Patent Description:
One example of a packaging machine that packages articles, such as cans or bottles into a wrap-type carton is the Marksman® brand machines, including the Marksman® MMI6HS1 brand machine manufactured by Graphic Packaging International, LLC. Other types of packaging machines are especially adapted to package products into sleeve-type or fully enclosed cartons and into basket- type cartons, such as Graphic Packaging International, LLC's Quikflex® and Autoflex® machines. Many of these machines include one or more elongate conveyor systems or assemblies that extend from a carton blank feeder positioned at a first end or upstream section, to a second end or downstream section where the filled cartons or packs are discharged. The main conveyor moves articles, such as bottles or cans, and the carton blanks that become filled packs, through the machine toward the downstream or discharge end. Positioned along the main conveyor are various units or stations that incorporate the necessary components that perform required functions with the articles or the carton. For example, in packaging machines designed to process wrap-type cartons, at the upstream section the products are delivered adjacent to the machine in mass, and moved to an article or product selection station where they are grouped into desired configurations, such as a <NUM> by <NUM> article group, a <NUM> by <NUM> group, <NUM> by <NUM> group or a <NUM> by <NUM> group of articles. Other group configurations are possible. In a machine that packages articles in a wrap-type carton, a carton blank feeder delivers carton blanks, one at a time, to a station that wraps the blank around a formed article group, such as a group of six articles (a "<NUM> pack") arranged in a <NUM> x <NUM> configuration. These wrap-type carton blanks have a locking assembly, typically tabs and either slits or holes, that cooperate or engage with one another on opposite bottom edges of the carton to close the wrap-type carton blank around the article group. All of these functions occur while the article group is moving continuously in the downstream direction on a main conveyor. Another element, such as a wheel or cam surface can tuck carton flaps to secure the articles into a filled pack. After the carton blanks are wrapped around the product group in this manner, the group is held securely within the now formed and filled carton or pack. As used herein the term "carton blank" refers to either a flat blank or to a carton blank that has been partially constructed, for example by gluing, especially as in sleeve-type and basket-type carton blanks. The term "carton" or "pack" refers to a carton blank that has been fully assembled either around or that contains the articles.

Various Marksman® brand packaging machines have been developed by Graphic Packaging International, LLC and are in commercial use. These machines include features such a product diverter station positioned at the downstream end of the machine, that can divert a packaged carton group or pack into selected lanes for a variety of purposes, such as to direct packs to an area for palletizing. Some packs that do not meet the pack quality requirements are diverted to a pack reject lane. Some Marksman® brand machines also include a pack turning unit that turns or reorients the pack as it is in continuous motion through the machine in the downstream direction. For example, <CIT>, assigned by the current applicant, discloses a packaging machine having a main rod-type conveyor system that supports a slat bed, and a filled a pack turner assembly that is at least in part positioned below the main machine conveyor system. A pack divider section also is disclosed. The turner/divider unit disclosed in <CIT>, for example, includes pins that extend downwardly from the slats riding on the rod-type continuous motion conveyor, and also pins that project upwardly to contact the sides of the pack. A main conveyor extends essentially the length of the packaging machine downstream of a feeder to the collection tray or to another conveyor. A cam track positioned below the main conveyor and the slats receives the downwardly extending pins to facilitate turning the pack on the slats. The divider section is positioned downstream of the turner unit. Other types of turning units or stations in packaging machines also are well known, including overhead turning units that contact and turn the carton from above the main conveyor using a turner head that engages the top portion of the moving pack, which is then rotated by the overhead assembly. This is shown, for example in <CIT>. Prior machines also have used the method of turning the pack from below using two different speed belts or conveyors. Principally underside turning is also known that includes pins on slats, as shown in <CIT>. This Marksman® brand machine that includes a pack diverter unit or station is capable of moving the packs transversely with respect to the longitudinal direction of operative movement of the main rod conveyor in order to place each pack in the proper position or lane for exiting the machine. Carton blanks adapted to wrap around an article group and machine elements to accomplish that are well known, as shown in <CIT> and <CIT>, both owned by Graphic Packaging International, LLC, the present owner of the inventions disclosed herein. <CIT> discloses a product control apparatus includes means for conveying products along a path, and means for engaging a product to change the orientation of the product relative to the conveying means. The means for engaging the product are selectively operable such that a product conveyed along the path may be turned independently of other products conveyed along the path as set in a product turning sequence. Furthermore, <CIT> discloses a wrap-around cartoner with inter alia a sheet supply means and article supply means which supplies a batch of accumulated articles. The prior art, however, still leaves room for improvement. According to various aspects disclosed herein, the invention is generally directed to a packaging machine for packaging articles into cartons and methods, as recited in the independent claims. Further embodiments are recited in the dependent claims.

The present invention includes improvements over known packaging machines, the turning assemblies for continuous motion packaging machines, and the method of packaging and turning the packs. The invention disclosed herein utilizes pack turning assemblies having flight drive assemblies positioned on each side of the main conveyor downstream of the article wrapping station where the articles are secured into the carton or pack. This flight drive assembly includes elements, such as flight assemblies having turner rods. Each flight assembly includes turner rods to contact the two sides of a filled carton, or pack, in locations on the sides of the packs that are both upstream and downstream, respectively of the pack center point (top wall center point) as viewed from above the pack. This contact with the turner rods extending progressively transversely to the main conveyor direction and opposing flight drive assemblies will push and so turn the pack on top of the slats. In this operation, the distal ends of the turner rods extend past the pack side walls before being retracted. This extension of the turner rods controls the turning of the pack, especially at high speeds of, for example, <NUM> packs per minute, and keep the packs from overturning, or turning past the desired amount as shown herein. During the contact of the turner rods with the pack, the flight assemblies that are contacting the moving packs are also being driven progressively in the downstream direction in timed relationship with the packs, which direction is in the downstream moving direction of the main conveyor. The turner rods eventually are retracted and removed from contacting the pack, and driven by drive belts upstream with respect to the conveyor direction, that is, in the opposite direction of the top of the main conveyor that supports the packs, to a starting position to again contact and turn another pack. This upstream movement occurs after the packs have been turned, and the turner rods release contact with the moving packs. The push rods or turner rods are mounted to flight assemblies that travel on belts or chains around the flight drive assembly that supports the belts and allow the belts to move the flight assemblies in timed relationship to the packs moving downstream on the main conveyor during the turning phase of the pack. Numerous flight assemblies spaced at desired locations are carried on the flight drive assembly. For example, with a packaging machine operating to fill approximately <NUM> six packs in a <NUM> x <NUM> arrangement per minute, there can be <NUM> flight assemblies on each flight drive assembly. More or less flight assemblies can be included on the flight drive assemblies, depending upon factors such as machine/conveyor speed and pack size and configuration. After the flight assemblies release contact with the respective pack, those flight assemblies are driven back in the upstream direction relative to the conveyor's operative movement to a starting position, in order to repeat the process on another pack.

