Can end counting system

A can end counting system comprises an elongate trough-like member for receiving and guiding a plurality of can ends in a substantially upright, nested condition. The trough-like member defines a longitudinal axis and has an entrance end and an exit end relative to the direction of travel of can ends therethrough. A pusher is provided adjacent the entrance end of the trough-like member for pushing the can ends therealong. A resisting apparatus is located along the trough-like member for engaging the can ends in a fashion for maintaining a controlled degree of resistance of the can ends relative to the pusher so as to maintain the can ends in the desired upright and nested condition as they travel through the trough-like member. A counting apparatus is located adjacent the exit end of the trough-like member for producing a discrete detectable signal in response to the passage of each can end thereby, such that the discrete signals may be detected and counted to maintain a count of the can ends passing through the counting system.

BACKGROUND OF THE INVENTION 
This invention relates generally to devices for handling and counting 
discrete articles, and more particularly to a novel and improved can end 
handling apparatus capable of receiving a continuous flow of can ends 
either in a nested or stacked condition or individually, and delivering a 
stack of nested and accurately counted can ends to a packaging or bagging 
station. 
In the manufacture of cans, the bodies and ends of the cans are generally 
separately fabricated and packaged for later assembly in connection with 
the filling process. Generally speaking, the producer of the canned 
product purchases the necessary number of can bodies and can ends for 
subsequent assembly. The bodies may have one end preformed in the material 
of the body or one end pre-attached when a cylindrical, open-ended type of 
body is used. It is therefore necessary that the number of separate can 
ends delivered to the producer be substantially equal to the number of can 
bodies delivered, so that production runs are not interrupted due to an 
insufficient supply of ends. 
As mentioned, the can ends are shipped pre-packaged, preferably in a 
stacked or nested condition in elongated kraft paper bags. Preferably, 
each bag should contain substantially the same, preselected number of 
ends. Often the can ends are shipped in lots or bags of 300 or more. It is 
preferable that, regardless of the size of the bag, a relatively accurate 
count of can ends be maintained within a relatively small margin over a 
relatively large number of bags forming a given shipment or order. Since 
the number of can ends in a given order or shipment may run into the 
millions, it will be appreciated that manual counting of the can ends in 
each bag is impractical. 
While a number of mechanized or automated counting methods were employed 
and attempted in years past, none has proven particularly reliable or 
workable, until relatively recently. More recently, we developed a novel 
and reliable apparatus for counting and packaging can ends, as shown and 
described in our U.S. Pat. No. 3,971,189, issued July 27, 1976. While this 
apparatus has found widespread commercial acceptance, there is room for 
further improvement. In particular, the increasing use of cans having ends 
with preformed tab-like closures, often popularly called "pop-top" cans 
has given rise to some additional problems. These tab-like closures may be 
completely removable, or may be designed to be retained on the can end 
following opening thereof. In either instance, the provision of can ends 
with such tabs preformed thereon has created some novel problems in the 
handling, counting and packaging or bagging of can ends. 
More specifically, it is generally desirable that the can ends be handled 
and packaged in a stacked or nested condition. In this regard, the 
peripheral edge of each can is generally formed in a reversely bent edge 
known as the "curl". It is desired that the ends nest in an abutting 
curl-to-curl relationship to form a relatively compact stack of ends. This 
relatively closely stacked or nested condition of the can ends generally 
permits preformed stacks or "sticks" as they are often called in the art, 
to be relatively easily fed through conveyor systems utilizing generally 
tubular or arcuate trough-like guides or the like. 
However, it will be appreciated that the additional provision of a slightly 
protruding tab member on one surface of the can end tends to make the 
desired nesting or stacking more difficult to achieve and maintain. This 
occurs because the tabs often become spaced outwardly somewhat from the 
surface of the can and take a slight set such that a slight spring-like 
action is experienced when the cans are pressed together into the desired 
nested or stacked condition. Moreover, the outermost extent of the tab 
relative to the can end surface is usually off center somewhat, such that 
the spring-like action tends to cause relative tilting or canting of one 
can end relative to the next adjacent can end in a stack or stick. 
