U.S. patent application number 11/092981 was filed with the patent office on 2005-10-06 for packaging apparatus.
Invention is credited to Colwell, Paul Andrew, Groom, Francis Richard, Walker, Michael John.
Application Number | 20050217209 11/092981 |
Document ID | / |
Family ID | 32247644 |
Filed Date | 2005-10-06 |
United States Patent
Application |
20050217209 |
Kind Code |
A1 |
Colwell, Paul Andrew ; et
al. |
October 6, 2005 |
Packaging apparatus
Abstract
The invention provides a machine for packaging a product. The
machine has a feed end for receiving products to be packaged, a
delivery end from which packaged products are discharged, and a
plurality of packaging lanes. Each packaging lane is adopted for
packaging a row of products so that the machine can simultaneously
package a plurality of rows of products.
Inventors: |
Colwell, Paul Andrew;
(Hartley, GB) ; Groom, Francis Richard;
(Northfleet, GB) ; Walker, Michael John;
(Dartford, GB) |
Correspondence
Address: |
STITES & HARBISON PLLC
1199 NORTH FAIRFAX STREET
SUITE 900
ALEXANDRIA
VA
22314
US
|
Family ID: |
32247644 |
Appl. No.: |
11/092981 |
Filed: |
March 30, 2005 |
Current U.S.
Class: |
53/202 ;
53/251 |
Current CPC
Class: |
B65B 5/106 20130101;
B65B 35/40 20130101; B65B 21/242 20130101 |
Class at
Publication: |
053/202 ;
053/251 |
International
Class: |
B65B 035/30 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 31, 2004 |
GB |
0407380.5 |
Claims
1. A machine for packaging a product, the machine comprising: a
feed end for receiving products to be packaged; a delivery end from
which packaged products are discharged; and a plurality of
packaging lanes, each packaging lane being for packaging a row of
products such that the machine can simultaneously package a
plurality of rows of products.
2. A machine according to claim 1, wherein each packaging lane
includes: packaging input means to provide a row of packets for
said row of products, each packet being suitable for packaging a
respective product from said row of products; loading means for
loading each product into its corresponding packet to form a
packaged product; and conveying means for transporting the products
and packets through the machine.
3. A machine according to claim 2 having two or more packaging
lanes on vertically spaced levels, wherein the packaging input
means of the packaging lane or lanes on one level is horizontally
displaced from the packaging input means on an adjacent level.
4. A machine according to claim 2, wherein a single motor runs the
conveying means on more than one of the packaging lanes.
5. A machine according to claim 2, wherein the conveying means
includes a conveyor belt with flights for holding the
packets-located on the side walls of said conveyor belt, one of
said side walls being laterally movable to allow the conveyor belt
to be adjusted to hold different sized packets.
6. A machine according to claim 2, wherein the conveying means
includes a conveyor belt with an overhead rail for holding the
packets down on the conveyor belt, said overhead rail being movable
to allow access to the conveyor belt.
7. A machine according to claim 2 having two horizontally adjacent
packaging lanes, wherein the loading means of said two horizontally
adjacent packaging lanes load the products into their respective
packets sideways in opposite directions.
8. A machine according to claim 2, wherein a single packaging input
unit is the packaging input means for two or more horizontally
adjacent lanes.
9. A machine according to claim 2, wherein the conveying means
moves the products at a linear speed of less than 6.3
ms.sup.-1.
10. A machine according to claim 1 having two or more horizontally
adjacent packaging lanes.
11. A machine according to claim 1 having two or more packaging
lanes vertically spaced from one another.
12. A machine according to claim 1, wherein the packaging lanes are
parallel to one another.
13. A machine according to claim 1 having four packaging lanes
arranged in a 2.times.2 matrix configuration.
14. A machine according to claim 1, wherein two or more of the
packaging lanes are synchronised.
15. A machine according to claim 1, the machinery being housed
within a single frame.
16. A machine according to claim 1 having mirror symmetry about a
central vertical plane.
