Accumulation device and box packing system having same

An accumulation device is adapted to accumulate a plurality of products according to at least one prescribed accumulation pattern. The accumulation device includes a receiving unit, a first accumulation processing unit, a second accumulation processing unit and a discharge unit. The first accumulation processing unit is configured and arranged to perform a first accumulation processing to a first group of the products received in the receiving unit. The second accumulation processing unit is disposed parallel to the first accumulation processing unit with respect to the receiving unit, and configured and arranged to perform a second accumulation processing to a second group of the products received in the receiving unit. The second accumulation processing is different from the first accumulation processing. The discharge unit is configured and arranged to transfer the products processed in the first and second accumulation processing units toward a downstream portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Japanese Patent Application No. 2006-250709 filed on Sep. 15, 2006 and No. 2006-272077, filed on Oct. 3, 2006. The entire disclosures of Japanese Patent Application Nos. 2006-250709 and 2006-272077 are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to accumulating and box packing of a product. More specifically, the present invention relates to an accumulation device for accumulating (stacking) a plurality of packaged confections or other products according to at least one prescribed accumulation pattern, and to a box packing system that is provided with the accumulation device.

2. Background Information

Checking devices, accumulation devices, box packing devices, and the like are currently used in production lines that include a combination weighing device or a bag manufacturing and packaging machine. Examples of checking devices include seal checkers that check for defects in the sealed portion of a confection bag or the like, weight checkers for verifying whether the weight of a product is within a prescribed range, and other checkers. An accumulation device arranges a plurality of bags of normal products, whose checking is completed, into a prescribed pattern. A box packing system packs a bundle of a plurality of accumulated bags into a cardboard box.

For example, Japanese Laid-Open Patent Application Publication No. 2004-155428 (published on Jun. 3, 2004) discloses a box packing system for packing bundles of a plurality of packaged products into a box at high speed from the horizontal direction in multiple levels, wherein the products are accumulated so as to stand sideways on a conveyor device. Also, Japanese Laid-Open Patent Application Publication No. H05-262304 discloses a box packing device that includes a belt conveyor having a convening surface that is selectively extendable in a conveying direction. Furthermore, Japanese Laid-Open Patent Application Publication No. 2005-119723 discloses a box packing system that is provided with a guide mechanism that is arranged to adjust a position or posture of the packaged products as the packaged products are transported on the conveyor.

In view of the above, it will be apparent to those skilled in the art from this disclosure that there exists a need for an improved accumulation device and box packing system. This invention addresses this need in the art as well as other needs, which will become apparent to those skilled in the art from this disclosure.

SUMMARY OF THE INVENTION

The conventional accumulation devices described above have some drawbacks as follows. Specifically, the conventional accumulation device disclosed in Japanese Laid-Open Patent Application Publication No. 2004-155428 is configured so that the packaged products can be accumulated only in a prescribed accumulation pattern in which the products are in a prescribed sideway standing-up position between substantially L-shaped brackets that move along the conveying surface of the conveyor device. The accumulation pattern and the size of the products that can be accumulated using such conventional accumulation device are therefore limited. Thus, the accumulation process for implementing a plurality of accumulation patterns is difficult to perform in a single device when products of different sizes are accumulated, or the products are accumulated in varying orientations, for example. As a result, products and the like having different sizes or accumulation directions cannot be processed in a box packing system or the like that is disposed downstream of the accumulation device, and box packing therefore needs to be performed manually.

It has been proposed to provide an orientation changing unit to an accumulation device, in which a plurality of delivery platforms is provided to a rotating support plate. The orientation changing unit is arranged to rotate a product fed from a conveyor along with a delivery platform so as to change the orientation of the product. However, in such accumulation device, the position of the distal end of the conveyor in the conveyance direction is set so that a product is transferred completely onto the delivery platform, and the product does not come in contact with the conveyor. However, the products also made in a variety of sizes. If the distal end position of the conveyor is set for a large-sized product, then the distance of the space between the conveyor and the delivery platform will be too large when a small-sized product is transported from the conveyor to the delivery platform. In such case, the orientations of the products being conveyed become inconsistent. There is also a risk of damaging the package contents as a result of inconsistent orientation. Furthermore, the ability to transport the products can also be reduced, and the cycle time can increase.

The present invention was conceived in view of the foregoing drawbacks. One object of the present invention is to provide an accumulation device capable of efficiently accumulating or stacking the packaged products according to a plurality of accumulation patterns in a single accumulation device, and to provide a box packing system that is provided with the accumulation device.

Another object of the present invention is to provide an accumulation device capable of transferring a product to an orientation changing unit regardless of the size of the product and without the orientation of the product becoming inconsistent, and of transferring the product to the orientation changing unit in a prescribed cycle time without damaging the package contents, by varying the length of a conveyor according to the size of the product.

In order to achieve the above objects of the present invention, the accumulation device according to a first aspect of the present invention is adapted to accumulate a plurality of products according to at least one prescribed accumulation pattern. The accumulation device includes a receiving unit, a first accumulation processing unit, a second accumulation processing unit and a discharge unit. The receiving unit is configured and arranged to receive the products. The first accumulation processing unit is configured and arranged to perform a first accumulation processing to a first group of the products that are received in the receiving unit. The second accumulation processing unit is disposed parallel to the first accumulation processing unit with respect to the receiving unit, and configured and arranged to perform a second accumulation processing to a second group of the products that are received in the receiving unit. The second accumulation processing is different from the first accumulation processing. The discharge unit is configured and arranged to transfer the products processed in the first and second accumulation processing units toward a downstream portion.

In this arrangement, the products that have been received in the same receiving unit are processed in parallel in two accumulation processing units (the first accumulation processing unit and the second accumulation processing unit) that are disposed parallel to each other, after which the accumulated products are transferred from the same discharge unit to, for example, a box packing system or other device that is disposed downstream of the discharge unit.

The first and second accumulation processing in the first accumulation processing unit and the second accumulation processing unit includes, for example, processing for accumulating while aligning the plurality of products, and/or processing for only varying the orientation of a single product.

Usually, bundles of the plurality of products are formed according to a specific accumulation pattern in an accumulation device that accumulates the plurality of products in a prescribed accumulation pattern in this manner and transfers the products to a downstream box packing system or the like. Therefore, in such cases as when products having multiple shapes are packed into a single box, or the orientations of identical products are varied in box packing, the irregular products, irregularly oriented products, or the like must be manually packed, which is troublesome.

In the accumulation device according to the first aspect of the present invention, two accumulation processing units that are disposed parallel to each other are provided between a shared receiving unit and discharge unit. Thus, according to the accumulation device of the first aspect, even when products of different sizes are received, or the same product is accumulated in different orientations, these products can be processed in parallel with normal accumulation processing. As a result, a plurality of products can be accumulated according to a plurality of accumulation patterns in a single accumulation device without reducing the processing efficiency.

The accumulation device according to a second aspect of the present invention is the accumulation device according to the first aspect, wherein the first accumulation processing unit and the second accumulation processing unit are aligned with respect to each other in a vertical direction.

In this arrangement, the two accumulation processing units that are disposed parallel to each other are disposed to be aligned vertically in the accumulation device. Thus, according to the accumulation device of the second aspect, the plurality of products can be efficiently accumulated in accordance with a plurality of accumulation patterns without increasing the size of the device footprint.

The accumulation device according to a third aspect of the present invention is the accumulation device of the first aspect, wherein the first accumulation processing unit has a transport mechanism configured and arranged to accumulate the first group of the products, and a transfer mechanism configured and arranged to transfer the first group of the products one at a time from the receiving unit onto the transport conveyor.

In this arrangement, the transport mechanism for accumulating and arranging a plurality of products, and the transfer mechanism (e.g., a transfer platform, a paddle or the like) for lining up the products one at a time on the transport mechanism are used as the first accumulation processing unit. Thus, according to the accumulation device of the third aspect, a prescribed arrangement pattern can be formed by transferring the products received in the receiving unit onto the transport mechanism one product at a time.

The accumulation device according to a fourth aspect of the present invention is the accumulation device according to the first aspect, wherein the second accumulation processing unit has a vacuum transport mechanism configured and arranged to apply suction to the second group of the products to transport the second group of the products.

In this arrangement, the vacuum transport mechanism capable of vacuum-transporting the product is used as the second accumulation processing unit. Thus, according to the accumulation device of the fourth aspect, even in such cases as when a product is handled that has a different size than a product processed in the first accumulation processing unit, or the orientation of a product needs to be varied with respect to that of normal accumulation, the product can be accumulated in a different accumulation pattern than that of the first accumulation processing unit.

The accumulation device according to a fifth aspect of the present invention is the accumulation device according to the first aspect, wherein the first accumulation processing unit is configured and arranged to perform the first accumulation processing of the first group of the products concurrently with the second accumulation processing of the second group of the products by the second accumulation processing unit.

