calculate a corresponding desired position Pb_des at the transfer sensor 81 b of the upper blank 2b based on the actual position Pa_act2 of the lower blank 2a. The desired position Pb_des of the upper blank 2b is the position in which the upper blank 2b is aligned with the lower blank 2a in the direction of transportation T. That the upper blank 2b is aligned with the lower blanks 2a means that the upper blank 2b is conveyed to be superposed onto the lower blank 2a in a position which corresponds to a prescribed assembly position in the direction of transportation T.

The control unit 91 is configured to calculate the desired position Pb_des of each upper blank 2b by determining the actual position Pa_act2 for each associated lower blank 2a and performing an algorithm stored in the memory 93.

Due to the inclined upper transportation path Pb being longer than the lower transportation path Pa, the actual transportation speed Vb_act of the upper blank 2b upstream of the junction point J may be higher than the actual transportation speed Va_act of the lower blank 2a.

As the length of the upper transportation path Pb may change depending on the contact length Lcb of the extendable upper alignment device 34b, a theoretical transportation speed Vb_t of the upper blank 2b can be calculated by the control unit 91 based on the position of the upper feeder device 32b. The position of the upper feeder device 32b may be determined from the longitudinal length La of the lower blanks 2a. The position of the upper feeder device 32 may thus determine the length of the upper transportation path Pb and a theoretical transportation speed Vb_t. The theoretical transportation speed Vb_t. may thereafter be calibrated with the sensing system 83 such that the upper blank 2b arrives in a suitable position in relation to the lower blank 2a. The suitable position allows a position correction with the position correction device 86.

The position correction device 86 is configured to correct the position of the upper blank 2b by either accelerating or decelerating each upper blank 2b in the direction of transportation T.

The upper blank 2b is preferably conveyed with a selected displacement Ad_selected in the direction of transportation T. The selected displacement Ad_selected is a purposely selected displacement distance in relation to the predefined register position Pb_reg of the upper blank 2b at the upper transfer sensor 81 b. This selected displacement Ad_selected ensures that each upper blank 2b consistently arrives with a register displacement distance Adb at the upper transfer sensor 81 b.

The selected displacement distance Ad_selected is selected to an amount which can be corrected by the position correction device 86. The displacement distance Ad_selected is preferably between 10 and 15 mm.

This purposely selected displacement distance Ad_selected is either a delay or an advance. The delay means that each upper blank 2b consistently arrives too late to the transfer sensor 81b in relation to the register position Pb_reg. The advance means that each upper blank 2b consistently arrives too early to the transfer sensor 81b in relation to the register position Pb_reg. The selected displacement distance Ad_selected can be provided selecting the actual transportation speed Vb_act of the upper blank 2b such that a predefined selected displacement Ad_selected always occurs at the location of the upper transfer sensor 81 b.

In another and advantageous embodiment, the release timing of the upper feeder device 32b can be selected such that the upper blank 2b is conveyed with a selected displacement Ad_selected. This displacement is thus effective already when the upper blank leaves the upper feeder device 32b. This time deviation is a time delay or a time advance of the upper blank 2b in relation to the register position Pb_reg of the upper blank 2b..

The upper feeder device 32b has a theoretical release time t_b_register such that the upper blank 2b is in the register position and aligned with the lower blank 2a. Similarly, the lower feeder device has a theoretical release time t_b_register such that the discharge of the lower blank 2a is timed and in the register position.

A time deviation At_b is thus added to the theoretical release timing t_b_register of the upper blank 2b.

The actual release timing tb_actual of the upper blank 2b is selected as: tb_actual = t_b_register + At_b

In this embodiment, the actual transportation speed Vb_act of the upper blank 2b is selected such that the upper blank 2b is theoretically positioned in the register position and thus arrives at the upper transfer sensor 81b in the register position. The actual transportation speed Vb_act on the upper blank 2b may be higher than the actual transportation speed Va_actual of the lower blank 2a, but only to accommodate for the difference in length between the upper transportation path Pb and the lower transportation path Pa.

At the upper transfer sensor 81 b, a displacement Adb of the upper blank 2b in relation to the register position Pb_reg of the upper blank can be calculated from the arrival time of the upper blank 2b to the upper transfer sensor 81 b. This is effective regardless if the upper blank 2b is provided with a time deviation At_b or a transportation speed which gives rise at the selected displacement at the upper transfer sensor 81b. This displacement Adb includes the selected displacement Ad_selected, the feeder displacement error Adb_feeder and the transportation displacement Ad b_tran s po rtati o n .

Figure 9 shows a first operation mode 01 in which the upper blanks 2b are conveyed with time deviation At_b in the form of a delay added to the release timing tb_actual. Alternatively, the actual transportation speed Vb_act is lower than the theoretical required speed Vb_t. This results in that a predefined and selected negative displacement Ad_selected is added to each upper blank 2b. Hence, all upper blanks 2b arrive with a time delay at the upper transfer sensor 81b.

Figure 10 shows a second operation mode 02 in which the blanks are conveyed with a time deviation in the form of an advance At_b added to the release timing tb_actual. Alternatively, the actual transportation speed Vb_act is higher than the theoretical required speed Vb_t. This results in that a predefined and selected positive displacement Ad_selected is added to each blank. Hence, all upper blanks 2b arrive with an advance at the upper transfer sensor 81 b.

