Article control assembly

An article transfer mechanism of an article transfer device comprising a support structure having a central axis, at least one engagement member extending from the support structure perpendicular to the support structure axis. The engagement member contacts an article at a first predetermined location thereon. The mechanism also includes a synchronized vacuum control system which provides vacuum to the engagement member. At least one article control member is further provided to contact the article at a second predetermined location and apply a force thereto, whereby the synchronized engagement member and article control member permit the article to be transferable at high speed.

BACKGROUND OF THE INVENTION 
This invention relates to article transfer devices for the pickup, 
transfer, and delivery of articles. Particularly, this invention relates 
to an article control assembly for use with an article transfer mechanism 
of an article transfer device to increase the speed and reliability of 
transferring articles from and to a plurality of predetermined locations 
and in a plurality of transfer paths. 
It has become increasingly necessary and desirable in mechanized 
manufacturing, assembly, and packaging operations to enable the pickup, 
transfer, and delivery of articles of various shapes and dimensions in the 
most reliable, precise, and high-speed manner. Many types of such devices 
have been developed, including the utilization of rotary transfer devices 
having one or more article transfer mechanisms. 
However, due to the many configurations, shapes and sizes of articles 
required to be transferred and processed, it has become increasingly 
difficult for manufacturers and assemblers to use suitable article 
transfer mechanisms which enable the precise, reliable and high speed 
pickup, transfer, and placement of these articles. 
The article control assembly and its associated article transfer mechanism 
of this invention are for use in an article transfer device, such as a 
rotary transfer device, to increase the efficiency, accuracy and speed of 
transferring and placing various articles at predetermined locations. 
Particularly, the article control assembly is useful with a high speed 
rotary transfer device to transfer carton blanks, to open them, and to set 
them in a particular position, all at high speed, for subsequent packaging 
purposes. The article control assembly functions in cooperation with 
standard vacuum cups of an article transfer mechanism to pickup, hold and 
place the articles during transfer. The article control assembly of this 
invention comprises a separate control vacuum cup or cups constructed and 
arranged to engage articles at a predetermined location and for a 
predetermined period, in timed synchronization with the standard vacuum 
cups of the article transfer mechanism. An additional feature of the 
article control assembly is a stabilizing member which places a 
predetermined force on a predetermined location on the article, also in 
synchronization with the vacuum cup members. 
Although various means have been taught to transfer articles from one 
location to another, and although one reliable and desirable means is the 
utilization of a rotary transfer mechanism, shortcomings and limitations 
with respect to the effective transfer of articles still exist. These 
limitations and shortcomings include the inability of the transfer 
mechanism to reliably pickup, transfer and place articles all at high 
speed. For example, during high speed pickup, engagement may be incomplete 
or misplaced, thus, causing a failure in the subsequent transfer and 
placement processes. Also, during high speed transfer, certain article 
configurations may have a tendency to loose their structural integrity and 
either become dislodged or unable to become properly erected. And, during 
placement, disengagement at high speed may be unsteady causing misaligned 
placement. These shortcomings and limitations generally relate to the 
structure of the articles, as well as limitations inherent in the design 
of the article transfer mechanisms themselves. Particularly, the 
shortcomings and limitations are due to the inability of the transfer 
mechanisms to hold and stabilize articles so as to maintain their desired 
structural configurations at high rates of transfer. This is particularly 
a problem for articles having tall configurations relative to their width. 
The article control mechanism of this invention having the control vacuum 
member and stabilizing member is designed to overcome the limitations of 
the prior known mechanisms. As far as is known, and despite the need for 
article control assemblies of this nature, no such devices have been 
disclosed or proposed. 