In this arrangement, even when a plurality of products that is transported from the same receiving unit is accumulated according to different accumulation patterns, the accumulation of the products can be performed simultaneously in parallel fashion. Thus, according to the accumulation device of the fifth aspect, the first and second accumulation processing by the first and second accumulation processing units can be performed automatically and simultaneously for irregular products as well without increasing the time required for accumulation processing.

The accumulation device according to a sixth aspect of the present invention is the accumulation device according to the first aspect, wherein the first accumulation processing unit is configured and arranged to accumulate the first group of the products with a main surface of each of the first group of the products being oriented substantially vertically, and the second accumulation processing unit is configured and arranged to accumulate the second group of the products with a main surface of each of the second group of the products being oriented substantially horizontally.

According to the accumulation device of the sixth aspect, in the first accumulation processing unit, a normal accumulation state, in which the products are oriented vertically, is formed and box-packing processing is performed. On the other hand, in the second accumulation processing unit, products that are lying flat that have been accumulated in the second accumulation processing unit can be box-packed in, for example, a gap between the internal wall of the box and the plurality of products that is box-packed after being accumulated in the first accumulation processing unit. As a result, an accumulation device can be provided that can adapt to various box-packing patterns.

The accumulation device according to a seventh aspect of the present invention is the accumulation device according to the first aspect, further including a lift mechanism configured and arranged to transport a bundle of at least one of the first and second groups of the products for which the first and second accumulation processing have been performed, respectively, to the discharge unit.

In this arrangement, the lift mechanism is used as the transport unit for transporting a bundle of a plurality of products that is accumulated in separate accumulation patterns in two accumulation processing units to a shared discharge unit position. Thus, according to the accumulation device of the seventh aspect, after the products, which are transported in from the shared receiving unit, are accumulated according to different accumulation patterns, the bundle of accumulated products is moved to the discharge unit using the lift mechanism, whereby the bundle of products accumulated according to a prescribed accumulation pattern is discharged downstream from the shared discharge unit.

The accumulation device according to an eighth aspect of the present invention is the accumulation device according to the first aspect wherein the receiving unit is configured and arranged to receive the products that are packaged in a flexible packaging material.

In this arrangement, the flexible packaging is used as the products that are accumulated according to a prescribed accumulation pattern. Thus, according to the accumulation device of the eighth aspect, even in the case of accumulating packaged confections and other flexible packaging in which a plurality of products is difficult to accumulate in a perfectly aligned state compared to, for example, box-shaped products, the products can be accumulated according to a prescribed accumulation pattern in the first accumulation processing unit and the second accumulation processing unit.

A box packing system according to a ninth aspect of the present invention includes the accumulation device according to the first aspect, and a packing unit configured and arranged to move a bundle of a prescribed number of the products that are aligned in the accumulation device into a box.

According to the box packing system of the ninth aspect, even when products of different sizes are received, or the same product is accumulated in different orientations, for example, these products can be processed in parallel with normal accumulation processing. As a result, a plurality of products can be accumulated according to a plurality of accumulation patterns in a single accumulation device, and the products can then be efficiently box-packed by the packing unit without reducing the processing efficiency.

An accumulation device according to a tenth aspect of the present invention is adapted to generate a bundle of a plurality of aligned products while transporting the products with each of the products having a pair of main surfaces and at least one connecting bottom part that connects the main surfaces. The accumulation device includes a conveying unit, an orientation changing unit and an aligning unit. The conveying unit has a transport surface configured and arranged to transport the products in a first direction while each of the products is oriented in a horizontal orientation so that one of the main surfaces is supported on the transport surface. The orientation changing unit is configured and arranged to receive the products from the conveying unit and to change an orientation of the products from the horizontal orientation to an upright orientation in which the main surfaces are aligned with the first direction and a vertical direction. The aligning unit is configured and arranged to accumulate the products in the upright orientation in a second direction that is perpendicular to the first direction so that the products are stacked with the main surfaces of an adjacent pair of the products being contacting each other. The conveying unit is configured and arranged to selectively extend and retract in the first direction to change a distance between the conveying unit and the orientation changing unit according to a length of each of the products in the first direction.

According to the accumulation device of the tenth aspect, by varying the length of the conveying unit according to the size of the products, the products can be transferred to the orientation changing unit without the orientation of the products becoming inconsistent, and the products can be transferred to the orientation changing unit in a prescribed cycle time without damaging the product contents regardless of the size of the products. In order to selectively extend the conveying unit in the first direction, the length of a single conveyor can be extended. Alternatively, the conveying unit can include a plurality of conveyors, and the length of the entire conveying unit can be extended in the first direction by changing an overlap range of the two or more conveyors to extend.

The accumulation device according to an eleventh aspect of the present invention is the accumulation device according to the tenth aspect, wherein the conveying unit is configured and arranged to selectively extend so that a distal end of the conveying unit approaches the orientation changing unit when the length of each of the products is short, and the conveying unit is configured and arranged to selectively retract so that the distal end of the conveying unit is spaced apart from the orientation changing unit when the length of each of the products is long.

According to the accumulation device of the eleventh aspect, in the case of product with a short length, the space distance between the conveying unit and the orientation changing unit decreases, and the products are therefore stably transferred from the conveying unit to the orientation changing unit. In the case of a product with a long length, the space distance between the conveying unit and the orientation changing unit is large, and there is therefore no interference between the products and the conveying unit when the orientation of the products that have been transferred onto the orientation changing unit is changed.

The accumulation device according to a twelfth aspect of the present invention is the accumulation device according to the eleventh aspect, wherein the conveying unit is configured and arranged to selectively extend and retract so that a position of the distal end of the conveying unit is changed according to a size of a bag of each of the products.

According to the accumulation device of the twelfth aspect, the position of the distal end of the conveying unit can be changed according to the bag size, and stability of operation and other effects can therefore be anticipated by receiving a size signal from an upstream packaging device or main control device even when the length of the products is not detected.

The accumulation device according to a thirteenth aspect of the present invention is the accumulation device according to the tenth aspect, wherein the conveying unit includes an annular conveyor belt, a first moving roller, a first fixed roller, a second moving roller and a second fixed roller. The annular conveyor belt forms the transport surface. The first moving roller is in contact with an internal peripheral surface of the conveyor belt, and is disposed at a downstream end portion of the conveying unit in the first direction. The first fixed roller is in contact with the internal peripheral surface of the conveyor belt, and is disposed at the downstream end portion of the conveying unit in the first direction. The second moving roller is in contact with an external peripheral surface of the conveyor belt, and is disposed between the first moving roller and the first fixed roller. The second fixed roller is in contact with the internal peripheral surface of the conveyor belt, and is disposed at an upstream end portion of the conveying unit in the first direction.

According to the accumulation device of the thirteenth aspect, the first moving roller also shifts upstream when the second moving roller is shifted upstream. When the second moving roller is shifted downstream, the first moving roller also shifts downstream. The conveying unit thereby extends. In this case, the surface of the conveyor belt for transporting the products is continuous, and significant level differences and the like do not occur. The products are therefore smoothly transported.

The accumulation device according to a fourteenth aspect of the present invention is the accumulation device according to the tenth aspect, wherein the orientation changing unit includes a support plate and at least one transfer platform. The support plate is configured and arranged to rotate about a first rotational axis that extends along the first direction. The transfer platform is parallel to the first rotational axis on the support plate, the transfer platform being configured and arranged to receive the products in the horizontal orientation and to change the orientation of the products to the upright orientation by rotating about the second rotational axis.

According to the accumulation device of the fourteenth aspect, the orientation can be changed while the transport direction is varied.

The accumulation device according to a fifteenth aspect of the present invention is the accumulation device according to the tenth aspect, wherein the aligning unit includes a support surface, a dividing panel and a back panel. The support surface is configured and arranged to support the bottom parts of the products. The dividing panel is configured and arranged to contact with one of the main surfaces of one of the products disposed at a leading end of a row of the products. The back panel is configured and arranged to contact with one of the main surfaces of one of the products disposed at a trailing end of the row of the products.

According to the accumulation device of the fifteenth aspect, the products can be held in alignment between the dividing panel and the back panel.

The accumulation device according to a sixteenth aspect of the present invention is the accumulation device according to the fourteenth aspect, wherein the conveying unit is configured and arranged to be placed in an extended state when the products are transferred to the transfer platform and in a retracted state while the orientation of the products are changed.

According to the accumulation device of the sixteenth aspect, there is no risk of interference between the products and the conveying unit when the orientation of products that are transferred onto the orientation changing unit is changed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

First Embodiment

Referring first toFIGS. 1 through 10, a box packing system101(e.g., case packer) having an accumulation device in accordance with a first embodiment of the present invention will be explained.

