Note: Descriptions are shown in the official language in which they were submitted.
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A PACKAGING MACHINE
This invention relates to a packaging machine for packaging primary articles
such as cans and bottles into multiple packaged cartons and in particular to a
packaging machine which can package primary articles into cartons selected
from
two or more sizes or types of carton
The majority of known packaging machines are dedicated machines which
construct only one size of one type of carton. Therefore, modern bottling
plants
are required to use a plurality of packaging machines to package different
carton
types, each machine taking up considerable floor space and being expensive to
both
purchase and operate.
A limited number of packaging machines are capable of packaging different
sizes or types of carton, for example six, eight or twelve packs of a wrap
around
carton. All such machines require adjustment when switching from one size or
type of carton to another. This adjustment includes the manual removal of all
of
the cartons within the packaging machine and possibly the mechanical
adjustment of
components in the machine. During this change over period, which can be thirty
minutes or more, a machine cannot be used (known as "down time"), which is an
expensive delay in a bottling plant. Such a delay may even result in down time
for
the entire bottling line, not just the packaging machine, if problems arise
during the
change over procedure.
It is an object of the present invention to provide a packaging machine
which overcomes the technical and commercial disadvamages of known packaging
machines.
It is a further object of the present invention to provide a packaging machine
which is capable of switching from one carton type or size to another with a
minimal down time.
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According to a first aspect of the present invention there is provided a
packaging machine for packaging articles into cartons selected from, at least,
a first
carton or a second carton, said first and second cartons being of a different
type or
size, said cartons being stored in at least one hopper, and picked for packing
by a
carton engaging means arranged to remove cartons from said at least one hopper
and transport them sequentially to a first predetermined position, from where
the
cartons are transferred to a paper feed chain which transports the cartons to
a
second predetermined position, from where the cartons are combined with said
articles,
the paper feed chain comprising a support means carrying a first endless
chain from which is depended a first set of guide lugs and a second endless
chain
from which is depended a second set of guide lugs, said guide lugs being
interleaved to produce carton receiving zones, the length of which can be
altered,
for different carton sizes or types, by altering the relative positions of the
first and
second set of guide lugs, and the support means being movable such that when
the
relative positions of the lugs is changed, this change can be compensated for
such
that the position of the first set of lugs with respect to said first
predetermined
position is unaltered.
Preferably, the relative position of the first and second sets of guide lugs
is
arranged by control of the motor which power one of the first and second
endless
chains.
Preferably, the position of said support means is arranged by the control of
a pneumatic cylinder which positions said structure.
Preferably, the packing means comprises a control means which controls the
operation of each of the components of the machine during operation and change
over between cartons of different type or size.
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Preferably, the packing means comprises a first hopper for storing said first
cartons, ancf a second hopper for storing said second cartons, and transfer
means to
transfer the cartons from either hopper to said first predetermined position,
said
carton engaging means being operable in a first position for engaging cartons
from
the first hopper and a second position for engaging cartons from the second
hopper.
Preferably, the packing means comprises means to place one of said hoppers
in an operative position and control means to select the position of carton
engagement means corresponding to the operative hopper selected.
Preferably, said carton pick up and transfer means is rotatable about a fixed
axis in an orbital path.
Preferably, the first and second pick up positions are located at different
points on said orbital path.
Preferably, the packing means comprises means to place one of said hoppers
in an operative position in the form of a frame mounted to a second fixed axis
and
wherein said first and second hoppers are mounted to the frame each hopper
being
oppositely disposed about the second fixed axis.
Preferably, said operative hopper is adjacent the orbital path of said carton
pick up and transfer means.
Preferably, the packing means comprises an apparatus for sequentially
manipulating out of said at least one hopper collapsed cartons having
oppositely
disposed face contacting panels and for initiating set up thereof into an open
ended
condition, said apparatus being operable with said carton engaging means which
sequentially engaging one of said face contacting panels and far withdrawing
from
the hopper a collapsed carton which includes said one of said face contacting
panels
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and transferring orbitally about a rotatable axis from said hopper to said
first
predetermined position, wherein said apparatus includes panel engagement means
disposed outside the path of orbit for engaging the other of said face
contacting
panels so as to pull said other face contacting panel in a direction away from
the
carton pick up means thereby to initiate opening of the carton.
Preferably, the panel engaging means is moved in a first plane by a linear
servo motor.
Preferably, said panel engaging means is mounted to a slide member in a
substantially perpendicular relationship with a guide rail and wherein said
slide
member is moveable relative said guide rail whereby said panel engaging means
is
moveable in two planes.
Preferably, said panel engaging means is moved in a second plane by a
further linear servo motor.
Preferably, control means are arranged to control the movement of the panel
engaging means.
Preferably, said panel engaging means comprises a suction cup and cup
holder mounted onto said slide member, said suction cup being connected to a
vacuum supply during said carton opening.
Preferably, said face contacting panels comprise opposition side walls of the
carton.
Preferably, the packing means has an article feed means arranged to
progress articles at a predetermined rate along a feed path for combination
with
cartons at a measured rate.
