Adjustable guide for a bottle handling system

The present invention is directed to an adjustable guide for a container conveyor system. The guide includes multiple pairs of pivoting mechanisms located along the conveyor. Each pivoting mechanism includes a first pivot arm and a second pivot arm which can be independently manipulated to locate a guide within a container envelope. The multiple pairs of pivoting mechanisms are operable coupled by a set of drive cables to permit simultaneous adjustment of the pivoting mechanisms.

FIELD OF THE INVENTION

The present invention relates to a container handling system, and more particularly to a bottle handling system which includes an adjustable guide system along a conveyor.

BACKGROUND OF THE INVENTION

Currently, various packaging and shipping methods are used to transport containers, such as bottles, from one location to another. As such, it is often necessary to provide a bottle conveyor to transfer bottles from one machine to another in the handling process. Such conveyor systems will often utilize a guide rail assembly to maintain the proper orientation of the bottle as it is transferred along the conveyor. One such conveyor system is an air conveyance system which requires relatively accurate side rail positions to ensure efficient and accurate movement of the bottles along the length of the conveyor. Thus, guide rail assemblies of this type are typically constructed as a fixed element relative to the conveyor structure and having a means for making minor adjustments to the rail position.

One conventional method for supporting and positioning such guides along the conveyor involves the use of air cylinders. A plurality of air cylinders are coupled along the conveyor to provide guides for the body of the containers. Adjustments to the guides are made by actuation of the air cylinders. Such systems require extensive plumbing of air line to individually adjust end guide location. This conventional method is designed for specific bottles. When the bottles to be produced are changed the entire system must be reworked. If desired, the cost for such a change can approach the initial cost of the conveyor system.

In recent years, however, variations in shapes and sizes of containers have proliferated. Accordingly, it is desirable to have a system which allows guide rails along a conveyor to be continuously adjusted so that an initial system may accommodate any bottles in the future.

SUMMARY OF THE INVENTION

The present invention positions guides along a conveyor for a container packaging system. As such, the present invention provides the following advantages: substantially simultaneous adjustment of a plurality of guide rails, thereby providing rapid repositioning; adjustable along a nonlinear conveyor path; readily adaptable to be retrofitted to existing conveyor systems; provides for independent 2-axis adjustment for bottle height and width; utilization of a single drive mechanism for adjustment of guide rails along an extended length of conveyor; and flexibility for the location of the drive mechanism relative to the conveyor system (i.e. upstream or downstream location).

A pivoting structure for positioning a guide along a conveyor for a container packaging system according to the principles of the present invention includes a pivot base. A first pivoting member is rotatably connected to the pivot base, and a second pivoting member is rotatably connected to the first pivoting member. A guide is disposed on an end of the second pivoting member. A first connecting element is coupled to the first pivoting member and operable to rotate said first pivoting member through a first range of motion. A second connecting element is coupled to the second pivoting member and operable to rotate said second pivoting member through a second range of motion independent of the first range of motion. The second connecting element is arranged at a location to avoid unwanted torque on the first pivoting member. Movement through the first range of motion and the second range of motion locates the guide within a container shape envelope.

In another aspect of the present invention, a conveyor system having adjustable guides includes a system base and a conveyor for a container packaging system. A plurality of pivoting structures are coupled along the conveyor, and an actuation system is coupled to the pivoting structures. The pivoting structures are coupled along opposing sides of the conveyor. Multiple guides along a common side of the conveyor are intercoupled to form guide assemblies. The pivoting structures are operable by the actuation system to locate each of the guide assemblies to corresponding positions within a container shape envelope.

In another aspect of the present invention, a method of positioning guides along a conveyor for a container packaging system is disclosed. The method includes: (1) manipulating a drive element to substantially simultaneously operate a plurality of pivoting structures to locate a guide assembly associated therewith in a container shape envelope and (2) fixing the drive element with respect to a conveyor to locate guides of the pivoting structures to corresponding positions within the container shape envelopes.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now toFIG. 1, a conveyor system10for a container packaging system is shown. Conveyor system10includes conveyor12along which containers14are transported from infeed machine16to discharge machine18. Infeed machine16collects a plurality of containers14and introduces them to the conveyor system10which accumulates and transports containers to discharge machine18. Conveyor system10also includes a plurality of pivoting structures20coupled along conveyor12. Pivoting structures20are operable to locate guides along conveyor12as is described in more detail below.

