Abstract:
This device is for the formation and transfer of rows of articles. In particular, the device is for the formation of a row of articles on a layer formation table and the transfer of the row from one processing operation to another. A programmable robot and EOAT easily sweeps or pushes the load (tier) down the layer formation table returns to it&#39;s original position. A single, programmable robot performs all functions. The absolute unique end of arm tooling (EOAT) is fitted to the robot. The articles of one row are nested in the voids between articles in an adjacent row.

Description:
CROSS REFERENCE TO PRIOR APPLICATION 
       [0001]    This application claims the benefit of provisional patent application Ser. No. 60/997,087 filed Oct. 1, 2007 and of provisional patent application Ser. No. 60/898,499 filed Jan. 31, 2007. 
     
    
     TECHNICAL FIELD 
       [0002]    This invention relates to a case/bulk layer formation table and process including a multiaxis programmable, robot. In one embodiment, the invention relates to innovative end-of-arm tool on the cantilevered arm of the robot designed to transfer rows of bulk product (bottles). The invention is programmed to build a load on the layer formation table. 
       BACKGROUND OF THE INVENTION 
       [0003]    Conveyors are commonly used in manufacturing and processing operations to move articles or goods from one operation to another. For many types of operation it is advantageous to have the articles grouped for batch processing. Such typical batch-processing operations include applying labels to bottles or cans or other types of containers, packing bottles, cans or boxes into crates, or filling containers with liquid or semi-liquid material. A number of devices or systems are known that group articles for batch processing. Many of the systems known in the prior art use a system that run alongside one side or both sides of the conveyor transporting the articles to be processed. 
         [0004]    The prior art devices have several disadvantages. They are cumbersome and require space to each side of the conveyor and above the conveyor. They also are material-intensive and thus, expensive. Further they also are power-intensive because they run continuously. Furthermore, these devices do not change configuration of the number of articles abreast, i.e., they do not convert a single or double file feed of articles to multiple articles abreast, but merely create a distance between one group of rows of articles and a following group. 
         [0005]    Typically prior art transfer is carried out with an overhead frame. The prior art unit uses a complicated system including assemblies extending transversely of the apparatus in and being vertically movable toward and away from one another in a vertical transverse plan. Upper and lower crankshafts are intermittently drive through a one-revolution cycle often by a chain and sprocket drive mechanism. After sweeping or pushing the load, the device must be raised, moved back to its starting point and lowered on the next load. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0006]    The present invention relates to a device and process for the formation and transfer of groups of articles. In particular, the present invention relates to a device for the formation of a group of articles on a conveyor and the transfer of the group from one processing operation to another. More particularly, the present invention relates to a device for transferring groups of articles at right angles to the initial feed direction. The programmable robot and EOAT easily sweeps or pushes the load (tier) down the conveyor and returns to it&#39;s original position. 
         [0007]    The preferred embodiment is an apparatus for transferring articles comprising: a layer formation table; and a means for supplying articles to the layer formation table wherein at least one row of the articles is formed on the table. The at least one row of the articles is formed at a first end of the layer formation table. The apparatus further comprises a programmable robot including an end of arm tool for transferring the row of the articles. The robot transfers the row of articles towards a second end of the layer formation table. 
         [0008]    In this invention, the single, programmable robot for transferring performs all functions. The absolute unique end of arm tooling (EOAT) is fitted to the robot. This eliminates the complicated overhead transferring structure of the prior art. 
         [0009]    The invention is programmed to build a load on the layer formation table. 
         [0010]    The articles used to build a tier of products may vary widely. The articles may be any type of container. In a preferred embodiment, the articles may be bottles or cans. In another embodiment, the articles may be boxes or cartons. In another preferred embodiment the articles may be a single case of product. In another embodiment, the articles may be cases of product. 
         [0011]    Other objects and advantages of the present invention will become apparent to those skilled in the art upon a review of the following detailed description of the preferred embodiments and the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a top schematic view showing a packaging system in which the apparatus of this invention may be used. 
           [0013]      FIG. 2  is a perspective view of a programmable multi-axis robot used with this invention. 
           [0014]      FIG. 3  shows the mounting plate of the robot of  FIG. 2 . 
           [0015]      FIG. 4  is a schematic view showing an EOAT for sweeping rows of bulk product (bottles). 
           [0016]      FIG. 5  is a side schematic view showing another view of the EOAT of  FIG. 4  showing a pusher for sweeping cases of bulk product. 
           [0017]      FIG. 6  is a top schematic view showing a grouping and transfer station receiving a continuous single file feed of bulk product (bottles). 
           [0018]      FIG. 7  is a top schematic view showing a grouping and transfer station so that adjacent rows are staggered so that the bottles are nested. 
