Abstract:
An article assembly apparatus and method employs rotary pick and place technology to deposit one component of an apparatus within another at a relatively high rate of speed. A substantially disk-shaped component is inserted within a substantially cylindrical component with a relatively tight fit between the two. The substantially disk-shaped component is carried at a fixed, predetermined angle, relative to a radius of a rotating wheel carrying the component, permitting the smooth placement and depositing of the substantially cylindrical component within the substantially cylindrical component. The substantially disk-shaped component may comprise a piston and the substantially cylindrical component may comprise a body of a bottom filled airless container undergoing assembly following the placement of a substance to be dispensed within the body.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates, in general, to article assembly apparatuses and methods, and, more particularly, to apparatuses and methods for the insertion of round discs into open ended cylinders at a high rate of speed. 
         [0003]    2. General Background of the Invention 
         [0004]    Article assembly apparatuses are known. One type of article assembly apparatuses employs rotary pick and place technology to pick up, transfer, and place an article from one location to another. Pick and place technology may be employed, for example, to deposit an article upon a moving linear transport. 
         [0005]    To accomplish this, rotary pick and place devices may be employed. One such prior art rotary pick and place device is disclosed in U.S. Pat. No. 4,901,843 to Lashyro. Such rotary pick and place devices are commonly relatively complex in design and operation, involving motorize mechanisms having multiple axes of rotation in order to smoothly deposit an article upon a moving linear transport. 
         [0006]    Accordingly, it is an object of the present invention to provide an article assembly device and method that is capable of depositing one component of an apparatus within another at a relatively high rate of speed. 
         [0007]    It is another object of the present invention to provide an article assembly device and method capable of inserting a substantially disk-like component within a substantially cylindrical component, wherein there is a relatively tight fitting, with narrow clearance, of the substantially disk-shaped (i.e., relatively squat and cylindrical) component within a substantially cylindrical component. 
         [0008]    It is yet another object of the present invention to provide an article assembly device and method for assembling at least a portion of a bottom-filled airless pump-type dispensing container, by inserting a disk-like piston into a substantially cylindrical body of the container through a circular bottom opening of the container. 
         [0009]    These and other objects and features of the present invention will become apparent in view of the following specification, drawings and claims. 
       BRIEF SUMMARY OF THE INVENTION 
       [0010]    The present invention comprises an apparatus and method for high speed assembly of an article and employing rotary pick and place technology. In one embodiment of the invention, the article to be assembled comprises a bottom-filled airless pump-type container, having a substantially cylindrical outer body and a substantially disk-like piston. Each of the plurality of containers to be assembled is inserted, bottom opening facing up, into an associated carrier for linear conveyance along an assembly line. As each container and associated carrier reaches the present assembly apparatus, it is gripped by two opposing pairs of counter-rotating star wheels, also known as indexing wheels. In particular, one pair of opposing counter-rotating star wheels grips the carrier, and, simultaneously, the other pair of opposing counter-rotating star wheels grips the cylindrical container. 
         [0011]    In timed coordination with the linear movement of the conveyor and the horizontal rotation of the star wheels, a vertically orientated and rotating vacuum wheel, also known as an indexing wheel, sequentially retrieves and releasably grips substantially disk-like bottom pistons from a supply chute, carries the piston for a portion of a complete rotation of the vacuum wheel, and then releases and inserts each piston through a circular opening of the substantially cylindrical outer body of the airless container. In one embodiment of the invention, the vacuum wheel includes ten vacuum stems, spaced on equidistantly spaced radii extending from a center of the vacuum wheel and radiating outwardly from a circumferential outer surface of the vacuum wheel. 
         [0012]    A vacuum manifold receives a supply of external vacuum and applies the vacuum to each vacuum stem during only a predetermined segment of the overall 360° rotation of each vacuum stem. This, in turn, causes vacuum to be applied to a distal gripping surface of a collar of each vacuum stem, beginning immediately prior to each empty vacuum stem coming into proximity with the piston dispensing chute, and ending upon the placement of the piston through the circular bottom opening of the airless container cylindrical body and into the interior of the container body. As the vacuum stem completes a rotation together with the remainder of the vacuum wheel, it is ready to repeat the foregoing cycle with another piston disposed at a pick-off location of the piston supply chute. 
