Abstract:
A machine for forming a carton from a carton blank. The machine includes at least one mover including a picker for picking the carton blank from the hopper and associating the carton blank with the mover. A controlled motion track is provided for moving the at least one mover and picker along a path of travel to a stationary position for engaging the carton blank in the hopper. A further aspect relates to maintaining a suction force on the carton blank during conveyance, including along a linear portion of the track associated with a lugged conveyor for assisting in erecting the blank into a carton. Another aspect relates to a rotatable bucket for receiving and supporting the product, and a controlled motion track for positioning the bucket and associated product for delivery to the carton. Related methods are also described.

Description:
[0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/126,907, the disclosure of which is incorporated herein by reference. 
     
    
     Field of the Invention 
       [0002]    This disclosure relates to the cartoning arts and, more particularly, to a carton forming or feeding machine using controlled motion. 
       BACKGROUND 
       [0003]    Machines for forming cartons from blanks, and then delivering a product for loading into the carton, are well known. Typically, the carton is erected from a blank during a “pick and place” operation using a machine known in the vernacular as a “rotary feeder.” Versions of rotary feeders may be found in U.S. Pat. Nos. 4,881,934 and 8,047,530, as but two examples. 
         [0004]    While these types of machines work well for their intended purposes, the picking and erecting of the carton blank in a rotary environment requires a sophisticated arrangement of cams, gears, linkages, etc., and, thus, considerable engineering to develop and effort to maintain. Individualized control or independent adjustment of the particular structures used to pick and place the carton is usually not possible in this type of arrangement, which can lead to complications, especially when different sizes of cartons are being handled. The same is typically true for the corresponding machines used to deliver and then load product in the formed cartons, which loading sometimes requires reorienting the product for insertion into the carton from an open side prior to sealing. 
         [0005]    Accordingly, a need exists for improved carton forming or feeding machines that avoid any one or all of the foregoing limitations, and perhaps others yet to be identified. 
       SUMMARY 
       [0006]    In accordance with one aspect of the disclosure, a machine is provided for forming a carton from a carton blank in a hopper. The machine comprises at least one mover including a picker for picking the carton blank from the hopper and associating the carton blank with the mover. A controlled motion track is provided for moving the at least one mover and picker along a path of travel to a stationary position for engaging the carton blank in the hopper. 
         [0007]    In one embodiment, the picker comprises an actuator for moving in a linear direction for engaging and withdrawing the carton blank from the hopper while the mover is in the stationary position. The picker may comprise at least one vacuum cup for engaging the carton blank, the vacuum cup being mounted to the mover by a support including a vacuum source for supplying vacuum pressure to the vacuum cup. A latch may be provided for latching the picker in a home position and a rotary union may be provided for delivering gas to the support. 
         [0008]    The track may include a curved portion corresponding to the location of the hopper and a linear portion. A takeaway conveyor may be provided for receiving the carton blank during erection, the takeaway conveyor being located opposite a linear portion of the track. In one embodiment, a plurality of movers are provided, and the controlled motion track is adapted for controlling the movement of each mover to stop at the hopper. In one embodiment, the mover comprises a first mover, and further including a second mover having an actuator for moving in a linear direction for engaging and withdrawing the carton blank from the hopper while the mover is in the stationary position. 
         [0009]    According to a further aspect of the disclosure, a machine for forming a carton from a carton blank in a hopper is provided. The machine comprises a plurality of movers, each including a picker connected to an actuator for causing the picker to pick the carton blank from the hopper. A controlled motion track is provided for delivering the movers and associated blanks to a position for erection of the blank into the carton, the track including a linear portion. 
         [0010]    The controlled motion track may be adapted for moving the at least one mover and picker along a path of travel to a stationary position for engaging the carton blank in the hopper. The picker may comprise at least one vacuum cup for engaging the carton blank, the vacuum cup being mounted to the mover by a support including a vacuum source for supplying vacuum pressure to the vacuum cup. A rotary union may be provided for supplying gas to the support, and a latch may be provided for latching the picker in a home position. 
         [0011]    The track may comprise a curved portion corresponding to the location of the hopper and a linear portion. A takeaway conveyor may be provided for receiving the carton blank during erection, the takeaway conveyor being located adjacent a transition from a return run of the track to a forward run. The takeaway conveyor may comprise lugs for assisting in erecting the carton from the carton blank during conveyance along the linear portion of the track by the combined action of the lugs and the picker. 