           [0019]      FIG. 8  is a schematic view showing cases of product being fed to the layer formation table. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    This invention is a case/bulk layer formation table including a multiaxis programmable, robot. In one embodiment, the invention relates to innovative end-of-arm tool on the cantilevered arm of the robot designed to transfer rows of bulk product (bottles) or cases. 
         [0021]    The process for transferring articles comprising the steps of: providing a layer formation table; supply articles to the layer formation table; forming at least one row of the articles at a first end of the table; and providing a programmable robot including an end of arm tool for transferring the row of the articles towards a second end of the table. The process further comprises the step of configuring the robot to build a tier of products on the layer formation table. 
         [0022]      FIG. 1  shows system  10  for packaging load  12  comprising bulk product feeder  14 , tier case station  16  and programmable, articulate robot  18 . Dunnage supply line  19  feeds system  10 . System  10  also includes pallet station  20 , tier sheet station  22 , tier staging area  24 , load build area  26 , top frame station  27 , programmable, articulate, robot  28  and tier pick up area  30 . Robot  18  is a single means for placing tiers  32  of the bulk product  34  or cases  36  in load build area  26 . Robot  28  is a single means for placing pallets  38 , tier sheets  40  and top frame  42  in load build area  26 . Robot  18  picks up tier  32  at tier pickup area  30  and discharges it at load build area  26 . 
         [0023]    In one embodiment, robot  18  picks up case  36  from tier case station  16  and places them in load building area  26 . The two robot system provides flexibility in that the line can still run if one side is down for repair, maintenance or product set up. In this embodiment, robot  28  picks up top cap  43  instead of top frame  42 . Pallets, tiers, tier sheets, top frames and top caps often are referred to as dunnage. 
         [0024]    Bulk product feeder  14  typically comprises a multiplicity of parallel conveyor belts  45  which carry rows of bulk product  34  (bottles). Frame  48  support belts  46 . The rows are fed to the tier staging area  24 . Tier staging area  24  typically includes a conveyor which comprises frames and supporting feed belts. Usually tier staging area  24  is at the end of bulk product feeder  14 . 
         [0025]    Tier case station  16  typically comprises a multiplicity of parallel conveyor belts  56  which carry cases  36  of product  34  (bottles). Frame  58  support belts  56 . The cases are fed to load build area  26  for pick up by robot  18 . 
         [0026]    Cases as used herein may vary widely. Typically cases means a case of 24 beer bottles. Cases may include a 6 pack, 12 pack, 18 pack, 30 pack and the like. The case may be corrugated cases, chip board cases or film wrapped bundles of product. A typical film wrapped case is a film wrapped package of six or twelve rolls of paper towels. 
         [0027]    Tier sheet station  22  comprises conveyor which includes a frame supporting rollers. Tier sheet station  22  is next to pallet station  20  and also parallel to load build area  26 . Robot  28  picks up pallet  38  from pallet station  20  and locates it at load build area  26 . This is followed sequentially by alternating layers of tier sheet  40  and tier  32  (cases  36 ). In one embodiment where no pallet  38  is employed, the first layer is tier sheet  40 . 
         [0028]    The rows of product  34  form tier  32  on a conveyor. The conveyor then transports tier  32  to tier staging area  24 . As will be shown later, tier  32  is located in load build area  26  by robot  18 . Dunnage supply line  19  provides pallets  38  to pallet station  20  and top frames  42  to top frame station  28 . Line  19  feeds to stations  20  and  28 . Pushers such as chain transfers  54  and  56  move pallets  38  and top frames  42  to stations  20  and  28 , respectively. 
         [0029]    Pallet station  20  comprises conveyors which includes frames supporting a multiplicity of rollers. Pallet station  20  usually is near load build area  26 . Tier sheet station  22  comprises conveyors, frames and a multiplicity of rollers. 
         [0030]    Dunnage line  19  comprises conveyors which includes frames supporting a multiplicity of rollers. 
         [0031]    Top frame station  28  comprises conveyors which includes a frame supporting a multiplicity of rollers. 
         [0032]    When the tier comprises cases  36 , top frame station  28  feeds top caps  43  instead of top frames  42 . 
         [0033]    Load conveyor  50  removes load  12  from load building area  26 . Conveyor  50  comprises frames and rollers. Typically, conveyor  50  transfers load  12  strapping area  52 . 
         [0034]      FIG. 1  also shows control  44 , which may be a programmable logic controller (PLC), and power control panel to operate system  10  through conventional circuitry not shown. Control  44  controls robot  18  and robot  28  and co-ordinates their operation with dunnage line  19 , feeder  14  and station  16 . 
