Title: Case tab-lock slitting and flap sealer in combination with a continuous radial motion case packing apparatus and method
Abstract: A case packing and case flap separation apparatus is disclosed for packing articles into cases and closing the cases. The cases typically have first and second major and minor flaps interconnected by tab-locks and held in folded positions adjacent vertical ends and sides of the cases. The apparatus includes a conveyor having a radial transport path adapted to transport successive cases through an article insertion section, first and second tab slitting sections, and a case exit section. Tab slitters are associated with the first and second slitting sections adapted to sever the tab-locks so that the major and minor flaps can be separated. First and second flap guides are associated with the first and second slitting section adapted to engage and elevate the separated major flaps away from the vertical walls after the tab-locks have been severed. Preferably, the case packing station and first and second tab slitting sections are located in proximity along the transport path so that the tab-locks are severed while the articles are inserted and gripped in the cases. By gripping the articles with the pickup heads, the articles and their cases can be guided by the pickup heads through the slitting sections as well as weighted down. A pickup head motion converter is operatively connected to the pickup heads to move the pickup heads in a compound motion to effect a first generally linear path at the pickup station for reliable article pick up and a secondary generally linear path at the flap separation station for reliable flap separation.
Patent Number: 6,883,296 Issued on 04/26/2005 to Hartness, et al.
| Inventors:
|
Hartness; Thomas P. (Greenville, SC);
Hartness, III; William R. (Greenville, SC);
Davidson; Mark W. (Greer, SC);
Dillard; Robert Leslie (Easley, SC);
Scott; David Lee (Greenville, SC)
|
| Assignee:
|
Hartness International, Inc. (Greenville, SC)
|
| Appl. No.:
|
637740 |
| Filed:
|
August 8, 2003 |
| Current U.S. Class: |
53/492; 53/247; 53/534; 53/381.2; 53/382.2; 53/382.3 |
| Intern'l Class: |
B65B 043//26; B65B 005//00 |
| Field of Search: |
53/3811,381.2,382.1,382.2,382.3,492,247,534,539
414/411,412
|
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| |
| Foreign Patent Documents |
| 4216721 | Nov., 1993 | DE.
| |
Primary Examiner: Huynh; Louis K.
Attorney, Agent or Firm: McNair Law Firm, P.A.
Parent Case Text
BACKGROUND OF THE INVENTION
This is a continuation-in-part application of application Ser. No. 10/232,550,
filed on Aug. 29, 2002, now U.S. Pat. No. 6,722,101, which is a continuation-in-part
of a application Ser. No. 09/418,619, filed on Oct. 15, 1999, entitled CONTINUOUS
CIRCULAR MOTION CASE PACKING AND DEPACKING APPARATUS AND METHOD, now U.S. Pat.
No. 6,729,103, which is a continuation-in-part of Ser. No. 09/301,394, filed Apr.
28, 1999, entitled Continuous Motion Case Packing Apparatus And Method, now U.S.
Pat. No. 6,571,532, which is a continuation-in-part of application Ser. No. 09/137,327,
filed Aug. 20, 1998, entitled Continuous Motion Case Packing Apparatus, now abandoned,
which is a continuation-in-part of application Ser. No. 08/338,026, filed on Nov.
10, 1994, entitled Continuous Motion Case Packing Apparatus, which is now U.S.
Pat. No. 5,588,282, and the above applications and patent disclosures are incorporated
herein by reference.
Claims
1. A continuous motion case packing and flap closing apparatus for continuously
picking up groups of articles at a pickup station and transferring the articles
to an article insertion section where the articles are inserted into cases having
major flaps and minor flaps maintained in a folded position adjacent sidewalls
of the cases, said apparatus comprising:
a frame;
a single, central vertical axis;
a plurality of reciprocating pickup heads carried by said frame in a manner to
rotate in a radial path about said central axis for picking up the articles at
said pickup station and inserting the articles at said article insertion section;
a flap separation station where said major and minor flaps are separated from
the sidewalls of the cases;
a rotary conveyor transporting said cases through said article insertion section,
and said flap separation station;
a pickup head motion converter operatively connected to said pickup heads to
move said pickup heads in a compound motion that includes a secondary rotation
and a translation to effect a first generally linear path at said pick-up station
for reliable article pick up and a second generally linear path at said flap separation
station for reliable flap separation.
2. The apparatus of claim 1 wherein said flap separation station includes flap
guides for raising the separated flaps to facilitate closure over the inserted articles.
3. The apparatus of claim 2 wherein said pickup heads have an article release
position, and said pickup heads being placed in said release position after said
flaps have been raised so that the flaps may be closed.
