Patent ID: 12258222

We must clarify that in the present description and in the claims the terminology used, such as for example the terms vertical, lower, upper, top and bottom, with their declinations, have the sole function of better illustrating the present invention with reference to the drawings and must not be in any way used to limit the scope of the invention itself, or the field of protection defined by the attached claims.

Moreover, persons of skill in the art will recognize that certain sizes, or features, in the figures may have been enlarged, deformed, or shown in an unconventional or non-proportional way, to provide a version of the present invention that is easier to understand. When sizes and/or values are specified in the following description, the sizes and/or values are provided for illustrative purposes only and should not be construed as limiting the field of protection of the present invention, unless such sizes and/or values are present in the attached claims.

To facilitate understanding, identical reference numbers have been used, where possible, to identify identical common elements in the drawings. It should be understood that elements and features of one embodiment can be conveniently combined or incorporated into other embodiments without further clarification.

DETAILED DESCRIPTION OF SOME EMBODIMENTS OF THE PRESENT INVENTION

With reference toFIG.1, a feed apparatus10, according to the present invention, for feeding casings100(FIG.3) for smoking articles, is configured to be associated with, or to be part of, a machine200(FIG.2) for the preparation of smoking articles, such as cigarettes, or suchlike.

The machine200is schematized in the block diagram ofFIG.2and, for example, comprises: a filling station201configured to fill the casings100with a smoking product, for example loose material, such as tobacco, other smokable substances, or a combination thereof; a packaging station202configured to package the already filled casings100, for example to adequately close them; and a distribution station203, for example for forwarding the smoking articles to a packing station204, possibly outside the machine200, but is not limited thereto. The machine200may also include a suitable transport apparatus205configured to transport the casings100and the finished smoking articles adequately and in a coordinated manner, from the apparatus10at least toward the distribution station203.

At least the filling station201, the packaging station202, the distribution station203and the transport apparatus205can be of any known type, or a type that will be developed in the future, or, for example, such as those described in related patent applications for industrial invention filed by or assigned to the Applicant of the present patent application.

For example, the transport apparatus205comprises a transport member211(FIGS.1,2,5and8), having the shape and function of a shuttle and is configured to slide along a transport axis X, for example horizontal. In the example provided here, the transport member211comprises four hollow seatings212, each of which has a truncated cone shape with sizes mating with those of a casing100, or at least of a lower part thereof. It is clear that the number of seatings212can also be different from four.

Each seating212is symmetrical with respect to a substantially vertical axis Y and is configured to house a casing100that can be inserted from top to bottom (FIGS.8and9). By way of indication, in the example provided here, the axes of the four seatings212are indicated respectively with Y1, Y2, Y3and Y4(FIGS.5and6).

The distance D between two adjacent seatings212is defined in the design phase of the apparatus10and/or of the machine200and is suited to the management of the plurality of casings100, as will be described in detail below.

Before describing the apparatus10and its functioning in detail, we will now describe an example of a casing100(FIG.3).

Each casing100is made of sheet material, for example very thin paper, or other material suitable for making a cigarette, or other smokable product, and is normally provided with a filter102of a known type.

The casings100have a length L which can vary according to the smoking article to be obtained and is comprised, for example, between about 50 mm and about 150 mm, preferably between about 70 mm and about 120 mm.

Furthermore, each casing100has a shape such that it can be easily stacked to form, with other casings100, a vertical stack101. For example, each casing100can have a truncated cone shape and comprise a first end103in correspondence with the filter102and a second open end104, opposite the first end103into which another casing100can be inserted. Consequently, the first end103has a diameter smaller than the diameter of the second end104.

In the example provided here, each stack101(FIG.4) includes a determined number of casings100, for example between two and twenty.

In order to better understand the apparatus10and its functioning, which will be described later, the casing100disposed in the lowest part of the stack101is defined here as the first casing100A, while the one inserted therein is defined as the second casing100B and so on up to the last casing, which is therefore the uppermost one in the stack101.

The apparatus10(FIGS.5and8) comprises a support structure11on which a feed unit12is mounted, disposed higher than the transport member211and configured to house and support, temporarily and in an orderly manner, a plurality of stacks101.

Between the feed unit12and the transport member211there is a conveyor unit13configured to convey one casing100at a time from each stack101present in the feed unit12and automatically insert it into a corresponding seating212of the support member211, as will be described in detail below.

The support structure11comprises a plate15, substantially horizontal, and disposed in a fixed position at a determined distance from the transport member211.

