Packing apparatus for packing multiple layers of containers into a receptacle

A packing apparatus for packing multiple layers of containers into a receptacle is shown. The packing apparatus includes a placement assembly and a carriage assembly. The placement assembly includes a plurality of pickup devices mounted on one end of a moveable arm. The arm is moveable so that the pickup devices can pick up and transfer the containers to the receptacle. The receptacle is supported by the carriage assembly. The carriage assembly includes a moveable carriage that adjustably moves the position of the receptacle, relative to the placement assembly, to enable the articles to be placed into the receptacle in a preselected pattern. A system controller controls the timing, sequence, and movement of the placement assembly and the carriage assembly, both individually and relative to each other, in order to place and pack the containers into the receptacle in the preselected pattern.

FIELD OF THE INVENTION
 The present invention relates to a packing apparatus. In particular, the
 present invention relates to a packing apparatus for packing multiple
 layers of containers into a receptacle in a preselected pattern.
 BACKGROUND OF THE INVENTION
 As part of material handling systems, it is common to pack manufactured
 products and goods, such as containers, into receptacles, such as a case
 or a box, for shipment. Typically, the containers to be packed are
 assembled at a designated packing location and transferred by an automated
 packing device or similar type of apparatus to the receptacle. The packing
 device reduces the time and labor costs that would otherwise be required
 to pack the containers into the receptacle manually.
 Often, to facilitate packing, the containers at the packing location are
 prearranged into a pattern before they are picked up and packed into the
 receptacle. The pattern is selected relative to how the containers will be
 packed in the receptacle. The prearrangement of the containers into a
 pattern is commonly used when multiple layers of the same pattern of
 containers are to be packed into a single receptacle. However, packing
 devices that rely upon the containers to be prearranged into a pattern
 before packing are inherently large and costly to operate. They are also
 limited to packing the containers into the receptacle in the prearranged
 pattern, rather than having the flexibility to pack the containers in a
 variety of different preselected patterns.
 In addition, many packing devices pack the containers by using a technique
 that simply drops the containers into the receptacle. The dropping
 technique is inherently unreliable because many of the containers often
 fall out of position, and can prevent additional containers from being
 packed in the receptacle. The problems associated with the dropping
 technique are even more apparent when containers of relatively light
 weight, such as empty plastic containers, are packed by packing devices.
 Empty plastic containers are prone to tilt or fall out of position due to
 their light weight if they are not placed into the receptacle with care.
 To be effective, the packing of a receptacle requires the containers to be
 packed with care and precision. This is often difficult to achieve with
 regularity with most packing devices known in the art, as discussed above.
 Contributing to the problem of packing containers into a receptacle with
 precision is the use of plastic liners in receptacles. Plastic liners are
 used in receptacles such as cardboard boxes to prevent water or moisture
 from damaging the containers. However, the folds, creases, and excess
 plastic of the liners often cause the containers in the receptacle to tilt
 or fall out of position.
 Accordingly, it is desirable to provide a packing apparatus that can
 accurately and rapidly pack multiple layers of containers into a
 receptacle with precision. It is also desirable to provide a packing
 apparatus that can pack multiple layers of containers into a receptacle in
 a preselected pattern.
 SUMMARY OF THE INVENTION
 The present invention relates to a packing apparatus for packing a
 plurality of containers delivered to a packing location into a receptacle
 in a preselected pattern. The packing apparatus includes a placement
 assembly and a carriage assembly. The placement assembly has a plurality
 of container pickup devices mounted on one end of a moveable arm. The arm
 is moveable so that the container pickup devices can pick up the
 containers from the packing location and transfer them to the receptacle.
 The carriage assembly includes a moveable carriage that supports the
 receptacle. The moveable carriage is adapted to move relative to the
 placement assembly to enable the containers to be placed into the
 receptacle in the preselected pattern. A system controller is provided for
 adjustably controlling the timing, sequence, and movement of the carriage
 assembly and the placement assembly, both individually and relative to
 each other, to place and pack the containers into the receptacle in the
 preselected pattern.

