Note: Descriptions are shown in the official language in which they were submitted.
CA 02477664 2004-08-16
Application number,'numero de demande: 2 ~ l~ ~'~
Figures:
Pages: i4 ~2c' 2~ , 22 ,~1, ZH . 2S' 2f~ . 2~~ 32 T33 , ~~ ~a5
3~,31,38,3q,~1,~2,s+S~N'1
~~sc~ox~s~e.
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received with this application
(Request original documents in File Prep. Section on the 10th Floor)
Documents rebus avec cette demande ne pouvant titre balayes
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CA 02477664 2004-08-16
VARIABLE-SIZED MOLDED PRODUCT TRAY DENESTING APPARATUS
BACKGROUND OF THE INVENTION
[0001] The present application claims priority from provisional patent
application
Serial No. 60/495,208 entitled "Variable Size Molded Product Tray Denesting
Apparatus"
filed August 14, 2003, having the identical inventors and assignee of the
present invention.
1. Field of the Invention
[0002] The present invention relates to tray dispensing devices. More
particularly it
relates to a tray dispensing device for molded trays of a variety of sizes
which retains a stack
of nested trays and dispenses individual trays from the nested stack.
2. Description of the Related Art
[0003] Trays for dispensing food items are widely known. Automatic tray
dispensers
for use in the packaging of such food items may be found in U.S. Patent No.
5,788,116,
Adjustable Tray Dispenser. Similarly, the following ten United States Patent
describe
denesting devices which utilizes suction at some point in the apparatus: U.S.
Patent Nos.
6,623,236; 6,159,322; 5,704,194; 5,700,004; 5,133,169; 5,064,093; 5,013,213;
4,991,741;
4,350,466; and 4,260,311. However, a problem has remained in the tray
denesting field for
accurately separating one tray from a stack of trays, for preventing jamming
of such
denesting apparatus and for denesting trays having irregularly shaped surfaces
thereon. In
addition, although adjustable tray denesting apparatus have been provided in
the past, no
CA 02477664 2004-08-16
known apparatus includes automatic adjustment of the hopper for a specified
number of
different size trays.
[0004] It has also been known in the art to use suction devices from removing
a single
item from a stack of items. However, such devices have had the single item
removed from
the top o the stack. It was unknown to remove a single item, such as a tray,
from the bottom
of a stack using suction.
SUMMARY OF THE INVENTION
[0005] A tray denesting apparatus is provided which includes a receptacle for
holding
a nested stack of trays. The receptacle further includes a tray size
adjustment apparatus. The
tray size adjustment apparatus is movable between a first position and a
second position prior
to loading of the trays into the receptacle so as to allow dispensing of a
plurality of tray sizes.
(0006] The apparatus further includes a mechanism for denesting individual
trays
from the nested stack of trays and for depositing the individual trays onto a
conveyer belt
upon release from the receptacle.
[0007] The tray size adjustment apparatus includes a front adjusting bar, a
rear
adjusting bar disposed in parallel alignment with the front adjusting bar, a
first side adjusting
bar, and a second side adjusting bar disposed in parallel alignment with the
first side
adjusting bar. The front adjusting bar is disposed in perpendicular alignment
with the first
side adjusting bar. As a result, an opening of the desired size and shape is
provided for
receiving trays of a selected size. The front adjusting bar, the rear
adjusting bar, the first side
adjusting bar and the second side adjusting bar are all selectively variable
in length to provide
the desired size opening. The front adjusting bar, the rear adjusting bar, the
first side
adjusting bar and the second side adjusting bar may be independently
adjustable to move the
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tray size adjustment apparatus between the first and the second position or
the side adjusting
bars may be adjusted simultaneously and then the front rear adjusting bars
subsequently
adjusted. The tray size adjustment apparatus may further include a middle
adjusting bar
disposed in parallel alignment with both the first side adjusting bar and the
second side
adjusting bar. Alternatively, the front and rear adjusting bars can be moved
followed by a
single one of the side adjusting bars to create the desired size opening.
