Carton blank erector and feeding and shuttle machine

A carton blank feeding and shuttle machine includes a first driven belt supported by a first plurality of pulleys and a second driven belt supported by a second plurality of pulleys, a first rod attached to the first driven belt and a second rod attached to the second driven belt. Each of the rods extend across the first and second opposing sides. At least one controller controls motions of (a) the first driven belt and (b) the second driven belt, and a plucking head is supported by the first and second rods such that the first and second driven belts create common motion to move the plucking head along a transport path and relative motion to extend and retract the plucking head. A linkage assembly includes a plurality of links configured to move a plucking head along a shaft in response to movements of the first and second belts.

TECHNICAL FIELD

This document relates generally to carton blank erectors, and more specifically to a carton blank feeding and shuttle machine.

BACKGROUND

Machines for forming cartons from blanks, and then delivering a product for loading into the carton, are well known. Typically, the carton is erected from a blank during a “pick and place” operation. This movement is traditionally accomplished by using two separate feeder and shuttle mechanisms. In addition, these mechanisms traditionally support carton blank stacks in an elevated position such that the blanks are plucked and subsequently transported to a lower position for forming into cartons. This requires the carton blank stacks to be lifted into position above the machine.

Accordingly, a need exists for an improved carton blank feeding and combined shuttle machine that avoids any one or all of the foregoing limitations, and perhaps others yet to be identified.

SUMMARY OF THE INVENTION

In accordance with the purposes and benefits described herein, a carton blank feeding and shuttle machine is provided. The carton feeding and shuttle machine may be broadly described as comprising a first driven belt supported by a first plurality of pulleys attached to a first side and a second driven belt supported by a second plurality of pulleys attached to an opposing second side, a first rod attached to the first driven belt and a second rod attached to the second driven belt, each of the first and second rods extending across the first and second opposing sides, at least one controller for controlling movements of (a) the first driven belt and (b) the second driven belt, and a plucking head supported by the first and second rods such that common motion of the first and second driven belts moves the plucking head along a transport path between an initial position from which the plucking head engages a carton blank and an intermediate position from which the plucking head disengages the carton blank.

In one possible embodiment, the plucking head is further supported by the first and second rods such that relative motion of the first and second driven belts extends the plucking head from a first position to a second position from which the plucking head engages the carton blank.

In another possible embodiment, the first and second driven belts may be driven such that the plucking head extends from the first position to the second position while moving along the transport path between the intermediate position and the initial position.

In yet another possible embodiment, the first and second driven belts may be driven such that the plucking head retracts from the second position to the first position while moving along the transport path between the initial position and the intermediate position.

In still yet another possible embodiment, a first end of the first rod is attached to the first driven belt, a first end of the second rod attached to the second driven belt, and a second end of the first rod is supported for movement relative the first end of the first rod and a second end of the second rod is supported for movement relative the first end of the second rod.

In still another possible embodiment, the plucking head includes at least one linkage assembly supported by the first and second rods.

In one other possible embodiment, the plucking head includes first and second linkage assemblies supported by the first and second rods, and wherein a support bar extends between the first and second linkage assemblies and supports at least one vacuum cup attached to first and second supports associated with each linkage assembly.

In another possible embodiment, a carton blank erector is provided. The carton blank erector may be broadly described as comprising a frame supporting at least one of a carton former, a hopper supporting a plurality of cartons, a take-away conveyor, and a feeding and shuttle machine, the feeding and shuttle machine including (a) a first driven belt supported by a first plurality of pulleys attached to a first side and a second driven belt supported by a second plurality of pulleys attached to an opposing second side, (b) a first rod attached to the first driven belt and a second rod attached to the second driven belt, each of the first and second rods extending across the first and second opposing sides, and (c) a plucking head supported by the first and second rods such that common motion of the first and second driven belts moves the plucking head along a transport path between an initial position from which the plucking head engages a carton blank and an intermediate position where the plucking head disengages the carton blank, and at least one controller for controlling movements of (a) the first driven belt and (b) the second driven belt.

