Abstract:
A unitary panel sorting and packing machine receives vinyl siding panels from an extruded production line. The machine includes a panel receiving section which includes lifting and flipper arms for selectively inverting panels for packing efficiency. From the panel receiving section, the panels are transferred to a panel accumulation section. The machine also includes a box folding section for folding corrugated paper box blanks along predetermined score lines. The box folding section is preferably parallel and adjacent to the panel receiving section and the panel accumulation section and includes retractable arms which selectively position the box in a ready position for packing panels therein. After the box is full, conveyor mechanisms carry the box from the box folding section through a box lid glue applying station and then into a box end folding and gluing station. This machine can substantially reduce repetitive stress caused injury to the operator.

Description:
FIELD OF INVENTION 
     This invention relates to production line machinery for sorting and packing articles, and in particular to such a machine for sorting and packing vinyl siding panels. 
     BACKGROUND OF THE INVENTION 
     Vinyl siding is popularly used as a substitute for clapboard siding and has the advantage of low maintenance and high resistance to weathering. Vinyl siding is easily applied by home remodelers and do-it-yourselfers. This siding is made by a known extrusion process with a common panel size of 8 inches wide by 12 feet long, although other lengths and widths can be used as appropriate. The siding is normally formed with a hanger strip along one edge which interlocks with a mating strip along the edge of an adjoining strip. These hanger strips complicate packing the strips in stacks within a box or carton, and to achieve maximum space efficiency, the strips are normally alternated in orientation. Moreover, stacking and packing of the panel strips is done by hand in most manufacturing plants. Repetitive hand and wrist movement is required, which can lead to repetitive stress injury. The panel strips are stacked in boxes or cartons which are then sealed and routed for shipment. The boxes arrive at the manufacturing plant as flat, corrugated blanks which have predetermined score lines along which the blanks are folded. The boxes are normally assembled by hand, and because the corrugated board is quite stiff, folding the boxes is another source of repetitive stress injury to the hands and wrists of the operator. 
     Various attempts have been made to automate the siding sorting and packing process, including those disclosed in U.S. Pat. Nos. 4,941,309 and 5,024,045 to CertainTeed Corporation. These disclose separate machines that prefold boxes from corrugated blanks but which still require significant amounts of hand work. 
     Accordingly, the objects of the present invention are: to provide a combined siding sorting and box folding machine that automatically folds and positions a box adjacent a siding panel receiving station; to provide such a machine that is able to selectively orient siding panels for saving space within the box; to provide such a machine which is able to seal boxes once they are filled; and to provide such a machine that is compact and well suited for the task. 
     Other objects and advantages of the invention will become apparent from the following description taken in connection with the drawings which disclose an exemplary embodiment of the present invention. 
     SUMMARY OF THE INVENTION 
     A unitary vinyl siding sorting and packing machine includes a panel receiving section positioned in line with a panel strip extrusion production line combined with a box folding section. The panel receiving section and box blank folding section are positioned parallel and generally adjacent to each other for minimal operator hand movement. Vinyl siding panels are deposited on a panel accumulation section platform and several panels are allowed to accumulate. The accumulated panels are then moved toward an open box by slide carriers in the platform and the operator completes the movement of the panels into the open box which has been readied for receipt of the panels. The panel receiving section includes lifting and flipping arms which can be selectively actuated to invert selected panels for efficient stacking of panels within the box. The box blank folding section folds and positions a box for most efficient stacking and minimal hand movement. Extensible arms form a carrier for holding a flat box blank and the carrier retracts, folding the box and positioning it partially under the panel receiving section to minimize hand movement. The box lid is held open in this position. After the box is filled by the operator and the lid closed, a switch is actuated and a conveyor moves the box downstream through stations which hold the box lid closed and glue it down. The filled box next passes into a box end folding and gluing station which accurately positions the box and smoothly secures the box end flap. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a plan view of a sorting and packing arrangement for siding panels embodying the present invention. 
     FIG. 2 is front elevational view of the sorting and packing arrangement. 
     FIG. 3 is a side elevational view taken from the right side as shown in FIG.  1  and showing the arrangement receiving an unfolded box blank. 
     FIG. 4 is a side elevational view in sequence to FIG.  3  and showing the arrangement with a partially folded box blank. 
     FIG. 5 is a side elevational view in sequence to FIG.  4  and showing the arrangement with a box blank in position to receive siding panels. 
     FIG. 6 is a perspective view showing an adjustment and stop mechanism for controlling box blank folding sub assemblies. 
     FIG. 7 is a sectional view taken along lines  7 — 7 , FIG.  1  and showing flipping arms in a first, retracted position. 
     FIG. 8 is a sectional view taken along lines  8 — 8 , FIG.  1  and showing the flipping arms in a second, lifting position. 
     FIG. 9 is a perspective view of the flipping arm mechanism shown in FIGS. 7 and 8. 