DETAILED DESCRIPTION OF THE INVENTION
 Referring to the drawings, wherein like numerals indicate like elements,
 there is shown a packing apparatus 10 for packing multiple layers of
 containers into a receptacle 11 in a preselected pattern. The invention is
 discussed herein for an application where the containers to be packed are
 cylindrically shaped, empty containers 12, which may be made of plastic
 material, and the receptacle 11 is a typical cardboard box or carton.
 However, the packing apparatus 10 is applicable to numerous other types of
 items, products, or goods that may be packed into a variety of different
 types of receptacles 11.
 Referring to FIG. 1, the packing apparatus 10 of the present invention
 includes a placement assembly 14, a carriage assembly 16, and a system
 controller 18. In the illustrated embodiment, the system controller 18
 controls the timing, sequence, and movement of the placement assembly 14
 and the carriage assembly 16, individually and relative to each other, to
 place and pack the containers 12 into the receptacle 11 in a preselected
 pattern.
 As shown in FIG. 1, the containers 12 are delivered from a source (not
 shown) to a packing location 20, located under the placement assembly 14.
 The containers 12 are delivered on a conventionally driven conveyor 22 in
 a single file, one after each other, moving from left to right as seen in
 the illustrative figures. Each container 12 has an open top facing
 upwardly and a bottom which rests on the conveyor 22.
 The containers 12 are accumulated at the packing location 20 by a stopping
 device or bar 24. The stopping device 24 is situated at the end of the
 packing location 20 and includes a first rail 26 and a second rail 28. The
 first rail 26 extends longitudinally along and parallel to one side of the
 conveyor 22. The first rail 26 helps to prevent the containers 12 from
 falling off the conveyor 22 as they accumulate at the packing location 20.
 The second rail 28 is connected to one end of the first rail 26 and
 extends across the conveyor 22 to prevent the containers 12 from advancing
 beyond the packing location 20. As shown, the first and second rails 26,28
 cause the containers 12 to arrange themselves into a line below the
 placement assembly 14.
 As illustrated in FIGS. 1 and 1A, a sensor 30 is provided along the
 direction of movement of the conveyor 22, located toward the rear of the
 packing location 20, for sensing when a preselected number of containers
 12 have accumulated. The sensor 30 includes a pendulum-type contact member
 32 that lies in the path of movement of the containers 12 and is caused to
 swing in response to contact with each container 12 that is advanced
 toward the placement assembly 14 by the conveyor 22. As each container 12
 passes the sensor 30, it will contact and cause contact member 32 to swing
 out of position relative to the contour of the container 12, as shown in
 the isolated view of sensor 30 of FIG. 1A. After the container 12 passes,
 contact member 32 will return to its initial position until it contacts
 another container 12. By sensing the movement of contact member 32, the
 number of containers 12 can be counted.
 When a preselected number of containers 12 have accumulated at the packing
 location 20, no more containers 12 can move past sensor 30, and thus the
 contact member 32 will stop swinging. Once the contact member 32 stops
 swinging, a processor associated with the sensor 30 will generate and
 relay a status signal to the system controller 18, indicating that the
 preselected number of containers 12 have accumulated. Once the status
 signal is received, the system controller 18 will respond by coordinating
 the movement of the placement assembly 14 and the carriage assembly 16 to
 pack the receptacle 11. Those of ordinary skill in the art will appreciate
 that other means for determining when the preselected number of containers
 12 have been accumulated at the packing location 20 may be used, such as
 photo sensors, electronic or mechanical counters, and other types of
 devices, as a few examples.