Overall Structure of Box Packing System101

The box packing system101according to the first embodiment is a device for transporting products (e.g., products in the flexible packaging) X1, X2, which are substantially rectangular packaged confections obtained by wrapping, for example, snack confections in flexible packaging, and packing the products X1, X2into a cardboard box Y, as shown inFIGS. 1 and 2. The box packing system101is provided with a conveying device110(receiving unit), an orientation change mechanism120, a transport mechanism130, a vacuum transport mechanism140, a discharge device150(discharge unit), and a flap opening device160. In the first embodiment of the present invention, the accumulation device includes the conveying device110, the orientation change mechanism120, the transport mechanism130, the vacuum transport mechanism140and the discharge device150. Moreover, the orientation change mechanism120(example of a transfer mechanism) and the transport mechanism130preferably constitute at least a part of a first accumulation processing unit of the accumulation device, and the vacuum transport mechanism140preferably constitutes at least a part of a second accumulation processing unit of the accumulation device.

In this example, the product X1is a regular-size packaged confection for box packing, and the product X2is a service-pack packaged confection having a larger size than the product X1.

Structure of Conveying Device110

The conveying device110is a transport conveyor that is disposed in an upstream portion of the box packing system101, and that transports the products X1, X2being transported from an upstream conveyor along a sequential transport direction “a” (seeFIG. 5) to the orientation change mechanism120that is disposed downstream, as shown inFIGS. 1 and 2.

The products X1, X2transported in the conveying device110are transported in an orientation in which the products lie flat (e.g., the main surfaces of the products X1, X2are supported on an transport surface of the conveying device10).

Structure of Orientation Change Mechanism120

The orientation change mechanism120is disposed directly downstream of the conveying device110, and the orientation change mechanism120receives the products X1that are transported downstream along the transport direction “a” (seeFIG. 5) from the upstream conveying device110, and sequentially arranges the bags in an upright orientation in a prescribed position Q (seeFIGS. 5 and 7). As shown inFIGS. 3 and 7, the orientation change mechanism120also has a support plate121, four transfer platforms122, and a first rotation shaft123(first rotational axis).

As shown inFIG. 3, the support plate121is a substantially circular plate that is supported by the first rotation shaft123so as to be able to rotate, and is attached to the lateral surface part of a body case101aso as to substantially face the transport direction “a” downstream of the conveying device110.

The four transfer platforms122are each arranged on the same circle with respect to the surface of the substantially circular support plate121directly downstream of the conveying device110, and each transfer platform122has a mounting surface that is partially comb-tooth-shaped. The operation of the transfer platforms122will be described in detail in a subsequent section.

The first rotation shaft123is attached to the center portion of the substantially circular support plate121, and is the center of the rotational path of the four transfer platforms122.

Operation of Transfer Platforms122

The transfer platforms122rotate about the first rotation shaft123in conjunction with the rotation of the support plate121, and receive the products X1that are transported from the conveying device110on the upstream side in a state in which the longitudinal direction of the transfer platforms122is substantially horizontal in the position P1shown inFIG. 8.

The support plate121then rotates approximately 90° in the rotation direction “d” about the first rotation shaft123as shown inFIG. 8. During this rotation, the transfer platforms122rotate in the rotation direction “e” approximately 90° about the second rotation shafts122aso that the products X1are in an upright orientation, and the transfer platforms122move toward the position P2shown inFIG. 8. After the products X1are placed in an upright orientation in the prescribed position Q in the transport mechanism130, the transfer platforms122move so as to retreat upward while rotating about the first rotation shaft123without touching the products X1. At this time, one of the buckets131,132(described in detail hereinafter) of the transport mechanism130is stopped in the abovementioned prescribed position Q where the products X1are received in the upright orientation and aligned while being intermittently transported in the prescribed direction.

Furthermore, while the support plate121rotates about the first rotation shaft123approximately 90° in the rotation direction “d” from the position P2shown inFIG. 8, the transfer platforms122rotate approximately 90° in the rotation direction “e” about the second rotation shafts122a, and the transfer platforms122move to the position P3shown inFIG. 8. In the same manner, the transfer platforms122move from the position P3to the position P4in the rotation direction “e” about the second rotation shafts122a.

In the first embodiment, the four transfer platforms122disposed on the side surface of the support plate121sequentially perform the type of operation described above about the second rotation shafts122a, whereby a plurality of products X1can be transferred to the prescribed position Q in an upright orientation, to form a bundle of the products X1.

Although not illustrated inFIG. 8in the first embodiment, a suction device can be provided to the orientation change mechanism120for applying suction to the products X1loaded on the transfer platforms122so as to draw the products X1to the transfer platforms122(as explained in detail in the second embodiment below).

Structure of Transport Mechanism130

As shown inFIGS. 1 through 5, the transport mechanism130is disposed directly downstream of the orientation change mechanism120and directly upstream of the discharge device150, and accumulates a prescribed number of products X1in the upright orientation that have been transferred in the same orientation from the orientation change mechanism120in the prescribed position Q (seeFIGS. 5 and 7) while transporting the bundle in the transport direction “b” (seeFIG. 5) to a discharge position R.

In the first embodiment, a state is assumed in the transport mechanism130in which a prescribed number of products X1are accumulated, and the products X1are transported through a transport path (first transport path) such as the one shown inFIG. 6Ato a 2F layer that is a shared discharge position in the discharge device150.

As shown inFIGS. 7,9and10, the transport mechanism130is structured so as to include a pair of buckets (transport conveyors)131,132, a dividing panel133a, a dividing panel133b, back panels134a,134b, and drive motors M1through M3. The transport mechanism130sequentially receives the products X1that are received in an upright orientation in the prescribed position Q from the orientation change mechanism120, and intermittently transports a prescribed number of the products X1at a time to the downstream discharge position R.

The buckets131,132are provided one at a time on the upstream side and the downstream side, respectively, in the transport mechanism130. The bucket131travels in a loop along a chain that is extended between sprockets s2, s2that rotate about rotational axis135. The bucket132travels in a loop along a chain that is extended between sprockets s2, s2that rotate about rotational axes136. The buckets131,132transport a bundle of a plurality of products X1that is placed thereon from a prescribed upstream position P to the downstream discharge position R. The buckets131,132are each composed of a combination of a plurality of bottom panels131a,132a.

The dividing panels133a,133bare attached to the bottom panels131a,132a, respectively, that are disposed furthest downstream (towards the leading end) among the plurality of bottom panels131a,132a. The plurality of products X1that is subsequently transferred can be aligned on the buckets131,132while the product X1at the leading end of a bundle of a plurality of products X1that is transferred from the transfer platforms122is maintained in the upright orientation by the dividing panels133a,133b. The dividing panels133a,133bare each independently driven via the sprockets s1, s2by the drive motors M1, M2described hereinafter. Furthermore, the surfaces of the dividing panels133a,133bthat come in contact with the products X1are comb-shaped, and are formed so as to intersect with the comb-shaped portions of the abovementioned transfer platforms122without touching each other.

The back panels134a,134bare members for supporting from below a bundle of the plurality of products X1that are placed on the buckets131,132, and one each of the back panels134a,134bis provided to the dividing panels133a,133b, respectively. The back panels134a,134bare driven by the drive motor M3that is a shared drive source, and are attached in positions that face each other in the moving loop. The back panels134a,134bare thus driven by a drive source that is separate from that of the dividing panels133a,133b, whereby the bundle of products X1can be held between the dividing panels133a,133b, and the bundle of products X1can be stably transported to the discharge position R even when the number of the prescribed number of products X1to be boxed is changed. The aspect whereby the surfaces of the back panels134a,134bthat come in contact with the products X1are comb-shaped, and are formed so as to intersect with the comb-shaped portions of the abovementioned transfer platforms122without touching each other is the same as in the dividing panels133a,133b.

The sprockets s1through s3have the same diameter and are disposed at both end portions in the transport mechanism130. The dividing panel133a, the dividing panel133b, and the back panels134a,134bcan thereby be moved at the same speed and at the same rotational speed.

In the first embodiment as described above, a configuration is adopted whereby the dividing panel133a, the dividing panel133b, and the back panels134a,134bare each independently driven; a first loop is formed by the drive motor M1that drives the dividing panel133a; a second loop is formed by the drive motor M2that drives the dividing panel133b; and a third loop is formed by the drive motor M3that drives the back panels134a,134b.

Bundles of a plurality of products X1are transported so as to be held between the dividing panel133aand the back panels134a, and between the dividing panel133band the back panel134b, whereby the products can be transported in the transport mechanism130with significantly greater stability than in the conventional technique.

The method for transporting a bundle of products X1using the transport mechanism130will be specifically described below using the bucket131as an example. Transport in the other bucket132is performed in the same manner as described below.

