Device for singulating and passing on upright containers

A device for singulating and passing on upright containers preferably comprises a feed device for transporting the containers in a single row and a singulation unit having a first star wheel and a second star wheel, each of which comprises receiving pockets to accept, when in a first and second receiving position, the containers being transported to them and to transport these containers to a first and second discharge position. The star wheels comprise parallel rotational axes but opposite rotational directions. In addition, the device comprises a pusher unit, which comprises at least one plunger, which, in the area of the first and second discharge position, is movable back and forth in a direction parallel to the rotational axes of the star wheels and through the associated receiving pockets to push the containers out of the receiving pockets of the star wheels and into product holders.

RELATED APPLICATIONS

The present patent document claims the benefit of priority to European Patent Application No. EP 14164366.8, filed Apr. 11, 2014, the entire contents of which are incorporated herein by reference.

FIELD AND BACKGROUND OF THE INVENTION

The present disclosure relates to a device for singulating and passing on upright containers.

Devices of this type are used in, for example, the pharmaceutical industry to singulate bottles, ampuls, or other containers.

There are many different ways of configuring a device of this type for separating or singulating a transport stream of upright containers.

In a simple embodiment of a device for separating a transport stream of upright containers according to US 20110308915 A1, the containers are transported by a feed device in a single row to the distribution point, where they are divided into two transport streams by one or more rollers of plastic or metal, which are driven around a vertical rotational axis.

Other devices for separating and singulating a transport stream of upright containers use star wheels, which are provided with receiving pockets for the containers. A device of this type is known from U.S. Pat. No. 3,967,717, for example. This device serves to divide a single row of transported objects into three onward-leading rows. The device comprises two counter-rotating star wheels, which are coupled together. Each of the containers of the product stream being supplied in a single row is first taken up by a receiving pocket of one of the star wheels and transported to a discharge position. By means of pusher elements attached to the star wheels, the containers are pushed out of the receiving pockets at that point and deflected into one of the three onward-leading paths. This device is mechanically complicated and divides the product stream into only three horizontal branches, in the course of which further packaging steps for the containers must then also be carried out.

SUMMARY OF THE INVENTION

According to an aspect of the present disclosure a device for singulating and passing on upright containers is provided that provides an active introduction of the singulated containers into product holders provided for the purpose and which also has a robust and compact structure.

According to an aspect of the present disclosure, the device for singulating and passing on upright containers comprises a feed device for transporting the containers in a single row and a singulation unit with a first star wheel and a second star wheel. The star wheels comprise receiving pockets, which, when in a first or second receiving position, accept the containers being transported to them and then transport them to a first and second discharge position, wherein the star wheels comprise parallel rotational axes but opposite rotational directions. The device also comprises a pusher unit, which comprises at least one plunger, which, in the area of each discharge position, is movable back and forth in a direction parallel to the rotational axes of the star wheels and through the associated receiving pocket.

With this configuration, a robust and compact device is created, which serves to rapidly singulate upright containers and to actively introduce the singulated containers into the product holders provided for the purpose.

To provide an independent operation of the first star wheel and of the second star wheel, the first star wheel preferably comprises a first drive, and the second star wheel preferably comprises a second drive. The star wheels can therefore be actuated independently of each other, and any suitable pattern of movement of the two star wheels which ensures an optimal sequence of pickup, transport, and discharge of the containers can be configured.

It is especially advantageous for the first and second drives to be actuated in such a way that they produce a timed movement of the star wheels. This simplifies the process of introducing the containers into the receiving pockets of the star wheels and of discharging the containers from the pockets.

It is especially advantageous for the first and second drives to be actuated in such a way that the receiving pockets of the first star wheel are offset in time from receiving pockets of the second star wheel as the star wheels move between the receiving position and the discharge position. This assures that each receiving pocket of both star wheels will acquire a container in the receiving position and transport it to the discharge position.

So that the plunger does not become jammed or one of the star wheels damaged during the pushing operation, the first and second drives are stopped during the pushing operation in the discharge position.

To accelerate the throughput, the pusher unit preferably comprises two plungers.

For ergonomic reasons, it is advantageous for the two plungers to comprise a common, third drive.

The two plungers are preferably connected to each other by a rigid connecting web, as a result of which the movement of the two plungers in the discharge position of the first and second star wheels occurs simultaneously.

The third drive is preferably a cam drive.

To assure that the containers are pushed reliably into their product holders, the at least one plunger passes through, preferably completely through, the receiving pocket of the associated star wheel during the pushing operation.

The singulation unit preferably comprises a housing with side walls, a top, and a bottom, wherein the housing comprises a guide element with two guide surfaces, which laterally surround the star wheels in the area of, respectively, a third and a fourth quadrant of the star wheels, as a result of which the containers are guided in the third and fourth quadrants by the receiving pockets and the guide surfaces. This assures that, as the containers are being transported from the receiving position to the discharge position, they remain at all times in the receiving pockets of the associated star wheel.

The device comprises a support plate to serve as a support surface for the containers during the rotational movement.

So that the containers can slide out of the receiving pockets in the discharge positions, the support plate preferably has through-openings in the area of the discharge positions.