Each turner rod can be driven inwards and outwards, toward and away from the centerline of the main conveyor. There are identical flight drive assemblies and flight assemblies of the pack turning assembly that are positioned across from each other along the main conveyor at the desired position to turn the pack, that is, typically between the carton blank wrap station and the diverter station and pack accumulation area. If a pack diverter station or unit is included, that diverter unit is position adjacent to the machine discharge end, downstream of the turner unit. The flight drive assembly moves each flight assembly by a drive belt in a path around the elongate flight drive assembly as discussed herein, so that a flight assembly can be positioned to turn a pack, and then moved around the downstream end of the flight drive assembly and then back in an upstream direction to operatively engage another pack as it moves downstream. A turner rod in its operative position in one embodiment of the flight assembly extends toward the pack and is positioned to contact the pack forward or downstream of the pack center point, as defined herein, as the pack moves downstream while the pack is resting on slats. The second or opposite flight drive unit, that is positioned on the opposite side of the main conveyor from the first flight drive unit and also carrying identical flight assemblies, includes cooperating turner rods that extend transversely toward the first flight drive assembly. This second flight drive assembly cooperates with and is timed with a corresponding flight assembly of the first flight drive assembly so that an opposite turner rod of the second flight assembly contacts the same pack rearward or upstream the pack center point. These cooperating turner rods on flight assemblies of opposing flight drive units are positioned so that the space between the respective rods is approximately equal to a pack width, as measured along the pack's shorter side dimension. In, for example, a <NUM> x <NUM> article configured carton that has a shorter side dimension and a longer side dimension, the turner rods contact the pack approximately a pack width both upstream and downstream from the pack center point. In a pack that holds articles in a <NUM> x <NUM> arrangement, the pack exits the carton wrapping assembly with the shorter dimension of the pack oriented downstream. This orientation has the <NUM> articles leading the pack in the downstream direction, along the longitudinal path of the main conveyor as the pack approaches the pack turner station. A carton pitch station, that includes two pitch drive assemblies having chains or belts that carry spaced lugs in order to create the proper longitudinal distance or pitch between successive packs, include pitch drive assemblies on opposite sides of the main conveyor. The pitch drive assemblies move the spaced lugs faster than the main conveyor speed, so that a lug from each pitch drive assembly contacts a pack simultaneously to accelerate that pack on the slat bed, and so create the proper carton pitch. This carton pitch station is positioned along the main conveyor between the pack wrapping station and the pack turning station.

As the flight assemblies continues to extend the opposing and cooperating turner rods towards the centerline of the main conveyor, to turn the pack, the pack eventually is rotated approximately <NUM> degrees. After the pack is turned by the cooperating turner rods, the pack now is oriented on the slat bed of the main conveyor with the <NUM> article side facing in the transverse direction to the longitudinal path of the main conveyor, and the <NUM> article side facing forward or downstream as the pack continues to move toward the machine's discharge end. Once the pack is fully rotated, the opposing push rods then remain in contact with the upstream side or side wall and the downstream side or side wall, respectively, of the pack, while the pack still is moving downstream on the slat bed by the main conveyor and toward the diverter station adjacent the discharge end of the machine. In this position, the cooperating push rods now stabilize the pack as it continues to move downstream and prevent over turning. The turner rods are then removed from contacting the carton as described herein, or mechanically retracted transversely and away from the conveyor's longitudinal centerline. Such retraction of the turner rods will withdraw these turner rods from an operative position in order to not interfere in the transfer of the pack to the diverter station or machine discharge area.

The flight drive units positioned opposing one another on each side of the main conveyor can be driven together by a mechanical drive take off from the main machine drive assembly. Otherwise, the flight drive units can be driven separately, in timed relationship, by separate drive assemblies using either conventional, such as mechanical drives from the main machine drive, or by separate servo motors that are timed with the movement of the main conveyor. Either way the flight drive assemblies are actuated, the drive which is utilized permits the timing of the push rods to the moving pack. Each type of flight drive assembly also is adjustable in order to allow for the flight assemblies and the push rods to be selectively positioned along the flight drive assemblies at various positions to contact the moving pack in the desired areas forwardly and rearwardly of the pack center, regardless of the size or dimensions of the pack. As referenced herein, the number of flight assemblies is determined by the pack dimensions and speed of the main conveyor , the number of filled packs per minute, such as in the example above. As with either a conventional drive, that is mechanical drive from the main machine, or with a servo drive, the drive for the flight drive assemblies can incorporate a common head shaft. However, if separate drives and head shafts for each flight carrying unit, better pack clearance and access to the carrying unit may be accomplished.

