AU632057B2 - Collating apparatus - Google Patents

Description

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I 1 632057 COMMONWEALTH OF AUSTRALIA The Patents Act 1952-1969 Name of Applicant(s): Address of Applicant(s): Actual Inventor(s): Address for Service: R.L. WINDSOR SON PTY. LTD.

RANDLE ROAD,

MEEANDAH,

QUEENSLAND 4008

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r t t it ROBERT N. WINDSOR MAXWELL C. DOWZER G.R. CULLEN COMPANY, Patent Trade Mark Attorneys, 79 Eagle Street, Brisbane, Qld. 4000, Australia.

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a 4-t COMPLETE SPECIFICATION FOR THE INVENTION ENTITLED: "COLLATING APPARATUS' Ba tt Ia tL al' The following statement is a full description of the invention including the best method of performing it known to us:- :i i a 2 The invention relates to a packaging apparatus for placing a plurality of containers in a carton. In particular, the invention relates to a collating apparatus for use in a packaging apparatus. The invention will be described by way of example with referenc- to a collating apparatus for a carton over product (COP) packaging apparatus. It should be appreciated that this is by way of example only and that the collating apparatus of the invention may be employed in packaging apparatus other than that of the COP type.

*o A carton over product packaging apparatus is disclosed in 00 United States Patent Specification 4742670. The text and tit I II drawings of USP4742670 are incorporated herein by way of cross reference.

The apparatus of USP4742670 had an infeed conveyor for conveying a plurality of containers to be packaged. These containers were conveyed to a collating zone in which they were collated into a plurality of rows. A container indexing means was located adjacent the collating zone for moving the containers downstream from the collating zone to a packing zone. A carton erector was located above the packing zone for erecting cartons from a carton supply. A carton positioning means received an erected carton from the carton erector and placed it over the containers in the packing zone. Carton closure means was located downstream of the 3 packing zone for closing top and bottom closure flaps of the carton.

The collator in USP4742670 included a stop arm which extended across the infeed conveyor and at a downstream location in the collating zone. Two transversely spaced side forming stops were located upstream of the stop arm. A partition was located between the side stops and was transversely movable to selectively move containers against or towards the side stops to form a plurality of rows of containers from a single row introduced to the collating zone by the infeed conveyor.

The movable partition was initially located on one side of the row of containers introduced to the collating zone and once a desired number of containers in a row were present, the partition would move that row against the opposed side stop. A further row of containers was then formed in the collating zone and the partition was then returned to its original position to thereby move the second row of containers against or towards the other sid a stop. A subsequent row of containers was then introduced and by then 4 1 not moving the partition three rows of containers were then 1111; formed in the collating zone and could be subsequently moved downstream by the indexing means.

In this earlier arrangement more than three rows of 4 containers could be collated from a single infeed row. This could be achieved by altering the spacing between the side stops and changing the sequence and degree of travel of the partition.

With this earlier collator the containers were not restrained during the act of collation and also during indexing from the collating zone. The containers tended to become unstable if unrestrained during infeed and collation.

This was particularly so where the containers were flexible containers with upper necked portions such as bottles made of plastics material. Instability became more pronounced with grenter speed and throughput of containers through the packaging apparatus.

V: Two other types of known collating systems also suffered from d the deficiency referred to above.

One other known collating system employed a single infeed line and a diverter. The diverter directed containers from the line between a plurality of partitions to form rows of containers between the partitions. Once the desired number of containers were collated into the rows they could then be indexed downstream of the collating zone. The movement into the space between partitions did not restrain the containers to a sufficient degree. The partitions generally needed to j 'A be spaced apart by a distance greater than the width of the containers to provide clearance between the containers and the partitions. In addition, such a collating system was normally set up to produce a collated pattern of containers having a particular number of rows. The system could not readily be adapted or adjusted to produce a collated pattern having a greater or lesser number of rows than the particular number.

