Note: Descriptions are shown in the official language in which they were submitted.
37
-- 1 --
SYSTEM FO~ ~OXING E'ORMS
BACKG~OUND OF T~E INVENTION
This invention relates generally to the packay-
ing of forms, and more particularly to the bo~lny of
stacked forms, such as continuous orm paper of the t~pe
used by computer printers.
Computer printout paper is conventionally
printed from large rolls, divided lengthwise into a
desired width, and perforated and accordion-folded at
page intervals to form a stack of continuous forms~ The
following description proceeds with reference to forms
of this ~ype, but the invention is also applicable to
packaging of other kinds of forms.
For ease of shipment and handling, it i5 desir-
able to package the forms in boxes. Conventionally,this task is performed manually, using a reyular slotted
container (RSC), which is a cornmonly available type of
corrugated cardboard box having flaps on both top and
bottom~ This procedure typically requires at least two
workmen for each form manufacturing and packaging line.
Conventional form printing and cutting machinery out-
feeds the form paper in several parallel continuous
stacks onto a tray. There, one workman separates from
each continuous stack discrete stacks of equal numbers
of sheets, for example, 4,000 sheets per stack. The
containers are conventionally provided in folded form,
known as "knockdown" containers, which the second work-
man erects by manually opening them one at a time, up-
side down and folding and taping the bottom flaps there-
of. Then, with the container still turned upside-down,
it is fitted downwardly over a discrete stack of forms.
The top flaps of the container assist in guiding the
sides of the box downward along the edges of the stacked
forms. Once filled, each container is turned over and
closed by the workmen manually pressing down the stack
of forms and folding and taping the top flaps down atop
the forms.
~2~;~63~7
- 2 --
Ideally, ~he containers are .sized in their
vertical dimension betweerl the top and bottom flaps
(i.e., height) such that the forrns are level with the
fold lines of the flaps. ~t is undesirable to ~nderfill
the boxes because the forms will shift and wrinkle dur-
ing shipment. It is likewise undesirable ~o overfill
the box because that makes it difficult to close the top
flaps without bending them above their fold lines.
Unfortunately, this ideal is difficult to meet,
consistently with providing an equal number of forms in
each container in a large production run of forms. The
caliper of the forms paper is not constant from roll to
roll and therefore the height of stacks of forms of
equal number of sheets can vary significantly. This
circumstance makes it very difficult to provide a con-
stant number of forms in a single size box and yet
neither underfill nor overfill the box. Workmen are
unable manually to compress a tall stack of forms by a
substantial amount if the container is overfilled.
Therefore, various measures have been adopted in an
effort to deal with this problem.
One approach is to use a regular-slotted con-
tainer of sufficient height to accept a stack of forms
of ~he thickest typical caliper and then to add corru-
gated cardboard shims in sufficient number to fill out
any containers which are underfilled by paper of thinner
caliper. However, this approach is wasteful, both in
the cost of using larger size boxes and in the use of
substantial quantities of corrugated cardboard as shims.
Another approach is systematically to provide
more sheets in each stack of forms than is specified tothe customers, Eor example, 4,100 sheets where 4,000
sheets is specified, and to use a regular-slotted con
tainer sized to accept the median height of the stacks
of forms. Substantially fewer shims are required to
fill out underfilled containers. If the container is
o~erfilled, a portion of the stack of forms is torn off
~2~ 3~
- 3
and discarded to enable closing the box. Elowever, this
approach is also was~eful and substantial care ~nust also
be taken to avoid shorting the customers on the number
of sheets supplied in a stack. Moreover, reyardless of
which approach is taken to filling the bo~es, substan-
tial labor is required manually to package the forms.
Two attempts are known to have been made to
automate the boxing of forms. One system proposed to
provide an infeed conveyor ~or infeeding a stack of
forms in an infeed direction to an elevator positioned
beneath mechanism for erecting and supporting a regular
slotted carton. Knockdown cartons are infed from the
opposite direction to the erecting apparatus. This
design called for elevating the stack of Eorms and at
the same time lowering the carton to insert the stacked
forms into the open bottom of the carton. ~rhereupon, a
bottom~folding mechanism comprising a pair of hinged
plates folds the minor bottom flaps of the carton one at
a time as the elevator, constructed in two vertically
2G divided parts, was retracted downwardly one part at a
time. Then, the major bottom flaps are closed. Next,
with the bottom-closing mechanism still supporting the
filled carton, the carton was to be pushed in the infeed
forms direction onto an outfeed conveyor spaced above
the forms infeed conveyor and below the carton infeed
mechanism, for closing the top flaps. This design was
subsequently abandoned without testing.
A second proposal provided apparatus for erect-
ing a regular slotted container and positioning the con-
tainer beneath an elevated form-dropping mechanism.
Knockdown containers are in~ed to a container erecting
mechanism spaced a distance laterally ~rom the dropping
mechanism, on opposite sides of a low wall. During
erection, the knockdown containers were oriented on
their sides with their top and bottom flaps e~tending
laterall~ in opposite directions. One at a time, each
container is opened and its bottom flaps closed and
~2~i3~;3~
glued. Then, the container would be flipped over the
low wall to right it on a box infeed conveyor, bottorn
flaps down, and positioned to aliyn it beneath the
dropping mechanism.
The form-dropping rnechanisrn includes two pairs
of parallel, end-~o-end abutting finyers, in the form of
powered conveyor rollers. Each set of fingers is
mounted on a normal frame member laterally movable to
separate the fingers lenythwise to drop the forms. A
pair of walls or fences is positioned above the fingers
parallel to the frame members and movable laterally to
center the stack in the dropping mechanism.
Stacks of forms are infed in the opposite
direction from the direction containers are input via a
conveyor to an elevator to be raised, one stack at a
time, to the elevation of the dropping mechanism for
dropping into the underlying box. The top flaps of the
container are retained in an upwardly laterally extended
position so as to funnel the dropped stack of forms
downward into the box. After being filled, the box is
conveyed normally of stack infeed conveyor out from
beneath the dropping mechanism and to a case sealer.
The case sealer included a pressing mechanism in the
form of separate "feet" for compressing the forms in the
box and then quickly retracting to allow closure of the
top flaps. The top flaps were then glued and the box
discharged. Meanwhile, the stack infeed elevator is
lowered to the infeed conveyor to receive another stack
of forms. The case erector proceeds to erect another
regular slotted container and to flip the same over the
wall to be positioned beneath the orm-dropping mecha-
~ism.
Such a system was constructed and operated for
a time, but was never able to be made to operate satis-
factorily. Use of this system also suffered from all ofthe above-described drawbacks of manually packaging the
forms in regular-slotted containers, particularly in the
i37
-- 5
requirement of a capability to insert sufficient shims
to fill out an underfilled box. E~or these reasons and
because of its ~ery substantiaL cost, this desiyn was
ultimately abandoned.
Accordingly, a need remains for an effecti~e
and economical system including apparatus and method for
boxing printed forms.
SUMMARY OF THE INVENTION
One object of the invention is to automate the
packaging of stacked forms.
A second ob~ect is to reduce the labor required
for packaging forms.
A third object is to minimize the disadvanta-
geous effects of variations in paper thickness in boxing
printed forms.
Another object is to eliminate the need to pro-
vide more than a specified number of sheets of paper in
a stack of forms and to minimize the wastage of forms.
A further object is to eliminate the need for
oversized containers and cardboard shims to fill unused
space in the containers.
