Note: Descriptions are shown in the official language in which they were submitted.
SYSTEM FOR UNSCRAMBLING AND ORIENTING PAD-LI~E ARTICLES
BAC~GROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a new and
improved system and method for unscrambling a random
rate, non-oriented flow of pad-like articles such as
soap pads moving in a continuing stream from a source of
production, and orienting the pads into precisely
oriented groups of a predetermined number ready for
quality control inspection, counting and eventual inser-
tion into containers or cartons.
2. Background of the Prior Art
The present invention is an improvement over
the system and method disclosed in U.S. Patent No. RE
27,190, which patent is incorporated herein by refer-
ence.
OBJECTS OF THE INVENTION
It is an object of the present invention to
provide a new and improved system and method for
unscrambling and orienting pad-like articles received
from a moving stream.
It is an object of the present invention to - -~
provide a new and improved system and method in accor-
dance with the foregoing object wherein the articles are
moving at random rates and diverse orientations in said
~tream from a production resource. `
It i8 another ob~ect of the present invention
to provide a new and improved system and method of the -~
MSE #1825 - - ;
o
--2--
character described capable of ~eparating said articles
into groups of predetermined Rize and orientation in
readiness for insertion into containers.
Moreover, it i5 yet another ob~ect of the pre-
sent invention to provide a new and improved system and
method of the character described wherein said articles
may be visually inspected for quality and count and are
readily removed and replaceable in said groups before
insertion into said containers.
Yet another object of the present invention is -~-
to provide a new and improved system and method of the - -
character described including means for providing a reg-
ulated supply of said articles for easier quality
inspection and count prior to insertion in cartons.
Yet another object of the present invention is
to provide a new and improved system and method of the
character described wherein the mechanical complexity is
reduced resulting in simplified maintenance, hiqher car-
toning throughput rates are achieved, an improved worker
environment is attained resulting from an improved
reject return system and higher levels of output at
higher quality standards are attained.
BRIEF SUMMARY OF THE PRESENT INVENTION
In accordance with the foregoing and other -~
25 objects of the present invention, there is provided a ~-~
new and improved system and method for unscrambling and -
orienting into groups of a predetermined size, a plural-
ity of three-dimensional pad-like articles moving in a
randomly oriented fashion along a supply stream moving
on a path at random flow rates. The system includes
flow diverting apparatus for the controlled diversion of ~-
at least some of the articles as they reach a prese-
lected location on the supply path in a direction away
from the path and toward~ a regulated pad supply sta-
tion. The regulated pad supply station includes a con-
veyor and movable fingers for leveling out the flow of
MSE #1825 ;
, ,Li.,50
-3-
articles into a moving layer havinq a substantially con-
sistent depth. An unscrambler or separating ~ystem is
provided for formlng the moving layer of articles into
successive groups with a selected number of articles in
each group displayed in a matrix-like pattern of columns
and rows in a horizontally moving display in readiness
for visual quality inspection and counting of the arti-
cles in each group. The unscrambler includes a moving
conveyor having a plurality of fixed wall, slotted
buckets, into which a selected number of articles are
dispersed to form an elongated row or column of the
matrix pattern. These row or column oriented articles
are then transferred as a group into a cartoner bucket
conveyor. Each group of articles in a cartoner bucket
is squeezed or compressed by pusher mechanisms in two
different directions in readiness for transfer into an
awaiting carton that is provided in a cartoning con-
veyor. The filled cartons are then sealed and moved on
to a packing station for subsequent delivery and distri-
20 bution. '
In another aspect of the present invention, aplurality or pair of regulated supply stations are pro-
vided for moving layers of articles to flow along two
parallel paths for quality inspection and counting of
the articles. After quality inspection and counting of
the articles moving along each path, the articles are
transferred into a single cartoning bucket conveyor
ready for subsequent squeezing or compression treatment
to reduce the size of each group in width and depth so
that a compressed group of articles may be transferred
into an awaiting open carton in a cartoning machinè.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present
invention, reference should be had to the following
detailed description taken in conjunction with the draw-
ings, in which~
MSE #1825
-4-
FIGS. lA and lB illu~tratQ a top plan view o~
a new and improved apparatus for diverting, un~crambling
and orienting into groups of predetermined ~ize, a plu-
rality of three-dimensional pad-like article~ flowing
along a supply conveyor in readiness for quality inspec-
tion, counting and eventual cartoning; and
FlG. 2A and 2B is a side elevational view of
the apparatus looking in a direction of arrows 2A and 2B
of FIGS. lA and lB, respectively.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
OF THE INVENTION
Referring now more particularly to the draw-
ings, therein is illustrated a new and improved appara-
tus 10 for unscrambling and re-orienting into groups of
predetermined size and quality, a plurality of three-
dimensional pad-like articles, such as soap pads 12 and
the like, which pads are supplied in randomly oriented
fashion moving along a supply stream or path 14. The -;
articles or pads 12 are moved along a path 14 at random ~-
20 flow rates, by means of a belt conveyor 16, which con- .
veyor receives batches or loads of pads 12 from one or
more drying ovens (not shown) on a random basis as dry- -:
ing is completed.