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Preferably, the article feed means includes a pair of star wheels which
collect articles from a first feed belt and move them to a second feed belt at
said
predetermined rate.
Preferably, gripper blocks are arranged on opposite sides of said second
feed belt to collect a predetermined number of articles and arrange them as an
individual unit for packaging into a carton.
According to a second aspect of the present invention there is provided a
method of
packaging articles into cartons comprising the steps of:
a) selecting from, at least, a first carton or a second carton, said first
and second cartons being of a different type or size, said cartons
being stored in at least one hopper;
b) picking cartons for packing using a carton engaging means arranged
to remove cartons from said at least one hopper and transport them
sequentially to a first predetermined position;
c) transferring said cartons to a paper feed chain which transports the
cartons to a second predetermined position from where the cartons
are combir~d with said articles, the paper feed chain comprises a
support means carrying a first endless chain from which is depended
a first set of guide lugs and a second endless chain from which is
depended a second set of guide lugs, said guide lugs being interposed
to produce carton receiving zones, the length of which can be
altered, for different carton sizes or types;
d) altering said length by altering the relative positions of the first and
second set of guide lugs; and
e) moving the support means when the relative positions of the lugs is
changed, so as to compensate for said change, such that the position
of the first set of lugs with respect to said first predetermined
position is unaltered.
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Preferably, the relative position of the first and second sets of guide lugs
is
'arranged by control of one of the motors which power the first and second
endless
chains.
Preferably, the position of said support means is arranged by the control of
a pneumatic piston which positions said structure.
Preferably, the method comprises the use of a control means which controls
the operation of each of the components of the machine during operation and
change over between cartons of different type or size.
Preferably, the carton engaging means is positioned for engagement with
cartons from a first hopper in a first position and is positioned for
engagement with
cartons from a second hopper, in a second position, the carton engagement
means
being movable between said first and second positions.
Preferably, the method comprises placing one of said hoppers in an
operative position and selecting the position of the carton engagement means
corresponding to the operative hopper selected.
Preferably, the method includes rotating said carton pick up and transfer
means about a fixed axis in an orbital path.
Preferably, the first and second pick up positions are located at different
points on said orbital path.
Preferably, the method comprises mounting said first and second hoppers on
a frame such that each hopper is oppositely disposed about a second fixed
axis.
Preferably, the method includes the location of said operative hopper
adjacent the orbital path of said carton pick up and transfer means, when in
use.
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Preferably, the method comprises sequentially manipulating out of said at
.least one hopper collapsed cartons having oppositely disposed face contacting
panels a~ initiating set up thereof into an open ended condition, by
sequentially
engaging one of said face contacting panels and withdrawing from the hopper a
collapsed carton which includes said one of said face contacting panels and
transferring orbitally about a rotatable axis from said hopper to said first
predetermined position, wherein panel engagement means is disposed outside the
path of orbit for engaging the other of said face contacting panels so as to
pull said
other face contacting panel in a direction away from the carton pick up means
thereby initiating opening of the carton.
Preferably, the method includes moving the engaging means in the first
plane by a linear servo motor.
Preferably, said method includes mounting said panel engaging means to a
slide member in a substantially perpendicular relationship with said guide
rail and
IS moving said slide member relative said guide rail whereby said panel,
engaging
means is moveable in two planes.
Preferably, said panel engaging means is moved in a second plane by a
linear servo motor.
Preferably, the method includes the use of control means arranged to control
the movement of the panel engaging means.
Preferably, the method includes the use of said panel engaging means which
comprises a suction cup and cup holder mounted onto said slide member, and the
connection of said suction cup to a vacuum supply during said carton opening.
Preferably, said face contacting panels comprise opposite side walls of the
carton.
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Preferably, the method comprises the use of article feed means to progress
articles at a predetermined rate along a feed path for combination with
cartons at a
measured rate.
Preferably, the method comprises the use of a pair of star wheels to collect
articles from a first feed belt and move them to a second feed belt at a
predetermined rate.
Preferably, the method comprises the use of gripper blocks on opposite
sides of said second feed belt to collect a predetermined number of articles
and
arrange them as an individual unit for packaging into a carton.
According to a third aspect of the present invention there is provided a
control means for a packaging machine as hereinbefore described, the control
means comprising a central processor , a manual input means, and separate
means
controlled by said central processor for individually positioning the first
and second
sets of guide lugs and the support means carrying said guide lugs on the paper
feed
chain.
Preferably, the means for positioning the support means is a pneumatic
cylinder.
Preferably, the control means is arranged for use with a packaging machine
having two hoppers accessed by a single carton engaging means, wherein the
control means comprises a means of positioning the carton engaging means in a
first position for engaging cartons in said first hopper and a second position
for
engaging cartons in said second hopper.
Preferably, the means for positioning the carton engaging means is operable
to position the engaging means in a third position, from which the carton
engaging
means cannot engage cartons in either hopper.
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Preferably, said means is a pneumatic cylinder.
Preferably, the control means is arranged for use with a packaging machine
having an opening means for opening cartons picked from each hopper, wherein
the locus of motion of pick means on said opening means can be altered so that
the
opening means can open cartons picked from either hopper.