In another embodiment of the present invention, an additional turner rod or rods, such as two spaced, parallel turner rods on each flight assembly, both extending toward the conveyor centerline and the article pack, may be utilized on each flight assembly in order to pre-turn the article packs. This embodiment is useful, for example, to rotate packs that are square and so having sides or side walls of equal dimensions, such those wrapped around and carrying articles in a <NUM> x <NUM> or a <NUM> x <NUM> arrangement. In this embodiment, one of the two rods is moved forward of its companion rod on the flight assembly in order to contact the pack side wall before the adjacent rod on that flight assembly contacts the pack side wall. This effectively allows for pre-turning of the square pack by one of the pair of rods and the adjacent rod to complete the pack turn. These rods also can be controlled to move both toward and away from the main conveyor centerline (that is in the 'inward' direction and the 'outward' or transverse direction, respectively), to accomplish the pre-turning and proper positioning or squaring of the carton on its slat bed.

The present invention discloses a continuous motion packaging P machine having a carton or pack station turning T (<FIG>). The present invention is described herein for use in packing machines designed to package articles in a wrap-type carton, such as the Marksman® brand packaging machine referenced herein. It is possible, however, for such a turning unit to be employed with other types of packaging machines, such as those adapted to place articles into a sleeve-type carton or a basket-type carton if desired. For the purposes of disclosing the present description, however, a packaging machine adapted to package articles in a wrap-type carton is discussed.

The packaging machine P includes any well-known article input station (not shown) where the articles <NUM> (<FIG>) are delivered in mass and then grouped onto slats S supported by the main conveyor C into the desired article configuration. The article group typically is comprised of cans or bottles, that are glass or plastic, but can include any articles <NUM> that can be placed into a wrap-type carton, a sleeve-type carton or a basket-type carton. The cartons or packs <NUM> can be comprised of paperboard, but also can be of any suitable natural fiber or synthetic material. The various types of packaging machines, including those referenced herein, typically include a carton blank feeder F that is positioned at the upstream end <NUM> of packaging machine P, which also corresponds with the upstream end of a main conveyor. The main conveyor C runs essentially the length of the packaging machine from upstream end <NUM> adjacent to the carton feeder, to a downstream end <NUM> adjacent to an accumulation or delivery area (not shown). The pack <NUM> accumulation area receives the fully loaded or packed cartons. As shown in <FIG> and described in <CIT>, there also can be an article diverter unit D downstream or adjacent to the machine end <NUM>. Otherwise, the filled packs can be received upon a dead plate or other conveyor separate from the main conveyor C, downstream of end <NUM> without pack diverting, for movement away from the end <NUM> of the packaging machine P. Generally a number of the grouped packs are palletized. A carton blank wrap station (not shown) receives individual blanks B from feeder F and wraps the carton blank B over the article group, as is well known. As discussed herein, the "transverse direction" is normal to the longitudinal direction of conveyor C, which downstream, longitudinal direction of the main conveyor is indicated by arrow A. The longitudinal centerline of the conveyor C runs through the center point of the conveyor C, measured transversely, and is parallel to the side edges of the conveyor C. Conveyor C is a looped conveyor, and so the conveyor will be moved back upstream, under the top of the conveyor as shown in <FIG>, after it delivers the packs <NUM> to the accumulation area. <FIG> also shows the slat bed, or slats S, attached to and carried by the main conveyor C in order to support the filled cartons or packs <NUM>.

In a Marksman® brand wrap-type machine, the wrap station (not shown) receives the carton blank B and places or wraps the blank over the article group to secure the articles into the locked pack <NUM>. This process is accomplished continuously and sequentially during operation of the packaging machine P. In these wrap-type packaging machines that package the articles <NUM>, in, for example, a <NUM> x <NUM> arrangement having two shorter side edges (the "<NUM> by" article sides) and a longer side edges (the "<NUM> by" article side), the leading or downstream side of the packaged carton <NUM> as the carton moves in the downstream direction, arrow A, immediately away from the carton blank wrap unit W is that end of the carton surrounding two articles <NUM> of the group (the "<NUM> by" article side). <FIG>, illustrates packs <NUM> in a <NUM> x <NUM> article (cans) arrangement having opposing shorter sides that are partially open, opposing longer sides and a top wall or side as the carton leaves the wrap station and moves on conveyor C into the pack turning assembly T. The packs <NUM> also include a bottom wall or side (not shown) that in wrap-type cartons includes the carton locking arrangement. The leading side of pack <NUM> in this position, therefore, is the shorter side of the pack, as measured in the transverse direction to the longitudinal centerline of the main conveyor. The longer side of the carton or pack in this position containing this <NUM> x <NUM> arrangement therefore extends along the longitudinal direction, or direction of flow of the main conveyor along arrow A as the carton leaves the carton wrap station. It is desirable, however, in some instances then to rotate the loaded carton approximately <NUM> degrees so that the longer side (the "<NUM> by" article side in a <NUM> x <NUM> article configuration) leads in the direction of arrow A after wrapping station W and prior to its delivery to the diverter unit or to a pack accumulation area (not shown). This second orientation, following pack <NUM> rotation, can facilitate pack <NUM> handling as the packs are gathered for palletizing.

The present invention includes a pack turning assembly or station T positioned along the conveyor C between the carton wrap station (not shown) and the pack diverter area <NUM> or the article accumulation area (not shown) that is downstream of the pack diverter area <NUM> (<FIG>). The pack turning assembly T includes opposed flight drive assemblies <NUM> and <NUM> (<FIG>) spaced along the main conveyor C, with flight drive assembly <NUM> on the left side of the main conveyor C and flight drive assembly <NUM> on the right side of the main conveyor C, as viewed in the downstream direction. The flight drive assemblies <NUM> and <NUM> are positioned opposite one another on each side of the main conveyor C, such as the rod conveyor disclosed in <CIT> referenced herein. These flight drive assemblies <NUM> and <NUM>, however, can be located in any available position of packaging machine P after wrapping station W and before the diverter station or the pack accumulation area.

