U.S. patent application number 10/864242 was filed with the patent office on 2004-11-11 for method for automated produce bag loading.
This patent application is currently assigned to Germunson & Main LLC. Invention is credited to Germunson, Gary G., Main, Timothy B..
Application Number | 20040221551 10/864242 |
Document ID | / |
Family ID | 31993421 |
Filed Date | 2004-11-11 |
United States Patent
Application |
20040221551 |
Kind Code |
A1 |
Main, Timothy B. ; et
al. |
November 11, 2004 |
Method for automated produce bag loading
Abstract
An apparatus and method for automatic opening of bags uses bags
in a folded configuration that include a small aperture near the
top thereof. The aperture allows a number of bags to be hung in a
substantially vertical orientation on an angled protruding member.
A vacuum-operated device engages one side of one of a first bag on
the side of the bag opposite to the aperture and retracts, thus
opening the bag using the force generated between the protruding
member and the vacuum-operated device. This allows the bag to be
opened without extraction from the protruding member. The open bag
is clamped in position and loaded using conventional technology.
The fully loaded bag is moved out of the loading position onto a
conveyor belt. The movement of the fully loaded bag tears the back
portion of the bag near the aperture thus freeing the bag from the
protruding member. The loaded bag may be subsequently sealed and
processed for shipping.
Inventors: |
Main, Timothy B.; (Selah,
WA) ; Germunson, Gary G.; (Yakima, WA) |
Correspondence
Address: |
DAVIS WRIGHT TREMAINE, LLP
2600 CENTURY SQUARE
1501 FOURTH AVENUE
SEATTLE
WA
98101-1688
US
|
Assignee: |
Germunson & Main LLC
Yakima
WA
|
Family ID: |
31993421 |
Appl. No.: |
10/864242 |
Filed: |
June 8, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10864242 |
Jun 8, 2004 |
|
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|
10255004 |
Sep 24, 2002 |
|
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|
10864242 |
Jun 8, 2004 |
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09905434 |
Jul 13, 2001 |
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Current U.S.
Class: |
53/459 ;
53/386.1; 53/572 |
Current CPC
Class: |
B65B 43/18 20130101;
B65D 33/14 20130101; B65B 43/30 20130101; B65D 33/01 20130101; B65B
43/28 20130101 |
Class at
Publication: |
053/459 ;
053/572; 053/386.1 |
International
Class: |
B65B 043/26 |
Claims
What is claimed is:
1. A method for automatic produce packing in shipping containers
comprising: hanging a multi-wall paper bale on a single protruding
member in an automatic produce packing machine, the paper bale
having sufficient size to receive and sufficient strength to retain
during shipping a plurality of consumer sized bags of produce and
having an elongated front panel, an elongated flat back panel,
elongated left and right side panels adjoining the front and back
panels, a closed bottom panel joining the front and back panels
with the left and right side panels, an open top portion, an
aperture in the back panel proximate the top portion and sized to
receive the protruding member with the back panel having a
continuous perimeter surrounding the aperture, and a cut-away
portion in the front panel proximate the top portion to expose the
aperture wherein the aperture is in the back panel only, the paper
bale being hung on the protruding member in a substantially
vertical orientation and retained on the protruding member;
activating a vacuum-operated engagement member having an operating
surface to engage the front panel of the paper bale; repositioning
the engaged engagement member to open the paper bale; clamping the
left and right side portions of the opened paper bale; positioning
the opened and clamped paper bale in proximity with a loading
chute; and loading the plurality of consumer sized bags of produce
into the opened and clamped paper bale.
2. The method of claim 1, further comprising disengaging the
engagement member following clamping of the left and right side
portions of the opened paper bale.
3. The method of claim 1, further comprising unclamping the left
and right side portions of the opened paper bale after completion
of the loading.
4. The method of claim 3 wherein unclamping the left and right side
portions permits the loaded paper bale to tear loose from the
protruding member.
5. The method of claim 1 wherein opening the paper bale comprises
repositioning the vacuum-operated engagement member to thereby
exert a force on the front panel of the paper bale using the
engagement member and exerting a force on the back panel of the
paper bale using only the protruding member to thereby open the bag
using the engagement member and the protruding member.
6. A method for automatic produce packing in shipping containers
comprising: hanging a multi-wall paper bale on a single protruding
member in an automatic produce packing machine, the paper bale
having sufficient size to receive and sufficient strength to retain
during shipping a plurality of consumer sized bags of produce and
having an elongated front panel, an elongated flat back panel,
elongated left and right side panels adjoining the front and back
panels, a closed bottom panel joining the front and back panels
with the left and right side panels, an open top portion, an
aperture in the back panel proximate the top portion and sized to
receive the protruding member with the back panel having a
continuous perimeter surrounding the aperture, and a cut-away
portion in the front panel proximate the top portion to expose the
aperture wherein the aperture is in the back panel only, the paper
bale being hung on the protruding member in a substantially
vertical orientation and retained on the protruding member;
activating a first vacuum-operated engagement member having an
operating surface to engage the back panel of the paper bale;
repositioning the vacuum-operated engagement member to remove the
paper bale from the protruding member; activating a second
vacuum-operated engagement member having an operating surface
opposed to the operating surface of the first engagement member to
engage the front panel of the paper bale; increasing the distance
between the first and second engagement members to open the paper
bale; clamping the left and right side portions of the opened paper
bale; positioning the opened and clamped paper bale in proximity
with a loading chute; and loading the plurality of consumer sized
bags of produce into the opened and clamped paper bale.
7. The method of claim 6, further comprising deactivating the first
and second engagement members.
8. The method of claim 7 wherein deactivating the first and second
engagement members occurs prior to loading the plurality of
consumer sized bags of produce.
9. The method of claim 6, further comprising unclamping the left
and right side portions of the opened paper bale after completion
of the loading.
10. The method of claim 6 wherein the protruding member is equipped
with a cutting surface and removing the paper bale comprises
drawing the paper bale across the cutting surface in a position
adjacent to the aperture.
