Abstract:
An apparatus for the pressureless division of a flow of objects from a conveyor system into multiple paths. The apparatus is ideally suited for use in conveying and combining streams of bottles. The apparatus generally is connected to a feed conveyor carrying a bulk flow of articles. The apparatus may include a conveyor system which permits the division of a bulk flow of bottles into discrete delivery channels. The apparatus may also include detectors to monitor and allow adjustment of the flow of bottles in each delivery channel.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to conveying apparatus concerned with combining conveyed products, such as bottles, into multiple discrete product paths. 
     2. Description of the Prior Art 
     In the prior art, numerous conveyor systems have been developed to separate a mass of articles into discrete delivery paths leading to labelling, filling or other packaging devices. To this end, it is known to use deflectors, guides and separators placed in the stream of articles being conveyed so as to achieve a single aligned stream. However, those conveyor systems promote frictional contact between the products being conveyed and result in surface wear of the products, noise and a propensity to jam and damage the products being conveyed. 
     It is also known to use what are commonly called “pressureless” conveyors systems such as described in U.S. Pat. No. 4,974,720. Those conveyor systems generally comprise a feed conveyor on which a mass of articles, such as bottles, are disposed at random and advance forward. The feed conveyor leads to an intermediate multi-track conveyor. Each track is driven at a different speed according to a speed gradient. This accelerates the bottles on the side of the conveyor having the fastest track. This promotes separation of the bottles and gradual flow alignment. Moreover, the intermediate conveyor is equipped with a curved guide plate channelling the bottles to a single file output. Once in a single file, the bottles transfer onto a delivery conveyor and exit the pressureless conveyor. However, such systems are designed for single file output and must be installed in parallel in order to provide multiple aligned feed lines as required by most packaging machines. Installing many such machines in parallel consumes valuable factory floor space, adds to cost, noise pollution and requires additional maintenance. 
     Thus, the present invention addresses the need for a machine that can combine a mass flow of product into two or more discrete output paths with automatic control of the flow of each output path. Moreover, the present invention also addresses the need for a machine which can be operated to selectively switch from two or more discrete output paths to a single file output path. As an added benefit, the present invention also addresses the need for a machine that can separate a single file product input trail into two or more discrete output paths with automatic control of the flow of each output paths. 
     Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that this detailed description, while indicating preferred embodiments of the invention, is given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a multilane combiner for combining a mass input flow or alternatively a single file input flow into two or more distinct and controlled output flows. The apparatus of the invention is designed for installation in a conveyor line of the type used to feed a machine requiring the orderly and sequential input of articles. The apparatus of the invention is used for the division of a flow of objects travelling on said conveyor line into multiple output paths, said apparatus comprising: 
     (a) an input conveyor portion for supporting and advancing a mass of objects in a generally longitudinal direction; 
     (b) a drive mechanism for driving said input conveyor; 
     (c) an intermediate multi-track conveyor generally downstream from and connected to the bulk feed conveyor for receiving the objects from the bulk feed conveyor, said multi-track conveyor having guide means mounted orthogonally with respect to said conveyor surface to urge said objects transversely from one conveying track to the next, each conveying track of said multi-track conveyor being driven at a velocity gradient with the fastest conveying track being located the furthest from said guide means; 
     (d) at least one drive mechanism for driving said intermediate conveyor; 
     (e) a separation conveyor generally downstream from and connected to the intermediate conveyor for receiving the objects from the intermediate conveyor, said separation conveyor having at least two tracks; each track of said separation conveyor being driven at a velocity gradient with the fastest conveying track being located the furthest from said guide means of said intermediate conveyor thereby achieving a separation of the objects between each track, said tracks each bearing a single file procession of articles; 
     (f) at least one drive mechanism for driving said separation conveyor; 
     (g) an output conveyor assembly comprising at least two output channels each connected to a track of the separation conveyor for the linear transfer of articles exiting each track of said separation conveyor; 
     (h) a drive mechanism for driving each said output channels of said output conveyor assembly; 
     (i) detection means for detecting the flow of articles in said apparatus including the flow of articles in each said output channels and for generating a signal corresponding to the detected flows; 
     (j) computer means for receiving the flow signals from said detection means and for processing a response signal selectively directing said drive mechanisms connected respectively to said input, intermediate and output conveyors so as to maintain a substantially even flow of articles in all of said output channels. 