The belt conveyor 16 travels longitudinally
along a trough structure 18 having opposite upstanding
side walls 20 and at appropriate locations or positions -
22 and 24 along the travel path 14, openings are formed
in the side wall 20 to permit the diversion of at least
some of the pads 12 away from the supply stream into
discharge chutes 26 and 28. .
At each of the side wall openings 22 and 24 ::~
there is provided a flow diverting vane or plow 30 :~
mounted on an upstanding rotatable shaft or spindle 32.
Rotation control of each spindle 32 is provided to posi- :
tion the diverter plow 30 to a selected position within
an arcuate range (arrows A - FIG. lA) bounded by a fully -:
closed position and a fully open or maximum flow rate
MSE #1825
(,l li,j-iO
-5-
diverting po~ition. The rotational position of the
spindles 32 are controlled by electric stepping motore
34 or other types of motor mechanisms. An electrical
signal is generated by a sensor such as an electric eye
36 appropriately located as described hereinafter to
initiate pivotal movement of the spindles 32 to pre-
cisely control the position of the plows 30 relative to
the flow path 14 and thereby regulate the flow rate of
pads 12 diverted through the openings 22 and/or 24 into
respective discharge or diversion chutes 26 and 28.
The discharge chutes 26 and 28 slope down-
wardly and outwardly away from the conveyor side wall 20
so that the pads 12 that are diverted from the supply
path 14 move down rapidly toward the lower end of the
chutes. The chute 26 is adapted to feed a flow of pads
12 to a regulated pad supply station 40 and the chute 28
is adapted to feed a flow of pads 12 to an identical
regulated pad supply station 42. The regulated pad sup-
ply stations 40 and 42 are arranged in parallel with
20 each other and are substantially identical in construc- `
tion and operation so that identical reference numbers
will be used in connection with a description thereof. ~ .-
Each regulated pad supply station 40 and 42
includes an endless belt conveyor 44 having a lower
25 level, horizontal run 46 at an inlet end, an upsloping --
or inclined intermediate run 48, and an upper or high
level horizontal run 50 adjacent an outlet end (FIG.
2A). The endless belt conveyors 44 are mounted in con- ~ ~
tainment housings 52 having pairs of opposite side walls - -
30 54 with elevational profiles similar to that of the end- .
less belts. Each housing 52 includes a bottom wall 56,
an upstanding inlet end wall 58 and is open on the top.
At a forward or discharge end 60, the housing is open so
that a regulated discharge flow of pads 12 is delivered
to a connected, downwardly sloping and narrowing width,
discharge chute 62.
MSE #1825
,i. j J ()
-6-
In accordance with the present invention, the
endless belts 44 are provided with up~tanding flight~ 64
extending transversely across the width of the belts and
spaced apart at an appropriate dimension designed so
that generally a consistent quantity of pads 12 can be
contained between adjacent pairs of flights.
In addition, each regulated pad supply station
40 and 42 is provided with a rotating doffer assembly 66
comprising a shaft 68 supported in parallel with the
flights 64 at a level above the inclined or upsloping
intermediate run 48 of the endless belt 44. A plurality
of fingers 70 formed of resilient material such as rub- --
ber or plastic are mounted on the shafts 68 to extend
radially outwardly thereof. The fingers 70 are aligned
at spaced apart intervals in radial rows on the shafts
68 as shown in FIGS. lA and 2A and the outer end of each
finger 70 moves in a circular path 72 (FIG. 2A) in a
clockwise direction (arrow B), which circular path is :
spaced slightly above the level of the upper edges of ~ -
the flights 64 on the upwardly moving (arrow C) interme-
diate run 48 of the endless belt 44. The close proxim- -~
ity of the downwardly traveling outer free ends of the
rotating fingers 70 to the upper edges of the upwardly
traveling flights 64 of the intermediate run 48 of the ~-
25 belt conveyor 44, results in a consistent depth, layer ::
of pads 12 remaining on the belt above the level of the -
fingers 70 at the closest point of approach to the belt
run 48. Any of the pads 12 tending to form excessively :
deep on the traveling belt 44 are removed and knocked
back downwardly toward the inlet end of the regulated
pad supply stations 42 and 44 by the action of the
rotating fingers 70 of the doffer assemblies 66.
