Note: Descriptions are shown in the official language in which they were submitted.
CA 02869017 2016-08-18
CARTON DECASING SYSTEM
Field of the Invention
[0002] The present invention generally relates to article packaging and
handling systems, and
in particular to a system for removing cartons and/or carton blanks from cases
or other
packaging for the cartons or carton blanks and transporting the removed
cartons or carton
blanks in stacks to a carton magazine for a packaging machine.
Background of the Invention
[0003] In automated product packaging systems, articles such as cans,
bottles, individually
wrapped food-stuffs, etc., generally are fed into a product packaging machine
where such
articles can be grouped or otherwise sorted and thereafter placed within or
wrapped with a
product cartoning material such as a paperboard, cardboard or other, similar
material. Such
product cartons can be provided as a series of folded and glued carton sleeves
that are open at
their ends for insertion of the products therein, or can include substantially
flat carton blanks
that will be folded by the product packaging machine and wrapped about a group
of articles or
products placed thereon. Typically, the carton sleeves or carton blanks will
be loaded into a
carton magazine for the product packaging machine in stacks, which carton
magazine then will
feed individual carton sleeves or carton blanks into the packaging machine for
loading with
products or for wrapping about a series of product groups.
[0004] The cartons, whether formed as carton sleeves or carton blanks,
themselves typically
are formed by outside vendors who ship the cartons in sleeve or blank form
stacked in boxes or
cases. Accordingly, before the cartons can be loaded into a carton magazine of
a packaging
machine, the cartons themselves first must be removed from their cases and
thereafter stacked
or loaded into the carton magazine. Even though automated carton stacking and
loading
systems have been developed for automatically loading stacks of cartons within
the carton
magazines of packaging machine or similar automated packaging equipment, it is
still
necessary to first remove the stacks of cartons from their containers or cases
and thereafter load
the stacks of cartons on the magazines or on automatic magazine loaders for
feeding to the
magazine for a packaging machine.
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[0005]
Generally, even though some automated removal systems have been developed, the
removal
of cartons from their boxes or cases typically has been a manual operation
requiring an operator to
manually remove the cases from about the cartons, and thereafter stack or
restack the cartons,
including in some cases inverting the cartons, and load them on a magazine
loader or directly into the
carton magazine of a packaging machine. Such manual operations can, however,
cause repetitive
strain injuries due to the repetitive handling of heavy carton loads by
workers. In addition, when the
cartons are removed from their cases, either manually or by current automated
systems, it is often
difficult to maintain the cartons in an ordered stack and prevent at least
some of the cartons within the
cases from being lifted with the case when the case is removed due to friction
between the carton
edges and case walls. As a result, workers often have to restack or remove
portions of the stack of
cartons from a case after the case has been removed, which takes additional
time and can further
contribute to repetitive strain injuries, or cause inefficiencies in
operation.
[0006]
Accordingly, it can be seen that a need exists for a system and method for
removal of stacked
cartons from their cases or containers that addresses the foregoing and other
related and unrelated
problems in the art.
Summary of the Invention
[0007]
Briefly described, the present invention generally relates to a system and
method for
automatically removing cartons or carton blanks from cases or other, similar
containers in a stacked
configuration such as for feeding into a magazine of a downstream product
packaging machine.
According to one example embodiment of the carton decasing system according to
the principles of
the present invention, cases containing stacks of cartons, such as, for
example carton blanks or sleeves
for packaging bottles, cans or other products in 2x6, 2x8, 2x12, 4x6 or other
varying product
configurations, will be loaded onto a carton infeed. The cases can be queued
up along the carton
infeed for presentation to an inverting assembly at the downstream end of the
case infeed, and
typically, will be loaded with the upper ends of the cases being open, and
with notches or recesses
also generally being formed in the upstream and downstream side walls of the
cases.
[0008] The
cases initially are fed into the inverting assembly which includes an inverter
head that is
pivotally mounted on a support frame. The inverter head further generally
includes a pair of
adjustable side guides and a pair of top and bottom support guides that are
vertically adjustable with
respect to one another so as to define a receiving area therebetween for
receiving a case of a
predetermined or preselected size therein. As the inverter head is rotated or
pivoted about its support
frame, the cases with the cartons stacked therein are correspondingly
reoriented and are deposited on a
downstream magazine or stacking conveyor, with the closed bottom end of each
case generally being
realigned in upwardly facing attitude or direction. The inverter head and
magazine conveyor further
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are adjustable vertically to enable adjustment of the position of the cases
with respect to an overhead
case lifting mechanism, so as to accommodate different height or size cases as
needed.
[0009] The
cases are initially deposited on a carton decasing assembly for removal of the
case from
the stack of cartons contained therein. The carton decasing assembly generally
includes an adjustable
framework having laterally adjustable side guide rails on which the cases are
received and initially
supported, and a series of containment rod mechanisms mounted on supports or
holders that are
moveable longitudinally with respect to the side guide rails so as to enable
adjustment of the
longitudinal position of the containment rod mechanisms. The adjustment of the
side guide rails
laterally, together with the longitudinal adjustment of the locations of the
containment rod
mechanisms enables the carton decasing assembly to be adjusted to accommodate
varying
length/depth and width cases.
