Device for diverting a moving flow of products, particularly for packaging machines

In a device for diverting a moving flow of products, the products advance on a flexible belt conveyor which turns downwardly in the region where it converges with a second conveyor line so as to form an output edge which is aligned substantially in the direction in which the flow of products is to be diverted. A receiving element on the side opposite the belt conveyor is constituted, for example, by a disc which is almost in contact with the output edge. The disc moves at an angular velocity such that its outer edge, which is substantially coplanar with the transportation plane of the flexible belt conveyor, moves substantially in synchronism with the products. The preferred application of the device is to automatic packaging devices.

BACKGROUND AND SUMMARY OF THE INVENTION 
In general, the present invention addresses the problem of diverting a 
moving flow of products. It has been developed with particular attention 
to its possible use in the field of automatic packaging plants (automatic 
packaging machines). 
In this field of application (but also in other situations of use) the need 
arises to be able to divert a flow of products which are advancing 
continuously or substantially continuously in a certain initial direction 
so that the flow of products in question moves in a final direction which 
is inclined at a generally acute angle to the initial direction, that 
is--according to the meaning to be attributed to this term in the present 
description and, where necessary, in the following claims--at an angle of 
less than 30.degree.. 
This need is experienced in particular in any situation in which two flows 
of products or articles are to be made to converge in a generally 
"Y"-shaped arrangement. 
It arises, for example, in situations in which the two input branches of 
the "Y"-shaped convergence are represented respectively by a flow of 
products to be packed and a flow of accessory elements, for example cards, 
to be inserted beneath one or more products so as to form the base of a 
package. The output branch of the "Y" is thus constituted by a flow of 
articles, possibly in groups, disposed on respective cards; this output 
flow can thus be sent, for example, towards a wrapping machine for forming 
wrappers of the type currently known as "flow-packs" or "form-fill-seal" 
wrappers or simply FFSs, so as to produce finished packages, each of which 
contains one or more articles disposed on a base card and wrapped in a 
tubular wrapper of sheet material closed at its ends by sealing flanges 
(or flaps). In this field of application, the cards can be supplied by a 
conveyor line (for example, a chain conveyor with entrainment teeth or 
nibs) which defines or is aligned with the supply line to the wrapping 
machine. The flow of articles to be placed on the cards therefore 
converges with the main entrainment line from one side at a generally 
acute angle so that the flow of products has to be diverted angularly as 
the products are loaded onto the base cards. 
In the field referred to by way of example (it should be noted, however, 
that the same problems may also arise in a practically identical manner in 
quite different situations of use) in order to achieve a completely 
satisfactory angular diversion of the flow it is necessary to take account 
of various factors, such as: 
the growing tendency to use ever-faster operating rates in automatic 
packaging plants--and hence ever-faster linear velocities of movement of 
the products processed--which means that even quite light products acquire 
considerable momentum and thus exhibit a certain inertia in relation to 
any operations to divert the direction of the flow; 
the need to avoid discontinuities in the surfaces which support the 
products between conveyor elements disposed in cascade, particularly for 
small products which themselves exhibit fairly unstable equilibrium (for 
example, pralines in respective pleated paper cases) since discontinuities 
may cause the products to fall over or even roll along the conveyor lines; 
the need to conserve precise relative positioning between successive 
products even after the flow has been diverted; the diversion of the flow 
is in fact often carried out on products which are already "synchronised", 
that is to say, already located in precise temporal and spatial 
relationships relative to the elements which have to receive and process 
them in the stations of the plant further downstream, and 
the fact that the products processed may themselves be very delicate (for 
example, very soft or doughy confectionery products) so that too firm a 
handling operation may give rise to damage to the product which is 
disadvantageous both as regards the possible alteration of the product, 
and as regards the risk that parts of the product may be detached 
therefrom and fall onto the conveyor line, resulting in jamming. 
Naturally, in some particular situations of use, the list of problems 
outlined above may not be exhaustive. 
The main object of the present invention is to provide means for diverting 
a moving flow of products without giving rise to the problems cited above. 
This and other objects and advantages are achieved by the flow diversion 
device according to the invention, in which a stream of products is 
conveyed in an initial direction to a point of diversion, by a flexible 
conveyor belt having a discharge edge formed by a roller, or a so-called 
feather edge, which is substantially parallel to a final direction of 
advance. A receiving element in the form of a circular disc, which is 
coplanar with the conveyor belt and has its periphery substantially 
tangential to the discharge edge, receives the products and transfers them 
to a second conveyor which is aligned in the final direction of advance. 