11. A method for automated commercial produce shipping comprising:
positioning a plurality of multi-layered paper bales on a single
wicket in a substantially vertical orientation in a produce packing
machine wherein the plurality of paper bales are fully supported by
the wicket, each of the plurality of paper bales having sufficient
size to receive and sufficient strength to retain during shipping a
plurality of consumer sized bags of produce and having first and
second opposing panels having an unfolded upper portion, first and
second opposing side panels adjoining the first and second opposing
panels, a closed bottom panel joining the first and second opposing
panels with the first and second opposing side panels, an open top
portion, an aperture in the unfolded upper portion of the first
opposing panel proximate the top portion with the first opposing
panel having a continuous perimeter surrounding the aperture, the
aperture sized to slideably fit onto the wicket, and a cut-away
portion in the second opposing panel proximate the top portion to
expose the aperture wherein the aperture is in the first opposing
panel only; contacting a first one of the paper bales with a first
vacuum device; using the first vacuum device to open the first
paper bale; positioning the opened paper bale in proximity with a
loading chute; and loading the plurality of consumer sized bags of
produce into the opened paper bale.
12. The method of claim 11 wherein using the first vacuum device to
open the first paper bale comprises: engaging the first opposing
panel of the first paper bale with the first vacuum device; and
repositioning the engaged first vacuum device to thereby exert a
force on the first opposing panel of the first paper bale using the
first vacuum device and exerting a force on second opposing panel
of the first paper bale using only the wicket to thereby open the
bag using the first vacuum device and the wicket.
13. The method of claim 12 wherein positioning the opened paper
bale in proximity with a loading chute comprises opening the bag
using the first vacuum device and the wicket in proximity with the
loading chute whereupon the paper bale is positioned in proximity
with the loading chute during the process of opening the first
paper bale.
14. The method of claim 12, further comprising clamping the first
and second opposing side panels of the opened paper bale.
15. The method of claim 14, further comprising disengaging the
first vacuum device following clamping of the first and second
opposing side panels of the opened paper bale.
16. The method of claim 14, further comprising unclamping the first
and second opposing side panels of the opened paper bale after
completion of the loading.
17. The method of claim 16 wherein unclamping the first and second
opposing side panels of the opened paper bale permits the loaded
paper bale to tear loose from the wicket.
18. The method of claim 11 wherein contacting the first paper bale
with the first vacuum device further comprises engaging the second
opposing panel of the first paper bale with the first vacuum device
and repositioning the engaged first vacuum device to thereby remove
the first paper bale from the wicket using the first vacuum
device.
19. The method of claim 18 wherein the wicket is equipped with a
cutting surface and removing the paper bale comprises drawing the
paper bale across the cutting surface to thereby cut the first
paper bale free from the wicket.
20. The method of claim 18 wherein using the vacuum device to open
the first paper bale comprises: engaging the second opposing panel
of the removed paper bale with a second vacuum device; and
increasing the distance between the first and second vacuum devices
to open the removed paper bale.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention is related generally to bale bag
loading and, more particularly, to an apparatus and method for
automatic bale bag loading.
[0003] 2. Description of the Related Art
[0004] Automated processes for package loading are desirable since
it decreases labor costs and increases production efficiency. For
example, there are known techniques for automatically loading
cartons of fruit, such as apples. As noted above, automatic loading
of cartons of fruit reduces labor costs and thus the cost of the
finished product. In addition, production efficiency is greatly
increased by such automated processing.
[0005] Despite the desirability of automated processing, not all
processes have been automated. In one example, prepackaged bags of
products, such as potatoes, are placed in a large shipping bag
called a bale. In one example, a bale contains five individual 10
lb. bags of potatoes. Previous attempts to automate the bale
loading process have been unsuccessful. Therefore, it can be
appreciated that there is a significant need for an automatic
process for loading bales. The present invention provides this and
other advantages as will be apparent from the following detailed
description and accompanying figures.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention is embodied in an apparatus and method
for bale bag loading. The apparatus is for use with bags having an
aperture in a top portion on one side thereof. The apparatus
comprises a protruding member sized to fit through the aperture in
the bags and thereby retain the bags in a substantially vertical
orientation. An engagement member has an operating surface to
engage a first one of the bags on a first side of the bag opposite
the side of the bag having the aperture. The engagement member
retracts to a second position such that the side of the bag having
the aperture is still retained on the protruding member to thereby
open the first bag.
[0007] In one embodiment, the engagement member is a
vacuum-operated device to engage the first side of the first bag.
If the bag is a paper bag, the vacuum-operated device is operated
with a predetermined vacuum level to engage a first run of the bags
on the first side of the bag. In an alternative embodiment, the bag
is a plastic bag, and the vacuum-operated device is operated with a
predetermined vacuum level to engage a first run of the bags on the
first side of the plastic bag.
[0008] In yet another alternative embodiment, the engagement member
comprises an air source to direct an air stream at the first side
of the bag to at least partially open the bag in a mechanical
finger assembly operating to engage the first side of the first bag
subsequent to the at least partial opening.
[0009] The system may further comprise a retaining member to engage
and retain the first bag during a loading operation. The retaining
member may be positioned to engage and retain the left and right
side portions of the first bag during the loading operation.
[0010] The system may further comprise a loading chute located in
proximity with the first bag when the vacuum-operated device is in
the second position to permit products to be loaded into the first
bag.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0011] FIG. 1 is a top plan view of the inventive apparatus.
[0012] FIG. 2 is a side view illustrating details of the inventive
apparatus.
[0013] FIG. 3 is a perspective view of a bale bag used with the
inventive apparatus.
[0014] FIG. 4 illustrates the bag of FIG. 3 in an open
configuration.
[0015] FIG. 5 is a partial enlarged front elevation view of the bag
of FIG. 3.
[0016] FIG. 6 is a top plan view illustrating the manufacture of
the bag of FIG. 3.
[0017] FIG. 7 is a side view of the inventive apparatus.
[0018] FIG. 8 is a top plan view illustrating the apparatus in
operation.
[0019] FIG. 9 is a top plan view illustrating the extraction of a
bale bag.
[0020] FIG. 10 is a top plan view illustrating linear displacement
of the extracted bag.