         [0013]    To impart coordinated, timed rotational movement of both the pairs of star wheels and the vacuum wheel, a main drive motor turns an associated motor output pulley to, in turn, move a timing drive belt coupled to the motor output pulley. The timing drive belt, in turn, causes the opposite rotation of two star wheel timing pulleys, each coupled to an associated star wheel shaft. A shaft coupling is employed to couple one of the star wheel shafts to a gearbox drive shaft while, at the same time, permitting vertical height adjustment of the gearbox and vacuum wheel. The gearbox transfers rotation from the gearbox driveshaft to the vacuum wheel drive shaft to, in turn, impart rotation of the vacuum wheel. The gearbox may employ fixed or adjustable gear ratios to, in turn, impart a desired rotational speed of the vacuum wheel, relative to a desired rotational speed of the star wheels. In one embodiment of the invention, the gearbox has a fixed, 1:1 input to output ratio. 
         [0014]    Unlike prior art rotary pick and place apparatuses and methods that employ relatively complex mechanisms that involve the rotation of the retrieved article about multiple axes of rotation, the present apparatus is able to accomplish the high speed insertion of a substantially disk-shaped component through a closely fitting aperture of a cylindrical body, only slightly larger in diameter than that of the disk-shaped component, while carrying the disk-shaped component through only a single axis of rotation. In particular, it has also been discovered by the inventor that, by disposing the disk-shaped component at a particular angle, relative to radii of the vacuum wheel, only a single axis of rotation is necessary in order to smoothly deposit the disk-shaped component through the tightly-fitting aperture and into the cylindrical body. Specifically, the inventor has also discovered that a specific angle relative to the radii emanating from the center of the vacuum wheel, denoted as θ (theta), of between 20° and 30°, works optimally in this regard. 
         [0015]    In an apparatus and in a method of the present invention, a component transfer mechanism is provided for inserting a first component, such as a substantially disk-shaped piston of a bottom-filled airless pump-type dispensing container, within a second component, such as a substantially cylindrical body of a bottom-filled airless pump-type dispensing container, having a circular bottom aperture and in motion along a horizontal axis. A least one first component gripping member, which may comprise a vacuum stem coupled to a vacuum wheel, is provided and is supported above the horizontal axis by a frame or other support for rotation in a substantially circular path about a center point. The at least one first component gripping member is disposed along a radius extending from the center point and in a plane of rotation of the at least one first component gripping member. The at least one first component gripping member grasps and holds the first component beginning at a first position along the substantially circular path and at a predetermined, fixed angled offset relative to the radius, and carries the at least one first component gripping member carrying the first component through a portion of a complete rotation of the first component gripping member about the center point. The at least one first component gripping member places at least a portion of the first component through an aperture of the second component and within at least a portion of an interior region of the second component when the at least one first component gripping member is at a second position along the substantially circular path. The at least one first component gripping member releases its hold on the first component after placing at least a portion of the first component within at least a portion of the second component when the at least one first component gripping member is at a third position along the substantially circular path, thereby inserting at least a portion of the first component within the second component. 
         [0016]    In an embodiment of the present invention, the at least one first component gripping member holds the first component at a fixed angle of about 20 degrees to about 30 degrees relative to the radius emanating from the center point of the vacuum wheel. During assembly, the at least one first component gripping member places a leading edge of the first component through the aperture of the second component and within at least a portion of the interior region of the second component at an oblique angle, relative to the aperture, when the at least one first component gripping member is at the second position along the substantially circular path. 
         [0017]    The at least one first component gripping member further comprises a channel extending through at least a portion of the at least first component gripping member and coupled to a periodic source of vacuum pressure. The at least one first component gripping member holds the first component when vacuum pressure is applied to the channel and releases the first component when vacuum pressure is removed from the channel. 
