Abstract:
The invention relates to an object carrier comprising a two-dimensional array of receptacles for trays having n rows and m lanes, with n and m each being integers equal to or greater than 2. The object carrier includes a plurality of notch elements provided on one or two mutually parallel outer sides. The invention further relates to a packaging system comprising a packaging machine, a transport system, at least one processing unit, and several multi-row object carriers. Several stop systems are provided along the transport system and are configured to stop an individual object carrier in an intermittent mode at consecutive notch elements of the object carrier in order to have at least one row of trays be processed by the processing unit.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This Application claims priority to European Patent Application Number 15154871.6 filed Feb. 12, 2015, to Lars Ickert and Alireza Taghipour, currently pending, the entire disclosure of which is incorporated herein by reference. 
       FIELD OF THE INVENTION 
       [0002]    The invention relates to an object carrier and a packaging system. 
       BACKGROUND OF THE INVENTION 
       [0003]    Not yet published European Patent Application Number 14197424.6 discloses a packaging system with a packaging machine, a loading station for trays and a lifting station for sealed packages. Object carriers are provided that can each accommodate a plurality of trays. The object carriers are transported via conveyor belts from one station or packaging machine, respectively, to the other station. For example, all trays are loaded at a loading station into an object carrier while the latter is stopped at a designated position. Such an automated device for loading the trays is still somewhat inflexible in spite of all its advantages. 
       SUMMARY OF THE INVENTION 
       [0004]    One object of the present invention is to provide even more flexible and more efficient operation of such a packaging system. 
         [0005]    The object carrier according to one embodiment of the present invention comprises a carrier plate, a two-dimensional array of receptacles for packaging trays having n rows and m lanes, and is characterized in that the object carrier comprises a plurality of notch elements (or latch elements) that are provided at one or two outer sides during operation that is parallel to the intended direction of transport. Here, n and m are integers and are each at least 2. The object carrier may be stopped by way of the notch elements at different positions on a conveyor belt at a processing unit, so that the processing unit can consecutively treat an individual row or a group of adjacent rows of trays, respectively. This can reduce the cost and effort for the processing unit and increases flexibility, in contrast to simultaneous processing of an entire format consisting of several rows and lanes. 
         [0006]    By arranging the notch element on the outer sides parallel to the intended direction of transport, one notch element can be provided at each one of the n rows, since a row of receptacles, trays or packages of an object carrier is oriented transverse to a direction of transport. 
         [0007]    Receptacle is understood within the context of one embodiment of the present invention to be a depression or even an end-to-end opening into each of which a packaging tray can be inserted so that this tray, during transport by way of the object carrier, maintains a defined position on the object carrier. If the tray has an edge, a shoulder for example, can be provided within the receptacle or a web encircling the receptacle adjacent to the receptacle, on which the edges of the tray can rest. 
         [0008]    The carrier plate of the object carrier may have a length and width of at least 300 mm×300 mm. A thickness of 10 to 30 mm has proven to be advantageous. The carrier plate can comprise, for example, aluminum or stainless steel or even be made entirely of one of these two materials. 
         [0009]    It is conceivable that the notch elements are formed integrally with the carrier plate, for example, by a milling operation. 
         [0010]    The notch elements may be disposed on one or on both sides of the object carrier equidistant from one another, for example, at respective outer sides of the carrier plate of the object carrier. The distance between mutually adjacent notch elements on the same side of the object carrier preferably corresponds to the distance (for example, the center-to-center distance) of the receptacles of adjacent rows of receptacles or an integral multiple thereof. It is conceivable, for example, that the distance between adjacent notch elements corresponds to two or three times the distance between two rows of receptacles from reach other. 
         [0011]    In one embodiment, the object carrier comprises one notch element for every row in order to achieve a low structural complexity and low cost expenditure for the tools of the processing units. 