[0021] FIG. 11 is a top plan view illustrating the engagement of
the extracted bag to open the bag.
[0022] FIG. 12 is a top plan view illustrating the activation of
the apparatus to open the extracted bag.
[0023] FIG. 13 is a top plan view of the inventive apparatus
illustrating linear displacement of the extracted opened bag into a
loading area.
[0024] FIG. 14 is a top plan view of an alternative embodiment.
[0025] FIG. 15 is a side view illustrating details of the
alternative embodiment.
[0026] FIG. 16 is a side view illustrating the alternative
embodiment.
[0027] FIG. 17 is a side view of the embodiment of FIG. 16
illustrating an open bale bag.
[0028] FIG. 18 is a top plan view illustrating the operation of the
alternative embodiment of FIG. 14.
[0029] FIG. 19 is a top plan view illustrating the extraction of a
bag by the apparatus of FIG. 14.
[0030] FIG. 20 is a top plan view of the apparatus of FIG. 14 with
a bag in the open position.
[0031] FIG. 21 is a side view illustrating another alternative
embodiment.
[0032] FIG. 22 is a side view of the embodiment of FIG. 21
illustrating an open bale bag.
[0033] FIG. 23 is a top plan view of a portion of the system used
to mechanically grasp and retain a bag.
[0034] FIG. 24 is a top plan view of the embodiment FIG. 23
illustrating mechanical engagement of the bag.
[0035] FIG. 25 is a side view illustrating an alternative
embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The present invention is directed to a technique that
automatically extracts a bag, such as a bale bag, opens the bag,
and positions the bag for loading. The present invention is
embodied in a system 100 illustrated in the top plan view of FIG.
1. As illustrated in FIG. 1, a plurality of bags 102 are placed on
a protruding member 104. In one embodiment, the protruding member
104 is a rod mounted at an upwardly projecting angle, as
illustrated in FIG. 2, to permit gravity feeding of the bags
102.
[0037] FIG. 2 is a side elevational view of the protruding member
104 illustrating its attachment to a frame 106 by a mounting
bracket 108. The mounting bracket 108 may be attached to the frame
106 using screws, nuts and bolts, rivets, or other known mechanical
attachment components. Those skilled in the art will recognize that
the protruding member 104 may be directly mounted to the frame 106
using well-known conventional techniques, such as welding,
adhesives, or the like. The protruding member 104 may have a
rounded terminal portion 104t to minimize the potential to damage
to the aperture 124 when loading the bags 102 onto the protruding
member. The rounded terminal portion 104t also makes it easier to
place the bags 102 on the protruding member 104.
[0038] A cutting blade 110 is mounted at the lowest portion of the
protruding member 104. The cutting blade 110 may be a razor blade,
knife blade, or other known device. In one embodiment, the cutting
blade 110 may be mounted in a slot (not shown) in the protruding
member 104. The cutting blade 110 may be retained within the slot
using conventional means, such as a set-screw, adhesive, or the
like. As will be described in greater detail below, the cutting
blade 110 is used to extract a bag 102 from the protruding member
104.
[0039] In one embodiment, the protruding member 104 is formed from
a circular rod. The bag 102 is similar to a conventional bale bag,
but is modified for use with the automatic system of the present
invention. The bag 102 may be formed from one or more layers of
brown paper. The bag 102 is illustrated in a folded or closed
configuration in FIG. 3. The bags 102 are folded in the manner of a
conventional grocery bag to permit ease in shipping and storage.
The bag 102 is shown in an unfolded or open configuration in FIG.
4. FIG. 4 also includes an enlarged portion illustrating the
multi-layer arrangement of the bag 102. In the folded
configuration, the dimensions of the bag 102 are approximately 13
inches wide by 32 inches long. When in the unfolded configuration,
shown in FIG. 4, the bag has a depth of approximately 7 inches and
an opening of approximately 7 inches by 13 inches. Although the bag
102 may have the standard dimensions described above, those skilled
in the art will recognize that the system 100 can be used with bags
of virtually any dimension. The only accommodation for bags of
different size may be the relative location of the various
components of the system 100.
[0040] The bag 102 may be manufactured from a single large piece of
paper, illustrated in FIG. 5, that is cut, folded into several
panels or portions, and glued in a conventional manner. The bag 102
has left and right side portions 112l and 112r, respectively. The
bag 102 also includes front and back portions 114f and 114b,
respectively. A strip 120 projects from the right side portion
112r. The strip 120 is glued to the back portion 114b when the bag
102 is formed. The left and right side portions 112l and 112r have
flaps 121, which are used to seal the bottom of the bag 102.
Similarly, the front and back portions 114f and 114bhave flaps 123
that are also used to seal and form a bottom portion 116, as
illustrated in FIG. 3.
[0041] Once the bag 102 has been cut from stock material, it may be
folded along fold lines 125 to form the front and back portions
114f and 114b and left and right side portions 112l and 112r. The
strip 120 may be glued to the back portion 114b to seal the various
portions. The bag also includes fold lines 127. The flaps 121 and
123 are folded at the fold lines 127 to form the bottom portion
116. The flaps 121 from the left and right side portions 112l and
112r are folded. The flap 123 from the front portion 114f is folded
and glued to the flaps 121. Finally, the flap 123 from the back
portion 114b is folded and glued to the flap 123 from the front
portion 114f to seal the bottom portion 116 of the bag 102. In this
manner, the bag 102 may be manufactured.
[0042] The bag 102 may be formed with creases to assist in folding
the bag following manufacture. As illustrated in FIG. 4, the bag
102 may include a front crease 122f on the front portion 114f
extending from the left side portion 112l to the right side portion
112r near the bottom 116 of the bag. The precise location of the
crease 122f is typically dependent on the dimensions of the bag.
