Container loading system

A loading system for loading articles into containers includes a container handling assembly and an article handling assemby, the paths of which intersect at a loading station. The container handling assembly carries a series of empty containers which it intermittently drives for moving the forwardmost one to the loading station while pushing a filled container from the loading station. The article handling assembly includes an input conveyor which moves the articles to a loading conveyor having alternating conveyor sections and window sections passing over the loading station. A platen carries a plurality of upwardly extending pins and is movable vertically between a receiving position with the pins disposed through complementary holes in the bottom of the container at the loading station and a depositing position wherein the pins are withdrawn from the openings in the container. Stop means accurately positions each container at the loading station and shifting means feeds articles from the conveyor section at the loading station and into and through the trailing window section to deposit them gently on the pins. A control system includes a plurality of solenoids, relays and sensing switches for synchronizing the operations of the container handling assembly and article handling assembly.

BACKGROUND OF THE INVENTION AND PRIOR ART STATEMENT 
The present invention relates generally to improvements in loaders for 
loading packages into containers, and specifically for loading into 
containers pliable packages of a plurality of fragile items to be 
maintained in a predetermined relation with respect to each other. 
The present invention is an improvement of the apparatus disclosed in U.S. 
Pat. No. 4,030,620, issued to Maynard R. Euverard et al. on June 21, 1977 
and assigned to the assignee of the present invention, the disclosure of 
which prior patent is incorporated herein by reference. While the Euverard 
et al. patent discloses an effective means for loading packages of fragile 
items into a container, it discloses no structure for handling the 
containers and for automatically moving empty containers to the loading 
station and for removing filled containers from the loading station. 
The Edwards et al. U.S. Pat. No. 2,830,416, issued Apr. 15, 1958, and the 
Bauer U.S. Pat. No. 3,653,178, issued Apr. 4, 1972, both disclose bottle 
casing machines which utilize a plurality of retractable pins somewhat 
like those disclosed in the Euverard et al. patent, for lowering an array 
of bottles into a container. Each of the Edwards et al. and Bauer patents 
also discloses means for moving cases or containers to and from the 
loading station. However, both of these patents disclose a zigzag or 
dogleg path for the containers and, therefore, require a plurality of 
motive means for moving the containers along the various sections of the 
container path. 
For example, in Edwards the containers slide down a chute in a first 
direction to a position adjacent to the loading station, then are pushed 
by a pusher in a second direction perpendicular to the first direction 
into the loading station and, after being filled, are pushed by a second 
pusher from the loading station in a direction parallel to the first 
direction. Similarly, in Bauer the containers are pushed horizontally to 
the loading station then, after being filled, are lowered to a discharge 
station at which point they are pushed by a pushing mechanism from the 
discharge station in a horizontal direction opposite to the direction in 
which they moved to the loading station. 
Copies of these prior patents are filed herewith. 
SUMMARY OF THE INVENTION 
The present invention provides a loader for loading packages of a plurality 
of fragile items into containers and for automatically and simply moving 
the containers to and from a loading station. 
It is a general object of the present invention to achieve an automatic 
handling of the empty and loaded containers in a simplified manner with a 
minimum of driving means. 
It is another object of this invention to move the containers in a single 
direction to, through and from the loading station. 
Another object of this invention is the provision of a loader of the type 
set forth, which includes apparatus for synchronizing the operation of the 
article handling assembly and the container handling assembly. 
Another object of this invention is the provision of a loader of the type 
set forth which is selectively operable for loading either one or two 
layers of articles into each container. 
Still another object of this invention is the provision of a loader of the 
type set forth which includes means for accumulating subsets of articles 
into a single set for loading into a container. 
In summary, these objects are achieved by providing in a loader for loading 
into containers at a loading station sets of grouped individual articles, 
container handling apparatus comprising container transfer means for 
moving an empty container along a container path to the loading station 
while simultaneously removing a filled container from the loading station 
along the path and thereafter supporting the empty container at the 
loading station, stop means movable between a stop position in the path of 
a container accurately to position it at the loading station and a release 
position out of the path of the container to accommodate removal thereof 
from the loading station, conveying means for transporting a set of 
grouped individual articles along an article path to the loading station 
and into a container thereat, and control means coupled to the container 
transfer means and to the stop means and responsive to operation of the 
container transfer means in moving a container to the loading station for 
moving the stop means to the stop position thereof and for subsequently 
stopping the container transfer means, the control means being responsive 
to completion of the loading of a container for moving the stop means to 
the release position thereof and restarting the container transfer means 
to move a new empty container to the loading station and to remove the 
filled container from the loading station. 
Further features of the invention pertain to the particular arrangement of 
the parts of the loader whereby the above-outlined and additional 
operating features thereof are attained. 
The invention, both as to its organization and method of operation, 
together with further objects and advantages thereof, will best be 
understood by reference to the following specification taken in connection 
with the accompanying drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring now to FIGS 1 and 2 of the drawings, there is shown a container 
loading system, generally designated by the numeral 20, for loading 
packages 30 of articles into containers 40, the system 20 including a 
package handling assembly 50 and a container handling assembly 100. The 
packages 30, the containers 40 and the package handling assembly 50 may 
all be as disclosed in the aforementioned U.S. Pat. No. 4,030,620. More 
particularly, each package 30 may be a package of sliced hamburger buns or 
the like, enclosed in a wrapping of a plastic, such as polyethylene or 
polypropylene plastic, it being necessary to maintain the upper and lower 
halves of the sliced buns in registry throughout the loading operation. 
The containers 40 may be in the form of plastic baskets, each being 
generally rectangular in shape and including a pair of opposed side walls 
41 and a pair of opposed end walls 42 all closed by a flat rectangular 
bottom wall 43 having a plurality of holes or apertures therethrough, with 
the end walls 42 preferably extending downwardly a predetermined distance 
below the bottom wall 43 to define front and rear legs 44 (see FIG. 4) to 
facilitate handling and stacking of the containers 40. The package handing 
assembly 50 is arranged to load either one or two layers of the packages 
30 in each of the containers 40, depending upon the thickness of the 
articles in each package 30. 