[0010] Once
deposited or located on the carton decasing assembly, a series of gripping
lugs, which
are also mounted on the longitudinally sliding supports or holders that carry
the containment rod
mechanisms, are pivoted into engagement with the cartons, typically moving or
passing through the
recesses or gaps formed in the cases so as to engage and compress the stack of
cartons inwardly. The
compression of the stack of cartons within the cases by the gripping lugs
creates spacings/openings
between the cartons and case walls in which the extensible containment rods
can be received. The
containment rods are inserted into and pass between the foremost and rearmost
cartons of the stack of
cartons and the front and rear side walls of their case so as to hold the
cartons in a stacked
configuration as the case is removed therefrom and prevent the walls of the
case from frictionally
engaging or otherwise dislodging cartons from the stack. As a result, each
case is removed from its
stack of cartons with the cartons being maintained in a stacked, substantially
aligned configuration.
Thereafter, the cartons are conveyed further along the magazine conveyor as
the emptied cases are
removed for disposal.
[0011] As a
stack of cartons is conveyed by the carton decasing assembly toward a
discharge point or
end of the magazine conveyor, and/or approaches a rearmost carton of a
previously decased stack of
cartons on the magazine conveyor, a stack pusher assembly will correspondingly
engage the stack of
cartons for urging the stack of cartons forwardly with the continued forward
motion of the magazine
conveyor. Thereafter, at about the same time, the containment rods can be
disengaged from the stack
of cartons and the carton decasing assembly retracted back to its initial,
loading or case receiving
position adjacent the inverting assembly. The stack pusher assembly generally
will include at least
one stack pusher that, in one embodiment, can comprise a pair of extensible
pusher rods each moved
between extended and retracted positions by an actuator, such as a pneumatic
or hydraulic cylinder, or
other similar actuator. The pusher rods further can be carried by an overhead
support linked to a drive
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system connected to the drive mechanism for the magazine conveyor so as to
move with the forward
movement of the magazine conveyor.
[0012] The drive system of the stack pusher assembly also can be
disconnected from the magazine
conveyor so as to be independently driven for moving the stack pusher assembly
to a retracted
position as needed for engaging a next stack of cartons loaded on the magazine
conveyor. Thus, as
the next loaded stack of cartons approaches a prior loaded stack of cartons,
the pusher rods will be
retracted as the decasing assembly conveys the next stack of cartons into a
combined, stacked
arrangement against the prior loaded stack of cartons. The drive mechanism for
the stack pusher
assembly also can be disengaged from the magazine conveyor, and operated to
retract the stack pusher
assembly to a position behind the rearmost carton of the next stack of cartons
being loaded, after
which the pusher rods can be extended into an engaging position against the
combined stack of
cartons as the containment rods of the carton decasing assembly are retracted
and the carton decasing
assembly is moved back to its initial, loading position. The drive mechanism
of the stack pusher
assembly further can be reengaged with the magazine conveyor to continue its
forward motion with
its pusher rods engaging and supporting the combined stack of cartons as the
cartons are fed to the
discharge point of the magazine conveyor.
[0013] Various features, objects and advantages of the present invention
will become apparent to
those skilled in the art upon a review of the following detailed description,
when taken in conjunction
with the accompanying drawings.
Brief Description of the Drawings
[0014] Fig. 1 is a perspective illustration of the automatic carton
decasing system according to the
principles of the present invention.
[0015] Fig. 2 is a perspective view of the inverting assembly and stacking
conveyor for receiving and
inverting the packaged cartons for removal of the case therefrom.
[0016] Fig. 3A is a perspective view of the inverting assembly with a case
of stacked cartons
received therein.
[0017] Figs. 3B and 3C are side elevational views illustrating the
inverting of the carton cases at
different heights for different size or geometry cartons.
[0018] Figs. 4A and 4B are perspective illustrations of the carton decasing
assembly with the
containment rods thereof shown in retracted and raised positions.
[0019] Fig. 4C is an end view of the extensive containment rods of the
carton decasing assembly.
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100201 Fig. 4D is a perspective view of the fore or proximal end of the
stacking conveyor and the
carton decasing assembly.
[0021] Figs. 5A-5C are perspective illustrations showing the engagement of
the grippers and
containment rods of the carton decasing assembly for engagement and holding of
a stack of cartons as
the case is removed therefrom.
[0022] Fig. 6 is a perspective view of the stacking conveyor, illustrating
the stack pusher assembly
and carton decasing assembly according to the principles of the present
invention.
[0023] Figs. 7A-7D are schematic illustrations of the operation of the
stack pusher assembly for
moving the stacks of cartons to a discharge point after removal of the cases
therefrom.
[0024] Fig. 8 is a perspective illustration of an alternative embodiment of
the carton decasing system
according to the principles of the present invention.
[0025] Figs. 9A-9C are side elevational views schematically illustrating
the extended orbital
movement of the inverter head of the decasing system of Fig. 8.
[0026] Fig. 10 is a plan view of the decasing system of Fig. 8.
100271 Those skilled in the art will appreciate and understand that,
according to common practice, the
various features of the drawings discussed below are not necessarily drawn to
scale, and that
dimensions of various features and elements of the drawings may be expanded or
reduced to more
clearly illustrate the embodiments of the present invention described herein.
