Abstract:
There is disclosed a unit for forming a layer of a batch of groups of articles, comprising a first conveyor adapted to convey a plurality of groups in an abutting relationship; and a second conveyor adapted to separate batch from the remaining groups for a gap; unit further comprises manipulating means adapted to manipulate separated batch on an area defined by second conveyor, so as to form layer.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims priority to European Patent Application No. 12199778.7, filed Dec. 28, 2012, the entirety of which is hereby incorporated by reference, 
       FIELD OF THE INVENTION 
       [0002]    The present invention relates to a unit and a method for forming a layer of batches of articles, in particular containers filled with a pourable food product. 
       BACKGROUND OF THE INVENTION 
       [0003]    Bottling lines are known which comprise a plurality of units for carrying out respective operations on containers. 
         [0004]    Very briefly, the known bottling lines comprise a rinsing unit for rinsing containers, a filling unit for filling containers with a pourable food product, a capping unit for capping the containers, and a packaging unit for packaging together a given number of containers so as to form a plurality of groups of containers. 
         [0005]    The bottling line comprises an end station fed with groups of containers travelling on one or more, typically two, rows on a horizontal conveyor along a horizontal advancing direction. 
         [0006]    The end station comprises a unit for forming batches of groups of containers. 
         [0007]    The above-mentioned unit is, in particular, adapted to separate a plurality of batches of groups of container of a given length along the direction from the remaining groups and to form a layer of groups of containers. 
         [0008]    An example of end station is shown, for example, in U.S. Pat. No. 7,896,151. 
         [0009]    The unit of that known end station substantially comprises: a distribution belt which receives a plurality of containers in abutting relationship with each other; a conveyor belt for forming a plurality of batches separated by a gap from the containers conveyed by distribution belt; and a forming belt for forming the row or the layer of the previously formed batches. 
         [0010]    Furthermore, the unit comprises: a first motor for driving the distribution belt; a second motor for driving the conveyor belt; and a third motor for driving the forming belt. 
         [0011]    In detail the first motor and the second motor drive the distribution belt and the conveyor belt respectively at different speeds in order to allow the separation of the batches onto the conveyor belt from the groups still travelling on the distribution belt. 
         [0012]    Still more precisely, the first motor intermittently accelerates the first conveyor, moves it at a constant speed and decelerates the first conveyor until the latter stops. 
         [0013]    The second motor drives the conveyor belt at a constant speed. 
         [0014]    A need is felt within the industry to simplify the construction of the above unit. 
         [0015]    Furthermore, a need is felt within the industry to avoid the inevitable errors in the positioning of the batches upstream of the conveyor belt penalizes the correct separation of the batches form the remaining groups. 
         [0016]    Finally, a need is felt within the industry to avoid that the precision in the gap between the batches is penalized by the fact that the first conveyor is intermittently accelerated and decelerated. 
       SUMMARY OF THE INVENTION 
       [0017]    It is an object of the present invention to provide a unit for forming a group of articles, which meets at least one of the above requirements. 
         [0018]    The aforementioned object is achieved by the present invention as it relates to a unit for forming a layer of batches of groups of articles. 
         [0019]    Furthermore, the present invention relates to a method for forming a layer of batches of groups of articles. 
         [0020]    The present invention also relates to a method for forming a batch of groups of articles. 
         [0021]    Finally, the present invention relates to a method for forming a batch of groups of articles. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0022]    One preferred embodiment is hereinafter disclosed for a better understanding of the present invention, by way of non-limitative example and with reference to the accompanying drawings, in which: 
           [0023]      FIGS. 1 and 2  schematically show a top view and a lateral view of a unit for forming a group in accordance with the present invention; 
           [0024]      FIG. 3  shows the speed and displacement profiles versus time of a first and a second conveyor of the unit of  FIGS. 1 and 2 ; 
           [0025]      FIG. 4  shows the updating of the speed profile of the second conveyor of  FIG. 3 ; and 
           [0026]      FIG. 5  shows the speed profiles of the first and second conveyor of  FIGS. 3 and 4  during an operation step in which a gap between the batches is formed. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0027]    With reference to  FIGS. 1 to 5 , numeral  1  indicates a unit for forming batches  2  of groups  3  of articles, in particular containers filled with pourable products. 