 Turning now to FIG. 2, the placement assembly 14 is shown. The placement
 assembly 14, which may also be referred to as a placement device, includes
 a moveable arm or transfer apparatus 34 and a plurality of container
 pickup devices or suction elements 36. For illustrative purposes, six
 container pickup devices 36 are shown, it being understood that any number
 may be used without departing from the invention. The moveable arm 34
 includes a first arm member 38 and a second arm member 40.
 The first arm member 38 is pivotably secured to a shift assembly 42 (best
 seen in FIG. 3) by a pivot mechanism 44. The shift assembly 42 is provided
 so that the placement assembly 14 can move both laterally and rotationally
 to pick up the containers 12 from the packing location 20 and transfer
 them to the receptacle 11. The shift assembly 42 is movably secured to a
 support track 46, positioned over the packing location 20. The support
 track 46 is in the form of a pair of spaced apart rails (best seen in FIG.
 2) that extend parallel to the direction of movement of the conveyor 22. A
 drive mechanism is operatively connected to the shift assembly 42 so that
 the shift assembly 42 can move laterally along the rails. The drive
 mechanism responds to command signals generated by the system controller
 18.
 The pivot mechanism 44 is provided to allow the first arm member 38 to
 rotate relative to the shift assembly 42 and the packing location 20. The
 pivot mechanism 44 includes a base plate 48 secured to the first arm
 member 38. The base plate 48 has a shaft about which the first arm member
 38 rotates. In the embodiment shown in FIGS. 2 and 3, the first arm member
 38 rotates in a vertical plane perpendicular to the packing location 20.
 The rotation of the first arm member 38 may be anywhere between 0.degree.
 and 180.degree., although 0.degree. to 90.degree. is presently preferred.
 For purposes of illustration and discussion only, the first arm member 38
 shown in FIGS. 2 and 3 may be considered to be in its full upright
 vertical position at 0.degree. and is adapted to rotate radially both
 clockwise and counterclockwise relative to the packing location 20. Those
 of ordinary skill will appreciate that the rotation of the first arm
 member 38 does not have to be within a vertical plane. It is contemplated
 that the rotation of the first arm member 38 can have any orientation that
 may be desired, such as horizontally, so that the placement assembly 14
 can pick up the containers 12 from the packing location 20.
 It should be appreciated that mounting the first arm member 38 to the shift
 assembly 42 as described above, for lateral movement of the placement
 assembly 14, provides several advantages. The shift assembly 42 provides
 flexibility in the design and location of the components of the present
 invention, such as the location of placement assembly 14 and packing
 location 20. The lateral movement of the placement assembly 14 may be used
 to eliminate any problems associated with aligning the packing location 20
 with the position of the receptacle 11 to be packed. For example, the
 system controller 18 may be used to maintain the coordinates of the
 packing location 20 and the coordinates of the position of the receptacle
 11 to be packed. As a result, the system controller 18 can move the shift
 assembly 42 along the support track 46 as necessary, so that the placement
 assembly 14 can pick up the containers 12 from the packing location 20 and
 transfer them to the receptacle 11. As such, the physical position of the
 packing location 20 and position of the receptacle 11 to be packed can
 vary and is not limited to the precise arrangement shown in the drawings.
 As further shown in FIG. 3, the second arm member 40 is both extendable and
 retractable relative to the first arm member 38 to pick up the containers
 12 from the packing location 20 and transfer them to the receptacle 11. As
 shown, the second arm member 40 is movably captive within a pair of guide
 members 50 which depend from the first arm member 38. Each guide member 50
 includes a pair of rollers or bearings positioned on opposite sides of the
 second arm member 40 so that the second arm member 40 may slide relative
 to the first arm member 38. Other means or mechanical devices for
 permitting the second arm member 40 to move relative to the first arm
 member 38 may be used.
 In operation, as the first arm member 38 rotates, it will take with it the
 second arm member 40 which is held by the guide members 50.