It will be understood that the present invention is also useful for loading 
a set of individual items, such as individual portion pies, for example, 
into a basket, the items being grouped, and it being desirable to maintain 
the items in the group in their respective relationship with respect to 
each other and with respect to the group. Hereinafter, the phrase "set of 
grouped individual articles" is to cover both products such as the package 
30, as well as sets of individual articles which may not be surrounded by 
a plastic cover. Furthermore, although the invention will be described in 
detail as applied to handling a package 30 containing hamburger buns in a 
so-called "pillow-pack", it is to be understood that the principles of the 
loading system 20 are also applicable to many other types of items that 
are to be loaded into a wide variety of shipping containers. Accordingly, 
it is to be understood that the following description is illustrative and 
is in no way to be considered a limitation of the use or application of 
the loading system 20. 
The package handling assembly 50 includes a frame, generally designated by 
the numeral 51, comprising a plurality of upstanding posts 52 arranged in 
a generally rectangular pattern, and being interconnected by lower side 
beams 53, upper side beams 54 and end beams 55 to form a rigid framework. 
Extending upwardly from the upper side beams 54 adjacent to one end 
thereof are four vertically upstanding short posts 56 arranged in a 
rectangular configuration for supporting thereon, by means of suitable 
crossbeams, a control box 57 for housing the electrical control circuitry 
for the present invention. Communicating with the interior of the control 
box 57 at one end thereof and extending therefrom to the other end of the 
frame 51 substantially midway between the upper side beams 53 a 
predetermined distance thereabove and parallel thereto is a hollow conduit 
rail 58. Supported by suitable means just beneath the conduit rail 58 
substantially parallel thereto is a center support rail 59 for a purpose 
to be explained more fully below. 
Carried on the frame 51 is an infeed conveyor, generally designated by the 
numeral 60, which includes a pair of longitudinally spaced-apart and 
laterally extending parallel shafts 61, each provided at the opposite ends 
thereof with suitable bearings 62 for mounting thereon sprockets 63, with 
each pair of sprockets 63 at corresponding ends of the shafts 61 being 
engaged with the corresponding one of a pair of laterally spaced-apart 
endless roller chains 64 which cooperate to support therebetween a 
plurality of free rollers 65. Suitable guide means (not shown) maintain 
the rollers in the upper flight of the infeed conveyor 60 in a parallel 
configuration for cooperation to define a substantially planar support 
surface. The frame 51 may be provided at the opposite sides thereof with 
side plates 66 to protect the infeed conveyor 60. The input end of the 
infeed conveyor 60 (disposed to the right, as viewed in FIGS. 1 and 2) 
extends a slight distance to the right of the frame 51 and is positioned 
to receive packages 30 from upstream processing apparatus, such as a 
packet (not shown). 
The shaft 61 at the output end of the infeed conveyor 60 carries an outer 
sprocket 67 at one end thereof for meshing engagement with a drive chain 
68, which is in turn disposed in meshing engagement with one sprocket of a 
double sprocket assembly 69 coupled to the output shaft of an electric 
drive motor 70 mounted on the frame 51. The other sprocket of the double 
sprocket assembly 69 is disposed in meshing engagement with a drive chain 
72 which is in turn coupled to one sprocket of a double sprocket assembly 
73 mounted at one end of a horizontal shaft 74 extending transversely of 
the frame 51. Also mounted on the shaft 74 is a pneumatic brake/clutch 75 
which includes solenoid-actuated valves for operating the brake/clutch in 
a brake condition for stopping the shaft 74 or a clutch condition for 
accommodating rotation of the shaft 74. Mounted on the shaft 74 at the 
other end thereof is a sprocket 76, the sprocket 76 and the other sprocket 
of the double sprocket assembly 73 being respectively connected by drive 
chains 77 to sprockets 78 which are respectively mounted on stub shafts 79 
at opposite sides of the frame 51. 
Also mounted on each of the stub shafts 79 are inner sprockets 81 (see FIG. 
11) which respectively engage laterally spaced-apart roller chains 85 of a 
loader conveyor, generally designated by the numeral 80. Each of the 
chains 85 also engages an idler roller 83 which is mounted on an 
associated stub arm 82 carried by a vertical upright member 71 of the 
frame 51. Each of the conveyor chains 85 also engages three sprockets 84 
which are respectively mounted on corresponding stub shafts for 
cooperation to define generally rectangular parallel paths disposed in 
vertical planes for the conveyor chains 85, as illustrated in FIG. 1. The 
loader conveyor 80 includes two conveyor sections 87, each comprising a 
plurality of free rollers interconnecting the roller chains 85, the 
conveyor sections 87 being spaced apart by window sections 88 in which 
there are no rollers. The loader conveyor 80 is so mounted that when the 
conveyor sections 87 thereof are disposed along the upper flight of the 
loader conveyor 80, the rollers 86 cooperate to define a support surface 
substantially coplanar with that along the upper flight of the infeed 
conveyor 60. Preferably, idler rollers 89 are disposed between the output 
end of the infeed conveyor 60 and the adjacent entry end of the loader 
conveyor 80 to bridge the gap therebetween. Further details of the 
construction of the infeed conveyor 60 and the loader conveyor 80 are set 
forth in the aforementioned U.S. Pat. No. 4,030,620. 
Situated between the conveyor chains 85 of the loader conveyor 80 and just 
beneath the upper flight thereof is a loading station. Disposed at the 
loading station is a generally rectangular horizontal platen 90 mounted by 
suitable pneumatically driven means (not shown) for vertical movement 
between a full down or depositing position (see FIGS. 1 and 3) and a full 
up or receiving position (see FIG. 10). The platen 90 carries thereon a 
plurality of upstanding pins 91 which are arranged in a regular pattern 
substantially covering the surface of the platen 90 and being adapted and 
arranged respectively to extend through the openings in the bottom wall 43 
of an associated container 40 when it is disposed at the loading station, 
as will be explained more fully below. 