Continuous motion packaging machines typically include a frame <NUM> that supports the main conveyor C (<FIG>). The frame <NUM> can support components of the packaging machine both from below the machine conveyor C and from above the conveyor C as shown in <FIG>. The main conveyor C either is driven from a gear or pulley take-off of the main machine drive, or by separate servo motors, as is well known. As discussed herein, the flight drive assemblies <NUM>, <NUM> are timed with the movement of the main conveyor C. The flight assemblies <NUM>, <NUM> (<FIG>) are themselves adjustable along the length of the flight drive assemblies <NUM>,<NUM>. The conveyor C in one example of the present invention is the same type of rod conveyor pulled or carried by chains connected to each end of the transversely extending, parallel rods, as disclosed in <CIT>. The conveyor C carries a series of slats S between each transverse conveyor rod <NUM>, which slats S are designed to support and carry respective packs of articles above rods <NUM> toward the discharge or downstream end <NUM> of the conveyor C and toward a collection tray or an article diverter unit. Since the slats are attached to the conveyor C between the parallel conveyor rods <NUM>, the slats S can move with conveyor C around the head drive shaft (not shown) and the tail drive shaft (not shown). The conveyor C, therefore, is driven from the machine upstream end <NUM> and toward the machine downstream end <NUM>, to convey both articles <NUM> and packs <NUM> along a downstream longitudinal path of travel in the direction of arrow A toward the downstream end <NUM>. Various other units or stations can be supported by frame <NUM> on one or both sides of the main conveyor to accomplish tasks, including grouping articles, effecting placement of articles into a carton, and tucking or folding various parts of the carton.

At the upstream end <NUM> of the conveyor, the carton blank feeder F picks carton blanks B, one at a time, from a carton supply magazine M. Also positioned at or near the upstream end <NUM> of the machine is an article grouping station (not shown) that places articles <NUM> in a desired grouping configuration onto the main conveyor. Such article grouping stations are well known. The article group is conveyed to a wrap station (not shown) downstream from the article grouping station. This carton wrap station receives a carton blank B from the carton blank feeder F, places the carton blank over and around the article group, and locks the wrap-type carton blank B around the article group to form an enclosed carton or pack <NUM> filled with articles <NUM>. Often such filled packs <NUM> have one or both of the shorter end sections at least partially open, with some flaps tucked downwardly or inwardly into the pack <NUM> to stabilize the article group within the pack.

The filled packs <NUM> of articles <NUM> then are moved on the conveyor slats S further downstream toward a discharge end <NUM> of the machine. In the case of a wrap-type pack <NUM> with the articles in a <NUM> x <NUM> configuration or any configuration having longer side edges and shorter side or end edges, at this position before the packs are turned, a shorter side edge of the carton (<FIG>) is the leading or downstream side in the direction of the main conveyor direction of movement, arrow A. These packs <NUM> then consecutively and continuously pass through pack turning station T.

The turning assembly or station T of the present invention, however, differs from the turning assembly disclosed in <CIT>, in that the packaging machine P of the present invention includes a different method and apparatus for turning the packs <NUM>. The turning method and apparatus disclosed in <CIT> is not utilized in packaging machine P of the present invention. Fight drive assemblies <NUM> and <NUM> function cooperatively to turn the filled pack <NUM> as the packs are moved continuously toward the downstream end <NUM> by conveyor C. The packs <NUM> of <FIG> are <NUM> x <NUM> packs with longer and shorter sides. Each of these assemblies, <NUM> and <NUM>, have identical elements, except for the exact shape of their respective cam tracks, as shown and discussed herein. <FIG> shows the bottom view of flight drive assemblies <NUM> and <NUM>, and includes the downstream directional arrow A, the downstream moving direction of conveyor C. Flight drive assembly <NUM> (on the left side of conveyor C, as shown in <FIG>) includes several flight assemblies <NUM> spaced from one another (<FIG>), although for illustration in <FIG>, only one complete flight assembly <NUM> is shown. Flight drive assembly <NUM> (on the right side of conveyor C, as shown in <FIG>) also includes several flight assemblies <NUM> spaced from one another, although for illustration, also only one complete flight assembly <NUM> is shown in <FIG>. The flight assemblies <NUM> and <NUM> include linear bearings, rods and shafts commercially available from PBC Linear of Rockford, Illinois.

<FIG> and <FIG> show flight drive assemblies <NUM> and <NUM> in exploded or partially exploded views. Each flight drive assembly supports upper and lower beds that define cam tracks therein, head and tail gears that pull belts to move the flight assemblies and to which each flight assembly is attached, and the necessary frame elements to support these components. As discussed herein, these principal components drive the flight assemblies that include turner rods, from a starting position and then progressively moved in the downstream direction, beneath and across a lower plate that includes a first cam track. This cam track of the lower plate causes the turner rods to be moved toward and away from the pack <NUM> and longitudinal centerline of conveyor C. The flight assemblies then are further driven around a head or drive gear and thereafter in the upstream direction, across an upper plate that also includes a differently shaped, second cam track that further actuates and retracts the rods until the flight assemblies are moved around a tail drive gear and to their initial starting position. The cam tracks defined by each plate of flight drive assemblies <NUM> and <NUM> are further discussed herein. The positioning and use of several, spaced flight assemblies <NUM> and <NUM> that are driven by each flight drive assembly accomplishes the sequential turning or rotation of consecutive packs <NUM> moving through turning assembly T. This sequential turning of continuously fed packs is due to the actuation of the cooperating and opposing turner rods. This turning is accomplished continuously from turning the first contact if the turner rods until the pack is fully rotated, approximately <NUM> degrees, with certain phases illustrated in <FIG> on consecutive packs <NUM>, and is timed with the movement of the packs <NUM> downstream on conveyor C.