When substantial numbers of pads 12 are
knocked back down the inclined runs 48 of the belt con-
veyors 44, the pads 12 gather into a relatively largemass several layers high at the horizontal inlet runs 46
of the belt conveyors 44. When a mass of pads 12
MSE #1825
t~ a
-1 -
reaches certain predetermined 1BVQ1S above the belt rune
46, a light beam 74 (dotted arrows - FIG. lA) emanating
from a light source 76 is interrupted and/or deflected
or diffused and does not reach the opposite sensor 36
with the same strength, intensity or focus as when there
are only a few pads 12 above a single layer. When this
condition occurs, the sensor 36 generates a signal for
driving the stepping motor 34 to move the respective
shaft 32 and vane or plow 30 thereon towards a closed
position. This condition, in turn, reduces the flow
rate of pads 12 that are diverted away from the supply
conveyor 16 to flow down the chutes 26 and/or 28 so that
the mass or masses of pads 12 on the inlet runs 46 of
the belts 44 do not increase in height so as to plug up -
the system. Moreover, when the mass or masses of pads
12 declines in size, the sensor 36 generates a signal to
the stepping motors 34 to move the plows 30 toward a
more open position thereby to increase the diversion
flow rate of pads 12 to the respective regulated pad
20 supply stations 40 and 42. - -
The sensors 36 and light beam sources 76 may -
have a multiple level control capability so as to main~
tain the plows 30 in an intermediate angular position ~
range between a fully open and a fully closed position ~ -
so that an adequate diversion flow rate of pads 12 is
provided to maintain the masses at a relatively constant
level to insure that neither plug-up conditions nor pad
saturation conditions occur. In this type of arrange-
ment the plows 30 may only move back and forth between
partially open and partially closed positions and are
only driven to fully closed or fully open positions when
absolutely necessary because of supply interruptions or
other outages.
In accordance with the present invention, the
apparatus 10 includes a plurality of pad unscrambling
stations 80 and 82. Each station 80 and ~2 includes a
pair of endless belt or chain conveyors adapted to
MSE #1825
~. I L .L j . j O
recelve a controlled flow of pads 12 at an inlet end
from the discharge chutes 62 of the respective regulated
pad supply stations 40 ~nd 42 as ~hown in FIGS. lA and
2A.
The conveyors of the unscrambling station~ 80
and 82 are substantially identical and each includes a
pair of endless chains or belts 84 on opposite sides
entrained around sprockets 86 and 88 at opposite ends.
The endless chains 84 support opposite ends of a plural-
ity of slotted buckets 90 having a plurality of elon-
gated slots or troughs 92 extending transversely between
opposite ends of the buckets between a pair of endless
chains or belts 84. The slotted buckets 90 are open at
the upper end when moving along the upper runs of the
lS endless belts 84 and each transverse trough 92 is posi-
tioned in readiness to receive a single row or column of -
pads 12 with the pads generally aligned longitudinally
end to end.
The width, depth and length dimensions of the
individual slots or troughs 92 of the buckets 90 are
chosen in relation to the nominal size dimensions of the
pads 12 being handled so that generally only a single
line of end to end pads 12 will be accommodated when the :
troughs 92 are filled which corresponds to the largest
pad count matrix to be run on the system. Each bucket
90 contains a plurality of adjacent troughs 92 separated -
by sloped, fixed, dividing wall structures with the
result that when an entire bucket 90 is completely
filled, the individual pads 12 filling the buckets 90
are arranged in a matrix pattern or group of predeter-
mined size having columns and rows in an array so that
quality inspection of the pads 12 as well as pad count
can be obtained by inspectors 96. The inboard wall of
sach pad unscrambling station 80 is adjustable so as to
expose varylng longitudinal dimensions of the troughs
92, thereby enabling various counts of pads 12 to fall
MSE #1825
" l, i ,l. ) .l ' ~
- 9 -
into the slots and form matrice~ of different predeter-
mined sizes and corresponding to different pack si~es.
In the event a pad 12 i~ of inferior quality
or is damaged, an inspector 96 can easily remove the pad
from the group in a filled bucket 90 and provide a
replacement pad of good quality. Moreover, any excess
or deficit in the number of pads 12 contained in a
bucket 90 can be readily corrected by the inspectors 96
because of the excellent view afforded and the easy
access to the open troughs 92 of the slotted buckets
90 . , .