In one other possible embodiment, the plucking head is further supported by the first and second rods such that relative motion of the first and second driven belts extends the plucking head from a first position to a second position where the plucking head engages the carton blank.

In another possible embodiment, the plucking head includes at least one linkage assembly supported by the first and second rods and the at least one linkage assembly supports at least one vacuum cup.

In another possible embodiment, a carton blank feeding and shuttle machine is provided. The carton blank feeding and shuttle machine may be broadly described as comprising a first driven belt supported by a first plurality of pulleys attached to a first side and a second driven belt supported by a second plurality of pulleys attached to an opposing second side, a first rod attached to the first driven belt and a second rod attached to the second driven belt, each of the first and second rods extending across the first and second opposing sides, at least one controller for controlling motions of (a) the first driven belt and (b) the second driven belt, and a plucking head supported by the first and second rods such that the first and second driven belts create common motion to move the plucking head along a transport path and relative motion to extend and retract the plucking head.

In one possible embodiment, the common motion moves the plucking head along a reciprocating transport path between an initial position from which the plucking head engages a carton blank and an intermediate position from which the plucking head disengages the carton blank.

In another possible embodiment, the carton blank feeding and shuttle machine of claim12, wherein the relative motion extends the plucking head from a first position to a second position from which the plucking head engages a carton blank.

In yet another possible embodiment, the carton blank feeding and shuttle machine of claim13, wherein the first and second driven belts may be driven such that the plucking head extends from the first position to the second position while moving along the transport path between the initial and intermediate positions.

In still yet another possible embodiment, the carton blank feeding and shuttle machine of claim13, wherein the first and second driven belts may be driven such that the plucking head retracts from the second position to the first position while moving along the transport path between the initial and intermediate positions.

In still another possible embodiment, a first end of the first rod is attached to the first driven belt, a first end of the second rod attached to the second driven belt, and a second end of the first rod is supported for movement relative the first end of the first rod and a second end of the second rod is supported for movement relative the first end of the second rod.

In one other possible embodiment, the plucking head includes at least one linkage assembly supported by the first and second rods.

In yet another possible embodiment, the plucking head includes first and second linkage assemblies supported by the first and second rods, and wherein a support bar extends between the first and second linkage assemblies and supports at least one vacuum cup attached to first and second supports associated with each linkage assembly.

In still yet another possible embodiment, the relative motion extends the plucking head from a first position to a second position from which the vacuum cup engages a carton blank.

In yet one other possible embodiment, the carton blank feeding and shuttle machine further includes a first drive supported by the first side for moving the second driven belt and a second drive supported by the second side for moving the first driven belt.

In the following description, there are shown and described several embodiments of carton feeding and shuttle machines, carton blank erectors including the carton feeding and shuttle machine, and related methods. As it should be realized, the erectors and machines are capable of other, different embodiments and their several details are capable of modification in various, obvious aspects all without departing from the machines as set forth and described in the following claims. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not as restrictive.

Reference will now be made in detail to the present embodiments of the carton feeding and shuttle machine and related methods of staging a carton for subsequent forming, examples of which are illustrated in the accompanying drawing figures, wherein like numerals are used to represent like elements.

DETAILED DESCRIPTION

Reference is now made toFIG.1which illustrates an overall perspective view of one embodiment of a carton blank erector10. While the term carton blank describes a typically flat material which is formed into a carton, carton blanks will simply be referred to as cartons throughout the specification. As shown in bothFIGS.1and2, the carton erector10includes a frame12supporting a hopper14, a carton feeding and shuttle machine16, a carton former18including a takeaway conveyor20, and an input device22mounted on an extendable arm24. As is known in the art, a plurality of see-through doors26are positioned on each side of the frame12other than the hopper side. The plurality of see-through doors26minimize the risk of an object entering a carton erecting area (generally within the frame12) while allowing operator(s) to visually monitor the carton feeding, shuttling, and forming operations occurring within the area. As shown, the frame12is supported by extendable, leveling feet28at each corner and casters30. The feet28support the erector10in a stationary position during use, shipment, or storage and the casters30support the erector for movement during non-use. In some embodiments, the casters may be retractable and/or one or more locking casters may be utilized in lieu of feet, or the erector may utilize solely feet, or neither.