As will also be explained more fully below, it is necessary to cause the 
free rollers 86 of the loader conveyor 80 to rotate in a counterclockwise 
direction, as viewed in FIG. 1, when they are at the loading station, and 
to this end there has been provided a shoe 95 which is mounted adjacent to 
one end of the rollers 86, and essentially overlying all rollers disposed 
along the upper reach of the loader conveyor 80 except for those 
immediately adjacent to the sprockets 84. The shoe 95 is secured by a pair 
of mounting arms 94 (one shown) to a pivot shaft 96 mounted for rotation 
about an axis parallel to the shoe 95, one of the arms 94 being coupled to 
the piston of an air motor 97 which is mounted on a bracket 98 for 
effecting pivotal movement of the shoe 95 between a retracted position out 
of engagement with the rollers 86 and a loading position pressed firmly 
against the free rollers 86 to effect a rotation thereof in a clockwise 
direction, as viewed in FIG. 1, for unloading a package from the loader 
conveyor 80 in the manner which is more fully described in the 
aforementioned U.S. Pat. No. 4,030,620. 
Referring now also to FIGS. 3 through 6 of the drawings, the container 
handling assembly 100 includes a frame, generally designated by the 
numeral 101, comprising a pair of upstanding posts 102 spaced laterally 
from the frame 51 and cooperating therewith to support a pair of parallel 
lower beams 103 which extend substantially normal to the side beams 53 of 
the frame 51 a predetermined distance thereabove, the lower beams 103 
being interconnected at the opposite ends thereof by crossbeams 104, one 
of which is supported on an adjacent one of the side beams 53 by stub 
posts 105. Extending upwardly from the opposite ends of each of the 
crossbeams 104 are upright members 106, the upper ends of which are 
interconnected by cross members 107 which extend parallel to the 
crossbeams 104 and by upper beams 108 which are parallel to the lower 
beams 103. 
The upper cross members 107 are also interconnected by a pair of container 
track rails 110 and 111 which are respectively disposed a slight distance 
inwardly of the upper beams 108 and parallel thereto. Each of the 
container track rails 110 and 111 is preferably in the form of an angle 
member having one flange thereof upstanding, the other flanges extending 
horizontally inwardly toward each other and being substantially coplanar, 
whereby the container track rails 110 and 111 cooperate to define a track 
112 dimensioned to support on the horizontal flanges thereof the opposite 
side edges of containers 40. The track 112 extends all the way through the 
loading station above the platen 90 and below the upper flight of the 
loader conveyor 80, the track 112 having an input end disposed to the 
left, as viewed in FIG. 3, and an output end disposed to the right, as 
viewed in FIG. 3, the length of the track 112 being such as to accommodate 
at least two of the containers 40 thereon in end-to-end relationship. For 
a purpose explained below, the vertical flange of the container track rail 
110 terminates at an end edge 109 (see FIG. 7) spaced a predetermined 
distance short of the output end of the horizontal flange. 
Two flat rectangular guide plates 113, each having a horizontal upper guide 
surface 114, are respectively fixedly secured to the horizontal flanges of 
the container track rails 110 and 111 intermediate the ends thereof and 
extend inwardly a predetermined distance beyond the inner edges thereof. 
Each of the guide plates 113 is substantially shorter than the 
corresponding container track rail 110 or 111 and terminates at an exit 
end edge 115 disposed adjacent to but outside the loading station. 
Respectively carried beneath the upper beams 108 adjacent to the input ends 
thereof are laterally aligned pillow blocks 116 respectively rotatably 
supporting the opposite ends of a shaft 117 which extends tranversely of 
the track 102 and supports thereon a pair of spaced-apart sprockets 118 of 
a container drive conveyor, generally designated by the numeral 120. 
Respectively engaging the sprockets 118 are two endless roller chains 121 
which also respectively engage sprockets 122 on a transverse shaft 123 
supported in pillow blocks 124 on brackets 125, the shafts 117 and 123 
being spaced apart a distance such that the guide plates 113 are disposed 
entirely therebetween, and with the shaft 123 preferably being disposed 
outside the loading station. The shaft 123 carries thereon a drive 
sprocket 126 which engages a drive chain 127 which is in turn coupled to a 
brake/clutch 75a at the output of a drive motor 128 carried upon support 
arms 129 beneath the lower beams 103. 
The roller chains 121 respectively carry thereon two laterally aligned 
drive lugs 130 which are identical in construction, whereby only one of 
the drive lugs 130 will be described in detail. Referring in particular to 
FIGS. 4 through 6, each of the drive lugs 130 includes a pair of 
attachment arms 131 which are respectively disposed on opposite sides of 
the associated roller chain 121 and are pivotally connected thereto by 
pivot pins 132 adjacent to the forward ends of the attachment arms 131. 
Each of the attachment arms 131 has a lower guide surface 133 and is 
integral at the pivot end thereof with a short arm extending therefrom 
substantially normal thereto, the short arms 134 being interconnected by a 
bight member 135 along the outer periphery of the roller chain 121, the 
forward surfaces of the arms 134 and bight member 135 being coplanar to 
define a drive surface 136. The drive lug 130 is pivotally movable between 
a drive position, illustrated in FIGS. 4 and 6, wherein the guide surface 
133 is disposed for parallel sliding engagement with the upper guide 
surface 114 of the associated guide plate 113, and a release position, 
illustrated in FIG. 5, wherein the attachment arms extend inwardly of the 
loop of the roller chain 121 and the bight member 135 lies against the 
roller chain 121. 
Referring also to FIGS. 7 and 8 of the drawings, the container handling 
assembly 100 includes a container stop assembly, generally designated by 
the numeral 140, which includes a bracket 141 supported on one of the 
upper beams 108 and having pivotally mounted thereto one end of an air 
motor 142, the piston rod of which is pivotally mounted adjacent to one 
end of a clevis bracket 143, the other end of which is fixedly secured to 
an elongated flat rectangular stop bar 144 intermediate the ends thereof, 
one end of the stop bar 144 being secured to a pivto shaft 145 carried by 
the bracket 141, and the distal end of the stop bar 144 extending toward 
the output end of the track 112. Slidably mounted on the stop bar 144 is 
an adjustable stop lug 146 which projects inwardly from the stop bar 144 
substantially normal thereto and may be fixedly secured thereto by 
suitable fastening means (not shown). 