For example, the crease 122f may be located at a distance from the
bottom portion 116 that is approximately one-half of the distance
between the front portion 114f and the back portion 114b when the
bag is in the open configuration. In addition, the bag 102 may
include creases 122l and 122r on the left and right side portions
112l and 112r, respectively. The crease 122l and 122r are located
approximately midway between the front portion 114f and the back
114b when the bag is in the open configuration. The creases 122l
and 122r extend from the top portion 118 to a point near the bottom
portion 116. The creases 122l and 122r extend to a point
approximately equal to the location of the crease 122f to
facilitate folding of the bag 102. From the terminating point of
the creases 122l and 122r, additional creases extend from the
midline of the side portions 112l and 112r to the junctions of the
side portions 112l and 112r with the front and back portions 114f
and 114b near the bottom portion 116 of the bag 102.
[0043] The bag 102 also includes an aperture 124 in the top portion
118 of the back portion 114b. In an exemplary embodiment, the
aperture 124 is approximately 0.625 inches in diameter and is
located a short distance from the top of the back portion 114b. For
example, the aperture 124 may be spaced apart from the top of the
back portion 114b by approximately 0.25 inches. The short
separation between the aperture 124 and the top of the back portion
114b of the bag 102 permits the easy extraction of the bag from the
protruding member 104. In one embodiment, the bag 102 may be
removed from the protruding 104 simply by tearing the back portion
114b at the point of narrow separation between the back portion and
the aperture 124. The cutting blade 110 (see FIG. 2) may be used to
slice the back portion 114b at the aperture 124 thus preventing an
undesirable tear. Alternatively, the bag 102 may include a
perforated portion above the aperture to control the tearing. In
this embodiment, the cutting blade 110 can be eliminated.
[0044] In the embodiment illustrated in FIGS. 3-5, the aperture 124
is circular in shape to match the cylindrical shape of the
protruding member 104. The cylindrical shape of the protruding
member 104 and the circular aperture 124 permit easy loading of
bags 102 onto the protruding aperture. In addition, the bags 102
slide easily down the cylindrical protruding member 104.
[0045] Those skilled in the art will appreciate that the protruding
member 104 may have different shapes and that the aperture 124 may
be circular or may have a shape that corresponds to the selected
shape for the protruding member. For example, the protruding member
104 may have a semi-circular shape with a rounded portion on top
and a flat portion on the bottom. The bags 102 may still have the
circular aperture 124, as illustrated in FIGS. 3-5, or may have a
shape selected to correspond to the shape of the protruding member
104. Other shapes, such as triangular, rectangular, or the like may
also be used satisfactorily with the system 100. The present
invention is not limited by the specific geometric form of the
protruding member 104 or the aperture 124.
[0046] FIG. 5 is a fragmentary front elevational view of the bag
102 illustrating the location of the aperture 124 in the back
portion 114b of the bag. A curve cutout 126 in the front portion
114f of the bag 102 more fully exposes the aperture 124 in the back
portion 114b and allows easy insertion of the protruding member 104
through the aperture when loading the bags. The bag 102 may also
have a series of ventilation holes 129 in the front and back
portions 114f and 114b to allow ventilation of the packaged
produce.
[0047] Returning again to FIG. 1, the system 100 also includes a
set vacuum-operated suction devices 130a and 130b to engage and
extract a first bag 102 from the protruding member 104. The bags
102 are extracted from the protruding member 104 in the same
sequence in which they are placed on the protruding member (i.e.,
first on-first off). As illustrated in FIG. 1, the vacuum-operated
devices 130a-b have a terminal vacuum-operated suction cup 134a and
134b, respectively. As the vacuum-operated devices 130a-b make
contact with the bag 102, the bag is retained by virtue of the
vacuum-operated suction cups 134a-b. The vacuum-operated devices
130a-b are mounted on air cylinder slides 136a and 136b,
respectively. The air cylinder slides 136b move in a direction
indicated by a reference arrow 132 to allow the suction cups 134a-b
to engage a first of the bags 102 on the protruding member 104. The
vacuum-operated devices 130a-b may be positioned to engage the bag
102 at any desirable position. In an exemplary embodiment, the
suction cups 134a-b engage a first side of the bag 102 on the back
portion 114b (see FIG. 4) near the top portion 118 at a distance of
approximately 1.5-2 inches in from the left and right sides 112l
and 112r, respectively.
[0048] The vacuum-operated devices 130a-b generate sufficient
vacuum to engage a bag on the protruding member 104, extract the
bag and support the weight of the bag. The precise vacuum level is
not critical, but must be sufficiently strong to perform the tasks
outlined above. A vacuum may be readily generated using Venturi
devices in which air is passed over the open end of a tube in order
to create a suction at a distal end of the tube. In the system 100,
the vacuum-operated devices 130a-b are commercial products
available from Vaccon Vacuum Generator.
[0049] In the embodiment illustrated in FIG. 1, a pair of
vacuum-operated devices 130a-b are used to support the bag 102. The
use of dual vacuum-operated devices provides greater stability and
relatively uniform extraction pressure on the bag 102 on both sides
of protruding member 104 such that the bag is drawn smoothly
against the cutting blade 110. Additional vacuum-operated devices
may be used to provide additional stability or if the size of the
bag 102 warrants extra support. However, if the bag 102 is
relatively small, a single vacuum-operated device may be sufficient
to extract the bag from the protruding member 104. Thus, the system
100 is not limited by the number or specific layout of the
vacuum-operated devices used to extract the bag 102 from the
protruding member 104.
[0050] In operation, the air cylinder slides 136a-b and the
vacuum-operated devices 130a-b move in the direction indicated by
the reference arrow 132 to engage the bag 102 on the protruding
member 104. Upon contact with the bag 102, the suction cups 134a-b
engage a first side of the bag (i.e., the back portion 114b) and
retain the bag. As the air cylinder slides 136a-b and the
vacuum-operated devices 130a-b move away from the protruding member
104 in the direction indicated by the reference arrow 132, a single
bag 102 is extracted from the protruding member and held in
position by virtue of the suction cups 134a-b. Thus, the system 100
is capable of automatically extracting a single bag 102 from the
protruding member 104. As the vacuum-operated device 130 moves away
from the protruding member in the direction indicated by the
reference arrow 132, the cutting blade 110 slices through a portion
of the bag 102 to allow its easy removal from the protruding
member.