As shown inFIG.3, the hopper14is an ergonomic low-level hopper configured to support first and second carton stacks32such that a next-in-line carton can be picked or plucked from a side of the stacks facing the carton feeding and shuttle machine16. In other words, the next-in-line carton is picked from a bottom of the carton stacks32. In other embodiments, fewer or more carton stacks may be supported by the hopper14. In one embodiment, for example, an erector with three carton stacks may be utilized. In such an arrangement, as with the described two stack embodiment, the carton feeding and shuttle machine acts to pluck, move, and form a carton from each stack in a combined operation. In this manner, the erector10can form two, three or more times as many cartons compared to an erector with a single carton stack. The remainder of the description, however, will treat the erector10as if its hopper14supports a single carton stack32.

As further shown, a plurality of guides36extend generally perpendicular to a face38of the hopper14. The guides36guide the cartons in the carton stack32into position during placement onto the hopper14and limit lateral movement of the cartons during operation. A hopper tray40in combination with one or more tabs42and a roller bar44support the carton stack32in position on the hopper14. More specifically, the tray40prevent the cartons within the carton stack32from sliding down the hopper face38and the one or more tabs42and roller bar44prevent the carton stack from falling through a generally rectangular or other carton-shaped aperture46defined by the hopper face through which a next-in-line carton travels when plucked or pulled from the carton stack.

The roller bar44extends across the aperture46in the hopper face38and between a lower edge of the aperture (not visible inFIG.3due to the tray40) and a midway point and, in the described embodiment, is positioned about one fourth of the total height of the aperture above the lower edge. In this arrangement, the one or more tabs42are positioned along an upper edge48and side edges50of the aperture. The one or more tabs42extend into the aperture46sufficient to prevent the carton stack32, including the next-in-line carton, from falling through the aperture. In the described embodiment, the one or more tabs42extend into the aperture46approximately one quarter of an inch or so. In operation, one or more plucking heads52grasps an upper portion of the next-in-line carton pulling a flexing upper portion thereof past the one or more tabs42and through the aperture46while a lower portion of the next-in-line carton flexes horizontally around the roller bar44. As the carton feeding and shuttle machine16moves the plucking heads52and the next-in-line carton from its initial position within the carton stack32toward an intermediate position, the next-in-line carton is pulled upward, through the aperture46, and away from the carton stack32. This plucking action and carton movement is described in greater detail below.

FIG.4illustrates a perspective view of the carton feeding and shuttle machine16which is supported by the frame12as shown inFIGS.1and2. In the described embodiment, a plurality of angle brackets54are used to attach the carton feeding and shuttle machine16to corresponding supports of the frame12using bolts or other fastening means. Returning toFIG.4, the carton feeding and shuttle machine16includes opposing sides56,58attached together via a plurality of static rods60extending therebetween. In other embodiments, the rods may be square or L-shaped bars, or any other shaped rigid material and the length thereof may vary as well depending on a desired width of the carton feeding and shuttle machine16. The opposing sides56,58are essentially mirror images of one another in the described embodiment but work together to create motion and relative motion for control of the plucking heads52as will be described in greater detail below.

As shown, side58of the carton feeding and shuttle machine16supports a first servo drive66which drives a timing belt68. More specifically, a drive shaft of servo drive66extends through a first timing belt pulley70. Rotation of the drive shaft imparts motion to the first timing belt pulley70and timing belt68which in turn rotates a second timing belt pulley72. Rotation of the second timing belt pulley72rotates a transfer shaft74extending between sides56and58, causing rotation of a drive pulley76supported by side56, shown inFIG.5.