In <FIG>, flight drive assembly <NUM> (shown in a top, exploded view) includes frame assembly <NUM>' that supports upper plate <NUM>', lower plate <NUM>' and pulleys or gears <NUM>', <NUM>', <NUM>' and <NUM>'. Similarly, flight drive assembly <NUM> includes frame assembly <NUM> that supports upper plate <NUM> lower plate <NUM> and gears or pulleys <NUM>, <NUM>, <NUM> and <NUM>. While the components of frame assemblies <NUM> and <NUM>' of the present invention are shown in <FIG>, those skilled in the art understand that the frame assemblies <NUM> and <NUM>' could include other elements, as long as the respective upper and lower plates and the gears of each flight drive assembly are appropriately supported. <FIG> illustrates another exploded view of flight drive assemblies <NUM> and <NUM>. In <FIG>, flight belts <NUM> and <NUM> also are shown on flight drive assembly <NUM>. Flight belt <NUM> loops around pulleys or gears <NUM> and <NUM>, while flight belt <NUM> loops around gears <NUM> and <NUM>. The flight drive assemblies <NUM> also include a flight belt (not shown) looped around gears <NUM>' and <NUM>', and another flight belt (not shown) looped around gears <NUM>' and <NUM>' just as with flight drive assembly <NUM>. The gears <NUM>' and <NUM>' are connected by a head or drive shaft <NUM>, and gears <NUM>' and <NUM>' are connected by a tail shaft <NUM>'. Pulleys or gears <NUM> and <NUM> are supported by tail shaft <NUM>'. Curved sweeps, such as sweeps <NUM> and <NUM>', preferably are mounted to each frame assembly adjacent to and spaced from pulleys or gears <NUM>, <NUM>, <NUM>' and <NUM>' to protect the flight assemblies <NUM> and <NUM> as they are driven around these pulleys. Head shaft <NUM> also carries an adjusting pulley or gear <NUM>, so that shaft <NUM> can be rotated using gear <NUM> when the flight drive assembly <NUM> is in a stopped mode, in order to adjust the belts (not shown) around the gears of assembly <NUM> either in the upstream or the downstream directions, as desired, and thereby adjust the starting and pack <NUM> engaging positions of the flight assemblies carried by those belts, as discussed herein. The use of such adjusting gears to position a shaft and accompanying drive gears is well known.

Similarly, gears <NUM> and <NUM> of flight drive assembly <NUM> are connected by head or drive shaft <NUM>. An adjusting pulley or gear <NUM> is carried by head shaft <NUM> so that the shaft <NUM> can be rotated using gear <NUM> when the flight drive assembly <NUM> is in a stopped mode. Shaft <NUM> and gears <NUM> and <NUM> thereby can be rotated, adjusting the longitudinal positions of belts <NUM> and <NUM> around the gears of assembly <NUM>. This adjustment of the belts <NUM> and <NUM> will change the starting and engaging positions of each of the flight assemblies <NUM> carried by those belts, identically as discussed with the belts of flight drive assembly <NUM>. The flight drive assemblies also can be driven either by servo motors connected to drive shafts <NUM> and <NUM>, respectively, or by a mechanical drive take off D (<FIG>) from the main machine drive (not shown) so that the flight drive assemblies <NUM> and <NUM> are moved in timed relationship with conveyor C. In <FIG>, shown with top plates <NUM>, <NUM>' removed and not shown, which is taken along cross-section <NUM>-<NUM> of <FIG>, frame assemblies <NUM>, <NUM>' that are utilized to support the cam plates are depicted. As discussed herein, however, any suitable frame for the flight drive assemblies that will support the elements of those flight drive assemblies, including the cam plates, pulleys and flight assemblies.

As shown in <FIG>, flight assembly <NUM> of flight drive assembly <NUM> is connected to belt <NUM> at one end and belt <NUM> an its opposite end, so that assembly <NUM> is moved or driven by belts <NUM> and <NUM>, with belt <NUM> being driven around pulleys or gears <NUM>' and <NUM>', and belt <NUM> being driven around pulleys or gears <NUM>' and <NUM>'. Belts <NUM> and <NUM> are driven together by drive shaft <NUM>. Also, flight assembly <NUM> is connected to belt <NUM> at one end and belt <NUM> an its opposite end, so that assembly <NUM> is moved or driven by belts <NUM> and <NUM>, with belt <NUM> being driven around gears <NUM> and <NUM>, and belt <NUM> being driven around gears <NUM> and <NUM>. Belts <NUM> and <NUM> are driven together by drive shaft <NUM>. As <FIG> shows the drive assemblies <NUM>,<NUM> from a bottom view, the flight assemblies <NUM>,<NUM> are driven in the direction of arrow A, the main conveyor direction as it moves the packs in the downstream direction. Flight assembly <NUM> and flight assembly <NUM> include identical elements and features. Assembly <NUM> includes flight shafts <NUM> and <NUM>' (<FIG>,<FIG>) which are mounted by pins or other similar elements to belts <NUM> and <NUM> near to their opposite ends <NUM>, <NUM>, and <NUM> and <NUM>.

The flight shafts <NUM> and <NUM>' pass thorough a block, such as bearing block <NUM> that contains the liner bearings referenced above, so that block <NUM> can slide along the flight shafts both toward and away from the conveyor C longitudinal centerline and toward and away from flight drive assembly <NUM>. <FIG> shows an exploded view of a flight assembly <NUM> with the block <NUM> separated from rods <NUM> and <NUM>' for illustration. Block <NUM> generally is triangular-shaped and defines an enclosed channel <NUM> along its length on one side (<FIG>). Flight shaft <NUM> is received within channel <NUM>. The side of block <NUM> that defines channel <NUM> is the downstream side of the block <NUM> as the block <NUM> moves across and beneath plate <NUM>' in the downstream direction, arrow A. Block <NUM> also defines a second, but open channel <NUM> at the opposite side from channel <NUM>, as shown in <FIG>. Flight shaft <NUM>' is received within channel <NUM>. Channel <NUM> therefore is "C-shaped" with an open side <NUM> facing in the upstream side of the block <NUM> as the block <NUM> moves beneath and across plate <NUM>' in the downstream direction, arrow A. Flight assembly <NUM> also includes a turner rod <NUM> that mounted by pins or other suitable elements to linear block <NUM> along its top side <NUM> through holes <NUM> and <NUM>. Turner rod <NUM> defines a free or distal end <NUM> extending toward flight drive assembly <NUM>, which end <NUM> preferably is not flat, but a tapered shape such as being rounded, to facilitate the type of contact with and turning of a pack <NUM>, as discussed herein. The turner rods could be any cylindrical shape with a hemispherical end out of any material or a rectangular shape with a distal end having a curve or radius. The distal end <NUM> of the rod can have a plastic tip to facilitate smooth contact and movement against a pack <NUM> side. As the block <NUM> slides on flight shafts <NUM> and <NUM>' as described herein, the turner rod <NUM>, being attached to block <NUM>, also moves both toward and away from the conveyor C centerline and toward and away from flight drive assembly <NUM>. A cam follower <NUM> (<FIG>) extends upwardly from liner block <NUM> and is received within a cam track <NUM> of bottom or lower plate <NUM>' in this view.