[0008] In order to effect movement of the adjusting bars and change the size
of the
receptacle, either pneumatic cylinders, electric motors or hydraulic cylinders
may be utilized.
The first and second positions of the adjusting arms correspond approximately
to standard
size trays, such as those used in the fruit packing industry which include
standard trays of
12x19'/z inches typically stacked in four, five or six layers and in a 42 lb.
bushel box or Euro
Trays~ which are 14 5l8 x 22 'h inches and are packed in 27 lb. cardboard
boxes in one; two,
or three layers or reusable plastic containers (RPC) in two or three layers.
[0009] In a preferred embodiment the invention, a plurality of receptacles are
provided so that trays can be sequentially denested from each stack of trays
and deposited
onto a moving conveyer belt which extends below the receptacles. The conveyor
belt can
then direct the denested trays to a second conveyor used for loading of
products such as fruit
into the trays. Alternative size trays can be deposited for stacking purposes,
or the same size
trays can be stacked in reversed position, also for stacking after being
filled with fruit. The
receptacle maintains each of the trays in a face up alignment biased towards
the bottom end
of the receptacle.
[0010] In a preferred embodiment the mechanism for denesting or removing a
single
tray from the stack of trays includes at least one set of soft flexible
suction cups operatively
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connected to and disposed on a bellows assembly the suction cups being
disposed below the
conveyor belt. The bellow assembly is movable between a first position not in
contact with
the trays and a second position in contact with the bottom tray so that the
suction cups may
adhere to the first one of the trays. i.e. the bottom tray. The bellows
assembly further
includes a plurality of shafts, one of the soft flexible suction cups being
disposed on the top
end of each of the plurality of shafts. The shafts are mounted on pivotable
and extendable
arms so as to allow adjustment to a desired location on the tray size desired.
The bellows
assembly is connected to a source of vacuum which is operated sequentially so
that when the
suction cups come into contact with the bottom tray on the stack of trays, the
vacuum is
conveyed through the suction cups so that the suction cups adhere to the
bottom tray. The
bottom tray may then be denested by lowering the suction cups. An advantage of
the present
invention is that a single tray can be removed from the bottom of a stack
using suction, which
firmly grips the tray and allows a shorter movement of the tray onto the
conveyor. This
allows higher speeds and less wear and tear on the apparatus.
[0011] In operation, a method for denesting a tray from a stack of trays in a
receptacle
is provided. The method includes the steps of selecting a desired size
parameter and
adjusting the receptacle to correspond with the selected size parameter. A
plurality of trays
are loaded into the receptacle having dimensions equal to the size parameter.
The soft
flexible suction cups are moved from a rest position to a contact position
with a bottom tray
in the stack. Vacuum is applied through the suction cups and thereby to the
tray. The suction
cups are then lowered causing the tray to be removed from the stack of trays
from the
receptacle and deposited onto a conveyor belt. The suction cups are then
returned to a rest
position.
4
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(0012] In alternative embodiment of the invention, an additional mechanism is
provided for denesting individual trays. A gripper blade assembly is provided
which is
located within the conveyor belt. When actuated, the gripper blade assembly
extends
upwardly into contact with the bottom tray in the stack of trays in the
receptacle. A pair of
gripper blades then are actuated and moved towards each other so as to grip
the edges of the
bottom tray. The gripper blades and suction cups are then lowered
simultaneously so as to
securely denest the bottom tray from the stack of trays while allowing the
remaining trays to
remain in place in the receptacle. The bottom tray is then deposited onto the
conveyor belt
running through the apparatus. Alternatively, the gripper blade assembly alone
may be
utilized.
