U.S. patent application number 13/234247 was filed with the patent office on 2012-03-22 for orbital feeder.
This patent application is currently assigned to R.A. Jones & Co. Inc.. Invention is credited to Paul A. Frederick, Robert M. Kalany, Robert J. Thiemann.
Application Number | 20120067004 13/234247 |
Document ID | / |
Family ID | 45816472 |
Filed Date | 2012-03-22 |
United States Patent
Application |
20120067004 |
Kind Code |
A1 |
Kalany; Robert M. ; et
al. |
March 22, 2012 |
ORBITAL FEEDER
Abstract
An improved orbital carton feeder comprises at least one carton
gripping suction cup rotatably mounted to a rotatable wheel and
moving in a hypocycloidal path having cusps, one of which defines a
curved path portion coordinated with a blank placement station.
Multiple cusps, cups and operational stations are disclosed, as
well as a preferred cusp angular relationship responding to an
angle of a carton blank at a discharge or pickoff station and an
angle of disposition of a blank received conveyor.
Inventors: |
Kalany; Robert M.;
(Florence, KY) ; Thiemann; Robert J.; (Crestview
Hills, KY) ; Frederick; Paul A.; (Harrison,
OH) |
Assignee: |
R.A. Jones & Co. Inc.
Covington
KY
|
Family ID: |
45816472 |
Appl. No.: |
13/234247 |
Filed: |
September 16, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61403605 |
Sep 17, 2010 |
|
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|
Current U.S.
Class: |
53/381.1 |
Current CPC
Class: |
B65B 43/285 20130101;
B31B 50/804 20170801 |
Class at
Publication: |
53/381.1 |
International
Class: |
B65B 43/26 20060101
B65B043/26 |
Claims
1. An orbital blank feeder having a blank transporter moving in a
hypocycloidal path having a plurality of cusps wherein one of said
cusps is defined as the apex of a curved path, said feeder having a
blank pick-off station, a blank placement station and a blank
pre-opening station between said pick-off and placement stations,
each station oriented proximate one of said cusps.
2. A feeder as in claim 1 wherein said one cusp is operably
oriented adjacent a blank conveyor for transferring a blank to said
conveyor at said placement station.
3. A feeder as in claim 2 including at least four cusps.
4. A feeder as in claim 2 including at least five cusps.
5. A feeder as in claim 2 including at least six cusps.
6. A feeder as in claim 1 wherein said feeder includes a blank
magazine having a discharge station presenting a blank at an angle
to horizontal, and each cusp is in an angular relationship with
respect to adjacent cusps, said angular relationship being
approximately equal to the sum of the angle of a blank at a
discharge station to horizontal and an angle from horizontal of an
adjacent blank conveyor operably oriented to receive a blank from
said feeder.
7. A feeder as in claim 1 wherein said pick-off station is oriented
proximate a first cusp of said path and said pre-opening station is
located proximate a second sequential cusp of said path.
8. A feeder as in claim 7 wherein said placement station is
oriented proximate a third cusp of said path.
9. An orbital feeder for feeding carton blanks from a blank
magazine to a carton conveyor through a portion of a hypocycloidal
path, said path having at least four cusps, said feeder comprising
a blank pick-off station at said magazine and proximate a first of
said cusps, a blank pre-opening station proximate a second of said
cusps and a blank placement station proximate a third of said
cusps.
10. A feeder as in claim 9 wherein said cusp path defines at least
two pointed cusps and one U-shaped cusp oriented proximate said
blank placement station.
11. A feeder as in claim 10 wherein said first and second cusps are
pointed.
Description
RELATED APPLICATION
[0001] The application claims priority to U.S. Ser. No. 61/403,605
filed Sep. 17, 2010, the disclosure of which is hereby incorporated
herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to orbital feeders such as rotary
carton feeders and more particularly to such feeders which pick up
a flat carton blank from a magazine and deliver it to a conveyor
for carton erection and loading.
BACKGROUND OF THE INVENTION
[0003] Rotary carton feeders are well known. U.S. Pat. Nos.
4,518,301 and 4,596,545 show, for example, features of the R. A.
Jones & Co. Inc. "Orbi-Trak" orbital feeder. These two patents
are both incorporated expressly herein by reference and made a part
hereof as if fully set forth herein.