         [0018]    In an embodiment of the invention, the at least one first component gripping members comprises a plurality of first component gripping members, such as ten first component gripping members, with each of the first component gripping members being disposed about a circumference of a wheel, such as a vacuum wheel, rotating about the center point. 
         [0019]    The wheel may include a stationary vacuum manifold and a rotating hub adjacent the vacuum manifold. The channel extending through at least a portion of the least one first component gripping member is coupled to the rotating hub, causing the vacuum manifold to supply vacuum pressure to the rotating hub and the channel through only a portion of a complete rotation of the first component gripping member about the center point. 
         [0020]    A motorized drive mechanism is provided to impart rotational movement of the at least one first component gripping manner in synchronization with the motion of the second component along the horizontal axis. A chute is provided to supply a plurality of first components for sequential picking up and holding by the at least one first component gripping member. 
         [0021]    The center point and, in turn, the wheel and at least one first component gripping member, all may be supported above the horizontal axis along which the second component moves in a height adjustable manner, thereby accommodating second components of varying dimensions. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0022]      FIG. 1  is an elevated side sectional view of an airless container apparatus capable of partial assembly via the apparatus and method of the present invention; 
           [0023]      FIG. 2  is an elevated side sectional view of the airless container apparatus of  FIG. 1 , shown upside down and with the piston and bottom plate in position for assembly; 
           [0024]      FIG. 3  is an elevated left side view of the present assembly apparatus; 
           [0025]      FIG. 4  is an elevated front view of a portion of the present assembly apparatus; 
           [0026]      FIG. 5  is an elevated rear perspective view of a portion of the present assembly apparatus, with the star wheels, conveyor, and shaft coupling, among other components, being removed for clarity; 
           [0027]      FIG. 6  is an elevated perspective view of the piston supply chute of the present assembly apparatus; 
           [0028]      FIG. 7  is a simplified schematic diagram of the primary power and drive train components of the present assembly apparatus; 
           [0029]      FIG. 8  is a simplified schematic diagram of the operation of the timing belt and associated pulleys and idlers of the drive train of the present assembly apparatus; 
           [0030]      FIG. 9  is an exploded elevated side sectional view of a vacuum stem of the present assembly apparatus; and 
           [0031]      FIG. 10  is a simplified elevated side view of the operation of the vacuum wheel, showing, in particular, the selective application of vacuum to the vacuum stems and the positioning of the vacuum stems relative to the bottom aperture of the cylindrical body of the airless containers undergoing assembly. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0032]    While the present invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail, one specific embodiment, with the understanding that the present disclosure is intended as an exemplification of the principles of the present invention and is not intended to limit the invention to the embodiment illustrated. 
         [0033]    A prior art bottom-fill airless container  10 , such as the MEGA® container manufactured by MegaPlast GmbH, is shown in  FIGS. 1 and 2  as comprising cylindrical body  11  having top end  12 , bottom end  13 , and circular bottom aperture  14  opening into the interior of body  11 . Operably coupled to body  11  are actuator top  16 , actuator collar  18 , upper valve  18 , bellows  19 , and lower valve  20 . A reservoir region  21  for fluids, such as lotions or creams for cosmetic application, for example, is disposed within body  11  between lower valve  20  and piston  30 . End cap  40  secures piston  30  in place within body  11  adjacent bottom aperture  14 . Top cap  15  provides a protective cover about actuator top  16 . As shown in  FIG. 2 , a predetermined volume of a desired fluid is poured into reservoir region  21 , and then piston  30  is placed through bottom aperture  14  and body  11  is sealed by end cap  40 . 
         [0034]    Airless container assembly apparatus  10  is shown in  FIGS. 3-10  as comprising support frame  110 , top plate  120 , conveyor  130 , main drive motor  140 , first star wheels  150  and  150 ′, second star wheels  155  and  155 ′, shaft coupling  160 , gear box  170 , piston supply chute  180 , vacuum wheel  200  comprising vacuum stem hub  210  supporting ten vacuum stems  220 , vacuum wheel support  270 , and vacuum supply hose  280 . 