Accordingly, should the can ends in a stack become sufficiently separated 
during handling, or should one or more leading or trailing ends in a stick 
begin to tilt or cant due to the above-described action of the preformed 
tabs, clogging or jamming of the handling equipment may result. Such 
clogging or jamming requires a shutdown of relatively high speed 
production and handling equipment to correct the problem, and this is 
relatively expensive, time consuming and hence undesirable. 
Advantageously, our present invention provides for the handling and 
counting of can ends while maintaining the same in the desired closely 
stacked or nested condition throughout the handling and counting 
procedure. Hence, the invention not only prevents relatively costly 
clogging and jamming of the machinery due to tilted or dislodged can ends, 
but also maintains a relatively accurate count of ends fed to a bagging or 
packaging station.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT 
Referring now to the drawings, initially to FIG. 1, a can end handling and 
counting system incorporating features of the invention is designated 
generally by the reference numeral 10. In many respects, the system 10 is 
similar to the apparatus illustrated and described in our prior U.S. Pat. 
No. 3,971,189, issued July 27, 1976, to Moyden, et al., upon which the 
present invention improves in several respects. Hence, reference is 
invited to this earlier patent for a discussion of some of the details of 
the apparatus 10 which do not form a part of the present invention. In 
operation, it is intended that a more or less continuous stream or flow of 
can ends is fed to an inlet side 12 of the apparatus 10, wherein the can 
ends are maintained in a stacked or nested condition and accurately 
counted by counting apparatus in accordance with the present invention. 
Thereafter, the counted can ends are fed to an initially or inlet portion 
of a further apparatus 14 for separating the nested or stacked ends into 
groups of the desired number for packaging or bagging. In this regard, the 
can ends are shown in the drawings in phantom line, designated generally 
by reference numeral 25. 
As previously noted, it is desired to keep the can ends in a substantially 
upright stacked or nested condition as they pass through the handling and 
counting portion of the apparatus, prior to the separating apparatus 14. 
However, many can ends are provided with a preformed removable tab or 
"pop-top" member, maintaining such ends in the desired closely stacked and 
nested condition often proves difficult in practice. This occurs because 
the tab member tends to exhibit a spring-like action relative to the 
surface of the can end, which action tends to cause a relative tilting or 
canting of one can end relative to the next adjacent can end. 
At the inlet end 12 of the apparatus, there is provided a novel pushing or 
can end-advancing and repositioning means or apparatus designated 
generally by reference numeral 20. This apparatus 20 is disposed at the 
forward or entering end of an elongate trough-like member or guide means 
22. The can ends are accepted by this advancing and repositioning means 20 
and fed into an inlet end 27 of the trough 22 in a stacked or nested 
condition. In this regard, the can ends may be delivered to the inlet end 
12 already in the stacked or nested condition, but in practice, the can 
ends are normally delivered to inlet 12 following application of a liner 
compound to the inner rim thereof. Accordingly, the ends will often arrive 
at inlet end 12 in a spaced, edgewise relationship. The details of the 
advancing and repositioning means or pushing means 20 will be discussed 
more fully hereinafter. 
Disposed along the trough or guide means 22 is a monitoring or counting 
station 24. This station 24 may include means for visually observing or 
otherwise monitoring or sensing the stream or flow of can ends 
therethrough. In accordance with the present invention, however, the 
station 24 includes a counting means or apparatus, designated generally by 
reference numeral 26 which is generally located near or adjacent to an 
exit end 28 of the trough 22. This counting means or apparatus 26, as will 
be more fully described later herein, is adapted to produce a discrete 
detectable signal in response to the passage of each can end thereby. 
Accordingly, this discrete signal may be detected and counted by suitable 
related apparatus (not shown) in order to maintain an accurate count of 
the can ends passing through the counting system 10 and into the 
separating or grouping apparatus 14 for packaging or bagging of the 
desired numbers of ends in discrete packages. 
In order to maintain the can ends in the desired upright and closely 
stacked or nested condition throughout the trough-like member 22, the 
invention provides novel resisting means, designated generally by 
reference numeral 30 (and best viewed in FIG. 2) for engaging the can ends 
in a predetermined fashion so as to maintain a controlled degree of 
resistance of the can ends relative to the pushing or advancing means 20. 
This controlled degree of resistance is such as to maintain the can ends 
in the desired upright and nested condition as they travel through the 
trough or trough-like member from entrance end 27 to exit end 28 thereof. 