4. The apparatus of claim 3 wherein said radial transport path of said rotary
conveyor and said radial path of said pickup head are parallel and coincident.
5. The apparatus of claim 3 wherein said first tab slitting mechanism is located
upstream of said case packing station so that said first tab-lock is severed without
said articles deposited in said case.
6. A case packing and case flap closure apparatus for picking up groups of articles
at a pickup station and packing the articles into cases; said cases being transported
from a case delivery section to a case exit section; and said cases having first
and second minor and major flaps interconnected in folded positions adjacent end
walls and sidewalls of the case by first and second tab-locks wherein said apparatus comprises:
a frame;
a plurality of reciprocating pickup heads carried by said frame for rotation
in a radial path about a single vertical axis for picking up said articles at said
pickup station and placing said articles in said cases;
a rotary conveyor plate rotating with said pickup heads about said single axis
having a radial transport path, said conveyor adapted to receive and transport
successive cases from said case delivery section to said case exit section;
a case packing and flap separation station disposed between said case delivery
section and said case exit section along said radial transport path where said
articles are inserted and packed into said cases and said major and minor flaps
are separated from said case end walls and sidewalls for closure and sealing;
said case packing and flap separation station including a first tab slitting
section for severing said first tab-lock to provide separated first minor and major
flaps, and a second tab slitting section for severing said second tab-lock to provide
separated second minor and major flaps; and
said rotary conveyor plate transporting said cases through said case packing
and flap separation station along said radial transport path;
whereby cases are continuously packed with articles, tab-lock severed, and case
flaps are separated for closure while conveyed along said radial transport path
about said single axis.
7. The apparatus of claim 6 including a pickup head actuator having a grip position
where said pickup heads grip the group of articles, and a release position where
the articles are released from said pickup heads, said pickup heads being maintained
in said grip position with the articles inserted in the cases being transported
along said radial path through at least one of said tab slitting sections.
8. The apparatus of claim 7 including a motion converter carried by said frame
operatively connected to said pickup heads to cause said pickup heads in said grip
position to move generally in a straight-line and thereby guide said articles and
cases linearly through said at least one of said tab slitting sections.
9. The apparatus of claim 6 including a motion converter carried by said frame
and operatively connected to said pickup heads causing said pickup heads to move
generally in a straight-line path in parallel alignment with said articles as said
pickup heads are lowered to engage and pick up said articles at the pickup station.
10. The apparatus of claim 6 including a motion converter carried by said frame
and operatively connected to said pickup heads causing said pickup heads to move
generally in a straight-line path in parallel alignment with said articles as said
pickup heads are lowered to engage and pick up said articles.
11. The apparatus of claim 6 wherein said case packing and flap separation station
is arranged along said transport path so that said articles are inserted in the
cases when said first and second tab-locks are cut whereby the weight of the articles
holds the cases down for reliable tab-lock cutting.
12. The apparatus of claim 6 including first and second tab slitting mechanisms
carried at said first and second flap slitting sections operative to sever the
first and second tab-locks during transport of said cases on said conveyor plate.
13. The apparatus of claim 12 wherein said first slitting section includes an
outer guide and an inner guide arranged adjacent inner and outer edges of said
rotating conveyor plate to assist the positioning and guiding said cases along
a generally linear path during movement through said first slitting section.
14. The apparatus of claim 13 wherein said first slitting mechanism includes
a cutting blade carried adjacent said inner guide of said first slitting section,
said cutting blade being positioned to move between a first vertical sidewall of
said case and a first major flap to disconnect said first major flap from a first
minor flap as said case is transported through said first slitting section.
15. The apparatus of claim 14 including an upper guide plate arranged over said
inner guide of said first slitting section, said upper guide plate being adapted
to prevent vertical movement of said case on said rotating plate during transport
through said first slitting section.
16. The apparatus of claim part
12 wherein said second flap slitting section
comprises an inner guide and an outer guide arranged adjacent inner and outer edges
of said rotating plate, said inner and outer guides of said second slitting section
positioning and guiding said cases on said rotating plate through said second slitting
section for effective tab-lock cutting.
17. The apparatus of claim 16 wherein said second slitting mechanism includes
a flap separating guide and a slitter blade pivotally carried adjacent said outer
guide of said second slitting section, a drive associated with said separating
guide and said slitter blade, said drive being operative to pivot said separating
guide into a position between a second vertical sidewall of said case and a second
major flap of said case to separate said second major flap away from said second
vertical sidewall, said drive being further operative to pivot said slitting blade
into position to cut said second tab-lock and disconnect said second major flap
from said second minor flap.
18. The apparatus of claim 17 wherein said separating guide and said slitter
blade comprise a single blade member pivoted at substantially its center and extending
in diverging upward directions from said center about a pivot.