Specifically, the bucket131, which is standing by in the prescribed position Q to which the products X1are transferred, receives the product X1at the leading end while the product X1is retained in the upright orientation by the dividing panel133awhen the products X1are transported from the upstream transfer platforms122. The bucket131moves downstream a prescribed interval that corresponds to the thickness of the bags of the products X1, whereby the plurality of products X1are received in an aligned state behind the product X1that is received at the leading end. At this time, the back panel134astands by downstream of the prescribed position Q (seeFIG. 7) in which the products X1are received. The dividing panel133bthat corresponds to the downstream bucket132stands by immediately downstream of the back panel134a. In this arrangement, when a prescribed number of products X1have been transferred into a bundle, the bundle of the plurality of products X1held between the dividing panel133aand the back panel134ais transported to the downstream discharge position R (seeFIG. 7) in the transport direction “b.” At this time, the dividing panel133bthat was standing by immediately downstream in the transport direction “b” (seeFIG. 5) of the back panel134arapidly moves downstream of the back panel134aand receives the next batch of products X1from the transfer platforms122.

In each of the buckets131,132, the plurality of bottom panels131a,132ais disposed in positions that elevate from the upstream side to the downstream side, as shown inFIG. 1. Therefore, the leading bottom panels132aof the bucket132can overlap on the downstream bottom panels131aof the bucket131in the lowest position, for example. Since the bucket132can thereby be caused to stand by in a closer position to the prescribed position Q at which the products X1are received from the transfer platforms122, when a prescribed number of products X1are placed on the bucket131and moved downstream, the products X1can be rapidly moved to the prescribed position Q and received, thereby enabling high-speed operation. The bucket131can also overlap the downstream bottom panels132aof the bucket132in the same manner.

Structure of Vacuum Transport Mechanism140

The vacuum transport mechanism140is a mechanism for processing products X2that differ in size from the products X1that are accumulated in the transport mechanism130described above, and for processing products X1that are accumulated according to a different accumulation pattern than the transport mechanism130. The vacuum transport mechanism140is disposed above the transport mechanism130in the substantially vertical direction. The vacuum transport mechanism140has a vacuum unit141, a three-dimensional transport unit142, and a transport platform143, as shown inFIGS. 3 and 4.

The vacuum unit141has vacuum ports141aat the portion that makes contact with the products X2or the like, and the direction of the products X2is changed, or the products X2are transported in a prescribed direction in a state in which the products X2are retained by a negative pressure generated in the vacuum ports141a.

The three-dimensional transport unit142is a transport mechanism that has the same function as a so-called robotic arm that moves the vacuum unit141toward a prescribed position. As shown inFIGS. 3 and 4, the three-dimensional transport unit142includes a first horizontal transport part142a, a second horizontal transport part142b, and a vertical transport part142c. The first horizontal transport part142amoves the vacuum unit141along the direction viewed from the front of the device, i.e., the accumulation direction of the products X1in the transport mechanism130. The second horizontal transport part142bmoves the vacuum unit141along the left-right direction as viewed from the front of the device, i.e., the direction that intersects with the accumulation direction of the products X1in the transport mechanism130. The vertical transport part142cmoves the vacuum unit141in the vertical direction.

The transport platform143is on a higher level than the transport surface of the conveying device110, and is disposed below and diagonal to the standby position of the vacuum unit141. Products X2that are lifted from the transport surface of the conveying device110by the vacuum unit141and the three-dimensional transport unit142are accumulated according to a prescribed accumulation pattern. In the first embodiment, an accumulation pattern in which two products X2are accumulated on the transport platform143is adopted for large-sized products X2, as shown inFIG. 3.

Specifically, in the vacuum transport mechanism140, when products X2that are larger than the products X1are transported in the conveying device110, the vacuum unit141is moved by the three-dimensional transport unit142from the prescribed standby position to a vacuum position S (seeFIG. 6B) at which the products X2are vacuum retained. The vacuum transport mechanism140vacuum-retains the products X2in the vacuum position S on the transport surface of the conveying device110, and moves the products X2from the transport surface of the conveying device110to the transport surface of the transport platform143that is disposed above.

In the first embodiment, the three-dimensional transport unit142moves the vacuum unit141to the prescribed position, whereby products X2that are larger than the products X1accumulated via the first transport path can be transported to the 2F level in the discharge device150as a discharge position that is shared with the products X1, via a separate transport path (second transport path) such as the one shown inFIG. 6B.

Structure of Discharge Device150

As shown inFIGS. 3 through 5and other diagrams, the discharge device150is disposed directly downstream of the transport mechanism130and the vacuum transport mechanism140described above, and the bundle of products X1accumulated in the upright orientation that are transported by the transport mechanism130to the discharge position R on the buckets131,132, or the products X2that are accumulated in the vacuum transport mechanism140described hereinafter, are pushed horizontally into a cardboard box Y (seeFIG. 1). As shown inFIG. 4, the discharge device150has a first cross-feed mechanism151, a second cross-feed mechanism (packing unit)152, and a lift mechanism153as cross-feed mechanisms for cross-feeding in two levels.

The first cross-feed mechanism151cross-feeds the bundle of products X1that is moved to the discharge position R in the abovementioned transport mechanism130and transports the bundle onto the lift mechanism153. The first cross-feed mechanism151has a pusher151afor pushing the bundle of products X1, and a movement mechanism151bfor moving the pusher151aback and forth within a prescribed range.

The pusher151ais a panel-shaped member that stands by in the vicinity of the discharge position R in the transport mechanism130. The pusher151apushes the bundle of products X1that is sequentially transported by the buckets131,132towards a transport direction “c” (seeFIG. 5) that is substantially orthogonal to the transport direction “b,” and moves the bundle of products X1onto the transport surface153aof the lift mechanism153that is standing by in the 1F level portion shown inFIG. 4.

The movement mechanism151bsupports the pusher151afrom above and drives the pusher151aso that the bundle of products X1is moved from the transport mechanism130onto the transport surface153aof the lift mechanism153.

The second cross-feed mechanism152is disposed in an upper level of the first cross-feed mechanism151, and pushes the bundle of products X1that is lifted from the 1F level to the 2F level by the lift mechanism153described hereinafter, or the products X2that are lowered by the lift mechanism153from the 3F level to the 2F level, into a cardboard box Y from off the transport surface153aof the lift mechanism153. The second cross-feed mechanism152also has a pusher152aand an electric cylinder152b.

After the bundle of products X1is pushed into the cardboard box Y by the second cross-feed mechanism152, the abovementioned products X2are pushed in the same manner by the second cross-feed mechanism152into the space between the upper end part of the bundle of products X1and the inner wall at the top of the cardboard box Y.

As shown inFIG. 4, the pusher152astands by in the position facing the cardboard box Y so that the lift mechanism153is held between the pusher152aand the cardboard box Y in which the products X1, X2are packed.

The electric cylinder152bis disposed behind (on the opposite side from the surface of contact with the products X1, X2) the pusher152a, and pushes the pusher152a, whereby the bundle of a plurality of products X1that is moved upward by the lift mechanism153, or the products X2that have been moved from the 3F level to the 2F level by the lift mechanism153, are transported toward a box-packing mechanism164and packed into the cardboard box Y.

As shown inFIGS. 6A and 6B, the lift mechanism153moves the bundle of a plurality of products X1cross-fed from the transport mechanism130by the first cross-feed mechanism151, or the large-sized products X2that are accumulated in the vacuum transport mechanism140, in a substantially vertical direction to a position that is at a height that allows cross-feeding by the second cross-feed mechanism152. Specifically, the lift mechanism153moves through the three levels that include 1F, 2F, and 3F shown inFIG. 4, and moves the bundle of products X1accumulated in the transport mechanism130, and the products X2accumulated in the vacuum transport mechanism140from the 1F level and the 3F level to the 2F level portion that is the shared discharge position.

In the box packing system101of the first embodiment, products X1and products X2that are accumulated in different accumulation patterns can be smoothly transported in the prescribed direction and packed into a cardboard box Y from the orientation change mechanism120via the transport mechanism130or the vacuum transport mechanism140in the manner described above. Therefore, even when accumulation processing is performed according to different accumulation patterns in the box packing system101, products X1, X2having different sizes or accumulation patterns can be automatically packed into a box, and the efficiency of the operation from accumulation processing to box packing of the products X1, X2can be significantly enhanced.

Structure of Flap Opening Device160

As shown inFIG. 1, the flap opening device160is disposed in a position that faces the transport direction “c” (seeFIG. 5) in which the discharge device150pushes the products X1, X2, and the flap opening device160opens a flap for covering the opening of the cardboard box Y in order to pack the cardboard box Y with the products X1, X2that are transported from the discharge device150. The flap opening device160has a first transport mechanism161, a second transport mechanism162, a flap opening part163, a box packing mechanism164, and a discharge part165, as shown inFIG. 1.

The first transport mechanism161transports an empty cardboard box Y to a position at which a tab attached to the distal end portion of the flap opening part163is inside the opening of the cardboard box.