In order to reduce the chances that pads 12 ~-
falling into the troughs 92 from the chutes 62 may rest
on top of one another and thus constitute more than a ~ ~
15 single layer of pads in a matrix pattern or group, the -
pad unscrambling stations 80 and 82 are provided with a
plurality of sequentially staged, rotary doffer assem-
blies 100 having flexible, radial fingers mounted on -
transversely extending rotating shafts. The doffer
assemblies 100 are positioned above the path of the
slotted buckets 90 so that the flexible fingers move in
circular paths 102 in a clockwise direction D and the
outer ends of the fingers pass in close proximity to the
buckets 90 in a direction opposite to the direction of
25 travel of the filled slotted buckets 90 moving from left :.
to right (FIG. 2A). This results in kicking back
(toward the left) any pads 12 resting above the upper
edges of the slotted buckets 90 and generally results in
a single layer deep row or column of pads 12 in each
matrix-like group or pattern contained in a filled
bucket trough 92. The inspectors 96 are stationed at a
region downstream of the doffer assemblies 100 and can
readily correct any errors in count because of under-
filling or overfilling of the slots or troughs 92 of
each bucket 90.
In accordance with the present invention, the
apparatus 10 includes only a single cartoning conveyor ~ -~
MSE #1825 ~-
" ll i)J ~
--10--
102 for receiving groups of pad~ 12 of a selected size
simultaneou~ly from both of the pad unscrambling sta-
tlons 80 and 82 for eventual loading of the pads into a
cartoning machine 104. An inlet or left hand end of the
cartoning conveyor 102 is positioned between the outlet
ends of the conveyors of the unscrambling stations 80
and 82 and the conveyor 102 has an outlet or discharge
end extending to a region laterally adjacent the carton-
ing machine 104.
After counting and quality inspection by the
inspectors 96, each group of pads 12 contained in a :
slotted bucket 90 is transferred to the cartoning con-
veyor 102 by means of one or more lateral transfer con-
veyors 106~ Each conveyor 106 has a pair of endless
belts or chains 108 supporting a plurality of pusher
assemblies 110. The transfer conveyors 106 are disposed
on opposite sides of the input end of the cartoning con-
veyor 104 and are operative to move the pads 12 from a
pair of slotted buckets 90 as they simultaneously reach
the output end of the respective pad unscrambler sta-
tions 80 and 82. The cartoner conveyor 102 includes a
pair of endless belts or chains 112 on opposite sides
supporting opposite ends of cartoner buckets 114 having
an open upper end (FIG. 2B) and a channel-shaped cross-
section but without any internal divider walls forming
troughs or the like. The cartoner buckets 114 are open
on opposite sides in order to simultaneously receive a
group of pads 12 from a pair of slotted buckets 90 in
flanking positions on either side.
The pusher assemblies 110 of the lateral
transfer conveyors 106 travel with the supporting end- :
less belts 108 and each pusher assembly includes a slide
bar 116 having depending fingers 118 adapted to contact
the pads 12 in each trough 92 of a slotted bucket 90 to
move out a row of pads 12 contained therein into the
awaiting cartoner bucket 114 which is traveling at the
same speed in the same direction.
MSE #1825
;~ L L .j .j ~J
The pusher bars 116 and fingers 118 move in a
transverse direction toward and away from the cartoning
conveyor 104 and movement is controlled by roller cam
followers 120 mounted on the pusher bar~ and biased into
camming engagement against inwardly and outwardly
directed, elongated bar cams 122 and 124, respectively.
It will thus be seen that each cartoner bucket 114 nor-
mally receives and holds two groups of pads 12 by virtue
of the transfer conveyors 106 which act to simultane-
ously push the pads from a pair of flanking slottedbuckets 90 toward the central cartoner conveyor 102
therebetween.
In accordance with the present invention, the
apparatus 10 includes a pair of lateral pad compressor
devices 126 which are similar in construction and opera-
tion to the lateral transfer conveyors 106 previously
described. Each pad compressor 126 includes a pair of
endless belts or chains 128 for supporting a plurality
of pusher bar assemblies 130. Each pusher bar assembly
130 is movable transversely toward and away from the
cartoning conveyor 102 and includes a pusher bar 132
having a pressure plate 134 at the inner end adapted to
engage and compress or squeeze the pads 102 contained in
an adjacent cartoner bucket 114 moving in unison there-
with. Travel of the individual pusher bar assemblies130 toward and away from the cartoning conveyor 102 is
controlled by roller cam followers 136 mounted on the
pusher bars 132 and biased to engage inwardly canted bar
cams 138 and outwardly canted bar cams 140. As best -
illustrated in FIG. lB, as the cartoner buckets 114 move
between the pair of a lateral pad compressors 126 dis-
posed on opposite sides of the cartoner conveyor 104,
the pressure plates 134 are moved inwardly from opposite
open sides of the buckets to compress the pads 12 into a
tight and more compact mass or cluster of pads.