[0013] An additional means of retaining the trays in the receptacle is
provided by two
or more reset platform rails which are selectively extended to support the
stack of nested
trays or withdrawn to allow denesting of the bottom tray. The rails are
extended or
withdrawn by means of one or more pneumatic cylinders. The stack of trays are
also
supported in the receptacle by a plurality of spring loaded tray clamps. As a
result of both the
reset platform rails and the tray clamps, the stack of trays is secured, but
the bottom tray may
be removed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIGURE 1 of the drawings is a front perspective view of the tray
denester of
the present invention.
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[0015] FIGURE 2 of the drawings is a front perspective view of the tray size
adjustment apparatus of the present invention, as used in the tray denester of
FIG. 1 of the
drawings.
[0016] FIGURE 3 of the drawings is a top view of the tray size adjustment
apparatus
of FIG. 2.
[0017] FIGURE 4 of the drawings is a side view of the tray size adjustment
apparatus
of FIGS. 2 and 3.
[0018] FIGURE 5 of the drawings is a front view of the tray size adjustment
apparatus of FIGS. 2 and 3.
[0019]
[0020] FIGURE 6 of the drawings is a front elevational view of sets of soft
flexible
suction cups mounted on the top end of a plurality of shafts which, in turn,
are connected to a
bellows assembly, as utilized in the tray denester apparatus of FIG. 1.
[0021] FIGURE 7 of the drawings is a side view of the suction cups, shafts and
bellows assembly of FIG. 6.
[0022] FIGURE 8 of the drawings is a top schematic view of the suction cups,
shafts
and bellows assembly of FIGS. 6 and 7, showing pivotable and adjustable arms
which effect
selected movement of the suction cups to a desired position for each tray
size.
[0023] FIGURE 9 of the drawings is a front perspective view of the suction
cups,
shafts and bellows assembly of FIGS. 6, 7 and 8.
[0024] FIGURE 9 of the drawings is a front perspective view of the suction
cups and
shafts of FIGS. 6, 7 and 8 mounted on a suction base plate and showing an air
cylinder for
selective movement of the shafts and suction cups.
r;
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[0025] FIGURE 10 of the dxawings is a top view of the suction base plate
having
shafts, suction cups and an air cylinder disposed thereon.
[0026] FIGURE 1 l of the drawings is an exploded front perspective view of a
gripper
blade assembly for use in the tray denester of FIG. 1.
[0027] FIGURE 12 of the drawings is a front perspective view of the gripper
blade
holder assembly, blade holder and blade utilized in the gripper blade assembly
of FIG. 11.
[0028) FIGURE I 3 of the drawings is a side view, partially broken away,
showing the
tray denester of FIG. I and showing, in particular, two stacks of trays in
parallel receptacles,
two bellows and suction cup assemblies, a conveyor belt for receiving trays
after they have
been denested, a drive motor and a drive chain for the conveyor belt, a
magnetic position
sensor to determine the proximity of trays, an air supply valve for providing
pneumatic force
to the bellows and for creating a vacuum in the suction cups, and a control
panel for operating
the denester.
[0029] FIGURE 14 of the drawings is a front view of the control panel of FIG.
13,
showing in particular pneumatic cylinders and solenoid valves, air pressure
regulators, an air
supply valve, wiring terminals, a DC power supply, a programmable controller,
a main power
disconnect and a warning light for jams.
[0030] FIGURE 15 of the drawings is a top view of the tray denester of FIGS.
13 and
14, showing in particular proximity sensors and tray clamps in the tray
receptacles, a stack of
nested trays in the tray clamps and the vacuum pumps used for providing
suction to the
suction cups.
(0031] FIGURE 16 of the drawings is a electrical schematic of the tray
denester of the
present invention.
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[0032) FIGURE 17 of the drawings is a pneumatic schematic of the tray denester
of
the present invention.
[0033) FIGURE 18 of the drawings is a front prospective view of a suction cup
template used for adjusting the position of the suction cups shown in FIGS. 1,
and 6 - 10 for
desired sized tray.
[0034) FIGURE 19 of the drawings is a front view of the control panel of FIG.