         [0012]    A further aspect of the invention pertains to a machine for forming a carton from a carton blank. The machine comprises a controlled motion track having a curved portion and a linear portion, and a hopper for holding the carton blank, the hopper being located along the curved portion of the track. At least one mover is provided for moving along the track, the mover including at least one picker for engaging the carton blank in the hopper and conveying the carton blank along the curved portion of the track to the linear portion of the track. A conveyor, such as a lugged takeaway conveyor, is provided for receiving the carton blank and at least partially erecting it, the conveyor being located along the linear portion of the track, such that the picker engages the carton blank at least partially during erection by the conveyor. The picker may be adapted for applying suction to the carton blank during conveyance along the curved portion and the linear portion of the track. 
         [0013]    According to a further aspect of the disclosure, a machine for feeding product for delivery to a carton is provided. The machine comprises a rotatable bucket for receiving and supporting the product, and a controlled motion track for positioning the bucket and associated product for delivery to the carton. 
         [0014]    A cam follower assembly may also be provided for rotating the carrier from a first orientation for receiving the product from an infeed conveyor to a second orientation for delivering the product to an open end of a carton. The cam follower assembly comprises a Geneva wheel rotatably mounted to the carrier and a cam follower positioned at a fixed location along the track for engaging a groove in the Geneva wheel. A retainer may also be provided for retaining the product on or in the carrier, such as an actuator for engaging the product on delivery to the carrier. The controlled motion track may also be adapted for halting the bucket for receiving or releasing the product. 
         [0015]    In one additional aspect, a carton feeder comprises a selectively movable linear actuator including a picker for picking a carton blank from a hopper solely in a linear direction. 
         [0016]    Another aspect of the disclosure pertains to a method of forming cartons from carton blanks. The method comprises picking a carton blank from a hopper using a stationary mover associated with a continuous motion track adapted for controlling the stationary mover independent of another mover associated with the track. The method may further include the step of picking the carton blank in a purely linear direction. 
         [0017]    Still another aspect of the disclosure pertains to a method of feeding a product for loading into a carton. The method comprises providing a controlled motion track including a plurality of independently movers, at least one including the product, and rotating the product associated with the mover between a first received orientation and a second orientation for loading the product into the carton. Each mover may include a carrier, and the step of rotating the product may comprise rotating the carrier from a first orientation for receiving the product from an infeed conveyor to a second orientation for delivering the product to an open end of the carton. 
         [0018]    Still a further aspect of this disclosure pertains to a method of forming a carton. The method comprises conveying a support supporting an actuator including a picker for picking a carton blank from a hopper in a linear direction, halting the conveying of the support for engaging the actuator with the carton blank, and conveying the support for at least partially erecting the carton blank into the carton. 
         [0019]    Yet another aspect of the disclosure pertains to a method of forming a carton from a carton blank, comprising: (1) conveying the carton blank along a curved portion of a conveyor while applying suction to the carton blank; and (2) erecting the carton along a linear portion of the conveyor while maintaining the suction on the carton blank. The method may further include the step of picking the carton blank from a hopper positioned along the curved section using suction. 
         [0020]    As can be appreciated, the machines and methods described above may be used together or apart from each other. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]      FIG. 1  is a perspective view of one embodiment of a continuous motion device for a carton forming and feeding machine; 
           [0022]      FIG. 2  is a side view of a carton forming and feeding machine including the continuous motion device of  FIG. 1 ; 
           [0023]      FIG. 3  is a partially cutaway top view of the machine of  FIG. 2 ; 
           [0024]      FIG. 4  is an enlarged portion of the view of  FIG. 3 ; 
           [0025]      FIGS. 5-14  are sequential views of a carton forming and feeding operation using the disclosed machine with continuous motion; 
           [0026]      FIG. 15  is a side perspective view of a carton loading machine including a continuous motion device; and 
           [0027]      FIG. 16  is an enlarged view of a part of the machine of  FIG. 15 . 
       
    
    
     DESCRIPTION 
       [0028]    Reference is now made to  FIG. 1 , showing an overall perspective view of one embodiment of a carton forming machine  10 . In the illustrated embodiment, the machine  10  includes a track  12  supporting one or more movers  14 . Each mover  14  in turn supports a carrier, which may comprise a suction device, which may include selectively actuatable vacuum cups  16 . Although not all movers  14  are shown with this structural arrangement in  FIG. 1 , it should be appreciated that all may be identically constructed. 
         [0029]    The cups  16  serving as the carrier engage the carton blank B in a hopper H ( FIGS. 2 and 5 ), which may be positioned along, opposite or above a curved portion of the track  12  corresponding to a return run (that is, where the carriers transition from forward movement along the upper end of the track  12  to the lower end). Once engaged, the cups  16  via the associated mover  14  (and via the suction force provided) advance the blank B to a position for erection into a carton C (including possibly by assisting in the erection process, and also possibly followed by further conveyance for product loading purposes, as outlined in more detail in the following description). 