The second transport mechanism162is disposed between the box packing mechanism164and the flap opening part163in the vertical direction, and transports the cardboard box Y that is opened by the flap opening part163to the box packing mechanism164disposed below the flap opening part163.

The flap opening part163is disposed adjacent to and downstream of the first transport mechanism161, and performs preparation prior to packing the products X1, X2into the cardboard box Y. Specifically, the flap for covering the opening of the cardboard box Y is opened by inserting the tab attached to the distal end portion into the closed cardboard box Y to hold the cardboard box Y open.

The box packing mechanism164is disposed adjacent to and downstream of the second transport mechanism162and the discharge device150, and the products X1, X2that are discharged by the discharge device150are pushed into and stored in the cardboard box Y that is transported by the second transport mechanism162in a state in which the flap is opened.

The discharge part165is disposed adjacent to and downstream of the box packing mechanism164, and the cardboard box Y for storing the products X1, X2that is rotated so that the opening faces upward is discharged to the outside of the device.

Characteristics of Box Packing System101

(1) In the box packing system101of the first embodiment, the products X1(a first group of the products) and the products X2(a second group of the products) transported from the conveying device110are accumulated according to a first accumulation pattern in a first accumulation processing unit (the orientation change mechanism120and the transport mechanism130) and according to a second accumulation pattern in a second accumulation processing unit (the vacuum transport mechanism140) that are disposed parallel to each other, as shown inFIGS. 6A and 6B. The products X1, X2accumulated in the transport mechanism130and the vacuum transport mechanism140, respectively, are discharged towards the flap opening device160that is disposed downstream from the 2F level portion of the discharge device150, which is a shared discharge position.

According to this configuration, even when products X1, X2of different sizes are accumulated according to different accumulation patterns, for example, the products can be efficiently processed in a single device by accumulating the products X1, X2in the transport mechanism130and the vacuum transport mechanism140, respectively, as two accumulation processing units that are disposed parallel to each other. As a result, even when products X1, X2of different sizes are packed into the same cardboard box Y, for example, there is no need for manual box packing, the process from accumulation to box packing can be automated, and increased efficiency can be anticipated. Furthermore, since there is no need to provide an accumulation device for each accumulation pattern, reduced cost and reduced space requirements for the production line can be anticipated.

(2) In the box packing system101of the first embodiment, the transport mechanism130and the vacuum transport mechanism140as two accumulation processing units disposed parallel to each other are disposed in a vertical alignment as shown inFIGS. 3 and 4, and other diagrams.

According to this configuration, even when a plurality of accumulation processing units is mounted, the device can be prevented from increasing in size, and reduced space requirements can be anticipated by performing accumulation processing according to different accumulation patterns in a plurality of accumulation processing units (transport mechanism130and vacuum transport mechanism140) that is disposed so as to align vertically.

(3) In the box packing system101of the first embodiment, the orientation change mechanism120for transferring the products X1onto the buckets131,132of the transport mechanism130so as to be in a prescribed accumulation pattern, and the transport mechanism130for accumulating the products X1in an aligned state that are received from the orientation change mechanism120are used as one of the two accumulation processing units that are disposed parallel to each other, as shown inFIG. 7.

According to this configuration, accumulation processing can be performed in a plurality of accumulation patterns such as an upright orientation, a “sashimi” format, a lay-flat format, or other accumulation pattern by controlling the timing and other characteristics of the products X1transferred onto the buckets131,132of the transport mechanism130from the orientation change mechanism120. As a result, a box packing system101can be obtained that is capable of adapting to accumulation according to various accumulation patterns in addition to the accumulation pattern created in the other accumulation processing unit (vacuum transport mechanism140).

(4) In the box packing system101of the first embodiment, the vacuum transport mechanism140is used as the other accumulation processing unit of the two accumulation processing units that are disposed parallel to each other, as shown inFIG. 4and other diagrams.

According to this configuration, by vacuum-transporting products X2that are larger than the plurality of regularly accumulated and packed products X1, and that cannot be accumulated in the transport mechanism130, the products can be transported to the 2F level of the discharge device150as the shared discharge position after the orientation is changed, and accumulation processing is performed via a separate transport path. As a result, a box packing system101can be obtained that is adaptable to an even greater variety of accumulation patterns.

(5) In the box packing system101of the first embodiment, accumulation processing according to different accumulation patterns is performed in parallel fashion in the two accumulation processing units that include the transport mechanism130and the vacuum transport mechanism140, as shown inFIGS. 6A and 6B.

According to this configuration, even when products having different sizes such as the products X1, X2, for example, are accumulated according to different accumulation patterns, a plurality of accumulations can be efficiently performed through parallel processing.

(6) As shown inFIG. 4, the box packing system101of the first embodiment is provided with the lift mechanism153for transporting the products X1, X2that are accumulated in the two accumulation processing units that include the transport mechanism130and the vacuum transport mechanism140from the 1F and 3F levels to the 2F level as the shared discharge position.

According to this configuration, the products X1, X2received from the conveying device110as a shared receiving unit can be smoothly transported to the 2F level as the shared discharge position after accumulation processing is performed according to different accumulation patterns via different transport channels for each product. As a result, a box packing system101can be obtained that is capable of efficient accumulation processing according to a plurality of accumulation patterns without increasing the size of the device.

(7) As shown inFIG. 3and other diagrams, in the box packing system101of the first embodiment, flexible packaging products X1, X2in which confections or the like are placed are used as the products that are accumulated in the plurality of accumulation processing units that includes the transport mechanism130and the vacuum transport mechanism140.

According to this configuration, even when the products are flexible packaging whose orientation is difficult to control during transport and other processes in relation to a box-shaped product or the like, for example, various accumulation patterns can be adapted to in the transport mechanism130and the vacuum transport mechanism140, and the prescribed accumulation processing can easily be performed for the flexible packaging products X1, X2.

(8) In the box packing system101of the first embodiment, the products X1, X2that are accumulated according to different accumulation patterns in the two accumulation processing units (transport mechanism130and vacuum transport mechanism140) described above are packed into a cardboard box Y by the second cross-feed mechanism152, as shown inFIGS. 1,4, and other diagrams.

According to this configuration, even when accumulation processing is performed according to different accumulation patterns, the different accumulations can be efficiently performed by performing the accumulation processing in the respective transport mechanism130and vacuum transport mechanism140as the two accumulation processing units that are disposed parallel to each other. As a result, a box packing system101can be obtained whereby the process from accumulation to box packing can be automated, and increased efficiency can be anticipated, reduced cost and reduced space requirements for the production line can also be anticipated.

Accordingly, with the accumulation device of the first embodiment of the present invention, a plurality of products can be accumulated according to a plurality of accumulation patterns in a single accumulation device without reducing the processing efficiency.

Modified Examples of First Embodiment

Although the first embodiment of the present invention was described above, the present invention is not limited by the embodiment described above, and various modifications may be made within the intended scope of the invention.

(A) In the first embodiment described above, an example was described in which the orientation change mechanism120and the transport mechanism130for accumulating the products X1in an upright state on the buckets131,132as received from the orientation change mechanism120, and the vacuum transport mechanism140that has the vacuum ports141aat the distal end and accumulates the products X2that are larger than the products X1were used as the first accumulation processing unit and the second accumulation processing unit for performing accumulation processing according to different accumulation patterns, as shown inFIG. 3. However, the present invention is not limited by this configuration.

For example, the combination of the first accumulation processing unit and the second accumulation processing unit as described above is not limiting, and a configuration may be adopted that includes a plurality of only the orientation change mechanism120and the transport mechanism130disposed parallel to each other as the first accumulation processing unit described in the abovementioned embodiment, or a configuration that includes a plurality of only the vacuum transport mechanism140as the second accumulation processing unit disposed parallel to each other.

Even in this case, by performing accumulation processing according to different accumulation patterns in each of a plurality of accumulation processing units disposed parallel to each other, the same effects as those described above can be obtained, whereby accumulation processing according to a plurality of accumulation patterns can be efficiently performed in a single device.

(B) An example was described in the first embodiment in which the orientation change mechanism120and transport mechanism130as the first accumulation processing unit, and the vacuum transport mechanism140as the second accumulation processing unit were disposed vertically, as shown inFIG. 3. However, the present invention is not limited by this configuration.

For example, the configuration whereby the first accumulation processing unit and the second accumulation processing unit are disposed in the vertical direction is not limiting, and an arrangement thereof in the left-right direction is also possible.

However, the configuration in which a plurality of accumulation processing units is disposed in a vertical arrangement as described in the first embodiment is preferred in terms of preventing the space requirements of the device from increasing, and for enabling a plurality of accumulations.

(C) An example was described in the first embodiment in which the plurality of products X1was accumulated in an upright state on the buckets131,132in the transport mechanism130that corresponds to the first accumulation processing unit, as shown inFIG. 7. However, the present invention is not limited by this configuration.