As further shown inFIG.5, rotation of the drive pulley76moves a drive belt78along a circuitous path adjacent a sidewall80of side56. The drive belt path extends from drive pulley76along a guide wheel82, a first idler pulley84of a double idler pulley86, back along the guide wheel, through a guide rail62, around idler pulley136and tensioner pulley90, and back to the drive pulley. Also shown inFIG.5, side56supports a second servo drive92which drives a timing belt94. Again, a drive shaft of servo drive92extends through a first timing belt pulley96. Rotation of the drive shaft imparts motion to the first timing belt pulley96and timing belt94which in turn rotates a second timing belt pulley98. Rotation of the second timing belt pulley98rotates a transfer shaft100, extending between sides56and58, causing rotation of a drive pulley102supported by side58, shown inFIG.4.

Staying withFIG.4, rotation of the drive pulley102moves a drive belt104along a circuitous path adjacent a sidewall106of side58. The drive belt path extends from drive pulley102along a guide wheel108, a first idler pulley110of a double idler pulley112, back along the guide wheel, through a guide rail64, around idler pulley128and tensioner pulley116, and back to the drive pulley.

Rotation of the second timing belt pulley72caused by movement of the timing belt68also imparts motion to a third belt120along a different circuitous path adjacent the sidewall106of side58. The third belt path extends from pulley122along a guide wheel124, a second idler pulley126of the double idler pulley112, back along the guide wheel, through the guide rail64, around idler pulley114and a tensioner pulley130, and back to the pulley122. Similarly, as shown inFIG.5, rotation of the second timing belt pulley98caused by movement of the timing belt94also imparts motion to a fourth belt132along another circuitous path adjacent the sidewall80of side56. The fourth belt path extends from a pulley, not shown but positioned between the second timing belt pulley98and the sidewall80on shaft100, along a guide wheel134, a second idler pulley of the double idler pulley86, back along the guide wheel134, through the guide rail62, around idler pulley88and a second tensioner pulley138, and back to the pulley positioned between the second timing belt pulley98and the sidewall80on shaft100.

As is known in the art, the servo drives66and90are utilized to provide precise location control for the first and second (drive) belts78and104, via timing belts94and68respectively, throughout use. As schematically illustrated inFIG.6, the servo drives66and90receive command signals from a controller140/control system, amplify the signals, and transmit electric currents to servo motors of the servo drives in order to produce motion proportional to the command signals which, in this instance, represent desired positions. The command signals may be generated via user input through input device22, for example, or other input. In the described embodiment, the input device22is a touch screen display. As suggested and described above, each of the first and second drive belts78and104is individually servo driven via its respective timing belt. However, the drive belts work together to create the motion and the relative motion for control of the plucking heads52mentioned above and described in more detail below.

As best shown inFIG.7, a pivot block142is attached to drive belt104for movement therewith within a guide track154. The guide track154extends within the guide rail64between an outer wall156and a divider158. The divider158extends between the guide tracks154and170to ensure separation of the belts104and120during movement through the guide rail64. A support rod144extends between pivot block142and a corresponding pivot block146attached to belt132such that the pivot blocks142and146form a first pivot block pair. Pivot block146is similarly attached to drive belt132for movement therewith within a guide track160that extends within the guide rail62between an outer wall162and a divider164.

As further shown, another pivot block148is attached to drive belt78for movement therewith within a guide track166. The guide track166extends within the guide rail62between an inner wall168and the divider164. The divider164extends between the guide tracks160and166to ensure separation of the belts132and78during movement through the guide rail62. A support rod150extends between pivot block148and a corresponding pivot block152attached to belt120such that the pivot blocks148and152form a second pivot block pair. Pivot block152is similarly attached to drive belt120for movement therewith within a guide track170that extends within the guide rail64between an inner wall172and the divider158.

In operation, common motions of the servo drives66and90move the first and second pairs of opposing pivot blocks to create motion to move the plucking heads52along a transport path while small differences in motion between the servo drives66and90move the first and second pairs of opposing pivot blocks to create relative motion to control the plucking heads52via a corresponding one or more linkage assemblies180. In the described embodiment shown inFIG.8, the carton feeding and shuttle machine16utilizes two plucking heads52and corresponding linkage assemblies180for plucking cartons from the first and second carton stacks32. Each plucking head52and corresponding linkage assembly180are the same and only one such head and assembly will be described in detail. As noted above, however, one or more plucking heads and corresponding linkage assemblies may be used in different embodiments of the invention.