 Once the first arm member 38 has been rotated to the desired radial
 position, the second arm member 38 can be extended or retracted relative
 to the first arm member 40. As the second arm member 40 is extended, it
 will slide along the guide members 50 in a plane generally parallel to the
 radial position of the first arm member 38. To retract the second arm
 member 40, it is moved upwardly in an opposite direction relative to the
 first arm member 38.
 The movement of both the first arm member 38 and the second arm member 40
 is controlled by an actuator 52. The actuator 52 includes a motor or other
 form of mechanical device that responds to command signals generated by
 the system controller 18. The actuator 52 may include a spring or pulley
 system that is operatively connected to the first arm member 38 to help it
 rotate relative to the pivot mechanism 44 of the shift assembly 42.
 For example, when the system controller 18 receives the status signal from
 the sensor 30, it will respond by activating the actuator 52. The actuator
 52 will rotate the first arm member 38 to its full vertical position at
 0.degree., as illustrated in FIGS. 2 and 3. Next, the system controller 18
 causes the actuator 52 to extend the second arm member 40 downwardly so
 that the container pickup devices 36 can pick up the containers 12 that
 have accumulated at the packing location 20.
 Turning now to FIG. 4, the container pickup devices 36 are shown. The
 container pickup devices 36 are mounted on one end of the moveable arm 34.
 As shown in FIG. 4, the container pickup devices 36 are supported by a
 support member 53 secured to the lower end of the second arm member 40.
 Each container pickup device 36 includes a suction head 54 in pneumatic
 communication with a suction source 56 via a suction line 58 as shown in
 FIG. 24. Each suction head 54 is shaped and dimensioned to engage at least
 one container 12 at the packing location 20. In the preferred embodiment
 of FIG. 4, the suction heads 54 are beveled downwardly, or tapered, to
 sealably fit within the open top of the containers 12.
 As illustrated in phantom in FIG. 4, the container pickup devices 36 are
 moveable up and down. In operation, the container pickup devices 36 are
 moved downwardly by the extension of the second arm member 40 relative to
 the first arm member 38 until each suction head 54 has engaged the open
 top of at least one container 12. A compression spring 60 is mounted
 intermediate the suction heads 54 and the support member 53. The
 compression spring 60 absorbs a portion of the downward movement of the
 second arm member 40 and also urges the suction heads 54 into close
 contact with the containers 12 so that the suction heads 54 will not
 damage the container 12 upon engagement and so that a good seal is
 assured. After the suction heads 54 engage the open tops of the containers
 12, thereby sealing the interior thereof, the system controller 18 will
 activate the suction source 56 to enable the container pickup devices 36
 to pick up the containers 12 through suction.
 Those of ordinary skill in the art will appreciate that other types of
 gripping or grasping devices other than suction heads, such as robotic
 arms, hands, or other mechanically operated devices, may be used to grasp
 and pick up the containers 12. Moreover, the suction heads 54 can be
 shaped to pick up any type of container 12, including containers that are
 filled and have a lid or top secured thereto.
 Once the suction source 56 is activated and suction is created, the
 actuator 42 will retract the second arm member 40 upwardly relative to the
 first arm member 38 to clear the packing location 20. As a result, the
 container pickup devices 36 will pick up or lift the containers 12 from
 the conveyor 22, holding them by suction. As the second arm member 40
 clears the packing location 20, another set of containers 12 will begin to
 accumulate at the packing location 20.
 The suction created in the container pickup devices 36 may also be
 advantageously used to detect defects in the containers 12. A sensor may
 be provided that measures the flow rate of air drawn in by the suction
 source in each container pickup device 36. The sensor may generate and
 relay a signal to the system controller 18 relative to the flow rate. The
 system controller 18 may then calculate and maintain a running average of
 the flow rate of the container pickup devices 36, which may be used, in
 turn, to measure the flow rate in each suction head 54. If the flow rate
 of any particular container pickup device 36 exceeds a certain level above
 the average, the system controller 18 may generate a condition signal that
 identifies the container pickup device 36 on a display. In turn, the
 condition signal may be used to indicate that the container pickup device
 36 did not properly seal or engage the container 12 or to indicate that
 the container 12 is defective. Devices to measure the airflow or suction
 as discussed above are known in the art, and are available from several
 manufacturers.