[0051] The use of air cylinder slides, such as the air cylinder
slides 136a-b is well known in the art and need not be described in
greater detail herein. Alternatively, the vacuum devices 130a-b may
be moved back and forth in the direction indicated by the reference
arrow 132 through other known techniques, such as stepper motors,
servo motors, drive chains, belts, or the like. The system 100 is
not limited by the specific technique used to move the
vacuum-operated devices 130a-b in the direction indicated by the
reference arrow 132.
[0052] In addition to movement in the direction indicated by the
reference arrow 132, the vacuum-operated devices 130a-b are capable
of moving in the direction indicated by a reference arrow 138. To
permit this movement, the vacuum-operated devices 130a-b are
coupled to respective support brackets 140a and 140b. In turn, the
support brackets 140a-b are slidably coupled to a support member
142. Movement of the support brackets 140a-b and thus the
vacuum-operated devices 130a-b in the direction indicated by the
reference arrow 138 is controlled by a stepper motor (not shown).
In an exemplary embodiment, the vacuum-operated devices 130a and
130b move in unison in the direction indicated by the reference
arrow 138. The vacuum-operated devices 130a-b may be locked
together and controlled by a single stepper motor. Alternatively,
the vacuum-operated devices 130a and 130b may be independent with
the position of each of the vacuum-operated devices being
controlled by individual stepper motors.
[0053] The positioning of the vacuum-operated devices 130a-b can be
precisely controlled with stepper motors. Signals to control the
operation of the stepper motors are generated by a conventional
computer (not shown), such as a personal computer (PC), a single
board microcomputer, microcontroller, or the like. Displacement of
the vacuum-operated devices 130a-b is precisely controlled by the
number of pulses provided to the stepper motor. Alternatively, the
stepper motor may be replaced by other conventional drive means,
such as air cylinder slides, servo motors, chain drives, belt
drives, screw drives, and the like. Drive mechanisms, such as chain
drives, may use position sensing microswitches (not shown) to
control movement of the vacuum-operated devices 130a-b in the
direction indicated by the reference arrow 138. Use of such
position sensing devices are well known in the art and need not be
described in greater detail herein.
[0054] The system 100 has a second pair of vacuum-operated devices
150a and 150b that are positioned in opposition to the
vacuum-operated devices 130a-b. A suction cup 154a and 154b is
mounted at the terminal end of the vacuum-operated devices 150a-b,
respectively. As will be described in detail below, the
vacuum-operated devices 150a-b engage a bag 102 that has been
previously been extracted by the vacuum-operated devices 130a-b. As
previously described, the vacuum-operated devices 130a-b move in
the direction indicated by the reference 132 until the suction cups
134a-b engage a single bag 102 on a first side of the bag (i.e.,
the back portion 114b). The vacuum may be activated as the air
cylinder slides 136a-b are activated such that a vacuum is
established before the suctions cups 134a-b make contact with the
bag 102. Alternatively, the vacuum can be established as the
suction cups 134a-b approach the bag 102. The vacuum is activated
such that the suction cups 134a-b engage the first side of the bag
102. As the vacuum-operated devices 130a-b move away from the bags
102 in the direction indicated by the reference arrow 132, a single
bag is extracted from the protruding member 104.
[0055] Following extraction of a single bag, the vacuum-operated
devices 130a-b move in a direction indicated by the reference arrow
138 until the vacuum-operated devices are substantially aligned
with the vacuum-operated devices 150a-b. The vacuum-operated
devices 130a-b move in the direction indicated by the reference
arrow 132 toward the vacuum-operated devices 150a-b until the
suction cups 154a-b engage the second side of the bag 102 (i.e.,
the front portion 114f) opposite the vacuum-operated devices
130a-b. The vacuum-operated devices 150a-b are positioned to engage
the front portion 114f of the bag 102 on the opposite side of the
bag from the vacuum-operated devices 130a-b.
[0056] When the suction cups 154a-b have engaged the second side of
the back of the extracted bag 102, the vacuum may be activated and
the vacuum-operated devices 130a-b moved in a direction indicated
by the reference arrow 132 away from the vacuum-operated devices
150a-b to thereby unfold the bag. Alternatively, the vacuum for the
vacuum-operated devices 150a-b may be activated as the extracted
bag 102 approaches. The precise moment of activation of the
vacuum-operated devices 150a-b is not critical to satisfactory
operation of the system 100.
[0057] It should be noted that the vacuum-operated devices 150a-b
are not mounted on air cylinder slides, such as the air cylinder
slides 136a-b used to move the vacuum-operated devices 130a-b in
the direction indicated by the reference arrow 132. The
construction and operation of the system 100 are simplified by
fixing the position of the vacuum-operated devices 150a-b so that
no movement occurs in the direction indicated by the reference
arrow 132. Such an arrangement simplifies the system 100 by
eliminating need for air cylinder slides and the associated
measurement and control circuitry. However, if the system 100 is
installed in a location that limits the movement of the
vacuum-operated devices 130a-b in the direction indicated by the
reference arrow 132, it is possible to mount the vacuum-operated
devices 150a-b on air cylinder slides to permit movement in the
direction indicated by the reference arrow 132. In this embodiment,
both sets of vacuum-operated devices (i.e., the vacuum-operated
devices 130a-b and 150a-b) are positioned on air cylinder slides
(e.g., the air cylinder slides 136a-b).
[0058] The vacuum-operated devices 150a-b are also capable of
movement in a second direction indicated by the reference arrow
158. The vacuum-operated devices 150a-b are coupled to support
brackets 160a and 160b. The support brackets 160a-b are slidably
connected to a support member 162 to permit movement in the
direction indicated by the reference arrow 158. Movement of the
vacuum-operated devices 150a-b in the direction indicated by the
reference arrow 158 is controlled by stepper motors. As discussed
above with respect to the vacuum-operated devices 130a-b, a single
stepper motor may be sufficient to move both vacuum-operated
devices 150a-b. In this embodiment, the vacuum-operated devices
150a-b are coupled together for movement controlled by the single
stepper motor. Alternatively, a stepper motor may be associated
with each of the vacuum-operated devices 150a and 150b.
