APPARATUS AND METHOD FOR TRANSPORTING PRODUCTS

A transporter apparatus for products includes a first conveyor, provided with seats for receiving said products and provided to move said products in a first advance direction, a compaction unit, positioned downstream of the first conveyor and a second conveyor positioned downstream of said compaction unit. The compacting unit includes a support surface on which the products coming from the first conveyor are deposited, and a movement member provided to move the products placed on the support surface towards each other in a second advance direction, so as to form compact columns of products substantially parallel to the second advance direction.

FIELD OF THE INVENTION

The present invention relates to an apparatus and a method for transporting products, in which, within an industrial production plant, the products being processed are advantageously repositioned so as to adjust any configuration defects resulting from previous processing.

The present invention preferably applies, though not exclusively, to the field of preparing and packaging products for food use and not, an example of which is represented by capsules for brewing beverages, such as coffee, a product to which reference will be made hereinafter without losing generality.

BACKGROUND

In this technical sector, production and packaging apparatuses are known in which a plurality of empty capsules are individually filled with the product to be packaged, such as coffee powder, and then, after being closed by an appropriate membrane, are sent to the final steps of packing into boxes and packaging.

In particular, the packing step often provides placing the capsules inside the boxes according to a predefined ordered configuration, so as to optimise the space occupied by the capsules inside the boxes, as well as to give the final package a neat and tidy appearance which is generally appreciated by customers.

SUMMARY

In the present description as well as in the claims enclosed thereto, certain terms and expressions are deemed to have, unless otherwise expressly indicated, the meaning set forth in the following definitions.

The term “product” means any object within an industrial production and/or packaging line that can be picked up, moved and deposited in a box.

The products are preferably equal to each other, but may also differ in some characteristics such as form, composition or colour.

Products can be, for example, food or sweets already packed in individual containers or wrappers, such as coffee capsules or other brewing beverages, bottles and cartons of beverages, yoghurt pots, individual chocolates (wrapped or naked), candies, small boxes, pouches containing solid, liquid or semi-solid food products; also, ceramic industry products, sanitary napkins, products of the tobacco industry, cosmetic industry products, pharmaceutical industry products, personal & home care industry products.

The term “box” means any container suitable for containing products, in particular any container suitable for packaging products to be subsequently marketed. Preferably the box is intended to contain a plurality of products in an ordered configuration. The box is preferably made of cardboard and has a closable lid, but other configurations and materials can be provided.

“Configuration” of a plurality of products means the arrangement of the products in space, referring in particular to their mutual positioning and orientation in space.

A configuration is said to be “ordered” when the products, in a certain position of the packaging apparatus, maintain a predefined spatial arrangement, preferably constant over time.

In a plurality of products, it is understood that products are moved “towards each other” when the distance between the products is reduced as a result of a relative motion between the products. Preferably, products are moved “towards each other” as they are moved in a same direction, so that the products that follow reduce the distance from the products preceding them.

In a plurality of products moved within the packaging apparatus along an advance direction, one or more “columns” of products and/or one or more “rows” of products may be identified, where a “column” of products is defined as a plurality of products aligned with each other substantially parallel to the advance direction, and a “row” of products is defined as a plurality of products aligned with each other substantially perpendicularly to the advance direction.

The advance direction may be substantially rectilinear or curved.

In a column or a row, products may be spaced apart from, or in contact with each other.

A column or row is considered as “compact” when in that column or row the products are substantially close to each other, so that the distance between adjacent products is zero (mutually contacting products) or substantially reduced, in any case lower than the size of one product. In other words, the potential distance between adjacent products must be zero or negligible, so that there is no space between them to insert another product.

In a row or column of products in an ordered configuration, a “gap” is present when the respective product is missing in one position of said ordered configuration.

A “support surface” may be any surface on which products can be placed during their production and/or packaging process. Preferably the surface is a plane surface, however it is envisaged that it may also be curved, preferably slightly curved.