The feed unit12is mounted above the plate15, and comprises a rotating member16substantially in the form of a carousel with a substantially cylindrical bulk and rotatable with a direction of rotation S, clockwise or counterclockwise, with respect to the plate15, about a substantially vertical axis of rotation Z.

The rotating member16comprises a central hub17coaxial to the axis of rotation Z and to which an upper disc19and a lower disc20are attached perpendicularly, which are therefore parallel to each other.

The upper disc19is provided with a first plurality of through holes21, which have their centers lying on four circumferences concentric to the axis of rotation Z and are disposed radially aligned on rows disposed along a plurality of radial segments. The distance between two adjacent circumferences on which the through holes21lie is equal to the distance D between two seatings212of the transport member211. In this way, the through holes21are divided into groups of four, that is, the same number of seatings212.

The angle α (FIG.1) between two groups of four adjacent through holes21is a whole submultiple of 360° and in the example shown here is 20°, since there are eighteen groups of four through holes21, but the present invention is not limited to this. In fact, other embodiments of the present invention, not shown in the drawings, can provide different dispositions and different numbers of through holes21, since it is sufficient that their position and number are correlated to the position and number of the seatings212of the transport member211.

The lower disc20(FIGS.5and6) is provided with a second plurality of through holes22, which are disposed exactly in correspondence with the first plurality of through holes21.

An equal plurality of tubular elements23is attached between the upper disc19and the lower disc20and in correspondence with the two pluralities of through holes21and22, and are parallel to the axis of rotation Z and configured to each house a stack101of casings100to guide it toward the transport member211below, as will be described in detail below.

The feed unit12also comprises a closing disc24(FIGS.5-8), configured to selectively separate the feed unit12, that is, the rotating member16, from the plate15.

The closing disc24is associated with the rotating member16, so as to be disposed coaxial with respect to the central hub17and below the lower disc20.

The closing disc24is provided with a plurality of apertures25(FIG.7) consistent in shape, size and number, with the second plurality of through holes22of the lower disc20, possibly having a slightly larger size than the through holes22.

The feed unit12comprises a control knob58, for example protruding above the upper disc19, connected to the closing disc24by means of a suitable mechanical connection, of a type known per se and not described in detail, which can comprise for example, a shaft which operatively connects the control knob58to the closing disc24by means of one or more connection members, also of a known type.

The control knob58, configured to be rotated manually by an operator, allows the closing disc24to be alternately brought into a closed position or an operating position, by means of a rotation of a determinate angle about the axis of rotation Z, for example by an angle equal to approximately half of the angle α.

In the closed position the closing disc24prevents the descent of the stacks101of casings100from the tubular elements23toward the conveyor unit13below, while in the operating position it allows said descent of the stacks101of casings100.

In the operating position (represented by a broken line inFIG.7), the apertures25are aligned with respect to the second plurality of through holes22, and therefore with respect to the tubular elements23, and the passage of the stacks101of casings100is allowed. On the contrary, in the closed position (shown with a solid line inFIG.7) the apertures25are angularly offset with respect to the position of the through holes22, thus preventing the stacks101from descending.

The presence of the closing disc24allows the rotating member16to be disassembled from the plate15, for example when the casings100contained therein are finished, or when it is necessary to carry out maintenance or cleaning operations. The rotating member16can be replaced by another rotating member16, identical in structure and functionality, the tubular elements23of which have been previously completely filled with a plurality of stacks101of casings100, as schematized inFIG.8. This filling can be carried out in a filling station, not shown, either manually by an operator, or automatically or semi-automatically with the aid of one or more dedicated devices.

When it is necessary to replace a rotating member16by another rotating member, the operator takes the closing disc24of both rotating members16into the closed position, so as to be able to move the rotating members16without the stacks101of casings100protruding from below, under the tubular elements23.

The plate15, in a determinate angular position, that is, in correspondence with the seatings212of the transport member211, is provided with four through holes26coaxial to the axes from Y1to Y4of the seatings212, so that four stacks101of casings100can pass freely through them, guided by four corresponding first tubular guide elements23.

Alternatively, instead of the four through holes26on the plate15, a single slot could be made, having a width equal to the diameter of one of the through holes26and a length suitable to allow the four stacks101to pass at the same time.

The feed unit12also comprises a first electric motor27(FIG.5), of a known type, which is positioned below the plate15and is connected to the rotating member16by means of a transmission belt28and two pulleys29and30, one attached to the shaft of the electric motor27and the other to the central hub17. The first electric motor27is configured to rotate the rotating member16preferably in angular increments, that is, step by step, equal to the above said angle α.