The stop bar 144 is pivotally movable by means of the air motor 142 between 
a stop position, illustrated in solid line in FIGS. 2 and 7, and a release 
position illustrated in broken line in FIG. 7. It will be appreciated 
that, in the stop position thereof, the stop bar 144 extends substantially 
parallel to the adjacent container track rail 110, with the stop lug 146 
being positioned just beyond the end edge 109 of the vertical flange of 
the container track rail 110 and dimensioned to project laterally into the 
path of the container 40 therealong for engagement with the leading end of 
a container 40 to stop its movement along the track 112 in a loading 
position overlying the platen 90, with the openings in the bottom of the 
container 40 being respectively aligned with the pins 91. In the release 
position of the container stop assembly 140, the stop lug 146 is disposed 
out of the path of the container 40 to permit removal thereof from the 
loading station along the track 112. The sliding adjustability of the stop 
lug 146 along the stop bar 144 permits accurate positioning of the 
container 40 at the loading station. 
In operation, there are normally a plurality of containers 40 arranged in 
end-to-end relationship along the track 112, the containers 40 being fed 
to the input end of the track 112 by an associated infeed conveyor 147 and 
being removed from the output end of the track 112 by an associated 
outfeed conveyor 148 (see FIGS. 1 and 3). Referring also to FIGS. 9 and 
10, in the preferred embodiment there are at all times at least portions 
of three different containers 40 on the track 112, although it will be 
appreciated that the length of the track 112 could be such that any other 
desired number of containers 40 could be accommodated thereon. But 
normally the containers 40 are arranged on the track 112 in a contiguous 
series or train, the dimensions of the track 112 being so related to the 
dimensions of the containers 40 that when the forwardmost container in the 
series is positioned at the loading station in engagement with the stop 
lug 146, only the front part of the rearmost container 40 will be disposed 
on the track 112, extending slightly forwardly of the sprockets 118. 
It will be appreciated that as the drive lugs 130 come around the sprockets 
118, they will be in the release position illustrated in FIG. 5. As the 
drive lugs 130 move along the upper flight of the container drive conveyor 
120, the guide surfaces 133 come into camming engagement with the leading 
ends of the guide plates 113 and are moved thereby to the drive position 
illustrated in FIG. 4, thereby bringing the drive surfaces 136 into 
driving engagement with the inner surface of the front leg 44 of the 
rearmost one of the containers 40 in the series of containers on the track 
112 for driving engagement therewith. At this time, the container stop 
assembly 140 will be moved to the release position thereof in a manner to 
be described more fully below, and the continued movement of the container 
drive conveyor 120 drives the series of containers 40 along the track 112 
to the right, as viewed in FIG. 3, thereby pushing the forwardmost 
container from the loading station and off of the track 112 to the outfeed 
conveyor 148, which is preferably moving at a greater linear speed than 
the container drive conveyor 120 to create a gap between the forwardmost 
container 40 and the next following container, which then becomes the lead 
container in the series on the track 112. 
When this next container reaches the loading station, it will engage the 
stop lug 146, which will since have been moved back to the stop position 
thereof by means to be described below. The guide plates 113 are so 
positioned that at or immediately prior to the engagement of the lead 
container with the stop lug 146, the drive lugs 130 will pass the exit and 
edges 115 of the guide plates 113 and fall by gravity to the release 
positions thereof illustrated in FIG. 5. In this release position, the 
drive surfaces 136 will be disposed at an angle to the inner surface of 
the front leg 44 of the rearmost container 40 for camming engagement 
therebeneath as the drive lugs 130 continue around the sprockets 122. This 
camming movement may momentarily lift the leading end of the rearmost 
container 40 and will simultaneously move the lead container 40 snugly 
against the stop lug 146. A new empty container 40 will then be fed by the 
infeed conveyor 140 into engagement with the rear end of the series of 
containers 40 to be in position for engagement by the drive lugs 30 in the 
next cycle. 
The container loading system 20 also includes a stop gate 149 which extends 
transversely of the infeed conveyor 60 intermediate the ends thereof (see 
FIGS. 1 and 2), the stop gate 149 being mounted by suitable means (not 
shown) for movement between a retracted position, illustrated in solid 
line in FIG. 1, out of the path of the packages 30 along the infeed 
conveyor 60, and a stop position, illustrated in broken line in FIG. 1, 
disposed in the path of the packages 30 along the infeed conveyor 60 for 
engagement therewith. The stop gate 149 is preferably pneumatically driven 
and is actuated by a photorelay 150 which includes a transmitter 151 and 
receiver 152 respectively disposed at opposite sides of the infeed 
conveyor 60 adjacent to the input end thereof for providing a light beam 
extending transversely of the infeed conveyor 60 and interruptible by 
packages 30 passing therealong, all for a purpose which will be explained 
more fully below. 
In order to control the operation of the container loading system 20, there 
are provided a plurality of limit switches, all connected in a control 
circuit, generally designated by the numeral 200 (see FIGS. 14 and 15). 
More particularly, limit switches 160 and 161 (see FIGS. 1 and 2) are 
respectively supported by the center support rail 59, and are respectively 
provided with lever actuator arms 158 and 159, which respectively depend 
into the paths of the packages 30 along the infeed conveyor 60 and the 
loader conveyor 80 for engagement and actuation thereby, limit switch 161 
being a double-pole switch. A limit switch 162 (see FIG. 2) is disposed 
adjacent to the input end of the track 112 for engagement by containers 40 
passing therealong, while limit switches 164 and 165 (see FIGS. 2 and 3) 
are disposed along the container drive conveyor 120 for engagement by the 
drive lugs 130, limit switch 165 being a double-pole switch. A limit 
switch 166 (see FIGS. 1 and 3) is disposed adjacent to the container track 
rail 111 at the loading station for engagement by a container 40 in the 
loading station. Double-pole limit switch 163 and limit switch 167 (see 
FIG. 1) are disposed at the loading station for engagement by the platen 
90, and limit switches 168 and 169 (see FIG. 1) are disposed at the 
loading station along the upper flight of the loader conveyor 80 for 
engagement by suitable lugs thereon (not shown). 