Alternatively, the movement of the vacuum-operated devices 150a-b
in the direction indicated by the reference arrow 158 may be
controlled by other conventional techniques, such as servo motors,
air cylinder slides, chain drive, belt drive, screw drive, and the
like. The present invention is not limited by the specific form of
the drive mechanism used to control movement of the vacuum-operated
devices 150a-b in the direction indicated by the reference arrow
158.
[0059] Following engagement of the front and back portions 114f and
114b of the bag 102, the vacuum-operated devices 130a-b and the
vacuum-operated devices 150a-b move in synchronization in the
direction indicated by the reference arrows 138 and 158,
respectively. In this manner, the extracted and opened bag 102 is
moved into position at a conveyor belt 170 where the bag may be
loaded. Conventional devices are used to automatically load the
opened bag 102. A set of clamps (not shown) attached to the top of
the side portions 1221 and 122r stabilize and retain the bag 102
while it is being loaded. As the product (e.g., individual bags of
potatoes) are loaded into the opened bag 102, the bottom 116 of the
bag rests on the conveyor belt 170. After the products have been
loaded into the bag 102, the side clamps (not shown) release and
the conveyer belt 170 is activated to move the loaded bag 102 out
of the loading area.
[0060] It should be noted that the sequence of opening the bag and
moving the bag to the conveyor belt 170 may be performed
interchangeably. That is, the extracted bag 102 may be unfolded and
subsequently moved to the conveyor belt 170, as described above.
Alternatively, the extracted bag 102 may be moved to the conveyor
belt 170 while still in the folded configuration (see FIG. 3). The
bag 102 may be subsequently opened into the unfolded configuration
(see FIG. 4) after arrival at the conveyor belt 170. Thus, the
present invention is not limited by the specific sequence of these
two events.
[0061] FIG. 7 is a side view of the system 100. As best seen in
FIG. 7, the vacuum-operated devices 130a-b and 150a-b are mounted
at approximately the same height, but facing towards each other. As
previously discussed, the vacuum-operated devices 130a-b and 150a-b
are coupled to support members 142 and 162, respectively, by
respective support brackets 140 and 160. In the exemplary
embodiment illustrated in FIG. 7, the support members 142 and 162
are rectangular supports that may conveniently be manufactured from
aluminum or other conventional materials. As can be seen from FIG.
7, the support members 142 and 162 each contain a channel 174. The
mounting bracket 140 is inserted in the channel 174 of the support
member 142 such that the vacuum-operated devices 130a-b may move
smoothly along the channel in a direction indicated by the
reference arrow 138 (see FIG. 1). Similarly, the support bracket
160 is inserted into the channel 174 of the support member 162 to
permit the vacuum-operated devices 150a-b to move easily along the
channel in the direction indicated by the reference arrow 158 (see
FIG. 1).
[0062] FIGS. 7-12 are top plan views of the system 100 illustrating
the positioning of the vacuum-operated devices 130a-b and 150a-b at
different stages of the process. In FIG. 8, the vacuum-operated
devices 130a-b advance in the direction indicated by the reference
arrow 132 until the suction cups 134a-b make contact with the first
bag 102 on the protruding member 104. It should be noted that the
vacuum device may be continuously activated at this step or may be
activated at any point before contacting the bag 102 or at the time
of contact of the bag. When the vacuum is activated, the suction
cups 134a-b engage and retain the first bag 102 on the protruding
member 104.
[0063] In FIG. 9, the vacuum-operated devices 130a-b move in the
direction indicated by the reference arrow 132 away from the
protruding member 104. Because the first bag 102 is held in
engagement with the suction cups 134a-b by virtue of the vacuum,
the first bag is extracted from the protruding member 104. As noted
above, the small section of the bag 102 above the aperture 124 (see
FIG. 5) is torn by the process of removal from the protruding
member 104. The cutting blade 110 (see FIG. 2) may be used to
control the extraction process by initiating the cut in the paper
just above the aperture 124. In yet another alternative embodiment,
the section of the bag 102 just above the aperture 124 may be
perforated to control the tearing process as the first bag is
extracted from the protruding member 104.
[0064] FIG. 9 illustrates the position of the vacuum-operated
devices 130a-b following the extraction of the first bag 102 from
the protruding member 104. At this point, the extracted bag 102 is
still in the folded configuration (see FIG. 3). In FIG. 10, the
vacuum-operated devices 130a-b are displaced in the direction
indicated by the reference arrow 138 until the vacuum-operated
devices are substantially aligned with the vacuum-operated devices
150a-b.
[0065] In FIG. 11, the air cylinder slides 136a and 136b are
activated to move the vacuum-operated devices 130a-b in the
direction indicated by the reference arrow 132 until the suction
cups 154a-b make contact with the second side of the extracted bag
102. It should be noted that the vacuum-operated devices 130a-b are
still activated such that the first side (i.e., the back portion
114b) of extracted bag 102 is held in position by the suction cups
134a-b. When the vacuum-operated devices 150a-b are activated, the
suction cups 154a-b engage and retain the second side (i.e., the
front portion 114f) of the extracted bag 102. As noted above with
respect to the vacuum-operated devices 130a-b, the vacuum-operated
devices 150a-b may be activated as the vacuum-operated devices
130a-b approach with the extracted bag 102 or after the suction
cups 154a-b make contact with the second side (i.e., the front
portion 114f) of the extracted bag.
[0066] In FIG. 12, the air cylinder slides 136a-b withdraw away
from the vacuum-operated devices 150a-b in the direction indicated
by the reference arrow 32. As the vacuum-operated devices 130a-b
move away from the vacuum-operated devices 150a-b, the extracted
bag 102 is opened into the unfolded configuration (see FIG. 4). The
bag 102 may be opened by moving one or both of the vacuum-operated
devices 130a-b and 150a-b away from each other. In an exemplary
embodiment, the vacuum-operated devices 150a-b are held in a
constant position while only the vacuum-operated devices 130a-b
move in the direction indicated by the reference arrow 132 away
from the vacuum-operated devices 150a-b. This process places the
extracted bag 102 in the unfolded configuration.