19. The apparatus of claim 18 including a sensor, said sensor being operative
to actuate said drive to move said slitter blade through selected positions as
said case reaches selected locations within said second slitting section.
20. The apparatus of claim 6 including minor flap raising members adapted to
engage and raise the first and second minor flaps after said tab-locks are severed.
21. The apparatus of claim 20 including a positioning member to further move
at least one of said minor flaps to a closed position after being raised, said
positioning member including a revolving horizontal plate element supported on
a vertical shaft which is yieldable upon impact with a misaligned case.
22. The apparatus of claim 21 wherein said support shaft is generally rigid,
and including a yieldable base securing said shaft to provide said yieldable shaft.
23. The apparatus of claim 20 including grid heads having grid fingers carried
for vertical motion with said pickup heads, and wherein said minor flap raising
members include engaging hooks carried by said grid heads, said grid heads positioning
said engaging hooks beneath said first and second minor flaps on downward movement
of said grid heads along said vertical path and during insertion of said articles
into said case allowing said engaging hooks to engage beneath said separated minor
flaps so that on upward movement of said grid heads along said vertical path, said
hooks engage and raise said separated minor flaps.
24. The apparatus of claim 23 wherein each said engaging hook is biased in a
direction toward said case, a lower end of each said engaging hook includes a cam,
said cam engaging with an upper surface of said case during said downward movement
of said grid head moving said hooks against said bias into a position outward of
and engaging end walls of said case.
25. The apparatus of claim 20 including first and second major flap guides carried
along said transport path for engaging and lifting separated first and second major
flaps after the tab-locks are severed.
26. The apparatus of claim 6 wherein said first slitting section includes a first
slitting mechanism for cutting said first tab-lock to separate a first major flap
from said first minor flap; and said second slitting section includes a second
slitting mechanism disposed downstream of said first slitting mechanism for cutting
said second tab-lock to separate a second major flap from said second minor flap
of said case.
27. The apparatus of claim 26 wherein said first slitting section includes an
inner guide rail adjacent an inner side of said rotary conveyor plate, said second
slitting section includes an outer guide rail carried adjacent an outer edge of
said rotary conveyor plate, said first and second slitting sections being arranged
so that said articles are inserted in the case to weigh the cases on said conveyor
as said first and second tab-locks are cut.
28. The apparatus of claim 27 include an adjustable mount for mounting said pivotal
arm and slitter blade so that the position of the slitter blade may be adjusted vertically.
29. The apparatus of claim 26 wherein said first slitting mechanism includes
a vertically extending slitter blade carried on a horizontal pivotal arm biased
in a direction to be engaged by said case transported on said conveyor entering
said first slitting section so that said slitter blade is aligned for engagement
between the first major flap and the sidewall of the case to sever said first tab-lock.
30. The apparatus of claim 26 wherein said second slitting mechanism includes
a rotary blade, and including a sensor for sensing the position of a case entering
said second slitting section to actuate said rotary blade at a proper time.
31. The apparatus of claim 30 including a pivotal trigger cam which pivots in
a horizontal plane having a cam portion extending into the path of the case entering
said second slitting section, said pivotal cam having a trigger portion which actuates
said proximity sensor when coming into proximity therewith.
32. The apparatus of claim 31 including a rotary actuator for rotating said rotary
knife, said rotary actuator being activated by said trigger portion of said cam
plate coming into proximity with the sensor.
33. The apparatus of claim 30 including a blade guard disposed below a free edge
of the second major flap of the case in a folded position, said blade guard overlying
said rotary blade in the folded position to prevent engagement between the case
and the tip end of said rotary blade as the case enters the second slitting section,
and said rotary blade and guard blade being disposed below said free edge of the
second major flap in the folded position.
34. The apparatus of claim 6 including a motion converter carried by said frame
and operatively connected to said pickup heads to cause said pickup heads to move
in a first straight-line path at said pickup station, and move in a second straight-line
path at one of said first and second tab slitting sections.
35. The apparatus of claim 34 wherein said motion converter imparts a secondary
rotation and a translation to said pickup heads in order to effect said straight-line paths.
36. The apparatus of claim 35 including a plurality of supports carried by said
frame, said pickup heads being slidably carried on said supports whereby said pickup
heads rotate on said supports when said secondary rotation is imparted.