     The apparatus of the present invention will advantageously be used to obtain, at will, one or two controlled single file delivery streams from a bulk conveyor feed. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a diagrammatic plan view of a pressureless multilane combiner of the present invention wherein the division is made from a bulk flow of articles to two output lanes; 
     FIG. 2 is a diagrammatic plan view of three pressureless multilane combiners as in FIG.  1  and shown in an arrangement in accordance with a preferred embodiment of the invention; 
     FIG. 3 is a diagrammatic plan view of a conventional (prior art) pressureless single file combiner; and 
     FIG. 4 is a diagrammatic plan view of a conventional arrangement of the pressureless single file combiner of FIG. 3 (prior art). 
     FIG. 5 is a diagrammatic plan view of a pressureless multilane combiner of the present invention wherein the division is made from a single line flow of articles to two output lanes. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In accordance with a preferred embodiment, the apparatus of the present invention comprises a pressureless multilane combiner intended for conveying a mass input flow of bottles or other similar articles and delivering the bottles in multiple single files for feeding in a packaging unit disposed downstream. One notable imperative in devising such equipment is to minimize damage to the articles being conveyed. Another design imperative is to minimize the size of the equipment to save crucial factory floor space. Yet another design objective is to allow evacuation of bottles which have fallen-over and should therefore not be conveyed to the packaging unit. A fourth objective is to balance the flow between a plurality of lanes of articles being conveyed. 
     With those imperatives in mind, a preferred embodiment of the invention comprises a two lane pressureless combiner from bulk. In other words, a mass flow of randomly advancing bottles are conveyed to the apparatus of the invention and exit in two single lanes having controlled flows. 
     It must be understood that although the apparatus of the present invention is ideally suited for use in a bottling plant, other uses are envisaged. For example, the apparatus could be used to convey other articles than bottles, such as plastic or metal containers, or many forms of consumer or industrial goods which require filling, labelling or packaging operations prior to the shipment. 
     It must also be understood that the apparatus of the present invention can be operated, at will, as a single file output conveyor as will be explained further below. 
     It must also be understood that the apparatus of the present invention can be combined with a “pressure” type device to funnel articles from bulk into a narrower stream by using curved guide plates, vibration plates, etc. 
     Referring now to the first preferred embodiment for combining a mass flow of bottles in two single files, the apparatus of the present invention will be described in more detail. Referring to FIG. 1, a bulk stream of bottles  10  enter the two lane pressureless combiner generally referred to as numeral  12 . The bulk stream of bottles  10  enter combiner  12  from an input bulk conveyor  14  having several tracks  16 ,  18 ,  20 , and  22  disposed side by side and driven at the same linear velocity. The drive mechanism of course comprises appropriate electrical motors  24  and linkages (not shown). 
     Bulk conveyor  14  leads to a multi-track intermediate conveyor  26  for accelerating and narrowing and thus separating the stream of bottles  10  received from the bulk conveyor  14 . 