Discussion of the Invention
[0028] Referring now to the drawings in which like numerals indicate like
parts throughout the
several views, Figs. 1-7D illustrate the automatic carton decasing system 10
and the operative
assemblies thereof for removal of stacks of cartons 11 from cases or other
containers 12 and for
automatically loading such decased or removed carton stacks into a carton
magazine 13 for feeding
into a feeder assembly of a downstream packaging machine, as indicated in Fig.
1. The cartons 12
can be received as stacks of flat carton blanks or as preformed carton
sleeves, or in other
configurations as needed or desired, and as will be understood by those
skilled in the art, and will be
oriented and removed from their cases in a stacked, substantially aligned
configuration. The
automatic carton decasing system further is designed to fit with and/or be
operable with a variety of
different type or size packaging machines, for example for use with a Quikflex
600, Quikflex 2100,
and/or G3 packaging machines such as manufactured by Graphic Packaging
International. The
automatic carton decasing system further can be designed for retrofitting to
existing packaging
machines in the field, and further is adapted to unload/remove and load a full
range of carton sizes
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and/or configurations as well as different case proportions and materials. For
example, the automatic
carton decasing system of the present invention can be utilized with 2 x 2, 3
x 4, 4 x 6 or other carton
sizes and can handle cartons of a variety of sizes and shapes, including long,
short cases,
substantially square cases and tall and wide cases, such as illustrated at 12A
and 128, respectively, in
Figs. 3B-3C and 5A 5C.
[0029] Fig.
1 generally illustrates one example embodiment of the automatic carton
decasing system
according to the principles of the present invention, which generally includes
an elongated frame
21, which frame generally can be adapted to match its parent packaging
machine. At an upstream
end or section 22 of the frame 21 comprises a case infeed 23. The case infeed
23 generally will
comprise a conventional conveying system 24 such as a chain conveyor, belt
conveyor or other
known type of conveying mechanism including belts, slats, chains or other
conveying elements 26
that are driven about a substantially continuous path in the direction of
arrow 27 by a motor or
similar drive mechanism (not shown). An operator can load the cases with
cartons stacked therein on
the upstream or first end of the case infeed conveyor 24, with the cases being
queued in a line or
supply arrangement.
[0030] As
indicated in Fig. 1, the cases 12 will be oriented on the case infeed conveyor
24 in an
upstanding attitude and with a top or upper end 16 of the cases 12 being open
and a series of
recesses, cut-outs, gaps or similar features 17 formed in the leading and
trailing side walls 18A/18B
of the cases. The case infeed conveyor 24 will convey the cases in series to
an inverting assembly
30, which inverts or otherwise reorients the cases so that the cases can be
quickly and easily removed
from the cartons while the cartons are maintained in a stacked configuration
as illustrated in Figs.
2-3B. Alternatively, the cases can be conveyed or transported to the inverting
assembly from a
remote location or an automatic depalletizer. As indicated in Fig. 1, the case
infeed conveyor further
can be designed with respect to the inverting assembly 30 so that different
length case infeed
conveyors and/or extensions of the case infeed conveyor can be provided in
either in-line or
perpendicular arrangements to suit available space in a desired or required
line layout. For example,
as shown in Fig. 1, the cases 12 can be loaded onto a first, upstream section
28A of the case infeed
conveyor, and can then be transferred to and/or reoriented on a second,
downstream section 28B,
which conveys the cases to the inverting assembly 30 at the downstream end
thereof.
[0031] As
illustrated in Figs. 1 and 2, the cases 12 with the cartons 11 stacked therein
are conveyed
to the downstream end of the case infeed conveyor and are brought into
engagement/registration with
the inverting assembly 30 positioned at the downstream end of the case infeed
conveyor. The
inverting assembly inverts or reorients the cases with the cartons contained
therein and places them
on a stacking or magazine conveyor 31 having a carton decasing assembly 32
initially located in a
first or case receiving position adjacent an upstream end of the magazine
conveyor, as indicated in
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Figs. 1 and 5A-5C. The inverting assembly thereafter will release each case,
which will be moved
with the decasing assembly along the magazine conveyor away from the inverting
assembly and to a
second or intermediate position for removal of the case as indicated in Fig.
1.
[0032] As
illustrated in Figs. 2 and 3A, the inverting assembly 30 generally includes an
inverter head
30A pivotally mounted on a pair of upstanding frame members or supports 33,
and includes a pair of
side guides or clamps 34 that are adjustable laterally so as to be
repositionable as needed to engage
different size cases. Each of the side guides 34 generally will include a
rearwardly projecting plate
or arm 36 typically having an outwardly flared first or guide portion 36A and
a substantially flat
body or second portion 36B mounted to an adjustable slide support 37. The
slide supports 37 are
movably mounted on a support rail 38 that extends laterally between a pair of
vertical slides or
supports 39, that further are mounted to a carrier or base frame member 41,
which pivotally attaches
and supports the inverter head 30A on frame members 33. As Fig. 3A indicates,
the slide supports
37 can be moved laterally toward and away from each other, and can be fixed in
place such as by set
screws 42, or other, similar fasteners, to define a width for a receiving area
40 of the inverter head
30A in which the cases 12 are received, with the outwardly flared guide
portions 36A of the side
guides 34 helping to center and guide the cases into the receiving area. For
example, as indicated in
Figs. 3A-3C, for taller, thinner cases, the side guides can be adjusted
inwardly to accommodate the
reduced width or thinner configuration of the cases.