To these ends, the invention includes a method
for boxing forms comprising erecting a half-slotted con-
tainer, aligning the container upright beneath a drop-
ping mechanism and dropping a stack of forms therefrom
into the container. The container is sized to a height
less than a predetermined height of the stack, even for
forms of less than median caliper. Thus, the half-slot-
ted container is always overfilled by at least a pre-
determined margin. Next, the stack is substantially
compressed, such as by a pneumatic press at 1200 pounds
of force, but the container is sufPiciently overfilled
that the compressed stack still has a height exceeding
the height of the container, e.g., by a margin of 1/2
inch to 3 inches after compression. A telescoping lid
is ~hen applied to the container and secured, preferably
3~i3~Y
-- 6
in a manner that maintains the stack of forms in com~
pression such as by strapping. The lid is sized, for
example, to a four~inch depth, to fit over the excess
thickness of forms, with a small overlappiny margin for
the maximum thickness of forms when compressed.
By compressing the stack before applying the
lid, inherent bowing in the forms can be minimized to
avoid wrinkling the top forms when the lid is applied~
A pad can also be provided beneath the stack of forms to
minimize wrinkling of the bottom sheets against the con-
tainer's bottom flaps and to protect such sheets during
handling by the apparatus. The container is also pre-
ferably sized to provide minimum clearance between its
interior sidewalls and the sides of the stack of forms
to air-cushion the stack of forms as it drops into the
container.
The invention further includes apparatus which,
in one aspect, comprises dropping means for dropping a
stack of forms into a container receivingly positioned
beneath the dropping means; accumulating conveyor means
for infeeding stacks of forms to the dropping means and
retaining a stack of forms thereon during operation of
the dropping means; accelerating conveyor means in line
with the accumulator conveyor means for infeeding a
stack of forms from the accumulating conveyor means to
the dropping means; and gate means between the accumu-
lating conveyor means and the accelerating conveyor
means for opening and closing a passageway to the drop-
ping means. The accelerating conveyor means is operable
at a speed greater than the speed of the accumulating
conveyor means so as to space a first stack of forms
apart from a second stack so that the gate means can
close between the stacks to detain the second stack of
forms on the accumulating conveyor during operation of
the dropping means to drop the first stack into the con-
tainer. The accelerating conveyor means preferably
includes a pair of side-by-side driven conveyors separa-
ble by horizontal movement to drop the stack of forms.
~:;
:
:
6~3~
-- 7
Means can be included for actuating the drop-
ping means and means cooperable with the actuating means
for opening the gate means to admit the first stack of
forms to the dropping means and then to close the gate
to exclude the second stack of forms until the first
stack is dropped.
In another aspect of the invention, the infeed-
ing means for infeeding stacks of forms to the dropping
means is preferably fixed at the same elevation as the
dropping means. The stack and container infeed means
are preferably arranged with the first over the second
to infeed in the same direction.
Means for discharging the container, after
filling with forms, should also be aligned with the
second infeeding means for discharging in the same pre~
determined direction.
The apparatus can include erecting means for
erecting a container at an infeed end of the receiving
position, means for infeeding an erected container to
the receiving position, and top guide means for guiding
the container into said guideway. Preferably, the top
guide means, form guide means and guideway defining
means are interconnected and include means for vertical
adjustment thereof as a unit.
The discharging means can include elevator
means for lowering the filled container relative to the
dropping means so as to provide vertical clearance
between the stack of forms and the dropping means for
discharge of a first container and raising to receive a
second container from the second infeeding means.
Sensor means can be positioned at a discharge
end of the container-receiving position for sensing the
presence of a box in said position and the discharge of
a box therefrom to control actuation of the container
infeeding means. Means responsive to the sensor means
can be provided to control the second infeeding means so
as to stop infeeding the container in said predetermined
6~37
-- 8
direction when a first end of the container is aligned
beneath an end of the dropping means so as to center the
container along said direction beneath the dropping
means.
The apparatus can further include first means
for sensing the presence of a stack in the dropping
means; second sensing means for sensing the presence of
a container in the receiving position; and means jointly
responsive to said first and second sensing means for
actuating the dropping means only when containing a
stack of forms and a container is in the receiving posi-
tion. Moreover, such apparatus preferably includes
means positioned at an infeed end of the receiving posi-
tion, beneath the first infeed means, for erecting a
container; third sensing means for sensing the presence
of an erected container at said infeed end of the
receiving position; and means jointly responsive to the
second and third sensing means for actuating the second
infeeding means upon sensing the absence of a container
in the receiving position and the presence of an erected
container at said infeed end.
The control means can also be responsive to the
third sensing means sensing absence of an erected con-
tainer for actuating the container erecting means.
The foregoing and other objects, features and
advantages o~ the invention will become more readily
apparent from the following detailed description of a
preferred embodiment of the invention, which proceeds
with reference to the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
Fig. 1 is a top plan view of a schematic of a
system for boxing printed forms in accordance with the
invention.
Fig. la is a schematic side elevational view
taken along lines la-la in Fig. 1.
~2~363'7 (
Fig. 2 is a schematic sectional view taken
along lines 2-2 in Fig. 1.
Fig. 3 is a horizontal sectional top plan view
of the apparatus shown in Figs. la and 2, ~aken along
lines 3-3 in Fig. la.
Fig. 3a is a detailed perspective view of the
folded boxing feed mechanism of Figs. 2 and 3, as viewed
in the direction of arrow 3a in Fig. 1.
Fig. 3b is a detailed perspective view of the
folded box guide used in the feed mechanism of Figs. 2
and 3, as viewed in the direction of arrow 3b in Fig. 1.
Fig. 4 is a detailed perspective view of the
box opening mechanism of Fig. 2 as viewed in the direc-
- tion of arrow 4 in Figs. 2 and 3.
Fig. 5 is a detailed perspective view of the
box pushing mechanism of Figs. la and 2, as viewed along
arrow S in Figs. 1 and 2.
Fig. 6 is a detailed perspective view of the
bot~om-closing mechanism of Fig. 2, as viewed along
arrow 6 in Fiys. 1 and 2.
Fig. 7 is a detailed perspective view along
arrow 7 in Fig. 1 of a second por~ion of the bot-
tom-closing mechanism and box-receiving conveyor, with
containers positioned in the container infeed passageway
and on the receiving conveyor.
Fig. 8 is an exploded perspective view of the
bottom-closing mechanism shown in Fig. 7, as viewed in
the direction of arrow 8 in Fig. 1.
Fig. 9 is a top plan ,view of the forms dropping
portion of the apparatus of Fi~. 1. ' `
,~
Fig. 10 is a cross-sectional view taken along
lines 10-10 in Fig. 9.
Fig. 11 is a cross-sectional view taken along
lines 11-11 in Fig. 9.
Fig~ 12 is a detailed perspective view along
arrow 12 in Fig, 1 of the structural interface between
3~37
-- 10 --
the form-dropping mechanism of Eigs. 9 and 10 and the
box-receiving conveyor and guide of Fig. 7, the vertical
adjustment arrangement in the upper portion of the view
being shown in a reduced scale.
Fig. 13 is a perspective view in the direction
of arrow 13 in Fig. 1 showing the box-receiving conveyor
and guides and outfeed conveyor in a lowered condition
for discharging a filled box of forms~
Fig. 14 is an exploded view of the apparatus of
Fig. 13 showing the conveyors and box in an elevated
position preparatory to receiving and filling a box with
forms.
Fig. 15 is a fragmentary perspective view of
the actuation system used in the apparatus of Fig. 1.