The support surface is considered as “substantially horizontal” when it has an inclination with respect to the horizontal plane, where a “horizontal plane” is a plane substantially perpendicular to a vertical direction defined by the direction of the force of gravity, lower than an angle of 15°, preferably lower than an angle of 10°.

Preferably, the inclination of a substantially horizontal support surface is such that products do not slide when placed thereon.

With reference to an advance direction of products on a support surface, the “discharge end” of the support surface is defined as the end towards which the products are directed in their movement along the advance direction.

“Conveyor” means any device or member capable of moving products along a predefined trajectory while maintaining the configuration of the products in a somewhat ordered configuration. Examples of conveyors may be conveyor belts with or without seats, or an inclined guide or a robotic arm.

The Applicant has preliminarily observed that the lack of one or more products being supplied to a packaging apparatus may result in a defective number of products being placed in the box, compromising the quality of the final package, which must necessarily be discarded.

This results in a consequent loss of production and a possible need for the operator to retrieve the products within the discarded box and return them to the production process.

The Applicant observed that this undesirable event occurs more frequently when a predefined number of goods must be in the box, in particular, when that predefined number of goods must be placed inside a box in a predefined ordered configuration.

On the other hand, the Applicant observed that, in the production step, it is not unusual for one or more products within an ordered group of products to be missing or to have to be discarded before being placed in a box due to lack of compliance with certain production specifications.

Such cases may occur, for example, in high-capacity production lines where processing is carried out simultaneously (or almost simultaneously) on a plurality of products using a corresponding plurality of identical working devices when one or more of these devices does not work properly.

For example, in a first type of production installation, which is particularly widespread, it is provided that products, e.g. coffee capsules, are moved along an advance direction between the various workstations on a multi-track conveyor where the products are individually received within seats arranged in rows parallel to each other and perpendicular to the advance direction. When a row of products arrives at a workstation, e.g. a filling station or a closing station, each product in the row is committed to a respective working device, and if one of these devices fails to work properly for any reason, the product leaving that device will be discarded. In this way, a “gap” (or, in other words, a “hole”) is created in the row of products being processed which, however, will continue the respective processing and packaging process, where, as mentioned above, it could result in defects in filling the final box.

Moreover, the Applicant observed that, in general, the presence of a gap in an ordered configuration may lead to production problems even at the workstations following the one where it originated, even before reaching the final step of packaging in a box.

The Applicant has therefore perceived that, in order to avoid that possible gaps of products formed within a production and/or packaging installation may negatively affect subsequent operations, it is necessary to provide, while transporting the products between two generic operating units, a step of compacting the products that restores the desired ordered configuration by filling the possible gaps of products formed in the previous stations.

Finally, the Applicant has found that a product transporter apparatus in which a product compaction unit is interposed between a first and a second conveyor, comprising a support surface for the products and a movement member moving the products of each column one next to the other in an advance direction, makes it possible to obtain compact columns of products without gaps.

Therefore, the present invention, in a first aspect thereof, relates to a transporter apparatus for products comprising a first conveyor, a compaction unit positioned downstream of said first conveyor and a second conveyor positioned downstream of said compaction unit.

Preferably, said first conveyor is arranged to move said products in a first advance direction.

Preferably, on said first conveyor a plurality of suitable seats are defined to receive said products.

Preferably, said compaction unit comprises a support surface arranged to receive said products from said first conveyor.

Preferably, said compaction unit comprises a movement member associated with said support surface and arranged to move products resting on said support surface towards each other in a second advance direction, thereby forming compact columns of products substantially parallel to said second advance direction.

Preferably, said second conveyor is designed to receive said compact columns of products and move them in a third movement direction.

Due to the above-mentioned features, the transporter apparatus of the invention is able to induce a relative motion between products arranged on a support surface so that the products are moved towards each other in an advance direction. This makes it possible to advantageously fill possible product gaps present in the product configuration of the first conveyor and to supply the second conveyor with subsequent rows of products without gaps.