Another known collating system employed a single infeed line and a pusher for transversely conveying a selected number of containers from the line across a table until a plurality of rows each with the selected number of containers in them was formed. Once again, in this system the containers were unrestrained and an added disadvantage was that the containers were caused to slide across the table rather than be conveyed. Such sliding action was also undesirable because it led to further instability and tended to scuff the base of the containers.

It is an object of the present invention to provide a collating apparatus and a packaging apparatus including such a collating apparatus which at least minimise the disadvantages referred to above.

According to one aspect, the invention provides a collating I i i i apparatus for a packaging apparatus having infeed means for conveying a plurality of containers to the collating apparatus and container indexing means for moving the containers downstream of the collating apparatus to a packing zone, said collating apparatus including a conveyor extending transversely of the packaging apparatus and having a plurality of zutw:ri! zitcnding spaced partitions with a container support member extending between adjacent said r 6rl Oliec'*('Or partitions and drive means for indexing the conveyorAin a stepwise fashion so that, in use, containers fed between o adjacent said partitions by the infeed means are collated and ooo Soo presented for downstream indexing by the container indexing means.

oj t According to another aspect, the invention provides a packaging apparatus including the collating apparatus referred to above.

e I I 4ILL~ The conveyor is preferably constructed as a continuous or endless conveyor having a forward and a return portion. The conveyor is guided for movement by the indexing means. The guiding may be achieved by one or more guide members. The guide members may comprise one or more arcuate end guides between which extend one or more guide rails. Preferably the forward portion is guided on two spaced guide rails extending transversely of a packaging apparatus of which the collating -I apparatus may form part.

The partitions are preferably of a height commensurate with the height of containers being collated. The partitions may be formed integrally with or be secured to the container support members. Preferably each partition is releasably secured to a respective container support member. The partitions, when the forward and return portions extend horizontally, preferably extend substantially vertically.

The partitions preferably are rectangular in shape with their o o o z length commensurate with the combined width represented by a 0o all row of containers to be collated. Preferably an edge of each 4:1f partition, when the partition is in the forward portion of 0

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the conveyor extends below the associated container support t rec-es ec member. Preferably that edge has a A r t portion the purpose of which will be described below. The edge, by rece sge 4 having a, ra;to portion forms a short extension below the container support member. The length of the extension is less than the total length of the partition.

The container support members may be in the form of conveyor slats with adjacent slats being hinged together to form a continuous conveyor. Thus, one slat may be formed with part of a hinge whilst an adjacent slat may be formed or provided with the remainder of the hinge. Preferably two separate hinges are employed to hinge one slat to an adjacent slat.

8 The hinges may be located adjacent opposed edges of an recesse associated partition and be located in a- reate- portion of the partition. A hinge pin may hold the hinge parts together. Preferably the hinge pins extend beyond side edges of the resultant endless conveyor and it is these hinge pin extensions which may run relative to the guide members previously referred to.

The drive means may function to drive the con-reyor. The drive means may engage part of the conveyor to drive it so as to present pairs of adjacent partitions for receiving containers from the infeed means. Preferably the drive means engages either the container support, members, the hinge pin or the partitions to drive the conveyor.

Preferably the partitions are engaged for driving the conveyor. This is preferred because adjacent pairs of I partitions may then more accurately be presented to receive t containers from the infeed means. The drive means may include a drive member for engagement with the partitions.

The drive member may comprise a rotating cam member.

Preferably a geneva wheel mechanism is employed having one wheel of the mechanism mounted eccentrically relative to a driven wheel of the mechanism. The one wheel may engage an extension of a partition during part of the rotation of the driven wheel to thereby move the conveyor. The one wheel may clear the partition by passing through the rebate portion Ii during another part c this way the conveyor present adjacent pair between them from the speed of rotation o addition, the one wh may be positioned at the driven wheel to Sspeeds.