         [0030]    The nature of the track  12  is such that the movers  14  may be individually advanced or halted at any point along an endless path of travel, and at a selected speed, thus providing a measure of controlled motion (which may include a lack thereof). The track  12  thus creates a “pitchless” arrangement (that is, there is no amount of fixed spacing between adjacent movers  14 ). One particular arrangement of such a track  12  is distributed by Rockwell Automation, Inc. under the trademark ITRAK. Such continuous movement arrangements are described in U.S. Pat. Nos. 8,896,241 and 6,876,107, as well as in U.S. Patent Application Publication Nos. 2014/0331888 and 2014/0265645, the disclosures of which are incorporated herein by reference. 
         [0031]    Thus, with reference again to  FIGS. 1 and 2 , as well as  FIGS. 3 and 4 , it can be seen that each mover  14  may be advanced along the track  12  to a “pick” position for selecting the next-in-line blank B from the hopper H. To do so, one or more actuators  18 , such as linear actuators (two shown, one for each side), may be associated with each mover  14  to advance a support  20  supporting the vacuum cups  16  to engage the blank B (note action arrow A and cam  21  in  FIG. 4  for associating with a follower  20   b  connected to support  20 ). Thus, the carrier or cups  16  and the support  20  coupled with actuator  18  thus together may be considered to form a picker. 
         [0032]    By supplying negative or vacuum pressure to the cups  16  (which may be achieved using a rotary union  22  to supply compressed air through a delivery line  24  to a vacuum generator (venturi) associated with support  20  to create the desired vacuum), the carton blank B may be engaged and the actuator  18  retracted to pick the blank in a secure, repeatable, and highly reliable fashion. Using the controlled motion feature of the track  12 , the mover  14  may briefly stop at the pick point to ensure that a proper engagement is achieved. 
         [0033]    As shown in  FIG. 3 , a selectively movable latch  26  may be associated with each mover  14  and the actuator  18  forming part of the picker in particular. This latch  26  may be used to ensure that the support  20  remains held in the retracted condition during continued conveyance, except when actuation is desired. The latch  26  may be movable in a transverse direction, and may pivot to associate with a pin or other portion of the support  20 . 
         [0034]    As should be appreciated, the arrangement provided means that the blank B may be drawn from the gate associated with the hopper H in a purely linear movement. Such is typically not possible using continuous rotary feed arrangements using cams and gears to effect the picking operation, since such halting or stopping is not possible. Once the carton blank B is engaged and removed from the hopper H, the corresponding mover then may continue to advance along a curved portion  12   a  of the track  12  to rotate and reorient the blank for purposes of eventual erection. As noted, the halting or stopping may be momentary only, and need only transpire for as long as it takes for the carton blank B to move clear of the hopper or other holder. 
         [0035]    It can be further understood that the linear movement is in the radial direction when the hopper H is located along a curved portion of the track  12 . A line corresponding to the linear movement is thus generally orthogonal to a line tangent to the curved portion of the track  12 . Of course, if the hopper H were positioned along a linear portion of the track  14 , such as the upper portion or the lower portion, the line corresponding to the linear movement would be generally orthogonal with a line parallel to the conveying direction of the mover  14  along the linear portion. 
         [0036]      FIGS. 5-14  sequentially illustrate the full sequence of the carton picking and forming operation in relation to the engagement of a selected mover  14 . In  FIG. 5 , the retraction of the carton blank B by one mover  14   a  is shown. This mover  14   a  may be moved along the track  12  such that the still not erected carton blank B associated with it engages an advance structure, such as a leading lug L on an adjacent takeaway conveyor, which starts the erection ( FIG. 5 ). 
         [0037]    As indicated, the picking of the blank B may occur above a midline of the track  12  (that is, along the upper curved portion), to allow for the carton blank B to be erected with the assistance of the movement of the mover  14  around the remainder of the curved portion, and ultimately to the underside of the track  12  along linear portion  12   b,  as shown in  FIG. 12 . The carton blank B eventually forms the carton C in an open condition and ready for receiving product, while simultaneously engaged by the lug L and the vacuum cups  16 , which may be released at the point of erection by discontinuing the vacuum pressure. During the latter part of the sequence, a trailing lug T may also be used to help square the nascent carton C and complete the forming process. 
         [0038]    As contrasted with past feeders and formers relying solely upon continuous rotary movement, it can be appreciated that this machine  10  uses controlled motion technology to allow for a more precise handling of the carton during picking and erection, and a consequent control of the timing of the required events to complete the erection sequence. The resulting pitchless arrangement may be used with a variety of different carton sizes (lengths in particular) without making any mechanical adjustment to the machine  10  (but of course possibly altering the relative positioning of the lugs L, T to accommodate the corresponding carton length). The arrangement also allows the movers  14  to be operated at variable speeds, which may be desirable in conveying the carton blanks for erection. This is simply not easily achieved or perhaps even possible using known arrangements of rotary feeders involving continuous rotation (as compared to controlled movement). 