37. A case packing and case flap closure apparatus comprising:
a single, central vertical axis;
a rotating conveyor plate continuously rotating about said central vertical axis
having a radial transport path passing through a case delivery section where empty
cases are delivered onto said conveyor plate; and a case exit section where packed
cases are removed from said conveyor plate;
a case packing and flap separation station disposed along said radial transport
path having an article insertion section where articles are inserted into the cases,
and first and second flap tab-lock slitting sections where tab-locks are severed
so that interconnected major and minor flaps by said tab-locks are separated from
one another;
engaging members adapted to engage and elevate said first and second separated
minor and major flaps within said case packing and flap separation station; and
a plurality of pickup heads picking up and gripping said articles while rotating
in a radial path about said central axis and said pickup heads adapted to insert
said gripped articles into the transported cases at said article insertion section.
38. The packing apparatus of claim 37 including an actuator controlling said
pickup heads between an article gripping position and an article release position,
said actuator maintaining said pickup heads in the gripping position while the
articles are inserted in the cases transported through said article insertion and
said tab-slitting sections.
39. The packing apparatus of claim 38 including connector mechanisms operatively
connected to said pickup heads to cause said pickup heads in the gripping position
to move linearly as well as radially during passage through at least one said tab
slitting section whereby said cases are guided linearly.
40. The packing apparatus according to claim 39 including flap guides carried
about said radial transport path for raising said flaps after said tab-locks have
been severed.
41. The apparatus of claim 37 wherein said case packing station and said tab-lock
slitting sections are disposed generally at the same location along said transport
path so that said inserted articles sufficiently weight said cases for effective
cutting of said tab-locks.
42. The apparatus of claim 41 wherein said tab slitting section includes a first
tab slitting mechanism on one side of said transport path for cutting a first tab-lock
and a second tab slitting mechanism on an opposing side of said transport path
for cutting a second tab-lock; and said first and second sections include flap
members for lifting said major and minor flaps after tab-lock cutting to close
said flaps.
43. A method for picking up articles, packing the articles into cases having
side major flaps and end minor flaps secured to sidewalls and end walls of the
case by tab-locks, and separating said flaps from the sidewalls and end walls of
the cases to facilitate closing, said method comprising:
continuously rotating a plurality of vertically reciprocating pickup heads in
a radial path about a central axis to pick up successive groups of the articles;
continuously transporting a plurality of empty indexed cases about said central
axis along a radial transport path;
placing the articles in said empty cases along a section of said radial transport
path to provide packed cases; and
severing at least one of said tab-locks securing said major and minor flaps along
a section of said radial transport path after said articles are placed in said
packed cases.
44. The method of claim 43 including continuing to grip the articles in the packed
cases transported along said radial transport path with said pickup heads, and
severing said tab-lock while the articles are gripped.
45. The method of claim 44 including causing said pickup heads to move in a generally
straight-line while rotating along said radial path to guide the packed cases linearly
for severing said tab-lock.
46. The method of claim 45 including causing said pickup heads to move in a generally
straight-line while picking up said successive groups of articles.
47. The method of claim 46 including causing said pickup heads to move generally
in a straight-line by swiveling said pickup head in a secondary rotation and in
translation while remaining ones of said plurality of pickup heads are moved only
along said radial path.
48. The method of claim 45 including severing all the tab-locks while guiding
said packed cases linearly using pickup heads gripping the articles and moving
on said straight-line.
49. The method of claim 48 including separating the major and minor flaps from
said case sidewalls and end walls, and thereafter closing the flaps over the case
for sealing.
50. The method of claim 43 including causing said pickup heads to move in a generally
straight-line while picking up said successive groups of articles.
51. The method of claim 43 including transporting said cases on a rotating conveyor
and rotating said conveyor about said central axis, and causing successive cases
to be indexed on said conveyor plate for rotation through said case deposit section
and said tab slitting section.
Description
BACKGROUND OF THE INVENTION
The invention relates to an apparatus and method for transferring articles into
cases using continuous motion, and particularly, where the continuous motion is
basically circular and at higher transfer speeds with a small footprint in which
case flap tab-lock slitting and flap sealing may also be accomplished.
In the art of case packing, large numbers of articles must be grouped and packaged
rapidly by an apparatus that will function dependably without damage to the articles
processed. Case packing apparatus has been generally categorized as either intermittent
case packing or continuous case packing. In intermittent case packing the article
flow and/or case flow is interrupted during article pick up and/or release. Most
recently, attention has been directed to continuous case packing in order to increase
production. However, the continuous case packing has brought increased problems
with handling the processed articles without breakage, damage, or interruption.
In the continuous case packing apparatus, articles are grouped together in successive
slugs or groups at a pick up position. The slugs are typically picked up at the
pick up position by article grippers carried by an orbital handling machine rotating
about two vertical axes. The slugs are transferred to a case loading position where
the grippers release the slug of articles into a case. The articles can be released
either simultaneously or sequentially as the case is conveyed beneath the slug
of articles. Apparatus of this type may be either of the "drop packer" type or
"placement packer type." In the drop packer type, the articles are allowed to drop
at least a small distance into the case after release. In the placement packer
type, the drop, if any, is minimal and the articles are essentially placed gently
onto the bottom of the case.