Other objects, advantages and novel features of the present invention will 
become apparent from the following detailed description of the invention 
when considered in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE DRAWINGS 
The appended, drawings relate specifically to one branch of an automatic 
wrapping machine of which all the parts (the framework, the support 
structure, the drive motors, etc.) which are not essential for the 
purposes of an understanding of the invention have been omitted for 
clarity of representation; these elements are in any case formed according 
to criteria widely known in the art. 
In FIG. 1, a chain conveyor line, indicated 10, has a plurality of teeth or 
nibs 12 for advancing a flow of cards 14 horizontally (generally from left 
to right with reference to the observation point of FIG. 1) from an 
upstream supply or loading station (not shown in the drawings) towards a 
wrapping machine (for example, an FFS wrapping machine which is also not 
shown in the drawings). 
In the supply station, the cards 14 are slid between two C-shaped lateral 
cheeks 16 which open towards each other and are spaced apart so that the 
upper, active pass 18 of the chain conveyor line 10 can pass freely 
between them. 
Products P constituted, for example, by pralines in respective pleated 
paper cases are to be arranged on the cards 14 for subsequent supply to 
the wrapping machine. 
In the particular embodiment illustrated, three products P are to be placed 
on each card 14. 
This is achieved, in known manner, by the coordinated control both of the 
distance between the products P on the belt 20 which causes them to 
converge with the conveyor line 10 in a Y-shaped configuration, and of the 
distance between the successive nibs 12 of the latter line. In practice, 
the distance between the nibs 12 is determined in dependence on the number 
of products P to be grouped in each package and the distance between the 
products P on the belt 20 is regulated so that, when they converge with 
the line 10, each nib 12 of the line 10 is inserted like a separator 
between sets of three adjacent products, thus gathering the products P 
together as a result of the entrainment towards the wrapping machine, so 
that separate groups of products to be packaged are formed downstream of 
the point at which the flow of products P converge with the line 10 and 
are safely deposited on the base cards 14. 
It should be stated, however, that, on the one hand, the use of the 
solution according to the invention is not restricted to the formation of 
groups of products but exhibits some of its best qualities in connection 
with the processing of articles taken individually. On the other hand, it 
should be noted that the presence of the cards 14 is not essential, 
particularly where individual articles are concerned. 
The present invention thus specifically addresses the problem of causing 
the flow of articles P from the belt 20 to converge with the chain line 10 
in a completely satisfactory manner. This is done whilst taking account of 
the fact that the initial direction of advance of the products P is 
inclined at a generally acute angle .alpha. to the final direction defined 
by the entrainment line 10, this term meaning an angle of up to 
approximately 30.degree.. 
For this purpose, the belt or mat 20 is made of flexible material (for 
example, a core of fabric covered with plastics material suitable for the 
processing of food products) and passes around a plurality of guide 
rollers, generally indicated 22 in FIGS. 1, 2 and 4, in a generally 
endless configuration. At least one of the rollers is driven so as to 
impart to the upper pass 20a of the belt 20, that is, to the portion of 
the belt on which the articles P (which generally come from a further belt 
N situated upstream and visible only in FIGS. 1 and 2) advance, the 
necessary movement towards the chain line 10. 
In particular, in the region in which it meets the line 10, the downstream 
end 20b (in the direction of advance) of the upper pass 20a of the belt 20 
passes downwardly around a return element constituted by a roller or, 
according to the currently preferred embodiment, a so-called feather-edge 
24. This enables the belt to turn downwardly with an extremely small 
radius of curvature (for example, of a few millimeters). 
An important characteristic of the invention is that the feather-edge 24 
and consequently the downward turn in the upper pass of the belt 20 in the 
region in which it meets the line 10 (in practice the downstream or output 
end of the active pass 20a of the belt 20) is oriented generally obliquely 
to the direction of advance of the products P and, more precisely, in the 
direction identified by the line of advance 20. 
In deliberately simplified terms, the belt 20 actually "disappears", so to 
speak, along the line of advance of the line 10. 
The products P which are supplied on the centreline of the upper pass 20a 
are therefore relinquished by the belt 20 precisely in the region where it 
meets the line 10, so that the direction of flow of the products is 
diverted. 
