Bottle transport system

Method and apparatus for handling bottles and the like in heat transfer labelling and similar applications with increased processing rates. Bottles are delivered on a single lane conveyor, through a preheating station, and then routed through various bottle handling stations which separate the bottles into two groups to be handled by separate labelling modules. The two groups of bottles are then recombined in a single lane for further processing. The bottle handling apparatus consists of a dividing station, a crossover station, and a combining station. A bottle loading gate may be included to control the rate of feed of bottles into the single lane input conveyor. The handling stations include gates, for controlling the spacing of bottles, and diverters, for guiding bottles into selected lanes. The user may activate the bottle handling stations to double the labelling rate, or deactivate the stations to label each bottle twice.

BACKGROUND OF THE INVENTION 
This invention is related to handling systems for bottles and other 
containers, and more particularly to a handling system for bottle 
labelling apparatus. 
Heat transfer labelling systems have come into wide use over the past few 
years. Such systems essentially include a conveyor for feeding bottles, a 
turret for positioning the bottles one at a time at a labelling station, a 
feed mechanism for transporting labels supported on a backing strip to the 
labelling station, and means for pressing the label against the bottle as 
the bottle and label are moved together. Examples are shown in U.S. Pat. 
Nos. 2,981,432; 3,036,624; 3,064,714; 3,208,897; 3,231,448; 3,261,732; 
3,313,667; 3,709,775; and 3,861,986. 
One aspect of such decorating systems which is of great importance to the 
user is the apparatus employed for transporting the bottles to and away 
from the labelling sites, and pre- and post-labelling processing stations. 
Several factors should be considered in designing such pre- and 
post-labelling apparatus so as to afford economies to the user. It is 
preferable to create a system which accommodates bottles of different 
cross sectional shape (e.g. round and oval), by means of minor adjustments 
in a single production line. This requires versatility in terms of the 
number of sides of any given bottle which will be labelled, as typically 
an oval bottle is labelled on two sides while a round bottle receives only 
one label. 
Another important criterion is that of the production rate of the 
decorating apparatus. It is desirable to provide decorating apparatus 
which will label containers at as high a speed as is possible consistent 
with the mechanical limitations of the label application apparatus, 
bearing in mind the number of labels which are to be applied to a given 
container. 
Another design factor which is of great practical significance is that of 
the compactness of the decorating apparatus and the convenience of access 
to various areas of operation. This factor is particularly relevant to the 
advantageous design of the bottle transport systems, which may occupy 
extensive space and impede the operator's access to the labelling area. 
SUMMARY OF THE INVENTION 
In accomplishing the above and related objects, the bottle handling system 
of the invention provides a means of incorporating two or more labelling 
modules into a single production line, in such a manner that the system 
may be easily adjusted to label one or more side of a given bottle. In its 
basic embodiment, the bottle handling system includes an inbound conveyor 
with a dividing system, a transfer conveyor with a crossover system, and 
an outbound conveyor with a combining system. 
In accordance with one embodiment of the invention, the various bottle 
handling stations comprise belt conveyors bordered by contoured guard 
rails, gates, and diverters. In accordance with a related aspect of the 
invention, the action of the gates and diverters is controlled by a timing 
signal from a first labelling module, which coordinates the bottle 
handling functions with the machine cycle of the labelling module. In a 
specific embodiment of the invention, the above timing signal is a pulse 
of air initiated by bottle-inflation control apparatus within the 
labelling module. 
In accordance with another aspect of the invention, the bottle handling 
system optionally includes a bottle loading gate which controls the feed 
of bottles onto the single lane inbound conveyor. In a preferred 
embodiment, an escapement type loading gate comprises a star wheel with 
arms at two different heights, and high and low air cylinders with 
detaining rods. 
In accordance with a further aspect of the invention, at the dividing 
station bottles are evenly spaced by a gate, and every other bottle is 
forced into a second lane by a diverter. Alternatively, the diverter is 
placed prior to the gate. 
In accordance with yet another aspect of the invention, the combining 
station spaces bottles at complementary intervals by means of two gates 
timed 180.degree. out of phase, and bottles from both lanes are 
alternately combined in a single lane. The converging means may be passive 
or active in nature. An advantageuos form of crossover station comprises a 
combining station followed by a diverter. Alternatively, the crossover 
station includes four gates and a reciprocating bottle pusher. In either 
form, the crossover station effects a transposition of bottle locations in 
two adjacent lanes. 
In accordance with still another aspect, a gate may comprise a pivoting 
member with two detaining flanges, or may comprise one or two air 
cylinders with projecting gates. In a related aspect of the invention, a 
diverter may comprise either a pivoting guide rail or an air pusher. 
