Automatic bag opening device

Abstract: An automatic bag opening device includes a housing (1) having a bag intake opening (1a) for receiving a filled shipping bag. A bag assist plate (3) forms a chute, allowing the bag to slide down and rest on a bag rest (5). A hollow penetrator (7) penetrates the bag to hold it in place while a bottom of the bag is cut. The bag rest moves away from the bottom of the bag, allowing the contents of the bag to spill out. An air blast through the penetrator helps the bag empty. Additional air blasts hit and shake the bag, knocking the contents loose. A bag pusher (4) pushes the empty bag into a set of rollers (8), folding the empty bag in half, and discharging the bag outside the housing. A dust collector within the housing collects loose dust, thereby enhancing safety and cleanliness of the workplace.

Description: BACKGROUND OF THE INVENTION This invention relates to an automatic bag opening device, and in particular, one that automatically opens and removes the contents of shipping bags. Shipping bags contain various types of powdered or granular substances such as grain, flour, other foods, chemicals, and pharmaceutical powders or granules. A wide variety of substances are in powdered or granular form ranging from foodstuffs to industrial raw materials. After being manufactured at a manufacturing facility, these substances are shipped to market in bags or plastic containers. Shipping is usually by ship, rail, or truck. Upon arrival at small or medium size plants, workers perform the operation of opening the bags and pouring their contents into a container, typically a hopper. Large scale plants and factories use automated equipment due to the volumes involved. In smaller plants, such operations are performed manually. A bag opening device opens and empties bags of these various substances. Several types of bag opening device are already on the market. A brief description of typical examples of these conventional bag opening devices follows. These devices commonly have four functional mechanisms: (1) a mechanism to supply to the device bags filled with various powdered or granular substances, (2) a mechanism to feed the bags into the device, (3) a mechanism to open the bags and discharge their contents, and (4) a mechanism for processing the emptied bags. Since the four mechanisms are mounted on a large frame, the device is necessarily large, thus requiring a large area for its installation. It is difficult to install such devices in a small plant where space is at a premium. An alternative device structurally different from the mechanism just described is a "bag opening hopper mechanism," which includes a fixed blade in a hopper over a vacuum device. Bags are suspended against the fixed blade which cuts a bag bottom to empty the bag's contents. However, variations in the weight and shape of the filled bags sometimes makes this device unusable, thereby limiting its range of application. Unexamined Japanese Patent Application No. HEI 6-40441 (1994), (see also Patent Abstracts of Japan JP 6 040 441) discloses a device intended to overcome these drawbacks in the prior art. The application discloses conveyance means for conveying the bags, a movable table for receiving the bags, means for standing the bags upright, an insertion tube having an air-blowing outlet, and a means for cutting the bag. The device maintains the interior of the bag at a positive pressure to remove the contents in a short time while leaving very little residue inside the bag. However, a detailed analysis of this and the prior art previously described reveals the following unsolved problems. First, the devices are far larger than they should be from the viewpoint of downsizing, which seeks to make the functions of the device as a whole integrated and compact, thereby reducing the installation space required. Second, the emptied bags are treated as trash waste products, with no thought given to recycling. OBJECTS AND SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to overcome the drawbacks and limitations of the prior art. Another object of the present invention is to provide an automatic bag opening device that combines compactness with efficiency, thereby reducing the required installation space. A further object of the present invention is to provide an automatic bag opening device that achieves a clean workplace environment during operation. A still further object of the present invention is to provide an automatic bag opening device which enhances recycling. Briefly stated, an automatic bag opening device includes a housing having a bag intake opening for receiving a filled shipping bag. A bag assist plate forms a chute, allowing the bag to slide down and rest on a bag