For example, a configuration may be adopted in which the products X1are accumulated in a so-called “sashimi-style” accumulation pattern (diagonal stacking) in which the plurality of products X1is accumulated at an angle on the buckets so that portions of the products X1overlap, or a so-called lay-flat-style accumulation pattern in which the products X1are laid flat in a non-overlapping state.

(D) In the first embodiment described above, an example was described in which products X2that are larger than the products X1accumulated in the orientation change mechanism120and transport mechanism130as the first accumulation processing unit were accumulated in the vacuum transport mechanism140as the second accumulation processing unit, as shown inFIG. 3. However, the present invention is not limited by this configuration.

For example, the products accumulated in the first accumulation processing unit and the second accumulation processing unit may have the same size. Even in this case, accumulation processing according to different accumulation patterns can be performed in parallel in a single device by varying the accumulation pattern in the processing of products that are the same size.

Specifically, bags2,3,4, . . . are accumulated in the orientation change mechanism (first accumulation processing unit)120, and bags1,5,9, . . . are accumulated in the vacuum transport mechanism (second accumulation processing unit)140, as shown inFIG. 11. Specifically, a large number of bags are accumulated at high speed by the orientation change mechanism120while bags are accumulated at a slower speed by the vacuum transport mechanism140, whereby box packing can be performed in a box packing pattern such as the one shown inFIG. 12A.

Furthermore, box packing can also be performed in a large variety of other box packing patterns, such as the ones shown inFIG. 12Band other diagrams.

(E) In the first embodiment, an example was described in which two products X2having a larger size than the products X1accumulated in the orientation change mechanism120and transport mechanism130as the first accumulation processing unit were accumulated and box-packed in the vacuum transport mechanism140as the second accumulation processing unit, as shown inFIG. 3. However, the present invention is not limited by this configuration.

For example, a configuration may be adopted in which only a single large-sized product X2is transported to the prescribed position and packed in the vacuum transport mechanism140as the second accumulation processing unit.

Even in this case, box-packing processing in which a plurality of accumulation patterns is combined may be performed in a single device by packing the product together with a bundle of a plurality of products that is accumulated according to a prescribed accumulation pattern in the first accumulation processing unit.

(F) In the first embodiment, an example was described in which products X1, X2that were bags formed by flexible packaging, such as packaged confections or the like, were used as the products accumulated according to a prescribed accumulation pattern, as shown inFIG. 3and other diagrams. However, the present invention is not limited by this configuration.

For example, products placed in a paper box or the like, or other products may be used instead of products that are packed in flexible packaging.

(G) In the first embodiment, an example was described in which the box packing system101was the accumulation device of the present invention, as shown inFIG. 1and other diagrams. However, the present invention is not limited by this configuration.

For example, the accumulation device of the present invention may be mounted in another industrial machine.

The same effects as those of the box packing system101according to the first embodiment can be obtained in this case as well.

Second Embodiment

Referring now toFIGS. 13 to 25C, a box packing system having an accumulation device in accordance with a second embodiment will now be explained. In view of the similarity between the first and second embodiments, the descriptions of the parts of the second embodiment that are identical to the parts of the first embodiment may be omitted for the sake of brevity.

Similarly to the first embodiment, packaged potato chips, snacks or the like, for example, are used as the product that is accumulated by the accumulation device. InFIG. 14, the product is indicated by chain double-dashed lines and labeled with the reference symbol M.

Specifically, the products M are bags that accommodate contents, wherein the bags are provided with a pair of main surfaces Ms and a bottom surface Mb that is continuous with the pair of main surfaces Ms. The products M are transported in a state (hereinafter referred to as the “upright orientation”) in which the bottom surface Mb is facing downward in contact with the transport surface.

Structure of Box Packing System

A box packing system that uses the accumulation device according to the second embodiment will first be described usingFIGS. 13 and 14. The box packing system is provided with the accumulation device1, a product row transporting device2, and a box packing apparatus3. The accumulation device1is provided with the conveying device10(an example of the conveying unit), an orientation change mechanism20(example of the orientation changing unit), a telescopic conveyor30, and a transport mechanism40(example of the aligning unit). Moreover, the conveying device10, the orientation change mechanism20and the transport mechanism40preferably constitute the accumulation device in accordance with the second embodiment.

As shown inFIG. 14, the conveying device10transports the products M in a state (hereinafter referred to as the “horizontal orientation”) in which the main surfaces Ms are in contact with the transport surface. The orientation change mechanism20changes the orientation of the products M transported by the conveying device10from the horizontal orientation to the upright orientation. The transport mechanism40aligns the products M with the main surfaces Ms being in contact with each other, and forms a product row ML.

The product row transporting device2then pushes the product row ML created by the transport mechanism40in the vertical upward direction Z1. The product row transporting device2then transports the product row ML to a shutter62in a first direction X as shown inFIG. 13.

The box packing apparatus3packs the product row ML transported by the product row transporting device2into a box. Specifically, the shutter62opens, whereby the product row ML that has been transported to the shutter62is placed on a raised lifting platform63(FIG. 13). The product row ML is then stacked in levels. The lifting platform63lowers in the vertical downward direction Z2in conjunction with the level stacking of the product rows ML. When the lifting platform63is in the lowered state, the product row ML stacked on the lifting platform63is packed in a box B by a box-packing pusher64. A cardboard box or the like, for example, is used as the box B.

The structure and operation of each component provided to the box packing system will next be described in detail.

Structure and Operation of Conveying Device10

FIGS. 15 and 16are diagrams showing the conveying device10. The conveying device10is provided with an induction conveyor11and a telescopic conveyor30. The products M transported downstream to the induction conveyor11are transported onto the telescopic conveyor30from the induction conveyor11.

Specifically, the products M are transported in the first direction X in the horizontal orientation (FIG. 14). At this time, the main surfaces Ms on one side of the products M are supported from below by the transport surfaces11s,30sof the induction conveyor11and the telescopic conveyor30, respectively.

Structure of Induction Conveyor11

As shown inFIGS. 15A and 15B, the induction conveyor11is provided with a pair of pulleys13,13and a conveyor belt11b. The pair of pulleys13,13is disposed so that one pulley is upstream and the other is downstream. The conveyor belt11bis endless, and extends between the pair of pulleys13,13.

The upstream pulley13can be rotated by the driving of a drive motor11M. The conveyor belt11bis rotated by the rotation of the upstream pulley13. The induction conveyor11thereby transports the products M on the transport surface11S toward the telescopic conveyor30.

Structure of Telescopic Conveyor30

As shown inFIGS. 15A and 15B, the telescopic conveyor30is provided with a first moving roller32, a first fixed roller34, a second moving roller33, a pair of second fixed rollers35,36, and a conveyor belt31. The conveyor belt31is endless (annular), and extends along the rollers32through36.

The first moving roller32contacts the internal peripheral surface of the conveyor belt31, and is disposed at the downstream end in the first direction X. The first fixed roller34contacts the internal peripheral surface of the conveyor belt31, and is disposed at the downstream end in the first direction X.

The second moving roller33contacts the external peripheral surface of the conveyor belt31, and is disposed between the first moving roller32and the first fixed roller34. The second fixed rollers35,36contact the internal peripheral surface of the conveyor belt31, and are disposed at the upstream end in the first direction X.

The conveyor belt31is composed of a transport surface30sfor transporting the products M between the second fixed roller36and the first moving roller32.

The second fixed roller36can be rotated by the driving of a second conveyor motor30M. The conveyor belt31is also rotated by the rotation of the second fixed roller36. The telescopic conveyor30thereby transports the products M on the transport surface30sthat have been transported from the induction conveyor11to the transfer platforms22of the orientation change mechanism20.

The first moving roller32and the second moving roller33are both capable of moving, and the telescopic conveyor30can extend and retract. This operation will be described in detail hereinafter.

Telescoping Mechanism of Telescopic Conveyor30

FIGS. 16A and 16Bare diagrams showing the telescopic conveyor30in the retracted state.FIGS. 15A and 15Bdescribed above show the telescopic conveyor30in the extended state.

The first moving roller32and the second moving roller33are both attached to a slider38so as to be able to rotate. The slider38is capable of moving in the first direction X along a guide rod39, and is able to slide with respect to the guide rod39. The guide rod39is provided substantially parallel to the first direction X.

A cylinder rod37aof an air cylinder37is fixed to the slider38. The slider38can be moved along the first direction X by the driving of the air cylinder37.

As shown inFIGS. 15A and 15B, when the slider38moves towards the orientation change mechanism20, the first moving roller32and the second moving roller33also move towards the orientation change mechanism20. The distance between the first moving roller32and the second fixed roller36thereby increases, and the telescopic conveyor30extends.

As shown inFIGS. 16A and 16B, when the slider38moves away from the orientation change mechanism20, the first moving roller32and the second moving roller33also move away from the orientation change mechanism20. The distance between the first moving roller32and the second fixed roller36thereby decreases, and the telescopic conveyor30retracts.