[0033] The
inverter head 30A further includes top and bottom case support guides 44 and
46 that
engage the top and bottom ends of the cases, for positively gripping and
holding the cases during
inversion or reorientation thereof to prevent the cartons from becoming
dislodged or otherwise
inadvertently released from the cases during inversion or reorientation
thereof by the inverting
assembly. As shown in Figs. 2 and 3A, the case support guides 44 and 46
generally are mounted to
vertical slides or supports 39, with the positions of the case support guides
being adjustable
therealong, such as by cranks or handwheels 47 to define a height for the
receiving area 40 of the
inverter head. As generally indicated in Fig. 3A, the case supports further
can include spaced forks,
tines or plates 44A/46A, or can include other types of supports. The inverter
head further can be
connected to or engaged by a drive belt 48 or similar conveying mechanism
driven by a motor such
as indicated at 49 in Fig. 3A for controlling the rotary motion of the
inverter head for lifting,
inverting and depositing the cases onto the magazine conveyor 31 (Fig. 2).
[00341
Accordingly, as the case support guides 44 and 46 engage and lift and pivot
the cases with the
cartons stacked therein, as indicated by arrows 51 in Figs. 3B and 3C, so as
to reorient the cases in an
inverted or upside down configuration, with the open top portions 16 of the
cases being placed in a
substantially downwardly facing alignment on the magazine conveyor 31. In
their initial stack
receiving position, the case support guides 44, 46 generally are separated by
a gap that is greater than
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the case height. As the inverter head 30A inverts, the lower case support
guide 46 can move toward
the upper case support guide 44, which closes this gap and thus conforms the
case support guides to
the case height. As a result, when the case is inverted, the lower case
support guide, which was
below the case on the infeed side, is now engaging on top of the case to
prevent the case from
tipping, and holding it square and upright to facilitate insertion of case
containment rods 60 (Figs.
4A-4C) during a decasing operation (Figs. 5A-5C).
[0035] As
further illustrated in Figs. 3B and 3C, the magazine conveyor 31 can be set at
varying
heights as needed depending upon the type of parent packaging machine and/or
the
type/configuration of cartons and cases being fed for decasing without
affecting the operation of the
inverting assembly 30. The geometry of the inverting assembly, and the
adjustability and/or closing
engagement of its side guides and case support guides with a case 12 during
inversion and placement
of the case on the magazine conveyor, allows a fixed height case infeed
conveyor 24 to be utilized
with variable height magazine conveyors, with the case inverting assembly
automatically adjusting
for case size and placing the case on the correct magazine height for the
packaging machine. For
example, as shown in Fig. 3B, a tall case can be inverted and placed on the
magazine conveyor, with
the magazine conveyor adjusted and set at a lowered height, while for shorter
or reduced height
cases, as shown in Fig. 3C, the magazine conveyor 31 can be set at a higher
level as needed for
feeding the cartons into the magazine, without requiring reconfiguration or
change-out of the
inverting assembly 30. Instead, a simple adjustment of the positions of the
side guides and case
support guides so as to readjust the receiving area in which the cases are
received and engaged, can
be made to ensure a secure lifting and reorientation of the cases.
[0036] As
further indicated in Figs. 1-2, the carton decasing assembly 32 generally is
initially located
at the upstream or first end of the magazine conveyor 31 in a first, case
receiving or loading position,
indicated at 55, for receiving and engaging the cases after they are inverted
by the inverting
assembly. Figs. 4A-5C generally illustrate the carton decasing assembly 32,
which is movable along
the magazine conveyor 31 between its first loading position, a second,
intermediate or case removal
position, indicated at 56 in Fig. 7A, and a third, downstream or disengaging
position indicated at 57
in Fig. 6. The movement of the decasing assembly 32 is controlled by a drive
mechanism 58 (Fig.
4D) that is independently operable from the magazine conveyor.
[0037] The
carton decasing assembly 32 (Figs. 4A-4B) generally includes an adjustable
framework
or sled 61 including laterally adjustable side guide rails 62 and 63 on which
the cases are initially
received, and a series of containment rod mechanisms 64. Each containment rod
mechanism
includes a vertically extensible case containment rod 60, which is extensible
between a lowered,
resting or non-engaging position (Fig. 4A) and a raised, engaging position
(Fig. 4B) by operation of
an actuator 66, such as a pneumatic or hydraulic cylinder or other, similar
actuator. Each of the
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containment rod mechanisms further is carried on adjustable supports or
holders 67 to enable
variation of the longitudinal positions of the containment rod mechanisms as
needed to accommodate
varying depth or length cases. A series of gripping lugs 68 also are pivotally
mounted to the supports
66 for the containment rod mechanisms, and are extensible/pivotable by
actuators, as indicated at 69,
so as to move through the recesses or gaps 17 (Figs. 5A-5C) formed in the
leading and trailing side
walls of the cases 12 and into engagement with the cartons within the cases
for gripping and applying
pressure to the stacked cartons, as illustrated in Figs. 5A 5C.