FIGS. 2 and 4 show in greater detail the path of the belt 20. In these 
drawings, the upper portion or pass on which the products P advance is 
indicated 20a and the oblique turn which is formed by the belt around the 
feather-edge 24 and which defines the output end of the conveyor pass 20a 
is indicated 20b. A first, lower pass, indicated 20c, however, is 
constituted by a respective portion of the belt 20 which moves away from 
the line 10, also obliquely and in practice at an angle of divergence 
which is symmetrical to the angle of convergence .alpha.. The lower pass 
20c passes downwardly around a first guide roller 22 and then moves 
towards a second guide element (shown here in the form of a guide 26) 
which achieves a diversion of the path of movement of the belt 
complementary to that achieved by the feather-edge 24 in correspondence 
with the entrainment pass of the line 10. As it passes around the lower 
guide 26 the belt forms a lower pass 20d which extends substantially along 
the same line as the upper conveyor pass 20a, to which it is connected by 
passing over a set of several guide rollers 22, one of which usually acts 
as a drive roller for the belt 20, which is hence a driven belt, whilst 
the axis of rotation of one of the other rollers can be moved selectively 
in order to tension the belt. This is all according to widely known 
criteria which do not need to be described in specific detail herein. 
The discharge of the products P by the upper pass 20a of the belt 20 would 
not by itself be sufficient to divert the direction of the flow of 
products P in a complete and reliable manner. 
In order to achieve this result in a wholly reliable manner, it is 
necessary to use an element for cooperating with the belt 20, the element 
being disposed on the opposite side of the line 10 and, in the embodiment 
to which FIGS. 1 to 3 relate specifically, being constituted by a 
horizontal disc 28. The disc 28 is rotated about its axis X.sub.28 
(clockwise with reference to FIGS. 1 and 2) at an angular velocity which 
is regulated (in known manner) by means of its drive unit 28a so that, 
taking account of the diameter of the disc 28 (for example, of the order 
of 40-50 cm) its peripheral velocity, that is, the velocity of its outer 
edge, is synchronised with and corresponds to the speed of advance of the 
line 10 (that is, in practice, with the speed of advance of the nibs 12). 
The fact that the disc 28 is thin means that its periphery (which has 
equally spaced notches 30) can be coplanar and almost in contact i.e. 
substantially tangent with the upper pass 20a of the belt 20 which turns 
downwardly over the feather-edge 24 (see in particular the sectional view 
of FIG. 3), at a distance which, in real terms, is, for example, of the 
order of one millimeter and thus such as to ensure that the disc 28 cannot 
under any circumstances touch the belt 20 so as to damage it. At the same 
time, the distance is such that, in practice, it eliminates the gap or 
slit which the products P have to cross to move from the belt 20 to the 
entrainment line 10. 
The presence of the perimetral notches 30 means that, in the region in 
question (again see FIG. 3), the nibs 12 can penetrate the periphery of 
the disc 28 so as to project upwardly from its surface (through the 
notches 30) as if they were associated with the disc 28 itself. Naturally, 
this effect is ensured by the synchronisation mentioned above between the 
speed of advance of the line 10 which carries the nibs 12 and the speed of 
rotation of the disc 28. 
The particular function of the disc 28 is essentially to receive the 
products P in order at least partially (that is, in the upstream portion 
in the direction of their advance on the input line defined by the belt 
20) to take over, so to speak, the products P which are to be relinquished 
by the belt 20 which turns downwardly around the feather-edge 24, and also 
for their general advance determined by the line 10. 
At the same time, with the arrangement illustrated, the upper pass 20a of 
the belt 20 (that is, the surface from which the products P are supplied) 
is substantially coplanar with the (partial) receiving plane defined by 
the disc 28. This is all achieved, in combination with a reduction of the 
gap which the products have to cross to a minimum value (for example, one 
millimeter), so that there is no risk of the falling-over or rolling of 
products P which have fairly high centres of gravity in comparison with 
their bearing surfaces. 