Flight assembly <NUM> includes flight shafts <NUM> and <NUM>' that are identical to flight shafts <NUM> and <NUM>' (<FIG>) that are mounted by pins or other similar elements to belts <NUM> and <NUM> near to their opposite ends identically to the mounting of flight shafts <NUM> and <NUM>' to belts <NUM> and <NUM>. Flight assembly <NUM> also includes a block <NUM>. Channel <NUM> defined by linear block <NUM> of assembly <NUM> receives flight shaft <NUM> while channel <NUM> having open or "C-shaped" side <NUM> receives flight shaft <NUM>'. Assembly <NUM> also includes a turner rod <NUM> mounted to block <NUM>, identically to the mounting of turner rod <NUM> of flight assembly <NUM>. As with flight assembly <NUM>, the side of block <NUM> that defines channel <NUM> of assembly <NUM> is the downstream side of the block <NUM> as the block <NUM> moves beneath and across plate <NUM> in the downstream direction, arrow A. The open and opposite side <NUM> of block <NUM> of assembly <NUM> therefore faces in the upstream side of the block <NUM> as the block <NUM> moves beneath and across plate <NUM> in the downstream direction, arrow A. The free or distal end <NUM> of turner rod <NUM> of assembly <NUM> extends toward flight drive assembly <NUM>. The end of turner rod <NUM> as shown in <FIG>, however, is not rounded but is tapered on opposite sides at end <NUM>, which tapered end also facilitates the turning of a pack <NUM>. As the linear block <NUM> slides on flight shafts <NUM> and <NUM>' (or <NUM> and <NUM>' in assembly <NUM>) as described herein, the turner rod <NUM>, being attached to block <NUM> of flight assembly <NUM>, also moves both toward and away from the conveyor C centerline and toward and away from flight drive assembly <NUM>. As flight assembly <NUM> passes beneath and across lower plate <NUM>, assembly <NUM> also includes a cam follower <NUM> extending upwardly from its block <NUM> and is received within a cam track <NUM> of bottom or lower plate <NUM>. <FIG> shows cam follower <NUM> of flight assembly <NUM> being driven in the direction of arrow A within cam track <NUM>.

As stated above, the drive pulleys or gears <NUM>, <NUM>, <NUM>' and <NUM>' of the flight drive assemblies <NUM> and <NUM> can be driven by servo motors (not shown). For example, there can be ten flight assemblies <NUM>, <NUM> equally spaced apart associated with each flight drive assembly, <NUM>,<NUM> and moved in timed relation to the conveyor C speed so that an assembly <NUM> and <NUM> are positioned to contact and turn each consecutive pack <NUM> as it moves through turner assembly T. More or less flight assemblies <NUM>, <NUM> can be utilized, depending upon the conveyor C speed and spacing of packs <NUM> along the conveyor.

<FIG> shows a plan view of a turner assembly T with packs <NUM> consecutively moving along conveyor C in the downstream direction of arrow A between flight drive assemblies <NUM> and <NUM>, respectively. When viewed from above (<FIG>) the drive belts <NUM>, <NUM>, <NUM>, and <NUM> are driven in the upstream direction of arrow A', opposite the direction of arrow A when pulled across upper plates <NUM> and <NUM>'. The turner rods <NUM> of the flight assemblies <NUM> and <NUM> move progressively toward the conveyor C centerline as they are driven back upstream in the direction of arrow A', opposite arrow A. (<FIG> shows the profiles of cam tracks <NUM> and <NUM>'). As the flight assemblies <NUM>,<NUM> move around their respective head or drive gears and are positioned just over the downstream end of upper or top plates <NUM>,<NUM>', the ends <NUM> of the turner rods <NUM> are positioned the furthest from the conveyor C centerline. In this position, turner rods <NUM> and are positioned or retracted away from successive packs as the flight assemblies are driven to the initial starting position. As also shown in <FIG>, the pack <NUM> enters the turner assembly T with its shorter side, or "<NUM> by" side, in the downstream direction along conveyor C.

As discussed further herein and shown in <FIG>, the flight shafts <NUM> of each flight assembly <NUM>,<NUM> on opposed flight drive assemblies <NUM>, <NUM> are actuated as they are driven beneath and across lower plates <NUM>, <NUM>' to extend towards pack <NUM> to contact pack <NUM> and assist in turning the pack. As the pack <NUM> moves further downstream through turner assembly <NUM>, each flight assembly <NUM>, <NUM> is driven around their respective tail gears <NUM>, <NUM>', <NUM> and <NUM>' as described herein, and actuated by the engagement of cam followers <NUM> in respective cam tracks <NUM>, <NUM>' defined in plates <NUM> and <NUM>', respectively to move back away from the contacted pack <NUM> and be driven by its flight drive assembly back to a starting position, where the process is repeated. As the packs <NUM> exit the turner assembly, the longer or "<NUM> by" side of the <NUM> x <NUM> configured pack <NUM> now is positioned in the downstream direction indicated by arrow A.

