Note: Descriptions are shown in the official language in which they were submitted.
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
-I-
CARTON MANIPULATION AND FEEDER APPARATUS
Background of the Invention
This invention is concerned with carton manipulation and feeder apparatus.
This invention relates to packaging of primary articles in sleeve type cartons
and is more
particularly concerned with a carton feed and transfer apparatus arranged to
feed such cartons
in collapsed condition from a hopper and for initiating a set up operation of
the cartons in
1o sequence, before transferring the partially set up carton to the infeed end
of a packaging
machine.
US-A-3,575,409 discloses a carton feeder mechanism wherein motion of the
cooperating
parts is basically rotary in nature and without sharp and sudden changes in
the direction or
movement of the parts so as to accommodate high-speed operation of the
mechanism.
US-A-3,991,b60 discloses a carton expander mechanism for sequentially
manipulating
collapsed open ended sleeve type cartons out of a hopper and into set up open
ended
condition by a main feeder arm for sequentially engaging a lower carton wall
to withdraw the
associated carton from the hopper together with a supplementary feeder arm
pivotally
mounted on the main feeder arm and arranged with an end portion thereof
adapted to project
through an aperture in the lower carton wall so as to engage an upper carton
face contacting
wall thereby to move such wall away from the lower wall to facilitate setting
up the collapsed
carton.
US-A-4,537,57 discloses a carton opening mechanism in which a first set of
vacuum cups
withdraws a collapsed carton from a hopper and swings such carton over into
firm
engagement with a second set of suction cups so as to condition the collapsed
carton for a set
up operation. In this patent, it would appear that transverse rotary movement
of the first set
3o of cups is tangential rather than radial relative to the carton to be
picked up and that the cups
would tend to slide along the wall of the carton in the hopper and thus might
interfere with
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
-2-
the appearance of the carton or with the efficiency of the set up operation.
In this patent, the
second cups do not move in a direction away from the first suction cups in
order to set up the
cartons.
US-A-4,605,393 discloses a carton blank removal, erection and transfer
apparatus in which a
rotatable element is mounted on a shaft which in turn is mounted on an arm
which is pivotally
mounted at an end thereof remote from the shaft on which the rotatable pick-up
device is
mounted. In this arrangement, rotation of the suction cups tends to blemish
the cartons and
pick-up operation is impaired by sliding movement of the suction cups along
the wall of the
to carton to be picked up.
Other types of orbital carton transfer and erection systems can be found in US-
A-5,102,385
and WO 99/14127.
A problem associated with the prior art is that the throughput of the machine
is often
restricted by the speed of the hopper. The present invention and its preferred
embodiments
seek to overcome or at least mitigate the problems of the prior art.
Summary of the Invention
According to one aspect of the invention there is provided an apparatus for
withdrawing from
a carton feed hopper collapsed cartons having oppositely disposed panels and
for initiating set
up thereof, the apparatus comprising carton pick-up means for sequentially
engaging one of
said opposed panels and for withdrawing from the hopper a collapsed carton
which includes
said one panel, means for transferring said carton orbitally about a primary
generally
horizontal axis from said hopper to an infeed end of a packaging machine,
wherein panel
engaging means are provided within the path of orbit for engaging an other of
said panels in a
manner to pull said other panel in a direction away from the said carton pick-
up means so as
to initiate opening of the carton.
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
-3-
It is an object of the present invention to devise an improved carton transfer
and initial set up
apparatus of the orbital type which further facilitates high speed packaging
and/or which can
provide better set up or transfer steps by avoiding supplementary carton
opening mechanisms
disposed and arranged to operate outside the path of orbit.
Preferably, the panel engaging means are constructed and arranged to disengage
from said
other panel when said carton has been opened to a predetermined level. The
panel engaging
means may be adapted to withdraw closer into the path of orbit after
disengaging from said
other panel.
to
The carton pick-up means are preferably mounted upon a rotatable member
mounted for
rotation upon said means for transferring about a secondary axis spaced from
but generally
parallel to said primary axis.