In accordance with a further aspect of the invention, the user may activate 
and deactivate the dividing, crossover, and combining stations. In the 
simplest case of two labelling modules, with the bottle handling stations 
in their activated state, the dividing station separates the bottles to be 
labelled into two groups, and each labelling module applies a single label 
to bottles in one group. With the bottle handling stations inactive, each 
bottle is labelled twice, once at each labelling module. 
The bottle handling apparatus of the invention allows the use of a minimal 
number of pre- and post-labelling stations, in that these functions are 
effected while the bottles are in a single lane. The incorporation of 
single input and output lanes facilitates integration of the decorating 
apparatus of the invention with previously installed bottle processing 
equipment.

DETAILED DESCRIPTION 
Reference should now be had to FIGS. 1 through 12 for a detailed 
description of the bottle handling system of the invention. As shown in 
the plan view of FIG. 1, a preferred embodiment of the bottle handling 
system 10 includes an input conveyor 15, loading gate 18, preheating 
station 20, dividing station 30, crossover station 40, combining station 
50, decorating stations 60 and 70, postheating station 80, and output 
conveyor 95. Input conveyor 15, output conveyor 95, and the various 
intermediate stages of the bottle transport illustratively comprise belt 
conveyors with guard rails. Input and output heating stations are of the 
type illustrated, for example, in U.S. Pat. No. 3,616,015. Preheating 
station 20, for example, includes flamers 21A and 21B, bottle turner 25, 
and flamers 23A and 23B. 
Loading gate 18 permits the passage of bottles onto input conveyor 15 at 
periodic intervals. A suitable form of loading gate is illustrated in 
FIGS. 2A through C. In the top plan view of FIG. 2A, loading gate 18 is an 
escapement type gate, which allows the passage of bottles one by one. 
Loading gate 18 consists of a star wheel 18A and air cylinders 18B and 
18C. Star wheel 18A illustratively includes a series of six arms 18A1 
through 18A6, which are alternatively arrayed at two different heights, 
corresponding to the heights of rods projected by air cylinder 18B and 
18C. Thus, in the sectional view of FIG. 2B, air cylinder 18B has been 
activated to project rod 18B1, which detains an arm 18A1 of star wheel 
18A. Star wheel 18A is subjected to counterclockwise torsion, so that the 
retraction of rod 18B1 will permit star wheel 18A to rotate until arm 18A2 
is engaged by rod 18C1, as shown in FIG. 2C. 
Rods 18B1 and 18C1 are alternatively projected and retracted in a 
complementary fashion, causing star wheel 18A to rotate in regular angular 
increments of 360.degree./number of arms. Every arm of star wheel 18A is 
of suitable form to prevent the passage of bottles on input conveyor 15. 
During rotation of star wheel 18A, a single bottle B1 is permitted to 
pass, while subsequent bottles B2, B3, etc. are urged by a backlog against 
the next arm of the star wheel. 
Bottle handling stations 30, 40, and 50 divide incoming bottles into two 
groups, with one group routed to a first decorating module 61 while the 
other group is routed to a second decorating module 71. These stations 
finally recombine the two groups into a single lane for further 
processing. An advantageous form for dividing staion 30 is shown in the 
plan views of FIGS. 3A and 3B. Bottles moving in direction A come in along 
a single lane 31, where they line up against gate 37, creating a backlog. 
As shown in FIG. 3A, gate 37 is a pivoting member of suitable length 
relative to the diameter of a bottle, with flanges at both ends for 
engaging a bottle surface. In a case other than that of a round bottle, 
the bottles have previously passed through orienting means (not shown), 
and gate 37 has a similar length to the dimension of the bottles along 
axis A. Gate 37 assumes one of two positions during the periodic operation 
of dividing station 30. In FIG. 3A, gate 37 is in an "impeding" position, 
with the forward end of the gate inserted into lane 31. While in this 
position bottles B1, B2, etc. move forward against the gate. During the 
other half of the cycle, gate 37 pivots so that its rearmost end is 
inserted into the lane 31, behind the forwardmost bottle lined up against 
the gate. Thus, in this "admitting" position, shown in FIG. 3B, gate 37 
allows the passage of a single bottle. 
As a result of the periodic activity of gate 37, bottles are spaces at 
regular intervals, reflecting the period of gate 37 and the line speed of 
the conveyor. These bottles are then divided into two groups, one in lane 
32 and the other in lane 33, by diverter 39. In the embodiment of FIGS. 3A 
and 3B, diverter 39 is a pivoting panel with two periodically alternating 
positions. In FIG. 3A, diverter 39 is in its activated position, causing 
bottle B1 to be deflected into lane 32. In FIG. 3B, diverter 39 is in a 
retracted position, allowing B2 to pass undeflected into lane 33. Diverter 
39 is coordinated in its operation with the timing of gate 37, so that 
bottles are alternately routed into lanes 32 and 33. 