[0038] As
further illustrated in Figs. 4A, 4B and 4C, each of the adjustable guide rails
62/63 is
adjustable laterally along rails 71 to accommodate different size or
configuration of cases, and the
positions of the containment rods 60 further are adjustable longitudinally,
such as by sliding
movement of their supports 66 along guide rails 72 to further enable
adjustment of the framework 61
of the carton decasing assembly to accommodate different size and/or
configuration cases 12, as
illustrated in Figs. 5A-5C. As indicated in Fig. 2, an adjustment mechanism
73, here shown as a
hand-wheel or crank, although it will be understood that other manual and
automatic adjustment
mechanisms also can be used, will be provided along the magazine conveyor 31
for adjustment of the
width of the magazine conveyor, and with it the width of the carton decasing
assembly, to
accommodate different width/size cartons. Preferably, a first side 74A of the
magazine conveyor and
the side guide rail (i.e., 63) associated therewith can remain fixed or
stationary, with the opposite or
second side 74B of the magazine conveyor being movable along laterally
extending guide rails, such
as shown at 75 in Fig. 4D, to adjust its position with respect to the first
side 74A of the magazine
conveyor, and with it, the position of side guide rail 62 with respect to side
guide rail 63 of the carton
decasing assembly.
[0039] The
adjustments of the magazine conveyor, and with it, the carton decasing system,
to
accommodate varying size and/or configuration cartons and their cases
generally will be made with
respect to the parent packaging machine into which the cartons are to be fed.
The parent machine
generally will act on a fixed score line date based on a crease or fold line
about which the cartons are
folded to provide a reference axis or line (indicated at phantom line 76 in
Fig. 1) for the X-Y-Z
adjustments of the magazine conveyor and carton decasing assembly. The
adjustments of the side
frame assemblies of the carton decasing assembly both laterally and
longitudinally accordingly are
part of the size change procedure for the automatic carton decasing system,
with such longitudinal
and lateral adjustments generally being controlled via manual drive mechanisms
and sensors so as to
match the spacing of the containment rods and gripper lugs to the particular
size and/or configuration
of the cases and accordingly the stacks of cartons contained therein.
Typically, the positions of the
containment rods will be adjusted to match the longitudinal size or thickness
of the stacks of cartons,
and to locate the containment rods approximately adjacent the fold or crease
lines of the cartons to
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ensure stable and even engagement therewith as the cartons are conveyed along
the magazine
conveyor with the containment rods.
100401 Figs.
5A-5C generally illustrate the operation of the decasing assembly 32.
Initially, after the
case has been inverted and placed on top of the magazine conveyor and moved
into registration or
otherwise located for engagement by the carton decasing assembly 32, the
gripper lugs 68 and
containment rods 60 are generally in their retracted, non-engaging positions.
Typically, the cases
will have been formed with cutouts 17 (Fig. 2) that enable access therethrough
by the gripper lugs 68
for engaging and holding the cartons (Figs. 5A-5C). Initially, the gripper
lugs will be engaged to
first centralize the carton load and at least partially compress the stacks of
cartons inwardly. This
engagement/compression of the stacks of cartons further will create spaced
gaps or openings along
the sides of the cartons to facilitate and/or enable entry of the containment
rods 60, between the
cartons and the leading and trailing side walls of the cases, as indicated in
Fig. 5B. Additionally, as
the cartons and cases are moved along the magazine conveyor, they will engage
and ride along a
sloped center guide 77 that assists in supporting the cartons and cases and in
keeping them in a
substantially square attitude or alignment as the containment rods are
inserted.
100411
Thereafter, as illustrated in Fig. 5C, with the cartons being held by the
containment rods, the
case will be lifted off of its stack of cartons by a lifting mechanism 80
(Fig. 1) as the rods remain in a
raised, engaging position for holding the stacks of cartons in place and as
the case is removed
therefrom. The containment rods will remain up for decasing and subsequent
transfer of the carton
load to the back of a carton magazine such as being combined with a prior
loaded stack thereon, thus
supporting the carton load until a stack pusher assembly 90 engages the stack
of cartons and locates
the stack of cartons against the back of previously loaded supply or stack of
cartons within the
magazine, as indicated in Figs. 7A-7C. A sensor 78 (Fig. 4D) generally can be
provided at an
upstream end of the adjustable frame/sled 61, which can be engaged by the
prior loaded stack of
cartons, as the sled approaches the stack. The activation of this sensor 78
signals the activation of
the pusher assembly and retraction of the carton decasing assembly. At the
same time, the gripper
lugs generally will release the cartons from engagement as the case is lifted
off of the stack of
cartons as shown by Fig. 5C, which gripper lugs will further be retracted
below the cartons as
indicated in Fig. 5A.
100421 As
illustrated in Figs. 1, 2, 6 and 7A-7D, the stack pusher assembly 90 generally
is located
along the magazine conveyor 31, downstream from the carton decasing assembly
32. The stack
pusher assembly 90 can include one or more stack pushers 91 movable along the
length of the
magazine conveyor, which stack pushers will engage the stacks of cartons after
they are removed
from their cases and will hold a final or rearmost carton at the back of a
stack of cartons being fed
into the discharge point 92 of the magazine conveyor. In one embodiment, the
at least one stack
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pusher 91 can comprise a pivoting arm, indicated at phantom lines 94 in Fig.