Continuous motion machines rotating about a single horizontal axis are
shown in U.S. Pat. Nos. 5,375,395, 5,257,888, and 5,313,764 using articulating
arms and pickup heads. A set of article grippers is carried on the ends of the
articulating arms. However, during the angular descent from the pick up position
to the case packing position, both horizontal and vertical accelerations are typically
encountered by the articles, which are gripped only at their tops or necks. Intermittent
circular machines rotating about a single vertical axis are shown in U.S. Pat.
Nos. 3,780,492 and 2,807,125.
Various other case packers, generally of the continuous motion type, using
a vertical orbital conveyor are shown in U.S. Pat. Nos. 5,212,930, 4,541,524, and
4,294,057. The first patent shows depositing the articles sequentially and individually,
rather than as a group or slug, into partitioned cases without positively gripping
the articles. The latter two patents use gripper devices to grip and place the
articles. U.S. Pat. No. 4,457,121 discloses a continuous motion bottle packer wherein
a plurality of grids are mounted individually on spokes of a vertical wheel so
that each grid moves through an article in feed position where groups of articles
are fed into the grid without interrupting the forward speed. Angular and horizontal
accelerations of the articles and their contents are encountered due to the rotary
wheel motion during the transfer which may be detrimental to the article and/or contents.
Continuous case packers are also known in which a horizontal rotary carousel
is used to move vertically reciprocating gripper sets in a horizontal plane about
two vertical axes. The reciprocating gripper sets pick up a slug of articles at
one position and transfer the slug of articles to a second position where the gripper
set is lowered to deposit the articles into a case. Typically the pickup and release
stations are on opposite sides of the carousel, requiring parallel conveyors on
each side. However, the disposition of the rotary carousel in a horizontal plane
requires an inconvenient floor layout, which also occupies a large amount of floor
space. The parallel conveyor arrangements needed for the in feed and out feed of
articles adds to the floor space problem. The path of the gripper sets between
the slug pick up position and the case packing position is also typically curved
producing angular and acceleration forces on the articles. The curved article transfer
path intersects the path of the conveyed case only for a brief interval making
timing a factor. In various of the rotary carousel types, it is known to deposit
the articles by lowering the articles, already gripped by the gripper set, through
resilient fingers that guide the articles into partitioned cases.
Case packers, generally of the intermittent type, are shown in U.S. Pat. Nos.
3,553,932 and 3,505,787 which also discloses using combinations of a lifting head
having suction cups and bottle grids having pockets for picking up containers and
depositing them into cases. The containers and the cases are conveyed on parallel
conveyors rather than in-line conveyors, and the transfer from the pick up position
to the case loading position is lateral, or transverse, to the flow of containers
and cases. U.S. Pat. No. 2,277,688 discloses another case packer using an arrangement
of a gripper set and a bottle guide set to package the containers into a case.
These types of case packers are generally non-continuous as compared to the continuous
motion in-line transfer case packers described above where neither the flow of
articles nor the flow of the cases is interrupted during operation of the packer.
The articles are packed in cases which typically have flaps held flush to the
sides of the case by tab-locks so the flaps do not interfere with case conveyance.
After the case is packed, it is necessary to slit the tab-locks so the flaps can
be folded over the top of the case and sealed. Typically, the packed cases with
locked flaps are conveyed from the case packer to a transfer location a distance
from the case packer. At the transfer location, the cases are metered onto a main
flight chain through a slitting section and a sealing section. The metering conveyor
and slitting and sealing sections normally require an additional 50 feet of floor space.
The case flap slitting and sealer mechanisms have been long known in the industry
for slitting the tab-locks holding the case flaps to the side of the case. These
mechanisms, such as manufactured by Standard Knapp, Inc. of Portland, Conn., comprise
an independent mechanism generally formed along a separate conveyor downstream
from the case packer. In practice, filled cases are removed from the packing apparatus
and delivered in an inclined fashion to the slitting and sealing mechanism. The
space required is substantially equal that of the packing apparatus. The equipment
and operation cost is also substantially equal that of the packing apparatus.
Accordingly, an object of the invention is to provide a continuous case
packing apparatus having a characteristic radial motion with case flap separation
and flap closure sections combined with the case packing apparatus and process.
Another object of the invention is to provide a continuous motion apparatus
and method which moves in a circular or radial motion to provide high speeds of
operation for case packing and flap closure and sealing.