[0004] Such feeders as described in these patents provide reliable
and reasonably fast carton feeding from a magazine of flat blanks
to an erected open position between trailing and lead lugs of a
carton conveyor, on which the cartons can be loaded (typically from
their ends), closed, sealed and discharged.
[0005] In any carton feeder, and particularly as carton throughput
speeds increase, it is necessary to feed the cartons from their
magazine to the lug conveyor accurately, and to insure reliable
opening of cartons once transported by the lug conveyor.
[0006] When dealing with flat blanks designed to eventually be
opened into cartons having a tube shape, which is primarily square
or rectangular when opened, it is desired that each fed carton be
handled in a way to reliably open. Such flat blanks are typically
side-seamed with eventually opposed panels lying flat against
adjacent respectively opposed panels (to provide an eventual square
carton configuration) or against a combination of opposed and
adjacent panels (to provide an eventual rectangular carton
configuration). Respective panels are defined along fold lines
either folded or scored for folding upon erection of the carton.
There are several circumstances which may obstruct this goal of
reliable opening.
[0007] For example, it will be appreciated that cartons are
typically, but not necessarily, fed from a horizontally-oriented or
slightly inclined magazine where cartons are oriented flat against
each other in a stack with the cartons resting on their lower edge.
A stack of cartons is moved along with successive cartons being
picked off the end of the stack at a pick-off position. There are
numerous and varied expedients to facilitate the reliable
separation of a carton at the stack end pick off position. Known
devices to this end are shown in U.S. Pat. Nos. 4,601,691;
4,429,864; 4,779,860; 4,934,682 and 4,093,207, all of which are
herein expressly incorporated by reference as if fully set forth
here. In U.S. Pat. No. 4,571,236, reliable carton squaring is
provided in part by a rearwardly inclined leading lug of the carton
lug conveyor. That patent is also expressly herein incorporated by
reference as if fully set forth herein.
[0008] Nevertheless, the parameters of stacked carton blanks, their
separation from the blank stacks in the feed magazines and the
transfer of the blanks from the pick-off position at the magazine
to erected condition between the leading and trailing transport
lugs of a carton conveyor continue to present considerations of
reliable blank transfer and erection, particularly as speeds
increase.
[0009] In this instance, where carton blanks are configured to
produce opened cartons of square cross-section, it will be
appreciated that the intermediate unfolded scored lines, about
which the blank will be folded, are parallel and lie immediately
adjacent each other in the flat blank. Viewing the flat blank as a
whole, the stiffness of the blank is affected by these proximate
fold lines, parallel with each other. In other words, such a blank
is more easily folded or bent in the area extended along these
scored lines, compared to a blank for a rectangular cross-section
carton where the unfolded score lines are not so closely
oriented.
[0010] With such a square configuration carton, and considering the
process of picking off from a magazine such a carton blank with a
suction cup, it is desirable to have the carton opened uniformly
when finally between the leading and trailing lugs of the carton
conveyor. One potential obstacle to this goal is the undesirable
creation of an "L"-shaped configuration during the blank pick-off,
transfer or deposit into the carton conveyor lugs. In this
undesirable configuration, the upper half of the blank is bent
forwardly of the carton, with the remainder oriented downwardly.
Typically, this occurs at a bending of the blank about the adjacent
fold lines of the blank, for a square configuration carton. This
artifact in a process can occur during the pickoff, transfer or
placement and results in an "L"-shaped blank between the conveyor
lugs which cannot be fully opened or erected as desired. Such an
"L"-shaped blank cannot be used and must be rejected.
[0011] It has accordingly been one objective of the invention to
provide a rotary carton feeder and process which eliminates or
reduces the possibility of producing "L"-shaped carton blanks in
the transfer process.
[0012] In another aspect of rotary carton feeders, it is known to
"pre-open" the carton blanks at location after the pickoff from a
magazine but prior to placing the blank in the conveyor lugs. Such
pre-opening can be useful in the facilitation of reliable opening
and placing of cartons in the carton conveyor.
[0013] Current applications providing a "pre-opening" operation,
however, are attended by further disadvantages. In one system, the
carton blank magazine must be placed above and directly over the
carton conveyor. Wheel-mounted suction cups pick off blanks, move
the blanks generally counterclockwise (when viewed from a position
with the stacked magazine and conveyor extended to the right), and
then place the pre-opened blank on the conveyor with flow to the
right. The disadvantage of such a system is the orientation of the
blank magazine over the carton conveyor in a space which should be
left open for conveyor access and adjustment or maintenance.
