AJ Engineering 281 East Rock Creek Rd. New Bern, NC 28562 (252) 636-1521
Layboys by AJE
AJE can provide you with a custom-designed Layboy using all or a combination of the components listed below. The particular options used will depend upon the material being cut, the knife used as well as other considerations. Layboy widths of 74" or less will be shipped as a single unit as shown above.
Before we can discuss the Layboy options available form AJE, it is important that we define several terms which are used interchangeably in the industry. These terms will help you better understand products available from AJE. We will begin with the High Speed Tapes (Knife Outfeed) and move downstream from there.
High Speed Tapes (Knife Outfeed) - This belt section takes material away from the knife and is run at a speed greater than line speed (usually 5%-10% overspeed). The High Speed Tapes are used to 'pull' a gap between sheets after they have been cut by the Rotary Knife. This allows us to control the sheets going into the Overlap or being dumped into the Divert Gate.
Divert Gate (Reject or Dump Gate) - The Divert Gate is used to remove sheets from the High Speed Tapes at speeds up to 800 fpm. With the push of a button, a pneumatic cylinder fires a clamping roll between a gap in the High Speed Tapes and material is sent into a Broke Box (Reject Bin) located under the Layboy.
Vacuum Slice - The Vacuum Slice is an Airfoil/sheet metal pan which uses the Venturi Effect to pull down the tail end of the sheets while they are being transferred onto the Slow Speed Tapes. This allows the secondary sheet to rest on top of the primary sheet and avoid head-to-tail collisions.
Overlap Section (Shingler or Snubber Wheels) - The Overlap is a set of soft plastic or urethane wheels across the machine used to decelerate the sheets coming from the High Speed Belts. The slower belt speeds of the Slow Speed Tapes and the Overlap Slow Down Roll causes the sheets to be shingled, allowing them to be sent down the machine in a continuous flow toward the Stacker.
AJE Offers Two types of Overlaps. The first is our Standard Overlap which is driven by the sheets being slowed. This works well for most applications. When sheet marking becomes an issue, we would suggest going to a Driven Overlap. The soft Urethane Wheels run at 1% over line speed and are driven by a custom-built set of reversing gears powered by movement of the bottom belt(s).
Slow Speed Tapes (Overlap Belts) - As the name suggests, this section of conveyor belts is driven at a slower speed than the High Speed Belts. As mentioned above, the sheets are shingled on this belt and delivered in a steady stream to the Stacker. If more overlap is desired, these belts can be slowed down simply by changing a parameter in the operator interface. If less overlap is desired, the belts can be run at a faster pace.
Continuous Operation Forks (Swords) - The Continuous Operation Forks are used to keep the machine running during a skid change. When a desired stack count has been reached, the table will automatically start down and the forks will extend to 'catch' the first sheets on the next skid. Once the operator has removed the full load and inserted a new skid into position, the forks will be automatically retracted and the new load (usually 2"-3" of material) will be dropped onto the empty skid. This option can increase production by up to 15% depending on machine setup and running speeds.
Kickoff - The Kickoff section contains the components needed to ensure the sheets get into the Stacker Bay in good order. Kickoff Dollies (Nip Wheels) provide the inertia and Separators (Edge Turners) provide the stiffness to get the sheets to the front end of the stack. Optional Kickoff Air is available for lighter grades.