The Applicant has in fact ascertained that, in this way, the gaps are advantageously moved to the rear of the columns advancing on the support surface, while keeping the front rows of products always complete. In other words, possible gaps within the individual column are transformed into a shorter column length, which can in turn be compensated for by the arrival of subsequent products.

Such gap movement may be continuous or discontinuous, depending on the operating modes of the movement member, and may in general be modulated according to process requirements.

The Applicant has also ascertained that such method is particularly effective in absorbing the gaps that are created in a substantially statistical manner within the ordered configuration of products. Such gaps may be due to random errors in the working devices upstream of the first conveyor and are therefore randomly distributed between the different product columns. In this way, the average number of gaps present in the different columns of products remains substantially the same over sufficiently long periods of time, and consequently, the length of the different columns of products remains substantially constant.

The present invention, in a second aspect thereof, relates to a method for transporting products in an apparatus for producing and/or packaging said products.

Preferably, said method comprises the step of arranging said products inside seats which are provided on a first conveyor.

Preferably, said method comprises the step of moving said products in a first advance direction of said first conveyor.

Preferably, said method comprises the step of transferring a plurality of said products from said seats and depositing them on a support surface.

Preferably, said support surface is substantially horizontal.

Preferably, said plurality of products is arranged on said support surface in columns which are substantially parallel to a second advance direction.

Preferably, said method comprises the step of applying a force to said products so as to move them on said support surface towards each other in said second advance direction, so as to form a plurality of compact columns of products.

Preferably, said method comprises the step of receiving said compact columns of products and moving them in a third advance direction.

Thanks to the method of the invention, it is therefore possible to solve the drawbacks arising from the presence of gaps within an ordered configuration of products that must be moved within an industrial production or packaging installation.

In fact, the products, while on the support surface, are moved to form compact columns before being delivered to a second conveyor, which is arranged to receive them and keep them in a compact form so that they can be conveniently processed according to production or packaging requirements. In this way, waste and production losses caused directly or indirectly by one or more product gaps in an ordered configuration are substantially reduced or eliminated.

The present invention, in a third aspect thereof, relates to a system for producing and/or packaging products comprising a transporter apparatus made according to the first aspect.

Preferably, this installation comprises an apparatus for packaging said products positioned downstream of a production apparatus for said products.

Preferably, said transporter apparatus is interposed between said production apparatus and said packaging apparatus.

In some embodiments, said transporter apparatus is provided within said production apparatus, preferably between two workstations of said production apparatus.

In at least one of the above aspects, the present invention may also have at least one of the preferred features set out hereinafter.

In some embodiments said movement member is configured to move said support surface between a first operating position, in which said support surface is substantially horizontal, and a second operating position, in which said support surface is inclined with respect to a horizontal plane.

Thanks to this feature, the products are slided in the advance direction in such a way that they are next to each other within the individual columns, by simply using the force of gravity.

This makes the operation easy to apply and globally cost-effective.

In addition, the degree of inclination may be varied to adequately balance the need for operation speed and the need to limit the force of impact between products while avoiding possible damage to the products. In addition, the degree of inclination may be easily adapted to the characteristics of the products and their ability to slide on the support surface.

In alternative embodiments, said movement member may comprise a plurality of nozzles connected to a pneumatic circuit and suitably directed to move the products along the second advance direction by air jets, or one or more drive belts configured to engage the products of a column and push them along the support surface parallel to the second advance direction.

Preferably, in said second operating position said support surface is inclined with respect to a horizontal plane by an angle greater than 30°, more preferably greater than 60°.

In an embodiment, said support surface is moved between said first and said second position by being pivoted about a rotation axis which is defined at a discharge end of said support surface.

Furthermore, it is preferred that said products are moved on said support surface in said second advance direction by inclining said support surface towards said discharge end.

In this way, the support surface may be inclined while keeping the discharge end and, in particular, its connection with the second conveyor, substantially fixed.