14.
(0035) FIGURE 20 of the drawings is a front view of the solenoid valves and
pressure
regulators as shown in the control mechanism of FIG. 14 of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0036) While the present invention is susceptible of embodiment in many
different
forms, there is shown in the drawings and will herein be described in detail
several specific
embodiments with the understanding that the invention is not limited thereto,
except insofar
as those who have the disclosure before them are able to make modifications
and variations
without departing from the scope thereof.
(0037) As shown in FIG. 1 of the drawings, a tray denesting apparatus 10 is
provided
having a plurality of receptacles 12 and 14 for holding nested stacks 16 and
18 of trays 20.
(Best seen in FIG. 13). As best seen in FIGS. 2, the tray denesting apparatus
10 includes a
tray size adjustment apparatus 22. The tray size adjustment mechanism 22 is
movable
between a first position wherein the receptacles 12 and 14 are approximately
12x19'/z inches
in width and length and a second position in which the receptacles 12 and 14
are
approximately 14 5/8x22 '/z inches in width and length. The first size
corresponds to a
standard tray used in the fruit packing industry and the second size
corresponds to a Euro
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Tray~ also used in the fruit packing industry for larger fruit. The standard
trays are typically
stacked using four, five or six layers in a 42 lb. bushel box (not shown). The
Euro Trays~
are typically packed in twenty-seven pound cardboard boxes in one, two or
three layers or
reusable plastic containers in two or three layers. Alternate tray layers
within a box are
typically rotated 180 degrees so the food and trays will interlock. This is
accomplished by
either loading the two receptacles 12 and 14 in opposite direction or by
stacking a standard
tray on top of a Euro Tray~.
[0038] FIGS. 1, 6 - 10 and 12 further show a mechanism 24 for denesting
individual
trays 20 from the nested stacks 16 and I 8 of trays 20. In a preferred
embodiment, tray
denesting apparatus 10 includes a conveyor belt 26 for receiving each of the
plurality of trays
20 upon release from the receptacles 12 and 14. In the embodiment shown,
conveyor belt 26
comprises a plurality of rubber bands 26A, B, C and D which are mounted on a
pair of
powered shafts 28 and 30, best seen in FIG. 13. Conveyor belts 26 in turn are
driven by a
drive motor 32 and drive chain 34 at a desired rate of speed. Conveyor belts
26 are used to
advance trays 20 onto packing lines for the depositing of fruit into
individual trays 20. It
should be noted in this regard, that in a preferred embodiment, individual
trays 20 have a
series of pockets 36, 38, 40 adapted for the reception of fruit. In Euro
Trays~, additional
pockets 42 are also found. Pockets 36 - 42 are by example only; the number of
pockets is
determined by the size of the fruit and the size of the tray. A plurality of
pockets such as
pockets 36 - 42 may be provided.
[0039] As seen in FIGS. 1 through 5, the tray size adjustment mechanism 22
includes
a front adjusting bar 44, a rear adjusting bar 46, disposed in parallel
alignment with the front
adjusting bar 44, a first side adjusting bar 48 and a second side adjusting
bar 50. The second
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side adjusting bar 50 is disposed in parallel alignment with the first side
adjusting bar 48 and
the front adjusting bar 44 is in perpendicular alignment with the first side
adjusting bar 48.
As best seen in FIGS. 3 through 5, the adjusting bars 44 - SO are adjustable
in length by
means of pneumatic cylinders 52 - 62. The pneumatic cylinders are connected by
means of
shafts 64 so as to extend the adjusting bars a desired length and to a desired
length and to a
desired width. Similar pneumatic cylinders 68 and 70 are seen in FIG. 5 for
extending or
decreasing the width of the receptacles 12 and 14. When required, the
individual adjusting
bars 44, 46, 48 and 50 may be adjusted individually as required. However, in a
preferred
embodiment, standards size dimensions for receptacle 12 and 14 are stored in
control system
72 (FIGS. 1, 14, 17 and 18) so that the desired lengths and widths can be
adjusted
automatically by use of a programmable controller 74 contained within control
system 72,
best seen in FIG. 14, which in turn actuates pneumatic cylinders and solenoid
valves 76 and
air pressure regulator 78 so as to cause pneumatic cylinders 52, 54, 56, 58,
60 and 62 to
extend or retract shafts 64, 66 and thereby enlarge or reduce in size
receptacles 12 and 14.