Additionally, conveyor system10includes an actuation system22operably coupled to the pivoting structures20. Actuation system22includes drive elements24coupled to a plurality of pivoting structures20for operating the pivoting structures substantially simultaneously as described in more detail below. Actuation system22may also include one or more actuators26. Each actuator26powers a drive element24to operate a plurality of pivoting structures20for locating the guides in a container shape envelope as is described in more detail below.

Referring now toFIG. 2, each pivoting structure20includes a pair of pivoting mechanisms120,220. Pivoting mechanisms120,200are each coupled along conveyor12. Conveyor12is a part of a container packaging system and includes neck guide38. Neck guide38supports the containers traveling along conveyor12and, in combination with the guides48of pivoting mechanisms120,220, routes the containers being transported along conveyor12. As pivoting mechanisms120,220are substantially similar, only pivoting mechanism120will be described in detail herein. It is to be understood that the description of pivoting mechanism120and its components equally applies to pivoting mechanism220and its corresponding components.

Pivoting mechanism120includes pivoting members40and42. First pivoting member40is rotatably connected to conveyor12at pivot44and is operable to rotate through a first range of motion. Second pivoting member42is rotatably connected to first pivoting member40at pivot46and is operable to rotate through a second range of motion independent of the first range of motion of first pivoting member40. Pivoting mechanism120also includes guide48. Guide48is disposed on an end of second pivoting member42. According to the principles of the present invention, guide48interacts with containers being transported along conveyor12. As pivoting mechanism120includes two pivoting members40and42with independent ranges of motion, guide48is able to be located in at least a two-dimensional area as described in more detail below.

Additionally, pivoting mechanism120includes two connecting elements50and52. As shown inFIG. 2, connecting elements50and52are coupled to pivoting members40and42with eyebolts54and56. Connecting elements50and52are coupled to drive elements60and62. As presently preferred, connecting elements50and52are made of flexible cabling supported along conveyor12by pulley structures66,68,166, and168. Pulley structures66and68are shown inFIG. 2, and pulley structures166and168are shown inFIG. 4A. Connecting element50follows a path underneath pulley structure66and over pulley structure68to couple to pivoting member40at point54. Connecting element52follows a path underneath pulley structure168and over pulley structure166to couple to pivoting member42at point56. Such paths orient connecting elements50and52in positions to operate pivoting members40and42.

Referring again toFIG. 2, connecting elements50and52are operably coupled to pivoting members40and42, respectively, to be able to operate the pivoting members through the independent ranges of motion described above. The combination of these ranges of motion with respect to guide48is shown inFIG. 2as travel envelope70. Travel envelope70shows that guide48can be located in a two-dimensional area.FIG. 2also shows container shape envelope72. Container shape envelope72represents an area of desired locations of guide48corresponding to various sizes and shapes of containers to be transported along conveyor12. Thus, travel envelope70substantially overlaps container shape envelope such that pivoting mechanisms120,220can be used to locate the guides48in a wide range of positions to accommodate different containers.

InFIGS. 3A and 3B, top views of drive elements60,62and related components are shown. Referring toFIG. 3A, drive elements60,62are shown and include a drive cable124. With reference toFIGS. 3 and 4, it is to be understood that the description of drive element60and its related components equally applies to drive element62and its corresponding related components. Drive cable124is coupled to base80via a spring assembly82. Spring assembly82is coupled between drive cable124and base80to maintain drive cable124in tension. Tension is needed in drive cable124in order to operate a plurality of pivoting structures substantially simultaneously as described in more detail below, as well as to minimize sag of the drive cable124.

Referring now toFIG. 3B, an enlarged view is shown of drive element60which couples drive cable124to pivoting mechanism120via connection elements50. Drive cable124is coupled to connecting element50by clamping element84. Clamping element84enables forces to be transmitted from drive cable124to connecting element50. Multiple clamping elements84coupled along drive cable124allow drive cable124to operate a plurality of pivoting structures substantially simultaneously as is described in more detail below. Pulley structures86and88maintain the alignment and position of drive cable124and connecting element50, respectively. A cable guide90is also included and is described in further detail below with reference toFIG. 4B.

Referring now toFIGS. 4A and 4B, connecting elements50and52are connected to drive elements60and62; pulley structures66,68,166, and168; and pivoting members40and42. With specific reference toFIG. 4B, an enlarged side view is shown of drive cable124coupled to drive element60as depicted inFIGS. 2,3A,3B, and4A. Drive cable124and connecting element50are coupled by clamping element84. Drive cable124is aligned and positioned by pulley structure86(shown inFIG. 3B) and connecting element50is aligned and positioned by pulley structure88. Connecting element50travels through cable guide90which functions to align connecting element50to engage pulley structure88.