Referring now to FIGS. 14 and 15 of the drawings, the electrical control 
circuit 200 for the container loading system 20 is shown. The system is 
powered from a 460-volt, 3-phase, 60 Hz source of electrical power, which 
is fed through a power switch 201, disconnect switches 202 and thermal 
overload switches 203 in parallel to the drive motors 70 and 128, the 
power being connected to the drive motor 70 through the normally-open 
contacts 204a of a relay 204, and to the drive motor 128 through the 
normally-open contacts 205a of a relay 205. Two of the three phases of the 
electrical power supply are connected to the primary of a transformer 206, 
the secondary coil of which has one terminal thereof connected through a 
fuse 207 to a conductor 208, and has the other terminal thereof grounded 
and connected to a conductor 209, the conductors 208 and 209 comprising 
control power input lines having a voltage therebetween of approximately 
115 volts. 
The conductor 208 is connected to the series combination of normally-closed 
safety switches 210, 211 and 212 and a normally-closed emergency stop 
switch 213. The safety switches 210-212 are limit switches which are 
coupled to various covers (not shown) which may be provided over certain 
parts of the container loading system 20 for protection of the apparatus 
as well as workmen operating it, the safety switches 210-212 being closed 
when the covers are closed and being opened when the covers are opened to 
de-energize the system. The emergency stop switch 213 is preferably a 
push-button type and is connected to the fixed contacts of both poles of a 
double-pole ON-OFF switch, preferably of the push-pull type. The other 
fixed contact of one pole of the ON-OFF switch 214 is connected through an 
indicator lamp 215 to the conductor 209, while the fixed contact of the 
other pole of the ON-OFF switch 214 is connected through the normally-open 
contacts 216a and coil of a relay 216 to the conductor 209, the lamp 215 
being in parallel with the coil of the relay 216. Connected in parallel 
with the coil of the relay 216 is a solenoid 217, which controls a valve 
in the pneumatic system of the present invention for bleeding air 
therefrom when the container loading system is de-energized. It will be 
noted that the ON-OFF switch 214 is a three-position switch having a start 
position with both poles closed, a stop position with both poles open and 
a standby/run position, illustrated in FIG. 14, with the pole connected to 
the relay contacts 216a closed and the other pole open. 
The conductor 208 is also connected through the normally-open contacts 216b 
of the relay 216 to a conductor 219, and is also connected to the 
conductor 209 through the series combination of a normally-closed pole 
161a of the limit switch 161, and the normally-open contacts 218a and coil 
of a relay 218. The conductor 219 is connected in parallel to the coils of 
the relays 204 and 205, respectively through their normally-closed 
overload contacts 204b and 205b, the coils 204 and 205 being in turn 
connected to the conductor 209. The conductor 219 is also connected 
through a normally-open pole 163a of the limit switch 163 to the junction 
between the contacts 218a and coil of the relay 218, this junction also 
being connected to the conductor 219 through one pole of a double-pole 
selector switch 220, the other pole of which is connected between the 
conductor 219 and a conductor 221. The selector switch 220 is arranged so 
that when one pole thereof is closed, the other is open, and is movable 
between a position illustrated in FIG. 14 for automatic operation of the 
container loading system 20, and another position for manual operation. If 
desired, the conductor 221 may be connected in parallel to relays 222 and 
223, respectively through their normally-closed overload contacts 222a and 
223a, these relay coils in turn being connected to the conductor 209 for 
respectively controlling the container infeed and outfeed conveyors 147 
and 148. 
The conductor 221 is also connected to the conductor 209 through the series 
combination of the normally-open limit switch 162, a normally-closed pole 
163b of the limit switch 163 and a solenoid 224. Also connected between 
the conductors 221 and 209 is the series combination of the normally-open 
limit switch 164 and a solenoid 225. The solenoids 224 and 225 control the 
valving on the brake/clutch 75a associated with the drive motor 128 of the 
container drive conveyor 120. The conductor 221 is also connected to the 
conductor 209 through the series combination of a normally-open pole 165a 
of the limit switch 165, the normally-open limit switch 166 and a solenoid 
226. A solenoid 227 is connected in parallel with the solenoid 226, the 
solenoids 226 and 227 respectively being operative to elevate the platen 
90 to upper and intermediate receiving positions thereof, in a manner to 
be described more fully below. 
The junction between the limit switch pole 165a and the limit switch 166 is 
also connected to the conductor 209 through a solenoid 228. Also connected 
across the conductors 221 and 209 is the series combination of the 
normally-open limit switch 167 and a solenoid 229, the solenoids 228 and 
229 controlling the valving for the air motor 142 of the container stop 
assembly 140 for respectively moving it to the stop and release positions 
thereof. The conductor 221 is also connected to the conductor 209 through 
the series combination of the normally-open contacts 218b of the relay 218 
and the coil of a relay 230 which has delay contacts (not shown) in the 
control circuit of an associated packer upstream of the package infeed 
conveyor 60 for stopping the packer a predetermined time after the relay 
218 is de-energized in the event of a prolonged stoppage of the container 
loading system 20. 
Also connected in series across the conductors 221 and 209 are the 
normally-open limit switch 168 and a solenoid 231. Connected in parallel 
with the solenoid 231 is the series combination of a solenoid 232 and one 
pole of a double-pole selector switch 233. Connected in parallel with that 
one pole are the normally-open contacts 234a of a relay 234, the coil of 
which is connected in series with the other pole of the selector switch 
233, the normally-closed limit switch 165 and the normally-open contacts 
235a of a relay 235 across the conductors 221 and 209. Connected in 
parallel with the relay contacts 235a are the normally-open contacts 234b 
of the relay 234. 
Also connected in series across the conductors 221 and 209 are the 
normally-open limit switch 160 and the coil of a relay 237, which coil has 
connected in parallel therewith the coil of a relay 236. Also connected in 
parallel with the coil of the relay 237 is the series combination of 
normally-closed delay contacts 237a of the relay 237, normally-open 
contacts 218c of the relay 218 and a solenoid 238. Also connected in 
series across the conductors 221 and 209 are the normally-closed contacts 
236a of the relay 236 and a solenoid 239. 
The solenoids 231 and 232 respectively control the lowering of the platen 
90 from its intermediate and upper receiving positions, while the 
solenoids 238 and 239 control the valving of the air motor 97, 
respectively to lower and raise the shoe 95. 