Another object of the invention is to provide a continuous, radial motion
case packing apparatus and method which rotates about a single, central axis to
provide a small footprint and high-speed operation in which case packing and flap
closure are carried out.
Another object of the invention is to provide a continuous, radial motion
case packing and flap closure apparatus and method in which groups of articles
are picked up at a pickup station and transferred to a case packing and flap separation
station where the motion of the pickup heads is converted from a radial motion
to a substantially straight-line motion during article pickup to align with the
articles and during tab-lock slitting to guide the cases.
Still another object of the invention is to provide a continuous, circular
motion case packing and flap closure apparatus and method wherein the articles
are picked up by pickup heads rotating in a radial path are inserted into cases
transported on a rotating conveyor disposed below the radial path of the pickup
heads rotating about the same axis where the flaps are separated and closed prior
to exiting the plate.
Still another object of the invention is to provide a case packing and flap
closure apparatus and method with a continuous rotary conveyor having a radial
transport path for transporting cases through a case delivery station, a case packing
and flap closure station, and a case exit section.
Another object of the invention is to provide coordinated case packing, case
flap separation by tab-lock slitting and flap sealing during radial transport of
the cases.
Yet another object of the invention is to provide a continuous motion apparatus
and method in which a revolving conveyor plate moves successive packed cases to
tab-lock slitting sections where the flaps of each case are separated from the
cases and closed.
Another object of the invention is the provision of a single continuous radial
motion apparatus and method which picks up articles arranged into groups using
pickup heads rotating continuously in a radial path, deposits the articles into
successive cases transported along the same radial path, slits the flap tab-locks
for separation, and elevates the case flaps for sealing during travel along the
radial path.
SUMMARY OF THE INVENTION
A case packing and case flap closure apparatus is disclosed for picking up groups
of articles at a pickup station and packing the articles into cases. The cases
have first and second minor and major flaps interconnected in folded positions
adjacent end walls and sidewalls of the case by first and second tab-locks. The
cases are transported from a case delivery section to a case exit section along
a radial transport path. The apparatus includes a frame; and a plurality of reciprocating
pickup heads carried by the frame for rotation in a radial path about a single
vertical axis, coinciding with the radial transport path, for picking up the articles
at the pickup station and placing the articles in the cases. A rotary conveyor
rotates with the pickup heads about the single axis and prescribes the radial transport
path. The conveyor is adapted to receive and transport successive cases from the
case delivery section to the case exit section. A case packing and flap separation
station is disposed between the case delivery section and the case exit section
along the radial transport path where the articles are inserted and packed into
the cases and the major and minor flaps are separated from the case end walls and
sidewalls for sealing. The case packing and flap separation station includes a
first tab slitting section for severing the first tab-lock to provide separated
first minor and major flaps, and a second tab slitting section for severing the
second tab-lock to provide separated second minor and major flaps.
The rotary conveyor plate transports the cases through the case packing and flap
separation station along the radial transport path whereby cases are continuously
packed with articles, tab-locks severed, and case flaps separated for closure while
conveyed along the radial transport path about a single axis. Advantageously, a
pickup head actuator has a grip position wherein the pickup heads grip the group
of articles, and a release position wherein the articles are released from the
pickup heads. The pickup heads are maintained in the grip position with the articles
inserted in the cases being transported along the radial path through at least
one of the tab slitting sections. A motion converter carried by the frame is operatively
connected to the pickup heads to cause the pickup heads, in the grip position,
to move generally in a straight-line and thereby guide the articles and cases linearly
through the tab slitting section. The radial motion converter also causes the pickup
heads to move generally in a straight-line path in parallel alignment with the
articles as the pickup heads are lowered to engage and pick up the articles at
the pickup station. The case packing and flap separation station is arranged along
the transport path so that the articles are inserted in the cases when the first
and second tab-locks are cut whereby the weight of the articles holds the cases
down for reliable tab-lock cutting. Preferably, the first and second slitting sections
include an outer guide and an inner guide arranged adjacent inner and outer edges
of the rotating conveyor plate to assist in the positioning and guiding of cases
along a generally linear path during movement through the first slitting sections.
In another aspect of the invention, a first flap guide is carried along the transport
path adapted to engage and raise a separated first major flap after the first tab-lock
is cut, and a second flap guide carried along the transport path for engaging and
lifting a separated second major flap after being cut. Grid heads having grid fingers
are carried for vertical motion with the pickup heads, and include minor flap engaging
hooks carried by the grid heads. The grid heads position the engaging hooks beneath
the first and second minor flaps on downward movement of the grid heads along the
vertical path and during insertion of the articles into the case allowing the engaging
hooks to engage beneath the separated minor flaps so that on upward movement of
the grid heads along the vertical path, the hooks engage and raise the separated
minor flaps.