Preferably, control means comprise X and Y oriented servo motors.
Preferably, the control means is arranged for use with a packaging machine
having an article feed means in the form of a star wheel, the control means
controlling the speed of rotation of the star wheel.
Preferably, control means cornrols a motor which rotates the star wheel.
According to a fourth aspect of the present invention there is provided a
control system for controlling the operation of a packaging machine, in order
to
change from first cartons in a first hopper to second cartons in a second
hopper,
comprising the steps of:
a) stopping the carton engaging means from picking any cartons;
b) continuing the paper feed chain until it is empty of cartons;
c) stopping the paper feed chain;
d) stopping the supply of articles;
e) repositioning the carton engaging means and the hoppers to enable
picking from the alternative hopper;
f) altering the relative position of the first and second sets of guide lugs
in said paper feed chain;
g) altering the position of the support means with respect to said first
predetermined position; and
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h) re-starting the carton picking and transportation process and the
supply of articles.
Preferably, the instruction to changeover is read from a pre-entered control
program.
Alternatively, the instruction to changeover is manually entered into a
control means.
Preferably, the packaging machine has a means for opening cartons, which
is also stopped during the changeover process.
Preferably, the locus of movement of a pick means in said carton opening
means is altered prior to restarting to enable the means to open cartons from
said
alternative hopper.
Preferably, the pick-up point and locus of the pick means in the carton
engaging means is altered during the changeover to enable picking of cartons
from
the alternative hopper.
Preferably, the speed of supply of articles is alterable as required depending
on the size or type of cartons in each of said hopptts.
Preferably, the relative positions and state of motion of each of the movable
components is sensed using i~ividual sensors and transmitted to the control
means.
An embodiment of the present invention will now be described, by way of
example, with reference to the accompanying drawings in which:
FIGL1RFS la and lb are perspective views of a basket type carton suitable
for use with the machine according to the invention in its blank and open
forms;
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FIGURE 2a is a perspective view of a fully enclosed carton blank suitable
for use with the machine according to the invention;
FIGURE 2b is a perspective view of an erected and loaded carton of the
type illustrated in Figure 2a in its blank form;
FIGURE 3a is a perspective view of a wrap around carton blank suitable for
use with the machine according to the invention.
FIGURE 3b is a perspective view of an erected and loaded carton of the
type illustrated in Figure 3a in its blank form.
FIGURE 4 is a perspective view of the infeed of a packaging machine
illustrating particularly the hopper unit, feed mechanism and paper feed
chain;
FIGURE 5 is a perspective view from the opposing side of the packaging
machine of Figure 4;
FIGURE 6 is a perspective view illustrating the hopper unit in a first
position;
FIGURE 7 is a perspective view illustrating the hopper unit in a second
pOSition;
FIGURE 8 is a perspective view of the feeder of Figure 4;
FIGURE 9 is an exploded view of the feeder of Figure 4;
FIGURE 10 is a perspective view of the vacuum feeder, back feeder and
paper feed chain of Figure 4;
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FIGURES 11, 12 and 13 are further representations of the apparatus of
Figure 10;
FIGURES 14 and 15 illustrate graphs showing the position, velocity,
acceleration and denied acceleration plotted against time of the X and Y servo
motors arranged to move the back feed of Figures 10 to 13;
FIGURE 15 is a plan view of an article feed means;
FIGURE 16 illustrates the downstream e~xl of the packaging machine of
Figure 4.
FIGURE 17 is a block diagram of a control means in accordance with the
present invention;
FIGURE 18 is a flow diagram of a control system in accordance with the
present invention.
A mechanism according to the present invention is capable of erecting a
variety of carton type for example, wraparound, fully enclosed and basket type
cartons. Any reference in this specification to carton type includes different
sizes
of a particular carton style. For example, the mechanism can load fully
enclosed
cartons for eight or twelve articles.
Referring to the drawings, and in particular Figures la and lb thereof,
carton 10 is a basket type carrier shown in Figure lb in a set up condition
ready
for lowering onto articles. The carton 10 includes opposed side wall panels
12, 14
and opposed end wall panels.16, I8 hingeably connected one to the next. The
carton further includes a handle structure which inter-connects end wall
panels 16,
18 and comprises transverse partition panels 22 inter-connecting each side
wall 12,
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14. Base panels 24, 26 are hingeably connected to each side wall panel 12, 14
respectively.
Referring now to Figure 2a and 2b of the drawings there is illustrated a
wrap around carton 30, shown in Figure 2a in its flat collapsed form. The
carton
blank includes opposed side wall panels 32, 34 and opposed end wall panels 36,
38
hingeably connected one to the next. The carton further comprises top panels
40,
42 and base panels 44, 46 hingeably connected to respective side walls 32, 34.
Articles are inserted into the carton from above or, as the case may be, from
below
and the top and base panels are then secured together to provide a fully
enclosed
carton.
