GB2580484A

GB2580484A - Automated sandwich packaging

Info

Publication number: GB2580484A
Application number: GB1915771.8A
Authority: GB
Inventors: Lovedale Antony; Quinn Alan; Clark Jason; Kozlovs Victor
Original assignee: Active8 Robots Ltd
Current assignee: Active8 Robots Ltd
Priority date: 2018-07-27
Filing date: 2018-07-27
Publication date: 2020-07-22
Anticipated expiration: 2038-07-27
Also published as: GB2580484B; GB201915771D0

Abstract

A robot picker 70 for picking a sandwich 30 and transferring it to a packaging container 85. The picker may have means for rotating the sandwich 30. The picker may have an actuated gripper 75 and means for n-line rotating a sandwich 30 whilst gripped prior to release. Th picker may have two, spaced grippers, with one gripper having a rotatable disc, the other with a rotating plate, wherein when a sandwich 30 is gripped the rotatable disc is driven to rotate and the plate rotates passively. An automated sandwich 30 packing apparatus may comprise the picker. The apparatus may comprise manipulation means for moving two sandwich halves 30a, 30b from a generally flat, adjacent configuration to an upright, side-by-side configuration. Also claimed is a sandwich 30 making process of preparing a sandwich 30, cutting the sandwich 30 in two halves 30a, 30b, orienting the sandwich halves 30a, 30b so that they are in an upstanding side-by-side configuration, using a robot to pick up the sandwich halves 30a, 30b together and placing the sandwich halves 30a, 30b into a container. The process may include rotating the sandwich halves 30a, 30b end-over-end prior to placing into the container.

Description

AUTOMATED SANDWICH PACKAGING

The present invention relates generally to a sandwich packaging process and particularly, although not exclusively, to the automation of one or more aspects of a packaging process.

Sandwich packing is often an entirely manual human process in which sandwiches are prepared (e.g. assembled and cut) and placed into a packaging container (such as a skillet).

The present invention seeks to provide improvements in or relating to the packaging of sandwiches.

An aspect of the present invention provides a sandwich manipulation apparatus comprising manipulation means for moving two sandwich halves from a generally flat, adjacent configuration to an upright, side-by-side configuration.

The manipulation means may comprise a pair of conveyors, such as belts.

In some embodiments the conveyors turn through approximately 90 degrees from a sandwich inlet end to a sandwich outlet end. For example in one embodiment at the sandwich inlet end the conveyors are generally horizontal and at the sandwich outlet end the conveyors are generally vertical, whereby both conveyors twist along their length so as to gradually fold the two sandwich halves together as they pass along therealong.

The apparatus may further comprising a presentation conveyor for presenting the sandwich halves to the manipulation means. Normally the sandwiches will be pre-prepared and pre-cut (for example using ultrasonic cutting).

In some embodiments the whole sandwich is generally square and it is cut into two generally triangular halves. Other embodiments can have different whole/cut shapes.

The term "halves" may mean two generally similar/identical pieces, but not necessarily.

The apparatus may further comprise an outlet conveyor for receiving sandwiches from the manipulation means.

The conveyor may comprise bays for receiving sandwiches in the upright, side-by-side configuration.

The conveyor may comprise guide means for preventing delamination of sandwich halves as they move through a picking station.

The apparatus may further comprise one or more robot pickers for picking sandwiches from the outlet conveyor and transferring them to a packaging container.

The robot may, for example comprise an actuated gripper.

The robot may comprise means for rotating the sandwich with the halves maintained in a side-by-side configuration. Inversion of the sandwich may be preferred for some containers.

An indexing conveyor for conveying containers (such as pre-assembled cardboard skillets) may be provided next to the outlet conveyor.

In some embodiments the packaging container is a preformed skillet, for example a cardboard skillet.

The present invention also provides a robotic picker for picking a sandwich from a conveyor, the picker comprising an actuated gripper and means for in-line rotating a sandwich whilst gripped and prior to release.

The present invention also provides a method of placing a sandwich into a packaging container, comprising the steps of: providing a pre-prepared sandwich; pre-cutting the sandwich into two halves; orientating sandwich halves from a flat configuration to an upstanding configuration; and placing the juxtaposed sandwich halves into a container.

The present invention also provides a sandwich making process comprising the steps of: preparing a sandwich; cutting the sandwich into two halves; orientating the sandwich halves so that they are in an upstanding, side-by-side configuration; using a robot to pick up the sandwich halves together; and placing the sandwich halves into a container.

In some embodiments the sandwich halves are inverted (rotated end-over-end) prior to placing into the container.

Some aspects and embodiments of the present invention relate to a system, machine or process for orientating and packing sandwiches into skillets, for example a sandwich skilleting machine.