SUMMARY OF THE INVENTION 
The present invention provides a high speed article transfer mechanism for 
engaging, transporting and disengaging articles, such as carton blanks, 
and for use with article transfer devices, such as a rotary article 
transfer device. The article transfer mechanism engages or picks up the 
article or carton at a first location, such as a magazine, transports the 
carton through a predetermined travel path and disengages or places the 
carton at a second location, such as a conveyor. The article transfer 
mechanism comprises a rectilinear support rod having a horizontally 
oriented central axis. The support rod is linked to an article transfer 
device and rotatable about the axis. The mechanism further has at least 
one first vacuum engagement member for engaging the carton at a 
predetermined location on one of a plurality of planar surfaces on the 
carton. The first vacuum engagement member has a rectilinear, hollow stem 
with an axial bore. A contact cup is disposed at the one end of the stem. 
The stem is connected to the support rod at a second end and extends 
therefrom so that the stem axis is perpendicular to the support rod axis. 
The article transfer mechanism further has at least one second vacuum 
engagement member for contacting the carton at a predetermined location on 
a second planar carton surface. The second vacuum engagement member also 
has a rectilinear hollow stem with an axial bore, and a contact cup 
disposed at one stem end. The opposite stem end is connected to the 
support rod via a connection bracket and extends therefrom so that the 
stem axis is also perpendicular to the support rod axis. Importantly, the 
second stem axis is further oriented so that it is non-parallel with the 
axis of the first vacuum engagement member. 
The article transfer mechanism further has a vacuum control mechanism which 
provides a vacuum to the first and second vacuum engagement members. The 
vacuum control mechanism provides vacuum to the first and second vacuum 
engagement members for first and second predetermined time periods, 
respectively. Additionally, the article transfer mechanism has at least 
one stabilizing member which contacts the article at a predetermined 
location on a third planar carton surface and places an extensive force 
thereon. The stabilizing member has an elongated predetermined 
configuration and is connected to the first vacuum engagement member stem 
via a connection bracket. 
These and other benefits of this invention will become clear from the 
following description by reference to the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring to FIG. 1, a rotary carton erecting device 10 is shown for the 
pickup, transfer and placement of articles. Rotary carton erecting devices 
of this structure are known in the art. For example, Applicant's assignee 
manufactures rotary transfer devices as disclosed in U.S. Pat. Nos. 
4,530,686, 4,643,633 and 4,802,324. These rotary transfer devices utilize 
frame structures upon which article pickup and deposit mechanisms travel 
in predetermined paths. The rotary transfer devices include a stationary 
gear, at least one planetary gear and structure for rotating the planetary 
gear about the stationary gear. An article transfer mechanism is in 
communication with each planetary gear for the pickup and delivery of 
articles, such as cartons. 
It is in within the purview of this invention to use the article control 
assembly with article transfer devices such as the rotary devices of the 
above referenced patents which are hereby incorporated by reference. 
Additionally, the article control assembly can be utilized with other 
prior art article transfer devices, such as rotary transfer devices which 
utilize chains to drive the article transfer mechanisms and those which 
utilize stationary pin arrangements to drive the article transfer 
mechanisms, for example. 
The article control assembly of this invention is particularly useful to 
aid the rotary carton erecting device 10 and the article transfer 
mechanism 13 of its associated article transfer device 11 in the transfer 
of cartons onto conveyors which are then merged with moving product 
groups, such as groups of bottles. For example, the article control 
assembly aids in increasing the speed of pickup, transfer and placement of 
cartons 19 from a storage magazine or hopper 18 to thereby increase the 
speed of the packaging operation. Increases in the rate of transfer of 
approximately 100 percent have been obtained utilizing the teachings of 
this invention. For example, a transfer rate of approximately 150 cartons 
per minute utilizing a standard article transfer mechanism has been 
increased to approximately 360 cartons per minute utilizing the article 
control assembly. 