)f the rotation of the driven wheel. In may be indexed in a stepwise fashion to s of partitions for receiving containers infeed means. It is preferred that the f the driven wheel be adjustable. In eel may be of a variety of diameters or selected eccentric positions relative to provide for indexing at a variety of 0*r It 0 0L The collating apparatus may include an end stop. The end stop is located downstream of the conveyor and opposed to the infeed means such that when containers are received between a selected pair of partitions they are restrained from progressing downstream of the partitions until such time as the collated containers are indexed to the packing zone. The end stop is preferably movable into and out of engagement with a downstream container located within the pair of partitions such that once a selected number of containers is received between the pair, the stop may be withdrawn so that the conveyor may be indexed to present a different pair of partitions to the infeed means. Preferably the end stop is provided by a cylinder assembly. More preferably, a pneumatic cylinder assembly having a ram for movement into engagement with a container is employed.

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11 i ii i: -:1 The end stop may also include a separate stop member for guiding downstream containers on the conveyor during indexing of the conveyor. The separate stop member is movable between a position guiding the downstream containers during indexing 5 of the conveyor to a position permitting indexing of the collated containers from the conveyor to the packing zone.

Preferably the separate stop member is pivotally movable. In one embodiment the separate stop member is a hinged finger or plate movable above a plane defined by the slats of the conveyor and into the plane defined by the conveyor slats.

The collating apparatus may include one or more gate members for prohibiting the infeed means from feeding containers between adjacent partitions during indexing of the conveyor.

The or each gate may include a member movable into and out of the path of containers on the infeed means. In one embodiment the gate(s) may be a finger or plate. In another embodiment the gate(s) may be movable by a cylinder assembly.

Preferably two opposed pneumatic cylinder assemblies are used with each having a stop block at an end of a ram.

Particular preferred aspects of the invention will now be described by way of example with reference to the drawings in which: igure 1 is a side elevational view of a packaging apparatus including the collating apparatus according to an embodiment r'"

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11 of the invention; Figure 2 is a perspective view of the collating apparatus according to an embodiment of the invention; Figure 3 is a plan view of the apparatus illustrated in Figure 2; Figure 4 is a detailed perspective view of a conveyor employed in the apparatus of Figures 2 and 3; Figure 5 is a transverse sectional view of the apparatus of Figures 2 and 3; and, Figure 6 is a view of the packing zone of the apparatus shown in Figure 1.

As shown in Figure 1, the packaging apparatus 10 has an upstream end 11 and a downstream end 12. Infeed means in the form of an infeed conveyor 13 conveys a row of containers 14 (see figure 2) to a collating zone 15 in which the collating apparatus 25 of the invention is located. A container indexing means like that illustrated in Figure 6 of U.S.

patent specification 4742670 is located adjacent the collating zone. A carton supply 16 is located above the collating zone and container indexing means. A carton erector 17 is located above packing zone 18. A flap closure station 19 is located downstream of the packing zone 18.

Gluing station 20 is located immediately downstream of the closure station 19 and cartons exit from the apparatus 10 via outfeed conveyor 21.

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12 The apparatus 10 is constructed in a similar fashion to the packaging apparatus, the subject of the previously referred to U.S. patent specification. The collating apparatus of the present invention and other changes made in the vicinity of the collating zone 15 are aspects described in the present application.