As shown, the linkage assembly180includes a plurality of links interconnected to pivot about the support rods144and150. In the described embodiment, six links are interconnected, however, alternate embodiments may utilize fewer or more links to achieve the desired motion along a shaft182. As shown, a first link184is supported by or attached to a base186at a first end and supported by support rod150at a second end. Similarly, a second link188is supported by or attached to the base186at a first end and supported by support rod144at a second end. Third and fifth links190,192are supported at first ends by support rod150.

The support rod150extends through apertures in the first ends of the third and fifth links190,192and the second end of the first link184such that the second end of the first link184is essentially sandwiched between the first ends of the third and fifth links. Spacers193may be positioned along rod150between the links184,190, and192. Similarly, third and sixth links194,196are supported at first ends by support rod144. The support rod144extends through apertures in the first ends of the third and sixth links194,196and the second end of the second link188such that the second end of the second link188is essentially sandwiched between the first ends of the third and sixth links. Again, spacers193may be positioned along rod144between the links188,194, and196. Second ends of the third and fifth links190,192and second ends of the third and sixth lengths194,196are attached to or supported by a head202attached to the shaft182.

A support bar204extends between head202of the first linkage assembly180and a head206of a second linkage assembly208. As shown, the support bar204supports first and second plucking heads52. In the described embodiment, each plucking head52includes first and second supports210and212for supporting the next-in-line carton throughout transport, push arms214and216for moving a carton in an intermediate position to a forward position, and support arms220and222. Each plucking head52further includes at least one vacuum tool or vacuum cup218for grasping the next-in-line carton as is known in the art. Although some type of vacuum hose(s) or line(s) is attached to each cup to apply a facility provided vacuum or suction force to a face of the next-in-line carton upon engagement in order to grasp the carton, the hose(s) or line(s) are not shown for clarity. In the described embodiment, each of the first and second supports210and212support a vacuum cup218.

As suggested throughout, relative movement of at least one of the pivot block pairs (shown by action arrows198) within their respective guide rails causes rotation of the links about the support rods144,150resulting in movement of the shaft182and heads202and206(shown by action arrows200). More specifically, the shaft182travels through the base186drawing the heads202and206closer to or pushing the heads away from the base. This movement allows the plucking heads52to move from a first to a second position. In the described movement, the plucking heads52extend from the first position toward the next-in-line carton to the second or plucking position for plucking. Further movement allows the plucking heads52to retract to allow unfettered movement of the plucking heads and plucked carton between an initial position where the carton is a part of the carton stack32and the intermediate position where the carton is released from the plucking heads onto a tray.

In the plucking position, as shown inFIG.9, the plucking head52is extended such that the vacuum cup218is engaging or grasping the next-in-line carton in its initial position within the carton stack32. It should be noted that an amount of extension of the plucking head52and/or various stop positions along the path may be adjusted, as noted above, through operator intervention, whilst the carton feeding and shuttle machine is cycling or otherwise, to accommodate variations within the system (e.g., bowed carton compensation). For instance, an operator may adjust an extension length of the plucking head52utilizing “up” and “down” arrows shown on the input device22to accommodate bowing of cartons within the carton stacks32or other less than optimal conditions.

As described above, the plucking head52engages and grasps an upper portion of the next-in-line carton in the plucking position as illustrated inFIG.10A. Once engaged, the plucking head52is retracted along shafts182via relative movement of the pivot blocks pairs. This movement pulls the flexing upper portion of the next-in-line carton past the tabs42and through the aperture46while the lower portion of the next-in-line carton flexes horizontally around the roller bar44. The servo drives66and/or92ensure that the plucking head52is generally perpendicular to a contact face of the carton blank being plucked.