In a preferred arrangement, the panel engaging means are mounted for rotation
upon said
means for transferring and adapted to rotate about a supplementary axis spaced
from but
generally parallel to the primary axis. The means for transferring may
comprise a rotor
mounted for rotation about the primary axis. In the rotor, the carton pick-up
means and the
panel engaging means are mounted. Conveniently, the panel engaging means
include at least
2o one vacuum cup. Such at Ieast one vacuum cup is preferably mounted upon a
rotatable
vacuum tube.
Preferably the means for transferring includes a primary fixed cam housing
defining a primary
orbital cam track and a secondary fixed cam housing defining a secondary
orbital cam track,
wherein the primary orbital cam track defines orbital motion of the carton
pick-up means, and
the secondary orbital cam track defines orbital motion of the panel engaging
means.
Conveniently the carton pick-up means and the panel engaging means can be
connected
respectively to primary and secondary cam followers which engage the
respective cam tracks
3o in a manner to define their said orbital motion.
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
-4-
The carton pick-up means may comprise an array of vacuum cups affixed to an
elongate arm.
Conveniently, the carton pick-up means and the panel engaging means may be
vacuum
operated and in communication with a common vacuum interrupter
Preferably the apparatus is arranged, in use, to at least partially open the
carton by more than
90 degrees preferably up to about 120 degrees to indicate folds in the carton
to be formed and
to prevent the partially set up carton from reverting to its original shape.
Preferably, the secondary fixed cam housing is mounted concentrically within
the primary
1o fixed cam housing in relation to the primary axis.
A second aspect of the invention provides a method of forming the carton
comprising the
steps of withdrawing from a carton feed hopper collapsed cartons having
oppositely disposed
panels and for initiating set up thereof, sequentially engaging one of said
opposed panels and
for withdrawing from the hopper a collapsed carton which includes said one
panel,
transferring said carton orbitally about a primary generally horizontal axis
from said hopper to
an infeed end of a packaging machine, and for engaging another of said panels
in a manner to
pull said other panel in a direction away from the said carton pick-up means
so as to initiate
opening of the carton.
Brief Description of the Drawings
In order that the invention may be illustrated, more easily appreciated and
readily carried into
effect by those skilled in the art, a preferred embodiment of the invention
will now be
described purely by way of non-limiting example with reference to the
accompanying
drawings, wherein:
FIGURE 1 is an isometric view of one embodiment of an orbital carton
manipulation and
feeding apparatus;
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
-5-
FIGURE 2 is a partial cut-away section on the axis of the rotatable shaft of
the apparatus of
Figure 1 with fixed cam housing removed; .
FIGURE 3 corresponds to the arrangement of Figure 2 but wherein the carton
pick-up means
has progressed in the direction of arrow A to an initial carton opening
configuration;
FIGURE 4 also corresponds generally with the Figure 2 configuration, but
wherein the carton
has become erected to a larger extent;
FIGURE S is a partial cut-away section representing a further stage in orbital
transfer beyond
the Figure 4 arrangement, wherein a substantially unfolded, erected carton is
being transferred
to a belt conveyor at the infeed end of a packaging machine;
FIGURE 6 is an isometric view of a second embodiment of an orbital carton
manipulation
and feeding apparatus;
FIGURE 7 is a partial cut-away section on the axis of the rotatable shaft of
the apparatus of
Figure 6 with fixed cam housing removed;
2o FIGURE 8 corresponds to the arrangement of Figure 6 but wherein the carton
pick-up means
has progressed in the direction of arrow A to an initial carton opening
configuration;
FIGURE 9 also corresponds generally with the Figure 6 configuration, but
wherein the carton
has become erected to a larger extent; and
FIGURE 10 is a partial cut-away section representing a further stage in
orbital transfer
beyond the Figure 8 arrangement, wherein a substantially unfolded, erected
carton is being
transferred to a belt conveyor at the infeed end of a packaging machine.