As illustrated in Figures 3a and 3b, carton 31 is a wrap around type carton,
shown in Figure 3a in its blank form. A carton blank 31 includes first base
panel
33, side wall 35, top panel 37, second side panel 39 and base panel 41
hingeably
connected one to next. Top panel 37 comprises three pairs of apertures 43, 45
spaced between the side edges of top panel 37 and adapted to receive upper
portion
of articles A, illustrated in Figure 3b.
It is envisaged that the cartons can vary depending upon the shape and or
quantity of articles to be packaged and accordingly, a machine in accordance
with
the present invention is adjustable in numerous respects so that it can
process a
wide variety of such cartons. The principal arrangements which are likely to
be
varied are shown in Figures la, 2a and 3b in which "H" is the overall height
of the
set up carton equivalent to the distance between the upper edge of the side
wall and
base panel, and "L" is the overall length of the carton when the base panels
have
closed.
Referring to Figures 4 to 7 of the drawings there is shown a packaging
machine 50 for processing cartons, for example, of the type outlined above.
The
upstream end of the machine includes a dual hopper 52 in which a multiplicity
of
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basket type and fully enclosed cartons 10, 30 in a collapsed condition are
held
ready for processing.
The hopper unit 52 (Fig 6 and 7) comprises two (or more) separate hoppers
58, 60 in adjacent positions. Each hopper 58, 50 is mounted onto a frame 62,
as
shown in Figure 6 and 7. The frame 62 is mounted onto a main shaft 64 which
can be rotated about axis X - X. Each hopper 58, 60 is a gravity feed type
whereby the carton blanks are held in their respective hoppers at an incline
to
provide a positive feed. It is envisaged that the hopper units could comprise
any
number of hoppers adapted to receive different carton types or sizes
encircling the
rotary feeder hereinafter described.
In this embodiment, a n pneumatic cylinder (not shown) is used to rotate the
frame between two positions: the first position, as shown in Figure 6, with
the first
hopper 58 placed in an operative position ready for fully enclosed cartons
held in
the first hopper to be fed into the packaging machine. Figure 7 illustrates
the
frame 62 in a second position with the second hopper 60, containing the basket
type cartons. placed in an operative position.
The position of the hoppers 58, 60 is controlled by a control means detailed
below.
As shown in Figures 6 and 7, when the first hopper 58 is in an operative
position a fully enclosed carton is removed sequentially by a pick up device,
preferably in the form of a rotary vacuum feeder 66. The vacuum feeder 66
comprises sets of suction cups 67, 69, for example three sets, each being
connected to a drive shaft 70 by a drive rod 72. The drive shaft 70 is
supported at
its end by a suitable conventional bearing 71, 73, mounted to the side frame
$4.
Suitable driving mechanism such as a servo motor 75 is provided to rotate the
drive
shaft. The drive rods 72 are connected to a cam track by a cam rod and
follower
which provides a uniform path for the suction cups when the drive shaft is
rotated.
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The path of the cam track enables the suction cups to extend towards the
hopper to
pick up a carton in a flat collapsed condition and thereafter to rotate the
suction
cups and carton to the infeed end of the machine.
In order for the blank to be transferred from the inclined position to a
vertical plane, it is necessary to offset the axis of rotation of the rotary
feeder from
the vertical plane, as illustrated in Figures 6 and 7.
A vacuum is applied to one set of suction cups 67, b9 to remove a carton
from the hopper 58, 60, when they come into contact with the side wall 32 of
the
carton 30. The vacuum is maintained as the carton is rotated to a predetermi~d
position. At the said predetermined position a vacuum break disconnects the
supply to release the carton 30 from the feeder 66.
If it is desired to package a different carton type for example a basket type
carton 10 held in the second hoppers, a number of adjustments are made to the
machine. The second hopper 60 is moved into an operative position, as
described
above. As the position of the second hopper relative to the rotary feeder 66
is
different to the first hopper 58, it is necessary to move the "pick up" point
of the
suction cups 67, 69 and to alter the "on" and "off" positions of the vacuum
supply.
These changes are carried out by moving the cam track and/or the cam
controlling
the supply of a vacuum to a second position. A servo motor 167, shown in
figure
8 controlled by the control system moves these sub-assemblies between the two
positions.
It is preferred to include a third position for the vacuum supply: this
position being the "default setting" whereby the vacuum supply is disconnected
throughout the rotation of the suction cups. The default position is adopted
during
carton changeover or if there is a fault in the machine.
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Figure 8 illustrates the pick up device adapted for the withdrawal of the
lower most collapsed carton from the hopper unit. As described above, the
preferred pick up device is in the form of a vacuum feeder 66 including
suction
cups 67, 69 which are supported on cup holders 74 and 76 respectively. Ct~p
holders 74 and 76 are preferably fixedly mounted respectively on an elongate
support rod 78 which is slidably mounted respectively on a collar structure
80,
which collar structure is rigidly secured to a main rotatable shaft 70. The
cup
holders 74, 76 are mounted onto cam rods 79 extending into the side frame 84
housing a cam track hereinafter described. As illustrated from Figure 8, three
sets
. of carton pick up devices are provided in association with the main
rotatable shaft
70. Only one set of such devices are described in detail because all three
sets of
pick up devices are of the same construction operating in an identical
fashion.