Further details of these resisting means will be described later herein. 
In the separating portion 14 of the packaging or bagging apparatus, a 
separator means or assembly 40 is activated after a predetermined number 
of can ends have been counted by the counter 26. This separator means may 
comprise an elongate, blade-like member 42 which may be inserted between 
the counted stacked or group of ends and the next adjacent end of the 
continuous stream of can ends flowing thereby so as to separate the flow 
of can ends into discrete counted stacks for packaging or bagging. Further 
preferred details of the separator means 40 and associated apparatus are 
shown in the above-referenced Moyden, et al. patent, to which reference is 
invited. 
Briefly, and referring to FIG. 3, the separating means or apparatus 
includes the aforementioned blade-like member 42 which is mounted for 
bi-directional motion generally along a complementary slot 44 by means of 
a drive or actuating shaft or member 46, coupled to suitable drive means 
designated generally in FIG. 1 by reference numeral 48. The separator 
blade 42 is arranged to intersect a receiving slot or opening formed in a 
generally tubular or cylindrical guide or conduit 48 through which the can 
ends pass upon entering the apparatus 14. The can ends are preferably 
drive through this conduit 48 by means of a pair of spaced apart toothed 
roller means 50, 52 which are also arranged to intersect the tube 48 to 
contact the edges of the can ends to advance the same therethrough. These 
toothed wheel or roller members 50, 52 have longitudinal grooves formed 
along their faces for this purpose, that is, the width of each groove is 
preferably sized to receive a single can end at its edge, at a time. The 
rollers are rotatably secured on respective shaft members 54, 56 which are 
in turn rotatably journalled to a transverse support member or beam 58. 
The shaft members 54, 56 are then rotated by suitable drive means 48, 
indicated diagrammatically in FIG. 1. 
Reference is next directed to FIG. 4, wherein details of the pushing means 
or advancing and repositioning means 20 are illustrated. Advantageously, 
the pushing means includes a pair of rotatably mounted roller members 60, 
62 which are disposed for contacting generally radially spaced peripheral 
edge portions of the can ends, which are indicated in phantom line at 
reference numeral 25. Departing from our above-referenced prior patent, in 
order to maintain the desired controlled degree of resistance of the can 
ends by the resisting means 30, these roller means 60, 62 are additionally 
coupled with means for rotatably driving at least one of the rollers in a 
direction for advancing the can ends along the trough-like member 22. In 
the illustrated embodiment both rollers 60 and 62 are so driven. 
Briefly, the drive means includes respective generally vertically oriented 
shaft members 64, 66 which mount the respective rollers and which shaft 
members are rotatably journalled intermediate respective upper and lower 
support or frame members 68, 70 and 72, 74. Preferably, an end portion of 
each shaft extends through its lower support or frame member 72, 74 and 
has coupled thereto a bevel gear member 76, 78. Complementary bevel gears 
80, 82 are provided in contact with bevel gears 76 and 78, respectively, 
and are mounted to a further rotatably journalled, horizontally extending 
or traverse shaft member 84. This latter shaft member 84 is rotatably 
journalled to opposite side wall or frame members 86, 88 and extends 
outwardly of the latter frame or wall member 88 to be driven by suitable 
rotatable drive means illustrated somewhat diagrammatically at reference 
numeral 90. Suitable motors, gearing and the like may be provided for this 
purpose, whereby the drive means 90 is somewhat diagrammatically indicated 
as an enlarged gear in FIG. 4. 
In accordance with a further feature of the invention, the rollers 60, 62 
have generally concave surfaces 61, 63 which are formed generally for 
complementary engagement with substantial portions of the can end 
peripheral edge parts. In this regard, it will be seen that each of these 
concave surfaces 61, 63 contacts the can end 25 along a substantial 
arcuate or angular extent of its peripheral edge. In the illustrated 
embodiment, the rollers are symmetrically disposed relative to the edge of 
can ends 25 and generally opposite transverse or horizontally disposed 
diametric opposed portions thereof so as to generally provide both 
vertical and horizontal support to the can ends as they are advanced 
thereby. Advantageously, the rollers are preferably formed from a somewhat 
resilient or elastomeric, rubber-like material to enhance the desired 
engagement with an advancement of the can ends 25 thereby. 