Also connected in series across the conductors 221 and 209 are the 
normally-open limit switch 169 and the coil of the relay 235. The 
conductor 221 is also connected to the conductor 209 through the series 
combination of the normally-open limit switch 160 and a solenoid 240 and 
through the series combination of the normally-open contacts 235b of the 
relay 235 and a solenoid 241, the solenoids 240 and 241 being connected to 
the valving for the brake/clutch 75, respectively to start and stop the 
loader conveyor 80. 
The conductor 221 is also connected through a single-pole selector switch 
242 to a conductor 243 and to the transmitter 151 of the photorelay 150, 
the receiver 152 of which is connected to the conductor 209. Connected in 
series between the conductors 243 and 209 are the normally-closed delay 
contacts 244a of a relay 244, the normally-open contacts 150a of the 
photorelay 150 and the coil of a relay 245. Connected in parallel with the 
photorelay contacts 150a are the normally-open contacts 245a of the relay 
245. The junction between the relay contacts 244a and 150a is connected to 
the conductor 209 through the series combination of the normally-closed 
contacts 150b of the photorelay 150, the normally-open contacts 245b of 
the relay 245 and a solenoid 246 which controls the raising and lowering 
of the stop gate 149. Connected in parallel with the solenoid 246 is the 
coil of a relay 247 which has normally-open contacts 247a connected in 
parallel with the relay contacts 150b and 245b. Also connected in series 
between the conductors 243 and 209 are the normally-open contacts 150c of 
the photorelay 150, the normally-open contacts 247b of the relay 247 and 
the coil of the relay 244. Connected in parallel with the coil of the 
relay 244 is the coil of a relay 248 which has normally-open contacts 248a 
connected in parallel with the relay contacts 247b. 
The operation of the container loading system 20 will now be described in 
detail. In its normal mode of operation, the container loading system 20 
is designed to load a single package 30 of articles or other set of 
grouped individual articles into each container 40. For this mode of 
operation, the control circuit 200 is initially in the configuration 
illustrated in FIGS. 14 and 15, with the selector switch 214 in its 
standby/run position, the selector switch 220 in the automatic position, 
the selector switch 233 in position for loading a single package into each 
container, and the selector switch 242 in the position indicated for the 
mode of operation wherein each set of grouped individual articles 
comprises a single package. Since the selector switch 242 is open in this 
position, it will be appreciated that the photorelay 150 and the circuitry 
controlling the stop gate 149 are all de-energized and inoperable. 
Referring to FIGS. 9 through 12 of the drawings, for purposes of 
discussion the system will be considered as being initially in the 
configuration illustrated in FIG. 9, with a series of three containers 
designated A, B and C on the track 112, with the forwardmost one thereof 
being disposed at the loading station and having a package 30 loaded 
thereinto, and with the platen 90 being disposed in its full down 
position. 
Upon closure of the power switch 201, power is provided at the transformer 
206 for producing a control voltage across the secondary winding thereof. 
When the ON-OFF switch 214 is moved to the ON position, closing the upper 
pole thereof, the lamp 215 is energized to indicate that power is being 
provided to the system 20, the solenoid 217 is energized to cut off the 
bleed from the pneumatic system, and the relay 216 is energized, thereby 
closing its contacts 216a to latch it in the energized position through 
the other pole of the ON-OFF switch 214 and closing its contacts 216b for 
energizing the relays 204 and 205, thereby closing the contacts 204a and 
205a thereof to energize the drive motors 70 and 128 and start the infeed 
conveyor 60. The loader conveyor 80 does not start because the 
brake/clutch 75 is initially in the brake condition. If the relays 222 and 
223 are connected in the circuit, they are also energized by the closure 
of the relay contacts 216b for respectively starting the container infeed 
and outfeed conveyors 147 and 148. 
It will be noted that while the energization of the relay 205 energizes the 
drive motor 128, the brake/clutch 75a thereof will normally be in the 
brake condition, thereby preventing movement of the container drive 
conveyor 120 unless a new empty container is positioned at the input end 
of the track 112 for engagement by the drive lugs 130, as indicated in 
FIG. 9, in which case that rearmost container (designated C in FIG. 9) 
will close the limit switch 162 for energizing the solenoid 224 through 
the pole 163b of the limit switch 163 which is held closed by the platen 
90 in its full down position. Energization of the solenoid 224 shifts the 
brake/clutch 75a on the drive motor 128 to the clutch condition for 
driving the container drive conveyor 120. 
It will be noted that the container stop assembly 140 will be disposed in 
the release position thereof, having been placed in that position by 
energization of the solenoid 229 through the limit switch 167 which had 
previously been momentarily closed by the platen 90 during its descent to 
its full down position. As the drive lugs 130 move around the sprockets 
118, they engage the front leg 44 of the rearmost one C of the containers 
40 on the track 112 for driving the series A-C of containers to the right 
along the track 112 in the manner described above, and pushing the filled 
containers A from the loading station onto the outfeed conveyor 148. As 
the drive lugs 130 move along the upper flight of the container drive 
conveyor 120, they engage the limit switch 165 for closing the pole 165a 
thereof and thereby energizing the solenoid 228 for actuating the air 
motor 142 to move the container stop assembly 140 back to the stop 
position thereof with the stop lug 146 disposed in the path of the 
oncoming empty container B, this movement being accommodated by a gap 
between the containers A and B which is caused by the fact that the 
outfeed conveyor 148 is moving at a linear speed greater than that of the 
container drive conveyor 120. 
At the time that the limit switch pole 165a is closed, the limit switch 166 
will already have been closed by the arrival of the leading end of the 
container B at the loading station, so that when the limit switch 165 
closes, the solenoids 226 and 227 will be energized for beginning the 
elevation of the platen 90 to its full up or upper receiving position. In 
this regard, it will be noted that the platen 90 is capable of disposition 
in a full down or depositing position and two receiving positions, viz., 
an upper receiving position and an intermediate receiving position, these 
positions being controlled by two separate pneumatic cylinders. When both 
of these cylinders are actuated, the platen 90 is moved between its full 
up and full down positions. As the platen 90 leaves its full down position 
the pole 163b of the limit switch 163 opens to de-energize the solenoid 
224 and the pole 163a closes to energize the relay 218, thereby closing 
its contacts 218a, 218b and 218c, closure of the contacts 218b energizing 
the relay 230. If the relay 230 thereafter is de-energized for a 
predetermined time, the associated packer will be stopped. As the drive 
lugs 130 pass the limit switch 165 its pole 165a reopens, de-energizing 
the solenoids 226-228, but the conditions of the pneumatic drives for the 
platen 90 and container stop assembly 140 remain the same until positively 
changed by solenoids 231, 232 and 229, as explained below. 