 As further shown in FIG. 4, the carriage assembly 16 is situated below the
 placement assembly 14. Preferably, the carriage assembly 16 is angled
 relative to the placement assembly 14 or to the horizontal so that it has
 a lower end underneath a portion of the packing location 20, as seen in
 FIGS. 4 and 5. The angle of the carriage assembly 16 facilitates the
 placement, packing, and arrangement of the containers 12 in the receptacle
 11, as discussed in more detail below. Although any angle may be chosen,
 20.degree. is presently preferred.
 The carriage assembly 16 includes a moveable carriage 62 that supports the
 receptacle 11. The carriage 62 includes a pair of wheels 63 adapted to
 travel on a support assembly or track 64 having a pair of spaced apart
 rails that extend underneath a portion of the placement assembly 14(see
 FIGS. 4 and 5). An actuator 66 located toward the rear of the track 64
 controls the movement of the carriage 62. The actuator 66 includes a drive
 or a motor mechanically coupled to the carriage 62 by an adjustable length
 mechanism 68, such a threaded shaft as shown in FIG. 4. In operation, the
 motor will rotate the shaft in a first direction to cause the carriage 62
 to move downwardly on the track 64 to a position underneath the placement
 assembly 14. When the motor is reversed, the carriage 62 will move in a
 second direction away from the placement assembly 14. The timing,
 sequence, and movement of the carriage 62 by the actuator 66 is controlled
 by the system controller 18 to enable the carriage 62 to accurately
 position the receptacle 11 to receive the containers 12.
 FIG. 5 shows a portion of the packing apparatus 10 to illustrate the
 packing of the containers 12 into the receptacle 11. As shown and
 discussed above, the carriage assembly 16 is disposed preferably at a
 20.degree. angle relative to the horizontal. The placement assembly 14 is
 in the full upright vertical position. With the placement assembly in the
 vertical position, the second arm member 40 of the placement assembly 14
 is extended downwardly (shown in phantom) and retracted upwardly to pick
 up the containers 12 at the packing location 20. Next, the first arm
 member 38 of the placement assembly 14 is rotated clockwise, taking with
 it the second arm member 40. The first arm member 38 is rotated so that
 the containers 12 supported by the second arm member 40 clear the packing
 location 20 (also shown in phantom). The degree of rotation of the first
 arm member 38 is selected by the system controller 18, relative to a
 precalculated placement position.
 The precalculated placement position is calculated by the system controller
 18. The system controller 18 will maintain data relative to the dimensions
 of the receptacle 11 (such as the length, width, and height) and the
 dimensions of each container 12 (such as the diameter, cross-section, and
 height). The way in which the system controller 18 may be programmed to
 receive, store, and process such data is well within the skill of the
 ordinary artisan and need not be described in detail. Based upon this
 data, the system controller 18 will calculate the number of rows, columns,
 and/or layers of containers 12 that may be packed into the receptacle 11.
 In accordance with these calculations, the system controller 18 will
 coordinate the movement of the placement assembly 14 and the carriage
 assembly 16 to pack the receptacle 11 with a preselected number, rows,
 layers, and pattern of containers 12.