Figure 9 serves to illustrate an exploded view of the rotary vacuum feeder.
A fixed cam plate 82 is mounted on the inner surface of side frame 84 and is
IS provided with an aperture 86 through which the drive shaft 70 extends. A
cam
track 88 is formed in the fixed cam plate 82 with cam followers (not shown)
disposed within the cam track 88. The purpose of the cam track 88 is to
facilitate
the cam rods 79 to be extended away from the main shaft 70 and into contact
with
the carton thereby to remove one of the cartons from the hopper 58 and to
rotate
the carton in a uniform path to the paper feed chain 100, discussed below. As
the
carton is rotated from its hopper a back feeder is used to separate opposing
side
panels and to assist in the erection of the carton.
A plurality of vacuum breaks are provided in the feeder mechanism 66
which is used in conjunction with a vacuum supply to set the vacuum connection
and cut off points.
Turning to the process of feeding a carton from the hopper to the paper feed
chain, the main shaft rotates the pick up device 66 in the direction indicated
by the
arrow "Z" in Figures 10 and 11. As the pick up devices rotate, the suction
cups
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67, 69 are moved into contact with a side wall 32 of the carton 30. A vacuum
is
then applied to the set of suction cups when the cups come into contact with
the
side wall 32 of the carton 30. Thus, the carton is withdrawn and then
transferred
to the paper feed chain 100. The vacuum is maintained during this transfer
state so
that the suction cups hold the carton wall. When the carton is deposited at
the
paper feed chain, a vacuum break disconnects the vacuum supply from the
suction
cups to release the carton. The speed of operation of the apparatus is thus
improved as well as its efficiency and durability.
As can be seen from Figure 12, the carton is moved from a collapsed
position to a fully set up coition at the paperfeed chain I00 . Of course, the
final set up operation is due in part to engagement with a back feeder (or
carton
opening means) 90.
Turning to the construction of the back feeder 90, shown in Figures 10 to
13, there comprises suitable engagement means for engaging one or more walls
of
the carton. In the present embodiment, the engagement means comprises a
suction
cup 92 supported on a cup holder 94 which is mounted onto a slide member 96.
Suitable means is provided to move the engagement means in "X" and "Y"
directions. For example, the slide member 96 is in turn mounted onto a
transverse
carriage 98 and is capable of being moved in a direction designated by the
letter X.
The transverse carriage 98 is preferably connected to a guide rail 99 which is
fixed
to a support frame (not shown): the transverse carriage being adapted to move
the
suction cup and slide member in a direction designated by the letter Y. Thus,
the
suction cup 92, is capable of moving towards or away from the rotary vacuum
feeder 66 and in perpendicular direction to the orbital path Z of a carton. If
desired, limit stops may be included at the ends of the slide member andlor
guide
rail.
It is envisaged that alternative components or configurations can be used to
provide an assembly which can move in X-Y directions.
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The slide member 96 is moved by suitable drive means for example a first
linear servo motor (not shown) which is controlled by a suitable control
system and
the transverse carriage 98 is moved by second drive means for example a second
linear servo motor (not shown) which is also controlled by the control system.
Therefore, the position of the back feeder suction cup 92 can be moved to any
desired position. In some embodiments, the control system is programmed to pre-
set suitable X-Y co-ordinates and to define the path of the suction cup. More
details of the control system are discussed below.
In use, the back feeder 90, separates one or more of the walls 34 of the
carton from the opposing wall 32 held by the rotary feeder 66. In this
embodiment, the opposing walls used are the side walls 32, 34. As the rotary
feeder 66 transfers the carton, the suction cup 92 of the back feeder 90, is
moved
forward into contact with a side wall 34 of the collapsed carton 18, shown in
Figure 10. Preferably, the point of contact is in a central portion of the
wall being
separated. Vacuum is applied to the suction cup 92 to hold the side wall 34.
As
the rotary feeder 66 continues to rotate the carton forward, the back feeder
suction
cup 92 moves away from the rotary feeder 66 to separate the two side walls,
32,
34 shown in Figure 11.
In this embodiment, the leading pair of suction cups 67, 69 of the rotary
feeder release the leading end panel 46. Thus, the carton is folded into a
part
erected condition with the side and end walls being placed in substantially
trapezoidal relationship. The back feeder vacuum supply is then disconnected
and
the carton is released from the back feeder shown in Figure 13.
Whilst it is preferred to use a suction cup to hold one of the walls, some
embodiments may adopt alternative components, for example, mechanical
connection means.
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As discussed above, the preferred "pick up" position of the back feeder
suction cup 92, is at an approximately central point of the carton side panel.
This
position will vary according to the type of carton, a~ in particular the
dimensional
variations of the side aml end walls for each carton type and for different
carton
sizes. Likewise, the path of the suction cup separate the two walls will also
vary
according to the particular carton type being erected. It is envisaged that
the
suction cup can follow an oscillatory path similar to that disclosed in WO
92115450. Alternatively, a rotary path could be used for some cartons. An
advantage of the back feeder is the flexibility offered by the system. In
particular,
the back feeder is able to move the suction cup 92 to any position to adopt
any
number of paths within the end stop limits of the slide member 96 and the
transverse carriage 98. An example of the paths followed together with
velocity
aixl acceleration components of the "X" and "Y" driving means is illustrated
in
Figures 14 and 15.