The movement of the platen 90 and the container drive conveyor 120 are 
synchronized so that the container B will have arrived at the loading 
station in engagement with the stop lug 146 by the time the pins 91 on the 
rising platen 90 enter the plane of the bottom wall 43 of the container 
40, so that they may pass through the complementary apertures in the 
bottom wall 43. When the container B engages the stop lug 146, the drive 
lugs 130 close the limit switch 164 to energize the solenoid 225 and 
actuate the brake/clutch 75a on the drive motor 128 back to its brake 
condition to stop the container drive conveyor 120. 
It will be appreciated that simultaneously with the operation of the 
container drive conveyor 120, the infeed conveyor 60 will be conveying a 
package 30 toward the loading station. When the package 30 engages the 
lever actuator 158 it closes the limit switch 160 to energize the solenoid 
240 for actuating the brake/clutch 75 to the clutch condition thereof to 
start the loader conveyor 80. The operations of the infeed conveyor 60 and 
loader conveyor 80 are synchronized so that when the package 30 arrives at 
the output end of the infeed conveyor 60, the leading edge of one of the 
conveyor sections 87 will simultaneously be arriving in position at the 
upper flight of the loader conveyor 80 for receiving the package 30 
thereon and carrying it to the loading station. By the time the package 30 
has arrived at the loading station, the platen 90 has been raised to its 
full up position, illustrated in FIG. 11, with the pins 91 extending 
upwardly through a container 40, and as the package 30 arrives at the 
loading station, it engages the lever actuator 159 for closing the pole 
161b and opening the pole 161a of the limit switch 161, the relay 218 
being maintained energized through the now-closed pole 163a of the limit 
switch 163. 
Closure of the pole 161b of the limit switch 161 energizes the relay 236 to 
open its contacts 236a for de-energizing the solenoid 239, and also 
energizes the solenoid 238 through the normally-closed relay contacts 237a 
and now-closed relay contacts 218c for actuating the air motor 97 to lower 
the shoe 95 into engagement with the rollers 86 of the loader conveyor 80 
to cause rotation thereof in a clockwise direction, as viewed in FIG. 1, 
thereby feeding the package 30 from the conveyor section 87 and through 
the trailing window section 88 onto the pins 91, all as is described in 
greater detail in the aforementioned U.S. Pat. No. 4,030,620. Closure of 
the pole 161b of the limit switch 161 also energizes the solenoid 237 and, 
after a predetermined short delay, the contacts 237a thereof open to 
de-energize the solenoid 238, the shoe 95 remaining down until the 
condition of the air motor 97 is positively changed by the solenoid 239. 
When the package 30 has been completely fed through the window section 88 
of the loader conveyor 80, it falls out of engagement with the lever 
actuator 159, thereby reopening the pole 161b and reclosing the pole 161a 
of the limit switch 161, for de-energizing the relay 236 and reclosing the 
contacts 236a thereof to re-energize the solenoid 239 and retract the shoe 
95. 
After the package 30 has been deposited on the pins 91, a lug on the loader 
conveyor 80 closes the limit switch 168 to energize the solenoids 231 and 
232 for lowering the platen 90 to its full down position, illustrated in 
FIG. 12, and thereby depositing the package 30 in the container 40 at the 
loading station. As the lug on the loader conveyor 80 passes the limit 
switch 168, it reopens to de-energize the solenoids 231 and 232, the 
platen 90 continuing down until the condition of the pneumatic drive 
therefor is positively changed by solenoids 226 and 227. The lug on the 
loader conveyor 80 then closes the limit switch 169 to energize the relay 
235, thereby closing the contacts 235b thereof to energize the solenoid 
241 which operates to shift the condition of the brake/clutch 75 to its 
brake condition to stop the loader conveyor 80, the solenoid 240 having 
been de-energized when the package 30 passed the lever actuator 158 
allowing the limit switch 160 to reopen. 
As the platen 90 lowers to its full down position, it closes the limit 
switch 167 for energizing the solenoid 229 to move the container stop 
assembly 140 back to the release position thereof with the lug 146 out of 
the path of the container 40, this movement being permitted by reason of 
the previous de-energization of the solenoid 228 upon reopening of the 
pole 165a of the limit switch 165 as the drive lugs 130 passed thereby. 
When the pins 91 are fully withdrawn from the openings in the bottom of 
the container 40, the platen 90 actuates the limit switch 163 to reopen 
the pole 163b thereof. In the meantime, a new empty container 40 will have 
been deposited in the input end of the track 112 by the infeed conveyor 
147, for reclosing the limit switch 162, so that when the pole 163b of the 
limit switch 163 recloses as the platen 90 reaches its full down position, 
the solenoid 224 is re-energized for restarting the container drive 
conveyor 120 in the manner described above, and starting another cycle of 
operation of the container loading system 20. The relay 218 remains 
energized through its latching contacts 218a and the now reclosed pole 
161a of the limit switch 161. 
If the selector switch 220 is switched to the hand-operated position, the 
upper pole thereof will be closed to maintain the relay 218 energized and 
the lower pole thereof will be open to de-energize the rest of the 
circuitry for testing and adjusting thereof. 
Referring to FIG. 13, it is a significant feature of the present invention 
that it may be operated to load either one or two layers of packages 30 in 
each container 40 at the loading station. In order to operate the system 
20 to load two layers of packages 30 in each container 40, the selector 
switch 233 is switched to the position designated "2" in FIG. 15, thereby 
opening the upper pole thereof and closing the lower pole thereof. The 
operation of the system 20 in this mode is identical to that disclosed 
above for the single-layer mode of operation until the first package 30A 
has been lowered through the window 88 of the loader conveyor 80 onto the 
pins 91 and the continued movement of the loader conveyor 80 closes the 
limit switch 168. At this point only the solenoid 231 is energized to 
lower the platen 90 only partway to its intermediate receiving position, 
illustrated in FIG. 13. In this position, the upper surface of the package 
30A on the pins 91 will be disposed substantially at the level at which 
the upper ends of the pins 91 were disposed when they were in their full 
up position. When the continued movement of the loader conveyor 80 closes 
the limit switch 169 to energize the relay 235, it stops the loader 
conveyor 80 in the manner described above, and also closes the contacts 
235a of the relay 235 for energizing the relay 234, thereby closing its 
latching contacts 234b for latching it in an energized condition, and 
closing its contacts 234a. Closure of the contacts 234a does not energize 
the relay 232, however, because the limit switch 168 has reopened as the 
lug on the loader conveyor 80 moved past it to the limit switch 169. 