As will be further discussed, the assembly preferably has a structural 
configuration to engage cartons at a plurality of predetermined locations 
at predetermined time intervals in their travel path. The article control 
assembly as shown, is particularly useful in the high speed transfer of 
relatively tall and narrow cartons with a plurality of separate planar 
portions. Referring to FIG. 1, in their initial flat configuration (carton 
blank), the cartons 19 have a facing wall 82 which is exposed in the 
magazine 18 for contact by elements of the article transfer device 11. A 
parallel and substantially coextensive back wall 83 is coupled to the top 
and bottom ends of the facing wall 82 via fold lines. Each wall further 
has a generally centrally disposed fold line which divides it into two 
planar panels upon erection (see carton 16). As shown, the top portion of 
the facing wall 82 becomes the trailing side panel 85 of the erected, 
conveyed carton 16 or 17, while the bottom portion of the facing wall 82 
becomes the top panel 84 of the conveyed carton. The top portion of the 
back wall 83 becomes the bottom panel 86 of the erected carton and the 
bottom portion becomes the leading side panel 87. Additionally, each wall 
82 and 83 is shown to have laterally extending tabs. The tabs are folded 
inwardly subsequent to placement to form the end panels of the erected 
cartons. As shown in FIG. 10, a slot is formed between the trailing panel 
85 tabs and the top panel 84 tabs which exposes a small area of the 
interior face of the back wall 83 leading panel 87. Also as will be 
discussed, the article control assembly additionally and preferably has a 
structural configuration to contact and exert a predetermined force at a 
predetermined location or locations of the carton to slightly space apart 
the facing and back walls 82 and 83 of the carton during transfer so that 
an air space is provided between the interior surfaces of the flat carton 
blanks to, thereby, increase their structural stability at high transfer 
speeds. 
As shown in FIG. 1, the rotary carton erecting device 10 has a frame 
structure 12 and an article transfer device 11 which has a number of 
article transfer mechanisms 13. The article transfer device 11 rotates in 
a continuous manner whereby the article transfer mechanisms 13 reach apex 
positions of travel at predetermined locations. Although, the device 11 as 
shown has three (3) apex positions, devices having alternate 
configurations, such as four (4) apex positions, are useable with the 
article control assembly of this invention. At an approximate 10 o'clock 
apex location, an article transfer mechanism 13 engages the article 
storage means 18 to remove a single carton 20. Each article transfer 
mechanism 13 rotates with respect to the rotation of the article transfer 
device 11 and reaches an approximate 6 o'clock apex position at its bottom 
to place the carton 16 or other article into an opened position for 
subsequent packaging to form groups of individual products, such as 
bottles. The cartons 17 are continuously moved adjacent and below the 
article transfer device 11 on a line conveyor 14 having spaced flights 15, 
which aid in carton erection. The carton structures 17 are placed onto the 
line conveyor 14 in proximity to an instream flow of individual products 
56 on a separate conveyor 57, as shown in FIG. 2. Thereafter, and as known 
in the art, the carton structures 17 form configurations whereby the 
product groupings, for example, four (4) packs of product containers 57, 
are subsequently inserted into the aligned carton configuration. 
Thereafter, and as also known in the art, the carton configuration is 
closed, for example, via tab insertion or gluing, to form a completed 
package, for example, a completed four (4) pack of product. 
FIG. 2 illustrates the article transfer device 11 having one of the article 
transfer mechanisms 13 for clarity. As is disclosed in U.S. Pat. No. '686, 
rotary carton erecting devices may have any number of article transfer 
mechanisms 13, for example, 1, 2, 3, or 4 mechanisms depending upon the 
types of articles being transferred, the size and shape of those products, 
and the desired speed of article transfer. However, the utilization of the 
article control assembly structure of this invention with an article 
transfer mechanism 13 is the same for any such article transfer device. 
The article transfer device 11 has a center shaft 30 mounted for rotation 
in journals 65 and 66 which are supported by the frame structure 12. Side 
plates 28, 29 are provided for supporting the remaining elements of the 
article transfer device 11 and which rotate with the center shaft 30. The 
movement of the article transfer device 11 is provided by a power source 
60, a drive shaft 61, and bevel gears 62 and 63. The shaft portion 64 of 
center shaft 30 extends from the beveled gear 63 to provide rotation for 
the center shaft 30. 
