Coordinated soft-touch case packer

Disclosed is a product case packing system with a gripping head assembly and a packaging grid assembly linked by a coordination arm that synchronizes the delivery of the product to be packaged and with the positioning of the grid assembly into the packaging container. The system includes a gripper head assembly extension control module, capable of controlling multiple travel distances of the gripper head assembly in a single packing cycle, a product assembly detection module, and a packaging release control element for subtle separation of individual packed containers.

Not Applicable

BACKGROUND OF THE INVENTION

This invention relates generally to automated packaging machines, and, more particularly, this invention relates to improvements of a coordinated movement of the gripper and grid sections for automatically packaging of groupings of distinct product items.

The field of automated packaging addresses the process of combining multiple distinct product units into a bulk container, to aid in storage and transportation for distribution, in a variety of ways. One common automated packaging machine may be seen to divide up the product and drop it into a box or case. Another machine stages the product as it flows, and captures a grouping of the product to relocate that grouping of product into the packaging box, or other suitable item, such as a carton, container, case, tray, or shell. These types of packaging machines can be seen to consist of a product feed section, a carton feed section, a load section, and an operator interface section. A quantity of product suitable for the capacity of a particular carton may be enough product to fill the carton, or enough to fill multiple cartons, or enough to fill a carton with multiple cycles of the packaging machine.

The operator interface section controls the system and allows the operator to manage the operation of the machine. It typically consists of a series of pushbuttons activators, along with read-out lights or displays, which enable the operator to start, stop, or alter the performance of the machine, and locate/correct any fault conditions.

The product feed section of the packaging machine includes a conveyor belt that transfers the product generally from an up stream process such as filling or labeling to the load section of the machine. The conveyor belt urges the product into lanes that align the product into a plurality of rows, and into the load section.

While the feed section fills the load section with product, the case feed section delivers empty boxes, cartons, or cases to the lift section via a conveyor. U.S. Pat. No. 3,353,331 issued to Rowekamp on 21 Nov. 1967, U.S. Pat. No. 3,561,189 issued to Raudat on 9 Feb. 1971, U.S. Pat. No. 2,921,425 issued to Seval on 19 Jan. 1960, U.S. Pat. No. 3,589,094 issued to Pearson on 29 Jun. 1971, U.S. Pat. No. 3,744,213 issued to Pearson on 10 Jul. 1973, U.S. Pat. No. 3,832,826 issued to Ullman on 3 Sep. 1974, and U.S. Pat. No. 4,457,121 issued to Johnson and Raudat on 3 Jul. 1984, demonstrate that the prior art teaches a variety of ways to deliver the grouped individual products into the cartons, once they are in the load section. However, none of these systems achieve the simplicity and compact footprint of the current system.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENT

Now, referring toFIG. 1, the exemplary embodiment of the current packing system100is shown to comprise a product feed section102, a packing unit104, and a packaging feed section106. The product feed section102is configured to assemble and position multiple distinct product units10into an orderly configuration for coordinated delivery into a bulk container. A product conveyor108transports the individual product units10, also referred to as product, into a product assembly unit110that detects proper configuration and permits product units10to be conveyed by the packing unit104. The packaging feed section106is configured to assemble and position multiple distinct carton units20, also simply referred to as cartons, into an orderly configuration for receiving groupings of product units10from the packaging unit104. A package conveyor112transports the cartons20into the carton management unit114, where the cartons20receive the coordinated product units10from the packaging unit104, and then are released to be assembled for bulk distribution.

The packing unit104transports the product10from the vicinity of the product assembly unit110to the cartons20positioned in the vicinity of the carton management unit114. The exemplary packing unit104is comprises a gripper head assembly116, a grid assembly118, a coordination arm120, three parallel arms122, and a gripper head elevator124. The gripper head assembly116and the gripper head elevator124are components of the exemplary pick-up assembly126. The grid assembly118may also be simply referred to as the grid, and the gripper head elevator124may also be simply referred to as the elevator. The coordination arm120and the parallel arm122are shown on one side of the gripper head assembly116. Each of the shown exemplary coordination arm120and the parallel arm122has a paired parallel arm on the opposite side of the gripper head assembly116. The rigidity of the exemplary packing unit104permits the exemplary design to forego placing an additional coordination arm120on the opposite side. In the exemplary embodiment, the gripper head assembly116is supported by the coordination arm120and three parallel arms122.