According to a variant, the first electric motor27could rotate the rotating member16continuously, at a determinate angular speed, such as to take each group of four through holes21and22in correspondence with the four through holes26with a desired timing, taking into account however that the continuous rotation of the rotating member16, beyond a certain speed, could lead to shearing of the casings100during the loading step, and therefore the rotation of the rotating member16with angular increments is more advantageous and preferable.

In accordance with the embodiment of the present invention shown here, the conveyor unit13comprises four identical pick-up devices31, each of which is disposed under one of the through holes26, that is, aligned with the axes Y1, Y2, Y3and Y4and is configured to receive a stack101of casings100and vertically feed one casing100at a time toward the transport member211below, inserting it into one of the seatings212, as will be described in detail below.

Each pick-up device31comprises a first gripping member33and a second gripping member35, vertically aligned with each other, each of which comprises a gripper having a pair of jaws36, respectively37, configured to open and close selectively, controlled by a corresponding actuator38, respectively39, which can be of any known type and which therefore is not described in detail here.

As will be clear from the detailed description of the functioning of the apparatus10, the first gripping member33is configured as a second stop means configured to move between an engagement position, in which it cooperates, for each stack101, with the second casing100B to temporarily stop the fall of the casings above the first casing100A, and a disengagement position, in which they free the second casing100B to let it fall downward. In the example described here, when the first gripping member33is in the engagement position, the pair of jaws36constituting the gripper that forms the gripping member is in the closed position so as to retain the second casing100B and the entire stack of casings100above it, while when the first gripping member33is in the disengagement position the pair of jaws36is in the open position.

In particular, all four first gripping members33(FIGS.4,8and9) are mounted on a first vertical plate40of the support structure11and are disposed at a determined distance H1from the fixed plate15, which is preferably greater than the length L of each casing100, but is not limited to this, and remains permanently in this position.

On the contrary, all four second gripping members35are configured as gripping means of the first casing100A to move together, in both directions, that is, upward and downward, along the corresponding vertical axis Y1, Y2, Y3or Y4, preferably by means of a single movement device41, common to all the four pick-up devices31, from a raised position P1, in which the relative jaws37are open and can be selectively closed to grip a casing100, to a lowered position P2, very close to the transport member211, in which the relative jaws37are reopened to release the casing100, so that the latter falls by gravity into the underlying seating212of the transport member211.

The distance H2between the first gripping members33and the raised position P1of the corresponding second gripping member35is substantially equal to, or greater than, the length L of each casing100, while the travel C between the raised position P1and the lowered position P2is advantageously greater than the length L of each casing100.

Between each through hole26of the fixed plate15and each first gripping member33a second tubular guide element42is positioned which is attached to the same fixed plate15and has the function of guiding a corresponding stack101during its descent from the rotating member16to the corresponding gripping member33.

A sensor43(FIG.6) is associated with each second tubular guide element42, close to the fixed plate15, and acts as a detection mean configured to detect the possible lack of a casing100with respect to a determined pre-established number of casings.

Furthermore, between each first gripping member33and the corresponding second gripping member35, a third tubular guide element44is disposed, supported by a horizontal plate45of the support structure11and having the function of guiding a stack101during its descent from the relative first gripping member33to the corresponding second gripping member35.

The movement device41comprises a slider46connected to the group of the four second gripping members35and sliding vertically together with them, guided by a second vertical plate47of the support structure11.

A second electric motor49, of a known type, is mounted on the second vertical plate47and is connected to the slider46, by means of transmission members of a known type and not shown in the drawings, to selectively move it between a raised position, corresponding to the raised position P1, and a lowered position, corresponding to the lowered position P2and vice versa.

The conveyor unit13also comprises a stop element50(FIGS.9and10), disposed horizontally preferably just below the second gripping members35and is configured to selectively stop the stacks101of casings100.

As will be evident from the following detailed description of the functioning of the apparatus10, the stop element50is configured as a first stop mean since it intervenes to stop the descent of the first casing100A, and cooperates with the second stop mean, that is, the first gripping members33, which intervene in a manner coordinated with it in order to stop the descent of the second casing100B and of the entire stack101of casings100above it.

In particular, the stop element50consists of a plate that has a comb shape with four teeth51disposed exactly in correspondence with the vertical axes Y1, Y2, Y3and Y4.