As is known, the center gear 25 is stationary and is connected to the frame 
12 by means of a connecting structure 55. A side plate 29 is shown 
connected to the idler gear 26 and the planetary gear 27. 
Extending for rotation with the planetary gear 27 is the vacuum shaft 54. 
The shaft 54 is shown to have a hexagonal (six-sided) cross-sectional 
structure, although alternate configurations as known in the art are 
useable, for example, round or square configurations. In the preferred 
embodiment, the rod further has partial axial vacuum bores at each end. A 
pair of first or standard vacuum engagement members 21 extend from the 
shaft 54 perpendicular to its axis, for rotation therewith through 
predetermined travel paths. Each engagement member 21 comprises a hollow, 
elongated stem 23 which has an elastomeric cup or head 24 disposed at one 
end. At its opposite end, the stems 23 are connected to the rotatable 
vacuum shaft 54 through an elongated channel 31 (see FIGS. 10 and 11) in 
the shaft 54. 
Referring also to FIG. 3, the length of extension of each stem 23 from the 
shaft 54 is adjustable via a pair of adjustment nuts 88. Additionally, the 
lateral position of each first engagement member 21 is adjustable along 
the length of the shaft channel 31. The two engagement members 21 are 
arranged spacially parallel to one another and are coplanar. The 
particular length of extension and spacing distance is dependent upon the 
characteristics of the carton blank or other article which is to be 
transferred. Two engagement members 21 are shown arranged for transferring 
a particular carton used to package four containers. The first engagement 
members 21 contact predetermined locations side-by-side on the top panel 
84 of the facing wall 82, just below the fold line separating the two 
panels 84 and 85 thereof. However, additional first or standard engagement 
members are useable depending upon container configuration and size, for 
example, a third first engagement member may be used for a six-pack 
container having a wider configuration. Similarly, a single engagement 
member could be used for smaller cartons. The above described structural 
elements generally comprise an article transfer mechanism as known in the 
art. 
A single second vacuum engagement member or control member 22 is also shown 
extending perpendicularly from the vacuum shaft 54 for rotation therewith 
through a predetermined travel path. The second engagement member 22 also 
has a rigid stem 23 with an elastomeric cup 24 at its extended end an 
additional, inoperative second vacuum engagement member 22 is shown 
without a cup 24. In the preferred embodiment, the stem 23 is connected at 
its opposite end to the vacuum shaft 54 via a mounting bracket 67 so that 
it is non-parallel with the first engagement members 21 and further forms 
an angle with respect to the first engagement members 21 of approximately 
20 degrees. Importantly, the second vacuum engagement member 22 is 
non-coplanar with the plane of extension defined by the pair of first 
vacuum engaqement members 21. The second engagement member 22 is aligned 
to contact a predetermined location on the carton facing wall 82 trailing 
panel 85, just above the fold line between the top and trailing panels 84 
and 85 thereof. The contact or engaqement location is generally centrally 
spaced with respect to the two carton contact locations of the first 
engagement members 21. In its operative engagement with this particular 
carton area, the second engagement member 22 provides additional holding 
force and stability to the flat carton during high speed transfer. 
Additionally, due to its angled configuration with respect to the first 
engagement members 21, the second engagement member 22 contacts (and 
engages due to its synchronized vacuum control period described below) the 
carton wall 82 at an earlier point, independent of the travel path of the 
first engagement members 21. This approach angle increases the reliability 
of engagement at high speed during the pickup phase of the transfer 
process. Additionally, the angled configuration allows the second 
engagement member 22 to release the article at an earlier point in the 
placement phase of the transfer process, thus, increasing the 
effectiveness and smoothness of placement, particularly at high speeds. 