The exemplary packing unit104additionally comprises a coordination actuator128that affects the coordinated motion of the pick-up assembly126and the grid118. The coordination actuator128functions to create coordinated motion through repeatable cycles, where in each full cycle a full carton20of product10is transported from the vicinity of the product assembly unit110to the carton20in the vicinity of the package management unit114.

A suitable exemplary grid assembly118is described in U.S. Pat. No. 4,075,819, issued to John L. Raudat et al., on 28 Feb. 1978, and U.S. Pat. No. 4,448,009, issued to John L. Raudat (the current inventor), on 15 May 1984, which patents are both incorporated herein by reference to provide a detailed description of exemplary grid assemblies118and their function.

Referring now toFIG. 2, the exemplary packing system100has a lower stop202positioned in the vicinity of the product assembly unit110. The lower stop202interrupts the full potential downward stroke of the gripper head elevator124at the precise level above the product10. The elevator124has the potential for a long stroke, useful in delivering the product10into the carton20. Separate short-stroke and long-stroke elevators may be employed as an alternative, but the lower stop202permits the use of a single elevator to facilitate both product10pick-up from the product assembly unit110, and delivery to the carton20in vicinity of the package management unit114. In the exemplary embodiment, packing system100has a right side and left side lower stop202, in order to engage on two sides of the gripper plate204, and more effectively distribute the forces at the stop point.

The exemplary gripper head assembly116comprises a gripper plate204, gripper tubes206, and grippers208. In the exemplary embodiment there is a specific gripper tube206and gripper208for each product unit10to be picked up by the gripper head assembly116in each cycle. A suitable exemplary gripper head assembly116is described in U.S. Pat. No. 7,522,570, issued to John L. Raudat et al., on 30 Jun. 2009, which patent is incorporated herein by reference to provide a detailed description of an exemplary gripper head assembly116and its function. A suitable exemplary gripper208is described in U.S. Pat. No. 2,873,996, issued to Charles J. Mchugh et al., on 17 Feb. 1959, which patent is incorporated herein by reference to provide a detailed description of an exemplary gripper208and its function.

In the present exemplary embodiment, the gripper head assembly116is raised and lowered in a straight line by the elevator124. When positioned in the vicinity of the product assembly unit110, the downward stroke of the gripper head assembly116is interrupted by the gripper plate204contacting the lower stop202. The exemplary lower stop202is designed to absorb the impact of the downward motion of the gripper head assembly116. The exemplary lower stop202is a rigid steel rod, with a resilient elastomeric cap that contacts the gripper plate204, and cushions the impact.

Components of the exemplary packing unit104are shown in greater detail inFIG. 3. The exemplary coordination arm120is shown to have a lead arm302and a follow arm304. The lead arm302is shorter than the follow arm304, and measures slightly over half the length of the follow arm304. The exemplary angle A between the centerline of the lead arm302and the follow arm304is 75 degrees, with angles from 70 degrees to 80 degrees believed to be operational. The coordination arm120and the parallel arms122are attached to the packing system100frame at frame pivot points306, and to the pick-up assembly126at pick-up pivot308. Frame pivot points306and pick-up pivot308for the coordination arm120and the parallel arms122are spaced an equal distance apart. Since the pick-up point may change as the characteristics of the particular product and carton vary, so the lengths of the lead arm302, follow arm304, and angle A can be adjusted to adapt to the particular product and carton dimensions.

The grid118is linked to the pick-up assembly126through rigid coordination arm120and grid link rod310. Grid link rod310is attached to the lead arm302at link rod pivot312, and the grid118at grid pivot314. Grid link rod310is a rigid material that maintains a set distance between the link rod pivot312and the grid pivot314, thereby coordinating the movement of the pick-up assembly126and the grid118. By adapting the lengths of the lead arm302and the follow arm304, as well as the grid link rod, other angles for angle A, between 85 degrees and 95 degrees, may be operational.