rest. A hollow penetrator penetrates the bag to hold it in place while a bottom of the bag is cut. The bag rest moves away from the bottom of the bag, allowing the contents of the bag to spill out. An air blast through the penetrator helps the bag empty. Additional air blasts hit and shake the bag, knocking the contents loose. A bag pusher pushes the empty bag into a set of rollers, folding the empty bag in half, and discharging the bag outside the housing. A dust collector within the housing collects loose dust, thereby enhancing safety and cleanliness of the workplace. According to the invention, an automatic bag opening device for opening and emptying a bag of its contents includes the features making up the combination of independent Claim 1. Advantageous embodiments are defined by dependent claims. The above features, and other objects and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a front elevation view of an automatic bag opening device according to an embodiment of the present invention. Fig. 2 is a partial sectional front view of the embodiment of Fig. 1. Fig. 3 is a perspective view of a roller used in an embodiment of the present invention. Fig. 4 is a partially cut away back elevation view of the embodiment of Fig. 1. Fig. 5a is a partial sectional top plan view according to an embodiment of the present invention. Fig. 5b is a partial sectional side elevation view according to an embodiment of the present invention. Fig. 6 is a partial sectional front view used in explaining the operation of the embodiment of Fig. 1. Fig. 7 is a partial sectional front view used in explaining the operation of the embodiment of Fig. 1. Fig. 8 is a partial sectional front view used in explaining the operation of the embodiment of Fig. 1. Fig. 9a is a partial sectional front view used in explaining the operation of the embodiment of Fig. 1. Fig. 9b is a side view of a roller assembly according to an embodiment of the present invention. Fig. 10 is a partial sectional front view used in explaining the operation of the embodiment of Fig. 1. Fig. 11 is a front elevation view showing an automatic bag opening device according to a second embodiment of the present invention. Fig. 12 is a partial sectional front view used in explaining the operation of the embodiment of Fig. 11. Fig. 13 is a partial sectional front view used in explaining the operation of the embodiment of Fig. 11. Fig. 14 is a partial sectional front view used in explaining the operation of the embodiment of Fig. 11. Fig. 15 is a partial sectional front view used in explaining the operation of the embodiment of Fig. 11. Fig. 16a is a partial sectional front view used in explaining the operation of the embodiment of Fig. 11. Fig. 16b is side view of a roller assembly according to an embodiment of the present invention. Fig. 17 is a partial sectional front view used in explaining the operation of the embodiment of Fig. 11. Fig. 18 is a partial sectional front view used in explaining the operation of an alternative embodiment of the present invention. Fig. 19 is a partial sectional front view according to a third embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to Figs. 1-2 and 6, a first embodiment of an automatic bag opening device includes a housing 1. A transport conveyor 2, adjacent to a bag intake opening 1a in housing 1, conveys a bag F filled with a powdered or granular substance to the device. A bag assist plate 3, rotatably mounted on a drive shaft 3a, rotates from the vertical toward conveyor 2 to form a chute for bag F. A bag rest 5, rotatably mounted on a drive shaft 5a, rotates in tandem with bag assist plate 3 so that a top surface of bag rest 5 is perpendicular to a surface of bag assist plate 3. Drive shaft 3a and drive shaft 5a are each affixed to housing 1 by a bearing 1d. As bag F enters housing 1, a control circuit (not shown) actuates drive shaft 3a and drive shaft 5a, tilting bag assist plate 3 and bag rest 5 to receive bag F. As a center of gravity of bag F crosses an end of conveyor 2, the weight of bag F forward of the center of gravity causes bag F to rotate onto bag assist plate 3. Bag F slides down bag assist plate 3 to rest on bag rest 5. When the control circuit detects that bag F is securely held by bag assist plate 3 and bag rest 5, it returns bag assist plate 3 and bag rest 5 to their upright position. Bag F is thus vertically positioned on bag rest 5 with a back side of bag F in contact with bag assist plate 3. Referring also to Fig. 7-8, a penetrator 7, opposite a front side of bag F, is driven by a penetrator drive actuator 7a. Penetrator 7 is a hollow tube with a sharp tip. When the control circuit detects that bag F is vertically positioned, the control circuit signals penetrator