Detailed Description of the Preferred Embodiments
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
-6-
Referring to the drawings and first, to the embodiment of Figure 1 thereof, an
orbital carton
manipulation and feeding apparatus is shown, wherein a carton hopper of flat
partially
assembled carton blanks is present but not shown in the interests of clarity.
The cartons fed
from the hopper, (not shown), are initially in collapsed form as shown by
carton 16 although
the cartons become attached to an array of vacuum cups as at I6a to effect
withdrawal from
the hopper.
The cartons have oppositely disposed flat panels comprising initially front
and rear surfaces,
each surface of which comprises two adjacent flat panels of the carton. As
will be described
1o in more detail hereafter, in the illustrated embodiment the carton pick-up
means comprises an
assembly of vacuum cups secured to a support affixed to an elongate vacuum
tube capable of
rotation. When the assembly of vacuum cups is in the appropriate position to
engage an
underneath surface panel of the carton I6, vacuum is applied whereby further
rotation of the
apparatus causes the carton positively to be withdrawn from the carton feed
hopper. The
means for transferring the carton orbitally comprises a motor driven rotor
mounted for
rotation about the primary axis.
The assembly of vacuum cups holds the carton in position as required during
fiuther orbital
movement of the rotor, until the carton has been partially opened whereby the
carton becomes
2o ready for transfer to the infeed end of the packaging machine. Four
supplementary
individually mounted vacuum cups also located on the rotor act upon an outer
surface panel
of the carton 16 to cause that panel to be moved away from the underneath
oppositely
disposed panels to commence unfolding of the carton. In this embodiment, each
supplementary vacuum cup acts as the panel engaging means and all being
situated within the
path of orbit of the apparatus.
The carton manipulation apparatus illustrated in Figure 1 includes a pair of
upstanding
support legs I, 2 in which a main rotatable shaft 3 is mounted for rotation in
suitable bearings
4 of known type and located at the upper-most ends of the support legs 1 and
2. A cylindrical
3o vacuum interrupter 5 of known type is located around the shaft 3 adjacent
the primary support
leg 1. An orbital rotor 6 is mounted for rotation with the main shaft 3 and,
in this
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
_~_
embodiment, has four arms extending radially from its central structure
attached to the shaft
3. Four radially spaced supporting blocks 7 are mounted in the central
structure of the rotor,
and to each of which a pick-up arm 8 is connected. Each of the four pick-up
arms 8 carry
vacuum cup supports 10 and vacuum cups 11 in an array of four such vacuum cups
11. The
vacuum cups 11 are in communication, through known means, with the vacuum
interrupter 5.
The four arms of the orbital rotor 6 are further provided at an outer region
with supporting
blocks 7a, each of which carries a supplementary arm 8a, provided with a
supplementary
vacuum cup l la. In the embodiment of Figure I, there is shown four vacuum
cups l la, each
Zo are similarly in communication through known means with the vacuum
interrupter 5.
Each support block 7 is mounted for rotation thxough an aperture (not shown)
of the rotor 6.
For example, a spigot (not shown) can project from one side of the supporting
block 7
through the aperture (not shown) to the cam plate at the remote side thereof.
Similarly,
is supplementary support blocks 7a, are mounted for rotation within the
orbital rotor 6, e.g. by
means of a spigot projecting through the respective apertures (not shown) in
the rotor 6 and
also affixed to a cam plate. Such spigots are offset from the longitudinal
axis of the vacuum
tube 8a so each tube 8a is capable of rotation independently about its spigot
in a manner to be
determined by rotation of the rotatable shaft 3.