By pre-programming the control system, the position and paths of the
suction cup 92 can be pre-set, thus reducing the amount of down time when
interchanging carton types or styles. According to this invention, the speed
of
operation of the apparatus is improved as well as its efficiency and
durability.
The carton 30 continues oa its orbital path until it domes into contact with
the paper feed chain 100. In particular, the leading edge 102 of the carton 30
comes into abutment with the leading lug 104 of the paper feed chain 100. The
leading lug 104 guides the leading edge 102 away from the suction cups 67, 69
of
the rotary feeder 66, thereby placing the front end panel 46 and side panel 34
in a
substantially perpendicular relationship. At the same time, the rear lug 106
moves
into contact with the rear end panel to assist in completing the set up.
Thereafter,
the suction cups 67, 69 of the rotary feeder 66 release the carton 30 and
continue
to move in direction "Z" and the carton 30 is moved downstream to the loading
station by the paper feed chain 100.
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Turning to the construction of the paper feed chain 100 as illustrated in
Figures 4 and 10, there comprises upper and lower side lug chains 108 and 110.
Each set is of similar construction and includes endless chains having a
plurality of
leading and trailing lugs 104 and 106. The upper chain 108 includes leading
lugs
104 and the lower chain 110 comprises rear lugs 106. Each chain set is moved
forward by drive means, for example one or more servo motors controlled by the
control system.
In order to alter the machine set up from one carton type to another, it is
necessary to alter the distance D between leading and trailing lugs.
Therefore,
during changeover, the servo motor controlling the lower chain moves the
trailing
lugs 106 relative to the leading lug 104 to increase or decrease the distance
between
the tugs. For example, the side walls of basket type carton are shorter than
the
fully enclosed carton so that if the carton changeover is from a fully
enclosed to a
basket type carton, then the distance D is reduced. Likewise, the opposite
changeover means the distance D is increased. In this embodiment, the distance
between leading and trailing lugs is increased or reduced by 10 cm.
The relative movement of the trailing lug 106 will alter the position at
which the trailing lug 106 comes into contact with the rear e~ pail of the
carton
described above. It is necessary for the rear lug 106 to come into contact
with the
e~xi panel whilst it is being rotated. If the rear lug 106 is moved forward,
the point
of contact is also moved forward. To restore the point of contact to the
correct
position, it is necessary to move the paper feed chain 100 backwards by the
corresponding distance (i.e. 10 cm). It will be appreciated by those skilled
in the
art that if the rear lug 106 is moved away from the leading lug to increase
distance
D, then the paper feed chain will have to be moved forward by a corresponding
distance. A pneumatic cylinder (not shown) is used to move the paper feed
chain
100.
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The erected carton is moved forward by the paper feed chain 100 and is
held in place by a horizontal plate (not shown) and onto the carton lowering
module 111. The base panels 46 of the carton are then outwardly folded by
guides
114 positioned either side of the carton.
After the cartons have been set up, they are transferred to the loading
station 120. Thus, the cartons leave engagement with the paper feed chain 100
and
engagement is gradually transferred as the cartons move downstream to a carton
lowering module 11, shown in Figures 3 and 4.
The carton lowering module comprises a conveyor, for example, a pair of
side lug chain sets 112 mounted on tables 113 respectively which are
downwardly
inclined towards the point of loading 114. Each side lug chain set 112 is of
similar
construction includes an endless chain 115 powered by a motor, such as a servo
motor. Suitable means connected to the side lug chain sets are provided to
periodically engage cartons supplied from the paper feed chain. In this
embodiment, the carton engaging means comprises a plurality of guide pin lugs
i 16
mounted on the endless chain which are operable to engage the opposed base
panels
24, 26 of a carton and to retain the base panels 24, 26, side panels 12, 14
and end
panels 16, 18 in a set up condition as it moves downstream.
Each lug 116 is preferably substantially wedge shaped and comprises a
support face 117 arranged at an acute angle with respect to a notional
vertical
plane. A plurality of pins, for example four pins 118 are mounted at spaced
intervals along the support face 117. Each pin 116 is positioned on the
support
face 117 so that during use they are received in corresponding apertures of
the
base panel being supported thereby to engage the carton. In this embodiment,
only the leading three of the four pins are required for the basket type
carton. Of
course, for the larger cartons such as the fully enclosed cartons, all of the
pins are
used. Conversely, a smaller carton may only require to be engaged by two of
the
pins.
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The endless chain is moved by a motor, for example a servo motor. As
each lug 64 moves along the path of a cam track (not shown), the cartons 10
are
maintained in a horizontal plane by the lugs 116 as they are lowered by the
endless
chain set 113 towards the loading station 120.
It is envisaged that the lowering module can be used to load cartons with
different configurations of articles, for example two mws or three rows.