Figure 2 of the drawings shows a perspective view of the collating zone 15 and illustrates various aspects of the collating apparatus 25 according to an embodiment of the present invention. The collating apparatus 25 includes a conveyor 26 comprising a plurality of partitions 27 and container support members or slats 28. Each partition is rigidly secured to a selected slat and the slats 28 are hinged to one another to form an endless conveyor. The slats 28 are provided with hinge members 29 through which a hinge pin may pass. The conveyor 26 is journalled to run between side frames 30 and 31 (see Figure End stop 33 is located on one side of the conveyor 26 and opposite the infeed conveyor 13. The end stop is reciprocally moveable so that containers 14 may abut against it when those containers are fed between two adjacent partitions 27 by the infeed conveyor 13. Once a desired number of containers is positioned between adjacent partitions 27, the end stop 33 is retracted and the conveyor 26 may be indexed to the right of Figure 2 to present the next two adjacent partitions 27 for receiving further containers 14 from the infeed conveyor 13. During indexing of the conveyor 26 gate fingers or blocks 34 and arranged on opposed sides of the downstream end of conveyor 13 may be moved towards one another to restrict the flow of containers 14. Once indexing of the conveyor 26 is complete, gate blocks 34 and 35 may be retracted to once again enable containers 14 to be fed between adjacent partitions 27 by the infeed conveyor 13.

At the downstream side of conveyor 26, guide fingers 36 and 37 are located. These fingers converge towards one another in the direction of arrow A. This ensures that the container indexing means (not visible in Figure 2) closely aligns the collated containers 14 relative to one another eliminating the inherent spacing between rows of containers caused by the thickness of the partitions 27.

Sensor 40 adjacent the end stop 33 is used to detect the presence of containers 14 between adjacent partitions 27 and indicates that a full row is present. Sensor 41 is arranged above the zone in which the containers 14 are collated and from which tT i i i! Crru they are moved to the packing zone by the indexing means.

Sensor 41 detects whether the containers have been properly collated and should a fault condition be detected, once again, the packaging apparatus may be de-energised.

Located upstream of the infeed conveyor is a rocker arm 42, a trailing end of which rests on upper portions of the containers 14. The arm 42 is free to pivot about shaft 43 and a leading edge of the arm 42 may be used to trigger a further sensor (not shown). Should a situation arise where containers 14 do not assume the position shown in Figure 2, the arm 42 is caused to pivot and trigger the sensors and once again the apparatus may be de-energised.

End stop 33 includes a head portion 44 which may be moved into and out of engagement with containers 14 once they are received between adjacent partitions 27. This movement is achieved by pneumatic cylinder assembly 45. The reciprocal movement of gate blocks 34 and 35 is also achieved by pneumatic cylinders 46 (only one of which is visible if Figure 2).

Figure 3 of the drawings shows a plan view of the collating apparatus 25 shown in Figure 2. For the sake of adequate description, part of the apparatus is shown in broken away detail. At the downstream end of the collating apparatus a r~P ~arr~ hinged moveable gate member 47 is shown. This member has a forward part 47A hinged to a trailing part 47B. The forward part 47A may be hinged so that its leading edge is raised above the plane along which the containers 14 move when transported to the packing zone by the container indexing means. In this way, that leading edge engages the containers at a location intermediate the ends of the containers. In this way, the portion 47A assists irestraining the containers located between partitions 27 as the conveyor 26 is indexed. Once a desired number of containers 14 are collated and ready for transport to the packing zone, portion 47A pivots downwardly out of engagement with the containers so that the containers may be indexed to the packing zone. Gate blocks 34, 35 include heads 34a and 35a with inwardly directed nose portions which assist in l 0 restraining containers when the blocks 34, 35 are moved together.

44 In the broken away part of the drawing, the drive means for the conveyor 26 is partly visible. This drive means includes .444 o 4 a cam wheel or drive wheel 48 eccentrically mounted to a driven wheel 49. These wheels function as a geneva drive mechanism. Cam wheel 48 engages a lower extension of each partition 27 during part of the rotation of the driven wheel recssed and moves through- rc-t portions on the partitions during a remaining part of the rotation of the driven wheel. With

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00 0 0 0q 4 4t 4 4 16 such an arrangement, the drive action is such that initial movement of the conveyor is slow, this movement gradually increases in speed and then gradually decreases once again to a slow final movement before stopping. During the movement of the cam wheel through the rebate portions of the partitions, the conveyor 26 is obviously stationary. This drive action will be further described in relation to Figure 4 and Figure 3 further shows that the infeed conveyor 13 has two spaced guide rails 50 and 51 between which the containers 14 may move so as to be accurately received between adjacent partitions 27. As is also shown in Figure 3, guide finger 36 continues downstream of the collating apparatus whilst guide finger 37 is relatively short. Guide 52 continues on downstream from the downstream end of finger 37. These guides ensure that the collated containers are adequately restrained during the movement of them from the collating zone to the packing zone.