Once at least the upper portion of the next-in-line carton is pulled through the aperture46or simultaneously therewith, the carton feeding and shuttle machine16initiates movement of the linkage assemblies180, the plucking head52, and the grasped carton toward an intermediate position as illustrated inFIG.10B. In the described embodiment, the intermediate position is resting upon a support tray226positioned above the carton feeding and shuttle machine16and generally horizontal as illustrated inFIG.9. Moving the linkage assemblies180and plucking head52necessarily moves the grasped carton pulling the lower portion over the roll bar44and through the aperture46. Retraction of the plucking head52from the plucking position continues throughout this movement at least sufficient to allow a lower end of the next-in-line carton pulled through the aperture to avoid contacting the hopper14and/or a subsequent next-in-line carton in the carton stack32as shown inFIGS.10B and10C.

As further illustrated inFIG.10C, the next-in-line carton is transported along a transport path from its initial position toward the intermediate position where support tray226is already supporting an intermediate-position-carton. As the plucking head52and carton-in-transport approach the intermediate position, the linkage assemblies180extend to raise the carton-in-transport above the tray226and the push arms214and216positioned along a leading edge of the plucking head52engage the intermediate-position-carton pushing the carton from the support tray226and toward a forward position as shown inFIG.4and sequentially illustrated inFIGS.10C and10D. In the forward position, the erector10can perform one or more next machine functions such as forming the carton and subsequently conveying the formed carton away from the erector. These machine functions are generally represented inFIGS.10A-10Fby reference numeral227. Take-away conveyor belts and carton forming machines, or machines for performing other functions within the carton forming process are generally known in the art and will not be described in detail herein. It should be noted, however, that glue nozzles228may be positioned adjacent the support tray226for depositing glue or adhesive onto passing cartons in support of the forming function as is known in the art. Even more, water nozzles may be positioned where the glue nozzles228are shown adjacent the support tray226and other components and/or tooling for sealing cartons using ultrasonic methods as is also known in the art may also be utilized.

Reiterating, the plucking head52is moved and retracted pulling the next-in-line carton through the aperture46and clear of the next-in-line carton and the hopper14. Subsequently, the plucking head52is extended while moving the carton-in-transport along the transport path sufficient to clear the support tray226. With the carton-in-transport in position above the support tray226and having pushed the intermediate-position-carton toward the forward position, the vacuum pressure is removed from the vacuum cups52releasing the carton-in-transport onto the support tray in the intermediate position. As the carton-in-transport is released, becoming a subsequent intermediate-position-carton, the plucking head52continues moving forward along the transport path in engagement with and pushing the intermediate-position-carton to the forward position as illustrated inFIGS.10D and10E. The actions of initially engaging and pushing the intermediate-position-carton toward the forward position, releasing the carton-in-transport onto the support tray226, and continuing to engage and push the intermediate-position carton to the forward position occur in a generally continuous manner such that the movement appears fluid.

With the intermediate-position-carton pushed to the forward position, the plucking head52is subsequently retracted enough to allow the push arms214and216to clear the support tray226during return travel along the transport path back toward the carton stack32where the cycle of movement is repeated and a subsequent next-in-line carton is engaged and transported along the transport path to the intermediate position. It should be noted that the path the carton travels during operation produces an ergonomic low-level carton hopper position combined with the servo control that allows for infinitely changeable carton pick and shuttle programmed positions. In this manner, the machine can be used with varying other cartoning equipment as well as varying sizes of cartons. A motion profile for the plucking head52may be configured for each individual carton blank size, shape, style, etc. One or more such profiles may be saved in a memory within or associated with the controller140for use in future scenarios when the same carton blank is utilized again.

The foregoing has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Obvious modifications and variations are possible in light of the above teachings. For example, the described embodiment utilizes two linkage assemblies180and two vacuum cups214per plucking head52while alternate embodiments may include one, three, or four similar linkage assembly/plucking head arrangements positioned along the support rods144and150allowing the transportation of one or more cartons in each cycle. Of course, corresponding support trays, glue nozzles, and other components would be required including multiple carton stacks and a suitably modified hopper. All such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.