Accordingly, either or both chain sets and tables are moveable towards or away
from each other, by means of a pneumatic cylirxier (aot shown). Further, the
carton lowering module can be raised or lowered by hydraulically powered
columns
that support the tables. The pneumatic cylinder and/or hydraulically powered
columns may be controlled by suitable control means.
Articles such as bottles 122 are fed into the machine by an end feed
conveyor 124 and the line pressure of the bottles is controlled by an infeed
star
wheel 126, as is well known (Figure 16). The articles are separated into
groups of
the correct number per carton 30 by means of a series of article grippers 128
which
also control the flow of the articles so that they can be introduced to the
carton at
the same rate as the carton flow.
Turning to the construction of article gripper assembly 128 positioned either
side of the article conveyor, there is provided pairs of four blocks or spacer
elements 131 mounted onto separate endless chains. Each block comprises four
semi-circular recesses 133 positioned one to the next and capable of receiving
part
of a bottle or can. The endless chain is mounted on a table. One or both of
the
gripper assemblies can be moved toward or away from the article conveyor
according to whether two or three rows of articles are required. In this
embodiment', gripper assembly is moved towards the second gripper assembly
when
it is desired to package two rows of articles. Thus, each gripper assembly is
adapted to grip part of those articles forming each outer row, as shown in
Figure
16. The distance between infeed star wheels is also narrowed to ensure that
the
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article flow is restricted to two mws, when required or moved to allow three
rows
when required. In those cartons which required six articles arranged in two
rows
of three articles each, the leading rebate in each gripper block remains
empty.
For those cartons requiring three rows of articles, the central row of
articles
is moved forward by means of the configuration adopted in Figure 15. Thus, the
correct number of articles is selected.
The articles gradually leave contact with the gripper assembly and are
transferred to the loading station by means of article conveyor.
At loading station 120 illustrated in Figure 4 the cartons are introduced to
the group of articles from above as the carton and article group are moved
forward
in unison. The carton is lowered onto the articles due to the downward incline
of
the endless chain sets on the carton lowering module, as described above. As
illustrated in Figure 3, lateral movement of the carton in the loading station
is
controlled by a pair of guides positioned above each chain set and adapted to
receive the free edges of each base panel. Vertical movement of the carton is
minimised by a pressure belt positioned above the endless chain sets and
adapted to
apply downward pressure to the handle structure or as the case may be the top
panel. It is envisaged that in some embodiments, the pressure belt could be
replaced by fixed guides or, where appropriate, vertically mounted endless
chain
and lug sets in accordance with common practice.
Once the cartons have been loaded with articles, they are transferred by
means of the article conveyor and/or pressure belt to a further set of endless
chains
with side lugs 210 which are used to transfer the carton to the outfeed end of
the
machine. During this stage, the base panels are folded around to the underside
of
the carton by suitable folding means for example fixed guides (not shown) and
are
interconnected by a locking mechanism known in the art. A second pressure belt
212 is provided to prevent unwanted upward movement of the carrier.
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Turning to the construction of wraparound type cartons, as illustrated in
Figures 3a and 3b, the machine is first adjusted to receive cartons of this
type.
Thus, the first and second pressure belts 206, 212 are also mounted on units
shown
in Figure 17 which are adjustable in a vertical plane by computer controlled
servo
motors.
In order to modify the machine to receive wraparound cartons of the type
illustrated in Figures 3a and b, the article grouping mechanism is adjusted as
described above, to supply the required number of article rows. The hopper 200
illustrated in Figure 17 holds a multiplicity of carton blanks 31 which are
held
ready for processing. The blanks are then removed sequentially by a rotary
vacuum feeder 202. In this embodiment, the vacuum feeder 202 is mounted
horizontally and is similar in construction to the feeder outlined above. It
is
envisaged that suitable feeders known in the art may be used. In this
embodiment,
the rotary feeder is provided with a cam track which enables the carton being
transferred to be placed directly on to the group of articles. Suitable
control means
is used to control the transfer of cartons a~ articles so that their movement
is
coordinated. In other embodiments, the blank is removed from the hopper 200
and
is fed one at a time to paper feed chain sets so that the base panels and side
panels
are supported.
The articles are introduced to the loading station 204 by the article conveyor
in the same way as described above.
At the loading station 204, upper portions of the articles are inserted
through apertures 43, 45 by lowering the cartons. In this embodiment, this
process
is achieved by the first pressure belt 206 which is positioned in a central
region to
lower the top panel and enable the neck portions of the articles to pass
thmugh the
apertures. In this embodiment, the first pressure belt is mounted onto a
hydraulic
platform 208, which is capable of being raised or lowered according to the
carton
type. Suitable control means is used to control the level of the platform.
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As the carton is moved downstream by side lug chain sets 210, the side
panels 35 are folded into a substantially perpendicular relationship with top
panel
39 by fixed guides (not shown) and the part erected carton is transferred to
the
second set of endless chains which transfer the carton to the outfeed end of
the
machine. In this embodiment, the second pressure belt 212, used to minimise
movement of the top panel/handle structure, can be raised or lowered as
appropriate to the carton. Likewise, the set of endless chains 210 are moved
apart
or brought closer together by means of horizontal adjustment which are
controlled
and powered by servo motors (not shown). The base is constructed by known
means 214 and, where appropriate, article retaining panels are formed by known
means 216. Thus, the carton is secured to complete the packaging operation.