[0040] As fiwther shown in FIGS. 1, 2 and 3, the tray denesting apparatus 10,
in a
preferred embodiment, further includes a middle adjusting bar 80 having a pair
of pneumatic
cylinders 82 and 84 operatively connected thereto for assisting in reducing
the width of
receptacles 12 and 14. Air cylinder 86 is similarly mounted on rear adjusting
arm 46.
Middle adjusting bar 80 is disposed in perpendicular alignment with the first
side adjusting
bar 48 and the second side adjusting bar S0. Although the tray adjusting
mechanism 50
shown in the drawings shows the use of pneumatic means for moving the
adjusting bars,
electric motor means may be substituted for the pneumatic cylinders 52, 54,
56, 58, 60, 62
and 84. Similarly, a hydraulic system utilizing a hydraulic pump may be
utilized for
CA 02477664 2004-08-16
extending or retracting the adjusting bars in order to effect changing the
size of receptacles 12
and 14.
[0041] As best seen in FIGS. I and 6 through 10, the means 24 for denesting a
single
tray 20 from the stack of trays 16 and 18 includes at least one set 88 of soft
flexible suction
cups 90, 92, 94 and 96. As shown in FIG. 1, similarly, (although partially
obscured in FIG.
1 ), a set of suction cups 98 - 104 may be utilized for denesting trays 20
from the stack of
trays 16 in first receptacle 12. As seen in FIG. 6 and 7, flexible~suction
cups 90 - 96 are
disposed on and operatively connected to a bellows assembly 106 and, as shown
in FIGS. 1
and 13, are disposed in a first position below conveyor belt 26. They may then
be extended
through conveyor belt 26 into contact with trays 20 as best seen in FIG. 13.
As a result, when
extended, suction cups 90 - 96 adhere to the bottom surface 107 of tray 20
which may then be
drawn downwardly by bellows 106 so as to deposit tray 20 onto conveyor belt
26. Vacuum is
then released from suction cups 90 - 96 allowing tray 20 to advance along
conveyor belt 26.
As shown in Figure 9 of the drawings, the suction cups 90, 92, 94, and 96 and
shafts 108,
110, 112 and 114 of FIGS. 6, 7 and 8 are mounted on a suction base plate 97,
which has an
air cylinder 213 for selective movement of the shafts 108, 110, 112 and 114.
[0042] As further seen in FIGS. 6 - 9, suction cups 90 - 96 are each mounted
on a
hollow shafts 108, 110, 112 and 114 respectively which in turn are connected
to a source of
vacuum 210 and 212 through bellows mechanism 106. Soft flexible suction cups
90 are
mounted at the top ends 115, 117, 119 and 121 of shafts 108, 110, 112 and 114.
[0043] In order to compress suction cups 90-96 against tray bottom 108,
suction cups
90-96 are preferably constructed in a ribbed configuration, being hollow on
the inside and
having a plurality of curved ribs 90A-90D, 92A-D, 94A-D, and 96A-D. This
allows
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cushioning of the suction cups 90-96 against the bottom 108 of tray 20, and
compression of
the suction cups 90-96 against bottom 107 of tray 20. This provides a better
vacuum seal and
improved gripping of the irregular surface of the bottom 108 of the molded
fiber tray 20.