 Turning now to FIG. 6, the placement and packing of the containers 11 into
 receptacle 11 is shown. To pack the receptacle 11 shown in FIG. 6 with a
 preselected number of rows and layers of containers 12, the system
 controller 18 positions the carriage 62 on the track 64 relative to the
 precalculated placement position. For purposes of describing the packing
 process, the first containers 12 placed into the receptacle 11 form a
 "first" row. The angle of the carriage 62 will cause the first row of
 containers 12 to lean against the inner surface of the wall of receptacle
 11. In this way, the containers 12 will not fall or move out of position.
 To place the containers 12 into the receptacle 12, the second arm member 40
 is extended downwardly to the precalculated placement position, as
 illustrated in FIG. 6. After the second arm member 40 has been extended,
 the system controller 18 will deactivate the suction source 56. By
 deactivating the suction source 56, the suction created in the pickup
 devices 36 will begin to decrease so that the suction heads 54 will
 release the containers 12 after the containers 12 are properly positioned
 within the receptacle 11. Preferably, air jets associated with each
 container pickup device 36 are used to facilitate the release of the
 containers 12. The air jets are in communication with a source, such as an
 air compressor, that is under the control of the system controller 18. In
 operation, once the carriage assembly 16 and the placement assembly 14
 have moved the container pickup devices 36 into proper position relative
 to the precalculated placement position, the system controller 18 will
 activate the compressor. Once the compressor is activated, the air jets
 will emit a stream or blast of air under pressure to cause each container
 12 to disengage from the suction heads 54. The use of air jets or similar
 devices permits rapid release and placement of the containers 12 into the
 receptacle 11, which may be necessary if it takes too long for the suction
 in the suction head 46 created by the suction source 56 to sufficiently
 decrease to release the containers 12 at the time of placement.
 To place the next succeeding row of containers (i.e., a "second" row), the
 system controller 18 will cause the placement assembly 14 to pick up the
 containers 12 accumulated at the packing location 20 and transfer them to
 the receptacle 11, as previously described above. Prior to the containers
 12 actually being placed in the receptacle 11, the system controller 18
 will incrementally move the carriage 62 downwardly on the track 64 (toward
 the right as illustrated in FIG. 6) to position the receptacle 12 relative
 to the precalculated placement position. After the carriage 62 has been
 moved and is in the proper position, the placement assembly 14 will place
 the containers 12 into the receptacle 11 at the precalculated placement
 position to form the second row.
 The angle of the carriage 62 on the carriage assembly 16 will cause
 neighboring rows of containers 12 to lean against each other. In that way,
 each container 12 will remain in position and will not interfere with the
 placement of incoming containers 12. Of course, the angle of the carriage
 assembly 16 may be eliminated, such that the carriage 62 will move in a
 plane under the placement assembly 14 that is generally parallel to the
 horizontal. If the angle is eliminated, the placement assembly 14 will
 have to move to an extent sufficient not only to clear the packing
 location 20 but also to place the containers 12 into the receptacle 11
 positioned underneath.
 With further reference to FIG. 6, the system controller 18 will move the
 carriage assembly 16 and the placement assembly 14, relative to each
 other, until the last or "nth" row of containers 12 is packed into the
 receptacle 11 which, in turn, forms a first layer of containers 12. After
 the last row is packed, the carriage 52 is moved upwardly on the track 64
 (to the left as illustrated in FIG. 6) so that a "first" row of a "second"
 layer of containers 12 may be placed into the receptacle, in the same way
 the first row of the first layer of containers 12 was placed. This process
 may be repeated for as many layers as necessary or desired to fill the
 receptacle 11. After the receptacle 11 is packed with the preselected
 number of rows and layers of containers 12, the system controller 18 will
 move the carriage 62 on the track 64 to a location where the receptacle 11
 can be removed either manually or is transferred onto a discharge conveyor
 70. As seen in FIGS. 5 and 6, the discharge conveyor 70 has an end located
 approximate the lower end of the track 64 which lifts the end of the
 receptacle 11 from the carriage 62 and conveys it upwardly to clear the
 packing apparatus 10.