17. A packaging input unit for providing a plurality of rows of
packets for use in two or more horizontally adjacent packaging
lanes, the unit comprising: a plurality of adjacent hold/release
mechanisms, each hold/release mechanism being for selectively
holding and releasing a packet; drive means for simultaneously
moving the hold/release mechanisms from a first position to a
second position, such that the mechanism can take hold of a packet
at the first position and release it at the second position.
18. A unit according to claim 17, wherein the hold/release
mechanisms are independently operable.
19. A unit according to claim 18, wherein a hold/release mechanism
comprises a set of vacuum suction cups.
20. A machine for packaging a product, the machine comprising: a
feed end for receiving products to be packaged; a delivery end from
which packaged products are discharged; and a plurality of
packaging lanes, each packaging lane being for packaging a row of
products such that the machine can simultaneously package a
plurality of rows of products; each packaging lane comprising:
packaging input means to provide a row of packets for said row of
products, each packet being suitable for packaging a respective
product from said row of products; loading means for loading each
product into its corresponding packet to form a packaged product;
and conveying means for transporting the products and packets
through the machine; and said plurality of packaging lanes
comprising at least four packaging lanes arranged in a 2.times.2
matrix configuration.
Description
FIELD OF THE INVENTION
[0001] This invention relates to machines which automatically
package products. It is particularly relevant to end-load cartoners
and sleevers.
BACKGROUND
[0002] End-load cartoners are machines which load products sideways
into boxes and then close and/or seal the boxes. Sleevers are
machines which automatically put the cardboard sleeve around the
product, e.g. a plastic tray containing a ready meal.
[0003] Known end-load cartoners (e.g. the RSB6 series machine
manufactured by Jacob White (Packaging) Ltd) have an input line of
products carried on drive chains. A product to be packaged is
either manually or automatically placed on to the drive chains,
e.g. the product may be put into a bucket for packing in a carton.
The cartons in which the product are to be packed are erected from
a magazine which holds carton blanks when a sensor detects the
presence of a product on the conveyor belt. A blank is drawn from
the magazine by vacuum pick off, and is placed in an erected state
into a continuously moving flighted chain. The chain and conveyor
belt are arranged so that the product is aligned with the carton at
the point of loading. A linear sliding pusher arm acts on the
product to push it sideways into an open end of the carton. The
machine can sense when there is no carton or no product before the
loading step, and can perform rejection if necessary.
[0004] After loading, the carton is closed and sealed
automatically. Tucking and/or gluing are used to close and seal
such cartons. Once closed, the cartons are discharged from the
machine by powered side belts.
[0005] There are disadvantages associated with known machines.
[0006] Firstly, a balance needs to be struck between output level
(i.e. number of cartons packed per minute) and cost of machine
manufacture and maintenance. To achieve a high output level, it is
necessary that the conveyor belt and chain in the machine have a
high linear speed. However, if high linear speeds are used, the
tolerances of the machine parts needs to be much higher because
great precision is required at high speed to avoid jams and/or
mis-loading. Manufacturing parts to higher tolerances costs more;
the benefit of higher output therefore has higher cost associated
with it. Moreover, the life expectancy of parts in a machine worked
at high speed is less than that of similar parts in a slower
machine. Thus, costs relating to maintenance and replacement parts
are increased for high speed machines.
[0007] A second disadvantage occurs when a packaging company wishes
to package different types of product but does not have factory
space for a plurality of packaging machines. To package different
products, it is necessary to perform one run of packaging for one
product, then stop the machine and re-configure it for the next
product, etc. Packaging time (and therefore overall output rate) is
reduced by the machine `down-time`, i.e. time when the machine is
not operating. This problem has a further important aspect with
regard to manufacturers who wish to market items which are
collections of a number of different individually packaged boxes. A
typical example is cereal selection packs, where a plurality of
boxes of different individually wrapped cereals are sold as a unit.
To manufacture these with the above-described machine, it is
necessary to package each type of product individually and, once
all of the different types of product have been packaged, to
collate the boxes into the correct combination. The packaging
process therefore has two distinct steps which are discrete; a
continuous production is not possible.