[0014] In another configuration, the magazine is above but not
directly over the carton conveyor, which extends to the right, and
is oriented on the left side of the clockwise-rotating transfer
wheel. Here, the cartons are picked off from the magazine and
transferred generally in a clockwise direction over and downwardly
to the carton conveyor lugs. Since, however, the blank is now
generally moving near the bottom of the wheel to the left, its
overall direction of movement must be reversed to match the
opposite machine direction of the carton transport lug conveyor.
This need for a "reverse" motion creates an abrupt and unreliable
placement and is one factor limiting operational speeds.
[0015] Even when such systems provide a vacuum or suction partial
pre-opening of the blank by presenting it to a suction cup, for
example, the foregoing inherent disadvantages are a concern.
[0016] Accordingly, it is yet a further objective of the invention
to provide an orbital carton feeder providing a suction generating
pre-opening of a magazine-fed blank but without the need to orient
the blank magazine over and above the carton conveyor, and without
requiring any reverse motion of the blank in connection with
placing it between leading and trailing lugs of a carton
conveyor.
[0017] A further objective of the invention has been to provide
apparatus and methods of rotary carton feeding for reliable opening
of magazine-fed carton blanks, including picking blanks from a
magazine, placing them between lugs of a carton conveyor, and at
higher speeds then heretofore available, with a pre-opening
operation option.
SUMMARY OF THE INVENTION
[0018] To these ends, a preferred embodiment of the invention
contemplates a rotary carton blank feeder having a rotating feeder
wheel carrying rotating blank holding vacuum cups rotating through
at least four cusps of an hypocycloidal motion pattern. This is
attained similarly to that apparatus of U.S. Pat. No. 4,596,545 but
wherein one or more suction cup supporting spindles are mounted on
a carrier or feeder wheel and the apparatus generates a preferred
four cusp movement with the operative cusp adjacent the blank
placement station defined in more of a "U"-shaped than sharp
configuration which results in a relatively smooth, softer and
slower placement operation.
[0019] Between the pickoff station defined at a first cusp of
motion, and the placement station defined at a third cusp of
motion, there is operationally oriented a pre-opening vacuum
station proximate a second cusp of motion. As the picked-off blank
is presented to this station, suction is applied to the blank's
opposite side to partially pre-open it. The now partially
pre-opened blank is then moved to the placement station at a third
cusp of motion.
[0020] Thereafter, the suction cup, having placed the blank, is
reoriented as the feeder wheel continues its rotation and the cup
is moved through yet a fourth cusp of motion back toward its proper
orientation for picking off a blank at the first cusp of motion
defining the pickoff station.
[0021] Several parameters of the invention will thus become readily
apparent. First any number of cusps can be used in apparatus
according to the invention so long as they prove pickoff and
placement stations as described as well as an optionally preferred
pre-open station, and then return of the suction cup from the
smooth placement station to operative position as it moves to the
pick-off station motion cusp.
[0022] The variations of operable motion cusps can be used to
provide large variations in the relative orientation of the blank
magazine to the carton conveyor on which blanks are placed. For
example, and with respect to the rotary feeder phases, the pick-off
and placement stations can be in a relative 180 degree phase
relationship or at some other phase where other
magazine-to-conveyor positions are desired.
[0023] Any number of spindles can be used for so long as the
hypocycloidal motion of the picked-off blanks is not obstructed by
other blanks or feeder elements, and with attendant speed
capabilities.
[0024] Accordingly, the preferred embodiment of the invention
provides a rotary feeder, with optional vacuum blank pre-opening
and soft, reliant placement for full blank erection between leading
and trailing conveyor lugs, without the need to orient the blank
magazine above and over the carton conveyor and without requiring
any motion reversal.
[0025] With more particularity, one embodiment of the invention
includes a generally horizontal blank magazine with a discharge
section declining the blank at about 45 degrees from horizontal at
a pick-off position defined at a first cusp of motion of an orbital
feeder according to the invention. At 180 degrees on the other side
of the orbital feeder of this invention from the pick-off position
is disposed an inclined portion of a carton transporting lug
conveyor, inclined at about 45 degrees to a downstream horizontal
position. It will be appreciated that this 180 degree relationship
can be varied to accommodate desired operational parameters.