<FIG> also shows adjacent flight assemblies <NUM>, <NUM> spaced along belts <NUM>, <NUM>, <NUM> and <NUM>. The flight shafts <NUM> of adjacent flight assemblies are adjustable relative to each other, and so can be adjusted to have two product diameters (for example, can diameters) between them by adjusting one or other of the drive pulleys by adjusting gears <NUM> and <NUM>, respectively. In the case of standard U. sized, <NUM> ounce beverage cans, the width dimension of a standard U. beverage can approximately <NUM> inches. The servos or mechanical take-offs driving the drive pulleys or gears then is timed to the parent machine conveyor C so the midpoint of the width between the pair of adjacent turner rods <NUM> is at the center point of the pack <NUM> along its upper side and center point of the machine pitch, which pitch is equal to the distance in the longitudinal direction, between center points of adjacent packs <NUM> passing through turner assembly T.

<FIG> show a plan view of turner assembly T, with the orientation of pack <NUM> progressively changing by rotation of packs <NUM> on slats S from the upstream end to the downstream end of assembly T by contact with turner rods <NUM> on flight assemblies <NUM>, <NUM>. Therefore it is understood that packs <NUM> are contacted and turned as the flight assemblies are moved under and across plates <NUM> and <NUM>'. It is noted that in <FIG>, many of the adjacent flight assemblies <NUM> and <NUM> associated with opposing and cooperating flight drive assemblies <NUM>, <NUM> have been removed for illustration purposes, the arrangement of adjacent flight assemblies <NUM>, <NUM> being shown in <FIG>. <FIG>, also show the blocks <NUM> and flight shafts <NUM> in various transverse positions as they are moved progressively downstream. The turner rods <NUM> are separated from their associated support or flight shafts <NUM> and <NUM>', for illustration. It is understood that each flight shaft pair <NUM>, <NUM>' associated with a block <NUM> also remains attached to block <NUM> and moves along with and supports block <NUM> as it moves downstream, as shown in <FIG>.

In <FIG>, viewing the flight drive assemblies <NUM>, <NUM> from below, flight assembly <NUM> is in an approximate starting position <NUM>, which is towards the upstream end of flight drive assembly <NUM>. Any position along each flight drive assembly <NUM>, <NUM> of flight assemblies <NUM>, <NUM> , however, could be considered a starting position, since the flight assemblies move in a closed loop path of travel. Similarly, flight assembly <NUM> of flight drive assembly <NUM> is in its starting position <NUM>'. As discussed herein, the starting positions of flight assemblies <NUM>,<NUM> are adjusted using adjusting gears or pulleys <NUM>, <NUM> so that the opposing flight shafts <NUM> of assemblies <NUM>, <NUM> will contact a pack <NUM> laterally from the pack <NUM> center point <NUM> (<FIG>). Also, the movement of the blocks <NUM> and associated cam follower <NUM> along the respective cam tracks <NUM>, <NUM> causes the blocks <NUM> and flight shafts <NUM> to move toward and away from pack <NUM>. <FIG> shows the distal ends <NUM> of respective flight shaft <NUM> just contacting the opposed, longer sides of pack <NUM>. As the flight assemblies <NUM>, <NUM> are moved further across plates <NUM> and <NUM>' by belts <NUM>, <NUM>, <NUM> and <NUM>, the movement of the cam followers <NUM> along the cam track causes the rods <NUM> to move progressively towards pack <NUM>, and progressively turn or rotate the pack. In <FIG>, the pack <NUM> is starting to be rotated further about its center point <NUM>. <FIG> shows flight assemblies <NUM>, <NUM> moved further in the downstream direction of arrow A, with the pack <NUM> being further turned or rotated. At this position the pack <NUM> is rotated between opposite contact arms <NUM> and <NUM>'(<FIG>), mounted adjacent flight drive assemblies <NUM> and <NUM> respectively. Contact arms <NUM> and <NUM>' are spring loaded and attached to a machine P stop switch (not shown) so that if a pack is pushed in one transverse direction or another sufficiently to contact and move either arm <NUM> or arm <NUM>' sufficiently, the machine stop switch is activated to stop the machine. This prevents the machine from crushing a pack <NUM> if the pack <NUM> is not rotated, but pushed transversely, out of the center of conveyor C. <FIG> shows the pack <NUM> fully rotated, with opposing rods aligned with the longer sides of pack <NUM>. In this position the blocks <NUM> and associated cam followers <NUM> are nearly at the apex <NUM> and <NUM>' of cam tracks <NUM> and <NUM>, respectively. <FIG> shows the fully rotated pack <NUM> moved further downstream from its position along conveyor C toward the downstream end <NUM> of machine P. At this longitudinal positon, the respective cam followers <NUM> of linear blocks <NUM> are at the respective apex positions <NUM> and <NUM>' of their associated cam tracks <NUM> and <NUM>. Also at this position the turner rods <NUM> of flight assemblies <NUM> and <NUM> are positioned transversely to extend at the furthest lateral or transverse positions toward the opposing flight drive assembly, <NUM> or <NUM> and the centerline of conveyor C. The turner rods <NUM> in this position and the position shown in <FIG> assist in controlling the article packs <NUM> during higher machine speeds, such as <NUM>-<NUM> packs per minute. This turner rod <NUM> positioning of opposed flight assemblies <NUM>,<NUM> also stabilizes each article pack <NUM> as it continues to move downstream and prevents over turning by the turning pack's inertia.

<FIG> shows the blocks <NUM> moved past the apex portions <NUM>, <NUM>' of cam tracks <NUM>, <NUM>. At these positions along cam tracks <NUM>,<NUM>, the opposed turner rods <NUM> are caused to move with blocks <NUM> away from the centerline of conveyor C, so that turner rods <NUM> slide along the sides of pack <NUM> to prepare to release pack <NUM> from engagement with turner rods <NUM>. <FIG> shows the turner rods <NUM> in nearly fully retracted positions, with the distal ends <NUM> of turner rods <NUM> being clear of the edges of pack <NUM>. The turner rods <NUM> can be retracted even slightly further than shown in <FIG> to ensure that the ends <NUM> of the flight shafts do not contact packs <NUM> as the packs are moved downstream and away from turner assembly T, toward either a pack <NUM> diverter station or a pack <NUM> accumulation area (not shown).