         [0039]    While different shapes may be used (such as, for instance, circular), it can also be appreciated that the track  12  shown is oblong. Thus, it includes curved portions  12   a,  as discussed above, as well as linear portions  12   b  (see  FIG. 5 ) along which the movers  14  move, including in a depending position during the erection sequence. As a result of this arrangement, and as can be understood from  FIGS. 5-14 , a mover (such as mover  14   b ) may advance with the carton C during the lug engagement and thus help to assure that the erection is reliably achieved. 
         [0040]    During the continued conveyance along the linear portion  12   b  of the track  12  corresponding to the lugged takeaway conveyor, the vacuum cups  16  may continue to engage and actively apply a suction force to the carton blank during some or all of the erection sequence. This may be advantageous not only in terms of helping to provide the force for erection, but also to ensure that it is achieved in a consistent, reliable manner. The corresponding linear portion  12   b  along the opposite side of the track  12  also provides a location where the movers  14  may be parked awaiting actuation for the next pick operation (note “park positions” in  FIG. 1 ). The movers  14  may also be accelerated for return to the park position once the carton C is formed. 
         [0041]    Once the erection sequence is complete, it may also be desirable to load the now-erected carton C with product. This may be achieved using an adjacent product delivery machine  100 , an example of which is shown in  FIGS. 15 and 16 . The machine  100  also includes a track  112  for providing controlled motion for individual movers  114  (that is, the movers may be independently moved along the track at a particular speed (or not)). The track  112  as shown includes an upper elongated portion  112   b  forming a forward run, as well as curved portions  112   a  for returning the movers  114  to the forward run. 
         [0042]    Each mover  114  may be adapted for receiving and supporting a product during conveyance. In the illustrated embodiment, the mover  114  includes a carrier, such as a bucket  116 , for achieving this function. The bucket  116  may be mounted to the mover  114  for relative rotation, and may have an open top as well as open ends for receiving product. 
         [0043]    As can be understood from the right hand side of  FIG. 15 , the bucket  116  may be initially oriented with one open end facing an infeed conveyor  118 , which in turn delivers the product thereto. Each mover  114  may be momentarily halted at the delivery point, and a retainer  120  (such as a vertically extending linear actuator) used to ensure that the product is retained in or on the bucket  116  prior to advancing along the track  112  (possibly with an acceleration to close any gap created by the delayed action). Advantageously, the controlled movement provided by the track  112  also allows for the flow of movers  114  to be controlled to correspond to the feed of product on the conveyor  118 , which may be random. 
         [0044]    With the product onboard, the mover  114  may then extend along the upper linear portion  112   b  of the track  112  to a remote point for delivery into the open end of the carton C (see  FIG. 15 ) associated with machine  10  (or a different machine, such as a conventional rotary feeder arrangement with a corresponding takeaway conveyor). As can be appreciated, when the machines  10 ,  100  run in parallel, the bucket  116  in the above-described condition is generally orthogonal to the orientation of the carton C. 
         [0045]    In such case, it would be necessary to reorient the bucket  116 , which may be achieved using a device, such as a turner  122  (such as a slotted, or “Geneva”, wheel  124  and a corresponding fixed cam follower  126 , as shown in  FIG. 16 ). With the bucket  116  reoriented in this fashion (which is shown as being a 90 degree counterclockwise turn), the product may then be delivered through the open end of an adjacent carton (such as by using a pusher (not shown) the push the product into place). The now-filled carton may then be sealed and thus completed. Along the return run of the track  112 , a device for turning or turner (not shown, but substantially identical to cam arrangement  122 ) may be arranged to return the bucket  116  to a position for receiving the product from the conveyor  118  at the infeed point, such that the sequence may be continuously repeated. 
         [0046]    As should be appreciated, the tracks  12 ,  112  described above are shown as including a particular number of movers  14 ,  114  (six in  FIG. 1 , nine in  FIG. 15 ). However, the number of movers provided may be varied depending on the particular application (and would typically be greater in the machine  100 , since there would likely be a desire for continuous conveyance of product). As can be appreciated, use of the controlled movement also allows for the movers  14 ,  114  to be halted at any point along the return run to await actuation upon being summoned to engage a carton or product, respectively. As noted above for the cartoning machine  10 , the movers  114  may also be controlled to regulate their relative spacing, depending on the size or length of the buckets  116  used. 
         [0047]    The foregoing description has been presented for purposes of illustration. It is not intended to be exhaustive or to limiting. The embodiments described provide an illustration of the inventive principles and the practical application thereof sufficient to enable one of ordinary skill in the art to utilize them in various other embodiments and with various modifications, as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.