         [0028]    In detail, unit  1  is fed with groups  3  of packaged articles, forms batches  2  having each a length L and separated by a gap D, measured along a direction X. 
         [0029]    Furthermore, unit  1  creates a layer  40  (only schematically shown in  FIG. 1 ) of batches  2  which will be eventually palletized into a not-shown pallet. 
         [0030]    Unit  1  substantially comprises, proceeding according to an advancing direction of groups  3  along direction X; a conveyor  5  which is fed with groups  3  from a machine arranged upstream of conveyor  5  and conveys groups  3  in abutting relationship with each other; and a conveyor  6  which separates, one after the other, each batch  2  from the remaining groups  3  for gap D. 
         [0031]    In the embodiment shown, conveyor  5  is fed with a single row of groups  3  from the upstream machine. 
         [0032]    Furthermore, conveyors  5 , 6  are belt conveyor. 
         [0033]    Unit  1  also comprises: a motor  7  for driving conveyor  5 ; and a motor  8  for driving conveyor  6 . 
         [0034]    In the embodiment shown, motors  7 ,  8  are brushless motors. 
         [0035]    Advantageously, unit  1  comprises manipulating means  9  for manipulating separated batches  2  onto an area  4  of conveyor  6 , so as to form layer  40 . 
         [0036]    Manipulating means  9  are movable along direction X, and along directions Y, Z orthogonal to each other and to direction X and may rotate about direction Z. 
         [0037]    More precisely, direction Y is horizontal and direction Z is vertical, in the embodiment shown. 
         [0038]    Gap D depends on the layer to be formed by manipulating means  9  and, in particular, on the time required by manipulating means  9  for forming the layer. 
         [0039]    Conveyor  5  comprises, in turn, proceeding according to the advancing direction of groups  3  along direction X: a section  11 ; and a section  12 . 
         [0040]    In the embodiment shown, section  11  is made by a material having a first friction coefficient and section  12  is made by a material having a second friction coefficient. 
         [0041]    The first friction coefficient is greater than the second friction coefficient. 
         [0042]    Conveyor  6  is made by a material having a third friction coefficient which is substantially similar to the second friction coefficient. 
         [0043]    In this way, the thrust of groups  3  in loading onto section  11  is contrasted by the friction of material of section  11 . 
         [0044]    Furthermore, due to the fact that the second and the third material have similar friction coefficient, the risk that groups  3  slide during the movement between section  12  and conveyor  6  is reduced. 
         [0045]    Unit  1  comprises ( FIG. 1 ): sensing means  15  arranged on conveyor  5  for sensing the passage of groups  3  on that conveyor  5 ; and sensing means  16  arranged on conveyor  6  for sensing the presence of groups  3  on that conveyor  6 . 
         [0046]    Sensing means  15  are preferably arranged close to an end  17  of conveyor  5  adjacent to conveyor  6 . 
         [0047]    Sensing means  15  are adapted to sense the accumulation of a given number of groups  3  onto conveyor  5 . 
         [0048]    Sensing means  16  are preferably arranged close to an end  18  of conveyor  5  adjacent to conveyor  5 . 
         [0049]    Sensing means  16  are arranged at a distance F from end  18  measured along direction X ( FIG. 2 ). 
         [0050]    Sensing means  15  comprise, in the embodiment shown, a first photocell formed by a receiver and an emitter aligned along direction Y orthogonal to direction X. 
         [0051]    In a completely analogous manner, sensing means  16  comprise, in the embodiment shown, a second photocell formed by a receiver and an emitter aligned along a direction Y orthogonal to direction X. 
         [0052]    Unit  1  also comprises a control unit  20  ( FIG. 2 ) for controlling motor  7  and, therefore, for generating a speed profile V 1  of conveyor  5 . 
         [0053]    Motor  8  is driven at a constant speed V 2 , which may be adjusted in dependence of the number of groups  3  fed to section  11  and of the number of groups  3  loaded on conveyor  5 . 
         [0054]    In the embodiment shown, motor  7  and  8  are functionally connected to each other. 