[0026] Preferably, and if desired, a pre-open or pre-break station
is oriented at a second cusp of blank motion, as will be described
in detail, for at least pre-breaking the blank to facilitate later
full erection on the conveyor.
[0027] The carton blank placement station is advantageously placed
within the inclined portion of the conveyor, at about 180 degree
phase of the orbital feeder from the pick-off position, and is
defined at a third cusp of motion of the orbital feeder. This third
cusp is so configured that its apex is not a point but is defined
over a more extended distance, resulting in a smooth, more gentle
carton blank placement movement as the blank is placed between the
lugs of the conveyor and then further erected.
[0028] From there, the spindle/suction cup is rotated through a
fourth and final cusp of motion for re-orientation to proper
position for presentation to the pick-off position through the
first cusp of motion.
[0029] As noted above, the orbital feeder according to the
invention may have one or a plurality of spindle carried, blank
holding suction cups. Such a feeder may also be configured with
other combinations or patterns of cusps, so long as the placement
cusp is more elongated to facilitate placement, is re-oriented
prior to arrival at the next cycle pick-off position, and
optionally provides for a cusp of movement defining a pre-opening
station between blank pick-off and placement. Within these
parameters, a variety of magazine and carton conveyor relationships
can be provided without requiring magazine orientation above and
directly over the carton conveyor, and without requiring any
reversal of blank motion to achieve proper placement on the
transport conveyor.
[0030] These and other objectives and results will be readily
appreciated by those of ordinary skill in the art from the
following detailed description of a preferred embodiment of the
invention and from the drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a diagrammatic elevational view of a carton
feeding and erecting system according to the invention and
including a carton magazine, rotary feeder and carton lug
conveyor;
[0032] FIG. 2 is a view similar to FIG. 1 illustrating the
invention comprising a rotary carton feeder having a preferred four
cusp following motion;
[0033] FIG. 3 is a view similar to FIG. 2 but illustrating a less
desirable four cusp constant velocity motion where each cusp is
identically configured;
[0034] FIGS. 4A-4E are diagrammatic views showing the progression
of the placement cusp at varied angular phases, with respect to the
pick-off cusp at the carton magazine as the cusp approaches and
departs the blank placement station;
[0035] FIG. 5 is a diagrammatic view illustrating use of suction
cup and breaker channel for pre-braking a carton blank;
[0036] FIG. 6 is a view of a suction cup and breaker channel before
release of a more fully-erected carton;
[0037] FIG. 7 is a view similar to FIG. 6 but also showing the
carton transport lugs receiving and erecting a placed carton;
[0038] FIG. 8 is a view similar to FIG. 6 but illustrating an
undesirable "L"-shaped carton blank configuration;
[0039] FIG. 9 is a view similar to FIGS. 8 and 7 but showing a
failed opening of an "L"-shaped carton blank;
[0040] FIGS. 10A and 10B illustrate respectively an alternate five
cusp following motion of an alternate rotary feeder and, for
contrast, a five cusp constant velocity motion; and
[0041] FIGS. 11A and 11B illustrate respectively an alternate six
cusp following motion of an alternate rotary feeder and, for
contrast, a six cusp constant velocity motion.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Turning now to the drawings, FIGS. 1, 2, 5, 6 and 7
illustrate features of a preferred embodiment of the invention.
FIG. 1 illustrates a carton feeding operation including carton
blank magazine 10, rotary blank feeder 12 and a carton lug conveyor
14 for receiving, erecting and transporting erected cartons. The
elements respectively define a pick-off station 16 at the discharge
end of a magazine 10 and a pre-open or pre-break station 18, and a
blank placement station 20, each station attended or defined by one
cusp of a multiple cusp motion orbital blank feeder of the type
described in U.S. Pat. Nos. 4,518,301 and 4,596,545 but with a
multiple cusp motion as described herein. One of ordinary skill
will appreciate the mechanical modifications necessary in the
apparatus of U.S. Pat. No. 4,596,545 incorporated herein, to
provide the hypocycloidal motion having at least four cusps.
[0043] More particularly, and according to the invention, the
rotary or orbital feeder 12 of a preferred embodiment includes
motion defined through four "cusps" 22-25. A first cusp 22 is
oriented at pick-off station 16, a second cusp 23 at pre-break or
pre-opening station 18, a third "following" cusp 24 at placement
station 20 and a fourth orienting cusp 25 operatively between cusps
24 and 22.