The grid118is attached to the coordination actuator128by grid drive rod316, which also attaches to the grid118at grid pivot314. Though grid drive rod316and grid link rod310both attach to grid118at grid pivot314, they may be attached independently. Grid drive rod316is a rigid material that imparts motion directly from the coordination actuator128to the coordinated components of the pick-up assembly126. In the exemplary embodiment, grid118travels along a part of the length of grid guides318. Exemplary grid guides318are straight, parallel, rigid rods that are housed within compressible springs, so that the grid guides318direct the travel of the grid into a precisely positioned carton20, and the springs assist the coordination actuator128to lift the grid118during part of the packing system100packing cycle.

Referring now toFIG. 4, the exemplary packing system100coordinatedly moves through a packing cycle400, that has an infinite number of positions to accomplish the steps of402staging product10,404picking up product10,406staging a carton20,408staging product, which in the exemplary embodiment includes simultaneously410positioning the grid118in the carton20and412transporting product10to a position over the grid118,414lowering the product10to the grid118,416releasing the product10through the grid118, and418returning the packing system100to the beginning of the packing cycle400to pick up another grouping of product10and repeat the process as appropriate.

Referring now also toFIGS. 5 through 11, the exemplary cycle400starts with product appropriately positioned by the product assembly unit110, and the gripper head assembly116in a raised position. The position of the coordination arm120in this example is referenced from the relative position of the pick-up pivot308of the follow arm304with respect to its path of travel in an arc around its frame pivot point306. So referenced, exemplary step404, picking-up product, is accomplished at 30 degrees before top dead center (“TDC”).

Step404, picking-up product, is accomplished by elevator124lowering gripper head assembly116until the gripper plate204rests on the lower stop202. At this point grippers208are each positioned over a product10, and an air supply is applied to the interior bladder of gripper208through gripper tube206, holding each product10in a respective gripper208firmly enough to affect the lifting and transport of the product10. Lifting is affected by elevator124, while transporting is affected by coordination actuator128, which rotates coordination arm120around its frame pivot point306through the linkage of the grid drive rod316, to the grid118, to the grid link rod310, to the coordination arm120.

While the gripper head assembly116secures the product10, the packaging feed section106performs step406, staging a carton20in the vicinity of the package management unit114. Once the carton20is in position, the packing system100may perform step408, staging product, which includes step410, positioning the grid118in the carton20, and step412, transporting product10to a position over the grid118. Packing system100performs steps410and412simultaneously, because of the geometric linkage of the pick-up assembly126and the grid118through the coordination arm120. Exemplary step410occurs as the coordination arm120rotates from 30 degrees before TDC, to TDC, to 30 degrees after TDC, and then to 60 degrees after TDC. During this rotation the grid118, which is attached to the shorter lead arm302, travels distance from a raised position above carton20, to a lowered position within a carton20. At the same time, exemplary step412occurs, since the coordination arm120links the grid118to the gripper head assembly116. During the rotation the gripper head assembly116, which is attached to the relatively longer follow arm304, travels a distance greater than the grid118, and moves from a position over the product assembly unit110to a position over the grid118.

In the exemplary embodiment, at 60 degrees after TDC the grid118stops a short distance from the bottom of the carton20. In this situation a short distance is a distance at which the grid118can controllably route the individual product10into the carton20from the gripper head assembly116without damage to the product10or carton20. Additionally, at 60 degrees after TDC the gripper head assembly is directly over the grid, but at a slightly too great of a distance to safely deliver the product10through the grid118.

In the exemplary embodiment, with the coordination arm120at 60 degrees after TDC, the packing system100performs step414, lowing the product10to the grid118by activating elevator124to complete a full downstroke, uninterrupted by lower stop202, which is only located on the frame over the product assembly unit110. In this position, at 60 degrees after TDC, and the gripper head assembly116lowered to within an effective distance of the grid118, the packing system100can perform step416, releasing the product10through the grid118, by releasing the vacuum applied to the product10through the gripper head assembly116.