The distance between the telescopic conveyor30and the transfer platforms22of the orientation change mechanism20can be adjusted by the extension and retraction of the telescopic conveyor30.

As described hereinafter, the transfer platforms22move downward with the products M placed thereon. When the products M are large in size, the telescopic conveyor30is retracted to increase the distance to the transfer platforms22, thereby enabling the transfer platforms22to move downward. If the telescopic conveyor30were extended at this time so as to reduce the distance to the transfer platforms22, the products M would be caught on the telescopic conveyor30when the transfer platforms22moved downward.

When the products M are small in size, the telescopic conveyor30is extended to shorten the distance to the transfer platforms22, thereby enabling the products M to move from the telescopic conveyor30to the transfer platforms22. If the telescopic conveyor30were retracted at this time so as to increase the distance to the transfer platforms22, the products M would fall between the telescopic conveyor30and the transfer platforms22.

The products M are transported at high speed on the transport surface30s, whereby the products M are thrown towards the transfer platforms22from the telescopic conveyor30and transferred to the transfer platforms22. The products M can therefore be transported onto the transfer platforms22even when the telescopic conveyor30and the transfer platforms22are apart from each other.

The length of the telescopic conveyor30is thus varied according to the size of the products M, thereby enabling the orientation of the products M to be stabilized during transport without regard to the size of the products M. The products M can thus be transferred to the orientation change mechanism20in a stable orientation. The products M can also be transferred to the orientation change mechanism20in the prescribed cycle time without damage to the contents of the products M.

Extension and retraction of the telescopic conveyor30may be automatically performed when the type of the products M changes, on the basis of size information of the products M or bags that is set in a controller provided upstream. More specifically, the accumulation device can be controlled to selectively extend or retract the telescopic conveyor30by, for example, receiving a size signal from an upstream packaging device or a main control device (e.g., implemented by a microprocessor, CPU, etc.) even when the length of the products M itself is not detected.

A case was described in which the telescopic conveyor30was extended and retracted for two size levels (FIGS. 15A through 16B) for the products M, but a stopper or the like, for example, may also be provided, and extension and retraction for three or more levels may be performed. This configuration makes it possible to adapt to products M having multiple sizes.

Furthermore, extension and retraction of the telescopic conveyor30may be controlled so as to occur for each transfer of a product M. Specifically, the telescopic conveyor30extends when products M are transferred to the transfer platforms22of the orientation change mechanism20, and retracts during orientation changing of the products M by the transfer platforms22.

Structure and Operation of Orientation Change Mechanism20

FIGS. 17 and 18are perspective views showing the orientation change mechanism20, andFIG. 19is a side view showing the orientation change mechanism20. The orientation change mechanism20is disposed directly downstream of the telescopic conveyor30. The orientation change mechanism20receives products M that are transported downstream along the first direction X from the upstream telescopic conveyor30, and sequentially arranges the products M in an upright orientation in a prescribed downstream position.

The orientation change mechanism20specifically has a support plate21, four transfer platforms22, a first rotation shaft23, and a suction device70(seeFIG. 20).

The support plate21is a substantially circular plate that is supported by the first rotation shaft23so as to be able to rotate, and can rotate about a first rotational axis L1at the center of the rotation shaft23. The support plate21is mounted downstream of the telescopic conveyor30in alignment with a surface that is orthogonal to the first direction X (FIGS. 17 and 18).

The four transfer platforms22are mounted to the surface of the substantially circular support plate21directly downstream of the conveying device10(directly downstream of the telescopic conveyor30). Specifically, the four transfer platforms22are each disposed on the same circle around the rotation shaft23, and each have a comb-shaped loading surface22d(FIG. 19). The detailed structure and operation of the transfer platforms22will be described hereinafter.

As shown inFIG. 20, the rotation shaft23is provided at the center of the substantially circular support plate21, and is the center of the rotational path of the four transfer platforms22. The rotation shaft23also moves the four transfer platforms22at a greater acceleration than the acceleration due to gravity g.

The suction device70is disposed in the vicinity of the rotational path of the four transfer platforms22, in a prescribed position P1outside the rotational path. The suction device70approaches a chamber part22eof the transfer platforms22described hereinafter and draws the products M loaded on the transfer platforms22onto the loading surface22d. The detailed structure of the suction device70will be described hereinafter.

Structure of Transfer Platforms22

Each transfer platform22has a rotation shaft22a, a loading surface22d, and a chamber part22e. A first opening22band a second opening22care also provided to the transfer platforms22.

The rotation shafts22aare rotation shafts for switching the orientation of the transfer platforms22, and support the transfer platforms22so as to be able to rotate. The rotation shafts22aare each attached to the support plate21, and can rotate about a second rotational axis L2that is parallel to the first rotational axis L1shown inFIG. 17. The transfer platforms22rotate about the rotation shafts22a, whereby the orientation of the products M received from the conveying device10(FIG. 14) is switched from the horizontal orientation to the upright orientation.

The loading surfaces22dare surfaces that contact the products M, onto which the products M transported in from the conveying device10(FIG. 14) are loaded.

The chamber parts22eare disposed on the opposite surface from the loading surfaces22d. A negative pressure can be generated in the internal spaces S (FIG. 20) of the chamber parts22e.

The first opening22bis composed of a plurality of circular holes and is formed in a portion (not including the comb-shaped portion) of a metal plate in the loading surfaces22don which the products M are loaded (FIGS. 15B and 16B). The first opening22bleads into the internal space S of the chamber part22efrom the loading surface22d. A product M can thereby be drawn to the loading surface22dby generating a negative pressure in the internal space S (FIG. 20) of the chamber part22e.

A second opening22ccomposed of a plurality of circular holes is formed in the distal end portion of the chamber part22eon the opposite side from the loading surface22d. The second opening22cis therefore linked to the first opening22bvia the internal space S.

When a transfer platform22is in the position P1during the process in which the transfer platforms22move along the rotational path about the rotation shaft23, the distal end portion of the chamber part22emakes contact with an elastic member72of the suction device70described hereinafter. Vacuum suction in the internal space S of the chamber part22eis thereby created by the suction device70via the second opening22c. A negative pressure can thereby be created in the internal space S.

Operation of Transfer Platforms22

The transfer platforms22rotate about the rotation shaft23in conjunction with the rotation of the support plate21. In the position P1shown inFIG. 20, the transfer platforms22receive the horizontally oriented products M transported from the upstream conveying device10without changing the orientation thereof (seeFIG. 14). At this time, the products M thus received are retained in the state of being drawn to the loading surface22dof the transfer platform22by the suction device70.

The support plate21then rotates approximately 90° in the rotation direction “d” about the rotation shaft23, and the transfer platform22moves from position P1to position P2. While the transfer platform22is moving from position P1to position P2, the transfer platform22rotates approximately 90° in the rotation direction “e” about the rotation shaft22aso that the product M is in the upright orientation.

The transfer platforms22load the products M in the upright orientation in the prescribed position Q in the transport mechanism40shown inFIG. 19. The transfer platforms22then retreat by moving upward (in direction “d”) while rotating in the direction of the arrow e about the rotation shaft23so as not to touch the products M. At this time, any one of the buckets41,42(described in detail hereinafter) is stopped in the prescribed position Q, and the products M are received and aligned so as to remain in the upright orientation.

Furthermore, the support plate21rotates approximately 90° in the rotation direction “d” about the rotation shaft23, and the transfer platform22is moved from position P2to position P3. The transfer platform22rotates approximately 90° in the rotation direction “e” about the rotation shaft22awhile moving from position P2to position P3. The transfer platform22moves back to position P1in the same manner after moving from position P3to position P4.

The four transfer platforms22disposed beside the support plate21sequentially perform the operations described above, whereby the plurality of products M is loaded in sequence in the upright orientation in the prescribed position Q, and a bundle of aligned products M is formed.

Structure and Operation of Suction Device70

The suction device70is a device for applying suction to the products M loaded on the transfer platforms22so as to draw the products M to the transfer platforms22, and has a main body71and an elastic member72.

The main body71is connected to a vacuum pump via an air duct (not shown). The vacuum pump is driven, whereby vacuum suction is created in the internal space of the main body71, and a negative pressure is generated in the internal space.

The elastic member72is attached to the main body71on the side of the rotational path of the transfer platforms22. A hole having substantially the same size as the second opening22cis provided to the elastic member72.

The elastic member72is disposed substantially parallel to the direction of a line tangent to the rotational path of the transfer platforms22. Therefore, in the position P1at which a transfer platform22receives a product M from the conveying device10, the elastic member72and the distal end portion of the chamber part22ecome in contact with each other, and the internal space S of the chamber part22eis evacuated. A negative pressure is thus created in the internal space S.

A rubber product, foam urethane, or another resin product may be used as the elastic member72.

