Abstract:
The present invention is directed to an adjustable guide for a container conveyor system. The guide includes multiple pairs of pivoting mechanisms located along the conveyor. Each pivoting mechanism includes a first pivot arm and a second pivot arm which can be independently manipulated to locate a guide within a container envelope. The multiple pairs of pivoting mechanisms are operable coupled by a set of drive cables to permit simultaneous adjustment of the pivoting mechanisms.

Description:
FIELD OF THE INVENTION 
   The present invention relates to a container handling system, and more particularly to a bottle handling system which includes an adjustable guide system along a conveyor. 
   BACKGROUND OF THE INVENTION 
   Currently, various packaging and shipping methods are used to transport containers, such as bottles, from one location to another. As such, it is often necessary to provide a bottle conveyor to transfer bottles from one machine to another in the handling process. Such conveyor systems will often utilize a guide rail assembly to maintain the proper orientation of the bottle as it is transferred along the conveyor. One such conveyor system is an air conveyance system which requires relatively accurate side rail positions to ensure efficient and accurate movement of the bottles along the length of the conveyor. Thus, guide rail assemblies of this type are typically constructed as a fixed element relative to the conveyor structure and having a means for making minor adjustments to the rail position. 
   One conventional method for supporting and positioning such guides along the conveyor involves the use of air cylinders. A plurality of air cylinders are coupled along the conveyor to provide guides for the body of the containers. Adjustments to the guides are made by actuation of the air cylinders. Such systems require extensive plumbing of air line to individually adjust end guide location. This conventional method is designed for specific bottles. When the bottles to be produced are changed the entire system must be reworked. If desired, the cost for such a change can approach the initial cost of the conveyor system. 
   In recent years, however, variations in shapes and sizes of containers have proliferated. Accordingly, it is desirable to have a system which allows guide rails along a conveyor to be continuously adjusted so that an initial system may accommodate any bottles in the future. 
   SUMMARY OF THE INVENTION 
   The present invention positions guides along a conveyor for a container packaging system. As such, the present invention provides the following advantages: substantially simultaneous adjustment of a plurality of guide rails, thereby providing rapid repositioning; adjustable along a nonlinear conveyor path; readily adaptable to be retrofitted to existing conveyor systems; provides for independent 2-axis adjustment for bottle height and width; utilization of a single drive mechanism for adjustment of guide rails along an extended length of conveyor; and flexibility for the location of the drive mechanism relative to the conveyor system (i.e. upstream or downstream location). 
   A pivoting structure for positioning a guide along a conveyor for a container packaging system according to the principles of the present invention includes a pivot base. A first pivoting member is rotatably connected to the pivot base, and a second pivoting member is rotatably connected to the first pivoting member. A guide is disposed on an end of the second pivoting member. A first connecting element is coupled to the first pivoting member and operable to rotate said first pivoting member through a first range of motion. A second connecting element is coupled to the second pivoting member and operable to rotate said second pivoting member through a second range of motion independent of the first range of motion. The second connecting element is arranged at a location to avoid unwanted torque on the first pivoting member. Movement through the first range of motion and the second range of motion locates the guide within a container shape envelope. 
   In another aspect of the present invention, a conveyor system having adjustable guides includes a system base and a conveyor for a container packaging system. A plurality of pivoting structures are coupled along the conveyor, and an actuation system is coupled to the pivoting structures. The pivoting structures are coupled along opposing sides of the conveyor. Multiple guides along a common side of the conveyor are intercoupled to form guide assemblies. The pivoting structures are operable by the actuation system to locate each of the guide assemblies to corresponding positions within a container shape envelope. 
   In another aspect of the present invention, a method of positioning guides along a conveyor for a container packaging system is disclosed. The method includes: (1) manipulating a drive element to substantially simultaneously operate a plurality of pivoting structures to locate a guide assembly associated therewith in a container shape envelope and (2) fixing the drive element with respect to a conveyor to locate guides of the pivoting structures to corresponding positions within the container shape envelopes. 
   Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
       FIG. 1  is a top view of a conveyor system according to the principles of the present invention; 
       FIG. 2  is a front elevation of a pair of pivoting structures according to the principles of the present invention; 
       FIGS. 3A and 3B  are top views of drive elements and related components according to the principles of the present invention; 
       FIGS. 4A and 4B  are side elevations of connecting elements and related components according to the principles of the present invention; 
       FIG. 4C  is a side elevation of an alternate arrangement of the connecting elements and related components according to the principles of the present invention; 
       FIG. 5A  is a top view of a conveyor with a nonlinear path according to the principles of the present invention; and 
       FIG. 5B  is a top view of an alternate arrangement of the conveyor with a nonlinear path according to the principles of the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
   Referring now to  FIG. 1 , a conveyor system  10  for a container packaging system is shown. Conveyor system  10  includes conveyor  12  along which containers  14  are transported from infeed machine  16  to discharge machine  18 . Infeed machine  16  collects a plurality of containers  14  and introduces them to the conveyor system  10  which accumulates and transports containers to discharge machine  18 . Conveyor system  10  also includes a plurality of pivoting structures  20  coupled along conveyor  12 . Pivoting structures  20  are operable to locate guides along conveyor  12  as is described in more detail below. 
   Additionally, conveyor system  10  includes an actuation system  22  operably coupled to the pivoting structures  20 . Actuation system  22  includes drive elements  24  coupled to a plurality of pivoting structures  20  for operating the pivoting structures substantially simultaneously as described in more detail below. Actuation system  22  may also include one or more actuators  26 . Each actuator  26  powers a drive element  24  to operate a plurality of pivoting structures  20  for locating the guides in a container shape envelope as is described in more detail below. 
   Referring now to  FIG. 2 , each pivoting structure  20  includes a pair of pivoting mechanisms  120 ,  220 . Pivoting mechanisms  120 ,  200  are each coupled along conveyor  12 . Conveyor  12  is a part of a container packaging system and includes neck guide  38 . Neck guide  38  supports the containers traveling along conveyor  12  and, in combination with the guides  48  of pivoting mechanisms  120 ,  220 , routes the containers being transported along conveyor  12 . As pivoting mechanisms  120 ,  220  are substantially similar, only pivoting mechanism  120  will be described in detail herein. It is to be understood that the description of pivoting mechanism  120  and its components equally applies to pivoting mechanism  220  and its corresponding components. 
   Pivoting mechanism  120  includes pivoting members  40  and  42 . First pivoting member  40  is rotatably connected to conveyor  12  at pivot  44  and is operable to rotate through a first range of motion. Second pivoting member  42  is rotatably connected to first pivoting member  40  at pivot  46  and is operable to rotate through a second range of motion independent of the first range of motion of first pivoting member  40 . Pivoting mechanism  120  also includes guide  48 . Guide  48  is disposed on an end of second pivoting member  42 . According to the principles of the present invention, guide  48  interacts with containers being transported along conveyor  12 . As pivoting mechanism  120  includes two pivoting members  40  and  42  with independent ranges of motion, guide  48  is able to be located in at least a two-dimensional area as described in more detail below. 
   Additionally, pivoting mechanism  120  includes two connecting elements  50  and  52 . As shown in  FIG. 2 , connecting elements  50  and  52  are coupled to pivoting members  40  and  42  with eyebolts  54  and  56 . Connecting elements  50  and  52  are coupled to drive elements  60  and  62 . As presently preferred, connecting elements  50  and  52  are made of flexible cabling supported along conveyor  12  by pulley structures  66 ,  68 ,  166 , and  168 . Pulley structures  66  and  68  are shown in  FIG. 2 , and pulley structures  166  and  168  are shown in  FIG. 4A . Connecting element  50  follows a path underneath pulley structure  66  and over pulley structure  68  to couple to pivoting member  40  at point  54 . Connecting element  52  follows a path underneath pulley structure  168  and over pulley structure  166  to couple to pivoting member  42  at point  56 . Such paths orient connecting elements  50  and  52  in positions to operate pivoting members  40  and  42 . 