Figs. 16a-16c are schematics of the electrical
circuit for controlling the electric motors and pneu-
matic actuators of the apparatus of Figs. 1-15.
DETAILED DESCRIPTION
General Arrangement
Referring to Figs. 1 and lA, a forms boxing
apparatus 20 in accordance with the invention is used to
package stacks of forms 22 assembled on an outfeed tray
24 of conventional form-printing, cutting and accordi-
on-folding apparatus 26. The principal elements of
apparatus 20 are a forms infeed and dropping subsystem
30, in which forms are moved in a predetermined direc-
tion indicated by arrow 32 and subse~uently dropped as
indicated by arrow 34, and a container erection, receiv-
ing and discharge conveyor subsystem 36, spaced below
and aligned with subsystem 30 so as to move the con-
tainers in the same direction, indicated by arrows 40,
42. A guide structure or framework 44 provides an
interface between subsystems 30 and 36 which is verti-
cally adjustable, as indicated by arrows 46, to accom-
modate containers of different heights of up to a maxi-
mum height 48.
37
Breaking the ~oregoing subsystems down/ sub-
system 30 comprises an accumulator conveyor 50 and a
dropping mechanism 52 (further detailed in Figs. 9 11)
for dropping stacks of forms one at a time into a con-
tainer receivingly positioned beneath conveyor subsystem3~. The dropping mechanism includes an accelerating
conveyor 54 and a gate arrangement 56 cooperable with
conveyors 50, 54 to detain one or more stacks of forms
on the accumulator conveyor while one stack 22 is being
dropped by the dropping mechanism and then to accelerate
the next succeeding stack 22a and thereby space it from
subsequent stacks (not shown) to provide a gap for
closure of the gate to admit one stack at a time into
dropping mechanism 52.
Referring generally to Fiys. 2 and 3, the con-
tainer erecting, conveying and discharge subsystem 36
includes a knockdown container infeed tray (detailed in
Figs 3a and 3b) or magazine 60, a container erection
mechanism 62 (Figs~ 4, 6 and 7), a container infeed or
pusher 64 (Fig. 5) and a receiving and discharge con-
veyor assembly 66. Subsystems 30, 36 are spaced verti-
cally apart by the supporting framework (shown frag-
mentarily in Figs. 4-7 and 15) of apparatus 20 by a pre-
determined distance 48 sufficient to accommodate
half-slotted containers of up to a predetermined
height. Framework 44 is vertically adjustable within
that distance to accommodate containers of lesser
height. The space beneath framework 44, generally out-
lined by container 68a in Fig. 2, is referred to as the
container infeed passageway.
Electrical, pneumatic and motor actuation and
control subsystems, discussed hereinafter with reference
to Figs. 15 and 16, orchestrate the operation of the
foregoing subsystems to infeed one stack at a time to
the dropping mechanism, to in~eed a carton to the
receiving conveyor and actuate erection of another
carton, to actuate dropping a stack of forms into the
~;~6363~ (
- 12 -
carton on the receiving conveyor, to lower the receiving
conveyor and provide c1eararlce or head room between the
top of the forms and the guide inter~ace 44, to dis-
charge the filled container of forms and return the
receiving conveyor to a raised position, and then repeat
the foregoing procedure as soon as the next container
and stack of forms are in the receiving position and
dropping mechanism respectively. Containers are erected
from knockdown cartons 68.
Each of the above-mentioned subsystems is
described in turn hereinafter, followed by a description
of set up and operation of the system as a whole.
Forms Infeed and Dropping Subsystem
Referring to Figs. 9 and 10, accumulator con-
veyor 50 is a friction roller-type conveyor such as the
SLIP TORQUE accumulating conveyor system manufactured by
Shuttleworth of Huntingdon, Indiana. Such a conveyor
has continuously rotating roller shafts 70 which are
driven by motor 71 (Fig. 5~ to rotate in the direction
of arrGW 72 all at the same speed. A plurality of annu-
lar disks 74 is mounted on each shaft and sized to an
inner dimension to loosely frictionally engage a shaft
so as to rotate with the shaft unless restrained.
Aligned with the accumulating conveyor is
accelerating conveyor 54, comprising two rows of
end-to-end, nearly abutting parallel horizontal live
roller fingers 76. Each row of fingers is mounted in
mirror image relationship on a horizontal fLame member
78, at a right angle thereto. The fingers are individu-
ally journaled for rotation at their lateral ends intheir respective frame member, are free at their medial
ends, and are opposed in pairs and spaced a short dis-
tance apart about a centerline 80 between the sides of
the conveyor. As indicated by arrows 82 in Fig. 10,
finger rollers 76 are rotated in the same direction as
accumulator roller shafts 72, but at a greater speed o~
rotation by a series of interconnecting chains 84, 86,
* trade-mark
- 13 -
connected to sprockets 88, 9U mounted on the journaled
ends of the roller fingers and housed within frame mem-
bers 78O The outer surEaces of the roller fingers are
formed of a smooth metal so as to slip easily on a pad
92 positioned under the bottom sheet of the stack of
Eorms when the stack is restrained. However, the
opposed pair of rollers 76a located nearest the accumu-
lator conveyor is provided with a latex or other highly
frictional sleeve 94 for promptly accelerating each
stack of fo~ms as it en~ers the dropping mechanism.
The side frame members 78 of the dropping
mechanism are supported by spreading arms 98a, 98b.
These arms are in turn supported for laterally slidable
movement on rod 102, connected at its lateral ends to
the supporting frame ~not shown), and by a pair of rol-
lers 104 received on a track 106 extending horizontally
across a frame plate 108. Just below rod 102, a square
shaft is slidably received in a drive sprocket in the
proximal end of member 78. This shaft is driven by a
motor 99 through gear box 100 (Fig. 15). The dropping
mechanism is opened by moving frame members 78 lateral-
ly, as indicated by arrows 110. This action is per-
formed by a pair of roller chains 112, 114, best seen in
Fig. 11. Chain 112 is connected at one end to a lower
portion of bracket 98a, extends through an opening 118
in a lower portion of bracket 98b and around a drive
sprocket (not shown) mounted on the frame and back to
another bolt 126 connected to an upper portion of
bracket 98b. A second bolt 128 axially aligned with
bolt 126 connects chain 114 to the upper portion of
bracket 98b and such chain extends through an opening
130 in the upper portion of bracket 98a around the drive
sprocket mounted in similar fashion on a second pusher
to connect by means of bolt 36 back to the lower portion
of bracket 98a. A pneumatic ram 125, supported by the
frame (Fig. 15), is connected to arm 98b to open and
close conveyor 54 to drop the forms.
.
~;~6~;37
~ 14
Mounted above arms 9~, in similaf fashion, is a
second pair of sprea~irly arms 13~ supported on a shaft
141 and by rol]ers on a runner 140. These arms are
interconnected by a pair of chains 14Z, 144 in the same
form and manner as chains 112, 11~, and likewise con-
nected to a pneumatic actuator 145 for opening and clos-
ing a pair of centering walls 146a, 146b, independently
of dropper conveyor elements 76, 78. Each wall is
formed by an angle member 148 extending horizontally in
the direction of the accumulating conveyor from members
138 and supporting four vertical, spaced upright members
150.