In practice, the direction of flow of the products P is diverted from the 
initial condition in which they advance on the upper pass 20a of the belt 
20, firstly by the partial discharge of the products from the belt 20 
which turns downwardly around the feather-edge 24 and their consequent 
partial transfer onto the surface of the disc 28 and, subsequently, by an 
advancing step in which the belt 20, on the one hand, and the disc 28, on 
the other hand, accompany the products P which are already oriented in the 
direction of advance of the line 10 so as to achieve a situation in which 
the products P, which are finally oriented along the line 10, are firmly 
taken over thereby both as a result of their crossing the end edge of the 
belt (that is, in practice, the downstream vertex of the turn line 20b 
defined by the feather-edge 24, in the direction of advance of the line 
10) and as a result of the movement of the periphery of the disc 28 away 
from the products P as they gradually move away from the position where 
the belt 20 and the line 10 meet, with the approximately simultaneous or 
slightly subsequent formation of the groups of products (if required) and 
their gradual entrainment towards the downstream station, usually between 
two fixed side retaining walls which are indicated 32 in FIG. 1 only. 
The products are generally only finally entrained positively by the nibs 12 
of the line 10 at this last stage since this entrainment is not necessary 
for diverting the flow. 
This is especially important when particularly delicate, fragile or soft 
products P are to be handled. In this case, the synchronisation ("timing") 
of the supply belt 20 can be regulated in relation to the advance of the 
nibs 12 so that the products P which are transferred to the line 10 with 
the use of the disc 28 are in any case slightly in advance of the 
positions in which the nibs 12 advance throughout the region in which the 
direction of the flow is diverted. 
In practice, the flow is diverted, in principle, by actions exerted 
exclusively on the supporting bases of the products, without the exertion 
of transverse restraints or forces (in practice on the sides of the 
products), except to a very marginal extent. 
In this connection, the presence of two lateral restraint structures with 
vertical walls, indicated 34 and 36 respectively in FIG. 1 and FIG. 2, 
may, however, be advantageous but is not essential. For accuracy, and to 
make the representation of the device according to the invention clearer, 
FIG. 1 shows only the element 34 in continuous outline, the space occupied 
by the element 36 being shown in broken outline. In FIG. 2, however, a 
complementary representation has been adopted, with the element 36 shown 
in continuous outline and the element 34 in chain outline. 
As can be seen in FIG. 1, the element 34, which is on the side of the line 
10 towards which the belt 20 converges (at the angle .alpha.), is 
constituted by an endless, driven belt which passes around respective 
rollers with vertical axes so as to form a first entrainment pass 34a (for 
reasons which will become clear from the following, it would be more 
correct to speak of accompaniment) which extends vertically above the 
upper pass 20a of the belt 20 in alignment with the direction of advance 
thereof. The pass 34a of the belt thus forms a first wall for restraining 
the products P which are still on the belt 20 and a second pass 34b of the 
same belt, which is further downstream, (naturally with reference to the 
general direction of advance of the products P), extends along the 
homologous side of the line 10 in alignment with the direction of advance 
thereof, immediately upstream of the respective fixed lateral restraint 
wall 32. 
The two passes 34a and 34b are connected in correspondence with a guide 
roller with a vertical axis, indicated X.sub.34 in FIG. 1, which is in the 
region in which the products P are (also) transferred onto the disc 28. 
The lateral restraint element 36 is also constituted by an endless 
motor-driven belt which passes around rollers with vertical axes and 
includes an active pass 36a which extends along the side of the line 10 on 
which the disc 28 is situated (that is, on the opposite side from the belt 
20), practically throughout the region in which the flow of products P is 
diverted. In this connection, it will be noted that the line 10 (which is 
intended also to entrain the cards 14) extends generally both upstream and 
downstream of the region of convergence of the belt 20 (the output edge 
20b). 
The criteria for the formation of restraint elements with movable walls 
such as those indicated 34 and 36 are well known in the art and certainly 
do not need to be repeated herein. 
It should also be noted that the movable walls defined by the belt portions 
34a, 34b and 36a--which move at a speed corresponding to the speed of 
advance of the products P--are not intended primarily for diverting the 
direction of the flow of products P but, on the contrary, only for 
accompanying the movement of the products so as to prevent any risk of 
their being diverted from their intended path. 
According to the invention, the flow of the products P is thus diverted 
primarily by a "supporting" action on the products P without appreciable 
lateral forces or constraints. 
As has been seen above, the perimetral notches 30 along the outline of the 
disc 28 are essentially for enabling the disc 28 and the nibs 12 of the 
entrainment chain 10 to interpenetrate in the region in which the 
direction of flow of the products P is diverted (see in particular FIG. 3) 
so as to achieve a minimal gap (for example, of the order of one 
millimeter) for the products to cross when they are discharged from the 
upper pass of the belt 20a. 