 Those of ordinary skill will appreciate that the packing apparatus 10 of
 the present invention is flexible enough to permit the containers 12 to be
 packed into the receptacle 11 in a variety of preselected patterns. As one
 example, the packing apparatus 10 may be used to pack the receptacle 11
 with containers 12 arranged in a staggered pattern. To pack the staggered
 pattern, the system controller 18 will shift or move the shift assembly
 42, and thus move the first arm member 38, laterally along the support
 track 46, before the containers 12 are placed into the receptacle 11. The
 first arm member 38 will be moved laterally to offset the position of the
 containers 12 to be placed into the receptacle 11 relative to those
 already placed therein and relative to the precalculated placement
 position. As illustrated in FIG. 7, the second row of containers 12 will
 be staggered traversely with respect to the first row of containers 12.
 Moreover, each of the containers 12 of the second row will be nested
 within a valley formed by two neighboring containers 12 of the first row.
 The nesting of the containers maximizes the space available within the
 receptacle 11 for packing the containers 12. To place the next row (i.e.,
 "third" row) of the staggered pattern, the first arm member 38 is returned
 to its initial position so that the containers 12 will be placed at or
 relative to the precalculated placement position. To pack the receptacle
 11 with a first layer of staggered rows, every other row will be offset as
 described above and illustrated in FIG. 7.
 In the preferred embodiment, the system controller 18 will move the
 carriage 62 in both a first direction and a second direction prior to
 placing the containers 12 into the receptacle 11. The carriage 62 will be
 moved in the first direction to a point below the precalculated placement
 position. Moving the carriage 62 in this manner will ensure that the
 containers 12 already placed in the container do not interfere with
 incoming containers 12. However, just prior to placing the row of
 containers 12 into the receptacle 11, the carriage 62 is moved in the
 second direction opposite to the first direction so that the containers 12
 are placed at the precalculated placement position. Moving the carriage 62
 in the second direction advantageously shifts any containers 12, already
 placed into the receptacle 11 and that have moved, into the proper
 preselected pattern. Indeed, moving the carriage 62 in the first direction
 and the second direction, in addition to the angle of the carriage
 assembly 14, facilitates the proper arrangement and placement of the
 containers 12 in the receptacle 11.
 As further shown in the preferred embodiment of FIGS. 1, 5, and 6, the
 packing apparatus 10 includes a hold-down assembly 72. The hold-down
 assembly 72 is provided to hold down the flaps that may be associated with
 the receptacle 11. Those of ordinary skill will appreciate that keeping
 the flaps of a receptacle 11, such as a box, down or out of the way during
 packing is often difficult. The hold-down assembly 72 helps to eliminate
 this problem.
 As best seen in FIG. 1, the hold-down assembly 72 includes a pair of
 adjustable height support members 74 located on each side of the track.
 Because each pair of support members 74 mirrors the other, the remaining
 components of the support members 74 will be hereinafter described as
 being representative of both.
 Each support members 74 includes a first member 76 moveably disposed within
 a second member or base 78. The first member 76 is adapted to move up and
 down relative to the second member 78. An arm 80 is secured to the
 adjacent first members 76. For purpose of this description only, the
 portion of the arm 80 attached to the first member 76 situated closest to
 the packing location 20, will be referred to hereinafter as a "first end".
 The portion of the arm 80 attached to the first member 76 furthest from
 the packing location 20, will be referred to hereinafter as the "second
 end".
 An actuator 82 is secured to the first end of the arm 80. The actuator
 includes a pressure cylinder in fluid communication with a pressure source
 via a flow line. The cylinder includes a shaft 91 having one end
 operatively connected to the first end of the arm 80 relative to the
 second end. As the cylinder is pressurized, shaft 91 extends to raise the
 first end of the arm 80. To lower the arm 80, the cylinder can be
 pressurized in the opposite direction to retract the shaft 91.
 Togther, each of the arms 80 support opposite sides of a plurality of
 rollers 84. The rollers 84 are provided to make light contact with the top
 edge of the receptacle 11, in order to hold the flaps down. Each roller 84
 is journaled at different locations into a plurality of holes provided
 within the arms 80. As illustrated in FIG. 1, the rollers 84 are not
 evenly spaced. One roller 84 is located downstream (i.e., proximate the
 first end) and the other is located upstream (i.e., proximate the second
 end). Although three rollers 84 are shown, any number of rollers 84 may be
 used.