Figure 4 of the drawings shows greater detail of the collating apparatus 25. The conveyor 26 consists of a plurality of partitions 27 each connected to a respective slat 28 by fasteners 53. As previously mentioned, hinge portions 29 provided on the slats 28 enable those slats to be connected together by hinge pins 54. Each partition has a I rec esseiej robet 4 portion 55 and 56 and an extension 57, which, when the partition is upstanding is lowermost. It is against the extension 57 that the cam wheel 48 may abut and that wheel recese may move through thNrbae portion 55 once stepwise indexing of the conveyor 26 has been achieved. By indexing the conveyor in this way there is no need to take into account tolerances and the like of the hinge connections between the slats. As the partitions are accurately moved by the wheel 48, the partitions are accurately positioned relative to the containers presented by the infeed conveyor 13.

Figure 5 of the drawings is a transverse sectional view taken immediately downstream of the conveyor 26 shown in Figure 4 I a I and looking upstream of the packaging apparatus. The container indexing means like the means illustrated in Figure 6 of U.S. Patent Specification 4742670 is shown generally by the numeral 55. As in the U.S. Patent, the container indexing means includes an arm 63 (the other arms of the means 55 are not visible) for transporting containers 14 downstream of the collating zone 15. The conveyor 26 with its partitions 27 and slats 28 is clearly shown. The conveyor 26 is trained over end guides 57 and 58. These end guides are mounted so as to be adjustable relative to each other to enable the spacing between them to be varied so as to accommodate different size conveyors 26. This adjustment is achieved by fasteners 60 which are received within slots .Vr 0 _j

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61. The location of the cam wheel 48 is clearly shown and this wheel is mounted relative to driven wheel 49. The driven wheel 49 is rotated by a gear box 62 which in turn is driven by motor 64. The motor 64 is adjustably mounted so that it may be moved either towards or away from end guide 58. This movement together with the provision of different size geneva wheel mechanisms and the relative movement provided between end guides 57 and 58 enables the collating apparatus 25 to readily accommodate conveyors 26 of a variety 1 0 of selected sizes. In this way, the apparatus 25 may be adjusted or adapted to be suitable for use with containers 14 of a variety of sizes. Should it prove necessary to remove the conveyor 26 and replace it with one of a different size all that need be done is to ensure that the cam wheel 48 rees&e4 is located in the rcwzt4 portion 55 of a partition 27, a selected pin 54 is then withdrawn from hinge portions 29 of adjacent slats 28 and the conveyor may then be removed and replaced with one of a different size having a different spacing between adjacent partitions 27. The geneva wheel mechanism will also need to be replaced to suit a conveyor having a different spacing between adjacent partitions.

Similarly, it may be necessary to alter the spacing between end guides 57 and 58.

Figure 6 of the drawings shows part of the packaging apparatus immediately downstream of the collating zone 0 C, 19 That part of the apparatus may be the same as the corresponding part of the packaging apparatus illustrated and described in U.S. Patent Specification 4742670 and is illustrated in Figure 6 in this application by way of example.

It should be appreciated that with the collating apparatus of the present invention the containers are restrained between adjacent partitions 27 as they are moved downstream by the infeed conveyor 13. During indexing of the conveyor 26, the containers 14 are positively transported for collating in the desired number of rows and rest upon a slat 28 whilst being restrained between adjacent partitions. To assist in further restraining the containers 14 end stop 33 is employed and it is against that end stop that the first container fed between adjacent partitions 27 may abut.