         [0012]    A centering element associated with every notch element can be provided in order to minimize or eliminate possible play of the notch element at a stop system by use of a centering device of the processing unit, so that maximum positioning accuracy can be obtained. The centering element may be a centering hole capable of cooperating with a centering pin in a structurally simple manner 
         [0013]    A packaging system according to one embodiment of the present invention comprises a packaging machine, a transport system, at least one processing unit and several multi-row object carriers, as described above, and may be characterized in that several stop systems are provided along the transport system and configured to stop an individual object carrier in an intermittent mode at consecutive notch elements of this object carrier in order to have at least one row of trays be processed by the processing unit. One advantage of this embodiment is a significantly reduced effort for retooling the processing units because only tools for processing one row of trays, products or packages need to be exchanged. The processing units do not need to comprise elaborate tools for large formats with several rows and lanes, but only for one row. 
         [0014]    The processing unit of the packaging system may be a tray loader, a filler, a product loader, a capper, a robot or a labeler. 
         [0015]    The packaging machine can be a tray sealer for sealing a top film onto trays that are located in the object carriers and filled with a product. Prior to sealing, the trays can further be evacuated and/or aerated to extend the shelf life of the products. 
         [0016]    In one embodiment, the processing unit comprises a centering device to align the object carrier by way of the centering element. An exact position of the object carrier or the row relative to the tool of the processing unit is thereby obtained. 
         [0017]    Other and further objects of the invention, together with the features of novelty appurtenant thereto, will appear in the course of the following description. 
     
    
     
       DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         [0018]    In the following, an advantageous embodiment of the invention is further illustrated using a drawing, where: 
           [0019]      FIG. 1  is a schematic perspective view of a packaging system according to one embodiment of the present invention; 
           [0020]      FIG. 2  is a perspective view of a stop system with an object carrier according to one embodiment of the present invention; 
           [0021]      FIG. 3  is a perspective view of a first embodiment of an object carrier; 
           [0022]      FIG. 4  is a perspective view of a second embodiment of an object carrier; 
           [0023]      FIG. 5  is a perspective view of a third embodiment of an object carrier; 
           [0024]      FIG. 6  is a plan view of a stop system in a standby position according to one embodiment of the present invention; 
           [0025]      FIG. 7  is a plan view of the stop system of  FIG. 6  in a working position; 
           [0026]      FIG. 8  is a plan view of the stop system of  FIG. 6  in a release position; 
           [0027]      FIG. 9  is a front view of a stop system in a standby position according to one embodiment of the present invention; and 
           [0028]      FIG. 10  is a front view of the stop system of  FIG. 9  in a working position. 
       
    
    
       [0029]    Same components are designated throughout the figures with the same reference numerals. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0030]    The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures. 
         [0031]    The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The present invention is defined by the appended claims and the description is, therefore, not to be taken in a limiting sense and shall not limit the scope of equivalents to which such claims are entitled. 
         [0032]      FIG. 1  shows a schematic view of a packaging system  1  according to one embodiment of the present invention with a tray sealer  2  and a transport system  3  having a direction of transport T. Provided downstream of tray sealer  2  in direction of transport T are processing units such as, for example, a labeler  4  for labeling finished packages, a removal device  5 , a loader  6  for trays in an object carrier  10 , a filler  7  and a loader  8 , for manually loading additional products or for placing a lid. By way of the transport system  3  comprising a plurality of conveyor belts  9 , the packaging system  1  may have a ring-like closed transport path for object carriers  10 . Based on a single conveyor belt  9 , T denotes the direction of transport of this conveyor belt  9  during operation. Based on the entire transport system  3  illustrated in  FIG. 1 , T denotes the direction of circulation of object carriers  10  along the entire ring-like closed transport system  3 . 
         [0033]    Each of processing units  4 ,  5 ,  6 ,  7 ,  8  can comprise a stop system  11 . Object carriers  10  can comprise three notch elements  12  that are in the direction of transport T on their left side  10   a , (i.e., on the side facing the inside of the ring-like closed transport path) so that stop system  11  stops object carrier  10  consecutively in an intermittent operation at individual notch elements  12  and thereby enables partial processing of a respective subgroup of trays  13  in object carrier  10 . This subgroup respectively contains all trays  13  in one, two or, for example, also three adjacent rows R of receptacles  14 . Exact positioning of trays  13  relative to processing units  4 ,  5 ,  6 ,  7 ,  8  may be achieved by associating notch elements  12  to stop system  11  and thereby to processing unit  4 ,  5 ,  6 ,  7 ,  8 . 