The teeth51are relatively narrow, so that there is sufficient space between them to allow the passage of the jaws37of the second gripping members35when they are open and the latter is ascending from the lowered position P2to the raised position P1.

In particular, the distance H3(FIGS.4and9) between the upper part of the teeth51of the stop element50and the lower part of the jaws36of the first gripping members33is slightly greater than the length L of each casing100.

The stop element50(FIG.5) is mounted slidingly with respect to the support structure11between a position of interference, in which its teeth51are positioned in correspondence with the vertical axes Y1, Y2, Y3and Y4, to stop the descent of the stacks101, and a position of non-interference, in which the same teeth51are retracted so as to be out of the travel of the casings100toward the transport member211. The selective movement of the stop element50is controlled by an actuator52of a known type.

In accordance with a variant embodiment, shown inFIG.11, each jaw37of the second gripping members35comprises a support arm53at the end of which a containing element54is disposed. The latter projects from the support arm53toward the other jaw37. In a preferred embodiment, one containing element54is disposed above the support arm53of a jaw37, while the other containing element54is disposed below the respective support arm53of the other jaw37.

Each containing element54comprises a shaped portion55, for example V-shaped, beveled and at least partly mating with the shape of the casing100.

The shaped portions55of the two jaws37reciprocally cooperate to form a housing seating56for the casings100. Preferably, in correspondence with the housing seating56on each support arm53there is a niche59with a substantially cylindrical or truncated cone shape, mating with the external surface of the zone close to the first end103of the casing100. The disposition of the containing elements54, and the conformation of their shaped portions55, allow to limit possible lateral movements, or undesired inclinations of the casing100with respect to the axis Y, which could compromise the correct closing of the jaws37in order to retain the first casing100A, so as to confer greater reliability on the second gripping members35, without damaging the casings100.

In another variant embodiment, the jaws36of the first gripping member33can also be similar to the jaws37described above in accordance with the variant embodiment shown inFIG.11.

In another embodiment of the present invention, which does not provide to use the second gripping members35, the stop element50could function as the first stop member, or mean, against which the first casing100A of a stack101stops, while each first gripping member33could selectively function as a second stop member, or mean, to temporarily stop, for each of the stacks101, at least the second casing100B and the other casings100above it. In this case, the actuation of the stop element50, while the corresponding first gripping member33is in the blocking position, would cause the first casing100A of a stack101to fall by gravity directly into the underlying seating212of the transport member211. The distance H3(FIG.4) between the upper part of the teeth51of the stop element50and the lower part of the jaws36of the first gripping members33is slightly greater than the length L of each casing100.

The apparatus10also comprises an electronic control unit57(FIG.12), for example of the programmable type, configured to control the first electric motor27, the second electric motor49, the actuators38,39and52. The sensors43are also electrically connected to the electronic control unit57.

The functioning of the apparatus10described heretofore, which corresponds to the method according to the present invention, comprises the following steps.

In an initial or rest condition, the feeding unit12is stationary, the second gripping members35are in their raised position P1, the jaws36and37of the gripping members33and35are open and the stop element50is in its position of interference, that is, with its teeth51in interference with the axes Y1, Y2, Y3and Y4.

Furthermore, the transport member211is in its loading position, with its seatings212exactly coaxial to the axes Y1, Y2, Y3, Y4and ready to receive four casings100, each from a stack101.

In a first step, a plurality of stacks101of casings100are loaded into the first tubular guide elements23of the rotating member16, through the first plurality of through holes21.

All the stacks101loaded will have their first casing100A, that is, the lowest one, in contact with the closing disc24below, disposed in the closed position. This step can be carried out either manually or automatically, for example by means of a robot, or an automated machine, even subsequently, while the rotating member16is rotating. Alternatively, a rotating member16with the stacks101already loaded could be mounted on the plate15and could be replaced by another rotating member16when the casings100are finished, thus allowing the stacks101to be loaded into a filling station, separate from the apparatus10.

At this point, the operator acts on the control knob58to take the closing disc24into the operating position, in which the stacks101begin the descent towards the conveyor unit13.

By means of the first electric motor27, controlled by the electronic control unit57, the rotating member16is made to rotate, for example step-by-step with increments equal to the above said angle α, for example in a clockwise direction, as indicated by the arrow S inFIG.2.

The stacks101loaded in a same group of four through holes21disposed aligned on the same radial segment, fall by gravity into the second tubular guide elements42below, and from these into the third tubular guide elements44. This happens when the rotation of the rotating member16takes the above said group of four through holes21into alignment with the four through holes26of the fixed plate15(FIG.6).

