Note: Descriptions are shown in the official language in which they were submitted.
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CARTON LOADING MECHANISM
This invention relates to packaging of primary articles such as cans and
bottles in multiple packaged cartons and is more particularly concerned with
feeding such cartons from a hopper and for initiating and then completing a
loading
operation of cartons in sequence and continuously.
One common method used by known packaging machines typically
comprises removing a collapsed carton from a supply of such cartons or blanks.
The collapsed carton is then erected, and the cans, bottles or other articles
to be
packaged are placed into the erected carton. Alternatively, a supply of
cartons in
the form of flat blanks may be provided. After withdrawal of the carton from
the
supply, the carton may first be partially formed, and is then placed onto the
articles. The carton is further formed into the completed package.
A number of different forms of machinery are known for practising these
basic methods. In one form of machinery, separated groups of articles
comprising
one or more article are formed and moved along a conveyor through the machine.
Cartons are also moved along the machine, and each carton is positioned over
one
of the article groups. As the group and carton continue to mover, the carton
is
lowered onto the group to load the articles into the canon. A known example of
such a machine is shown in WO 96/32324.
Machines of this type have several disadvantages. Many bottling plants
package cans and bottles into a variety of carton sizes, for example, cartons
which
hold six, eight or twelve articles. Various packaging machines have been
developed that may be adjusted to accommodate cartons of different sizes, but
the
machine must be shut down for a period of time (known as "downtime") while the
adjustment is made. Minimising downtime is therefore desirable.
Further , as can be seen in the tuachine disclosed in ~%~ 961~:,~~rt, the
carton
tx!ay be lowered alozig a downwardly inclined path onto the moving article
gzeup_
The angle o#' inclination must be kept ~t:ite small. because an angulazly-
oriented
carton wih act properly fit over the tops of the articles in the ~7roup. Bv
keepzztg the
angle of inclination small, however, the overall length of the machine is made
relatively large. This is undesirable. becauze it increases the amount of Moor
Apace
require;. in the bottling plant.
Th,e present invention seeks to overcome the catnmercial disadvar_titaes of
rnotvn packaging r~aehines by pzovidinb a carton loading mechanism whicl', a
able
to load more than one type or size of carton, and in which char~;eavez~
t~tween
cat ~on sizes or styles may be made rapidly. Further, the invention provides a
loading mechanism that requires relatively Little machine length to perform as
loadi~ function.
I~
The present invention can be used with a packaging inachil:e described in a
corresponding application, PCT Application Wt~ 9 914 1~0 . It is envisaged
that the
present invention can be used in various types of packaging machines.
.~ltet-z~.atively. the carton loading mechanism of the present invention can
b~e sold as
?0 azz individual module to be fitted to ne~~,~ equipment oT to eXlst:ng
equipment on a
tetra fit basis.
Cne aspect of the invention provides an apparatus for continuously loadia~~
?5 different types of cartons with articles delivered to the apparatus from an
i.nfeed
stream of a packaging machine, whica apparatus comprises conveying means
sequentially to deliver successive cartons from a supply, and to load said
cotton by
lowering said carton onto at least one article wherein said conveying meana
cozz~prises a plurality of carton engaging means mounted to respective ones of
a pair
30 of endless c;lains, wherein each said carton is held between s:rnchronised
carton
engaging means to maintain the carton in a set up condition as it is moved
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AMENDED SHEEZ
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downstream characterised in that adjustment means is provided to adjust one of
said
pair of endless chains relati~.le to the other said endless chain to receive a
deferera
carton type.
According to an optional feature or' this aspect of the :ni~entzon ;:omrol me~-
~
may be arranged to control tw~Ze adjusti'nent means. Preferably. the control
means
may be arranged to control tha speed of the carton engaci~ means to rzza; n~
the
carton speed with u'~e speed of the articles. Optionally, the control means
nay
controls the angle of incline of the carton engaging means.
AccardinQ to another optional featuxe of this aspect of the i_nven~on the
control means may comprise means fcr receiving infot~rnaciou regarding the
speed cf
articles in the feed path. Preferably, control means may comprise a ser~saz
arrarzoed
to measure the speed ef articles in the f°ed path.
l~
.4ccoxdinQ to a ~rther optional feature of this aspect of ta'~e invention ~h:
carton engaging means may comprise a plurality of spaced lugs. the lugs ring
adapted to engage opposed panels of t<'te carton at spaced locations
intermediate ends
and at _spaced locations intermediate its averse edges. Optionally. tt'ze lugs
may be
?0 shaped to er~gaQe and~'ez- maintain tr:e carton ~n a horizontal plane.
Accordin.o to another optional feature of this aspect of the invention. the
support lugs may comprise a support fact in juxtaposed relationship with the
panel
during the engaQemeat and a protzuding portion adapted to et>gage a recess or
~5 aperture of the pauel_ These may further comprise a second protruding
portion
spaced horizonta.tly from the protruding portion.
according to a further optional featuxe, each lug may be mo~.znted on a cam
track, ~~herein the cam track provides a path for the Lug to maintain the
support face
30 parallel to the panel during engagement.