Different aspects of the present invention may be used separately or together.

Further particular and preferred aspects of the present invention are set out in the accompanying independent and dependent claims. Features of the dependent claims may be combined with the features of the independent claims as appropriate, and in combination other than those explicitly set out in the claims.

Referring now to the drawings, wherein like reference numbers are used to designate like elements throughout the various views, several embodiments of the present invention are further described by way of example.

The example embodiments are described in sufficient detail to enable those of ordinary skill in the art to embody and implement the systems and processes herein described. It is important to understand that embodiments can be provided in many alternate forms and should not be construed as limited to the examples set forth herein.

Accordingly, while embodiment can be modified in various ways and take on various alternative forms, specific embodiments thereof are shown in the drawings and described in detail below as examples. There is no intent to limit to the particular forms disclosed. On the contrary, all modifications, equivalents, and alternatives falling within the scope of the appended claims should be included. Elements of the example embodiments are consistently denoted by the same reference numerals throughout the drawings and detailed description where appropriate.

Unless otherwise defined, all terms (including technical and scientific terms) used herein are to be interpreted as is customary in the art. It will be further understood that terms in common usage should also be interpreted as is customary in the relevant art and not in an idealised or overly formal sense unless expressly so defined herein.

In the following description, all orientational terms, such as upper, lower, radially and axially, are used in relation to the drawings and should not be interpreted as limiting on the invention.

Referring first to Figure 1 there is shown part of a sandwich assembly machine generally indicated 10.

The machine 10 comprises, in brief, a sandwich presentation conveyor 15, an orientation conveyor 20 and an outfeed conveyor 25.

Incoming sandwiches 30 are prepared and pre-cut into two generally equal triangular halves 30a, 30b before entering the sandwich presentation conveyor 15 in a generally flat, horizontal orientation.

The orientation conveyor 20 (described in more detail below) orientates each sandwich half using 90° twisted conveyors 35, 40.

The orientated sandwich passes onto the outfeed conveyor 25.

Conveyor guides 45, 50 are provided above the conveyor 25 and include, in this embodiment, two robot pick locations 55, 60. The sandwich 30 is guided to the robot pick locations to prevent delimitation (i.e. the guides prevent the sandwich halves from falling apart).

As also shown in Figures 2 and 3A to 3C, the orientation conveyors 35, 40 each comprise an endless belt 36, 41 which is secured at one end (the inlet end) by a horizontal roller 37, 42 and at the other end by a "vertical" roller 38, 43 -in this embodiment the roller actually inclined away from the vertical in a plane orthogonal to the line of travel. The vertical and horizontal rollers are oriented at approximately 90 degrees with respect to each other (along the line of sandwich movement). This means that the belts 36, 41 twist along their length.

As illustrated in Figures I and 2, this means that as sandwich halves 30a, 30b move from the inlet end to the outlet end of the orientation conveyor 20 they are gradually "folded" together by the belts 36, 41 so that they assume an upright, "vertical" configuration.

The robot picks the sandwich from a pick location along the presentation conveyor 25 using an actuated gripper (Figure 3A) then rotates the sandwich (Figure 3B) and releases into a pre-assembled skillet (Figure 3C).

In this embodiment the robot 70 comprises a pair of spaced grippers 75, 80. Either or both of the grippers can be moved inwards to grip sandwich halves.

The gripper 75 is provided with a rotatable disc 76 (see Figure 4C) and the gripper 80 has a rotating plate 81. When the sandwich is gripped the plate 81 is driven to rotate. In this embodiment the disc 76 rotates passively; in other embodiments both grippers have driven rotators.

After the sandwich is inverted/rotated the robot releases it into a pre-assembled skillet 85.

A skillet conveyor (not shown) is provided alongside the sandwich manipulation apparatus. A robot station (not shown) is also provided with one more robot arms.

In this embodiment the process is repeated with two robots until four skillets are completed.

In some embodiments a vision system may be used, for example to check that sandwich halves have been successfully folded together and/or to check that a sandwich has been correctly placed in a skillet A rejection system may also be provided.

Examples of further aspects and embodiments are listed in the following numbered paragraphs.

A sandwich manipulation apparatus comprising manipulation means for moving two sandwich halves from a generally flat, adjacent configuration to an upright, side-by-side configuration.

2. Apparatus as claimed in paragraph I, comprising a pair of conveyors.

3. Apparatus as claimed in paragraph 2, in which the conveyors turn through approximately 90 degrees from a sandwich inlet end to a sandwich outlet end.