     FIG. 10 is a cross sectional view of the box lid sealing station taken along lines  10 — 10 , FIG.  1 . 
     FIG. 11 is a plan view of a conveyor which transports the boxes containing stacks of panels from the box lid sealing station shown in FIG. 10 to a box end sealing station. 
     FIG. 12 is a front elevational view of the conveyor shown in FIG.  11  and showing the box end sealing station. 
     FIG. 13 is a perspective view of the box end sealing station. 
     FIG. 14 is an end elevational view of the box end sealing station. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As required, a detailed embodiment of the present invention is disclosed herein; however, it is to be understood that the disclosed embodiment is merely exemplary of the invention which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. 
     Referring to the drawings in more detail: 
     The reference numeral  1 , FIG. 1, generally refers to a sorting and packing arrangement or machine for siding panels embodying the present invention. The machine  1  generally includes a panel receiving section  2  positioned in line with a panel strip production line, which is not shown and would normally be positioned to the right of the machine shown in FIG.  1 . The machine  1  includes a box folding section  3 . Vinyl siding panels accumulate in the panel receiving section  2  and are shifted to a panel accumulation section  5  positioned parallel and directly adjacent the box blank folding section  3 . The accumulated panels are then slid by a carrier further sidewardly and into position for immediate hand movement into an open box which has been readied for receipt of the panels. The panel receiving section  2  includes flipping arm assemblies  6  which can be selectively actuated to invert selected panels for most efficient stacking of the panels within the box. Extensible arms form a carrier  8  for holding a flat box blank  9 , FIG.  3 . As shown in FIG. 5, the carrier  8  retracts, folding the box blank  9  into a box  10  and positioning the box  10  partially under the panel accumulation section  5  to minimize hand movement. After the box  10  is filled by the operator and the box lid is swung closed, a switch is actuated to cause a conveyor  12  to move the filled box downstream and through a box lid gluing station  14 . The box is next conveyed to a box end gluing station  16 , FIG. 12, which accurately positions the box and smoothly secures the end flaps. 
     In greater detail, the sorting and packing arrangement  1  has an open frame  16  supporting the panel receiving section  2 , which is generally formed of a planar length of stainless sheet material. A ramp up  17  leads into the section  2  for smooth entry of siding panel strips, facilitated by a roller  18 . As the siding panel strip arrives in the panel receiving section  2 , panels rejected by the operator for quality control may be manually shoved rearwardly or mechanically shifted rearwardly to fall into a reject tray  20 . A rack and pin lock latch  21 , FIG. 3, operates to vary the tilt of the reject tray. As the strips arrive, they are shifted laterally forwardly or rearwardly by the selective rotation of eccentric wheels  23  which are mounted below the panel receiving section  2 , FIGS. 7 and 8, and which extend upwardly through slot opening  24  during a portion of their rotation. The eccentric wheels  23  are mounted on a common shaft  26  on one end of which is a pulley  27  belt driven by a motor  28 . A photo electric eye  28 ′ conveniently placed below the panel receiving section  2  causes the motor  28  to rotate the wheels  23 , causing the rim of the wheel  23  to extend through the opening slots  24  and lift the siding strip, causing it to shift laterally. A selector switch adjacent the operator on a control panel  92  selects the direction of rotation of the motor to cause selection in the direction of shift of the siding strips. The wheel rim  29  has a non-skid rubber surface to facilitate gripping. A second roller  31  in the table surface aids longitudinal travel of the siding strips. As shown in FIG. 1, an adjustable position sensor  30 , such as an electronic eye may be mounted on a screw shaft and electrically connected to a controller (not shown) for the siding extrusion machine located upstream of the sorting and packing arrangement  1 . The sensor could be used in the control of the length of the siding strip. 
     Located adjacent, parallel to and forming part of the panel receiving section  2  is a panel transfer area  32  of the section  2  which receives siding strips as they are shifted laterally from the eccentric wheels  23  and from where the strips are transferred to the panel accumulating section  5 . The panel accumulating area  5  is likewise formed of stainless sheet material and is positioned at a level below that of the panel receiving section  2 . A plurality of lifting arms  34 , such as three, FIGS. 7,  8 , and  9 , extend selectively upwardly through slots  35  and carry individual siding panels to deposit them in the panel accumulating area  5 . Each lifting arm  34  is an assembly that swings upwardly on a common shaft  37  which is rotated by a pneumatic cylinder actuator  38  located adjacent the middle positioned lifting arm, FIG.  1 . Each lifting arm assembly  34  includes a mounting block  40  secured on the shaft  37  for rotation therewith. Bearings  41  adjacent each of the lifting arm assemblies  34  and mounted within brackets (not shown) provide support. Each lifting arm assembly  34  has an elongate arm  43  which, when the lifting arm assembly  34  is actuated, swings upwardly to carry a siding strip transferred to it from the eccentric wheels  23  and deposit the siding strip into the panel accumulation section  5 . The siding strips may simply slide off the arms  43  and land in the same orientation or may be inverted to land upside down in alternated manner for most efficient stacking and conservation of space. To flip the siding strips, the lifting arm assemblies  34  include flipping arms  45  secured to the mounting block  40  by a pivot pin  46  and swung by a pneumatic cylinder actuator  48  which is selectively actuated by a control switch (not shown) at the operator&#39;s position. The actuator  48  swings the flipping arm  45  as shown in FIGS. 8 and 9. When in the perpendicular position to the lifting arm  43 , the flipping arms  45  cause siding strips to flip and land upside down on the panel accumulating section  5  when the lifting arms  43  are swung upwardly. Conversely, when the actuator  48  is operated to swing the flipping arm  45  into an angle greater than 90 degrees relative to the lifting arm  43 , the siding strip slides off the lifting arm  43  and does not invert. 