         [0034]      FIG. 2  shows a view of stop system  11  with object carrier  10  according to one embodiment of the present invention in a position in which notch element  12 , in the direction of transport T of conveyor belt  9  being the leading one, is stopped by stop system  11 , so that a respective processing unit  4 ,  5 ,  6 ,  7 ,  8 , presently not shown in more detail, can process the first row R of trays  13 , products, or already sealed packages. 
         [0035]      FIG. 3  shows a schematic view of an object carrier  10  having an array F with n=6 rows R and m=4 lanes S of openings  14  in a carrier plate  14   a . Each opening may be adapted to receive a package tray  13 , wherein each opening may constitute a receptacle  14 . Object carrier  10  shown in  FIG. 3  is therefore configured to receive twenty-four trays  13  in twenty-four receptacles  14 . Object carrier  10  can comprise two mutually parallel outer sides  10   a ,  10   b  which are here shown as two mutually parallel outer sides of carrier plate  14   a . Adjacent rows R of receptacles  14  are spaced at a distance A. As shown in  FIG. 3 , this distance A can be measured either as the center-to-center distance of two adjacent rows R, or as the distance between corresponding outer edges of receptacles A in two adjacent rows R. 
         [0036]    One notch element  12  may be provided for each row R on the left side  10   a  of object carrier  10  in the direction of transport T. Notch element  12  can be arranged at least approximately in alignment with the axis of symmetry a of rows R. A stop system  11  can stop this object carrier  10  for each individual row R to enable chronologically consecutive processing of individual row R of trays  13  by processing unit  4 ,  5 ,  6 ,  7 ,  8 . A centering element  24  may be provided for each notch element  12  in the region of notch elements  12  in the form of a centering hole for being positioned precisely by an associated centering device of processing unit  4 ,  5 ,  6 ,  7 ,  8 . Notch elements  12  on side  10   a  of object carrier  10  can be arranged equidistant from one another. In  FIG. 3 , adjacent notch elements  12  are spaced at a distance B which is presently identical to distance A between two rows R of receptacles  14 . 
         [0037]      FIG. 4  shows a second embodiment of object carrier  10 , where twenty-four receptacles  14  are also provided like in  FIG. 3 , but with only three notch elements  12 . In this embodiment, processing of two rows R or eight trays  13 , respectively, is intended by way of processing unit  4 ,  5 ,  6 ,  7 ,  8 . In this embodiment, the distance B between notch elements  12  is equal to twice the distance A between two rows R (i.e., B=2*A). 
         [0038]      FIG. 5  shows a third embodiment of object carrier  10  with a different geometric shape of individual tray receptacles  14  and a division of the array F of tray receptacles  14  with n=4 rows R and m=3 lanes S, (i.e., with a reception capacity of twelve trays  13 ). Like in  FIG. 3 , one notch element  12  can be provided for each row R. This division optionally enables either stopping individual rows R in rows for processing or also stopping every second notch element  12 , for example, where simultaneous processing of two rows R is intended. 
         [0039]      FIG. 6  shows a plan view of stop system  11  in the standby position for receiving notch element  12  of an object carrier  10  in the direction of transport T. Stop system  11  can comprise a return pawl  15  which is by way of a spring element  16 , presently illustrated as a spring plate, disposed on a frame  17  of stop system  11 . A limiting element  18 , likewise being mounted on frame  17 , can be provided to limit the motion of return pawl  15  in the direction of object carrier  10 . Stop system  11  can include a stop  19  that may be movable via a damping device  20  by notch element  12  of object carrier  10  in the direction of transport T, namely to the extent that notch element  12  is held without play between return pawl  15  and stop  19  in a working position, as shown in  FIG. 7 . 