In step418, the packing system100returns to the beginning of the packing cycle400to pick up another grouping of product10. The packing system100returns the gripper head assembly116to a raised position by activating elevator124to its full upward stroke. Additionally, in the exemplary embodiment, coordination actuator128operates to push the grid118to its upward position, in turn driving the coordination arm120through the return arc from a position of 60 degrees after TDC, to 30 degrees TDC, to TDC, and on to 30 degrees before TDC, so that the pick-up assembly126is once again positioned over the product10assembled by the product assembly unit110.

Referring now toFIG. 12, an exemplary dual-conveyor drive motor assembly1200. The exemplary embodiment has a motor sprocket1204capable of driving multiple drive belts. In the exemplary embodiment, motor sprocket1204is configured to drive product drive belt1208, which in turn drives product sprocket1206, and package drive belt1212, which in turn drives package drive belt1210. The exemplary product sprocket1206includes a selective drive mechanism1214capable of permitting the product sprocket1206to stop, while the product drive belt1208continues to move. An exemplary suitable selective drive mechanism1214may be clutch1214, which may be controllably engaged and disengaged through a pressurized air supply used to control other components of the packaging system. Alternatively, the selective drive mechanism1214could be an electrically driven clutch. An assembly arm1216is shown in a raised position to restrain the product10in the vicinity of the product assembly unit110. An exemplary product assembly unit110is shown and discussed in greater detail inFIGS. 18 through 20, below.

Referring now toFIG. 13, an exemplary product assembly bumper1302includes individual components that sense the appropriate presence of product10in the vicinity of the product assembly unit110. The exemplary product feed section102assembles the product10into individual lanes. A plurality of assembly bumpers1302may be arranged so that each lane has a bumper1302. The exemplary bumpers1302are slightly spring loaded, to cause a bumper1302to move into a particular position when the respective product lane is filled with product10. Each bumper1302includes a body through which is a formed a sight channel1304. The exemplary embodiment employs a light source1306on one side of the bumper array, and sensor (not shown) on the other side of the array, to detect when the sight channels1304of the entire array of bumpers1302align, permitting the light source1306to shine light on the sensor (not shown).

Referring now toFIGS. 14 through 17, an exemplary package management unit114is shown to have a package stop1402, which is part of a package stop assembly1602. The exemplary package stop1402has a raised position, shown inFIGS. 14 and 16, and a lowered position, shown inFIGS. 15 and 17. Stop assembly1602may include a package stop1402, a stop actuator1604and a stop arm1606. The exemplary package stop1402is operatively attached to the stop actuator1604through stop arm1606.

An additional component of the exemplary embodiments ofFIGS. 14 through 17is a kicker wheel1404. Where the inside surfaces of the package conveyor112, which doubles back against itself, are separated by a distance h, the exemplary kicker wheel1404has a radius R, which is greater than ½ h. The greater radius means that the surface of the kicker wheel1404is raised slightly above the outer surface of the package conveyor. Additionally, the greater radius means that the surface of the kicker wheel1404moves at a greater circumferential velocity than the package conveyor112. The greater velocity results in giving a filled package20, which has been released by the stop1402, a slight boost of speed relative to the subsequent packages20. The boost of speed creates separation, permitting the stop1402to be raised after the filled packages20passes, just in time to stop the next package20to be filled.

Referring now toFIGS. 18 through 20, an exemplary product assembly unit110assembles the product10for pick-up by the pick-up assembly126. An exemplary product sprocket1206is operatively attached to product conveyor108to effect movement of the product units10thereon. Though a limiter bar (not shown) spanning between assembly arms1216on each side of the product conveyor108may effectively inhibit product10from going off the end of the product feed section102, the exemplary embodiment employs a selective drive mechanism1214to permit the product sprocket1206and product conveyor108to stop, while the drive motor1202continues to run to move packages20into position to fill, and on after being filled.