Referring next to FIGS. 2 and 5, resisting means 30 will be seen to 
comprise a plurality of elongate strips of resilient material extending 
axially along the trough-like member 22. In the illustrated embodiment 
these elongate resilient strips are four in number, designated by 
reference numerals 92, 94 and 96, 98. It will be appreciated that these 
strips of resilient material are disposed for generally extending into the 
path of the can ends 25 when the strips are in an undeformed condition. 
However, as illustrated in FIG. 2, these strips resiliently bend outwardly 
somewhat relative to the ends 25 for resilient engagement with the 
peripheral edges of the can ends 25 at a plurality of points about the 
respective peripheries thereof. Hence, these strips 92, 94, etc. tend to 
generally cooperate with the pushing force applied by rollers 60 and 62 
thereby to maintain the can ends in the desired upright and stacked or 
nested condition, facilitating the passage of the can ends in an upright, 
nested condition through the trough-like member 22 to be counted by the 
counter means 26. 
Suitable mounting means 100, 102 are provided for mounting the respective 
strips 92, 94, etc. and for locating these strips disposed for engagement 
with the peripheral can end edges generally at two pairs of diametrically 
opposed points thereupon. That is, as best viewed in FIG. 2, it will be 
noted for example that strips 92 and 98 engage the peripheral edge of can 
ends 25 at diametrically opposed points thereon, as do respective strips 
94 and 96. Preferably, the mounting means 100 and 102 mount or locate the 
strips so as to generally define these two pairs of diametrically opposed 
points at respective points located substantially at equal angular offsets 
from a substantially horizontal or transverse diameter of the can ends, 
that is, transverse to the axis or direction of travel of cans along the 
trough-like member 22, when the can ends are in the desired upright 
condition. This transverse diameter is indicated in phantom line at 
reference numeral 104. 
In the illustrated embodiment, each of the mounting means 100, 102 includes 
a generally rectilinear, elongate mounting block 106 which receives and 
engages the respective strips, such as strips 96, 98 at spaced vertical 
positions thereon as indicated in FIG. 2. This block 106 is mounted to one 
or more spaced, support members or struts 108 which are spaced along the 
length of trough 22, and are in turn mounted to one or more external 
frame-like support members 110. The mounting of struts 108 to frame or 
support members 110 may be by adjustable means or members 112 which may be 
bolts coupled to complementary threaded portions of shaft-like strut 108, 
so as to permit fine adjustment of the position thereof and hence of the 
position of the strips 92, 94, 96, 98, relative to the peripheries of the 
can ends 25, to achieve and maintain the desired degree of resistance, as 
described above. 
As best viewed in FIGS. 2 and 5, the counting means comprises a toothed 
wheel member 120 which is rotatably mounted and disposed generally 
vertically above the trough-like member 22. This wheel 120 preferably is 
positioned so as to extend into the path of travel of the can ends 25 for 
engagement of respective individual teeth thereof with respective 
individual can ends as each passes thereby. This engagement is such as to 
rotate the wheel by successive incremental amounts corresponding to 
individual can ends passing thereby. That is, the teeth 122 are preferably 
configured and spaced for accommodating but a single can end intermediate 
each adjacent pair of teeth for this purpose. Accordingly, an incremental 
amount of rotation of wheel 120 corresponding generally to the angular 
distance between any adjacent pair of teeth 122 thereupon will correspond 
to the passage of an individual can end. Hence, rotation of wheel 120 may 
be monitored by suitable means 124 indicated diagrammatically in FIG. 2 to 
maintain an accurate count of the can ends passing through the apparatus 
10. 
While particular embodiments of the invention have been shown and 
described, it will be obvious to those skilled in the art that changes and 
modifications of the present invention, in its various aspects, may be 
made without departing from the invention in its broader aspects, some of 
which changes and modifications being matters of routine engineering or 
design, and others being apparent only after study. As such, the scope of 
the invention should not be limited by the particular embodiment and 
specific construction described herein but should be defined by the 
appended claims and equivalents thereof. Accordingly, the aim in the 
appended claims is to cover all such changes and modifications as fall 
within the true spirit and scope of the invention.