Connected to the upright members 150a nearest
the accumulating conveyor, are a pair of vertical-
ly-spaced horizontal extensions 152, to the ends of
which are connected a pair of angle members oriented
vertically and with one leg 156 extending medially to
define gate 56 substantially in alignment with the end
set of friction rollers 74a (Fig. 9~ in the accumulator
conveyor. When centering walls 146 are opened, gate 56
opens, when they are closed, to center a stack of forms
on top of the floor of the dropping mechanism/ that is,
on rollers 76, the gate closes to detain any subsequent
stack 22a on the accumulating conveyor until stack 22
has been dropped and the roller fingers have been moved
medially back to a closed position, as shown in Fig. 9.
Thereupon, a control and actuation system, described
hereinafter, opens the centering walls 146 at gate 56 to
admit the next stack of forms.
As the next stack is moved by rollers 74 into
contact with the first pair of finger rollers 76a, the
highly frictional surface of such rollers engage and
accelerate the incoming stack onto the remaining finger
rollers 76.
A vertical member or stop 160 is supported at
the downstream end of the dropping mechanism by means of
an adjustable bracket 162 on rod 141 and a second
~3~3~7
- 15 -
adjustable bracket 164 positioned at a lower end of stop
160. As soon as the next stack 22a contacts stop 160,
the bare metal rollers 76 begin to slip beneath the
stack. Just prior to contacting stop 160, the front or
downstream end of the stack contacts a cat whisker 166
and accordingly actuates sensor 16~ which is connected
to the control system of Figs. 15 and 16 to cause the
centering walls to close. This action also closes gate
56 to detain the next succeeding stack, left behind when
the incoming s~ack was accelerated by finger rollers 76.
Container-Erecting Subsystem
1. Knockdown Container Infeed Arrangement
Referring to Figs. 2 and 3, as mentioned above,
container feed tray 60 provides a stack of knockdown
containers 68 standing on edge alongside the container
infeed passageway to receiving conveyor 66. Continuing
in general terms, each time another container is needed,
box-erecting mechanism 62, comprising a vertical-
ly-oriented rectangular rack 180 supporting four rectan-
gularly-positioned vacuum or sucker assemblies 182, is
moved transversely across the aforementioned passageway
by pneumatic cylinder 184 in the direction of arrow 186
to tray 60. Upon contacting knockdown carton 68a
nearest the passageway, vacuum cups 188 in the suction
assembly engage carton 68a on major panel l90a. Then,
referring particularly to Fig. 3, the control system of
Figs. 15 and 16 causes actuator 184 to reverse direc-
tion, as indicated by arrow 190 to pull knockdown con-
tainer 68a away from the stack 68.
A pair of arcuate members 182, also shown in
Fig. 5, are connected to the frame of machine 20 adja
cent an upstream end of the container infeed passageway,
between pusher 64 and tray 60 cammingly to engage minor
panel 190b of the container. This action causes the
remote side of the container to move transversely of the
direction of arrow 192, as indicated by arrow 196, to
open the container into a parallelogram and then ulti-
.
~;~63~3~7
- 16 -
mately into a rectangle, as the assembly lB0 rnoves
across ~he infeed passageway. This action is assisted
by a hook 198 extendiny from the underside of tray 60 at
the lower edge of containers 6~. The lower margins of
containers 68 are vertically slotted to define the bot-
tom flaps of the container, and the container is rectan-
gular so that the major flaps l91a, l91b are longer than
the minor flaps l91b. Accordingly, hook 198 is offset
from the center of the stack of knockdown cartons 68
toward arcuate member 194 so as to align with the slot
(not shown) between major flap l91a and minor flap
l91b. Consequently, the hook extends through the slot
to contact the major ~lap l91c to hold it back against
stack 68 while the vacuum assembly 62 is drawing panel
190a across the passageway to open the container in an
upright position. Once the container is fully opened,
major flap l91c bends slightly on its fold line to
release from hook 198 while the contacting surface 195
of members 194 maintains the carton in a rectangular
configuration.
As it is opened, the knockdown carton is pulled
into the container infeed passageway. There, it con-
tacts a sensor 200 (Fig. 2) which actuates a bot-
tom-closing mechanism 202a, 202b, described hereinafter
with reference to Figs. 6 and 8. As the container is
drawn across the passageway by the vacuum assembly and
when it is subsequently infed to the receiving conveyor,
it is guided along its upper edges by a flat plate hori-
zontally positioned beneath conveyor 50 and having an
upwardly inclined lip extending along the upper edge of
cartons 68. Once the bottom ~laps of the container are
closed, they resiliently bias the container upward
against the plate. Plate 204 is a part of guide frame-
work interface 44, which is described in further detail
hereinafter with reference to Fig. 12.
2. Container Feed Tra~ Assembly
Referring to Figs. 3, 3a and 3b, the folded
~L2~ 3~7
- 17 -
container ~eec1 tray 60 is oriented normal to the infeed
passageway and inclined downwardly toward it. Tray 60
comprises a pair of parallel rectanyular structural
members 210 interconnected at each end by perpendicular
flat members 216, 218, a pair of parallel cylindrical
guide rods 220 are spaced between members 210, 212 and
connected at their ends to members 216, 218. Optional-
ly, for higher speed operation (more than about 15 con-
tainers per minute), a sprocket 2~2 is mounte~ in each
end of each of the rectangular members 210, 212 for sup-
porting feed roller chains 224 in each such members. A
drive motor 226 is mounted on a panel 228 depending from
the lateral side of member 210 and has an output shaft
230 connected to a chain 232 and a pair of sprockets to
a drive shaft 234 which extends across the tray beneath
members 210, 212 and normal thereto. Sprockets 236 (see
fragmentary view in upper center portion of Fig. 3a)
mounted on shaft 234 beneath of each members 210, 212
drive the two chains 224 around an idler pulley 238.
For lesser operating speeds (10-15 containers per minute
or less), this drive roller chain arrangement can be
omitted.
A container backer or sliding "book-end"
assembly 240 includes a flat upright member 242 con-
nected at its lower end between plates 244 for engaginga backside of the stacked knockdown containers to hold
them upright. Assembly 240 is slidably mounted on
shafts 220 to support knockdown containers in a general-
ly vertical position, with their lower edges resting on
chains 224. This assembly travels behind the containers
under force of gravity as containers are used. It can
be slid back toward the motor end of the tray and
latched by spring catch 246 on member 218 to add more
boxes to the tray. Sliding outrigger 248 laterally
stabilizes assembly 240.
A first rail 250 is mounted along the remote or
upstream side of tray 60 for aligning the adjacent
;
~Z~i37
- 18 -
corners of the knockdown containers parallel to members
210, 212. Such rail is supported by a pair o~ upright
members 252, each adjustably connected to a cylindrical
leg 254 extending laterally from meMber 212 and normal
thereto. To substitute for assembly 2~0 while adding
more containers to the tray, a radial member 258 mounted
on a sleeve 259 is slidably received on a second shaft
257.