[0044] Rotary feeder 12 operates here in a general counterclockwise
direction of Arrow A (FIG. 2), A blank picking, breaking, transport
and placing rotary suction cup apparatus 28 (illustratively in FIG,
1 and in more detail in FIGS. 5, 6) includes a blank holding cup 29
(FIG. 5) situated within a breaker channel 30 having bars 31, 32.
Suction cup apparatus 28 is disposed on a rotatable shaft (not
shown) for rotation about minor axis 34 carried on feeder wheel 36
with the cup 29 thus moving in a hypocycloidal pattern of motion
having four cusps about major axis of rotation 38 of feeder 12 and
wheel 36. Suction cup 29 is operably connected to a hose 33 (FIG.
9) for supplying vacuum to the cup from a vacuum source to
facilitate the picking of a blank 13 from blank magazine 10.
[0045] As noted above, the mechanism and principle of operation of
feeder 12 and cup assembly 28 are fully disclosed in U.S. Pat. Nos.
4,518,301 and 4,596,454, incorporated herein, with the modification
of components to provide the particular cusp number and motions
described herein as will be readily apparent to one of ordinary
skill in the art. The feeder sun and planetary elements are
provided as appreciated by those skilled in the art to provide the
modified cusps and motion patterns according to the invention as
described herein.
[0046] For purposes of this disclosure then, a "cusp" is defined as
an outermost point in the motion, i.e. the outermost point of an
operative element (here the face 40 of cup 29) as it moves through
its hypocycloidal path about axis 38. Said in another way, a "cusp"
as that term is used herein is that point of motion of the
operative apparatus in its path where the point is in a direct
straight line including both major axis 38 and minor axis 34. In
the case of cusp 24, the point is the apex of an elongated curve
rather than a precise abrupt point as will be discussed.
Accordingly, it will be understood that a "cusp" is a point or apex
of a single curve in a hypocycloidal path as described.
[0047] In particular, where a four cusp pattern is used in a
preferred embodiment, first, second and fourth cusps 22, 23 and 25
are "point" cusps through which cup 29 (face 40) moves quickly with
a relatively constant velocity motion. Third cusp 24, however, is
defined by a "following" motion wherein the cusp is the apex of an
elongated curve rather than pointed in pattern as are the others.
In this way, the cup 29 at placement station 20 has a delayed or
slower motion as the cusp is more elongated. This results in a much
softer, gentler and accurate placement in both approach and release
duration of a carton blank between the trailing and leading lugs
42, 44 of conveyor 14 which receive, fully erect and transport the
blank.
[0048] In the preferred embodiment, it will be appreciated the four
cusps are spaced at 90 degree intervals about axis 38, with first
cusp 22 at 0 degrees, second cusp 23 at 90 degrees, third cusp 24
at 180 degrees (see FIG. 4C) and fourth cusp 25 at 270 degrees.
[0049] Accordingly, as wheel 36 of feeder 12 rotates about major
axis 38, a first cup apparatus 28 engages a flat carton blank B at
the pick-off station 16 located at a discharge from magazine 10.
The blank B is moved in the motion pattern of cup apparatus 28 both
generally about major axis 38 and in a circular path about minor
axis 34, thus in a general hypocycloidal path to pre-opening and
through station 18 where, by action of suction cup 29 pulling the
blank B against channel 30 and bars 31, 32 or by optional
application of suction by suction cup 45 (FIG. 1) operating on the
opposite side of a blank B, the blank is at least partially broken
open into a configuration illustrated by blank B-2 of FIG. 1. Blank
B can be broken by the suction of the blank toward bars 31, 32 as
the blank is moved away from pick-off station 16.
[0050] Thereafter, a blank in a shape as that of blank B-2 is
delivered to the placement station 20 and between lugs 42, 44 of
conveyor 14 as illustrated in FIGS. 6 and 7.
[0051] It will be appreciated the blanks of this embodiment, when
erected, are of square cross-sectional configuration, the opposed
panel lengths represented at 46, 48 and the opposite panel widths
50, 52. When blanks B are flat as in magazine 10, opposed scored
but unfolded fold line 54 lines alongside scored but unfolded fold
line 56. Panel 48 lies against panel 50 and panel 52 against panel
46 in this flat condition.