         [0055]    In greater detail, control unit  20  comprises an electronic cam which controls speed profile V 1  in dependency of speed of motor  8 . 
         [0056]    In other words, motor  8  is the master element of the electronic cam and motor  7  is the slave element of the above electronic cam. 
         [0057]    In this way, the speed profile V 1  of conveyor  5  varies with the variation of speed V 2  of conveyor  6 . 
         [0058]    In the embodiment shown, control unit  20  is configured for controlling motor  8  in such a way that conveyor  6  moves at constant speed V 2 . 
         [0059]    Control unit  20  is configured for controlling motor  7  in such a way that conveyor  5  cyclically moves for a time interval t 1  and stops for a time interval t 2 . 
         [0060]    As a result, speed profile V 1  comprises a work portion W and a rest portion R. 
         [0061]    In detail, work portion W comprises ( FIGS. 3 to 5 ): an accelerating section W 1  along which conveyor  5  moves for a length A 1  along direction X; a constant speed section W 2  along which conveyor  5  moves for a length A 2  along direction X; and a decelerating section W 3  along which conveyor  5  moves for a length A 3  along direction X. 
         [0062]    Conveyor  5  moves along section W 1 , W 2 , W 3  for respective time-intervals t 3 , t 4 , t 5 . 
         [0063]    It goes without saying that t 1 =t 3 +t 4 +t 5 . 
         [0064]    In the embodiment shown, control unit  20  controls motor  7  in such a way that conveyor  5 ; accelerates from a null speed to speed V 2  along section W 1 ; decelerates from speed V 2  to a null speed along section W 3 . 
         [0065]    Preferably, the speed of conveyor  5  varies with respect to time like a polynomial along sections W 1  and/or W 3 . 
         [0066]    Preferably, the speed of conveyor  5  along section W 2  equals speed V 2  of conveyor  6 . 
         [0067]    In particular, the electronic cam ensures that when, speed V 2  changes, conveyor  5  accelerates up to speed V 2  along section W 1 , travels at speed V 2  along section W 2  and decelerates from speed V 2  along section W 3 . 
         [0068]    Conveyor  6  moves for lengths A 2 , A 4 , A 6  during time intervals t 3 , t 4 , t 5  respectively. 
         [0069]    Furthermore, conveyor  6  moves for a length A 7  during time interval t 2 . 
         [0070]    With reference to  FIG. 3 , S 1  and S 2  indicates the displacement of conveyor  5  and  6  respectively versus time. 
         [0071]    Control unit  20  is configured for: receiving the signal generated by sensing means  16  and associated to the passage of batch  2  at a given position on conveyor  6 ; and updating speed profile V 1  of conveyor  5  along section W, on the basis of the signal generated by sensing means  16 . 
         [0072]    In greater detail control unit  20  is configured for updating the speed profile of conveyor  6 , from a nominal configuration, to an updated configuration, every time a new batch  2  is separated by conveyor  6 , as shown in  FIG. 4 . 
         [0073]    In the nominal configuration, control unit  20  is configured for generating a speed profile V 1  of conveyor  5  such that conveyor  5  travels for a length 2*L during time interval t 1 . In the updated configuration, speed profile V 1  of conveyor  5  is such that group  3  travels for a length L-F, after sensing means  16  sense the presence of batch  2  on conveyor  6 . 
         [0074]    In this way, conveyor  5  stops exactly when batch  2  of length L has been loaded on conveyor  6 , irrespective of the initial position of groups  3  forming batch  2 . 
         [0075]    Furthermore, with reference to  FIG. 5 , control unit  20  is configured to calculate length A 7  as: 
         [0000]        A 7= D− ( A 2 −A 1)−( A 6 −A 5).
 
         [0076]    In this way, the length lost by conveyor  5  relative to conveyor  6  along section W 1 —which equals to A 2 −A 1 —is recovered as well as the length lost by conveyor  5  relative to conveyor  6  along section W 3 —which equals A 6 −A 5 . 
         [0077]    A software is loaded onto control unit  20  which, when executed, implements the above operations. 
         [0078]    In use, conveyor  5  receives groups  3  of packaged containers from the upstream machine and feeds group  3  along direction X to conveyor  6 . 