drive actuator 7a to cause penetrator 7 to penetrate bag F. A bag cutter 6, driven by a cutter drive actuator 6a, slices a bottom of bag F laterally just above bag rest 5. The control circuit then rotates bag rest 5 clockwise away from the bottom of bag F, allowing the contents of the bag to spill out while bag F is suspended from penetrator 7. At the same time, high pressure air is injected through penetrator 7 into an upper portion of bag F. The injected air blows the contents of bag F into a chute connection opening 1c leading to a chute 1g or hopper (not shown). An air nozzle 9 in a lower corner of housing 1 under rollers 8 directs pulses of air onto the outside of bag F to shake bag F and help remove its contents. At least one inspection window 1e permits an operator to view the operation. Referring to Figs. 9a, 9b, and 10, a bag pusher 4 below drive shaft 3a is driven by a bag pusher drive actuator 4a. Opposite bag pusher 4, a plurality of pairs of rollers 8 are spaced apart horizontally. A vertical distance between rollers 8 accommodates bag pusher 4 and folded bag F. After bag F is emptied, bag pusher 4 pushes a middle of bag F between rollers 8. Bag F is folded in two as it moves between rollers 8. Bag F is pushed by rollers 8 through a bag discharge opening 1b. Referring also to Fig. 3, each roller 8 includes a hole H in one end and a slit S in its outer surface. High-pressure air A enters roller 8 through hole H, and is blown out through slit S, to remove any contents of bag F adhering to the outside of the bag. A relatively clean empty bag F is discharged to the outside. Referring to Figs. 4, 5a, and 5b, a back of housing 1 includes a bag assist plate drive actuator 3b that drives bag assist plate 3. A bag rest drive actuator 5b drives bag rest 5. In addition, housing 1 includes a dust collection treatment chamber Y in the space between a partition wall 1f and the back of housing 1. Dust collection treatment chamber Y is separate and independent from a bag treatment chamber X. Dust collection treatment chamber Y includes a dust collector DF. Powder and dust arise from the emptying operation of bag F as described above. The powder and dust mixed in with the contents of bag F are sucked into the dust collector and removed, as shown by the arrows in Fig. 5b. The interior of bag treatment chamber X is maintained at a negative pressure compared to atmospheric pressure. This ensures that dust is prevented from leaving bag treatment chamber. The automatic bag opening device of this working example accomplishes the following benefits. (1) Substantial labor savings are made possible because a series of steps are performed automatically according to a prescribed sequence. The steps of introducing a filled bag, opening it, discharging its contents, supplying the contents to a chute or hopper, folding the empty bag, and discharging the used bag outside the device are all automatic. (2) A significant savings in space is successfully achieved. This makes it easier to transport and install the equipment, which is installed in a small plant despite limited installation space. (3) An automatic air cleaning device is built into an automatic bag opening device, thus realizing a very hygienic device that solves the problem of miscellaneous germs caused by residual substances inside the device. (4) Emptied bags are automatically folded and cleaned. Because any substances adhering to the bags are automatically removed by air cleaning during the process, empty bags are recovered easily. in addition, pollution of the surrounding area from dust is completely eliminated. (5) Installation of separate dust collection equipment is not required since there is a dust collector inside the same housing. (6) The need for frequent cleaning of the inside of the device is eliminated. An automatic self-cleaning function keeps the inside of the device clean at all times during operation. (7) Since the dust collector is of the side-attachment type, the suction opening for sucking in powder and dust with negative pressure is placed near the discharge outlet for dust inside the device. This facilitates efficient recovery of powder and dust without waste. (8) The powdered or granular substances emptied from the bag are completely discharged due to the high-pressure air blowing inside the device. (9) The various drive functions of the device, such as actuators, motors, piping, and wiring, are all attached on the outside of the unit, thereby making maintenance and inspection very easy. (10) Using the device improves the workplace environment since the device generates no vibration, noise, or dust during operation. (11) The mechanisms of this device operate under the control of algorithms that simulate the manual