         [0035]    As best seen in  FIG. 6 , piston supply chute  180  provides a steady supply of pistons  30  as needed for airless container assembly through a rotating, caged track and via a gravity feed. A proximal end of piston supply chute  180  includes pickoff singulator  181 , having top gripping member  182  and side gripping member  183 , continually placing the next piston  30  into position for retrieval by an associated collar  260  of a vacuum stem  220 . 
         [0036]    Referring to  FIGS. 7 and 8 , main drive motor  140 , supplying motive energy throughout article container apparatus  10 , may comprise an alternating current electric motor, rated at ½ horsepower and operating at 1,750 rotations per minute. In an embodiment of the invention, main drive motor  140  has an internal 40:1 gear reduction ratio ahead of motor output shaft  141 , which is coupled to motor pulley  142 . Moreover, main drive motor  140  preferably includes, or is coupled to, a variable frequency drive controller, permitting adjustment to the rotational speed of motor output shaft  141  and, in turn, the rotational speeds of first star wheels  150  and  150 ′, second star wheels  155  and  155 ′, and vacuum wheel  200 . 
         [0037]    Motor pulley  142 , in turn, drives continuous timing drive belt  143 , which may be constructed of neoprene or another strong yet sufficiently resilient material. Timing drive belt  143 , is operably coupled to and imparts rotational movement to first star wheel timing pulley  152  in a clockwise direction, as viewed from above, and to second star wheel timing pulley  157  in a counterclockwise direction, as viewed from above. Four idler wheels  144 , at least one of which is preferably adjustable in position, provide tension on timing drive belt  143 , and ensures that an adequate length of timing drive belt  143  engages sufficient corresponding amounts of arc length of both first star wheel timing pulley  152  and second star wheel timing pulley  158  in order to smoothly rotate both pulleys. 
         [0038]    The rotation of first star wheel timing pulley  152  imparts rotation to first star wheel shaft  151 , operably coupled to first star wheel timing pulley  152 . As both star wheels  150  and  150 ′ are secured to first star wheel shaft  151  in a vertically spaced relation to each other, clockwise rotation of first star wheels  150  and  150 ′ are imparted by the rotation of first star wheel shaft  151 . Likewise, the rotation of second star wheel timing pulley  158  imparts rotation to second star wheel shaft  156 . As both star wheels  155  and  155 ′ are secured to second star wheel shaft  156 , counterclockwise rotation of second star wheels  155  and  155 ′ are imparted by the rotation of second star wheel shaft  156 . 
         [0039]    First star wheel shaft is further coaxially coupled to gear box drive shaft  171  via shaft coupling  160 . The use of shaft coupling  160  permits the vertical height of gearbox  170  and vacuum wheel to be adjusted to a desired height, in order to accommodate varying lengths of airless containers that are under assembly. Vertically oriented gear box drive shaft  171  drives gear box  170  which, in turn, drives horizontally oriented vacuum wheel drive shaft  171 . As vacuum wheel  200  is secured to vacuum wheel drive shaft  171 , corresponding rotation movement is accordingly imparted to vacuum wheel  200 . In an embodiment of the present invention, gear box  170  has a 1:1 gear ratio. Other ratios may alternatively be employed to impart different rates of rotation to vacuum wheel  200 . 
         [0040]    Main drive motor  140 , motor output shaft  141 , motor pulley  142 , timing drive belt  143 , first star wheel timing pulley  152 , second star wheel timing pulley  157 , and idler wheels  144  are all housed within an interior region of support frame  100 , shown in  FIG. 5 . Top plate  110  of support frame provides a supporting surface for conveyor  130  of  FIG. 4 , for example. First star wheel shaft  151  and second star wheel shaft  156  extend from the interior of support frame  100 , through corresponding apertures through top plate  110 . Vacuum wheel support  270  carries both vacuum wheel  200  and gearbox  170 , and slidaby engages two parallel rods extending vertically from top plate  110 . Threaded height adjuster  271  may be manually turned in order to raise or lower vacuum wheel support relative to top plate  110  to, in turn, raise and lower vacuum wheel  200  and gear box  170 , enabling Airless container assembly apparatus  10  to accommodate articles under assembly of varying overall height. 