Although a single second engagement member 22 is shown for use in the four 
pack cartoning operation, additional such second or control engagement 
members are useable depending upon carton configuration. The important 
consideration is that such second engagement members are non-coplanar with 
the first engagement member or members 21. 
FIG. 3 show three standard engagement members 21 and two control engagement 
members 22. However, only two standard and one control engagement member 
are operative and shown to have cups 24. The remaining stems are in 
position to be activated for use with six-pack cartons. 
Referring also to FIGS. 6 and 7 the mounting bracket 67 is shown to have a 
rigid angled configuration with first and second portions 68 and 70. The 
second portion 70 has a raised mounting ridge 71 which is mateable with 
the vacuum rod 54 channel 31. The mounting ridge 71 has a threaded 
aperture 72 for extension therethrough of a bolt for securement to the 
vacuum rod 54. The first portion 68 extends from the second portion 70 at 
an angle of approximately 20 degrees. The first portion 68 has an aperture 
69 for extension of the second engagement member 22 stem 23 end 
therethrough. The stem 23 is secured in this position via a securement nut 
disposed on each side of the first portion 68, and which also allow for 
adjustment of the extension length of the second engagement member 22. 
This structural configuration provides the proper spacial orientation 
between the first and second engagement members 21 and 22 as previously 
discussed. The angle between the first and second portions 68 and 70 of 
the mounting bracket 67 may be varied depending upon the particular carton 
configuration, contact locations thereon, and the type of vacuum rod used. 
Referring also the FIGS. 8, 9 and 10, an alternate embodiment of the 
mounting bracket 74 is shown. The bracket 74 has a center portion 75, with 
two angled side portions 78. A raised slotted mounting portion 76 includes 
an aperture 77 for coupling with the vacuum rod 54. Apertures 79 are 
located in each side portion 78 for mounting of a second engagement member 
22 at either end. 
Referring again to FIG. 2, the article transfer mechanism 13 is shown to 
have a pair of stationary article stabilizing members consisting of rigid 
elongated extension members 42 which are coupled to the stems 23 of the 
first engagement members 21, via couplings 43. Each extension member 42 
has a thin circular cross-sectional configuration which is oriented along 
side its respective first engagement member 21, extending beyond the 
respective vacuum cups 24 a predetermined distance and curving laterally 
away therefrom, and further has a rounded tip or end. During the pickup 
phase of operation, the ends of the extension members 42 are positioned 
through the slots formed in the carton blank facing wall 82, and contact 
the back wall interior side exposed thereby (see also FIG. 10). The 
extensive force exerted by the extension members 42 on the back wall 
interior separates the back wall 83 from facing wall 82 a slight distance, 
creating an air space or gap therebetween. The air gap allows air to go 
into the walls 82 and 83, which prevents back breaking of the cartons. The 
back breaking phenomenon is caused by the failure of the closely spaced 
walls 82 and 83 to separate during the placement phase of the transfer 
operation due to the creation of a vacuum or suction between the facing 
and back walls 82 and 83 during high speed travel. The extension distance 
between the end of the extension member 42 and the engagement member cup 
24 is proportional to the degree of wall separation. 
FIGS. 3-5 show an alternate embodiment of the article stabilizing members 
44 generally comprising an elonqated probe 51, a connection bracket 45 and 
a biasing spring 50. The mounting bracket 45 has a stem connection portion 
46 with a central aperture 58, through which is extended the stem 23 of a 
first engagement member 21. A lateral portion 47 is offset to the side of 
the connection portion 46 and has top and bottom arms 49. The probe 51 is 
disposed through aligned apertures 52 in the arms 49 and axially through 
the spring 50 which is disposed between the arms 49. Nuts 48 are provided 
to secure the probe 50. The spring biased stabilizing member embodiment 44 
provides a variable force upon the contact areas of the carton 
proportional to the particular point in the travel path of the stabilizing 
member 44. Shaft collars 53 are shown connected to the stem 23. 