[0067] Alternatively, the vacuum-operated devices 150a-b also move
in the direction indicated by a reference arrow 152 away from the
vacuum-operated devices 130a-b. If both vacuum-operated devices
130a-b and 150a-b move approximately the same distance, the
extracted bag 102 is placed in the unfolded configuration (see FIG.
4) approximately centered between the support members 142 and 162.
In yet another alternative, the vacuum-operated devices 130a-b may
be held in a constant position while the vacuum-operated devices
150a-b move in a direction indicated by the reference arrow 152
away from the vacuum-operated device 130. In any of these
combinations of movement, the extracted bag 102 is placed in the
unfolded configuration.
[0068] The extracted and unfolded bag 102 is moved into position
atop the conveyor belt 170, as shown in FIG. 13. This movement is
accomplished by synchronized movement of the vacuum-operated
devices 130a-b and the vacuum-operated devices 150a-b.
Specifically, the vacuum-operated devices 130a-b move in a
direction indicated by the reference arrow 138 toward the conveyor
belt 170 at a predetermined rate of movement. At the same time, the
vacuum-operated devices 150a-b move in a direction indicated by the
reference arrow 158 toward the conveyor belt 170 at the same
predetermined rate thus maintaining the position of the suction
cups 134a-b and 154a-b with respect to the extracted and unfolded
bag 102. While at the conveyor belt 170, the unfolded bag 102 is
filled in a conventional manner. As previously discussed, a
clamping mechanism (not shown) clamps the open bag in position on
the conveyor belt 170 to permit loading. The open bag 102 is
automatically loaded with prepackaged bags of produce using a
conventional automatic loading machine (not shown).
[0069] Once the clamps (not shown) have been activated to secure
the open bag 102, the process of extracting a new bag may be
repeated. That is, the vacuum is deactivated so that the
vacuum-operated devices 130a-b and 150a-b no longer support the
open bag 102. The vacuum-operated devices 150a-b return to their
original starting position. The air cylinder slides 136a-b retract
and the vacuum-operated devices 130a-b are returned to their
original position. The entire process is repeated to automatically
extract the next bag 102 from the protruding member 104.
[0070] Thus, the system 100 automatically extracts a single bag
from the protruding member 104, opens the extracted bag to an
unfolded configuration, and moves the extracted open bag into
position on the conveyor belt 170. As previously noted, it is
possible to move the extracted bag 102 into position above the
conveyor belt 170 before opening the bag. That is, the process of
opening the extracted bag 102 into the unfolded configuration (see
FIG. 4) may be performed in the sequence illustrated in FIGS. 11
and 12 or the process may be reversed such that the unopened
extracted bag 102 is first moved to the conveyor belt 170 and
opened into the unfolded configuration. In either event, the
process of extracting bags is automated by the system 100 thus
reducing labor costs and increase efficiency. In an exemplary
embodiment, the protruding member 104 is sufficiently long to hold
a large number (e.g., 50) of bags 102.
[0071] In an alternative embodiment, illustrated in FIGS. 14-20,
the system 100 utilizes only a single set of vacuum-operated
devices 130a-b to open the bag 102. In this embodiment, the system
100 relies on the protruding member 104 to retain contact with one
side of the bag 102. In the previous embodiment, the bags 102 are
inserted onto the protruding member 104 with the back portion 114b
facing toward the vacuum-operated devices 130a-b. As the
vacuum-operated devices 103a-b engage the first side of the bag 102
(i.e., the back portion 114b), the bag is drawn against the cutting
blade 110 to completely extract the bag 102 from the protruding
member 104, as illustrated in FIG. 9.
[0072] In contrast, the alternative embodiment illustrated in FIGS.
14-20 does not utilize the cutting blade 110 on the protruding
member 104. A side view of the protruding member 104 is illustrated
in FIG. 15. Furthermore, the bags 102 are mounted on the protruding
member 104 such that the front portion 114f of the bag faces toward
the vacuum-operated devices 130a-b.
[0073] In the alternative embodiment of FIGS. 14-20, the open bag
102 is loaded with product (e.g., pre-packaged bags of produce)
using a conventional automatic loading machine. FIG. 16 is a side
view illustrating a funnel or chute 176, which is positioned above
the bags 102. FIG. 17 is another side view illustrating an open bag
102, which is opened by the vacuum-operated devices 134a-b acting
on one side of the bag 102, (i.e., the front portion 114f, shown in
FIGS. 3-4) and the protruding member 104 acting on the opposite
side of the bag (i.e., the back portion 114b shown in FIGS. 3-4)
via the aperture 124. The product is deposited into the open bag
102 via the chute 176.
[0074] The operation of the alternative embodiment may be best
understood with respect to FIGS. 18-20. In FIG. 18, the
vacuum-operated devices 130a-b move in the direction illustrated by
the reference arrow 132 toward the first bag 102 on the protruding
member 104. In FIG. 18, the vacuum-operated devices 130a-b move to
a first position to engage a first side of the bag (i.e., the front
portion 114f) and retain the bag. The vacuum level may be adjusted
for the specific size and type of bag 102. For example, if the bale
bag 102 is paper, such as shown in FIGS. 3-4, the vacuum can be set
at a first level or set to a second level if the bale bag is
plastic, such as polyethylene.
[0075] As the air cylinder slides 136a-b and the vacuum-operated
devices 130a-b move away from the protruding member 104 in the
direction indicated by the reference arrow 132 in FIG. 20, the
first bag is at least partially opened. In this embodiment, no
vacuum devices need be applied to the second side of the bag (i.e.,
the back portion 114b) to open the bag. Rather, the aperture 124
(see FIG. 5) on the back portion 114b of the bag 102 is retained on
the protruding member. The air cylinder slides 136a-b retracts to a
second position such that the first bag 102 is not fully removed
from the protruding member 104, but is merely opened. Thus, the air
cylinder slides 136a-b and the vacuum-devices 130a-b reciprocate
between first and second positions, illustrated in FIGS. 18 and 19,
respectively, to contact and open a single bag 102.