SUMMARY OF INVENTION
[0008] At its most general, the present invention provides a
packaging machine capable of simultaneously packaging two or more
product lines. The machine can receive a plurality of different
types of product as input and can simultaneously pack those
products to produce an output of different types of packaged
products. The input lines may be synchronised such that the same
number of each different type of product is produced; this
facilitates continuous production of a `selection box` containing
different packaged products.
[0009] According to the invention, there is provided a machine for
automatically packaging a product having: a feed end for receiving
products to be packaged; a delivery end from which packaged
products are discharged; and a plurality of packaging lanes, each
packaging lane being for packaging a row of products such that the
machine can simultaneously package a plurality of rows of
products.
[0010] Preferably, each packaging lane includes: packaging input
means to provide a row of packets for said row of products, each
packet being suitable for packaging a respective product from said
row of products; loading means for loading each product into its
corresponding packet to form a packaged product; and conveying
means for transporting the product and packets through the
machine.
[0011] Thus, the machine may resemble a known packaging machine,
except that it simultaneously runs a plurality of product conveyors
(e.g. conveyor belts or bucketed conveyors (for holding the
product), slatted chains, or other types of product translation
means known in the art) and has the ability simultaneously to erect
and then load a plurality of cartons (or other packet). Indeed,
each packaging lane of the present invention may resemble the
packaging mechanism of known devices. However, the inventors have
found it is preferable to share common components, as explained
hereinafter.
[0012] The machine may have the packaging lanes arranged in any
configuration. However, due regard needs to be given to overall
size and accessibility.
[0013] The present invention allows one to have the packaging
ability of a plurality of machines whilst not requiring the same
amount of space as plurality of single-laned machines would take
up. The amount of factory floor space taken up by a machine is
known as the `footprint`. The inventors have found that by sharing
common components in the plurality of packaging lanes, the
footprint of one multiple-laned machine according to the invention
is much less than that of a corresponding number of single-laned
machines.
[0014] Significantly, the use of multiple packaging lanes enables a
reduction in the linear speed of products being transported through
the machine whilst maintaining or even increasing the overall rate
of throughput of products compared with prior art, single lane
arrangements. The handling of products is also simplified.
[0015] Accessibility to the inside of machines is important for
maintenance and repair purposes. It is also important to have
access to the mechanism in order to fix a jam or mis-loading
operation. Such fixing is generally carried out by hand. This means
it is desirable to have all elements in the machine within arm's
reach of the outside frame.
[0016] The machine may have a plurality of horizontally adjacent
packaging lanes. The number of horizontally adjacent lanes may be
limited so that they can all be accessed by arm's reach from a side
of the machine. Alternatively or additionally, a small gap may be
provided between lanes to allow access.
[0017] The machine may have packaging lanes split over two or more
vertical levels. Such an arrangement is desirable because it does
not affect the overall width of the machine. Therefore, more
packaging lanes can be included without increasing the footprint of
the machine and without affecting the ease of access to the lanes
from the outside frame.
[0018] The machine may have four packaging lanes arranged over two
levels in a 2.times.2 matrix formation. The lanes may be parallel
to one another.
[0019] The height of the machine may be another important factor.
This is true if one considers the multiple vertical level
arrangement; the higher lanes are preferably accessible to an
operator standing on the floor, i.e. a ladder is not required. The
components of the mechanism which add the most height may be the
packaging input means, i.e. the carton erectors. To reduce the
overall height of the machine, it is preferable to stagger the
location of the packaging input means on different vertical levels,
i.e. the packaging input means on one level is preferably
horizontally displaced from that on an adjacent, vertically spaced,
level.
[0020] Preferably, a single motor is used to drive the conveying
means on more than one of the packaging lanes. This is an example
of sharing common components. One motor may be used to drive all of
the conveying means in the machine. Alternatively some, or even all
of the conveying means may be driven by separate motors.
[0021] Preferably, the conveying means comprises the flighted chain
and conveyor belt or bucketed conveyor of the known packaging
device. The flights may be provided on side walls of the chain. One
of the side walls may be laterally movable so that the chain can be
adjusted to hold different sizes of packet. The side walls may be
independently movable so that the machine can simultaneously
package different sizes of product.