[0044] As further seen in FIGS. 7-10, the horizontal positions of the shafts
108, 110,
112 and 114 can be adjusted by means of air cylinder 213, to move the suction
cups 90, 92,
94 and 96 to the desired position for each size tray to be denested. These
positions and
adjustments can be stored in computer 74 or done manually. Shafts 108, 110,
112 and 114
are perpendicularly mounted on selectively pivotable and extendable arms 108A,
110A,
112A and 114A and are moved by cylinder 213.
[0045] Returning to FIG. 13, receptacles 12 and 14 maintain each of the
plurality of
packing trays 16 and 18 in face-up alignment and biased towards the bottom end
123 and 125
of receptacles 16 and 18. When tray denesting apparatus 24 is utilized, shafts
108, 110, 112
and 114 are moved upwardly, in direction 127 or downwardly in direction 129.
[0046] As mentioned previously, tray denesting apparatus 10 is particularly
designed
for denesting molded fiber trays 20 used for carrying fruit. The irregular
surfaces on a
molded fiber tray 20 make it difficult to grasp from below or from its edges
due to the
flexibility of the side edges of the tray. It has been found, as seen in FIGS.
11 and 12, that an
additional means of denesting trays generally and on molded fiber trays in
particular, is
through the use of a gripper blade assembly 116, which may be included as part
of the
mechanism 24 for denesting trays. Gripper blade assembly i 16 includes a
gripper blade slide
assembly 118, gripper blade slide assembly 118 includes a pair of tracks 120
and 122, a pair
of blade holder assemblies 124 and 126 having ribs 128, 130, 132 and 134
extending laterally
therefrom. Ribs 128, 130, 132 and 134 are sized and positioned for sliding
engagement
l?
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within tubular tracks 120 and 122. Gripper blades 136 and 138 are mounted
respectively on
gripper blade holders 124 and 126. In the embodiment shown, gripper blades 136
and 138
have a series of serrated teeth 140 and 142 extending along one edge of
gripper blades 136
and 138, respectively. tripper blade holders 124 and 126 each further have a
pillar 144 and
146, respectively upon which gripper blades 136 and 138 each rest. tripper
blades 136 and
138 are positioned and aligned horizontally with the toothed surfaces 140 and
142 when
facing each other. When actuated by pneumatic cylinder 148, gripper blade
holders 124 and
126 may be selectively advanced towards each other or retracted away from each
other.
tripper blades 136 and 138 also rest in an elevated position on pillars 144
and 146 so that
tray 20 can rest on top of the top body surface 150 and 152 respectively of
gripper blade
holders 124 and 126, and in fact surfaces 150 and 152 can be slid along the
bottom of tray 20
until toothed edges 140 and 142 grip the lateral edges of tray 20. tripper
blade holders 124
and 126 in turn, when retracted, slide into and are enclosed within gripper
blade covers 124A
and 126A so as to allow free movement of tray 20 along conveyor 26.
[0047] In the preferred embodiment gripper blade assembly 116 is mounted on
bellows assembly 106 so that when suction cups 90, 92, 94 and 96 grip tray the
bottom
surface 148 of tray 20, and gripper blades 136 and 138 may be used for further
gripping tray
20. Bellows 106 may then be retracted downwardly in direction 152 so as to
draw tray 20
down onto the surface of conveyor 26. tripper blades 136 and 138 may then be
separated in
direction 154 and suction released from suction cups 90, 92, 94 and 96 thereby
allowing tray
20 to be deposited onto conveyor belt 26 and advanced from denester 10.
Although in the
embodiment shown, pneumatic cylinders are used for advancing and retracting
gripper blades
134 and 136, other commonly known means of advancing and retracting mechanical
l;
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mechanisms such as electric motors, hydraulic means or even gears connected to
bellows
mechanism 106 may be utilized.