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AMENDED SHEET
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Another optional fearare of this aspect of the invention there tray be
provided
regulating means to cog=trot the flcr~~ Gr articles at the infeed end, the
re~ulxting
means iitrthez' comprising means to cant_rol the pressure of the articles into
the
d-nachine and means to determine the carrpct number of articies for each
carc:on.
Pre:erablv. the means to control the pressure oz the articles may c:amprise
a:n infeed
scar wheel.
A third aspect of the invention provides a packaging machine for
conrinuously packaging cartons with articles, including a carton supply and
set up
l~~ apparatus, an article infeed a-nd the apparatus for loading different
cartetz types with
articles.
An embodiment of the invention will new be described by way of example
with zeterence to the accompanying drawings in which:
1J
FIGURE la is a perspZCtive view or a carton suitable for use with a
pacica~ing machine. hereinafter described ;
FIGURE l b is a perspective v iew o1: an erected carton oW he t~ye illustrated
r0 in r i ire 1 a:
F):GURE 2 is a perspec:i ve v iew or an upstream end of a paci;aQina machine
incorporating; the loading mechar~isrn of one embodiment of the iztr'ention
~5 FIGURE 3 is a perspective view illustrating the loading mechanism of the
presentinvention;
wc~33~ ~~
~1M1:NDED ~;;EEa
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FIGURES 4 and 5 are perspective views illustrating the lug assembly; and
FIGURE 6 is a cross-sectional view of the lug assembly.
A mechanism according to the present invention is capable of loading a
variety of carton types, for example fully enclosed and basket type cartons.
Any
reference in this specification to a carton type includes different sizes of
any
particular carton style. For example, the mechanism can process fully enclosed
cartons for eight or twelve articles. The cartons are loaded by the same
method, so
only the loading of a fully enclosed carton is described.
Referring to the drawings, and in particular, Figures la and b of the
drawings carton 10 is a basket type carton, shown in Figure la in its flat
collapsed
form and formed from a unitary blank of paperboard or similar sheet material.
The carton blank includes opposed side wall panels 12, 14 and opposed end wall
panels 16, 18 hingeably connected one to next. The carton further comprises a
handle structure 20 which interconnects end wall panels 16, 18 and comprises
transverse partition panels 22 interconnecting each side wall 12, 14. Base
panels
24, 26 hingeably connected to respective side walls 12, 14. Articles (not
shown)
are inserted into the carton from above or, as the case may be, from below and
the
base panels are then secured together to provide a completed carton.
It is envisaged that the cartons will 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 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, "L" is the overall length of the carton when the base panels have
closed.
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The carton, whatever the type, will include apertures 28 struck from the
base panels 24, 26 which are used by the loading mechanism. in this
embodiment,
three triangular apertures 28 provided to support the base panels 24, 26
during
construction of the base, are also used by the loading mechanism.
Referring to Figure 2 of the drawings there is shown a machine 30 for
processing cartons of the type outlined above: The upstream end of the machine
includes a dual hopper 32 in which a multiplicity of cartons 10 in a collapsed
condition are held ready for processing. A back feeder 34 of the type referred
to
in corresponding application (Applicant's reference D-7723 ) and a rotary
vacuum
feeder 36 are positioned adjacent the dual hopper 32. The rotary vacuum feeder
36
transfers sequentially cartons from the hopper 32 to a paper feed chain 38.
The
back feeder 34 comes into contact with the carton during its orbital path and
separates opposing walls to part erect the carton. The paper feed chain 38 is
provided to complete the carton set up and to transfer the cartons downstream
to a
loading station 40. As the erected carton is moved forward by the paper feed
chain
38, a plate (not shown) maintains the carton in a horizontal plane. At the
loading
station, the base panels 24, 26 of the carton are outwardly folded by guides
(not
shown) positioned either side of the canon , before being transferred to a
carton
lowering module 50.
The carton lowering module 50 is described with reference to Figures 3 and
4. The module comprises a conveyor, for example one or more side lug chain
sets 52, 54 mounted on tables 56, 58 respectively which are downwardly
inclined
towards the point of loading 60. In this embodiment, a pair of side lug chain
set
52, 54 is used which are of similar construction and so only the near side set
52 is
described in detail. The endless chain set 52 includes an endless chain 62
driven
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 engagement means comprises a plurality of guide
pin lugs 64 mounted on the endless chain which are operable to engage the
r.._..~...~.,w....~.. .___~..-...,..~..._.. __. ~.__-.~......,..-.,.._.
_...._...~..,..-......~
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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.
In the embodiment shown in Figures 4 to 6, each lug 64 is preferably
substantially wedge shaped and comprises a support face 66 arranged at an
acute
angle with respect to a notional vertical plane Y-Y. A plurality of pins, for
example, four pins 68 are mounted at spaced intervals along the support face
66.