This solution certainly seems preferable for products P which are 
constituted, for example, by pralines housed in corresponding pleated 
paper cases, that is, products whose centres of gravity are very high in 
comparison with their bearing surfaces, so that any discontinuity in the 
sliding and/or entrainment surface may cause them to fall over. 
In the case of different, more stable products, that is, products which can 
better tolerate a certain discontinuity in the conveyor surface, a disc 28 
without notches for the passage of the nibs of the entrainment line 10 may 
be used, as shown schematically in FIG. 4. 
Naturally, in this case, the nibs 14 and the periphery of the disc 28 
cannot interpenetrate and the gap left between the output edge 20b of the 
belt 20 and the periphery of the disc 28 is therefore wide enough for the 
passage of the nibs 14. For example, the gap could be of the order of 
several millimeters. As stated, this solution may be tolerable for fairly 
long and stable products (for example, bars of chocolate or the like) 
which can easily bridge the slit without risk of sticking. 
FIG. 4 also shows yet another possible variant of the invention, in which 
the chain entrainment line 10 is constituted by a chain of the so-called 
"plate-top" type, which is constituted by a plurality of articulated links 
38 the flat upper faces of which are of a certain width (for example, 
several millimeters) so as themselves to form a surface for supporting and 
entraining the products P. 
The entrainment line 10 is thus arranged so that the upper surfaces of the 
links of the "plate-top" chain are substantially coplanar with the 
conveyor surface (the pass 20a) of the belt 20. 
In this case, the chain 10 itself acts as the element for receiving the 
products P in the sense that, during the transfer and thus the diversion 
of the direction of flow, the bases of the products P no longer bear 
partially on the output end of the belt 20 and partially on the surface of 
the disc 28 (as in the embodiment of FIGS. 1 to 3) but rather on the 
surface of the belt 20, on the surface of the "plate-top" chain 38, and 
also on the peripheral surface of the disc 28. 
If the nature of the product transported permits, the disc 28 may thus even 
be eliminated and the products transferred by moving from a condition in 
which they bear wholly on the belt 20 to an intermediate condition in 
which they bear partially on the output edge of the belt 20 and partially 
on the plates of the plate-top chain 38 (the diversion of the direction of 
flow) and, finally, to a final output condition in which they are 
transported solely by the plate-top chain 38. 
At a conceptual level, it can readily be seen that, from a certain point of 
view, this latter embodiment may be regarded as the use of a disc of 
infinite radius (the rectilinear element constituted by the upper surface 
of the plate-top chain) to achieve the restraint. 
At least in principle, it is possible to envisage the use of further 
variants, naturally all included in the scope of the present invention, 
for example, the use of a further flexible belt as a cooperating or 
receiving element on the side of the output line 10 opposite that towards 
which the flow of products P carried on the belt 20 converges, the further 
belt having, at least locally, a configuration specularly symmetrical to 
that of the input belt 20. It should be noted, however, that if a flexible 
conveyor belt is used as a receiving element it is necessary to take 
account of the fact that the belt will wear gradually in use and will thus 
require periodic replacement which is not the case, on the other hand, 
with the use of solid receiving elements (for example, the disc 28 and/or 
possibly a plate-top chain, which are usually made of metal). These 
elements do not need to be replaced as a result of wear (except at very 
long intervals of use); it is necessary, however, to replace the chain of 
the line 10 (and the disc 28 if it has perimetral notches 30) if the 
spacing between successive groups of articles output on the line 10 is to 
be changed, since the spacing is defined by the distance between 
successive nibs 12. 
For example, if one wishes to change from the situation of use to which 
FIGS. 1 and 2 relate (the formation of groups of three products P) to a 
solution which provides for the formation of groups of five products P or 
the formation of groups including only one product (products P to be 
wrapped individually), it will be necessary to replace the chain by a 
chain in which the spacing of the nibs 12 corresponds to the desired 
spacing of the products. If a disc 28 with perimetral notches 30 at 
spacings corresponding to the distances between the nibs 12 of the chain 
is to be used, the disc will have to be replaced by another disc with 
different spacings between the notches 30. 
Naturally, the principle of the invention remaining the same, the details 
of construction and forms of embodiment may be varied widely with respect 
to those described and illustrated, without thereby departing from the 
scope of the present invention.