[0048] As best seen in FIGS. 1 and 15 of the drawings, in a preferred
embodiment,
receptacles 12 and 14 include a plurality of tray clamps 156, 158, 160 and 162
in tray
receptacle 14 and tray clamps 164, 166, 168 and 170 in tray receptacle 12. In
a preferred
embodiment tray clamps 156 - 170, in the embodiment shown, are substantially
"L" shaped
plates laterally disposed in the four corners of each receptacle. The flat
surfaces of tray
clamps 158 - 170 facilitate reception of tray stacks 16 and I 8 and, but allow
sliding of
individual trays 20 from the bottom of the receptacles 12 and 14. In this
regard, tray clamps
158 - 170 include spring loaded flaps (best seen in FIG. 1) extending
therefrom, numbered
172, 174, 176, 178, 180, 182, 184 and 186. Spring loaded flaps 172 - 186
facilitate loading
of the trays with the spring mechanism (not shown) behind each of the spring
loaded flaps
172-186, holding the trays in place while allowing them to be dispensed
downwardly within
tray denester 10. Thus, tray clamps 156 - 170 holds the nay in place but allow
them to be
denested.
[0049] In a preferred embodiment in the invention, the tray denester 10 of the
present
invention can deliver a maximum of 35 standard trays 20 or 23 Euro Trays~,
permitting side
by side to a packing line. The trays can be delivered using an interlocking
pattern, as
required.
[0050] In order to control the bellows mechanism I 06 of the present
invention, as
seen in FIG. 13, a plurality of magnetic position sensors or reed switches 200
may be utilized.
The reed sensors are positioned to alert the control mechanism 72 that the
bellows
mechanism and thereby the suction cups and shafts are either at the low
position 188 below
l4
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the conveyor 26 in which a tray has been deposited on conveyor 26 or in the
extended
position 190 to in which the suction cups 90 - 98 are abutting against the
bottom surface 148
of tray 20, best seen in FIG. 13.
[0051] As seen in FIG. 14, control mechanism 72 contains a progammable
controller; i.e., computer 74, a DC power supply tool 204, pneumatic cylinders
and solenoid
valves 76, air pressure regulator 78 and an air supply valve 206. By means of
the pneumatic
cylinder 76 the size of receptacles 12 and 14 can be adjusted using the
controls 208, 206
shown in FIG. 1 on control mechanism 72, and the position of suction cups 90,
92, 94 and 96
can be moved. Electrical and pneumatic schematics of the control mechanism 72
may be
seen in FIGS. 16 and 17.
[0052] As shown in FIG. 15, vacuum pumps 210, 212 are disposed on bellows 106
for providing vacuum to suction cups 90-98. In order to determine whether
trays are ,present,
proximity sensors (electric eyes) 214 and 216 are provided. Proximity sensors
214 and 216
can also determine the appropriate distance between the front and rear of
receptacle 12.
[0053] In use, prior to operation, the operator selects the required tray size
20 and a
layer count to match production requirements. By layer count it is meant
whether to have
alternating sized trays or to provide a reverse position of trays in
receptacles 12 and 14 for
later stacking with product contained therein. Trays 16 and 18 are then loaded
into the
receptacles 12 and 14. Proximity sensors 214 and 216 then monitor the position
of the trays
20 in the stacks 16 and 18 and on the conveyor belt 26. The tray denester 10
will not begin a
cycle unless the conveyor belt 26 is clear and no trays 20 are jammed, as
determined by the
proximity sensors. A warning light 218, best seen in FIG. 14, alerts the
operator if there is a
tray jam, if there are no trays or if air pressure is too low to operate.