Figure 18 is a block circwit diagram illustrates the electrical and electronic
control of the packing machine 50.
Figure 18 illustrates a control means 130 having a central processor 132, a
manual input means 134 through which specific instructions can be programmed,
and a display 136 which indicates useful information to the machine operator.
The
central processor 132 and the display I36 can display operational information,
such
as, the speed of operation of the machine and its compliance with particular
safety
requirements, in the normal manner. In addition, the cezrtral processor i32
and
display 136 can also indicate information specific to the present machine,
such as
the feeder 58, 60 which is being used, the position of the guide lugs 104 and
106
and support means 112 and the position of the feeder 66 arrd the back feeder
90.
All of this information is provided through sensors shown generally at 138.
As discussed above, the control means 130 also controls the positions of the
moveable components as well as the speed of movement of variable speed
components. For example, the central processor 132 controls the motors 140
which power the feed means (drive belt, star wheel and blocks) which move
articles 122 to be packed into (the infeed end of) the machine 50.
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The processor 132 also controls the position of the feeder 66 through
actuation of a pneumatic cylinder 142 as well as the position of the back
feeder 90
through programmed and accurate control of X and Y servo motors 144. In
addition the central processor 132 also controls the paper feed chain 100
through
control either or both of the servo motors 146 which contml the endless chains
from which the guide lugs 104 and 106 are depended, as well as the pneumatic
cylinder 148 which controls the position of the support structure 112.
Suitable control means can be included to position the support tables of the
carton loading module at the desired location for a particular carton type or
size by
controlling the pneumatic cylinder andlor the hydraulically powered columns
96,
98. The control means may also control the motors driving each of the endless
chains to control and adjust the speed a~ to synchronise carton throughput
according to the carton type andlor size.
Additionally, the control means may control the wraparound carton feeding
and loading apparatus to place the apparatus in operative or inoperative
conditions,
as described above.
As will be discussed below the positions and speed of these devices can be
input manually or a specific pre-written programme can be loaded into the
central
processor for control of the packaging machine. Also, for the controlled
change
over of the machine from one carton type or size to another can be the result
of a
pre-written program or a manual input signal, as discussed below.
Regarding Figures 19 the change over process is started (box 150) either
due to a manual input request (box 152) or through the machine coming to the
end
of a pre-programmed run (box 154).
The first stage in the system is to cause the feeder 66 to stop picking
cartons
from one of the hoppers 58, 60 (box 156). At this time the back feeder or
carton
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opening means 90 is also stopped (box 158). The paper feed chain 100 is
continued to operate until empty of cartons. In the present invention this
requires
the four cartons placed between the first and second predetermined locations
to be
removed from the paper feed chain 100.
However, unlike prior art embodiments this removal is not manual but the
paper feed chain 100 is continued to operate until these cartons are removed
for
filling at the carton filling station 120, in the normal manner (box 160). At
this
point the paper feed chain I00 is stopped (box 162). Sensors, as discussed
above,
can provide the central processor 132 with information on a number of articles
to
be packed so that the article feed means can be stopped at such a point that
all of
the necessary articles have been forwarded for the packing of the four above
mentioned cartons (box 164).
At this point the guide lugs 104 and 106 on the paper feed chain are
repositioned, with respect to each other, as discussed above (box 166), and
the
support means is repositioned with respect to the first predetermined
position, also
as discussed above (box 168).
The feeder 66 is then repositioned for use with the other hopper 58, 60, as
discussed above (box 170).
Also, the program user which the locus of the cup 92 on the back feeder
or carton opening apparatus 90 is operating is controlled so that this device
will
operate with the carton feeder 66 so as to open cartons from the hopper now
being
used (box 172).
Finally, the article feed means is controlled so that the appropriate number
of articles is provided to the packing station 120 at the appropriate time, as
discussed above, (box 174).
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After each of these steps have been taken the packaging machine 50 can be
restarted and cartons removed from the newly used hopper for filling in the
usual.
fashion {box 176). It should be noted that the restart of the carton picking
process
and the article supply process are controlled such that no articles go
unpacked and
no cartons are supplied to the paclting station without corresponding
articles.
Modifications may be made without departing from the scope of the present
invention. In particular, alternate sensors and alternate means of positioning
each
of the moveable articles may be utilised without departing from the scope of
the
invention as claimed in the accompanying claims.
In addition, while the preferred embodiment described herein is for loading
bottles into cartons, it will be recognised that the invention is not limited
to cartons
for bottles. The invention may be used with machines for packaging cans,
paperboard "bricks" arai other containers into cartons. Further, the present
invention is able to process cartons comprising numerous configurations of
groups
of articles covering a range of carton size and shape, for example four, six;
eight
and twelve bottles without undue time being spent in adjusting the mechanism.