work. Therefore, the contents are treated gently, with no contamination from foreign matter. Referring to Figs. 11-13, a second embodiment of the present invention includes a housing 10 with a bag intake opening 10a for receiving a bag F from a transport conveyor 2. When a control circuit (not shown) powers on, the control circuit outputs a drive signal causing a bag assist plate 11 and a bag rest 13 to rotate and stop in a tilted position. When transport conveyor 2 is activated, bag F is transported to housing 10 where it enters through bag intake opening 10a as shown by the arrow. Bag F slides down along the tilted bag assist plate 11 to bag rest 13. Referring to Fig. 14, when the control circuit detects that bag F is stopped by bag assist plate 11 and bag rest 13, it outputs a drive signal returning bag assist plate 11 and bag rest 13 to their vertical states. Bag F assumes an upright state. The control circuit outputs a drive signal to a penetrator drive actuator 14a, inserting a tip of a penetrator 14 into an upper part of the upright bag F and holding the bag in place. Referring to Fig. 15, when the control circuit detects that bag F is completely held by penetrator 14, it outputs a drive signal causing bag rest 13 to rotate to the rear, leaving bag F suspended from penetrator 14. Then the control circuit outputs a drive signal to a bag cutter drive actuator 16a, activating a bag cutter 16. Bag cutter 16 cuts open the bottom of bag F to let the contents fall. A high-pressure blast of air from an air nozzle 16b strikes bag F as shown by an arrow a . The various powdered or granular substances remaining in bag F are knocked loose. The contents of bag F fall through a chute connection opening 10c as shown by arrows b to a chute 10f or hopper (not shown). While subjecting bag F to high-pressure blasts of air to knock out the various powdered or granular substances inside bag F, a dust collector 17, near a ceiling of housing 10, is in operation. The powder and dust mixed in with the various substances knocked off from bag F are sucked in and removed by dust collector 17 as shown by arrows c . Referring to Figs. 16a-16b, the control circuit outputs a drive signal to a bag pusher drive actuator 12a, moving a bag pusher 12 against the now empty bag F. Bag F is folded in half as bag pusher 12 pushes bag F into a gap between upper and lower rollers R of a roller assembly 15. A pair of rollers R closest to bag pusher 12 are spaced apart sufficient for bag pusher 12 to pass between as it pushes bag F. A pair of rollers R furthest away from bag pusher 12 are spaced apart sufficient for only folded bag F to pass between. Rollers R rotate while high-pressure blasts of air A are released from slits (not shown) in an outer surface of rollers R. Bag F is cleaned by the high-pressure blasts of air A while being folded in half by the gap portion of the upper and lower rollers 15. Referring to Fig. 17, the now emptied and cleaned bag F is discharged outside housing 10 from a bag discharge opening 10b. Bag pusher 12 is retracted by bag pusher drive actuator 12a. The automatic bag opening device is now ready for another bag. Referring to Fig. 18, an alternative embodiment uses a bag suspension holding claw 18 to hold bag F in place during the cutting and air-blasting operations. A linear actuator 19 moves bag suspension holding claw 18 up and down, as shown by an arrow d , or left and right, as shown by an arrow e . A penetrator is not used in this embodiment. Blasts of air from air nozzle 9 shake bag F while the contents of the bag fall into a chute 20. The remainder of the operation is as described in the previous embodiments, so further description is therefore omitted. Referring to Fig. 19, a third embodiment of the present invention is similar to the first embodiment. Therefore, only the differences are discussed here. A plurality of hollow penetrators 7' include a plurality of spaced apart holes 21. After penetration of a filled bag (not shown), at least one hole 21 in each penetrator 7' preferably remains outside the bag. A bag assist plate 3' includes a plurality of recesses 3c horizontally aligned with penetrators 7'. Penetrators 7', after penetrating the bag, engage in recesses 3c to support the bag after bag rest 5 rotates from under the bag. After the bottom of the bag is cut by bag cutter 6, air blasts through holes 21 in penetrators 7' strike the inside and outside of the bag, thereby ensuring that all the contents of the bag are knocked loose. Since air blasts strike the outside of the bag from at least one hole 21, air nozzle 9 shown in previous embodiments is not required. Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope of the invention as defined in the appended claims.