The supporting block 7a shown at the upper part of Figure 1, at the remote
side of the rotor 6,
is secured to a cam plate 12 including two cam followers (although only one of
which I7 is
shown), e.g. a wheel or roller can be used as the cam follower located within
an indented
orbital cam track I4 in the secondary fixed cam housing 13. Although not
apparent from
Figure l, the mounting arrangement for pick-up arms 8 on which the carton pick-
up means 9,
I0, 1 I are located is similar in that a corresponding spigot projects through
other apertures in
the central port of the rotor 6 connected to a cam plate having cam followers
engaging a
primary orbital cam track of a primary fixed cam housing.
3o The main rotatable shaft 3 is driven by a motor 15, e.g. a linear servo
motor, which causes the
orbital rotor to rotate about the primary axis of the shaft 3 to provide
corresponding motion of
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
_g_
each of the four carton pick-up means and each of the four associated panel
engaging means
as the rotor orbits the fixed cam housings causing rotation and displacement
of the arms 8 and
8a, according to the paths of the indented cam tracks in the two fixed cam
housings.
Referring to Figure 2 of the drawings, there is shown an arrangement depicting
the orbital
tracks of the main vacuum cup housing 9 including the four arrays of vacuum
cups 11
attached thereto, and the orbital path of the four supplementary vacuum cups
11 a. Around the
main rotating shaft 3, a fixed bracket 20 is provided in which a connecting
rod 19 is slidably
mounted. The connecting rod is attached to the main vacuum housing 9 and
permits radial
to displacement of the main housing 9 in addition to its rotational motion.
Such radial
displacement is depicted by arrow B. The vacuum cups 11 attach by vacuum force
to carton
16 so as to withdraw such carton from a corresponding hopper (not shown). The
main
vacuum cup housing 9 is connected to a main cam plate 18 through which
spindles 21 and 22
pass and connected on the remote side to cam followers (not shown). Cam plate
18' is not
only rotated about the axis of the main rotating shaft 3 but is also adapted
to rotate in a
direction shown by arrow C according to the respective cam track 21 a in which
cam follower
on spindle 21 is located and track 22a in which cam follower on spindle 22 is
located. The
orbital route followed by the main vacuum cups 11 is depicted generally at l
lc, whereas the
orbital route followed by the supplementary vacuum cup lla is depicted
generally at 11b.
2o The boundary between the inner primary fixed cam housing and outer
secondary fixed cam
housing is depicted generally at 27.
Beneath the orbital carton manipulation and transfer means, there is provided
a transfer belt
23 arranged in the direction of the infeed end of a conveyor track 24 upon
which the at least
partially unfolded cartons are to be transferred.
With reference to Figure 3, the orbital rotor (not shown) has traveled further
in the direction
of arrow A whereby the main vacuum cups 11 have been withdrawn towards the
interior of
the assembly whilst the carton 16 is still attached thereto in a generally
flat condition. In this
3o configuration the supplementary vacuum cup 11a (not referenced) has become
rotated in the
direction of arrow D so that it can apply a vacuum force to an externally
disposed panel of the
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
-9-
carton 16. The orientation of the main cam plate 18 is such that the cam
followers (not
shown) attached to the remote ends of the spindles 21 and 22 are now following
generally the
same part of the track (21a, 22a) simultaneously causing the slidable rod 19
to be displaced
linearly within its mounting in the bracket 20. In the Figure 3 configuration,
the apparatus
approaches a stage where the carton is about to become partially opened before
transfer on to
the transfer belt 23. Fixed plates or lugs 25 and 26 are shown embedded in the
conveyor
track 24 to receive the at least partially unfolded carton as subsequently
described.
With reference to the Figure 4 configuration the orbital arm (not shown) has
rotated still
1o further in the direction of arrow A and the supplementary vacuum cup l la
(not referenced)
has become rotated clockwise in the direction D causing an at least partial
opening of the
carton 16a. The position of the main vacuum cup holder 9 radially corresponds
generally
with the arrangement in Figure 3 as such displacement is effectively
controlled by the cam
tracks in which the cam followers (not shown) attached to the spindles 21 and
22 are engaged.
is The partially unfolded carton 16a approaches still closer to the transfer
belt 23 in this
arrangement.