Structure and Operation of Transport Mechanism40

FIGS. 21 and 22are a top view and a side view, respectively, showing the transport mechanism40. The transport mechanism40has a plurality of buckets41,42, dividing panels43a,43b, back panels44a,44b, and drive motors M1through M3. The transport mechanism40sequentially receives the products M transported from the upstream orientation change mechanism20in the upright orientation at the prescribed position Q, and transports a prescribed number of products M at a time to the downstream position R.

InFIG. 22, the buckets41,42are disposed one each upstream and downstream, respectively, of the transport mechanism40. The bucket41travels in a loop along a chain that is extended between sprockets s1, s1that rotate about a rotation shaft45,46. The bucket42travels in a loop along a chain that is extended between sprockets s2, s2that rotate about a rotation shaft45,46.

The buckets41,42are combined with a plurality of bottom panels41a,42a, respectively, and the bottom panels41a,42aform support surfaces for supporting the bottom surfaces Mb of the products M.

A product row ML composed of a bundle of a plurality of products M is loaded onto the buckets41,42. The buckets41,42transport the product row ML from the prescribed upstream position P to the downstream position R.

The dividing panels43a,43bare attached to the bottom panels41a,42athat are disposed furthest downstream (toward the leading end) among the plurality of bottom panels41a,42a, respectively. The dividing panels43a,43bretain the leading-end product M in the upright orientation in the product row ML transferred from a transfer platform22. The sequentially transferred plurality of products M can thereby be aligned on the buckets41,42after the leading-end product M is received.

The dividing panel43ais driven by a drive motor M1(FIG. 21) described hereinafter via the sprocket s1. The dividing panel43bis driven by a drive motor M2(FIG. 21) described hereinafter via the sprocket s2. The dividing panels43a,43bare separately driven. Furthermore, as shown inFIG. 15, the surfaces of the dividing panels43a,43bthat come in contact with the products M are comb-shaped, and are formed so as to be able to meet and part with the comb-shaped portions of the aforementioned transfer platforms22without touching.

The back panels44a,44bshown inFIG. 19are members for supporting the product row ML loaded onto the buckets41,42from behind, and are provided one each to the dividing panels43a,43b, respectively. The back panels44a,44bare driven by a drive motor M3(FIG. 21) that is a shared drive source, and are attached so as to face each other in the moving loop. The back panels44a,44bare thus driven by a drive source that is separate from that of the dividing panels43a,43b. The product row ML can therefore be held between the dividing panels43a,43b, and the product row ML can be stably transported to the discharge position R even when the number of the prescribed number of products M to be boxed is changed. The aspect whereby the surfaces of the back panels44a,44bthat come in contact with the products M are comb-shaped, and are formed so as to be able to meet and part with the comb-shaped portions of the abovementioned transfer platforms22without touching each other is the same as in the dividing panels43a,43b.

The sprockets s1through s3shown inFIG. 21have the same diameter and are disposed at both end portions in the transport mechanism40. The dividing panel43a, the dividing panel43b, and the back panels44a,44bcan thereby be moved at the same speed and at the same rotational speed.

In the second embodiment as described above, a configuration is adopted whereby the dividing panel43a, the dividing panel43b, and the back panels44a,44bare each independently driven; a first loop is formed by the drive motor M1that drives the dividing panel43a; a second loop is formed by the drive motor M2that drives the dividing panel43b; and a third loop is formed by the drive motor M3that drives the back panels44a,44b.

Each product row ML is transported so as to be held between the dividing panel43aand the back panels44a, and between the dividing panel43band the back panel44b, whereby the products can be transported in the transport mechanism40with significantly greater stability than in the conventional technique.

The method for transporting a product row ML using the transport mechanism40will be specifically described below using the bucket41as an example. Transport in the other bucket42is performed in the same manner as described below.

Specifically, the bucket41inFIG. 19, which is standing by in the prescribed position Q to which the products M are transferred, receives the product M at the leading end while the product M is retained in the upright orientation by the dividing panel43awhen the products M are transported from the upstream transfer platforms22. The bucket41moves downstream a prescribed interval that corresponds to the thickness d1(FIG. 19) of the bags of the products M, whereby the plurality of products M are received in an aligned state behind the product M that is received at the leading end, as shown inFIG. 23A. At this time, the back panel44astands by downstream of the prescribed position Q (seeFIG. 24) in which the products M are received. The dividing panel43bthat corresponds to the downstream bucket42stands by immediately downstream of the back panel44a. As shown inFIG. 23B, when a prescribed number of products have eventually been transferred into the product row ML, the product row ML held between the dividing panel43aand the back panel44aas shown inFIG. 23Cis transported to the downstream discharge position R (seeFIG. 24) in the second direction Y, as shown inFIG. 23D. At this time, the dividing panel43bthat was standing by immediately downstream in the second direction Y of the back panel44arapidly moves downstream of the back panel44aand receives products M of the next batch from the transfer platforms22, as shown inFIG. 23B.

Structure and Operation of Product Row Transporting Device2

The product row ML that has been aligned for a prescribed number of bags by the transport mechanism40shown inFIG. 24is pushed onto a lifter52by a first pusher51of a discharge device50. As shown inFIG. 14, the product row ML on the lifter52is raised in the vertical upward direction Z1, then pushed out in the first direction X by a second pusher54and transported onto a transport surface65of the product row transporting device2shown inFIG. 13.

The lifting and lowering pusher61indicated by the chain double-dashed line inFIG. 14then pushes the product row ML in the first direction X. In this arrangement, a guide panel80is provided on both sides in the second direction (width direction) Y of the transport surface65of the product row transporting device2shown inFIG. 13. At this time, a linear continuous bar91(FIG. 14) is retained in an upright state in the second direction Y, whereby the rear end part of the product row ML in which the main surfaces Ms are guided by the guide panel80is pushed by the lifting and lowering pusher61against the bar91(FIG. 14), and the products M are aligned in a single row.

After alignment, the bar91(FIG. 14) collapses, and the product row ML is transported onto the shutter62.

After transport, the shutter62opens, and the product row ML is loaded onto the raised lifting platform63indicated by the chain double-dashed line, after which the lifting platform63is lowered in the vertical downward direction Z2. A box B is set so that the opening Bu faces horizontally. After the product row ML is layered on the lifting platform63, the lifting platform63is lowered to a position at which the lower opening Bu of the box B is at substantially the same level as the product row ML. After lowering, the product row ML is pushed into the box B and packed by the box-packing pusher64.

The box B for which packing is completed is rotated so that the opening Bu faces upward.

Modified Examples of Second Embodiment

FIGS. 25A to 25Cshow modified examples of the accumulation device1according to the second embodiment described above. As shown inFIGS. 25A and 25B, in this modified example, the length of the telescopic conveyor30is constant, and the telescopic conveyor30is moved in the first direction X according to the size of the products M.

As shown inFIG. 25A, the telescopic conveyor30is moved toward the orientation change mechanism20when the products M are small. As shown inFIG. 25B, the upstream end of the telescopic conveyor30is moved below the induction conveyor11, and the telescopic conveyor30is moved away from the orientation change mechanism20when the products M are large.

Other structural aspects are the same as in the second embodiment, the same reference symbols are used for corresponding components and components that are the same, and detailed descriptions thereof are omitted.

The telescopic conveyor30may be moved using a motor (not shown) provided to a movement device30A. In this case, a stepping motor or a pulse motor may be used as the motor to control the position of the telescopic conveyor30. Specifically, a unit for storing the rotation angle of the motor (a rotation angle storage unit) is provided, as shown inFIG. 25C. The counter number of an encoder according to the size of the products M, i.e., the rotation angle of the motor, is set and stored in advance in the rotation angle storage unit. The counter number is read from the storage unit according to the size of the products M, and the position of the telescopic conveyor30is controlled based on the counter number.

As described above, preferred embodiments were described with reference to the drawings, but various changes and modifications within a self-evident range can easily be conceived of by one skilled in the art based on the basis of the present specification.

For example, an air cylinder was used in the telescopic conveyor30of the second embodiment to extend and retract the telescopic conveyor30, but extension and retraction may be performed using a motor instead of an air cylinder, or the telescopic conveyor30may be manually extended and retracted according to the size of the product.

Moreover, it will be apparent to those skilled in the art from the disclosure of the present invention that the conveying device110of the first embodiment can be replaced with the conveying device10of the second embodiment to include the induction conveyor11and the telescopic conveyor30so that the length of the conveying device110in the first embodiment can be selectively extended and retracted according to the length of the products in the conveying direction as described in the second embodiment.

Such changes and modifications are accordingly construed to be within the range of the present invention as established by the claims.

The accumulation device of the present invention demonstrates effects whereby products can be efficiently accumulated according to a plurality of accumulation patterns in a single device, and the present invention can therefore be widely applied in various devices for accumulating products in a prescribed accumulation pattern, and then processing the products.

General Interpretation of Terms