     The intermediate conveyor  26  comprises a plurality of parallel and adjacent tracks  28 ,  29 ,  30 ,  31 ,  32 , . . . each driven at a different velocity (velocity gradient) increasing transversely relative to the linear direction of the bottles  10  when received from the bulk conveyor  14 . The adjacent tracks  28 ,  29 ,  30 ,  31 ,  32  are driven by a drive mechanism including an appropriate electrical motor  25  and linkages (not shown). Overlying this intermediate conveyor  26  is a curved guide plate  34  essentially orthogonal to the plane of conveyor  26 . The guide plate  34  is adapted to gently push and urge the bottles  10  from low speed tracks to higher speed tracks. Thus, the bottles  10  are gradually accelerated and the width of the stream of bottles  10  delivered to the intermediate conveyor  26  is gradually reduced. So far, this arrangement is conventional and known to those skilled in the art who can calculate and design the velocity gradient of the tracks, the dimensions of the intermediate conveyor  26  and the dimension and shape of guide plate  34  to obtain a single file of bottles  10 . Referring to FIG. 3 there is shown a typical prior art version of such single file lane combiner. 
     Surprisingly, the inventors have invented an improved conveyor which allows multiple single file outputs of articles such as bottles  10 . Referring once again to FIG. 1, it is shown how apparatus  12  is designed to provide a separation conveyor  37  downstream from intermediate conveyor  26 . The separation conveyor  37  includes two tracks  38  and  40 . 
     To achieve this, a velocity differential is maintained between track  38  and track  40 , whereby track  40  is maintained at a higher velocity so as to separate the bottles  10  in two discrete streams. Tracks  38  and  40  are respectively driven by motors  24   a  and  24   b  through suitable linkages. To perfect the separation process, bottles  10  which are misaligned on either of tracks  38  or  40  or which have fallen over will be discarded at drop-off zone  42  which comprises a recuperation bin  44  comprises a depression between a borderless split in tracks  38  and  40 . Any bottles  10  which as not properly aligned and standing on tracks  38  and  40  will fall into recuperation bin  44 . Tracks  38  and  40  are later juxtaposed once again but this time with combining wall  46  in between two avoid any mixing of the two discrete single files. Moreover, tracks  38  and  40  are connected to further conveying output tracks  41  and  43  defining an output conveyor and having their own linear velocity controls. As the bottles  10  reach the end of tracks  38  and  40 , bottles  10  will simply transfer onto tracks  41  and  43 , respectively. 
     To monitor the flow of bottles  10  on all tracks, detection devices  48 ,  48 A,  49 ,  49 A and  50 ,  50 A are installed and connected to a computer  52 . It is to be understood that the term “computer” is used in a general sense and is meant to encompass any other similar device such as any programmable logic controller or other form of microprocessor or similar device. The detection devices  48 ,  48 A,  49 ,  49 A and  50 ,  50 A can be of the various types commonly available and easily known to those conversant in the art. 
     Of course computer  52 , is designed to maintain even flows of bottles  10  in each track  38  and  40  so that the processing unit located downstream is equally fed in bottles  10 . Computer  52  is also designed to permit a gradual ramp-use and shutdown of combiner  12  to avoid causing bottles  10  to fall over or jam as a result of abrupt changes in speed. 
     Referring now to FIG. 2, there is shown a cluster of three similar combiners  54 ,  56  and  58  substantially as described above with reference to apparatus  12 . All three combiners  54 ,  56  and  58  are connected to a single bulk bottle conveyor  60 . Output paths are directed to a downstream packaging machine  62 . This arrangement has tremendous advantages over the prior art since it saves valuable space by essentially replacing the need for six single file combiners as taught in the prior art and depicted in FIG.  4 . The apparatus of the present invention saves valuable factory floor space and allows more flexibility in installation and operation. 
     It is to be understood that a similar apparatus could be adapted to provide not just two but up to three or more discrete output flows. Moreover, by stopping output track  40 , combiner  12  could essentially function as a single file output conveyor. Thus, the apparatus of the present invention can be switched, at will, from a dual output channel to a single output channel conveyor. 
     Turning now to FIG. 5, there is illustrated a diagrammatic plan view of a pressureless multilane combiner of the present invention wherein the division is made from a single line flow of articles to two output lanes. Such arrangement would be useful for dividing the flow of single file articles exiting from one apparatus, for example a bottle filling station, into two or more discrete output paths directed to a downstream packaging machine.