         [0041]    Referring to  FIG. 9 , the various components of one vacuum stem  220  are shown as comprising angled shaft  230 , inner shaft  240 , outer shaft  250 , and collar  260 . Collar  260  has tapered sides  264  and comprises central channel  262 , communicating between inlet port  263  disposed through outer face  265  and an outlet port disposed through an opposing side of collar  260 , permitting the transmission of vacuum pressure through central channel  260 . During operation of bottom fill airless container apparatus  10 , outer face  265  mates flush with a bottom surface of a piston  30 , with vacuum pressure being transmitted through central channel  262  to inlet port  263  to secure piston  30  to collar  260  for so long as vacuum pressure remains applied to vacuum stem  260 . 
         [0042]    Collar  260  is coupled to outer shaft  250 , with central channel  262  of collar  260  in axial alignment and communication with central channel  252  of outer shaft  250 . Outer shaft  250  is likewise coupled to inner shaft  240 , with central channel  252  of outer shaft  250  in axial alignment and communication with central channel  242  of inner shaft  240 . Moreover, inner shaft  240  is similarly coupled to angled shaft  230 , with central channel  242  of inner shaft  240  in axial alignment and communication with central channel  232  of angled shaft  230 . 
         [0043]    Angled shaft  230  includes vacuum stem attachment region having outlet port  233  extending through a proximal end of angled shaft  230 , and is coupled to a corresponding port of vacuum stem hub  210  of vacuum wheel  200 . In this manner vacuum pressure is communicated along the entire interior of vacuum stem  220 , with air flowing from inlet port  263  of collar  260  to outlet port  233  of angles shaft  230 . 
         [0044]    As shown in  FIG. 9 , a distal portion of angled shaft  230  has a primary longitudinal axis  237  that is aligned with the overall primary longitudinal axis of vacuum stem  220 , further extending through inner shaft  240 , outer shaft  250  and collar  260 . However, proximal vacuum stem attachment region  231  has a second axis  236  that is fixed at a predetermined angle θ  235  relative to longitudinal axis  237 . In a preferred embodiment, this angle is between 20° and 30°, which has been found by the inventor to work optimally for the insertion of piston  30  into cylindrical body  11  of bottom fill airless container  10 . 
         [0045]    Referring to  FIGS. 3 and 4 , conveyor  130  carries a succession of airless container assembly carriers  131  through a central region of airless container assembly apparatus  100 . Carriers  131  do not form any portion of overall bottom fill airless container  10 , but rather serve to firmly secure an associated airless container  10  in an upright orientation as they undergo filling and final assembly. As best seen in  FIG. 4 , star wheels  150  and  155  are identical to each other in construction, each containing ten arcuate indentations  153 ,  158 , sized to cooperatively surround a substantial portion of the outer circumference of each carrier  131  carried along conveyor  130 . Star wheels  150 ′ and  155 ′ are likewise identical to each other in construction, each containing ten arcuate indentations  153 ′,  158 ′, smaller than indentations  153  and  158 , sized to cooperatively surround a substantial portion of the outer surface of cylindrical body  11  of airless container  10 . 