On the downstream side of the tray, that oppo-
site rod 250, a second alignment guide 260, shown inFigs. 3, 3b and 7, is mounted on the downstream side of
the rectangular framework 262 surrounding the opening
into the infeed passageway through which the containers
are infed from tray 68. Guide 260 comprises a vertical-
ly-adjustable bracket 264 mounted on frame member 262a
mounting a sleeve 266 oriented to receive a shaft 268
for sliding movement in a horizontal direction normal to
tray frame members 210, 212 and thereby within the plane
o~ the knockdown containers. A vertical member 270 is
connected to the end of shaft 268 nearer the cartons. A
generally triangular guide plate 272 is mounted on mem-
ber 270 in a plane normal to shaft 268 for aligning the
downstream edges of the containers. Plate 272 has an
end portion 274 inclined away from the plane of the
corners of the cartons to aid in aligning the cartons in
camming action~
Mounted at the upper and lower ends of member
270, above and below member 272, are a pair of resilient
fingers extending generally toward the direction that
containers move when entering the infeed passageway, as
indicated by arrow 225, and biased toward the con-
tainers. Fingers 276 each have a stop or hook 278 at
the distal end thereof for engaging the downstream edge
of the innermost container 68a. The opposite, upstream
edge of container 68a is releasably retained by a roller
277 mounted on a plate 279 (Figs. 3 and 5). Set screws
with handles 280 fix the position of shaft 268 in sleeve
'37
-- 19 --
266. When it is desired to change to containers of a
different size, such set screws are loosened and shaft
260 is moved toward or away from the cartons as needed
for smaller or larger cartons, to keep ~he upstrearn
corners of the cartons always in the same position rela-
tive to ali~nment rod 250 and thereby relative to arcu-
ate members 194.
3. Vacuum Container_Opening Mechanism
Next, referring to Fig. 4, it can be seen that
opening mechanism 180 is carried on a framework 300
including a pair of sleeves 302 slidably received on a
pair of parallel rods 304 connected to opposite side
frame members 306, 307 of the machine 20 and extending
normal to such side frame members and to the direction
of infeed of erected cartons, indicated by arrow 40.
Extending between sleeves 302 are a pair of perpendicu-
lar cross members 308, which are in turn interconnected
by a flat member 310 spaced between sleeves 302 and con-
nected parallel to the sleeves to a ram 312 of pneumatic
cylinder 184. Mechanism 180 is mounted by means o~
vertically-adjustable sleeves 316 on a vertical standard
314. Connected to member 310, two U-shaped brackets 322
are vertically spaced on standard 314. Vacuum cups 188
are each mounted on a hollow shaft 320 and the shafts
are slidably mounted in parallel spaced relationship in
openings in opposite sides of the ~-shaped brackets.
Two coil springs 324 are received on each tubular member
between the sides of the bracket, separated by a collar
326 fixed to tube 320, in effect to spring-load the
tubular shafts. A second collar 330 is mounted on the
end of each shaft remotely of vacuum cup 1~8. Tubes 320
are connected by long, flexible vacuum hoses to a vacuum
pump 622 (Fig. 15) or other suitable source of subatmos-
pheric pressure operable by the control actuation system
of Figs. 15 and 16 to apply a vacuum at cups 188 each
time a new container is retrieved from the knockdown
container tray, and to maintain such vacuum to hold an
3~7
- 20 -
erected carton "on deck" until it is time to push the
next carton to the infeed passayeway to the receiving
conveyor (see Lines 39 and 40 of Pig. :L6b).
4. Bottom Tucker ~ssemblies
Next, reEerriny to Figs. 6, 7 and 8, following
transversal of the passageway by the container opening
mechanism 180, tucker apparatus 202a, 202b first close
the leading and trailing minor flaps l91b, l91d of each
carton, as indicated in Fig. la by arrows 294, 296,
respectively. Then, apparatus 202a closes the two major
flaps l91a, l91c, as indicated by arrows 298 in Figs. 2,
3 and 6, and hold them in place until the container is
infed by pusher 64.
Referring to Fig. 6, the trailing minor and
major flap tucker 202a is suspended by means of four
brackets 300a-300d from the framework of apparatus 20
beneath pusher 64 and is generally arranged to move in a
swinging motion lengthwise of the infeed passageway dur-
ing operation, as indicated by arrow 302. ~s shown in
Fig. la, this arrangement spaces the tucker apparatus
out of the way below the path of the containers during
opening but moves it close to the bottom, the container
once fully opened to close the bottom flaps.
Brackets 300a, 300b are spaced apart and sup-
port a transversely extending shaft 304a. Brackets300c, 300d are similarly spaced apart and at a distance
in the infeed direction 40 from brackets 300a, 300b so
that the four brackets altogether define a rectangle,
and likewise support a shaft 304b extending parallel to
shaft 304a. A pusher arm 306 is connected radially to
shaft 304a midway between the two supporting brackets
and extends downwardly and rearwardly at an inclination
to a connection 308 on the ram of a pneumatic cylinder
310~ This cylinder, referred to hereina~ter as the
trailing minor flap tucker, is connected at its rear end
312 to a bracket 314 supported on a transverse frame
member 316, as shown in Fig. 5.
- 21 -
Depending generally vertically frorn each sha~t
304 are a pair of support arms 318a-318d, equidistantly
spaced apart about arm 306 between support brackets
300. An elongated cylindrical sha~t 3Z0 parallel to
shaft 304a is received throuyh the lower ends of arrns
318a, 318b. Similarly, a short cylindrical shaft 322 is
pivotally supported by arms 318c, 318d. Centered
between arms 318 is a flat member 324 extending normal
to shafts 320, 322 and parallel to in~eed direction 40.
A flat, spade-like plate member 326 is connected in a
horizontal orientation to the underside o~ member 324 at
the downstream end thereof, that is, beneath shaft
304b. Plate 326 has a downstream end normal to member
324 for engaging the trailing or upstream minor flap of
a container during folding of same.
Shafts 304 are rotatably interconnected by a
linkage comprising arms 328a-328d, each mounted on an
end of one of the shafts in parallel relationship to
actuation arm 306 but extending in the opposite direc
tion therefrom. A tie rod 330a extends parallel to mem-
ber 324 between the distal ends of arms 328a, 328c. A
second tie rod 330b similarly interconnects the distal
ends of arms 328b, 328d. Upon actuation of cylinder 310
to extend its ram in a direction of arrow 332, shaft 304
and arms 328a, 328b are rotated in the direction of
arrow 334. Arms 328c, 328d rotate in the same direc-
tion, causing the entire structure depended from shafts
304 by means of arms 318 to swing as indicated by arrow
302~ This action causes plate member 326 to move in the
direction of arrow 40 and upwardly, as indicated by
arrow 296, to close the trailing minor flap l91b of an
opened container positioned in the inEeed passageway.
Mounted on shafts 320, 322, laterally outward
of arms 318, are brackets 338a-338d, which depend
vertically downwardly from their respective shafts.
Brackets 338a, 338c support a sleeve 340a which extends
parallel to member 324. A second such sleeve 340b is
37
- 2~ -
supported between brackets 338b, 338d. E~eceived in each
sleeve is a rotatable shaft 3~2a, 3~2b. A pair of
actuation arrns 3~4a, 344b is mounted at the wpstream end
of each shaft. ~ pair of depending arMs 346a, 346b,
each support a cylindrical rod 3~8a, 348b extending
parallel to shafts 340. A pneurnatic cylinder 350a, 350b
is connected to arm 3g4a, 344b by connector 352a, 352b
on its ram and is fixedly connected on the distal end of
shaft 320 by means of bracket 354a, 354b. Actuating
cylinders 350 rotates arms 344 in the direction indi-
cated by arrow 356a, 356b to cause rods 348 to rotate in
~he direction indicated by arrows 298 to close the major
flaps.