[0022] The chain preferably has a overhead rail to prevent the
packet from jumping vertically off the chain. To allow better
access to the inside of the machine, the overhead rail is
preferably movable in the vertical direction.
[0023] In the `double decker` arrangement, it may also be desirable
for the upper chain to be vertically movable to avoid interference
between the return flights on the upper chain and the overhead rail
of the lower chain when the overhead rail of the lower chain is
lifted.
[0024] As with known machines, a guard screen may be present around
the loading area to prevent unwanted intrusion into the device
during loading. The guard screen may be opened to allow access,
e.g. to fix a jam.
[0025] The machine may be provided in a single frame. In other
words, the machine would be a unitary device between the feeding in
of the product and the discharge of the packaged items.
[0026] The machine may exhibit mirror symmetry about a central
vertical plane of the machine. This configuration facilitates
keeping the footprint of the machine as small as possible.
Preferably, when there are two horizontally adjacent packaging
lanes, the loading means of each packaging lane sideways loads
products into packets in an opposite direction to the other lane.
Thus, the left-hand packaging lane effects loading sideways to the
right, and the right-hand packaging lane effects loading to the
left.
[0027] Preferably, a single packaging input unit (or carton
erector) is used for two or more horizontally adjacent lanes. This
is another example of sharing common components. The drive means of
the carton erector, i.e. the mechanism which moves the carton blank
from the magazine to the flighted chain may be the same for all of
the lanes on one horizontal level. This arrangement would also
facilitate synchronisation. Thus, the input unit may comprise a
plurality of adjacent hold/release mechanisms for holding the
carton blanks all movable by a common drive means. The hold/release
mechanism may be independently or selectively operable. Thus, if a
sensor detects that there is no product to be loaded on one of the
lanes, the hold/release mechanism for that lane is preferably
deactivated. The hold/release mechanisms may be vacuum suction
cups. The selective control may be achieved by having separate
control valves.
[0028] Preferably, the machine operates so that the conveying means
moves the products at a linear speed of less than 0.63 ms.sup.-1
(1500 inches per minute). More preferably the linear speed is less
than 0.5 ms.sup.-1 (about 1250 inches per minute). These operating
speeds do not require the tolerances of the mechanical parts to be
very high, yet because there are a plurality of lanes, the overall
output of the machine is high. For example, a four-lane machine
with each lane having a product separation of 5 inches operating at
1250 inches per minute produces 1000 packaged items per minute. A
single lane device would need a linear speed of 5000 inches per
minute to achieve this. In addition to the simple fact of increased
output, the fact that the multiple-laned machine operates at a
lower speed means the life expectancy of individual parts is higher
because less strain is exerted on the mechanism. Moreover, machines
that operate at lower speeds are easier to control and cheaper to
maintain.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] Embodiments of the invention will now be described with
reference to the drawings, in which:
[0030] FIG. 1 is a plan view of a cartoning machine that is an
embodiment of the invention;
[0031] FIG. 2 is a cross-sectional side, view of the machine of
FIG. 1;
[0032] FIG. 3 is a perspective view of a carton erector suitable
for use in a machine that is an embodiment of the invention;
[0033] FIG. 4 is a perspective view of another carton erector
suitable for use in a machine that is an embodiment of the
invention;
[0034] FIG. 5 is a side view of a staggered arrangement of carton
erectors; and
[0035] FIG. 6 is an end view of the flighted chains used in the
machine of FIG. 1.
DESCRIPTION OF EMBODIMENTS
[0036] FIG. 1 shows a four-lane cartoning machine 10 which is an
embodiment of the invention. The machine is operated by
programmable logic circuits and other basic components which are
the same as those used for known single-lane devices. The following
description is confined to the differences between the inventive
machine and known machines. A person skilled in the art would
understand how to implement the invention from the following
information.
[0037] The machine 10 extends between a feed end 1 and a delivery
end 2. At the feed end 1, four bucket infeed conveyors arranged in
a 2.times.2 matrix configuration feed the product into the machine
10. The plan view of FIG. 1 shows the upper two conveyors 16, 18.
The lower two conveyors (including conveyor 17, see FIG. 2) lie
directly below the two upper conveyors 16, 18.