2, having a pusher plate
96, and which is adapted to be pivotable into and out of the path of travel of
the stacks of cartons,
which is movable with the operation of the magazine conveyor to maintain the
stacks of cartons at an
upright, stacked attitude.
100431
Alternatively, as illustrated in Figs. 2, 6 and 7A-7D, in another embodiment,
these stack
pushers can include a pair of extensible pusher rod assemblies 100/101 mounted
above the magazine
conveyor and movable along a parallel path of travel therewith. The pusher rod
assemblies 100/101
generally will be spaced apart along a laterally extending support rail, with
the lateral position or
location of the pusher rod assemblies along the support rail 102 being
adjustable with respect to one
another to accommodate different size cartons. For example, the lateral
positions of the pusher rod
assemblies can be adjusted with respect to a centerline of the parent
packaging machine to align their
pusher rods 106 with creases or fold lines of the cartons. Typically, the
pusher rod assemblies each
will include an actuator 104, such as a hydraulic or pneumatic cylinder, and a
pusher rod 106 which
is extensible to a lowered, engaging position and can be retracted upwardly to
a non-engaging or
retracted position out of engagement with the cartons.
[0044] The
pusher rods 106 can be provided with a length sufficient to engage a variety
of different
height cartons, or alternatively, the position of the support rail 102 can be
adjusted vertically along
guide arm 107 to further adjust the vertical position of the pusher assemblies
100/101. Thus, the
height of the pusher assemblies can be further adjusted as needed to
accommodate variations in size
of the cases. As also indicated in Figs. 2 and 6, the support rail 102 is
slidable along an upper guide
rail 108, which helps control and maintain consistent movement of the pusher
assemblies in a
substantially parallel path of travel to the path of travel P of the cartons
along the magazine
conveyor. The vertical support 107 also connects the support rail 102 and thus
the pusher assemblies
100/101 mounted therealong to an independent drive system 110.
100451 As
indicated in Figs. 6-7D, the independent drive system 110 of the stack pusher
assembly is
disengagably connected to the magazine conveyor drive mechanism or system 111
so as to generally
be moved therewith as the cartons are fed along the magazine conveyor with the
pusher rods of the
stack pushers in engagement therewith. However, the drive system 110 for the
stack pusher
assembly further is separably operable as needed to permit the stack pusher
assembly to be moved
longitudinally, upstream and downstream, independently of the movement of the
magazine conveyor
as needed to retract and/or reposition the stack pusher assembly as indicated
in Figs. 7A-7D.
Thereafter, the stack pusher assembly can be re-synced with the movement of
the magazine conveyor
to maintain the stack pusher assembly in engagement with the stacks of cartons
being fed along the
magazine conveyor into the downstream magazine 13. Thus, when the stack pusher
is operated with
the magazine conveyor, its motor is at rest and the stack pusher sprocket is
engaged with the chain
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with the stack pusher(s) engaging the carton stack as the whole assembly moves
in concert.
However, when the stack pushers need to move upstream to go behind a new stack
of cartons, its
stack pusher motor drives the stack pusher assembly upstream, along its chain
and along the
magazine conveyor, whether the magazine is stationary or indexing to feed a
next carton.
[0046] The
operation of the stack pusher assembly is generally illustrated in Figs. 7A-
7D. After the
cases have been removed from the cartons, the cartons are conveyed in a
stacked configuration by the
carton decasing assembly 32 along their path of travel P along the magazine
conveyor 31 toward the
discharge end or point of the magazine conveyor. As indicated in Fig. 7A,
after the initial startup and
loading of a first stack of cartons on the magazine conveyor, the next stack
of cartons being conveyed
or moved along the magazine conveyor by the carton decasing assembly will
approach a previously
loaded stack of cartons 11, which stack of cartons is maintained in a
substantially upright, or slightly
forward leaning attitude by the engagement of the stack pusher assembly
therewith.
[0047] As
the next stack of cartons 11' approaches the previously loaded stack of
cartons 11, the
sensor 78 (Fig. 4D) at the upstream end of the sled 61 of the carton decasing
assembly 32 will be
engaged, such as by contacting a rearmost carton (Fig. 7B) of the previously
loaded stack of cartons.
Upon engagement and activation of the sensor 78 (Fig. 4D), as indicated in
Figs. 7B and 7C, the
activation of the sensor by the approach of the next stack of cartons being
carried by the carton
decasing assembly towards the rearmost carton of the preceding loaded stack of
cartons will cause the
disengagement of the stack pusher assembly. Upon a disengagement signal being
sent to the stack
pusher assembly, the pusher rods 106 will be retracted, as indicated in Fig.
7B, and the drive system
110 for the stack pusher assembly will be disengaged from the magazine
conveyor. Thereafter, as
indicated in Fig. 7C, the stack pusher assembly drive mechanism will be
independently operated so as
to move the stack pushers rearwardly, in the direction of arrow 115, to a
retracted position behind the
rearmost carton of the stack of cartons on the carton decasing assembly.