Referring to Figs. 7 and 8, leading minor flap
tucker apparatus 202b comprises a generally rectangular
base framework including a pair of longitudinal members
360a, 360b extending parallel to the container infeed
direction 40. Each member has, at its upstream end, an
upstanding extension 362a/ 362b. A flat member 364
interconnects the downstream ends of member 360 at a
right angle and spaces such members apart. Member 364
is adjustably connected to longitudinal members by bolts
366 received in elongated slots 368 and supports a
bracket 370 centered on the upstream side thereof
between members 360 ~or connecting a leading minor flap
tucker pneumatic actuation cylinder 372. Members 360
are also interconnected at their upstream end by a
second flat member 374 (omitted in Fig. 7). Mounted on
the upper or distal ends of upstanding portions 362 are
a pair of inwardly curved rods or bridge members 376a,
376b. Such members are substantially aligned with rods
348 of apparatus 202a, when in the major flap closure
position, as shown in Fig. 8. Members 376 are spaced
laterally apart to provide clearance for a tucker arm
378 to be raised and lowered by cylinder 372.
The tucker arm comprises an elongated member
extending generally parallel to members 360, having an
~3~37
- 23 -
L-shaped tucker head 380 at its upstream end, a first
transverse shaft 382 is positioned at its lo~er, down-
stream end. A second transverse shaft 3~ is positioned
midway between tucker head and shaft 382. A pair of
T-shaped arms 386a, 386b each have one lateral leg con-
nected to sha~t 382 on each side of arm 378~ The oppo-
site lateral leg is pivotally connected to ad~acent mem-
ber 360, as indicated by dashed lines, and its depending
leg connected to a transverse member 388 mounted on the
end of the ram of cylinder 372. r~O parallel arms 3g0a,
390b are mounted at one end on shaft 384 on each side of
arm 378. At the other end, each is connected pivotally
into one of a pair of coaxial holes 392 through each of
the upstanding portions 362 of members 360 just below
bridge members 376. The portion of tucker arm 378
between shaft 384 and tucker head 380 is longitudinally
adjustable. On extension of the ram of cylinder 372,
the foregoing assembly is operable to e~tend arm 378 and
tucker head 380 through a curved path upstream and
upwardly to close the leading minor flap, as indicated
by arrow 294 in Fig. la, ~y moving in a swinging motion
on members 386, 390, as indicated by arrows 392, to the
position shown in Fig. 8.
The actuation of cylinders 310 and 350 is co
ordinated so that the minor flaps are first closed, fol-
lowed by closure of the major flaps. While sucker
assembly 180 is traversing the feed passageway to open
container 68a, the major flap tuckers 348 are spaced
below and upstream of the container, as shown in dashed
lines in Fig. la. Trailing minor flap tucker plate 326
is likewise spaced below and upstream of the container.
Upon actuation of trailing minor flap tucker cylinder
310, structure 202a swinys downstream and upwardly
beneath the box to move rods 348 in the direction indi-
cated by arrow 302 and plate 326 in the direction indi-
cated by arrow 326. This action causes the tucker plate
to fold the trailing minor flap l91b in the direction of
~l~ Ei3~7
- 24 -
arrow 336 and positions rods 348 so that, upon operation
of the major flap tucker cylinders 350, rotating the
rods in the direction of arrows 298, the major flaps are
closed.
First, however, leading minor flap ~ucker 202b
swin~s as indicated by arrow 2~4 in Fig. la to close the
leading minor flap l91d. ~hen, as cylinders 350 are
actuated to swing rods 348 medially, as indicated by
arrows 298, cylinder 372 is actuated to retract its ram
and return the leading minor flap tucker to its lowered
position, relying on the major flaps to hold the leading
minor flap in position against the underside of the con-
tainer~ These rods and plate 326 remain in the closed
position until pusher 64 feeds the container onto the
receiving conveyor.
5. Carton Pushin~
Referring to Fig. 5, the carton pushing appara-
tus 64 is horizontally mounted on a base plate 400 in
the framework of the machine at the upstream end of the
con~ainer infeed passageway. ~ pair of parallel spaced
angle members 402a, 402b extending parallel to the
infeed directicn 40, are connected normally to base
plate 400 at their downstream end and interconnected by
a short angle member 404 at their upstream end. A long
pneumatic cylinder 406 is centered between and parallel
to members 402 and connected to base plate 400 and angle
member 404 at each end. Spaced along opposite sides of
the cylinder are two stabilizer rods 408a, 408b slidably
received in sleeves 410a, 410b connected to one side of
base plate 400. On the opposite side, the cylinders ram
412 and downstream ends of rods 410 are connected
normalIy to a flat plate 414 upon which are mounted a
pair of generally T-shaped pusher plates 416a, 416b.
Each plate is pro~ided with two pair of bolt holes, 418,
420 to enable adjustment of the width of the plates to
two different box sizes, for example, a narrow spacing
- ~s -
for 8 1/2-inch wide containers and a wider spacing for
14-inch wide containers.
Upon actuation of ram 406, plates 416 are
pushed against the upstrearn end of the container in the
infeed passageway to move the carton in the direction of
arrow 40. Referring to Figs. la and 3, the ram pushes
the container in a downstream direction, irst length-
wise off tucker plate 326 and rods 348, over the bridge
members 376 which retain the major flaps fold~d on che
bottom o~ the container and finally onto receiving con-
veyor 66. The ram continues to push until the container
is aligned with the dropping mechanism 52. Thereupon,
extension of ram 406 ceases and the ram is retracted to
make room in the infeed passageway for erection of the
next container.
Dropping-to-Receiving Interface Assembly
Referring to Fig. 12, interface 44 comprises a
horizontally-extending framework 450 and a vertical
adjustment mechanism 452. The framework generally com-
prises a pair of elongated flat members 454a, 454bspaced apart on opposite sides of the container infeed-
ing passageway. The members are interconnected at their
upstream end by guide plate 204 and at the downstream
end by a transverse bridging member 456. The central
portion of bridging member i5 vertically offset above
members 454 by portions 457 and the lateral end 458a,
458b, each support a vertically-extending suspension
screw 460a, 460b, respectively. Plate member 204 is
provided with a supporting rectangular Erame 462, upon
30 which are mounted a pair of screws 460c, 460d like 460a,
460b, extending vertically and spaced laterally apart
along a transverse mid-line through plate 204. Screws
460a and 460d are threaded oppositely of the other sus-
pension screws, i~e., le~t-hand threaded.
Received on each screw is a bearing 464 which
is bolted through a bracket 466a, 466b at the downstream
end and brackets 468a, 46~b at the upstream end to an
~2~i~3~
- 26 -
upper portion of framework of machine 20 supporting the
forms infeed ~onveyor and dropping snechanism. A cone
gear 470a-~70d is supported by each bearing and thread-
edly received on each screw 460 to support guide
assembly 450.
In adjustment mechanisJn 452, a transverse
rotating shaft 472 has cone gears 474 at each end mesh-
ing with gears 470a, 470b a-t right angles. A second
transverse shaft 476, offset from shaft 472, and driv-
ingly connected to it by a sprocket-chain drive 475,
extends laterally to a manually rotatable wheel 478
which is rotated to thread gears 470a, 470b vertically
on screws 45~a, 458b. Two longitudinal shafts 480a,
480b each have cone gears 482a, 482b at one end meshing
normally with gears 470a, 470b and extend upstream to
cone gears 484a, 484b to mesh with gears 470c, 470d for
threading those gears vertically on screws 460c, 460d.
Bearings 484 mounted near each end of shaft 472 support
that shaft in the framework of apparatus 20. Shafts 480
are journaled for rotation in bearing bolts 486a-486d
threading into brackets 466, 468 to connect the shafts
480 at their downstream and upstream ends, respectively,
to such brackets.