In the illustrated modes 01 , 02 of figures 9 and 10, the upper blank 2b has received a time deviation At_b, and the selected displacement Ad_selected is effective already at the upper feeder device 32b. If the actual transportation speed Vb_act is selected such create a displacement Ad_selected, the displacement Ad_selected, is preferably gradual and is effective in its full amount at the upper transfer sensor 81 b.

The sensing system 83 may further comprise an upper feed sensor 85b located at a distance downstream of the upper feeder device 32b, and a lower feed sensor 85a located at a distance downstream of the lower feeder device 32a.

The upper and lower feed sensors 85b, 85a detect the passage of the front leading edges E1b, E1a of the upper and lower blanks 2b, 2a, respectively. The passage of the front leading edges E1 b, E1a of the upper and lower blanks 2b, 2a can be used in order to determine the actual positions Pb_act1 , Pb_act1 of the blanks 2b, 2a at the respective feed sensors 85b, 85a and as they are discharged from the upper and lower feeder devices 32b, 32a. In the embodiment where a time deviation is provided to the upper blank 2b, the feeder displacement Adb_feeder and the actual position Pb_act1 of the upper blanks 2b at the feed sensor 85b can be determined by the following relationships:

Pb_act1 = P_reg1 - Adb_feeder - Ad_selected

Adb_feeder = Pb_act1 - Pb_reg1

The actual position Pa_act1 and the feeder displacement Ada_feeder of the lower blanks 2a at the lower feed sensor 85a can be determined by the following relationships:

Pa_act1 = P_reg1 - Ada_feeder

Ada_feeder = Pa_act1 = P_reg1

Based on the actual positions Pb_act1 , Pb_act1 provided by the upper and lower feed sensors 85b, 85a, an initial relative displacement Ad b_i n iti al of the upper blank 2b in relation to the lower blank 2a can be calculated. Based on the initial relative displacement, a preliminary required correction of the abutment 90 on the cleat belt 88 can be determined. Hence,

Adbjnitial = Adb_feeder - Ada_feeder

This initial preliminary required correction Adbjnitial is advantageous to calculate as the feeder displacements Ada_feeder, Adb_feeder are often higher than the transportation displacements Ada_transportation Adb_transportation. Based on the initial preliminary required correction Adbjnitial, the control unit 91 may determine if the position correction device 86 is able to correct the for the initial preliminary required correction Adb_initial. If the required correction Adbjnitial is larger than a correction threshold T_corr of the position correction device 86, the control unit 91 may generate a control signal to issue a warning or turn off the converting machine 1.

The register displacement Ada of the lower blank 2a at the lower transfer sensor 81a is calculated from the difference between the detected actual position Pa_act2 and a corresponding register position Pa_reg2 of the lower blank 2a. Hence, the following relationships apply:

Ada = Pa_act2 - Pa_reg2 Ada = Ada_feeder + Ada_transportation

For the upper blank 2b, the register displacement Adb at the upper transfer sensor 81 b and in relation to the predefined register position of the upper blank Pb_reg2 is:

Adb = Pb_act2- Pb_reg2

Adb = Ad_selected + Adb_feeder + Adb_transportation

The displacement Adb is thus the sum of a feeder register displacement Ad_feeder, a transportation displacement and the selected predefined displacement Ad_selected for the upper blank 2b.

The total relative displacement Adb_total of the upper blank 2b in relation to the lower blank 2a at transfer sensors 81a, 81b is the register displacement Adb of the upper blank 2b subtracted by the register displacement Ada of the lower blank 2a.

The total relative displacement Adb_total between the upper blank 2b and the lower blank 2a at the position of the upper and lower transfer sensors 81 b, 81a can thus be calculated as follows:

Adb_total = Adb - Ada

The position correction device 86 is configured to provide a displacement correction Ac to every blank 2b in the direction of transportation T. The correction Ac equals the total relative displacement Adb_total. In such a way, the upper blank 2b is displaced into the desired position P_des_b determined by the control unit 91. Hence,

Ac = Adb_total

In the first operation mode 01 , the position correction device 86 is configured to accelerate the upper blanks 2b in order to provide a position correction Ac to each blank 2b. In the first operation mode 01 , the position correction device 86 is positioned such that the abutment 90 contacts the rear edges E2b of the upper blanks 2b.

In the second operation mode 02, the position correction device 86 is configured to decelerate the upper blanks 2b in order to provide a position correction Ac to each blank 2b. The position correction device 86 thus decelerates each upper blank 2b before it arrives to the junction point J.

In the first operating mode 01 , and for upper blanks 2b with a small longitudinal length Lb, the position correction device 86 is preferably positioned closer to the junction point J than for longer blanks 2b.

Providing two modes of operation 01 , 02 may also allow the position correction device 86 to be set to abut against the most suitable edge of the front edge E1 b and the back edge E2b. Ideally, the most suitable edge is a straight or a uniform edge.

The position correction device 86 may further comprise a displacement motor 97 configured to automatically displace the position correction device 86 along the slide rail 95. The longitudinal position of the position correction device 86 is selected based on the type of correction mode 01 , 02 and the longitudinal length of the upper blank Lb.

The blank joining module 10 further comprises a gluing device 100 arranged upstream of the junction point J. The gluing device may comprise a glue reservoir, a pump and a dispensing nozzle. Preferably, the gluing device 100 is arranged to dispense glue on the top side of the lower blank 2a such that the glue is positioned in-between the upper blank 2b and the lower blank 2a. The gluing device 100 is preferably activated based on the detection time of the lower transfer sensor 81a.