With reference to Figure 5, the orbital rotor (not shown) has continued its
rotary motion to a
further stage whereby the supplementary vacuum cup lla detaches itself from
the panel to
20 which it was attached (in Figure 4) and becomes separated from the opened
carton 16a by
virtue of the track l 1b followed by the vacuum tube (8a in Figure 2). The
main vacuum cup
holder 9 is about to be further withdrawn radially towards the primary axis of
the main shaft 3
whilst the carton 16a becomes engaged between the lugs or plates 25 and 26 at
the infeed end
of the conveyor 24. Accordingly upon still further rotation of the orbital
rotor (not shown)
25 the supplementary vacuum cup l la becomes fully disengaged and withdrawn
closer into the
primary axis of the assembly, the vacuum supplied to the main vacuum cups 11
is
disconnected and these vacuum cups also become withdrawn closer into the
primary axis of
the main rotating shaft 3 thereby becoming detached from the opened carton
which by then
has become engaged between the lugs or plates 25 and 26 moving in the
direction of arrow E
3o at the infeed end of conveyor 24, for insertion of product or other
processing.
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
-10-
The second embodinnent of the ,orbital carton manipulation and feed apparatus
is shown in
Figures 6 to 10. The apparatus' is similar to the first embodiment in many
respects and,
therefore, like reference numerals have been used, with the prefix "1".
Therefore, only the
differences will be described in any great detail.
In the second embodiment, the panel engaging means is positioned in advance of
the carton
pick-up means, so as to engage a leading edge of the collapsed carton 116. (In
the first
embodiment, the engaging means contacts a trailing face of carton.)
As illustrated in Figure 6, the four arms of the orbital rotor 16 are further
provided at an outer
region with supporting blocks 17a, each of which carries a supplementary arm
18a, provided
with a supplementary vacuum cup 11 la. In the embodiment of Figure 6, four
vacuum cups
111 a are similarly in communication through known means with the vacuum
interruptor 15.
Each of the four pick-up arms I8 carry vacuum cup supports 110 and vacuum cups
111, in
this embodiment, in an array of two such vacuum cups 111. Again, the vacuum
cups 111 are
in communication through known means with the vacuum interrupter 15. It will
be seen from
Figure 6 that the supplementary vacuum cup l l la is positioned ahead of
vacuum cups 111 in
the direction of motion, so that the supplementary vacuum cup 111 a can engage
the leading
face of the carton 116.
The remaining features of the apparatus according to the second embodiment
shown in Figure
6, correspond to those features illustrated in Figure 1 and are described in
the preceding
paragraphs.
Referring to Figure 7 of the drawings, there is shown an arrangement depicting
the orbital
tracks of the main vacuum cup housing 19 including the four arrays of vacuum
cups 111
attached thereto, and the orbital path A' of the four supplementary vacuum
cups llla.
Around the main rotating shaft 13, a fixed bracket 120 is provided in which a
connecting rod
119 is slidably mounted. The connecting rod is attached to the main vacuum
housing 19 and
permits radial displacement of the main housing 19 in addition to its
rotational motion. Such
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
-11-
radial displacement is depicted by arrow B'. The vacuum cups 111 attach by
vacuum force to
carton I16 so as to withdraw such carton from a corresponding hopper (not
shown). The
main vacuum cup housing 19 is connected to a main cam plate 118 through which
spindles
12I and 122 pass and connected on the remote side to cam followers (not
shown). Cam plate
118 is not only rotated about the axis of the main rotating shaft 13 but is
also adapted to rotate
according to the respective cam track 121 a in which cam follower on spindle
121 is located
and track 122a in which cam follower on spindle I22 is located. The orbital
route followed
by the main vacuum cups 111 is depicted generally at 111 c, whereas the
orbital route
followed by the supplementary vacuum cup I l la is depicted generally at 11
Ib. The boundary
1o between the inner primary fixed cam housing and outer secondary fixed cam
housing is
depicted generally at 127.