As mentioned above, plate 204 initially guides
a container along its upper edges into the infeed
passageway between members 454. As the container is
pushed onto the receiving conveyor, its leading corners
are aligned with members 454 by convergently inclined
surfaces 487. The container then passes beneath two
L-shaped members 488~ one atop each member 454, extend-
ing medially of the passageway and supportingl at their
downstream ends, a pair of gravity stops 490 and a pair
of form guides 492. Members 488 are connected to each
frame member 454 by a slideway 494, secured therein by a
bolt releasable by handle 496 to allow longitudinal
adjustment, as indicated by arrow 498.
3~7
- 27 -
Lateral form g~ides 500, cotnprising two rectan-
gular plates, each having an inwardly inclined upper
portion 502 and a vertical lower portion 504, are
mounted on members 454. ELat elongated strips 506 are
sandwiched between members 454 and guides 500 and extend
upstream o~ the latter to plate 204. Guides 500 and
strips 506 are positioned to overhang members 454
inwardly to define guideways 505 for -the upper edges of
the containers.
Container-Receiving and
Discharging Conveyor Subsystem
Referring to Figs. 3, 13 and 14, the con-
tainer-receiving and discharge conveyor subsystem 66
includes a horizontal live roller conveyor section 520,
an inclined bel-t conveyor section 522 connected in line
end-to-end to section 52~ for articulation about a joint
524 pivotable about a horizontal axis. An elevator
mechanism 526, actuated by a pneumatic cylinder 523
through a rotatable linking arm 530 is connected beneath
conveyor 520 for raising conveyor 520, as shown in Fig.
14, to the receiving position and lowering it, as indi-
cated by arrow 532 in Fig. 13, for discharge of a
form-filled container 38, as indicated by arrow 42.
Roller conveyor 520 comprises a pair of
~5 parallel side rails 534a, 534b. A plurality of rollers
536 extend between the side rails and are journaled for
rotation therein. Drive shafts 538 on each o~ rollers
536 extend through side rail 534a to a series of drive
sprockets 540 and the rollers are interconnected in
pairs by a plurality of roller chains (not shown).
Conveyor 522 comprises an idler roller 542 co-
axially mounted at joint 524. Roller 542 has a shaft
journaled inside rail 534a, carrying a sprocket 544 for
driviny the downstream end roller 536a and thereby the
remaining rollers via a chain connected to the afore-
mentioned sprockets 540. Housing 541 encloses the
sprockets.
~3~3~
~ 28 -
Conveyor belt 522 has a drive roller 546
mo~nted in a support stand 548 in a position parallel to
roller 542 and spaced thereErom by a pair of side rails
550a, 550b. A conveyor drive motor 552 i~ drivinyly
connected to roller 546 through a gear box 554 mounted
on an outbvard end of floor stand 548, adjacent side
rail 550bo Side rails 550 are journaled to pivot on the
upper ends of uprights 556a, 556b of stand 54~ to
facilitate raising and lowering the upstream end of the
belt conveyor.
Referring to Fig. 13, support stand 548 is con-
nected at each end by frame members 560 extending paral-
lel to the side rails of the conveyors. Elevator
mechanism 528 is mounted by means of two bearings 562
spaced along each frame member 560. A pair of shafts
564a, 564b extend normal to frame members 560 from side
to side beneath conveyors 520, 522 through bearings
562. A pair of L-shaped flat linkage arm members 566
are mounted on each shaft and spaced apart in approxi-
mate alignment with the side rails of the conveyors.Linkage arms 566a, 566b on each side of the conveyor are
connected at their short depending distal ends by a
straight linking member 568 extending along the inner
side of frame member 560 and lying parallel thereto.
The longer leg of each of members 566 extends laterally
of shaft 564 in the upstream direction nearly parallel
to side rails 550 of conveyor 522 and is connected at
its distal end to a tab 570a, 570b depending from each
of side rails 534 through a short, straight, vertical-
ly-oriented linkage member 572a, 572b. Pivot arm 530 oE
actuator 528 is mounted on shaft 564b. A pair of
springs 574 are mounted on rods 576 to spring dampen
action of the elevator. The rods are arranged parallel
between linking members 568 and have an end 576 con-
nected thereto just downstream of shaft 564b. The down-
stream ends of shaft 576 extend slidably through tabs
580 depending from a flat member 582 extending trans-
537
-- 2g --
versely below the conveyors and connected to the supportstand 548 b~ mealls not shown.
Upon actuation of cylinder 528 to extend its
ram in the direc~ion indicated by arrow S~4, throuyh arm
S S30, shafts 56~ and linkage arms 566 are rotated in the
direction of arrow 586 to lift conveyor 520 as indicated
by arrow 588 to the receiving position while maintaining
such conveyor level.
A pair of container side guides 590 are spaced
apart at opposite sides of conveyor 520. Each guide
comprises a flat member with an outwardly-inclined up-
stream end 592 for centering a container infed in the
direction of arrow 40. Each guide is connected at two
points to its respective side plate 534 by means of two
upstanding posts 594a, 594b through a bolt 596 laterally
adjustable to adjust the spacing between guides 590. A
second pair of guides 598 is similarly mounted on side
rails 550 of the belt conveyor for maintaining a
form-filled carton in alignment with the direction of
outfeed, indicated by arrow 42.
Referring to Fig. 13, a cat whisker 600 of sen-
sor 602 extends into the passageway between guide rails
590 at the downstream end of rail 590b. Sensor 602 is
mounted on the side of rail 590b remote from the pass-
ageway and is adjustably positionable longitudinallyalong such rail to alter the position at which it is
actuated. This cat whisker is positioned to sense the
downstream end of a container as such end comes into
alignment with the downstream end stop 160 (Fig. 10) of
the dropping mechanism. A second such sensor 601 is
positioned along belt conveyor 522 for detecting dis-
charge of a container.
A pair of stops 60~, mounted on arms 605, is
positioned to raise and lower between the conveyor
rollers 536b and 536c, when conveyor 520 is raised, to
stop a box in precise lal~ignment with member 166, as
shown in Fig. 10. By precise alignment is meant that
~L2~;3~7
- 30 -
the inner surface at the downstream end of the container
is not upstream but is paralle:l with or very slightly
downstream of the upstream faciny surface of member
160~ Stops 604 are passively raised and lowered upon
raising and lowering o~ conveyor 520 by means of ele-
vator mechanism 526. Thus, the stops are raised when
the conveyor is in the receiving position, and lowered
when the conveyor is lowered for discharying a
form-filled container. When a container is infed to
receiving conveyor 520, substantially simultaneously as
its downstream end contacts stops 604, it is detected by
sensor 602 and, through controls describ0d hereinafter,
causes a pusher 64 of Fig. 5 to cease pushing the box in
the direction of arrow 40.
Control System
Referring to Fig. 15, the various sensors,
actuators and motors used in apparatus 20 are illus-
trated in their respective positions within the appara-
tus framework.
Additional sensors, shown only in Figsr 16 and
identified as ''LSI' for limit switch and "CS" for "con-
tact switch" are provided by magnetic switches in pneu-
matic actuators 145, 184, 372, and 528. Fig. 16a, upper
right, shows electrical circuitry ~or such sensors.
The pneumatic actuators are controlled by a
pneumatic control block 620 comprising a vertical-
ly-oriented stack of solenoid-operated pneumatic valves
to which pressurized air is provided through a conven-
tional pneumatic valve manifold (not shown). By opera
tion of the valves, the pressurized air is shunted
through tubing (not shown) to the various actuators.
One actuator not above described is a Venturi vacuum
device 622 connected to valve 3 in block 620 and oper-
able upon the input o~ air under pressure via line 624
to provide a vacuum on output lines 626 to vacuum
assembly 180.