Preferably, said second advance direction is substantially parallel to a direction of maximum slope of said support surface when it is inclined in said second position.

In this way, the movement of the products in the advance direction is more effective.

Furthermore, said rotation axis of said support surface is preferably substantially perpendicular to said second advance direction.

In some embodiments, in said first conveyor, each of said seats is arranged to receive one of said products.

In this way, the position of each individual product on said first conveyor is precisely defined so as to facilitate the full effectiveness of the processing to be carried out thereon.

In some embodiments, in said first conveyor said seats are arranged in a plurality of rows which are substantially perpendicular to said first advance direction.

In a preferred embodiment, said rows may be staggered from each other.

Preferably, in said first conveyor said seats are arranged on a plurality of columns which are parallel to said first advance direction.

In some embodiments, a gripping device is provided to take said products from said first conveyor and deposit them on said support surface.

Preferably, said gripping device comprises a plurality of gripping elements arranged to individually take said products from said first conveyor.

In some embodiments, on said support surface, a plurality of channels are obtained, each of which is formed to receive a single column of said products.

In this way, arranging the products in separate columns and keeping such arrangement when moving the products in the second advance direction are made easier, even during the step of compacting products.

Preferably, said channels are parallel to said second advance direction.

In this way, the products are effectively guided in their movement in the second advance direction, which, in fact, remains defined by the longitudinal development of the channels.

Preferably, said channels extend to said discharge end.

In some embodiments, said second conveyor comprises a plurality of guides, each arranged to receive one of said compact columns of products.

In some embodiments, said plurality of guides supplies a device for packing said products.

In alternative embodiments, said second conveyor is of the multi-track type, with a plurality of seats in which the products leaving the compaction unit are individually placed.

In this way, it is possible to supply a packing device or a transporter of the multi-track type with subsequent rows of products that are always free from gaps.

In one embodiment, said products are capsules for brewing beverages, preferably coffee capsules.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to the enclosed figures,1globally refers to a transporter apparatus of products2, made according to the present invention.

The transporter apparatus1is preferably inserted within a production and packaging installation100comprising a production apparatus101, configured for producing products2, and a packaging apparatus102, arranged for packaging the products2in boxes3.

In particular, the transporter apparatus1is substantially interposed between the production apparatus101and the packaging apparatus102.

In the embodiment described herein, the installation100is arranged for the production and packaging of coffee capsules, which thus constitute the products2and will be hereinafter referred to by that numerical reference.

Referring in particular toFIG.6, the capsules2are substantially identical to each other and comprise a semi-rigid container, e.g. made of plastic material, suitable for containing coffee powder. In this embodiment, the container has a truncated-conical form with a support base2afrom which a side wall2bis erected which is flared towards an upper opening, which, in turn, is perimetrically delimited by a protruding edge2cand is closed by a membrane coupled to such edge. The membrane and protruding edge2cdefine a head2dof the capsule2, which is axially opposed and substantially parallel to the support base2a.

Obviously, the capsules2may be made from different materials and in different forms, depending on their specific use.

The transporter apparatus1, in its main components, comprises a first conveyor5, arranged to move the capsules2in a first advance direction F, a compaction unit10and a second conveyor16.

The first conveyor5runs through the production apparatus101and moves the capsules2between its various workstations, which for example comprise a filling station, in which the capsules2are filled with coffee powder, and a closing station, in which the capsules2, containing the coffee powder, are closed with a membrane coupled, for example by welding, at the respective protruding edge. These workstations are conventional in themselves and are therefore not represented in detail in the enclosed figures.

In particular, the first conveyor5is of the multi-track type and comprises a plurality of seats6arranged in subsequent rows substantially perpendicular to the first advance direction F, where each seat is formed to receive a single capsule2.

In the end region of the first conveyor5, the capsules2are ready to be transferred to the packaging apparatus102to be duly packed.