An alternative embodiment of gate 37 is shown in FIGS. 4A and 4B. Gate 37' 
comprises two air cylinder gates 37R and 37F, which are alternately 
projected into lane 31. In the "impeding" configuration of FIG. 4A, 
forward gate 37F is projected and rearward gate 37R is retracted, so that 
bottles line up against gate 37F. In the "admitting" configuration of FIG. 
4B, gate 37R is projected between bottle B.sub.1 andthe next bottle, and 
gate 37F retracts to allow the passage of bottle B.sub.1. An alternative 
form of diverter 39 is illustrated in FIG. 5. An air pusher 39' engages 
selected bottles and pushes them into lane 32. Air pusher 39' is activated 
to divert every other bottle. 
In an alternative embodiment 30' of divide station 30 illustrated in the 
plan view of FIG. 6, a diverter 39' acts upon selected bottles, while a 
gate 37' spaces the undiverted bottles at desired intervals. The operation 
of divide station 30' involves two phases, as shown in FIGS. 7A and 7B. 
During the first phase (FIG. 7A), forward gate 37F has opened, allowing 
the passage of the foremost bottle B1 in lane 33, while rear gate 37R 
impedes the progress of a second bottle B2. During this phase, pusher gate 
39' forces a third bottle B3 into the second lane 32 and returns 
immediately to its original position. In this and other stations, the 
motion of the diverting air pusher is rapid relative to the belt speed of 
the underlying conveyors. During the second phase (FIG. 7B), forward gate 
37F closes while reargate 37R opens, causing the backlog of bottles to 
move up to gate 37F while bottles B1 and B3 advance freely. As a result, 
bottles are evenly divided between lanes 32 and 33 and emerge from divide 
station 30' at complementary intervals. 
An advantageous realization of combining station 50 is depicted in the plan 
view of FIG. 8. Incoming bottles travelling in direction A are closely 
bunched in lanes 51 and 52. Gates 55 and 56 allow single bottles to pass 
in a carefully timed relationship, as discussed below. Gates 55 and 56 are 
identical in operation to gate 37 in FIGS. 3A, 3B or gate 37' in FIGS. 4A, 
4B. These gates are timed 180.degree. out of phase, so that when gate 55 
is in the impeding position (as shown), gate 56 is in the admitting 
position, and vice versa. Thus, in FIG. 8, gate 56 has allowed bottle 
B.sub.2 to pass while gate 55 is in position to release bottle B.sub.1 
half a cycle later. The result is that bottles are spaced in two lanes at 
complementary intervals. The bottles in lane 51 continue on course into 
lane 53, while the bottles in lane 52 are urged by diagonal guide rail 54, 
which acts as a converging device into lane 53. Thus a single line of 
equally spaced bottles is formed, alternately provided by lane 51 and lane 
52. In an alternative embodiment of combining station 50, the converging 
means may comprise an air pusher, as in FIG. 5. 
FIG. 9 shows an alternative combining station 50' using air pusher gates 
55' and 56' and an air pusher converger 54'. 
FIG. 10 gives a plan view of an illustrative crossover station 40. In 
essence, this station comprises a combining station followed by a 
diverter. The components are timed in their operations so that bottles 
which start in lane 41 and are urged into lane 43 by converging means 46 
are allowed to pass by diverter 49. Contrarily, bottles which start in 
lane 42 are deflected by diverter 49 into lane 44. The net result is that 
bottles are laterally transposed. 
An alternative form of crossover station 40' is depicted in the plan view 
of FIG. 11. Crossover station 40' includes input lanes 41 and 42 and 
output lanes 44 and 45. Input gates 46' and 47', and output gates 48' and 
49', illustratively comprise air cylinder gates. Bottle crossover is 
effected by reciprocating air pushers 43'A and 43'B, as illustrated 
schematically in FIGS. 12A through 12D. At an initial time shown in FIG. 
12A, gates 46' and 49' are closed and gates 47' and 48' open, with pushers 
43' to the right. This creates a backlog of bottles against gates 46' and 
49'. In FIG. 12B, gates 46' through 49' have switched states, and pushers 
43' have rapidly moved bottle B2 to the left. The backlog of bottles in 
lane 41 forces bottle B2 against gate 48' and bottle B3 between pushers 
43'A and 43'B, while gate 49' releases bottle B1 into lane 45. In FIG. 
12C, gates 46' to 49' again reverse states, and pushers 43' transfer 
bottle B3 to the right. The backlog of bottles in lane 42 forces bottle B3 
against gate 49', and bottle B4 between pusher 43'A and 43'B. During this 
phase, bottle B2 (which originated in lane 42), is released into lane 44. 