 In operation, the system controller 18 will pressurize the cylinder to
 raise the first end of the arms 80. As the first end of the arms 80 are
 raised, the system controller 18 will move the carriage 62 of the carriage
 assembly 16 into position so that the placement assembly 14 can place the
 containers 12 into the receptacle 11. After the carriage 62 has moved into
 position so that the first row of containers 12 can be placed, the system
 controller 18 will cause the actuator 82 to retract the shaft to lower the
 arms 84. The arms 80 are lowered until the rollers 84 make light contact
 with the top edge of the receptacle 11. Flap rollers 93 may be used with
 receptacles 1 with the flaps up.
 In an alternative embodiment, a photo sensor may be used to sense when the
 receptacle 11 on the carriage 62 is in position. The photo sensor will
 generate and relay a stats signal to the system controller 18. The system
 controller 18 will respond to the status signal from the photo sensor to
 pressurize the cylinder of the actuator 82 to raise and lower the arm 84,
 as described above.
 In an alternative embodiment, the carriage 62 may also include a pair of
 oppositely disposed rollers 86, as best seen in Figure land 4. The rollers
 86 are mounted on a support that is secured to the carriage 62 and help to
 guide the location of the receptacle 11 on the carriage 62. The rollers 64
 may also be advantageously used be used to hold down the bottom end of the
 flaps or carton down members associated with receptacles 11 so the flaps
 will not interfere with the packing of the receptacle 11.
 In an alternative embodiment, the carriage 62 may be associated with an
 additional suction device (not shown). This particular suction device may
 be used to draw excess air that may form between plastic liners and the
 inside of the receptacles. This will reduce the air pockets that otherwise
 form when plastic liners are used. Such air pockets have a tendency to
 form folds and creases in the plastic liners which may cause the
 containers 12 placed into the receptacle 11 to fall or tilt out of
 position or into the path of incoming containers.
 In yet another alternative embodiment, a receptacle 11 in-feed assembly 88
 may be used, as shown in FIGS. 5 and 6. The in-feed assembly 88 is used to
 support empty receptacles 11 that will be transferred to and received by
 the carriage 62. As shown, the in-feed assembly 88 has an end 90 in
 communication with the track 64 of the carriage assembly 16, and is also
 disposed at an angle to the horizontal. In operation, an empty receptacle
 11 is received in the in-feed assembly 88 and awaits the carriage 62.
 After the carriage 62 has delivered a packed receptacle 11 to the
 discharge conveyor 70, it will move upwardly on the track 64 to the
 in-feed assembly 88. Once the carriage 62 comes into close proximity with
 the end 90 of the in-feed assembly 88, the empty receptacle 11 is released
 and received in the carriage 62. After the empty receptacle 11 is received
 in the carriage 62, the carriage 62 is moved into position by the system
 controller 18 to receive the containers 12 as previously described.
 Persons skilled in the art will recognize that there may be different
 devices, mechanisms, and methods of operation which are within the spirit
 and scope of the invention as defined in the claims. Also, it should be
 understood that the drawings, while useful in illustrating the invention,
 are not intended to be necessarily to scale. The dimensions and relative
 sizes and locations of the various parts shown can be varied, depending
 upon the particular receptacle 11 being packed, the size and dimensions of
 the containers 12, and the like, without departing from the scope of the
 invention. To the extent that the drawings imply dimensions and relative
 size positions, the drawings should be regarding as illustrative only and
 not limiting the invention to particular dimensions, sizes, position, and
 location of parts.
 Finally, the present invention may be embodied in other specific forms
 without departing from the spirit or essential attributes thereof and,
 accordingly, reference should be made to the appended claims, rather than
 to the foregoing specification, as indicating the scope of the invention.