   Referring again to  FIG. 2 , connecting elements  50  and  52  are operably coupled to pivoting members  40  and  42 , respectively, to be able to operate the pivoting members through the independent ranges of motion described above. The combination of these ranges of motion with respect to guide  48  is shown in  FIG. 2  as travel envelope  70 . Travel envelope  70  shows that guide  48  can be located in a two-dimensional area.  FIG. 2  also shows container shape envelope  72 . Container shape envelope  72  represents an area of desired locations of guide  48  corresponding to various sizes and shapes of containers to be transported along conveyor  12 . Thus, travel envelope  70  substantially overlaps container shape envelope such that pivoting mechanisms  120 ,  220  can be used to locate the guides  48  in a wide range of positions to accommodate different containers. 
   In  FIGS. 3A and 3B , top views of drive elements  60 ,  62  and related components are shown. Referring to  FIG. 3A , drive elements  60 ,  62  are shown and include a drive cable  124 . With reference to  FIGS. 3 and 4 , it is to be understood that the description of drive element  60  and its related components equally applies to drive element  62  and its corresponding related components. Drive cable  124  is coupled to base  80  via a spring assembly  82 . Spring assembly  82  is coupled between drive cable  124  and base  80  to maintain drive cable  124  in tension. Tension is needed in drive cable  124  in order to operate a plurality of pivoting structures substantially simultaneously as described in more detail below, as well as to minimize sag of the drive cable  124 . 
   Referring now to  FIG. 3B , an enlarged view is shown of drive element  60  which couples drive cable  124  to pivoting mechanism  120  via connection elements  50 . Drive cable  124  is coupled to connecting element  50  by clamping element  84 . Clamping element  84  enables forces to be transmitted from drive cable  124  to connecting element  50 . Multiple clamping elements  84  coupled along drive cable  124  allow drive cable  124  to operate a plurality of pivoting structures substantially simultaneously as is described in more detail below. Pulley structures  86  and  88  maintain the alignment and position of drive cable  124  and connecting element  50 , respectively. A cable guide  90  is also included and is described in further detail below with reference to  FIG. 4B . 
   Referring now to  FIGS. 4A and 4B , connecting elements  50  and  52  are connected to drive elements  60  and  62 ; pulley structures  66 ,  68 ,  166 , and  168 ; and pivoting members  40  and  42 . With specific reference to  FIG. 4B , an enlarged side view is shown of drive cable  124  coupled to drive element  60  as depicted in  FIGS. 2 ,  3 A,  3 B, and  4 A. Drive cable  124  and connecting element  50  are coupled by clamping element  84 . Drive cable  124  is aligned and positioned by pulley structure  86  (shown in  FIG. 3B ) and connecting element  50  is aligned and positioned by pulley structure  88 . Connecting element  50  travels through cable guide  90  which functions to align connecting element  50  to engage pulley structure  88 . 
   Referring now to  FIG. 4C  an alternate arrangement of the drive elements  60 ′ and  62 ′ is shown in which machined blocks are used in place of pulleys for directing the connecting elements  50 ′ and  52 ′ from drive cable  124  to pulley structures  66 ,  68 ,  166 , and  168  for operating pivoting members  40  and  42 . In this regard, drive elements include blocks  60 ′ and  62 ′ which have a machined radius formed therein to provide a guide surface over which the connecting elements  50 ′ and  52 ′ can slide. This configuration combines enables the functions provided be the pulleys and the guide elements illustrated in  FIGS. 4A and 4B  to be combined in to a single component. An adjustment elements  51 ′ and  53 ′ in the form of a turnbuckle or the like may be incorporated into the connecting elements  50 ′ and  52 ′ to provide a degree of adjustment for the lengths thereof. 