Alternatively, the support plate forms an ejection edge in the area of the discharge positions.

The device also preferably comprises a conveying means for product holders, into which the plungers push the containers during the pushing operation. The product holders into which the containers have been pushed are thus singulated and ready for further processing.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

FIGS. 1, 2, and 11show the basic configuration of a device according to the present disclosure. Upright containers2, such as bottles, ampuls, cartridges, or the like, are transported in a single row to a singulation unit4by means of a feed device3. The feed device3can be configured as a collecting belt conveyor or as a chute, etc. The feed device3regulates the continuous resupply of containers2in such a way that each container2is pushed forward into the singulation unit4by the containers2coming up from the rear.

The singulation unit4comprises a first star wheel6and a second star wheel8, wherein each of the two star wheels6,8is equipped with receiving pockets10to accept the containers2. In the example shown here, each of the star wheels6,8comprises six receiving pockets10. It is also possible, however, for each star wheel6,8to comprise any other desired number of receiving pockets10. The first star wheel6and the second star wheel8comprise parallel rotational axes12, around which the star wheels6,8rotate in opposite directions. In the example shown here, the first star wheel6rotates clockwise, the second star wheel8counterclockwise. The rotational axes12of the star wheels6,8are substantially perpendicular to the direction in which the containers2enter the singulation unit4. The star wheels6,8are close together and form a triangular entrance area, which allows the containers2, which are being transported in a single row by the feed device3, to be divided between the first star wheel6and the second star wheel8.

A container2is accepted into one of the receiving pockets10of the first star wheel6when the wheel is in a first receiving position A, and similarly a container2is accepted into one of the receiving pockets10of the second star wheel8when that wheel is in a second receiving position A. Because of the opposite rotational directions of the star wheels6,8, the containers2in the receiving pockets10of the one star wheel6,8are facing the other star wheel as the wheels rotate and are in this way transported to their discharge positions B.

In the embodiment shown here, the singulation unit4comprises a block-shaped housing18with side walls20, a top22, and a bottom. In the housing18, the two star wheels6,8are supported in such a way that their rotational axes12are parallel to each other. The height of the side walls20and thus the height of the housing18is preferably greater than or equal to the height of the star wheels6,8, so that the star wheels6,8are completely enclosed in the housing18. The housing18also comprises a guide element26with guide surfaces28, especially two guide surfaces28. The guide surfaces28are curved, extend over the entire height of the housing18parallel to the rotational axes12of the star wheels6,8, and thus surround the associated star wheel6,8over a certain arc of a circle. Because the guide surfaces28are arranged to be mirror images of each other, the guide element26has in cross section the form of a pointed mountain peak with rounded sides. If the numbering of the quadrants begins as usual at the upper right in the diagram and continues in the counterclockwise direction, the one guide surface28laterally surrounds the fourth quadrant of the first star wheel6. The receiving position A of the first star wheel6will then be located in the first quadrant of the first star wheel6. In analogous fashion, the second star wheel8is laterally enclosed by the other guide surface28of the guide element26in the third quadrant of the second star wheel8, whereas the receiving position A is located in the second quadrant of this star wheel8. In the fourth quadrant of the first star wheel6and in the third quadrant of the second star wheel8, the containers2are thus guided not only by the receiving pockets10but also by the guide surfaces28. This guarantees that the containers2remain in the receiving pockets10of the star wheels6,8as they are being transported from the receiving position A to the discharge position B, which, in the present example, is arranged in the transition area between the third and fourth quadrants.

Alternatively or in addition, gripper or suction mechanisms can be provided in the receiving pockets10to hold the containers firmly in the receiving pockets10as they are being transported from the receiving position A to the discharge position B. These would have to be deactivated no later than the time at which the discharge position B is reached.

In a preferred embodiment, the first star wheel6comprises a first drive27(shown schematically inFIG. 11), and the second star wheel8comprises a second drive29(also shown schematically inFIG. 11). As a result, the star wheels6,8can be actuated independently of each other, and thus the one star wheel6,8can be stopped while the other star wheel6,8continues to turn without change. The preferred way in which the first drive27and the second drive29function will be explained in greater detail below with reference toFIGS. 3-10.

The pusher unit30comprises at least one plunger32, which, in the area of the respective discharge position B, can be moved back and forth parallel to the rotational axes12of the first star wheel6and of the second star wheel8. As it executes the pushing operation, the plunger32passes completely through the receiving pocket10located in the discharge position B of the associated star wheel6,8.

In a preferred embodiment, the pusher unit30comprises, as shown, two plungers32, wherein each plunger32is arranged in the area of the discharge position B, parallel to the rotational axes12of the star wheels6,8. The two plungers32preferably comprise a common third drive34, which can be configured as a cam drive. The two plungers32are preferably connected to each other by a connecting web38. The connecting web38is connected in turn to the third drive34by a conrod36or a slider crank. The conrod36is attached to the connecting web38in such a way that, when the third drive34moves, the two plungers32are moved either jointly downward or jointly upward.