In operation, the product conveyor108moves product10into position to be picked-up by the pick-up assembly126, while the package conveyor112moves packages20into position to be filled by the pick-up assembly126. When each lane of product10is appropriately filled with product10, the array of bumpers1302permit the light source1306to activate the sensor (not shown), which in turn engages the clutch1214, stopping the movement of the product conveyor108. With the product conveyor stopped, the product assembly unit110can lower the assembly arms1216with assembly actuator1802. Lowering assembly arms1216lowers the attached limiter bar (not shown), so that product10, lifted by the pick-up assembly126, can clear the limiter bar without requiring greater lifting from the product conveyor108. Lowering the limiter bar additionally permits step408, staging product, which includes step412, transporting product10to a position over the grid118, to more rapidly follow step404, picking-up product, since the product10need only be lifted a short distance to clear the lowered limiter bar.

In the exemplary embodiment, the sensor attached to the bumpers1302engages the clutch1214, but does not disengage the clutch1214, since it would do so as soon as the product10is lifted from the product conveyor108, if not when the product conveyor108stops. A subsequent sensor disengages the clutch1214and starts the product conveyor108once the step412, transporting product10to a position over the grid118, moves the product10being packed out of the way. The exemplary embodiment uses a sensor that detects a position of the coordination arm120or parallel arm122that indicates the product10being picked-up are out of the way of the incoming product10.

Referring back toFIGS. 3, 12, 13, 18 and 20, exemplary step404, picking-up product, is accomplished at 30 degrees before top dead center (“TDC”), but a range between 25 degrees and 35 degrees may be adaptably suitable. Initiating step404with coordination arm120at a slightly greater degree off TDC, for example 31 degrees or 32 degrees, up to 35 degrees, or even greater, will create a steeper angle of ascent of the product10off product conveyor108, permitting the bottom of product10to more quickly clear the product assembly unit110, specifically the limiter arm (not shown) that extends perpendicular across the product conveyor108.

Various adjustments may then be made within the scope of the teachings of this disclosure to compensate for this additional angle during either or both lowering product step414and releasing product step416. The exemplary initiation of staging the product step408occurs as the coordination arm120rotates from 30 degrees before TDC, to TDC, to 30 degrees after TDC, and then to 60 degrees after TDC. Ranges between 25 degrees and 35 degrees before and after TDC may be adaptably suitable, and ranges between 55 degrees and 65 degrees after TDC may be adaptably suitable. The range of the range of motion of the staging the product step408may be adjusted by the travel length of the stroke of the coordination actuator128and the length of both the grid drive rod316and the grid link rod310. Any combination of a longer extension of the coordination actuator128, grid drive rod316and the grid link rod310will expand the before TDC angle at the picking-up product step404and the initiation of staging product step408. Any combination of a shorter extension of the coordination actuator128, grid drive rod316and the grid link rod310will expand the after TDC angles at the end of the staging the product step408. The total travel distance of coordination actuator128may be set to have staging product step408start at an angle of about 31 degrees or 32 degrees before TDC, and have staging product step408end at an angle of about 61 degrees or 62 degrees after TDC.

However, since angle A would remain the rigid the product10drop distance from when the product10is released from the gripper head assembly116until it is interfaces with grid assembly118to be controllably deposited into a carton20, barring any other geometric changes, would remain the same. In an alternate exemplary embodiment, coordination arm120may be lockably hinged, permitting the infinite adjustment of the angle A.

The foregoing disclosure and description is illustrative and explanatory thereof. Any present invention should only be limited by the allowed claims and their legal equivalents. The allowed claims should be given their broadest interpretation, given the reasonable meanings of the words used herein, combined with the reasonable interpretation of one having ordinary skill in the art of automated packaging machines. The inventor trusts and relies on these legal principle, in order to avoid being unnecessarily repetitive and verbose. Various changes in the details of the illustrated construction may be made within the scope of the appended claims by one having ordinary skill in the art without departing from the spirit of the invention and scope of the claims.