The latter, in its main components, comprises a box forming and filling unit20and a transporter30that transports the filled and packaged boxes towards possible subsequent stations responsible for their final packaging before being dispatched.

The transporter apparatus1further comprises a pick-up device7, arranged to take the capsules2from the first conveyor5and deposit them on the compaction unit10.

In particular, the pick-up device7comprises a gripping head8on which a plurality of gripping elements8ais mounted, for example of the suction cup type, which are arranged to engage and hold, by coupling, the individual capsules2transported by the conveyor5at the respective heads2d.

The gripping head8is mounted at the end of an arm9and is able to move vertically and horizontally as well as to rotate about its longitudinal axis.

The compaction unit10comprises a plate14, on which a preferably planar support surface11is defined, which is arranged to receive the capsules2deposited by the pick-up device7, as well as a movement member12, arranged to move the capsules2resting on the support surface11towards each other in a second advance direction X towards a discharge end13of the support surface11.

Advantageously, channels15are obtained on the plate14, which are substantially parallel to the second advance direction X and equally spaced apart from each other, within which the capsules2are received and guided in their movement towards the discharge end13. Each channel15extends to the discharge end13and is formed to receive a single row of capsules2able to slide therein.

The second advance direction X is substantially defined by the channels15which is substantially rectilinear and parallel to the support surface11.

The movement member12is configured to make the plate14pivot about a rotation axis Y defined at the discharge end13between a first operating position, in which the support surface11is substantially horizontal (seeFIG.7), and a second operating position, in which the support surface11is inclined with respect to a horizontal plane through a predefined angle, which may be for example about 90°, as represented inFIG.5.

Obviously, the inclination angle of the support surface11in the second operating position will be defined in the most appropriate manner, depending on the characteristics of the product2and the apparatus1, provided that it makes the products2slide towards each other in the support surface11towards the discharge end13. For example, the inclination angle of the support surface11in the second operating position may be lower than 90°, e.g. 70°.

The rotation axis Y is substantially perpendicular to the second advance direction X, so that the latter is substantially parallel to a direction of maximum slope of the support surface11when it is pivoted in the second operating position.

In alternative embodiments, the movement device12may be of another type suitable for moving the capsules2in the second advance direction X, such as belt or air-jet transporters.

The second conveyor16is positioned immediately downstream of the plate14, so as to receive the capsules2coming from the discharge end13.

The second conveyor16may be of any type suitable for transporting the capsules2in a third advance direction Z, which may or may not be distinct from the second advance direction X.

In the embodiment herein described, the second conveyor16comprises a plurality of guides (not shown in the figures) that are formed to appropriately position and orient the individual columns of capsules2coming from the channels15of the plate14.

The guides of the second conveyor16are inclined downwards so that the capsules2may slide therein by gravity.

Downstream of the second conveyor16, there is provided a packing device17which receives the capsules2and deposits them, in a predefined ordered configuration, inside the boxes3.

The packing device17comprises a plurality of gripping devices18, radially placed on a carousel19rotatable about a horizontal rotation axis.

For this purpose, each gripping device18may comprise a pair of grippers intended to laterally engage the row of capsules2being discharged from the second conveyor16, at the protruding edges2c. Each gripping device18is also advantageously provided with a radial movement, thus making it easier to either properly receive the capsules2being discharged from the second conveyor16and deposit them into the box3.

The box forming and filling unit20comprises a carousel21, having a horizontal rotation axis, provided with a plurality of equipment22, radially extended from the carousel21and arranged to form, in cooperation with one or more members external to the carousel21, a box3from a cardboard sheet3a, suitably shaped and creased (called blank) supplied individually to an equipment22by a feeder23.

Such operation of forming the box3, providing for example folding subsequently the blank and gluing together respective panels at predefined points, is in itself well-known in the packaging machine sector and will therefore not be explained in further detail.

The carousel21is synchronously associated with the carousel19of the packing device17, such that each row of capsules2taken from a gripping device18is deposited into a box3, formed but not yet closed, brought at the gripping device18by a respective equipment22of the carousel21.