[0048] Once
the stack pushers have been retracted to their rearward position, as indicated
in Fig. 7D,
the pusher rods will be extended into engagement with the rearmost carton of
the combined stack of
cartons and the drive system for the stack pusher assembly will be reengaged
with the drive system or
drive mechanism of the magazine conveyor. Additionally, as indicated in Figs.
6 and 7B-7C, as the
stack pushers are moved to their retracted position, a pair of shoes 116 can
engage and pass over the
top edges of the cartons to ensure that the cartons will not be caught or
otherwise engaged by the
pusher rods. These shoes also can be linked to a sensor to signal a fault
condition if movement of the
shoes along the cartons is disrupted or interfered with during retraction of
the stack pushers. After the
pusher rods of the stack pushers have been engaged with the rearmost carton of
the combined stack of
cartons, the containment rods of the carton decasing assembly can be
retracted, releasing the cartons
from engagement therewith, after which the carton decasing assembly can be
moved back to its initial,
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loading or carton receiving position adjacent the upstream end of the magazine
conveyor and the
inverting assembly. Thereafter, as indicated in Fig. 7D, the stack pushers
will continue to move
forwardly with the forward motion of the magazine conveyor as the cartons are
sequentially fed
through the discharge point of the magazine conveyor and into a downstream
packaging machine
magazine.
[0049] An
additional embodiment of the carton decasing system 200 according to the
principles of
the present invention is generally illustrated in Figs. 8-10. The embodiment
of the decasing system
200 shown in Figs. 8-10 is designed to enable access to the packaging machine
PM, as needed, such
as for loading additional materials, clearing jams, etc. For example, the
decasing system can be
adapted for use with "twin stack" type packaging systems and equipment wherein
a first stack or layer
of products, such as bottles or cans or other similar product, are placed upon
a carton, after which a
layer pad is placed over the first or lower stack of products placed on the
carton, after which a second
layer or stack of products is placed on top of the layer pad and the carton
folded thereabout to form a
"twin stack" product package. The layer pads typically are inserted between
the stacks of products at
an intermediate point along the path of travel of the products through the
twin stack packaging
machine and thus access must be provided to the layer pad magazine for loading
of additional layer
pads therein. The decasing system 200 according to the present embodiment is
adapted to provide the
automated decasing features of the present invention for use with such a twin
stack or other style
packaging machines while also enabling access to the layer pad magazine and/or
other areas of the
packaging machine by an operator, without requiring reconfiguration of the
packaging machine and/or
without substantial disruption in the decasing of the cartons for feeding into
the carton magazine of
the packaging machine.
[0050] As
illustrated in Figs. 8-10, the cases 12 with the cartons 11 stacked therein
will be fed along
the case infeed conveyor 24 to the inverting assembly 30 where the cases are
engaged by the inverter
head 30A thereof. The case infeed conveyor and inverter head 30A generally
will have substantially
the same construction as discussed above with reference to Figs. 1-3C. Thus,
as with the embodiment
of the carton decasing system illustrated in Figs. 1-3C, the inverter head
will generally be mounted on
adjustable frame members or supports 33 and generally will include side guides
or clamps 34 that are
adjustable laterally to receive cases of different sizes and/or
configurations, as well as top and bottom
case support guides 44 and 46 (Figs. 9A-9B) that likewise are vertically
adjustable along the frame
members of the inverter head to accommodate different size and/or
configuration cases.
[0051] In
the present embodiment of the carton decasing system 200, the inverter head
further will be
mounted on a carriage 201, which conveys the inverter head 30A about an
extended, orbital path over
and above a layer pad magazine access area or station 202 provided along the
path of movement of
the cases. This layer pad magazine access area 202 enables the operator to
access the twin stack
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packaging machine PM (Figs. 8 and 10) for loading of a stack or series layer
pads into the layer pad
magazine 203 of the twin stack packaging machine. Such access further is
provided without
disruption of the operation of the carton decasing system for removing stacks
of cartons form their
cases and feeding such stacks of cartons into a carton magazine 204 of the
packaging machine.
[0052] As
illustrated in Figs. 8-9C, the carriage 201, on which the inverter head 30A of
the carton
decasing system 200 is supported, is mounted on a radially extending track or
rail assembly 206. As
shown in the figures, this rail assembly 206 extends along an orbital path,
upwardly and over the layer
pad magazine access area 202, from the downstream end of the case infeed
conveyor to the upstream
magazine conveyor 31. The rail assembly 206 generally will include one or more
rails 207, which
could include V-rails, box rails, or other configuration rails, and which can
further include a series of
rollers mounted therealong for supporting the carriage as it is moved along
the rails. The rails 207 are
supported over the layer pad magazine access area by an orbital frame 208.