         [0079]    In greater detail, conveyor  5  cyclically advances for a time interval t 1  and rests for a time interval t 2 , following the speed profile V 1  ( FIG. 5 ). 
         [0080]    More precisely, conveyor  5  moves for lengths A 1 , A 2 , A 3  for respective time intervals t 3 , t 4 , t 5 . 
         [0081]    At the same time, conveyor  6  moves at speed V 2 . 
         [0082]    Accordingly, when conveyor  5  stops, conveyor  6  continues to move at speed V 2 . 
         [0083]    In this way, conveyor  6  separates, one after the other, batches  2  from the remaining groups  3 . 
         [0084]    More precisely, each batch  2  is distanced from the remaining groups  3  still travelling onto conveyor  5  for gap D. 
         [0085]    The passage of groups  3  of each batch  2  on conveyor  6  is sensed by sensing means  16  which generate a corresponding signal. 
         [0086]    Control unit  20  receives the signal generated by sensing means  16  and updates the speed profile of conveyor  5 . 
         [0087]    In detail control unit  20  controls motor  7  in such a way that conveyor  5  and, therefore, each batch  2 , travels for a length L-F after sensing means  16  have detected the passage of the same batch  2  on conveyor  6 . 
         [0088]    In this way, it is ensured that the whole length L of each batch  2  is separated by conveyor  6  from the remaining groups  3  still travelling on conveyor  5 . 
         [0089]    In other words, conveyor  5  stops after the whole length L of each batch  2  has been separated by conveyor  6  from the remaining groups  3 . 
         [0090]    Furthermore, control unit  20  calculates length A 7  as: 
         [0000]      7= D− ( A 2− A 1)−( A 6 −A 5).
 
         [0091]    Batches  2  are manipulated onto conveyor  6  by manipulating means  9 , so as to form a layer of the pallet. 
         [0092]    Speed V 2  may be adjusted in dependence of the number of groups  3  fed to section  11  and of the number of groups  3  loaded on conveyor  5 . 
         [0093]    Due to the fact that motors  7 ,  8  are functionally connected by an electronic cam, speed profile V 1  varies as a result of the variation of speed V 2 . 
         [0094]    Gap D is set on the basis of the shape of layer  40  to be formed by manipulating means  9  and of the time required by manipulating means  9  to form the layer. 
         [0095]    From an analysis of the features of unit  1  and of method for forming layer  40   
         [0096]    made according to the present invention, the advantages it allows to obtain are apparent. 
         [0097]    In particular, layer  40  is formed on the same conveyor  6  onto which batches  2  are separated. 
         [0098]    Accordingly, unit  1  requires only two motors, namely motors  7  and  8 , for creating layer  40 . 
         [0099]    As a result, unit  1  is cheaper, less bulky and easier to maintenance than the known unit disclosed in the introductory part of the present description. 
         [0100]    Furthermore, sections  11 , 12  of conveyor  5  have different friction coefficients. 
         [0101]    Accordingly, section  11  is capable of containing the thrust of groups  3  which are accumulating thereon, and section  12  avoids that groups  3  slide, during the movement between section  12  of conveyor  5  and conveyor  6 . 
         [0102]    Finally, control unit  20  updates speed profile of conveyor  5  every time batch  2  is separated from the remaining groups  3 . 
         [0103]    In this way, conveyor  6  separates a batch  2  of exact length L, irrespective of the initial positioning of batch  2  on conveyor  5 . 
         [0104]    As a result, the inevitable errors in the initial positioning of batch  2  and the movement of batch  2  relative to conveyor  5  do not affect the effectiveness of the separation action carried out by conveyor  6 . 
         [0105]    Control unit  20  also calculates length A 7  on the basis of the required gap D and of the lengths A 1 , A 2 ; A 5 , A 6 . 
         [0106]    In this way, the differences in lengths A 1 , A 2  and A 5 , A 6 , which are due to the fact that the acceleration/deceleration of conveyor  5  at speed V 2  is not immediate, do not affect the precision in the formation of gap D between batches  2   
         [0107]    Finally, it is apparent that, modifications and variants not departing from the scope of protection of the claims may be made to unit I and method for forming layer  40  of batches  2  of groups  3 .