The box forming and filling unit20also comprises a box closing station (not shown) which provides to close the box3after the capsules2have been inserted.

The production and packaging installation100, with particular reference to its transporter apparatus1, operates according to the following modes.

The empty capsules2are positioned in the seats6of the first conveyor5, which provides to move them between the different workstations of the production apparatus101in the first advance direction F. In this way, the capsules2are first filled with coffee powder and then closed with a special membrane.

The seats6are arranged so as to form on the first conveyor5a plurality of rows which are substantially perpendicular to the first advance direction F. However, during the production step, one or more capsules2may not be present within the respective seat6, or one or more capsules2may not comply with the production specifications such that they have been discarded or must be discarded at the end of the production step. In the latter case, for example, the capsules2to be discarded are not taken by the gripping head8and are dropped into a waste collection basket5aappropriately provided at the end of the first conveyor5.

These events may be due to many reasons, such as a jamming in the supply of empty capsules, or a malfunction of one or more of the devices for filling or closing the capsules2.

In such cases, gaps A are formed on the first conveyor5, i.e., seats6that are empty or occupied by non-compliant capsules2and therefore cannot be transported to the packaging apparatus102.

At the end of this production step, the capsules2, still carried by the first conveyor5, are taken from the pick-up device7by the gripping head8(FIG.1).

The latter is then raised by the arm9until it is at the height of the supply station11(FIG.2), rotated by 90° so as to align the gripping elements8awith the channels15(FIG.3), moved over the plate14and finally lowered to deposit the capsules2inside the channels15of the plate14(FIG.4). The capsules2deposited inside the channels15define respective columns C of capsules2, substantially parallel to the second advance direction X.

In order to properly receive the capsules2deposited by the pick-up device7, the plate14is maintained in the first operating position so that the support surface11is substantially horizontal (FIGS.1-4andFIG.7).

It will be noted that in this step of transferring the capsules2from the first conveyor5to the plate14, the gripping elements8aintended to take a capsule2at a gap A remain empty, without the respective capsules2.

In this way, the possible gaps A present on the first conveyor5are substantially carried over to the plate14(FIG.7), so that within the channels15the columns C of the capsules2may not be compact.

The plate14is then moved to the second operating position by rotating it about the rotation axis Y (FIG.5). During this rotation, well exemplified inFIG.8by the arrow R, the plate14is inclined with respect to the horizontal plane causing the capsules2to slide in the second advance direction X defined by the channels15in which they are located.

In particular, each capsule2slides towards the discharge end13in the respective channel15, until it comes to rest against a capsule2preceding it within the same column, so as to form a compact column C′, free from gaps A.

The gaps A are then moved to the rear of their respective columns C′, so that the length of each compact column C′ also depends on the number of gaps A present in the starting column C.

Such smaller column length, however, may possibly be recovered from the capsules2brought to the plate14by the pick-up device7in the following working cycle.

The capsules2arrived at the discharge end13are then received by the second conveyor16which moves them in the third advance direction Z up to the packing device17, where, each row of capsules2exiting the second conveyor16is taken by one of the gripping devices18and brought by the carousel19to a box3, formed and opened, held by an equipment22of the carousel21, within which it is deposited.

The box3, containing the capsules arranged in the desired configuration, is then closed at the following box closing station and deposited on the transporter30, which provides to bring it to the following stations.

It will therefore be noted that the rows of capsules2arriving at the packing device17from the second conveyor16are free from gaps A, so that the boxes3can be properly filled.

Thanks to the compaction unit10, the transporter apparatus1therefore allows to obviate (at least to a limited extent) possible drawbacks that may occur during the production step of the capsules2and that may cause undesired gaps in the ordered configuration leaving the production apparatus101.

Obviously, a person skilled in the art may, in order to meet specific and contingent application requirements, make further modifications and variants, all falling within the scope of protection as defined by the following claims.