[0076] The open bag 102 is retained in position below the chute 176
by gripper members or clamps 178a-b, illustrated in FIGS. 17 and
20. The clamps 178a-b may be operated mechanically, hydraulically,
electrically, or in other known manners to retain the open bag 102
in position for loading. A number of different known devices may be
used to implement the clamps 178a-b. The present invention is not
limited by the specific implementation of the clamps 178a-b.
[0077] As noted above, the bag 102 is opened by the vacuum force
applied by the vacuum-operated devices 130a-b on the front portion
114f of the bag while the back portion 114b of the bag is retained
by virtue of the force exerted via the protruding member 104
inserted into the aperture 124 (see FIG. 5). Once the bag 102 is
open, the clamps 178a-b grasp and retain the sides 112l and 112r
(see FIG. 4) during the loading operation. Once the clamps 178a-b
have grasped and retained the open bag 102, the vacuum-operated
devices 130a-b can be deactivated and moved to a position that does
not interfere with the loading operation.
[0078] After the open bag 102 is fully loaded, it may be placed on
the conveyer belt 170 for sealing and subsequent shipment. As the
fully loaded bag 102 is moved out of the loading position, it tears
free from the protruding member 104 simply by ripping the bag at
the aperture 124 (see FIG. 5).
[0079] Thus, the alternative embodiment illustrated in FIGS. 14-20
requires only a first set of vacuum-operated devices that move only
back and forth in the direction indicated by the reference arrow
132 (see FIGS. 17 and 19) and does not require the movement of an
extracted bag to a separate loading position. This alternative
embodiment results in lower overall costs for the system 100,
simplified operation of the system and greater throughput.
[0080] In some applications, additional mechanical elements may be
used to grip the partially extracted bag 102. For example, when the
bag 102 is a plastic bag, such as polyethylene, additional
mechanical gripping members 182a-b may be used in conjunction with
the vacuum-operated devices 130a-b to open and retain the partially
extracted bag 102. The operation of the gripping members 182a-b in
conjunction with the vacuum-operated devices 130a-b is illustrated
in FIGS. 21-22. In FIG. 21, the vacuum-operated device 130a is in
the first position spaced apart from the bags 102 on the protruding
member 104. In this position, the gripping member 182a is in a
resting position. The gripping member 182a is activated when the
vacuum-operated device 130a engages the first side (i.e., the front
portion 114f) of the bag 102 and begins to partially open the bag.
At that point, the gripping member 182a rotates into an active
position to mechanically grip and retain the front portion 114f of
the bag 102. When the bag is in the fully open position,
illustrated in FIG. 22, the bag is retained by the front gripping
members 182a-b and the clamps 178a-b.
[0081] Operational details of the gripping members 182a-b are
illustrated in FIGS. 23-24. As best seen in FIG. 23, the gripping
members 182a-b each comprise inner fingers 184 and outer fingers
186 to grasp and retain the partially opened bag 102 therebetween.
In FIG. 23, the inner and outer fingers 184-186 are rotated to a
horizontal position so as not to interfere with initial extraction
of the bag by the vacuum-operated devices 130a-b. For the sake of
clarity, the vacuum-operated devices 138a-b are not illustrated in
FIGS. 23-24.
[0082] When the bag 102 has been partially extracted and opened by
the vacuum-operated devices 130a-b, the inner and outer fingers
184-186 rotate such that the inner fingers 184 are projecting in a
substantially vertical downward orientation inside the front
portion 114f of the partially opened bag 102. At the same time, the
outer fingers 186 are also rotated in a substantially downward
vertical orientation so as to be positioned on the outside of the
front portion 114f of the partially opened bag 102. Thus, the front
portion 114f of the partially opened bag is positioned between the
inner and outer fingers 184 and 186, respectively.
[0083] Following rotation of the inner and outer fingers 184 and
186, the relative position between the inner and outer fingers is
decreased so as to mechanically grasp and retain the front portion
114f of the partially opened bag 102. This relative movement may be
readily accomplished through the use of electromechanical
actuators, motors, screw drives, vacuum-actuated devices, hydraulic
devices, or the like, to move the inner fingers 184 toward the
outer fingers 186. Conversely, the outer fingers 186 may be
designed to move toward the inner fingers 184. Alternatively, both
the inner and outer fingers 184-186 may be designed to move towards
each other. Operational details of operation of the gripping
members 182a-b are known to those of ordinary skill in the art need
not be described in greater detail herein.
[0084] The operation of the gripping members 182a-b has been
described in conjunction with the vacuum-operated devices 130a-b.
However, in an alternative embodiment, the gripping members 182a-b
may be used independent of any vacuum-operated device to open and
extract the bag 102. In this embodiment, the gripping members
182a-b are attached directly to the air cylinder slides 136a-b,
respectively, in place of any vacuum-operated device.
[0085] In this embodiment, an alternative technique must be
provided to initiate partial opening of the bag 102. A tube 188 is
coupled to an air source 190. As the gripping members 182-184 are
moved along the air cylinder slides 136a-b, respectively to the
first position, a burst of air from the air source 190 is directed
via the tube 188 to a position proximate the aperture 24 (see FIG.
5) of the bag 102. The burst of air from the air source 190 is
sufficient to partially open the bag. The gripping members 182a-b
operate in the manner described above to engage the front portion
114f of the partially opened bag.
[0086] As the gripping members 182a-b are withdrawn to the second
position along the air cylinder slides 136a-b, the inner and outer
fingers 184-186, respectively, of the gripping members 182a-b grasp
and retain the partially extracted bag 102. This technique is
particularly useful when the bags 102 are plastic bags. However,
the air source 190 may also be used to open, or at least partially
open, paper bale bags. The use of air bursts to partially open bags
is known to those of ordinary skill in the art and need not be
described in greater detail herein.
[0087] It is to be understood that even though various embodiments
and advantages of the present invention have been set forth in the
foregoing description, the above disclosure is illustrative only,
and changes may be made in detail, yet remain within the broad
principles of the invention. Therefore, the present invention is to
be limited only by the appended claims.
* * * * *