     The siding strips accumulate in stacks in the panel accumulation section  5  and may be positioned right side up or alternatively inverted for most efficient stacking. The panel accumulation section  5  also has a smooth stainless steel or other appropriate surface and includes slide carriers  50  traveling in slots  51  which move the accumulated stacks of siding strips forwardly. The slide carriers  50  are moved by pneumatic actuaters (not shown). 
     As shown in FIGS. 3,  4  and  5 , the panel accumulation section  5  is open underneath and a portion of the packing carton or box  10  such as the lid is positionable under the section  5  for ease of loading. To accomplish this, pairs of slide assemblies  55  are mounted on a support frame  57  connected to the frame  16 . The support frame  57  has rollers  58  positioned above and below an upper frame member  59  for forward and aft movement. An actuator  61 , such as a pneumatic ram, extends between the support frame  57  and a holding bracket  63  affixed to the frame  16  so that upon extension of the actuator, the support frame moves outwardly, or toward the operator. 
     Above the support frame  57  is mounted a deflector panel  65  which runs the length of the panel accumulating section  5  and is similarly formed of sheet metal. The deflector panel  65  is angled rearwardly and downwardly so that a flap portion  66  of the box blank  9  rests thereagainst as the blank is folded. The deflector panel  65  includes a lip  68  which forms a catch angle with the front lip of the panel accumulation section  5  in order to catch and hold the box blank edge as it is initially positioned for folding, FIG.  3 . 
     The support frame  57  supports the carrier  8  into which the box blank  9  is positioned for folding and packing. Referring to FIG. 6, the carrier  8  is preferably adjustable so that different sizes of boxes may be accommodated or adjustments can be made for tolerances in blanks. The carrier  8  includes a fixed base plate  70  extending longitudinally and mounting a telescoping rod  71 . The rod  71  extends between an outer end plate  73  sideably mounted on the end of the rod  71  and an inner, fixed mount  75 . A slide plate  77  is positioned above the base plate  70  and is moveable thereover, also fitting over the rod  71 . First and second threaded rods  79  and  80  provide means for adjustment of inner and outer movement and terminate at outer ends in adjustment knobs  81  located on the outer end plate  73  and terminating at inner ends in free spinning end plates  83  affixed to a mount  78  moving above plate  70 . Spaced side plates  85  are affixed to the framework  57  and hold the carrier  8  in position. Guides  86  are affixed to the side plates  85  and through which extend the respective threaded rods  79  and  80 . Side rails  88  extending forwardly from the mount  78  via wheels  89  positioned above and below the rails  88 . The rails have scales  91  for measurement of adjustment. The first rod  79  extends through a threaded stop  93  which hits against the front edge of the side plate  85  for limiting retraction movement of the carrier  8 . The second rod  80  extends through a threaded stop  93 ′ which hits against the rear edge of the side plate  85  for limiting extension movement of the carrier  8 . Together, the rods  79  and  80  provide forward and rearward adjustability of the carriage  8 . The rod  79  provides rearward or retraction adjustment whereas the rod  80  provides forward or extension adjustment for proper folding of the box blank  9 . Rollers  95  mounted adjacent the respective rails  88  adjoining the outer end plate  73  extend slightly above the level of the rails  88  and facilitate a loaded box  10  to be conveyed downstream, joining with the conveyor  12  and moving the box  10  through the box lid gluing station  14 . 
     A control panel  92  is mounted to extend from an end of the machine  1  for containing electrical power and control circuits, circuit breakers and the like. 