As the next package 30B being fed along the infeed conveyor 60 engages the 
lever actuator 158 to close the limit switch 160, the solenoid 240 is 
again energized for restarting the loader conveyor 80 in the manner 
described above, and the second package 30B proceeds to actuate the limit 
switch 161 for lowering the shoe 95 and shifting the package through a 
window section 88 of the loader conveyor 80 onto the top of the other 
package 30 already resting on the pins 91. When the lug on the loader 
conveyor 80 next closes the limit switch 168, both of the solenoids 231 
and 232 are energized, since the relay contacts 234a are now closed, 
thereby lowering the platen 90 all the way to its full down position for 
lowering the two layers of packages 30A and B into the container 40. As 
the platen 90 lowers to its full down position, it closes the limit switch 
167 to move the container stop assembly 140 back to its release position, 
and actuates the limit switch 163 to restart the container drive conveyor 
120 and move the loaded container 40 from the loading station onto the 
outfeed conveyor 148 in the manner described above. When the drive lugs 
130 on the container drive conveyor 120 actuate the limit switch 165, its 
pole 165a closes to again move the container stop assembly 140 back to its 
stop position and the pole 165b opens for de-energizing the relay 234 for 
the next cycle of operation. 
In the modes of operation heretofore described, it has been assumed that 
each layer of product in a container 40 comprises a single package 30 
which substantially covers the entire bottom area of the container 40. It 
is another important feature of this invention that it is also adapted 
selectively to operate in a mode of operation for loading what are known 
as "twin pack" packages into the containers 40. Each such "twin pack" is 
about one-half the size of a normal package 30, two such "twin packs" 
arranged in side-by-side or end-to-end relationship being required to 
cover the bottom of the container 40. In other words, each "twin pack" 
contains a subset of individual articles, two of which subsets are 
required to make a complete set of individual articles for comprising a 
complete layer of product in a container 40. The "twin packs" are fed 
individually from the associated packer to the infeed conveyor 60 in the 
same manner as are the fullsize packages 30. Therefore, the stop gate 149 
has been provided to stop the movement of the first package of the "twin 
pack" until the second package catches up with it, whereupon the two are 
released and continue moving as a single package unit to the loader 
conveyor 80 for loading into a container 40. 
Referring to FIG. 15 of the drawings, the control of the stop gate 149 in 
the "twin pack" mode of operation will be described. For this mode of 
operation, the selector switch 242 is closed by moving it to the "2" 
position, thereby energizing the photorelay 150 and producing a transverse 
light beam across the input end of the infeed conveyor 60. The photorelay 
150 is energized or actuated when the light beam thereof is interrupted by 
the passage of the first package of a "twin pack" therethrough, thereby to 
close the contacts 150a and 150c and open the contacts 150b thereof, 
closure of the contacts 150a energizing the relay 245, thereby closing its 
latching contacts 245a to latch the relay 245 energized and also closing 
its contacts 245b. When the first package of the "twin pack" has passed 
through the light beam, the beam is reestablished for de-energizing the 
photorelay 150, thereby reopening the contacts 150a and reclosing the 
contacts 150b thereof. However, the relay 245 remains energized through 
its latching contacts 245a, wherefore the solenoid 246 and relay 247 are 
now energized through the closed relay contacts 150b and 245b. 
Energization of the solenoid 246 lowers the stop gate 149 to its stop 
position in the path of the first package of the "twin pack". Energization 
of the relay 247 closes its latching contacts 247a and its contacts 247b. 
When the first package of the "twin pack" arrives at the stop gate 149 and 
is stopped thereby, the free rollers 65 of the infeed conveyor 60 pass 
therebeneath. 
When the second package of the "twin pack" breaks the light beam of the 
photorelay 150 and re-energizes it, the relay contacts 150b are opened, 
but the relay 247 and the solenoid 246 remain energized through the 
latching contacts 247a. Also, the photorelay contacts 150c are closed for 
energizing the relays 248 and 244 through the now closed relay contacts 
247b, thereby closing the latching contacts 248a. Upon energization of the 
relay 244, its contacts 244a will open after a predetermined delay, 
sufficient to allow the second package of the "twin pack" to catch up with 
the stopped first package thereof. Upon opening of the contacts 244a, the 
relays 245 and 247 and solenoid 246 will all be de-energized, permitting 
the stop gate 149 to return to its pass position under the urging of 
suitable bias means (not shown), and permitting the now joined packages of 
the "twin pack" to proceed as a unit along the infeed conveyor 60 to the 
loader conveyor 80 for loading into a container 40 in the usual manner. 
When the second package of the "twin pack" has passed through the light 
beam, the photorelay 150 is de-energized for reopening the contacts 150c 
thereof, thereby de-energizing the relays 244 and 248 and returning the 
"twin pack" control circuit to its initial condition in preparation for 
the arrival of the first package of the next "twin pack". 
It will be appreciated that the stop gate 149 should be so positioned and 
the delay on the relay contacts 244a should be such that the second 
package of the "twin pack" will catch up with the first package thereof 
before the second package exits the light beam of the photorelay 150. 
Otherwise, when the second package of the "twin pack" exits the light 
beam, the energization of the photorelay 150 will open its contacts 150c 
for de-energizing the relay 244 before the expiration of the delay on the 
contacts 244a, thereby preventing retraction of the stop gate 149 to its 
pass position. 
While there has been described what is at present considered to be the 
preferred embodiment of the invention, it will be understood that various 
modifications may be made therein, and it is intended to cover in the 
appended claims all such modifications as fall within the true spirit and 
scope of the invention.