4. Apparatus as claimed in paragraph 3, in which at the sandwich inlet end the conveyors are generally horizontal and at the sandwich outlet end the conveyors are generally vertical, whereby both conveyors twist along their length so as to gradually fold the two sandwich halves together as they pass along therealong.

5. Apparatus as claimed in any preceding paragraph, further comprising a presentation conveyor for presenting the sandwich halves to the manipulation means.

6. Apparatus as claimed in any preceding paragraph, further comprising an outlet conveyor for receiving sandwiches from the manipulation means.

7. Apparatus as claimed in paragraph 6, in which the conveyor comprises bays for receiving sandwiches in the upright, side-by-side configuration.

8. Apparatus as claimed in paragraph 6 or paragraph 7, in which the conveyor comprises guide means for preventing delamination of sandwich halves.

9. Apparatus as claimed in any of paragraphs 6 to 8, further comprising one or more robot pickers for picking sandwiches from the outlet conveyor and transferring them to a packaging container.

10. Apparatus as claimed in paragraph 9, in which the robot comprises an actuated gripper.

II. Apparatus as claimed in paragraph 9 or paragraph 10, in which the robot comprises means for rotating the sandwich with the halves maintained in a side-by-side configuration.

12. A robotic picker for picking a sandwich from a conveyor, the picker comprising an actuated gripper and means for in-line rotating a sandwich whilst gripped and prior to release.

13. A method of placing a sandwich into a packaging container, comprising the steps of: providing a pre-prepared sandwich; pre-cutting the sandwich into two halves; orientating sandwich halves from a flat configuration to an upstanding configuration; and placing the juxtaposed sandwich halves into a container.

14. A sandwich making process comprising the steps of: preparing a sandwich; cutting the sandwich into two halves; orientating the sandwich halves so that they are in an upstanding, side-by-side configuration; using a robot to pick up the sandwich halves together; and - placing the sandwich halves into a container.

15. A process as claimed in paragraph 14, in which the sandwich halves are rotated end-over-end prior to placing into the container.

Although illustrative embodiments of the invention have been disclosed in detail herein, with reference to the accompanying drawings, it is understood that the invention is not limited to the precise embodiments shown and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope of the invention.

Claims

CLAIMSI. A robot picker for picking a sandwich and transferring it to a packaging container.
2. A robot picker as claimed in claim I, comprising means for rotating a sandwich.
3. A robotic picker as claimed in claim I or claim 2, the picker comprising an actuated gripper and means for in-line rotating a sandwich whilst gripped and prior to release.
4. A robot picker as claimed in any preceding claim, in which the robot comprises means for rotating a sandwich with two sandwich halves maintained in a side-by-side configuration.
S. A picker as claimed in any preceding claim, comprising an actuated gripper.
6. A robot picker as claimed in any preceding claim, comprising a pair of spaced grippers.
7. A robot picker as claimed in claim 6, in which either or both of the grippers can be moved inwards to grip sandwich halves in use.
8. A robot picker as claimed in any preceding claim, in which one of the grippers has a driven rotator.
9. A robot picker as claimed in any preceding claim, in which both grippers have driven rotators.
10. A robot picker as claimed in any preceding claim, the picker comprises two spaced grippers, one gripper is provided with a rotatable disc and the other gripper has a rotating plate, wherein when a sandwich is gripped the rotatable disc is driven to rotate and the plate rotates passively.
II. Automated sandwich packing apparatus comprising a robot picker as claimed in any preceding claim.
12. Apparatus as claimed in claim II, further comprising manipulation means for moving two sandwich halves from a generally flat, adjacent configuration to an upright, side-by-side configuration.
13. Apparatus as claimed in claim 11 or claim 12, further comprising an outlet conveyor for receiving sandwiches from the manipulation means.
14. Apparatus as claimed in claim 13, in which the outlet conveyor may comprise bays for receiving sandwiches in the upright, side-by-side configuration.
15. Apparatus as claimed in claim 13 or claim 14, in which the outlet conveyor comprises guide means for preventing delamination of sandwich halves as they move through a picking station.
16. Apparatus as claimed in any of claims 11 to 15, further comprising an indexing conveyor for conveying containers.
17. Apparatus as claimed in claim 16, in which the indexing conveyor is provided next to the outlet conveyor.
18. A sandwich making process comprising the steps of: preparing a sandwich; cutting the sandwich into two halves; orientating the sandwich halves so that they are in an upstanding, side-by-side configuration; using a robot to pick up the sandwich halves together; and placing the sandwich halves into a container.
19. A process as claimed in claim 18, in which the sandwich halves are rotated end-over-end prior to placing into the container.
20. A process as claimed in claim 18 or claim 19, in which a robot picker according to any of claims 1 to 11 is used to pick up the sandwich halves and place them into a container.