As can be seen in <FIG>, the shape of cam tracks <NUM> and <NUM> in the plan view includes an initial sloping section <NUM> and <NUM>', starting at cam follower guide G and G', and then towards the centerline of conveyor C and to apex positions <NUM> and <NUM>'. Cam tracks <NUM> and <NUM> each then include a downstream sloping section <NUM> and <NUM>' which both slope outwardly away from the centerline of conveyor C to guides H and H'. The length and angle of the cam tracks can be changed by changing cam plates in order to alter the speed of the article pack <NUM> turning. Also, the cam track profile can be similarly adjusted to change the rate of radial article pack rotation so that the rate can be reduced as the distal ends of the turner rods <NUM> approach being opposite each other. The guides H and H' guide the cam followers <NUM> from lower plates <NUM> and <NUM>' to the cam tracks <NUM> and <NUM>' (<FIG>) defined in upper plates <NUM> and <NUM>'. The guides G and G' guide cam followers <NUM> from the cam tracks <NUM> and <NUM>' defined in upper plates <NUM>, <NUM>' to cam tracks <NUM> and <NUM>, respectively, defined in lower plates <NUM> and <NUM>'. As shown in <FIG>, starting at guides H and H', the cam tracks <NUM> and <NUM>' are shaped to include initial straight portions <NUM> and <NUM>' that are aligned with guides H and H'. The cam tracks <NUM> and <NUM>' then extend inwardly (that is toward the conveyor C centerline) by sloping portions <NUM> and <NUM>' and then upstream straight portions <NUM> and <NUM>', which align with guides G and G' respectively. The upper plate cam tracks <NUM> and <NUM>' receive the respective cam followers <NUM> of each flight assembly <NUM>,<NUM> and those flight assemblies <NUM>, <NUM> are driven around pulleys <NUM>, <NUM>, <NUM>' and <NUM>' and simultaneously through guides H and H' and back in the upstream direction, arrow A'. The inwardly sloping cam track sections, <NUM> and <NUM>' cause the flight assemblies <NUM>,<NUM> to be moved slightly inwardly toward conveyor C, passing over the packs <NUM> that are moving on conveyor C in the downstream direction, arrow A. The cam followers <NUM> and their respective flight assemblies <NUM>,<NUM> then enter cam track sections <NUM> and <NUM>', respectively and into their respective guides, G or G' as the flight assemblies are driven around pulleys or gears <NUM>, <NUM>, <NUM>', <NUM>'. After the cam followers of the flight assemblies pass around these pulleys at the upstream end of assemblies <NUM>, <NUM>, those cam followers <NUM> of flight assemblies <NUM>, <NUM> then enter the cam track <NUM> for flight drive assembly <NUM> and cam track <NUM>, for flight drive assembly <NUM>. The flight drive assemblies <NUM>, <NUM> are again positioned at the approximate starting positions <NUM> and <NUM>' (<FIG>). It is possible to reverse the upper and lower cam plates so that the cam track moving the turner rods <NUM> toward the main conveyor C centerline is facing upwardly and the cam track moving the rods <NUM> away from the main conveyor C centerline is facing downwardly.

As these cam followers <NUM> simultaneously enter cam tracks <NUM>, <NUM> at starting positions <NUM>, <NUM>', the process of progressively moving the flight assemblies <NUM>, <NUM> toward the pack <NUM> as discussed herein, to eventually contact the pack <NUM> at points both ahead and behind the pack center point, and so turn or rotate the pack so that the longer side faces in the downstream direction.

Claim 1:
A packaging machine (P) for packaging articles (<NUM>) into cartons (<NUM>, <NUM>'), the packaging machine (P) having a carton blank feeder (F), a main conveyor (C), an article infeed station downstream of the feeder (F) and adjacent to the main conveyor (C) that extends downstream in a longitudinal direction for arranging articles (<NUM>) in a desired configuration of an article group, an article wrap station for wrapping carton blanks (B) around the article group to form a pack (<NUM>, <NUM>'), a main packaging machine drive for moving the main conveyor (C), wherein the main conveyor (C) moves the article pack (<NUM>, <NUM>') downstream in the longitudinal direction,
the machine being characterised in further comprising
an article pack (<NUM>, <NUM>') turning station (T) for rotating the article pack (<NUM>, <NUM>'), the article pack (<NUM>, <NUM>') turning station (T) including two opposed flight drive assemblies (<NUM>, <NUM>),
each flight drive assembly (<NUM>, <NUM>) including two cam plates, each cam plate positioned adjacent to the main conveyor (C) and defining a track (<NUM>, <NUM>', <NUM>, <NUM>', <NUM>, <NUM>), wherein the cam plates include an upper cam plate (<NUM>, <NUM>', <NUM>) and an associated lower cam plate (<NUM>, <NUM>'), the upper and associated lower cam plates (<NUM>, <NUM>') being positioned over one another, wherein a gap exists between each upper cam plate (<NUM>, <NUM>', <NUM>) and the associated lower cam plate (<NUM>, <NUM>'), and
each flight drive assembly (<NUM>, <NUM>) further including a flight assembly (<NUM>, <NUM>) having a turner rod (<NUM>, <NUM>') that can be moved toward and away from the article pack (<NUM>, <NUM>') by way of engagement of the flight assemblies with the respective cam tracks in order to contact the pack (<NUM>, <NUM>') in two areas relative to a center point of the pack (<NUM>, <NUM>') to cause the pack (<NUM>, <NUM>') to turn or rotate, wherein the engagement of each of the flight assembly (<NUM>, <NUM>) with the respective cam track (<NUM>, <NUM>) in the lower cam plate (<NUM>, <NUM>') causes the turner rod (<NUM>, <NUM>') to contact the pack (<NUM>, <NUM>').