         [0040]    During the transport motion of object carrier  10 , notch element  12  with its outer side  12   a  may push return pawl  15  away in the direction of the arrow such that spring element  16  experiences increased pre-tension. Once notch element  12  has moved in the direction of transport T with its outer side  12   a  past return pawl  15 , return pawl  15  may again move against the direction of the arrow back to the position in which return pawl  15  abuts limiter  18 . During the motion of notch element  12  along return pawl  15 , a front side  12   b  of notch element  12  may push against stop  19  and moves stop  19  against damping device  20  which decelerates this motion and brings it to a standstill nearly or directly at a stop  20   a  of damping device  20 . This position corresponds to the position at which outer side  12   a  of notch element  12  has left return pawl  15  and return pawl  15  springs back against the direction of the arrow ( FIG. 6 ) and notch element  12  can thereby be stopped and positioned almost without play or at least with a tolerance of about +/−0.3 mm, for example, relative to stop system  11  and thus to work station  4 ,  5 ,  6 ,  7 ,  8 . This is shown in  FIG. 7  in a plan view of stop system  11  in the working position. 
         [0041]      FIG. 8  shows a plan view of stop system  11  in a release position in which stop  19  was retracted by use of a pneumatic cylinder  21  into stop system  11  while withdrawing from object carrier  10  in the direction of the arrow in order to enable movement of object carrier  10  in the direction of transport T. Once notch element  12  has been moved past stop  19 , pneumatic cylinder may  21  push stop  19  against the direction of the arrow back to the working position when the next arriving notch element  12  of the current or a subsequent object carrier  10  is to be stopped for processing by processing unit  4 ,  5 ,  6 ,  7 ,  8 . A sensor  22  of stop system  11  can be configured such that it can detect whether a notch element  12  is located in its working position at stop  19 , and can also detect whether or not that notch element  12 , after stop  19  is moved away perpendicular to the direction of transport T, has left the movement region of stop  19 . In one embodiment, sensor  22  is able to detect the position of the notch element without being influenced by the presence or absence of stop  19 . For this purpose, for example, notch element  12  can be metallic and stop  19  can be formed from plastic. If, for example, an inductive or capacitive sensor is used as sensor  22 , then it alone detects the position of notch element  12 , unaffected by the presence or absence of stop  19 . 
         [0042]      FIG. 9  shows a front view of stop system  11  in the standby position in which stop  19 , like shown in  FIG. 5 , has not yet been moved to the right by a notch element  12  of an object carrier  10 .  FIG. 10  shows a front view of stop system  11  in the working position, in which stop  19 , like in  FIG. 7 , is moved to the right to the extent that notch element  12  (not shown in more detail in  FIGS. 9 and 10 ) is held between return pawl  15  and stop  19 . Sensor  22  is shown as disposed above stop  19 . Also conceivable is an arrangement of sensor  22  below stop  19  in order to be activated in a like manner by notch element  12 . 
         [0043]    A variant of object carrier  10  is also conceivable comprising notch elements  12  on two oppositely disposed sides, namely the outer sides in the direction of transport T being the right and the left sides, to be able to provide stop element  11  on different sides at different processing units  4 ,  5 ,  6 ,  7 ,  8 . The position of notch elements  12  of the two sides can differ from the orientation, for example, relative to the axes of symmetry A, of rows R. 
         [0044]    Each processing unit  4 ,  5 ,  6 ,  7 ,  8  can comprise its own controller; or a controller  23  of tray sealer  2 , as shown in  FIG. 1 , may control one or more stop systems  11  along transport system  2 , and optionally also one or more processing units  4 ,  5 ,  6 ,  7 ,  8 . 
         [0045]    Conveyor belts  9  shown in  FIG. 1  can have a uniform speed, where these conveyor belts  9 , for example, may be configured as link belts, or exhibit friction that allows object carriers  10  to be stopped by stop systems  11  while conveyor belts  9  continue to move along under object carriers  10  resting thereon. 
         [0046]    As an alternative to a stop  19  that is movable in the direction of transport T and acting together with a damping device  20 , a stop can also be provided in the direction of transport mounted on stop system  11  in a stationary manner. In such an embodiment, object carrier  10  is by way of the controlled speed of conveyor belt  9  in a decelerated manner driven against stop  19  in order to prevent products from spilling out from tray  13 , in particular liquid or pasty materials. 
         [0047]    From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and sub combinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting. 
         [0048]    The constructions and methods described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.