Each pin 68 is positioned on the support face 66 so that during use they are
received in corresponding apenhures 28 of the carton panel 24 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. Preferably, the
trailing
end of the lug 64 includes a protruding portion 70 with a substantially
vertical
support face 72 to receive the trailing edge 74 of the panel 24 being
supported. In
use, the carton 10 may tend to tip forward so the protruding portion 70
maintains
the carton in its correct position and minimises any unwanted movement.
Each lug 64 is mounted to a support frame 76, shown in Figure 4: the
support frame 76 being mounted to the endless chain 62 at a suitable or
central
point by a suitable attachment means 78, for example a roller bearing, which
is
capable of rotational movement. In this embodiment, cam followers 80, 82
extend
from each end of the support frame 76.
As illustrated in Figure 3, the table 56 includes a recess 83 to receive the
endless chain 62 and one or more cam tracks 84, 86 to receive the iug cam
followers 80, 82. In this embodiment, the recess 83 and cam tracks 84, 86 are
ovoid in shape, but other configurations could be adopted without departing
from
the scope of protection. As each lug 64 moves along the path of the cam track
84,
86 the guide pins 68 and support face 66 are maintained in plane parallel to
the
paper feed chain 38. This arrangement allows the lugs 64 to be moved laterally
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_g_
designated by letter X, in Figure 3 at the upper end of the table 56 to assist
in the
smooth engagement of the pins 68 in the panel apertures 28. Thus, the cartons
10
are maintained in a horizontal plane by the lugs 64 as they are lowered by the
endless chain set 52.
Articles such as bottles B are fed into the machine by an infeed conveyor 90
and the line pressure of the bottles is controlled by an infeed star wheel 92,
as is
well known. The articles are separated into groups of the correct number per
carton by suitable means so that they can be introduced to the carton at the
same
rate as the carton flow.
At loading station 40 illustrated in Figure 2, the cartons are introduced to
the group of articles from above as the carton and article group are moved
forward
in unison by the carton lowering module 50 and an article conveyor 94
respectively. The carton 10 is lowered onto the articles due to the downward
incline of the endless chains sets 52, 54.
It is envisaged that the loading module can be used to load cartons with
different configurations of articles, for example two rows or three rows.
Accordingly, either or both chain sets 52 and tables 56, 58 are moveable
towards
or away from each other, by means of a pneumatic cylinder (not shown).
Advantageously, the lugs 64 and pins 68 minimise vertical and lateral
movement of the cartons 10 as they engage with the articles. Optionally,
vertical
movement of the carton is further minimised by a pressure belt (not shown)
positioned above the endless chain sets 52, 54 and adapted to apply downward
pressure to the handle structure 22 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.
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.._._....."n"....".~"........,...,._ ..._.......~..,~..~......._._.m.... ..
...___. ._ ...
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Once the cartons have been loaded with articles, the lugs 64 are disengaged
from the apertures 28. The path of the cam track 80, 82 at the lower end of
each
table 54, 56 enables the lugs 64 to move in a lateral direction, designated by
letter
Z, away from the carton 10 whilst maintaining the pins 68 in a parallel plane
to the
article conveyor 94. Thus, a smooth disengagement is achieved.
The loaded cartons are transferred by means of an outfeed conveyor 94
and/or pressure belt to a further set of endless chains with side lugs (not
shown)
which are used to transfer the carton to the outfeed end of the machine.
During
this stage, the base panels 24, 26 are folded around to the underside of the
carton
and are interconnected by a locking mechanism known in the art. A second
pressure belt is provided above the handle structure to prevent unwanted
upward
movement of the carrier. The completed carton is transferred to the outfeed
end of
the machine.
It will be understood that the loading mechanism of the invention has been
illustrated with reference to a specific embodiment and that numerous
modifications
are possible within the scope of the invention. The loading mechanism 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 spend in adjusting the mechanism. In particular, the
carton lowering module can be raised or lowered by hydraulically powered
columns
96,~ 98 that support the tables 54, 56 respectively.
Suitable control means is included to position the support tables 82, 84 at
the desired location for a particular carton type or size by controlling the
pneumatic
cylinder and/or the hydraulically powered columns 96, 98. The control means
may
also control the motors driving each of the endless chains so that lugs 64 of
each
chain are moved in synchronisation as described above. Further, the speed of
the
chains can be adjusted by the control means according to the carton type
and/or
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size and to synchronise carton throughput with the paperfeed chain 38 the
article
conveyor 90 and outfeed conveyor 94.
The control means may be a dedicated processor or may be a control means
for a packaging machine in which the loading mechanism is used. Alternatively,
the control means may preferably be a known programmable servo control system.
Advantageously, the speed of operation of the apparatus is improved as
well as its efficiency and durability as the carton is moved from a collapsed
position to a fully set up condition
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"
and other containers into cartons.
Moreover, while the preferred embodiment described herein is shown as
part of a machine for loading containers into vertically-loaded basket-type
carton,
the invention is not limited to cartons of this type. As will be recognised by
those
skilled in the art, the invention may be used with wrap-around or end-loaded
cartons.