         [0046]    In this manner, each airless container  10  undergoing assembly is carried along conveyor  130  at a predetermined position, due to the coordinated rotation of star wheels  150 ,  150 ′,  155 ,  155  and vacuum wheel  200 , permitting each vacuum stem  220  to repeatedly retrieve a piston  30  from chute  180  using suction created via the application of vacuum pressure at inlet port  263 , carry piston  30  through only a portion of a complete rotation of vacuum wheel  200 , and deposit piston  30  through a cylindrical bottom aperture  14  of cylindrical body  11  of airless container  10  before vacuum pressure is removed from vacuum stem  220 . Each airless container  10  moves along conveyor  130  being positioned by the star wheels so as to be appropriately located as an associated vacuum stem approaches, and as a distal portion of collar  260  of an associated vacuum stem  220  then passes through bottom aperture  14  of cylindrical body  11 , depositing a carried piston  30  in place within cylindrical body  11  immediately prior to the removal of vacuum pressure to vacuum stem  220 , releasing piston  30  thereby permitting piston  30  to be retained in place within cylindrical body  11  as the distal portion of collar  260  then exits the interior of cylindrical body  11  and completes its rotation, ready to retrieve another piston  30  from chute  180  as vacuum is again applied to vacuum stem  220 . 
         [0047]    As illustrated in  FIG. 10 , vacuum wheel  200  includes a stationary manifold  204 , which receives vacuum pressure via a central vacuum bore coupled to vacuum supply hose  280  of  FIG. 3 , for example. Vacuum manifold  204  includes vacuum active region  205 , comprising, in an embodiment of the present invention, approximately 250° of rotation of vacuum wheel  200 , and vacuum inactive region  207 , comprising, in an embodiment of the present invention, approximately 110° of rotation of vacuum wheel  200 . Ten vacuum stems  220  are coupled to vacuum stem hub  210 , each with a radius extending from the center of vacuum wheel  200  evenly spaced 36° apart from the adjacent radii of both the immediately preceding vacuum stem  220  and the immediately following vacuum stem  220 . Angled shaft  231  of each vacuum stem  220  is coupled to an associated port through an outer surface of vacuum stem hub  210 , with the central channel extending though vacuum stem  220  in communication with the interior of vacuum stem hub  210 . 
         [0048]    Accordingly, as shown in  FIG. 10 , as vacuum stem hub  210  rotates relative to adjacent vacuum manifold  204 , each vacuum stem  220  repeatedly travels with and transitions between vacuum active region  205  and vacuum inactive region  207 . Upon reaching the beginning of vacuum active region  205 , each vacuum stem  220  is in close proximity to piston supply chute  180 , where vacuum stem  220  picks up and holds adjacent a piston  30 . Further along vacuum active region  205 , a distal portion of each vacuum stem  220 , and, in turn, a piston  30  carried by vacuum stem  220 , passes through circular bottom aperture  14  of cylindrical body  11  of bottom fill airless container  10 , into the interior of cylindrical body  11 . Initially, each piston  30  enters a corresponding cylindrical body at angle, with a leading edge of piston  30  at a lower height than a trailing edge of piston  30 . As a distal end of each vacuum stem  220  reaches its lowest point, relative to top plate  110 , piston  30  is in a substantially horizontal orientation, and is substantially parallel to top plate  110 . Shortly afterwards, vacuum stem  220  reaches the transition point from vacuum active region  205  to vacuum inactive region  207 , and piston  30  is released within the interior of cylindrical body  11 . Next, as vacuum stem  220  continues its rotation, its distal end exits cylindrical body  11  through circular bottom aperture  14 . As best seen in  FIG. 10 , the carriage of each piston  30  by an associated vacuum stem  220  at a fixed angle of θ  235 , relative to a radii emanating from the center of vacuum wheel  200 , as opposed to holding each piston perpendicular to the radii (i.e., with no angle, or an angle of zero degrees), permits the leading edge of each piston to obliquely enter an associated cylindrical body  11 , and then rotate to a level orientation as cylindrical body proceeds in a linear manner, and as piston  30  simultaneously proceeds in an arcuate manner. As a result, airless container assembly apparatus  100  is capable of inserting pistons  30  within cylindrical bodies  11  at a high rate of speed, and with each piston being carried about only a single axis of rotation. 
         [0049]    Many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described. Various modifications, changes and variations may be made in the arrangement, operation and details of construction of the invention disclosed herein without departing from the spirit and scope of the invention. The present disclosure is intended to exemplify and not limit the invention.