Referring now toFIG. 4Can alternate arrangement of the drive elements60′ and62′ is shown in which machined blocks are used in place of pulleys for directing the connecting elements50′ and52′ from drive cable124to pulley structures66,68,166, and168for operating pivoting members40and42. In this regard, drive elements include blocks60′ and62′ which have a machined radius formed therein to provide a guide surface over which the connecting elements50′ and52′ can slide. This configuration combines enables the functions provided be the pulleys and the guide elements illustrated inFIGS. 4A and 4Bto be combined in to a single component. An adjustment elements51′ and53′ in the form of a turnbuckle or the like may be incorporated into the connecting elements50′ and52′ to provide a degree of adjustment for the lengths thereof.

By using flexible drive cable, the present invention is readily adaptable for use along a tortuous conveyor path which may rise or fall in elevation as well as turn in various directions. Referring now toFIGS. 5A and 5B, conveyor112, which has a nonlinear path, is shown. Pivoting mechanisms120are coupled along opposing sides of conveyor112. According to the principles of the present invention, pivoting structures120are operable to locate guides148,148′ disposed on ends of pivoting mechanisms120along conveyor112. Guides148,148′ can be coupled with other guides such as a guide bars248,248′ along the same side of conveyor112to form a guide assembly or alternately may separate but move in a coordinated manner with respect to guide bars248,248′. Drive cables124are coupled to pivoting mechanisms120and transmit power to operate pivoting mechanisms120substantially simultaneously. Pulley structures92engage with and route drive cables124along the nonlinear path of conveyor112.

The operation of the present invention is substantially consistent in a variety of configurations and along a variety of paths. First, actuators26are coupled to drive cables124and pull the drive cable124against the bias of spring82to operate a plurality of pivoting mechanisms20substantially simultaneously. Drive cables124move axially, and that movement is translated to connecting elements50and52through clamping members84. The movement of connecting elements50and52causes pivoting members40and42to rotate and guides48to change location. In this manner, drive element60is used to position pivot member40and drive element62is used to position pivot member42.

When the combination of movement has positioned guides48at the desired locations within container shape envelopes72, actuation system22then fixes drive cable124. As drive cables124are in tension, the positions of all the components are maintained. When a container14with a different shape needs to be accommodated, the locations of guides48may be changed accordingly.

A preferred configuration of the present invention would include one pivoting structure20on each side of conveyor12for every five feet of conveyor12. Additionally, a preferred configuration would include a multiple of actuators26, the number depending on the number of drive cables124in the system. As presently preferred, a single actuator26can be used to position one hundred feet of drive cable124in each direction. Thus, in such a configuration, one drive element24and one actuator26could operate up to forty pivoting structures20. Actuators26are included which can provide a desired accuracy corresponding to the size of container shape envelopes72. Suitable actuators26may include fluidic muscles, pneumatic motors, hydraulic and pneumatic cylinders stepper motors, servo motors, stepped air cylinders, and servo air cylinders, but it is anticipated that others may be used.

The components of the present invention can be made of a variety of materials. In a typical embodiment of the present invention, the drive elements and the connecting elements are flexible drive elements. As such, suitable materials for both include wire rope and steel cables. It is anticipated that other materials can be used for both of these elements. Pivoting members40and42, clamping members84, pulley structures66,68,86,88, and92, and directing structures90that are included in the present invention are preferably substantially rigid and can be made of a variety of suitable materials in accordance with the given application. Guides48can be shaped to correspond to the path of conveyor12and must be rigid enough to maintain shape while interacting with containers14traveling along the conveyor12.

According to the principles of the present invention, conveyor12can have paths of various shapes, and containers14can have a variety of shapes and sizes. It is anticipated that pivoting structures20can be located in various configurations along conveyor12. It is also anticipated that connecting elements50and52may be coupled to pivoting members40and42in a variety of ways. It is to be understood that pivoting mechanisms120,220can be configured to operate according to the principles of the present invention independent of pulley structures66,68,166, and168. Additionally, travel envelope70is variable with respect to the size and configuration of the components of pivoting structure120, and container shape envelope72varies with the applications of the container packaging system.

Additionally, pulley structure86is shown as an exemplary way to provide support for drive cable124. It is to be understood that a variety of structures could support drive cable124, including pulleys, semi-circular channels and tubes as dictated by the given application. The use of pulley structures or semi-circular channels would allow for less complicated assembly than the use of tubes. Pulley structures also would help prevent water build up in the system. Additionally, a tube could help prevent unwanted motion of a drive element which may cause the drive cable to jump off line.