[0052] The rigidity of the flat carton blank of eventual square
cross-section is thus weakest in the area of and along these
unfolded scored lines 54, 56. It is easier to suffer, then, a
reverse folding of the blank about these lines 54, 56 during the
pick-off and blank break in other equipment. Such undesirable blank
configuration is illustrated (as an "L"-shaped blank B-3) in FIGS.
8 and 9, wherein reliable squared-up blank placement opening and
erection cannot be obtained.
[0053] This undesirable anomaly is illustrated best in FIG. 9 where
a mis-formed "L"-shaped carton blank B-3 is placed between two lugs
42a and 44a of a conveyor 14a. This blank B-3 must be then
discharged as waste.
[0054] Use of the present invention described herein including the
cup apparatus 28 pre-break, or the passage of a blank through
pre-open station 18 prevents this from occurring, even with square
cross-section cartons.
[0055] Continuing with the description, and with reference to FIGS.
4A-4E, the progression of delivery of a blank, B-2, into and
between lugs 42, 44 of conveyor 14 is illustrated. Each FIG.
illustrates the angular progression of feeder wheel 36 from 150
degrees through 210 degrees. In this regard, the third cusp 24 is
in a static angular position at 180 degrees from the pick-off
station 16 at 0 degrees.
[0056] In FIG. 4A, the wheel 36 (not the "cusp", which is merely
part of a motion pattern) is at 150 degree rotation. A first lug
set 58 of conveyor 14 has carried away a previously placed blank
(B-4) while succeeding blank B-2 is moving in its hypocycloidal
path toward path cusp 24. In FIG. 4B, wheel 36 has advanced to 165
degrees angular rotation, and cup 29 has progressed to a point
approaching the elongated apex 60 of cusp 24. In FIG. 4C, the cup
29 and blank B-2 have reached and are in the middle of cusp 24 and
elongated following motion along elongated apex 60. Blank B-2 is
here fully and gently placed in a second set 62 of lugs 42, 44 at
placement station 20.
[0057] FIG. 4D illustrates the retreat of cup 29 back along path of
cusp 24, toward cusp 25, having now released blank B-2 and with
wheel 36 now at 195 degrees rotation. Finally, FIG. 4E represents
progress of wheel 36 through 210 degrees rotation with cup 29
having passed along cusp 24 toward a path taking it to cusp 25.
[0058] Also to be noted is that conveyor 14 is generally oriented
on an incline of 45 degrees in this embodiment, approximately
parallel to a 45 degree incline of a blank B at pick-off station
16. Thereafter, conveyor 14 may be operatively elongated, such as
in a horizontal direction, for further carton filling or
processing.
[0059] It will be appreciated then that cup 29 and a blank B-2 is
carried along in a hypocycloidal path to that portion defined by
third cusp 24. As the blank B-2 approaches the elongated apex 60 of
cusp 24, the blank may be decelerated for gentle, reliable
placement in lug set 58. Once the blank B-2 is released to the lugs
42, 44, the cup 29 can be accelerated back along its hypocycloidal
path for another cycle. The acceleration and/or deceleration
velocity parameter of the cup 29 with or without the blank B-2 can
be predetermined within the scope of the invention to accommodate
any desired motion facilitating carton feeding.
[0060] FIGS. 2 and 3 offer a side-by-side comparison of an
operative rotary feeder motion according to the invention (FIG. 2)
and a rotary feeder motion of constant velocity throughout for
comparison purposes. The operation of the feeder in the
hypocycloidal path 70 illustrated in FIG. 2 provides the benefits
of the invention. In FIG. 3, for contrast, each cusp is defined at
a sharp precise point of path reversal.
[0061] In contrast, operation of a feeder in the constant velocity
motion through the more symmetric hypocycloidal path 72 (FIG. 3)
about a wheel 36a, results in a four cusp path, with each cusp
symmetrical. Thus, at a placement station 73, near conveyor 14b,
the placement motion is constant and abrupt, resulting in a lesser
reliable blank placement at speed.