The stabilizing members 42 and 44 further cooperate with the second or 
control engagement members 22, and the first or standard engagement 
members 21 to improve the reliability of the article placement phase of 
the transfer process by exerting their extensive forces in synchronization 
with the release of vacuum actuated attractive forces by the respective 
engagement members 22 and 21. This cooperation assists in placing the 
cartons in the proper erected position between the flight 15 of the 
conveyor 14. An elongated, curved placement assist structure is shown to 
further assist in article placement. 
Referring to FIGS. 2 and 3, the vacuum control system of the apparatus 10 
is generally referred to as 80. The vacuum control system 80 is directly 
operative on the article transfer mechanism 13 to provide timed and 
synchronized vacuum to the first and second engagement members 21 and 22. 
The vacuum control system generally comprises two center valves 35 and 40 
which independently provide vacuum to the first and second engagement 
members 21 and 22, respectively. Each center valve 35 and 40 is linked to 
a planetary valve 36 and 41, respectively, via a flexible conduit 59. The 
planetary valves 36 and 41 are communicatively connected to separate axial 
vacuum bores in the respective ends of the support rod 54. The planetary 
valves 36 and 41 allow the support rod 54 to rotate while maintaining 
continuous connection. The vacuum bores in the support rod are connected 
to hose junctions 32 which mate with respective connection hoses or tabs 
33 and 34. The hoses 33 and 34 are coupled to the respective ends of the 
hollow stems 23 of the vacuum engagement members 21 and 22. 
As shown, the center valves 35 and 40 each consist of a rotationally 
communicating pair of internally ported and slotted nylon discs 37 and 38 
which are located axially at center shaft 30. This vacuum control 
arrangement is generally known in the art, and it generally functions as 
one disc 37 rotates along with the center shaft 30, while the 
communicating disc 38 remains stationary. The stationary disc 38 is 
secured in place via a connection plate 55. The stationary disc 38 has one 
or more slots which are communicatively connected to a vacuum pump or 
other vacuum source (not shown). The rotating disc 37 has one or more 
ports of a predetermined configuration which are connected to the 
connecting hose 59. Thus, as drive shaft 30 and rotary plates 28 and 29 
are driven by power means 60, the predetermined ports and slots within the 
pair of center valves 35 and 4 communicate when aligned through the travel 
path of the rotating disc 37 so as to provide periods of vacuum source and 
vacuum release operative on the respective first and second engagement 
members 21 and 22. 
The slot and port configurations of the center valves 35 and 40 are 
selected to yield predetermined periods of vacuum source and release to 
the respective first and second engagement members 21 and 22. And, because 
both valves 35 and 40 are linked to and rotate with the common center 
shaft 30, the vacuum source and release periods of the engagement members 
21 and 22 are synchronized. The first or standard center valve 35 provides 
timed vacuum source and release periods to the first engagement members 
21. Referring particularly to FIG. 1, its vacuum source period begins 
approximately at the 10 o'clock apex position of the first engagement 
member 21 travel path, where the first engagement members are 
perpendicularly oriented with a carton blank 20 facing wall 82, and 
extends through the 6 o'clock apex position. The second or control center 
valve 40 provides timed vacuum source and release periods to the second 
engagement member 22. Its vacuum source and release periods are 
synchronized to lead the vacuum source and release periods of the first 
engagement members 21, and further correspond to a generally perpendicular 
relationship with the engaged carton wall 82. Thus, the second engagement 
member 22 engages the carton 20 facing wall 82 earlier to enable high 
speed pickup, and disengages the trailing panel 85 of the facing wall 82 
earlier to enable high speed placement. 
As many changes are possible to the embodiments of this invention utilizing 
the teachings thereof, the descriptions above, and the accompanying 
drawings should be interpreted in the illustrative and not the limited 
sense.