In addition to lateral compression or squeez-
ing of the pads 12 contained in the cartoner buckets ~`
MSE #1825
/`l ; i Jtj~
-12-
114, the pads 12 are also equeezed or compressed in a
downward or vertical direction againet the bottom of the
cartoner bucket~ by means of an overhead pad compre~sor
142 (FIG. 2B). The overhead pad compressor 142 includes
a pair of endless belts or chains 144 which support hor-
izontal pressure platss 146 adopted to move toward and
away from the traveling cartoner buckets 114. Each
pressure plate 146 is dimensioned to compress or squeeze
a group of pads 12 in an adjacent cartoner bucket 114 in
a downward or vertical direction and then is retracted
upwardly after maximum pad compression is accomplished.
Control of the movement of the pressure plates 146 is
provided by cam roller followers 148 mounted on the
plates and biased to engagement with a downwardly slop-
ing compression cam bar 150 and an upwardly slopingretraction cam bar 152.
After the group of pads 12 in each cartoner
bucket 114 has been squeezed or compressed into a
desired smaller sized mass by lateral compression from
opposite sides by the lateral pad compressors 126 and in
vertically downward direction by the overhead pad com-
pressor 142, each compressed pad group is transferred
laterally from the cartoning conveyor 102 into the car-
toning machine 104 by means of a lateral transfer con-
veyor 154. :-~
The transfer conveyor 154 is adapted to feed
compressed groups of pads 12 laterally of the cartoner
conveyor buckets 114 into awaiting, open ended cartons
156 provided in the cartoning machine 104. In general,
the transfer conveyor 154 is similar in construction and
operation to the lateral transfer conveyors 106 previ-
ously described and includes a pair of endless belts or
chains 158 for supporting lateral reciprocally movable
pusher bar assemblies 160. Each assembly 160 includes a
pusher bar 162 slidable toward and away from the car-
toner machine 104 and each pusher bar includas an inner
MSE #1825
~ ,3~J
-13-
end plate 164 dimensioned to match the cro~s-sectional
shape of an awaiting open ended carton or container 156.
Movement of the pusher bar assembly 160 back
and forth is initiated and controlled by means of roller
cam followers 166 at the outer ends of the pusher bars
162 which are biased into cammed engagement with an
inwardly directed, elongated cam bar 168 for transfer of
the pads 12 into an open carton 156 and an outwardly
directed cam bar 170 for retraction of the pusher bar
end plate 164 from the carton 156.
The cartoning machine 104 includes an endless
belt conveyor 172 for supporting a line of open ended
cartons 156 during the pad insertion process and while
carton closing and carton sealing takes place. A supply
of flattened out cartons 156 is provided at the input
end of the cartoning machine 104 and the cartons are
then opened up and laid down on the side as shown by the
arrow E (FIG. 2B) with the end flaps open in order to
receive groups of pads 12 from the lateral transfer con-
veyor 154. After a group of pads 12 is transferred into
an open ended carton 156 and the pusher bar assembly 160 ~
has been withdrawn from the filled carton, the end flaps -
are closed, and adhesively sealed by conventional and
well known closing and sealing mechanisms indicated gen-
25 erally by the number 174 in FIGS. lB and 2B. -~
With the exception of the endless belts 144 of
the overhead pad compressor 142, all of the upper hori-
zontal runs of the endless belts or chains 84, 108, 112,
128, 158 and 172, in the apparatus 10 move in the same ~ ~
30 direction from left to right as illustrated by the ~ --
arrows not having numbers or letters thereof. In addi-
tion, the belts or chains are driven in synchronism to
travel at the same rate of speed 80 that lateral trans-
ferring of pads 12 and lateral compression of the pads
in the cartoner bucXets 114 can take place in an effi-
cient and speedy manner.
MSE #1825
o
-14-
Obviously, many modifications and variations
of the present invention are possiblQ in light of the
above teachings. Thus, it is to be understood that,
within the scope of the appsnded claims, the inventlon
may be practiced otherwise than as specifically
described above.
What is claimed and desired to be secured by
Letters Patent of the United states is:
MSE #1825