Even though it is preferable to provide two plungers32, it is also possible to provide only one plunger32, which then must be moved back and forth between the two discharge positions B and execute the two pushing operations one after the other, first at the one, then at the other discharge position B. The movements of two plungers32can also be offset from each other. This would require different drives for the plungers32.

During the rotation of the star wheels6,8, the containers2can be supported on a support plate40. The support plate40can be permanently attached to the housing18of the singulation unit4. It is also conceivable that the bottom surface24of the housing18itself could form the support plate40. In the area of the discharge positions B, the support plate40comprises through-openings42, through which the containers2drop. In another embodiment, the support plate40can end in the area of the discharge positions B and thus form an ejection edge.

Underneath the singulation unit4, a conveying means44is arranged, which transports product holders46. The product holders46are oriented so that their upper ends are near the bottom surface24of the housing18. The containers2thus drop through the through-openings42and directly into the product holders46without jamming. The size of the product holders46is adapted to the diameters of the containers2. The conveying means44can be configured in various ways. The conveying means44is preferably a conveyor belt or a turntable with receptacles for the product holders46. The product holders46themselves can serve as the end packaging for the containers2, or they can be subjected to further processing or packaging operations.

InFIG. 2, the discharge area B of the second star wheel8is completely visible in the cut-away part of the diagram. It can be seen that the plungers32, now in their downward position, are pushing the containers2into the product holders46and thus pass completely through the receiving pockets10of the associated star wheels6,8. This pressing action improves the retention of the container2in the product holder46, or it can activate a latching mechanism in the product holder46.

The sequence of events during the actuation of the device according to the present disclosure will now be described with reference toFIGS. 3-10. The containers2are essentially first transported by the feed device3into the area of the receiving positions A and are accepted there into receiving pockets10of the star wheels6,8. A container is loaded into a receiving pocket10as a result of the moving or pushing effect of the containers2arriving from the rear of the feed device3on the containers in front. Then the containers2are transported by the oppositely directed rotations of the two star wheels6,8to the discharge positions B. At the discharge positions B, the containers2drop into the product holders46and are then pushed firmly into the product holders46by the plungers32. The movements of the star wheels6,8occur in cycles, as will be explained in greater detail below.

InFIG. 3, the two star wheels6,8are in a starting position, in which a first receiving pocket10of the associated star wheel6,8has already been loaded with a container2. The discharge positions B, however are still empty. It can be seen inFIG. 3that the containers2can be guided from the receiving position A to the discharge position B by rotational movement of the star wheels6,8by a distance equal to two receiving pockets10. Thus there will never be more than two receiving pockets10filled simultaneously in the same star wheel6,8. Of course, other configurations can be present depending on the structure of the star wheels6,8and the locations of the receiving positions A and the discharge positions B.

InFIG. 4, the first star wheel6with the loaded receiving pocket10has started to move in the clockwise direction. The second star wheel8is still in its starting position.

InFIG. 5, the second star wheel8has now also started to move, rotating in the counterclockwise direction. The rotation of the second star wheel8is offset in time from the rotation of the first star wheel6but proceeds preferably at the same speed.

InFIG. 6, the first star wheel6has rotated to such an extent that a second receiving pocket10can be loaded with another container2. Shortly after reaching this position, the first star wheel6is stopped, while the second star wheel8continues to turn.

FIG. 7shows a state in which the first star wheel6is standing still, while the second star wheel8continues to turn and a second receiving pocket10, now in the receiving position A, of the second star wheel8is being loaded with a container2. Shortly thereafter, the second star wheel8also stops, so that a mirror-symmetric arrangement of the two star wheels6,8around the longitudinal center axis of the device is obtained.

The further rotation, first of the first star wheel6and then also of the second star wheel8, brings the first containers2, one after the other, into their discharge positions B (seeFIGS. 8-10), where they drop through the through-openings42into the product holders46. Then the containers2are pushed firmly, preferably simultaneously, into the product holders46by the plungers32, as can be seen inFIG. 2.

The offset, cyclic course of the movements of the star wheels6,8, as illustrated inFIGS. 3-10, is especially advantageous with respect to the insertion of the containers2into the receiving pockets10. After the receiving pocket10of the first star wheel6has been filled and a receiving pocket10of the second star wheel8is located in the receiving position A, the container2arriving from the rear slides along the container2already in the receiving pocket10of the first star wheel6and is thus guided into the receiving pocket10of the second star wheel8(seeFIG. 7). If, however, a receiving pocket10of the first star wheel6is in the receiving position A and the second star wheel8is rotating, the container2moving up from the rear will slide along the web48formed between two successive receiving pockets of the second star wheel8and will thus be guided into the receiving pocket10of the first star wheel6(seeFIG. 6). The same sequence also applies in reverse.

Of course, it also possible for the second star wheel8to rotate first and then for the first star wheel6to rotate. In addition, the rotational direction of the two star wheels6,8can be reversed. Many other sequences of cyclic movements of the two star wheels6,8are also conceivable, in which more or fewer than two receiving pockets10of each star wheel6,8are loaded simultaneously with a container2. The locations of the receiving positions A and of the discharge positions B are also variable.