Hinged gate member 27 also assists in further restraining the containers 14 during collating. The particular drive imparted to the conveyor 26 by the geneva wheel mechanism ensures that initial movement of the conveyor is slow and that this movement gradually builds up and then decreases in speed. This movement also assists in ensuring the containers do not become unstable during collating.

Claims (16)

1. A collating apparatus for a packaging apparatus having infeed means for conveying a plurality of containers I to the collating apparatus and container indexing means for moving the containers downstream of the collating apparatus to a packing zone, said collating apparatus including a conveyor extending transversely of the packing apparatus and having a plurality of utr~ 1 y cxtrfnrin spaced partitions with a container support member extending between djacent 1 0 said partitions and drive means for indexing the conveyorAin a stepwise fashion sn that, in use, containers fed between adjacent said partitions by the infeed means are collated and presented for downstream indexing by the container indexing means.

2. The collating apparatus of Claim 1 wherein said conveyor is an endless conveyor having a forward portion and a return portion.

3. The collating apparatus of Claim 1 or Claim 2 including one or more guide members for guiding the conveyor during indexing.

4. The collating apparatus of Claim 3 wherein said guide members include spaced arcuate end guides between which extend guide rails. The collating apparatus of any one of Claims 1 to 4 wherein said partitions are either formed integrally with a respective said container support or secured thereto. 21

6. The collating apparatus of any one of Claims 1 to wherein said partitions are substantially rectangular in shape.

7. The collating apparatus of any one of Claims 1 to 6 wherein each said partition has a portion extending below the associated container support member.

8. The collating apparatus of any one of Claims 1 to 7 wherein said container support members are hinged together to form part of said conveyor.

9. The collating apparatus of Claim 8 wherein each said container support member is formed with a complementary part of a hinge. The collating apparatus of any one of Claims 7, 8 or 9 when appended to Claim 7 wherein said drive means includes a drive member engageable with the partitions for indexing the conveyor.

11. The collating apparatus of Claim 10 wherein the drive member engages the portion of the partitions which exter.d below the container support member.

12. The collating apparatus of Claim 10 or 11 wherein said drive member comprises a rotating cam member.

13. The collating apparatus of Claim 10 or 11 wherein said drive member is a drive wheel eccentrically mounted to a driven wheel and said wheels provide a geneva wheel mechanism.

14. The collating apparatus of Claim 13 wherein said j -~1111~1 I| cecessed portion of said partition has a re*bate-portion through which said drive wheel may move during a part of the rotation of the driven wheel to thereby drive the conveyor in a stepwise fashion.

15. The collating apparatus of Claim 13 or 14 wherein the degree of eccentricity is variable. iS 16. The collating apparatus of Claim 13, 14 or wherein the speed of rotation of the driven wheel is variable.

17. The collating apparatus of any one of Claims 1 to tc(jac enK 16 including an end stoPARin-ae-am- the conveyor and opposite the infeed means for restraining the containers from S---"don-trza m movement prior to indexing of the containers to the packing zone.

18. The collating apparatus of Claim 17 wherein the i: istop is movable from between adjacent pair of said partitions to enable the conveyor to be indexed. pi 19. The collating apparatus of any one of Claim 1 to 18 i i Iincluding a separate stop member for guiding the containers during the indexing of the conveyor and movable to enable the containers to be indexed downstream by the container indexing means. The collating apparatus of Claim 19 wherein said separate stop means comprises a hinged gate downstream of the conveyor. 0- i I 1J 23 S21. A collating apparatus substantially as herein described with reference to the accompanying drawings.

22. A packaging apparatus in combination with the collating apparatus of any one of Claims 1 to 21. DATED this 7 day of August, 1989. R.L. WINDSOR SON PTY. LTD. j By their Patent Attorneys f G.R. CULLEN CO. I ri