Beneath the orbital carton manipulation and transfer means, there is provided
a transfer belt
123 arranged in the direction of the infeed end of a conveyor track 124 upon
which the at
least partially unfolded cartons are to be transferred.
With reference to Figure 8, the orbital rotor (not shown) has traveled further
in the direction
of arrow A' whereby the main vacuum cups 111-have been withdrawn towards the
interior of
the assembly whilst the carton 116 is still attached thereto in a generally
flat condition. In this
configuration the supplementary vacuum cup l I la is rotated in the direction
of arrow D' so
that it can apply a vacuum force to an externally disposed leading panel of
the carton 116.
The orientation of the main cam plate 118 is such that the cam followers (not
shown) attached
to the remote ends of the spindles 121 and 122 are now following generally the
same part of
the track (I2la, 122a) simultaneously causing the slidable rod 1I9 to be
displaced linearly
within its mounting in the bracket 120. In the Figure 9, the apparatus
approaches a stage
where the carton is about to become partially opened before transfer on to the
transfer belt
123. Fixed plates or lugs 125 and 126 are shown embedded in the conveyor track
24 to
receive the at least partially unfolded carton as subsequently described.
3o With reference to the Figure . 9 configuration the orbital arm (not shown)
has rotated still
further in the direction of arrow A' and the supplementary vacuum cup 1 I la
(not referenced)
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
-12-
has become rotated clockwise in the direction D1 causing an at least partial
opening of the
carton 116a. The position of the main vacuum cup holder 19 radially
corresponds generally
with the arrangement in Figure 8, but the cam plate 118 is caused to be moved
out of
alignment with rod 119 as such displacement is effectively controlled by the
cam tracks in
which the cam followers (not shown) attached to the spindles 121 and 122 are
engaged. The
partially .unfolded carton 116a approaches still closer to the transfer belt
123 in this
arrangement.
With reference to Figure 10, the orbital rotor (not shown) has continued its
rotary motion to a
to further stage whereby the supplementary vacuum cup l l la detaches itself
from the panel to
which it was attached (in Figure 9) and becomes separated from the opened
carton 116a by
virtue of the track l l 1b followed by the arm (18a in Figure 7). The main
vacuum cup holder
19 is about to be further withdrawn radially towards the primary axis of the
main shaft 13
whilst the carton 116a becomes engaged between the lugs or plates 125 and 126
at the infeed
end of the conveyor 124. Accordingly, upon still further rotation of the
orbital rotor (not
shown) the supplementary vacuum cup l l la becomes fully disengaged and
withdrawn closer
into the primary axis of the assembly in direction D1. The vacuum supplied to
the main
vacuum cups 111 is disconnected and these vacuum cups also become withdrawn
closer into
the primary axis of the main rotating shaft 13 thereby becoming detached from
the opened
2o carton which by then has become engaged between the lugs or plates 125 and
126 moving in
the direction of arrow E at the infeed end of conveyor 24, for insertion of
product or other
processing.
The present arrangement provides a number of advantages over known such
arrangements for
withdrawing cartons from feed hoppers and transferring them orbitally in that
it is possible to
avoid the complexity, cost and synchronization of carton-opening components
situated
outside of the orbital path of the carton blanks by deploying supplementary
vacuum cups
which can be affixed to the same rotor as the main carton withdrawing vacuum
cups through
use of a supplementary fixed cam housing to define their motion. Also as is
apparent
3o particularly from the Figures 3 and 9 arrangement the supplementary vacuum
cup l la and
llla engages a minimum edge part of the carton to assist in partial opening
thereof to
CA 02516800 2005-08-19
WO 2004/074108 PCT/US2004/004697
-13-
minimize the risk of such vacuum cup sliding on or unintentionally disengaging
from the
surface panel including that edge.
Such an arrangement in consequence can provide a further level of improved
operation at
higher speeds than similar known such equipment which can lead to efficiencies
in the
packaging process.