         [0035]    PLC&#39;s in a control panel controls system  10 , the load and dunnage conveying system. The PLC&#39;s in the control panel controls the tier building system. PLC&#39;s interface with the control, which controls robot  18  and robot  28 . PLC&#39;s also interfaces with other PLC&#39;s and is the main control for system  10 . Power control panels are wired to their respective drives and sensors and actuators. 
         [0036]      FIG. 1  also shows strapper  60  which straps load  12 . Control  62  controls strapper  60 . While strapping preferably is used for bulk product  34 , strapping may be with cases  36  as well. Orienting station  64  turns load  12  after a first strapping and sends load  12  back to station  60  for a second strapping perpendicular to the first. Load  12  then moves down conveyor  66  to storage or shipping. 
         [0037]      FIG. 2  shows robot  18  or  28  in greater detail. For this drawing, robot  18  will be used to illustrate either robot. Robot  18  mounts on main rotary axis  96  and can rotate 360° about axis  96 . Robot  18  also includes main support post  98  extending vertically from axis  96 . Cantilevered arm  100  extends from post  98  and carries end effector  102 . Effector  102  is capable of locating tiers  32  or cases  36  into load building area  26  to build load  12 . 
         [0038]    A distal end of cantilevered arm  100  carries mounting plate  104 . Plate  104  attaches to arm  100  with conventional fasteners and effector  102  attaches to plate  104  with similar mechanical fasteners. 
         [0039]    Robot  18  is a programmable multi-axis robot. Previously discussed controllers controls robot  18 . Typically the multi-axis robot  18  has five axes of motion. In another embodiment arm  100  may be a Cartesian arm. 
         [0040]      FIG. 3  shows mounting plate  104  in greater detail. 
         [0041]      FIG. 4  is a schematic view showing EOAT  120  for sweeping rows of bulk product (bottles)  14 . In system  10  of  FIG. 1 , robot  18  and EOAT  120  of this invention may be used in to load bulk product  14  or tier case station  16 . EOAT  120  shown comprises a multiplicity of guides which form lanes. The rows of bottles fill the lanes. Cylinders  122  fire clamping tools  124  which lock the rows of bottles in the lanes between the guides. Robot  18  then sweeps the load down the conveyor to the next station. Clamping tools  122  are released and robot  18  lifts EOAT  120  and returns it to its starting position. 
         [0042]      FIG. 5  is a side schematic view showing another view of EOAT  120  of  FIG. 4  in greater detail. EOAT  120  comprises a multiplicity of guides  126  which forms lanes  128 . Rows  130  of bottles  14  fill lanes  128 . Robot  18  sweeps rows  130  down conveyor  132  to station  134 . Tiers of product are built in staging area  202  by accumulating rows articles against tier accumulation stop  212 . Tier accumulation stop  212  is configured to raise in order to allow the tiers of product to move down conveyor  132  to station  134 . 
         [0043]    In another embodiment EOAT  120  acts as a pusher and pushes cases of bulk product in rows  130  down conveyor  132  to station  134 . In this embodiment, the EOAT is a pusher that pushes the cases down the conveyor instead of sweeping. 
         [0044]      FIG. 6  is a top schematic view showing a grouping and transfer station  200  receiving a continuous single file feed of bulk product (bottles)  14 . In  FIG. 6 , the grouping and transfer station  20  receives continuous single file feed  130  of bottles  14 , groups bottles  14  to rows of multiple bottles  14  abreast as illustrated. EOAT  120  transfers row  130  at right angles to the direction of the initial bottle feed to staging area  202 . Robot  18  EOAT  120  of  FIG. 4  sweep rows  130  onto downstream conveyor  132 . Staging area  202 , as well as a grouping area  200  are shown. Rows  130  are swept downstream to processing station  134 . 
         [0045]      FIG. 7  is a top schematic view showing the grouping and transfer station of  FIGS. 4-6  so that adjacent rows are staggered so that the bottles are nested in voids  210 . This apparatus for packing articles, particularly bottles, in units each consisting of a plurality of parallel rows or articles, each row comprising a plurality of articles, in side by side contact, and with the rows in contact, comprising means for collating articles into units. Each unit of articles, as formed, is deposited on a conveyor and conveyed by the robot and EOAT of  FIGS. 4-6 . In collating cylindrical bottles (or other cylindrical articles), the rows are staggered for nesting of bottles  14  to reduce voids  210  in the units. 
         [0046]      FIG. 8  is a schematic view showing cases of product being fed to the layer formation table. Cases  214  are fed to station  200 . 
         [0047]    The above detailed description of the present invention is given for explanatory purposes. It will be apparent to those skilled in the art that numerous changes and modifications can be made without departing from the scope of the invention. Accordingly, the whole of the foregoing description is to be construed in an illustrative and not a limitative sense, the scope of the invention being defined solely by the appended claims.