[0062] Diagrammatic FIG. 10A illustrated a five cusp hypocycloidal
path 74, in a feeder including a feeder wheel 76, and according to
an alternate embodiment of the invention. Here the cusps each have
a respective apex and these are oriented at a 72 degree angular
phase. Such an orientation accommodates use of a carton conveyor
14C (lugs not shown for clarity) inclined at only 19 degrees (see
FIG. 10A) where the conveyor is approximately tangent to a cusp 78
and elongated apex 80. Here, it is preferable to orient the
magazine discharge so blanks are presented for pick-off at about 55
degrees, and perhaps at 53 degrees, with some degree of variation
acceptable as needed.
[0063] Reviewing FIG. 10B in contrast, a feeder wheel 76a with a
five cusp constant velocity cusp path 74a is illustrated with
similar disadvantages at a placement station 78a as in FIG, 3.
[0064] FIGS. 11A and 11B illustrate six cusp paths. In FIG. 11A, an
alternate embodiment is disclosed where cusp 82 has an elongated
apex 84 proximate a preferably horizontal conveyor 14d (lugs not
shown for clarity). Cusp 82 is in a hypocycloidal path 86 about a
feeder wheel 88.
[0065] Blanks B in a magazine are discharged at a pick-off station
from about 55 degrees and carried to a placement position on
conveyor 14d defined proximate cusp 82.
[0066] It will be appreciated that conveyor 14d can be horizontal
or only slightly inclined or declined from the horizontal to offer
a landing or placement orientation complimentary to that of the
angled blank pick-off location, and in order to accommodate a
desired conveyor angle.
[0067] Hypothetically, it will be appreciated that the sum of the
angle of the blank pick-off orientation from horizontal, and that
of the receiving lug conveyor (here 14d) from horizontal preferably
approximates the segment of the relative phase of the cusps to each
other. Thus, in a four cusp path feeder, that sum angle is about 90
degrees; in a five cusp path feeder about 72 degrees and in a six
cusp path feeder, about 60 degrees, plus or minus two or three
degrees.
[0068] This relationship permits design of the rotary feeder
magazine and conveyor orientation in a large variety of
combinations, and is only a rule-of-thumb in providing the
invention for a multiplicity of desired spacings and component
locations of magazine, feeders and conveyor. Selection of the
number of path cusps is then a function of the desired
application.
[0069] In contrast, FIG. 11B illustrates a six cusp constant
velocity motion path 92 having six symmetric cusps generated about
feeder wheel 94 with a cusp 96 nearest conveyor 14d for potential
blank placement but where cusp 96 has a sharp, single point apex
98, as that of 78a in FIG. 10B or that of the cusp nearest conveyor
14b in FIG. 3, all of which are attended by the disadvantages of
the sharper, more abrupt motion at placement as noted above.
[0070] Finally, it will be appreciated that feeders of the
invention can be provided with as many suction cup apparatus or
spindles 28 as the carton size will permit accommodation through
motion about the path traversed. It will also be appreciated that
as the number of selected cusps changes, the overall feeder and
wheel size may change to accommodate any particular carton blank
size or alternately other geometric mechanical changes can be made
in the apparatus. Additionally, the wheel size may be affected by
the number of spindles used.
[0071] Accordingly, the invention in preferred and alternative
embodiments provides numerous advantages among which are included,
preferred blank placement dynamics, accommodation of a wide variety
of relative magazine and conveyor orientations, positive and
reliable carton placement and erection, elimination of adverse
carton configurations through the process even for difficult to
handle small, square cross-section cartons, all at high speeds now
demanded in carton feeding processes, and the provision of
additional blank handling stations by way of four or more cusps of
a hypocycloidal motion feeder.
[0072] Such invention is capable of handling a wide range of carton
speeds through a wide range of carton sizes, and up to at least and
over 800 cartons per minute.
[0073] Of course, it will be appreciated that the invention could
be used with a wheel operating in a clockwise direction to
accommodate a variation of magazine and conveyor orientations. In
this regard, the sequence of the cusp operations and the reference
to the cusps as first, second, third and fourth, and so on, would
be reordered.
[0074] Moreover, the invention contemplates providing a plurality
of blank operations by the use of four or more cusps, with
additional cusps provided to present a blank to one or more other
stations such as for printing, gluing or the like. Additionally,
cusps can be tailored in their path to present the blank as needed
at a particular station.
[0075] These and other modifications and variations of the
invention will be readily appreciated by the foregoing to those of
ordinary skill in the art without departing from the scope of the
invention and applicant intends to be bound only by the claims
appended hereto.
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