     In operation, the carriage  8  is moved outwardly to the position shown in FIG. 3 and a box blank  9  laid in position by an operator so that one side margin is adjacent to the outer end plate  73  and the other is engaging the lip  68 . The side plates  85  extend upwardly a distance less than the height of the box side wall and have a slanted top edge  96  of the same general angle as that of the deflector panel  68 . A sheet metal panel  97 , FIG. 1, is mounted across the top edges  96  and extends the length of the panel accumulation section  5 . After the operator places the box blank  9  as shown in FIG. 3, the operator actuates a switch to cause retraction of the carriage  8 , meanwhile lightly pushing downwardly on the blank  9  in the area between the outer end plate  73  and the side plates  85 . As the carriage  8  retracts, the blank  9  folds along its crease lines to the intermediate position shown in FIG.  4 . Another switch is actuated to cause retraction of the support frame  57  under the panel accumulation section  5  to complete the box folding, as shown on FIG.  5 . In this relation, hand movement by the operator is minimized and there is less likelihood of repetitive stress injury. The carriage  57 , with minimal assistance from the operator, folds the box blank  9  into an open position ready to receive siding strips, FIG.  5 . 
     In the strip receiving position shown in FIG. 5, the box  10  and carriage  8  is longitudinally aligned with the conveyor  12  which transfers the loaded box  10  from the strip receiving position to the box lid gluing station  14 . The conveyor  12 , in the illustrated example, has a carrier belt  99  driven by a motor, FIG. 10, located under an outlet end of the conveyor  12 . The box lid gluing station  14  is generally located adjacent an outlet end of the conveyor  12  and includes first and second top rollers  103  and  104  each preceded by a press down ramp  105  which initially urges the box lid  107  downwardly with the respective roller  103  and  104  applying still more downward pressure. The first roller  103  is angled off perpendicular whereas the second roller  104  is perpendicular to the line of travel of the conveyor  12 ; this arrangement smooths the box lid  107  downwardly. A vertical height adjustment mechanism  109 , FIG. 10, includes a hand wheel  110  which acts upon threaded shafts running through tubes  111  to vary the height of the rollers  103  and  104  and therefore control the pressure applied to the box lid  107 . The box  10  passes through the box lid gluing station  14 , which includes a glue head  113  positioned upstream of a movable side plate  115 . The glue head  113  applies hot glue to the sidewall of the box underlying the lid  107  and the movable side plate  115  next presses the lid  107  down and into contact with the glued sidewall. 
     From the conveyor  12 , the box  10  next travels to a box end gluing station  120 , FIGS. 11 and 12, which includes spaced box end gluing devices  121  and  122 . The box end gluing station  120  substantially consists of a conveyor  124  which in the illustrated example, is a free conveyor formed of a multiplicity of rollers  125  and the opposed box end gluing devices  121  and  122 . One of the rollers  125  such as the roller  126  may be powered by a drive motor (not shown) inside the roller for rotation. 
     From the box end gluing station  120 , a loading free conveyor  135  routes sidewardly for stacking the filled boxes or transfer to a loading dock area. To move the boxes  10  to the loading conveyor  135 , the conveyor  124  has several laterally extending chains  140  driven by a motor  127  which shift the box  10  sidewardly. A photo eye  141  located in the box end gluing station  121  senses the position of the box  10  and actuates the motor  127  to drive the chains  140  and shift the box  10  sidewardly. 
     FIG. 11 shows the box end gluing station  120  without the box end gluing devices  121  and  122  for purposes of illustration. Turning to FIG. 12, the box end gluing devices  121  and  122  are located on opposite ends of the box end gluing station  120  in order to glue the opposite ends of the box  10  as it is received in the gluing station  120  and shifted sidewardly therein. Box end gluing device  121  and  122  is the same with reference to FIGS. 13 and 14 for purposes of illustration. Each box end gluing device  121  or  122 , FIGS. 13 and 14, includes pusher members  130 ,  131 ,  146  and  150  and a glue head  133  to apply glue to the box end flap and push it closed. 
     Upon reaching the gluing device  121  or  122 , flap openers  143  rotate and pull open the box end flap at the top and bottom. Next, air cylinders  145  extend to swing respective closer arms  146  upwardly to close the box side, or minor flaps. Then, a bottom thruster  131  moves upwardly by action of air cylinder  148  to close the box bottom flap and the side closer arms  146  swing downwardly. Upper thruster  150  extends downwardly by action of air cylinder  152  to partially close the box upper flap as the bottom thruster  131  retracts. The box  10  next moves sidewardly by action of the laterally extending chains  140  to drive the box past the glue head  133  to apply hot glue to the box end. After the glue is applied, pusher members  130  extend via air cylinder  155  to push the upper end flap closed against the underlying glued surface. The chains  140  stop for a short time to permit the glue to cure and then start again to move the sealed box  10  outwardly, at which time the pusher members  130  retract simultaneously. 
     While the invention has been illustrated and described in its preferred form, it will be apparent that the invention is subject to alteration and modification without departing from the underlying principles involved, and the invention is not limited to its specific details illustrated and described except insofar as set forth in the following claims.