- 31 -
Operation o~ the motors and actuators of E~iy.
15 is controlled by an electrical ~ontrol circuit 700,
shown in E~iys. 16a, 16b and 16c~ r~'he organi~ation of
the control circuit and the elements controlled thereby
appears in detail in the notations in the E~igures and in
the following description o~ operation sequence, and so
is only described generally~
Referring first to Fig. 16a, lines 1-13, show
the three phase power circuitry for drive motors 71, 99,
552 (Fig. 15) and a step down transformer interface for
powering the control circuitry of Figs. 16b and 16c.
Startiny in Fig. 16b, control lines 16-20 con-
tain various switches for starting up machine 20, start-
ing and stopping the stack infeed conveyor motor (lM)
and indicators showing that the power is on and that the
infeed conveyor is operating. Lines 21-22 and lines
45-50 control operation of the dropping mechanism,
including sensing that a stack is in the dropping
mechanism and that a box is in position on the receiving
conveyor (referred to in the circuit notations as the
elevator). Such circuitry also controls operation of
the centering walls and finger or drop rollers to open
g~te 56 after closure of the dropping mechanism to admit
the next stack of ~orms, closing the gate, and opening
the dropping mechanism once a container is positioned on
the receiving conveyor.
Lines 24-3~ control operation of the con-
tainer-erecting mechanism and line 39, controlled
through line 40, maintains a vacuum on an erected con-
tainer "on deck" until the receiving conveyor is clearand the box pusher starts to infeed the next container.
Control lines 33-34, 42, 43 and 60 control operation of
the bottom closing mechanism, including holding the
major flap tuckers up until the box pusher has infed a
box on deck into the receiving conveyor, whereupon the
major flap tuckers are lowered and the bottom closing
637
- 32 -
apparatus is retracted out of the way of the next carton
to be erected by the erecting mechanisrn~
The elevator and discharge conveyor are con-
trolled by lines ~7, 51-57 and 59 serially to lower the
receiving conveyor and to .start the discharye conveyor
drive after a stack of forms has been dropped into the
container. Upon sensing that the container has cleared
the discharge conveyor, such circuitry raises the ele-
vator back to its receiving position.
Set-up and Operation Sequence
Apparatus 20 is preferably used in conjunction
with a downstream conveyor system (not shown) including
apparatus for performing the steps of compressing the
stack of forms, applying a lid and securing the lid to
the container. Accordingly, each container coming off
the discharge conveyor is conveyed to a forms compressor
comprising a pneumatic cylinder having a rectangular
flat member positioned on the end of its ram or pres-
sing the forms down into the box. Then, the container
passes over a conventional container bottom-taping
machine. From there, the container is conveyed to a
strapping machine to strap on a lid, applied anywhere
along the conveyor following the compressor. Alterna-
tively, a conventionally-available lid-forming and
applying machine can be inserted in the conveyor line
upstream of the strapping machine. From the strapping
machine, the cartons are preferably conveyed to a
pallet-forming machine to be stacked on a pallet.
Although apparatus 20 is shown as being provided with
forms from only a single form-making machine and the
immediately-preceding description indicates only one
such machine bo~ing forms ~or input to the downstream
conveyor system, it should be understood that stacks of
forms can be supplied to apparatus 20 from more than one
orm-making machine and that the output of several of
machines 20 can be input into the above-described down-
stream conveyor system.
~L2~3~
- 33 -
Following is a sequence of operation of appara-
tus 20, in which the terminology is the same as that
used in Figs. 16b and 16c.
l. Check Emergency STOP hutton (P~hould be in
OUT position).
2. Turn power switch to ON position.
3. Position SELECTOR switch for appropriate
CASE SIZE and adjust CASE FEED magazine to
proper position for CASE SIZE.
4. Fill magazine wi~h CASES.
S~ Start FORMS conveyor.
6. Start VACUUM PUMP (this starts sequence of
erection and placement of case).
7. When VACUUM PUMP starts:
A. VACUUM PICK UP extends to FETCH CASE.
B. VACUUM VALVE opens.
8. When VACUUM PICK UP is fully extended and
in contact with the CASE, TR3 TIMER is
energized.
9. When TR3 TIMER times out:
A. VACUUM PICK UP fetches CASE to FLAP
FOLDING POSITION.
B. CASE contacts LIMIT SWITCH which:
a. Confirms its arrival to FLAP FOLD-
ING POSITION.
b. Closes CASE ESCAPEMENT.
c. Energizes TR4 TIMER.
l0. TR4 TIMER energizes leading and trailing
MINOR FLAP TUCKERS simultaneously, causing
them to go to UP position.
ll. When MINOR FLAP TUCKERS reach fully UP
position, M~JOR FLAP TUCKERS go to UP
position.
l2. When MAJOR FLAP TUCKERS reach fully UP
position:
A. Leading MINOR FLAP TUCKER goes DOWN.
B. VACUUM VALVE CLOSES.
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13. At this tirne IF:
A. Leading MINOR FLAP rrucKER is DOWN.
B. ELEVATOR is UP.
C. NO CASE is in EI,EVAq'OR.
PUSHER will push ERECTED CASE' into posi-
tion to accept LOAD of FO~S.
14. When PUSHER extends to REED (Stroke
Limiter) SWITCH position selected by CA5E
SIZE SELECTOR SWITCH:
A. Trailing MINOR FLAP TUCKER DROPS.
B, MAJOR FLAP TUCKERS DROP.
C. PUSHER RETRACKS.
15. When the completion of this sequence is
verified, the process STARTS OVER again.
16. Machine is now prepared to ACCEPT FORMS
for LOADING.
A. GATE is open.
B. DROP ROLLERS are CLOSED and RUNNING.
C. CONVEYOR is RUNNING.
17. PLACE FORMS on conveyor in proper align-
ment with DROP ZONE GATE.
18. When FORMS enter DROP ZONE, a gap is drawn
between STACKS to prevent two STACKS from
entering the DROP ZONE at one time.
19. When FORMS trip LIMIT SWITCH in DROP ZONE,
Center Rolls CLOSE and TR4 TIMER is ener-
gized (TIMER is adjustable from 36 to 360
seconds. If FORMS are not dropped into
case before TIMER times OUT, Drop Roller
Drive Motor STOPS and RED light on operat-
ing panel comes ON).
20. IF:
A. CENTERING ROLLS are CLOSED.
B. CASE is in position to ACCEPT DROP of
FORMS.
DROP ROLLERS OPEN, dropping forms into
case and TR5 TIMER is energized.
~Zfi~i37
- 35 -
21. When TR5 TIMER times OUT:
A~ DROP ROLI,ERS CLOSE.
B. ELEVATOR LOWERS.
C. TR6 TIME~ is energized~
22. When TR6 TIMER times OUT:
A. CENTERING WALLS OPEN.
B. Next FORMS STACK enters DROP ZONE.
23. When ELEVATOR reaches BOTTOM, Discharge
Conveyor Motor STARTS, moving loaded case
OUT of machine.
24. When loaded case TRIPS Discharge Switch,
TR7 TIMER is energized.
25. When TR7 times OUT:
A. Discharye Conveyor Drive motor STOPS.
B. Elevator RAISES to position to accept
next erected case and the process can
START OVER again.
Having illustrated and described the principles
of our invention and a preferred embodiment thereof, it
should be readily apparent to those skilled in the art
that the invention may be modified in arrangement and
detail without departing from such principles. We claim
all such modifications coming within the scope and
spirit of the following claims.
~,
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