The process of FIG. 12B is repeated in FIG. 12D, and bottle B3 (which 
originated in lane 41) is released into lane 45. As in the embodiment of 
FIG. 10, the result is that bottles are laterally transposed and emerge at 
complementary intervals. 
Bottle handling stations 30, 40, and 50 all require a timing signal to 
control their operation. In loading gate 18 (FIG. 2A) this signal 
regulates the operation of air cylinders 18B and 18C. In dividing stations 
30 and 30' (FIGS. 3A, 6) this signal is applied to gates 37 and 37' and 
diverters 39 and 39'. In crossover station 40 (FIG. 10), this signal is 
applied to gates 47 and 48 and to diverter 49. In alternative crossover 
station 40' (FIG. 11) the signal controls the operation of the various 
gates as well as reciprocating air pusher 43'. In combining station 50 
(FIG. 8), the signal controls the operation of gates 55 and 56. In 
combining station 50' (FIG. 9) the signal additionally controls converging 
air pusher 54'. These signals are necessary to coordinate the operation of 
bottle handling devices within a given station, and to adjust the timing 
of the bottle transport mechanism to the speed of labelling at the 
labelling modules 60 and 70. One advantageous method of effectuating this 
signal utilizes apparatus within the labelling module for inserting a 
nozzle into a non-rigid botle and inflating the bottle to provide a firm 
labelling surface. This process is repeated once for each machine cycle of 
the labelling apparatus, and thus provides properly timed pulses of air. 
Suitable apparatus is disclosed, for example, in U.S. Pat. Nos. 3,064,714 
and 3,208,897. These air pulses operate the various devices pneumatically 
by means of connecting air lines. Because of the necessity of providing a 
single timing signal, if labelling modules 61 and 71 do not necessarily 
operate at the same rate, the signal will be produced only by first 
labelling module 61. In some cases it will be necessary to halve the 
period of the timing pulse to control the operation of a given gate or 
diverter. For example, gate 37 in dividing station 30 should change 
positions twice during every labelling machine cycle. 
The operation of the bottle transport system as a whole may be illustrated 
by further reference to FIG. 1. After bottles introduced by input conveyor 
15 have passed through preheater station 20, they emerge on conveyor 31, 
and are separated into two groups in lanes 32 and 33, as discussed above. 
The bottles in lane 32 (group A) are fed by lane 63i to labelling module 
61, and return on lane 63o. These bottles turn the corner onto lane 41, 
the change of direction to be effected by any suitable device well known 
to skilled practitioners of the art (for example, turning discs and guide 
rails). The bottles in group A are routed into lane 45 at crossover 
station 40, and turn the corner onto lane 52. At combining station 50, 
they are recombined with the labelled bottles of group B, which are 
transported as discussed below. 
The bottles of group B are routed by dividing station 30 into lane 33, and 
turn the corner into lane 42. They are transferred at crossover station 40 
into lane 44, and again turn the corner into lane 73i. After labelling at 
module 71, they return on lane 73o, and are recombined with the bottles of 
group A at combining station 50. The bottles, now in a single lane 53, 
pass through post-flamer 80 and onto output conveyor 95, where they may be 
easily routed to further conventional processing apparatus. This 
arrangement of the bottle transport apparatus affords easy access of the 
operator to the labelling modules and other processing stations. 
The labelling configuration discussed above, with all bottle handling 
stations activated, entails the division of incoming bottles into two 
groups with the application of a single label to each bottle. As a result, 
the limits of bottle handling rates, which are determined by the 
mechanical capabilities of the labelling modules, may be doubled by using 
two labelling modules in conjunction with the bottle handling apparatus of 
the invention. In the case of pre- and post-flamers, and similar 
processing devices which do not suffer such processing speed limitations, 
it is advantageous to incorporate these while the bottles are in a single 
lane, so that a single device may handle the entire workload. 
If it is desirable to apply more than one label to each bottle, each single 
labelling station may be replaced with a plurality of labelling stations, 
as disclosed, for example, in U.S. Pat. No. 3,861,986. Alternatively, one 
may apply two labels to every bottle at the basic labelling rate in the 
configuration of FIG. 1 by deactivating the gates and diverters at various 
bottle handling stations. In this arrangement, all bottles will travel in 
a single lane to labelling module 61, then to labelling module 71. 
While various aspects of the invention have been set forth by the drawings 
and the specification, it is to be understood that the foregoing detailed 
description is for illustration only and that various changes in parts, as 
well as the substitution of equivalent constituents for those shown and 
described, may be made without departing from the spirit and scope of the 
invention as set forth in the appended claims. In particular, while the 
bottle handling apparatus of the invention has been disclosed in the 
context of a transport system for bottle labelling apparatus, it is 
equally suitable for delivering bottles and similar objects to other types 
of processing apparatus.