   By using flexible drive cable, the present invention is readily adaptable for use along a tortuous conveyor path which may rise or fall in elevation as well as turn in various directions. Referring now to  FIGS. 5A and 5B , conveyor  112 , which has a nonlinear path, is shown. Pivoting mechanisms  120  are coupled along opposing sides of conveyor  112 . According to the principles of the present invention, pivoting structures  120  are operable to locate guides  148 ,  148 ′ disposed on ends of pivoting mechanisms  120  along conveyor  112 . Guides  148 ,  148 ′ can be coupled with other guides such as a guide bars  248 ,  248 ′ along the same side of conveyor  112  to form a guide assembly or alternately may separate but move in a coordinated manner with respect to guide bars  248 ,  248 ′. Drive cables  124  are coupled to pivoting mechanisms  120  and transmit power to operate pivoting mechanisms  120  substantially simultaneously. Pulley structures  92  engage with and route drive cables  124  along the nonlinear path of conveyor  112 . 
   The operation of the present invention is substantially consistent in a variety of configurations and along a variety of paths. First, actuators  26  are coupled to drive cables  124  and pull the drive cable  124  against the bias of spring  82  to operate a plurality of pivoting mechanisms  20  substantially simultaneously. Drive cables  124  move axially, and that movement is translated to connecting elements  50  and  52  through clamping members  84 . The movement of connecting elements  50  and  52  causes pivoting members  40  and  42  to rotate and guides  48  to change location. In this manner, drive element  60  is used to position pivot member  40  and drive element  62  is used to position pivot member  42 . 
   When the combination of movement has positioned guides  48  at the desired locations within container shape envelopes  72 , actuation system  22  then fixes drive cable  124 . As drive cables  124  are in tension, the positions of all the components are maintained. When a container  14  with a different shape needs to be accommodated, the locations of guides  48  may be changed accordingly. 
   A preferred configuration of the present invention would include one pivoting structure  20  on each side of conveyor  12  for every five feet of conveyor  12 . Additionally, a preferred configuration would include a multiple of actuators  26 , the number depending on the number of drive cables  124  in the system. As presently preferred, a single actuator  26  can be used to position one hundred feet of drive cable  124  in each direction. Thus, in such a configuration, one drive element  24  and one actuator  26  could operate up to forty pivoting structures  20 . Actuators  26  are included which can provide a desired accuracy corresponding to the size of container shape envelopes  72 . Suitable actuators  26  may include fluidic muscles, pneumatic motors, hydraulic and pneumatic cylinders stepper motors, servo motors, stepped air cylinders, and servo air cylinders, but it is anticipated that others may be used. 
   The components of the present invention can be made of a variety of materials. In a typical embodiment of the present invention, the drive elements and the connecting elements are flexible drive elements. As such, suitable materials for both include wire rope and steel cables. It is anticipated that other materials can be used for both of these elements. Pivoting members  40  and  42 , clamping members  84 , pulley structures  66 ,  68 ,  86 ,  88 , and  92 , and directing structures  90  that are included in the present invention are preferably substantially rigid and can be made of a variety of suitable materials in accordance with the given application. Guides  48  can be shaped to correspond to the path of conveyor  12  and must be rigid enough to maintain shape while interacting with containers  14  traveling along the conveyor  12 . 
   According to the principles of the present invention, conveyor  12  can have paths of various shapes, and containers  14  can have a variety of shapes and sizes. It is anticipated that pivoting structures  20  can be located in various configurations along conveyor  12 . It is also anticipated that connecting elements  50  and  52  may be coupled to pivoting members  40  and  42  in a variety of ways. It is to be understood that pivoting mechanisms  120 ,  220  can be configured to operate according to the principles of the present invention independent of pulley structures  66 ,  68 ,  166 , and  168 . Additionally, travel envelope  70  is variable with respect to the size and configuration of the components of pivoting structure  120 , and container shape envelope  72  varies with the applications of the container packaging system. 
   Additionally, pulley structure  86  is shown as an exemplary way to provide support for drive cable  124 . It is to be understood that a variety of structures could support drive cable  124 , including pulleys, semi-circular channels and tubes as dictated by the given application. The use of pulley structures or semi-circular channels would allow for less complicated assembly than the use of tubes. Pulley structures also would help prevent water build up in the system. Additionally, a tube could help prevent unwanted motion of a drive element which may cause the drive cable to jump off line. 
   The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.