The first slitting section includes a first slitting mechanism for cutting a
first tab-lock to separate a first major flap from a first minor flap; and the
second slitting section includes a second slitting mechanism disposed downstream
of the first slitting mechanism for cutting a second tab-lock to separate a second
major flap from a second minor flap of the case.
A further aspect of the radial motion converter is to effect a secondary rotation
and a translation to the pickup heads in order to effect the straight-line path.
For this purpose, a plurality of supports carried by the frame, and the pickup
heads are slidably carried on the supports whereby the pickup heads swivel on the
supports when the secondary rotation is imparted.
According to a method of the invention, a method includes picking up articles,
packing the articles into cases having side major flaps and end minor flaps secured
to sidewalls and end walls of the case by tab-locks, and separating the flaps from
the sidewalls and end walls of the cases to facilitate closing. The method includes
continuously rotating a plurality of vertically reciprocating pickup heads in a
radial path about a central axis to pick up successive groups of the articles;
and continuously transporting a plurality of empty indexed cases about the central
axis along a radial transport path. Next, the articles are inserted in the empty
cases along a section of the radial transport path to provide packed cases; and
at least one of the tab-locks securing the major and minor flaps is severed along
a section of the radial transport path after the articles are inserted in the cases.
Advantageously, the method includes continuing to grip the articles in the packed
cases while transported along the radial transport path with the pickup heads,
and severing the tab-lock while the articles are gripped. Further, the method includes
causing the pickup heads to move in a generally straight-line while rotating along
the radial path to guide the packed cases linearly for severing the tab-lock, and
causing the pickup heads to move in a generally straight-line while picking up
the successive groups of articles. Preferably, the pickup heads are moved generally
in a straight-line by swiveling the pickup heads in a secondary rotation and moving
the heads in translation while remaining ones of the plurality of pickup heads
are moved only along the radial path. All the tab-locks may be severed while guiding
the packed cases linearly using pickup heads gripping the articles and moving in
the straight-line. The method includes separating the major and minor flaps from
the case sidewalls and end walls, and thereafter closing the flaps over the case
for sealing. By transporting the cases on a rotating conveyor and rotating the
conveyor about the central axis, and causing successive cases to be indexed on
the conveyor plate for rotation through the case deposit section and the tab slitting
section while rotating the heads in a corresponding radial path for a fast and
efficient operation is provided for case packing and flap closure in a relatively
small space.
DESCRIPTION OF THE DRAWINGS
The construction designed to carry out the invention will hereinafter be described,
together with other features thereof.
The invention will be more readily understood from a reading of the following
specification and by reference to the accompanying drawings forming a part thereof,
wherein an example of the invention is shown and wherein:
FIG. 1 is a perspective view of a circular, continuous motion case packing,
and case flap slitting, and flap sealing apparatus;
FIG. 2 is a top plan sectional view of the apparatus of FIG. 1 taken generally
along line 2—2;
FIG. 3A is a top plan sectional view similar to FIG. 2 illustrating one embodiment
of a case packing and tab-lock slitting station according to the invention.
FIG. 3B is a simplified top plan view of FIG. 3A with arcuate process sections
illustrated in degrees of rotation for exemplary purposes only;
FIG. 4 is a perspective sectional view showing a first slitting section of the
case packing and tab-lock slitting section;
FIG. 5 is a perspective sectional view showing a second slitting section of
the case packing and tab-lock slitting station;
FIG. 6 is a perspective sectional view illustrating the second slitting section
relative to the case exit station and illustrating the relative positions of the
guide and slitting member initiating the flap separating action.