Claims: An automatic bag opening device for opening the bottom of and emptying a bag (F) of its contents, comprising: a bag assist plate (3); a bag rest (5); said bag assist plate (3) being capable of rotating between an upright position and a chute position; said bag assist plate (3) and said bag rest (5) being capable of moving said bag (F) to a standing position; bag holding means (7, 14; 18) for holding said bag (F) in said standing position; a bag cutter (6) attached to a bag cutter actuator (6a) for driving said bag cutter (6) to open said bottom of said bag (F) in said standing position such that contents of said bag (F) may be released; said bag rest (5) being capable of moving away from said bottom of said bag (F) to said releasing position such that said bag (F) is held by said bag holding means and said contents of said bag (F) are released; means for assisting release of said contents of said bag (F); said device characterized by: a housing (1); a bag intake opening (1a) in said housing (1); said bag assist plate (3) being rotatably mounted on a drive shaft (3a) connected to said housing (1); said bag rest (5) being rotatably mounted on a drive shaft (5a) connected to said housing (1) and being capable of rotating between a plurality of supporting positions and the releasing position; said bag rest (5) and said bag assist plate (3) capable of being coordinated to guide said bag (F) to said standing position and to support said bag (F) before, during and after rotation; a bag discharge opening (1b) in a wall of said housing (1); at least first and second rollers (8) with a gap therebetween, said gap adjacent to said bag discharge opening (1b); each of said at least first and second rollers (8) having at least one slit (S) and at least one opening (H) therein; said at least one slit (S) being capable of passing air inserted into said at least one opening (H); a bag pusher (4) attached to a bag pusher actuator (4a) located opposite said gap; and said bag pusher (4) being capable of extending and retracting to fold and push a position of an empty bag (F) into said gap so that said empty bag (F) is discharged through said bag discharge opening (1b). A device according to claim 1, wherein said bag holding means is characterized by a holding claw (18) in said housing (1); said holding claw (18) being capable of horizontal and vertical movement and said holding claw (18) being capable of opening and closing such that a bag (F) is held. A device according to claim 1, wherein said bag holding means is characterized by at least one penetrator (14) attached to a penetrator drive actuator (14a); and said penetrator drive actuator (14a) capable of extending said at least one penetrator (14) to penetrate and hold said bag (F), and retracting said at least one penetrator (14) to release said bag (F). A device according to claim 1, wherein said bag holding means is characterized by at least one hollow penetrator (7) attached to a penetrator drive actuator (7a); said penetrator drive actuator (7a) capable of extending said at least one hollow penetrator (7) to penetrate and hold said bag (F), and retracting said at least one hollow penetrator (7) to release said bag (F); and said at least one hollow penetrator (7) being capable of passing air to the interior of said bag (F) when held. A device according to any of claims 1 to 4, wherein said means for assisting is characterized by striking an exterior of sad bag (F) with at least one blast of air. A device according to claim 4, wherein said at least one hollow penetrator (7) is further characterized by a plurality of hollow penetrators (7'): each of said plurality of hollow penetrators (7') having a plurality of spaced apart openings (21) on a surface thereof; said bag assist plate (3') includes a plurality of recesses (3c); said recesses (3c) being adapted to supportably receive an end of extended ones of said pluraliity of hollow penetrators (7'); and said means for assisting is characterized by said plurality of hollow penetrators (7') being capable of directing air through said openings (21) to an exterior and an interior of said bag (F). A device according to claim 1, further characterized by: means for transporting said bag (F) to said bag intake opening (1a); and a dust collector (DF) in said housing (1).

Inventors: KATO FUMIO, KATO, FUMIO, Kato, Fumio, c/o Tsukasa Ind. Co., Ltd.
Applicants: TSUKASA KASEI KOGYO, TSUKASA INDUSTRY CO., LTD.
Application year: 1996
Main classification: B65B69
IPC codes: B65B69