[0038] The upper conveyors 16, 18 respectively carry linear sliding
product buckets 20, 22. The buckets 20 on the left hand upper
conveyor 16 are slidable to the right, whereas the buckets 22 on
the right hand upper conveyor 18 are slidable to the left. The
lower two conveyors are configured accordingly.
[0039] The machine 10 contains an upper rotary carton feeder 12 and
lower rotary carton feeder 14. The rotary carton feeders provide
cartons for packaging the products on the conveyors. The upper
rotary carton feeder 12 provides cartons 26, 27 for the buckets 20,
22 carried on the upper two conveyors 16, 18. The lower rotary
carton feeder 14 provides cartons 24, 25 for the buckets carried on
the lower two conveyors (not shown in FIG. 1).
[0040] Like known machines, when the buckets are fed into the
machine 10, sensors (not shown) detect whether or not a product has
been loaded into the bucket. If a product is sensed, the rotary
carton feeder draws a carton blank from the relevant magazine 40
(see FIGS. 2 to 4) and places it in an erect form into the main
flights of a conveying chain 80,84.
[0041] To reduce the overall height of the machine 10, the upper
rotary carton feeder 12 is provided further along the machine than
(i.e. laterally displaced from) the lower rotary carton feeder 14.
Thus, cartons are fed from the lower rotary carton feeder 14
first.
[0042] Moreover, each of the carton feeders provides cartons for
two lanes. This is discussed in more detail below.
[0043] Each of the upper conveyors 16, 18 (and each of the lower
conveyors) has a chain associated with it. FIG. 1 shows that the
associated chains are located on the inside of their respective
conveyors. As in known machines, the flighted chain is aligned with
the conveyor such that, at the loading stage, the bucket is slid
sideways up to an open side of the carton.
[0044] Loading takes place in the loading section 8 of the machine
10. Prior to reaching the loading section 8, a second set of
sensors (not shown) check for the presence of products and cartons.
If either are missing, the linear sliding pusher arms 28 will not
be triggered to push the product bucket into its corresponding
carton.
[0045] The linear pushing arms are arranged on both sides of the
machine 10. As in known devices, there are a plurality of pushing
arms. In the present invention, a set of pushing arms is provided
for each pair of conveyor and flighted chain. Thus, there are two
sets of pushing arms 28 on each side of the device in a tiered
arrangement.
[0046] If a `no load` situation occurs, the product will be
rejected on its own lane. Therefore total separation of products is
possible even after they have entered the machine.
[0047] Once the cartons are loaded, their remaining open flaps are
closed in a known manner. FIG. 1 shows a gluing technique. Glue is
supplied from tanks 30 to nozzles 32, which apply the glue to the
flaps to seal the product in the carton. FIG. 1 shows individual
glue tanks 30 for each conveyor, but it is also possible to have a
common glue tank which provides glue to all the nozzles 32. Closure
by tucking is also possible.
[0048] Once the cartons are sealed, they can be ejected out of the
delivery end 2 of the machine 10 via paired sets of acceleration
belts 34 on to standard modular conveyors belts 36, 38, which can
transport the cartons away to their final destination.
[0049] The above-described components of the machine 10 between its
feed end 1 and delivery end 2 are contained within a single frame
member 6.
[0050] FIG. 2 shows a side view of the machine 10 resting on the
ground 4. Here, the `double decker` arrangement of packaging lanes
is clearly visible. Moreover, the lateral staggering of the upper
rotary carton feeder 12 and the lower rotary carton feeder 14 can
also be seen. The magazines 40 for holding carton blanks prior to
use are visible.
[0051] FIG. 3 shows a perspective view of the upper rotary carton
feeder 12. The feeder 12 forms the open cartons and deposits them
on to the flighted conveying chain for holding the carton and
transporting it to the loading area 8.
[0052] FIG. 3 shows how a single rotary carton feeder 12 can load
carton blanks 26, 27 on to two horizontally adjacent flighted chain
conveyors 80,84 for subsequent loading of two respective lanes of
products on conveyors 16,18 (see FIG. 1). The rotary carton feeder
12 has a magazine 40 which holds two sets of carton blanks 42, 44.