FIG. 7A is a schematic top view illustrating a pre-position of the motions of
the pickup and grid heads wherein the heads are caused to move in a compound rotational
and translational motion to effect a straight line motion of the heads along an
article pickup station, as well as along any other section of the normal radial
path of the heads where desired;
FIG. 7B is similar to FIG. 7A showing the pickup and grid heads in the second
and normal position of the compound motion according to the invention;
FIG. 7C is similar to FIG. 7A showing the pickup and grid heads in the third
and post position of the compound motion;
FIG. 8A is a schematic top plain view illustrating a closed cycle path of the
pickup and grid heads during the transitory motion wherein their circular motion
is compounded to include a straight line motion according to the invention;
FIG. 8B is a partial perspective view of a motion-converter for unparking the
compound motion to the pickup and grid heads resulting in a straight-line motion
according to the invention;
FIG. 9 is a side elevation view illustrating a revolving turret head support
frames, and circular cam tracks controlling the vertical head positions;
FIG. 10A is a partial perspective view showing a minor flap engaging hook carried
by a grid head for movement relative to a case according to the invention;
FIG. 10B is similar to FIG. 10A showing the opposite flap engaging hook positioned
to raise the opposite minor flap;
FIG. 11A is an exploded view of the entry of a case exit station preparing the
case for exiting the rotating conveyor plate;
FIG. 11B is similar to FIG. 11A showing the minor flap in closed position beneath
the positioning rail;
FIG. 12A is a side view showing the rear flap closing disk and mounting structure
according to the invention;
FIG. 12B is similar to FIG. 12A showing flap closing disk mounting structure
in a break away position;
FIG. 13A is an exploded view of the entry area of a flap sealing apparatus with
the positioning rail folding down the raised front minor flap;
FIG. 13B is a progression of FIG. 13A showing the front and rear minor flaps
being moved into a closed position by the positioning rail;
FIG. 13C is a progression of FIG. 13B showing the major side flaps being positioned
to receive adhesive;
FIG. 13D is a progression of FIG. 13C showing the top flap closing structure;
FIG. 13E is a progression to FIG. 13D showing the retaining structure for holding
the closed flaps in position allowing the adhesive to set.
FIG. 14A is a top plan view illustrating another embodiment of the present invention
wherein cases are indexed and transported on a rotary conveyor through a case packing
and tab slitting station;
FIG. 14B is a simplified top plan view of FIG. 14A with arcuate process sections
illustrated in degrees of rotation for exemplary purposes only;
FIG. 15 is an enlarged perspective view taken from the outer side of a rotary
conveyor transporting cases through a first tab-lock slitting section of the case
packing and tab slitting station;
FIG. 16A is a top plan view with parts cut away of a packed case entering the
first tab-lock slitting section of FIG. 15 while transported on a rotary conveyor
according to the invention wherein the articles are deposited in the case while
still being gripped by the gripper head (not shown);
FIG. 16B is a partial top plan view of the case of FIG. 16A wherein the slitter
is engaged between a folded vertical major flap and a sidewall of the case prior
to engaging the tab-lock;
FIG. 16C is a partial top plan view of the first tab-lock slitting section wherein
the tab-lock on one side of the case has been severed and the slitter arm has returned
into the path of the next case entering the first tab-lock slitting section;
FIG. 17A is a partial top plan view of a packed case entering a second tab-lock
slitting section of the case packing and tab slitting station while transported
on a rotary conveyor wherein the second slitting mechanism is disposed on an outer
side of the rotary conveyor and the articles are still being gripped by gripper
heads (not shown);
FIG. 17B is a partial top plan view illustrating the case engaging a guard blade
and moving the guard out of the transport path to a position overlying a rotary
cutter blade;
FIG. 17C is a partial top plan view illustrating a case transported on the rotary
conveyor in a position where a proximity actuator triggers a proximity switch to
activate the rotary cutter blade;
FIG. 17D is a partial top plan view illustrating a case transported on the rotary
conveyor in a position where the tab-lock on a second side of the case has been
severed to separate second major and minor flaps of the case;
FIG. 18A is a perspective view illustrating a case entering the second tab slitting
section with the guard blade extended outward;
FIG. 18B is a perspective view illustrating the case in the tab-lock cutting
position wherein the guard blade is moved flush with the side of the case allowing
the rotary cutting blade to rotate and sever the tab-lock; and
FIG. 18C is a perspective view of the case transported on a rotary conveyor
illustrating the rotary cutter blade in a position wherein the blade has rotated
180 degrees and severed the tab-lock.
DESCRIPTION OF A PREFERRED EMBODIMENT
Referring now to the drawings, the invention will be described in more detail.
As can best be seen in FIGS. 1-3, apparatus and method for packing articles into
cases in a simple, continuous circular or radial motion, is illustrated generally
as A. The apparatus includes a rotating turret B which rotates about a single,
central vertical axis Y, and a stationary central column
10. A plurality
of article transfer arms
20 are carried by the rotating turret, as can best
be seen in FIGS. 2 and 9. A plurality of reciprocating grid heads
22 and
article pick up heads
24, are carried on the transfer arms by way of support
frames
12. The pickup and grid heads themselves may be of conventional construction
and form no part of the instant invention, and other types of article pickup arrangements
may be used with or without the grid heads where applications permit. They, therefore,
will not be further described, but reference may be had to the incorporated patents
and applications for more detail. FIGS. 1,
2 and
3 illustrate the
embodiment of the invention in the form of a case packing apparatus and method
in which articles are packed into cases. In the illustrated embodiment, the pickup
and grid heads are slidably carried on the transfer arms, and move in a combined
vertic