CA 02477664 2004-08-16
(0054] As best seen in FIGS. 1 and 15, reset platforms 220, 221, 222 and 223
are
laterally disposed along tray denester 10 and in parallel to conveyor belts
26. The reset
platforms 220 and 222 support and align the stacks 12 of trays 20. The forward
tray clamps
164, 166, 168 and 170 are extended to secure the stack 18. Reset platforms 220
and 222 are
then retracted. The tray stack 18 is now held from the sides by the tray
clamps 164 -170 so
that the bottom tray 20 can be denested. The bellows 106 rises to meet the
stack 16 by means
of either a hydraulic cylinder 107 or a pneumatic cylinder. The vacuum pumps
210 and 212
convey a vacuum through the suction cups which are advanced separately to the
bottom of
the tray 20. The bottom tray is then removed from the stack by lowering the
bellows until the
tray 20 contacts the belt conveyor 26. A magnetic position sensor 230 triggers
release of the
vacuum seal of the suction cups before the tray 20 hits the conveyor 26. A
short burst of air
from the air pump 206 then cleans the suction cups. The drive motor 32 runs
constantly
driving the conveyor belt 26 which transfers each tray 20 onto a packing line
(not shown).
The reset platforms 222 and 224 are then extended to support the stack of
trays 16 and 18 and
the tray clamps 158-170 are then retracted and the operating cycle is
complete. Similarly,
reset platform 221 and 223 support and align stack 14 of trays 20 and may be
withdrawn to
allow removal of tray 20 as required.
[0055] In operation, the power is turned on by means of a main power
disconnect 232
shown in FIG. 14. The tray selector 234 is turned to either standard or Euro
position. The
load run selector switch 236 is switched to a load position; and the mode
switch 238 is
switched to three, four or five tray mode. Stack of trays 16 and I 8 are
placed in the
receptacles 12 and 14. The load run selector switch 234 is then placed in a
run position. In a
16
CA 02477664 2004-08-16
preferred embodiment the air pressure used from the air supply 206 is
maintained at about 60
psi.
[0056] In order to reset the bellows 106 to factory alignment, the machine is
placed in
the load mode at the selector switch 234 shown in FIG. 19. The tray size
switch 236 is set to
Euro. This causes the rear, middle and side bars 44, 46, 50 and 52 to move to
the Euro
position. A template 240, shown in FIG. 18, may be aligned within the
receptacle 12 or 14 to
ensure proper sizing of the receptacles. The load run selector switch 234 is
then turned to the
off position. The extend bellows selector switch 242 is actuated causing the
bellows 106 to
rise. The knobs 250 - 260 shown in FIG. 6 - 10, and, in particular, FIGS. 9
and 10 may be
loosened and vacuum bellows 106 is adjusted to the Euro position. The knobs
250 - 260 are
then tightened; the raised bellows selector switch 236 is then placed in the
retracted bellows
position. The mode switch 234 is then placed in the load position, the
template 240 is
removed and trays 16 and 18 are loaded into the receptacles 12 and 14.
[0057] The main intake air pressure is preferably 80 psi, vacuum air pressure
is
preferably 50 psi, and tray clamp air pressure is 50 psi, varying with the
height of tray stacks
16 and 18. The air pressure switch 262 is preferably at 60 psi. The solenoid
valves 264, 266,
268, 270, 272, 274, 276, and 278, air supply regulator 286, tray clamp
regulator 280 and
vacuum bellows regulators 282 and 284 are shown in FIG. 20.
[0058) In order to further explain the operation of the present invention, the
Tray
Denester Operation and Maintenance manual is attached hereto and incorporated
herein. The
Tray Denester 10 of the present invention is controlled by an Allen Bradley
Micrologic
Programmable Controller. All movement of the tray denester 10 is generated by
pneumatic
cylinders controlled by three-way solenoid valves. The power supply is a 24
volt DC Idec
l7
CA 02477664 2004-08-16
ps5r-e24. Both the mechanical and electric parts are listed in the Spare Parts
List on page 30
and 31 of the Operators Manual as is the electrical schematic and the
pneumatic schematic on
pages 32 and 33.
[0059] In order to further show operation of the present invention, screen
shots from a
Windows Media viewer showing adjustment of the size of the receptacles and use
of the
suction cups and gripper blade assembly for denesting the bottom tray from a
stack of trays in
the receptacles is attached hereto and incorporated herein.
~e
CA 02477664 2004-08-16
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