At the bottom end of the magazine 40, a rotating drive unit 50 is
located. The drive unit 50 has two opposed rotating axles 43, 45
which are arranged to rotate about their own axis at the same time
as moving about the axis of the drive unit 50.
[0053] Two adjacent sets of vacuum suction cups 46, 47, 48, 49 are
located on each axle 43, 45. The two degrees of rotation of the
carton feeder 12 are configured so that the vacuum suction cups are
aligned to act on the carton blanks when their axle is located
adjacent the bottom of the magazine 40 and aligned to place the
folded carton blank on to the product when their axle is located
adjacent the conveyors. FIG. 3 shows the vacuum suction cups 46, 47
placing the folded carton blanks on the flighted chain conveyors
80,84.
[0054] The axles are operated by a single drive unit, which is
provided on one hub of the carton feeder 12. This enables the
conveyors to be located closer together, because there is no need
to position a drive unit between them. The sets of vacuum suction
cups 46, 47, 48, 49 on each axle are still independently
controllable however. Each set of suction cups has its own control
valve (not shown), hence is independently operable.
[0055] In use, a signal is given to the rotary carton feeder 12
either manually or automatically which turns on the suction to the
feeder. The suckers on the rotary carton feeder pull off a single
carton 26,27 from the pile of flat cartons in the rotary carton
feeder 12. As the carton is placed into the flighted conveyor 80,84
the angle at which the carton hits the flight will cause it to
erect open. As the carton subsequently travels through the
cartoning machine the carton flaps are held open by conventional
mechanisms to help with the loading of product into the carton.
Conventional mechanisms can also be employed for closing and
sealing of the flaps after the product has been loaded.
[0056] FIG. 4 shows a perspective view of an alternative upper
rotary carton feeder 12. In this drawing, the packaging machine is
actually a sleever, so a flighted chain for holding the carton
prior to loading is not required. Instead, the carton blank is
deposited directly on the product, on conveyors 16,18, ready to be
folded over it at the loading stage. However, the same reference
numbers have been given to parts which have a common function to
the machines in FIGS. 1 and 3.
[0057] FIG. 4 shows how a single rotary carton feeder 12 can load
carton blanks 26,27 on to products 20,22 on two horizontally
adjacent conveyors 16,18. In this example, the conveyors 16,18 can
be closer together than illustrated in FIG. 1 as there is no need
for the chain conveyors 19 between them.
[0058] In an alternative carton erection system (not shown) the
flat cartons are loaded vertically above the flighted conveyor. The
system sucks or otherwise draws the carton down into the conveyor,
again hitting the flights at an angle that will cause the carton to
erect.
[0059] FIG. 5 shows the staggered arrangement of two rotary carton
feeders 12, 14 (that may be as illustrated in FIG. 3 or FIG. 4)
working at different levels. It us clear from this drawing how
vertical space is saved by this staggered arrangement.
[0060] FIG. 6 shows a cross-sectional view of the flighted chains
for carrying cartons as arranged in the machine in FIG. 1 when
viewed down the length of the chain. There are four chains arranged
in the 2.times.2 matrix configuration: two upper chains 80, 84 and
two lower chains 82, 86 lying directly beneath them. Each chain
comprises the main carton flights 68, 69, 72, 73 and the return
flights 70, 71, 74, 75. The outer fixed walls 60, 62 hold one side
of each of the chains, whereas the other sides are held by
adjustable walls 64, 65, 66, 67. These walls are laterally movable
to adjust the width of the chain so that different sizes of cartons
can be held.
[0061] Each chain also has a set of overheads 76 located over it.
The overheads maintain the vertical position of the carton on the
chain, and prevent it from coming off the flights. The overheads
are vertically movable by hand to allow access to the chain. This
is useful in order to clear a jam. During the loading operation,
however, each overhead rail is locked in place by clamp screws (not
shown) to prevent them from moving vertically under force from the
cartons.
[0062] It is apparent to one skilled in the art that the present
invention can include alternatives or additions which are not
described in detail above without departing from the scope of the
claims.
* * * * *