[0053] The
carriage 201 of the inverter head 30A generally will engage and ride along the
rails of the
rail assembly 206 and will be moved about its orbital path, indicated by
arrows 209 in Fig. 9B, for
transporting a case with the stacked cartons therein over the operator and
layer pad magazine access
area 202 for depositing the case in an inverted position onto the magazine
conveyor 31. A drive
system 210 will control the orbital movement of the carriage 201 along the
rail assembly 206. The
drive system 210 generally will include a reversible, variable speed motor,
such as shown at 211, and
a drive mechanism or means, illustrated by phantom lines 212 in Fig. 8, that
transports the carriage
201 along its orbital path as shown in Figs. 9A-9C. The drive motor 211
generally will be a variable
speed, reversible motor sized for a duty cycle and load to accommodate varying
size and weight cases
containing varying size cartons stacked therein. The motors also can include a
reducer so as to
increase the torque of the motor to accommodate varying size/weight loads of
cartons and can be
operated at cycle rates of approximately 30-45 seconds per operational cycle,
although greater or
lesser cycle rates also can be used. The drive mechanism 212 further can
include one or more chains,
cables, belts, or a combination of chains, belts and/or cables (shown in
phantom lines 214 in Fig. 8)
that are received within and moves along the rails 207 of the rail assembly
206 in a reversible, back
and forth motion under operation of the drive motor 211. Also, the drive
mechanism could include an
orbital rack and pinion, with a pinion gear being driven by a motor mounted to
the inverter head.
[0054] As
illustrated in Figs. 9A-9C, once a case 12 with a stack of cartons therein has
been engaged
and contained within the inverter head 30A of the inverting assembly 30 by the
side guides and
bottom case support guides (the top support guide generally floating over and
conforming to the top
of the case as the case is inverted), the drive motor 211 generally will be
actuated to commence
inverting of the case and cartons. As indicated in Fig. 9B, the motor will
pull the drive chain or other
drive mechanism along the rails of the rail assembly 206, causing the carriage
201 to transport the
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inverter head 30A about its orbital path as shown by arrows 209, upwardly and
over the layer pad
magazine access area 202. The inverter head thus will be moved about its
expanded, orbital path for
inversion of the case, and will place the inverted case on the magazine
conveyor 31 as discussed with
respect to the prior embodiment of Figs. 1-6. Thereafter, a carton decasing
operation can be
commenced, as discussed above with respect to the prior embodiment and as
illustrated in Figs. 6-7D,
for removal of the cases from the stacks of cartons, after which the cases can
be removed from the
carton decasing system and packaging machine along their overhead conveyor,
while the stacks of
cartons are fed into the carton magazine 204 for the packaging machine PM. As
the cartons are fed to
the carton magazine, the drive motor 211 of the drive system 210 also can be
reversed, pulling the
drive chain(s) 214 of the drive mechanism 212 (Fig. 8) rearwardly so as to
transport the inverter head
in a reverse direction along its orbital path, back to its initial, home
position at the downstream end of
the case infeed conveyor for receiving a next case with a stack of cartons
therein.
100551 The
embodiment of the carton decasing system 200 illustrated in Figs. 8-10 thus
enables the
use of the carton decasing system according to the principles of the present
invention with additional
types of packaging machines, such as twin-stack type packaging machines, by
providing an operator
with walk-in access to the layer pad magazine of the packaging machine for
loading of additional
layer pads and/or for providing access to the packaging machine as needed for
clearing of jams, etc.
As further illustrated in Figs. 8-10, the access area 202 defined within the
carton decasing system 200
generally will include a series of protective panels or barriers, generally
indicated at 215 forming a
protective housing or cage 216 beneath the rail assembly 206 along which the
carriage 201 is
conveyed during a case inverting operation. Such barriers 215 can include
Plexiglas or safety glass
panels supported by frame members 217, which panels or barriers 215 can
further be removable or
otherwise pivotally mounted to the frame member so as to enable access to the
rail assembly 206 as
needed for maintenance or repair/replacement or other adjustments thereof.
Additionally, other panels
or barriers also can be used, including the formation of a wire cage or
similar protective housing, so
that the operator can be provided with substantially safe/protected access to
the layer pad magazine or
other areas of the packaging machine during operation of the inverting
assembly 30 of the carton
decasing system 200.
100561 The
automatic carton decasing system of the present invention thus is designed to
maximize
the use of space by utilizing the smallest footprint possible, while
maintaining front guard line and
maintenance side clearance as needed for the infeed conveyors. Additionally,
as noted, the case
infeed conveyor is provided with an in-line layout enabling extensions of the
case infeed conveyor as
needed. The automatic carton decasing system further is provided with open
access for each of the
operative assemblies for ease of changeover and maintenance, and is generally
adapted to be a self-
contained unit to enable magazine loading and unloading with or without
decasing functionality so
that the system can be utilized in various configurations and as a retrofit or
upgrade to existing
CA 02869017 2016-08-18
=
packaging systems. The system further can be primed by loading a limited
number of cartons
initially within the feeder to create an initial stack against which later
decased carton stacks will
be placed, while the empty cases are dischargeable along a high level conveyor
to help reduce the
system footprint, and which further can be reconfigured to provide case
discharge anywhere in an
approximately 1800 radius for discharging cases into a bin or baler or
directing them to some
other type of containment unit for collection and disposal or recycling.
100571
The foregoing description generally illustrates and describes various
embodiments of the
present invention and it should be understood that it is intended that all
matter contained in the
above description or shown in the accompanying drawings shall be interpreted
as being
illustrative, and not to be taken in a limiting sense.
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