At this point the electronic control unit57commands a pick-up cycle which begins with the drive of the actuators38and39(FIG.1) associated with the gripping members33and35to close the jaws36and37, according to a closing sequence that can possibly be temporally staggered, which provides to command the closure of the jaws36of the first gripping members33before closing the jaws37of the second gripping members35.

In this way, the first gripping members33move into the engagement position in which they grip the second casing100B (FIG.4) of each stack101to temporarily stop the fall of the casings above the first casing100A, allowing only this one to fall by gravity against the teeth51of the stop element50disposed in the position of interference. The second gripping members35grip this first casing100A of each stack101, for example and preferably in correspondence with its filter102.

The electronic control unit57, possibly after having received a consent signal from the actuators38and39that the operation of closing the jaws36and37has taken place, first commands the actuator52so that it moves the stop element50into its position of non-interference and then the second electric motor49, so that it commands the movement of the slider46and of the second gripping members35connected thereto from the first raised position P1to the second lowered position P2.

In this way, only the first casing100A of each stack101will be in the lowered position, with its filter102very close to the corresponding seating212of the transport member201, while the second casing100B of each stack101will have remained stationary, retained by the first gripping members33, together with all the other possible casings100of the same stack101above it.

Once the second gripping members35have reached the second lowered position P2, the electronic control unit57commands the actuator39so that it commands the opening of the jaws37of the second gripping members35, so that the first casing100A of each stack101falls by gravity into the underlying seating212of the transport member211.

Furthermore, when all the first casings100A of each stack101, descending, have passed the stop element50, the electronic control unit57first commands the ascent of the second gripping members35, by means of the second electric motor49, and subsequently it commands the actuator52to return the stop element50to its position of interference.

When the stop element50has again reached its position of interference, the electronic control unit57commands the actuators38so that they open the jaws36of the first gripping members33, so that the second casing100B can fall downward until it stops against the stop element50itself, thus becoming the new first casing100A, ready to be picked up by the second gripping members35and taken on the transport member in the subsequent work cycle.

The pick-up cycle described above is repeated so that four casings100at a time are inserted into the seatings212of different transport members211which sequentially will have been brought, in any suitable way, to the loading position, that is, with their seatings212exactly coaxial to the axes Y1, Y2, Y3, Y4.

When the electronic control unit57receives from the sensors43a signal indicating that in front of them there is no casing100of the four stacks101introduced into the second tubular guide elements42, it will command the first electric motor27, so that it carries out a new rotation by another angle α.

At this point the entire cycle described above is repeated, until all the casings100loaded on the feed unit12have been picked up and inserted into the seatings212of the various transport members211.

From the above it is clear that the apparatus10can also work in a continuous cycle, because the feed of the stacks101of casings100in the feed unit12is independent of the pick-up cycles carried out by the conveyor unit13.

It should be noted that the presence of the four sensors43allows to check the actual presence of casings100inside the second and third tubular guide elements42and44and, by means of the electronic control unit57and/or other control means of the machine200, it is possible to command the rotation of the rotating member16adequately, preventing it from erroneously shearing the casings100themselves.

Furthermore, the possible lack of one or more casings100on one or more of the second and third tubular guide elements42and44is managed by the electronic control unit57which, by means of the four sensors43and the actuators38, commands each first gripping member33, to selectively retain one or more stacks101in which one or more casings100are missing, compared with a determined pre-established number of casings100, to obtain the leveling of the casings100in the second and third tubular guide elements42and44. This function allows to obtain continuous functioning of the feed unit12even when there is a possible unbalanced loading of the stacks101, for example with a number of casings100different from the determined pre-established number, by an operator and/or a robot, or an automated machine.

It is clear that modifications and/or additions of parts or steps can be made to the feed apparatus10and feed method for automatically feeding casings100for smoking articles described heretofore, without thereby departing from the field of the present invention as defined by the claims.

For example, in general, every movement made with each of the electric motors cited above can be obtained by means of any type of actuation of another kind, for example pneumatic or fluid dynamic.

It is also clear that, although the present invention has been described with reference to a specific example, a person of skill in the art shall certainly be able to achieve many other equivalent forms of feed apparatus10and feed method for automatically feeding casings for smoking articles, all coming within the field of protection of the present invention.

In the following claims, the sole purpose of the references in brackets is to facilitate reading: they must not be considered as restrictive factors with regard to the field of protection defined by the claims themselves.