EP2858907B1 - Carton decasing system - Google Patents
Carton decasing system Download PDFInfo
- Publication number
- EP2858907B1 EP2858907B1 EP13800346.2A EP13800346A EP2858907B1 EP 2858907 B1 EP2858907 B1 EP 2858907B1 EP 13800346 A EP13800346 A EP 13800346A EP 2858907 B1 EP2858907 B1 EP 2858907B1
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- EP
- European Patent Office
- Prior art keywords
- cartons
- stack
- case
- assembly
- containers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B69/00—Unpacking of articles or materials, not otherwise provided for
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B43/00—Forming, feeding, opening or setting-up containers or receptacles in association with packaging
- B65B43/12—Feeding flexible bags or carton blanks in flat or collapsed state; Feeding flat bags connected to form a series or chain
- B65B43/14—Feeding individual bags or carton blanks from piles or magazines
- B65B43/145—Feeding carton blanks from piles or magazines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B43/00—Forming, feeding, opening or setting-up containers or receptacles in association with packaging
- B65B43/12—Feeding flexible bags or carton blanks in flat or collapsed state; Feeding flat bags connected to form a series or chain
- B65B43/14—Feeding individual bags or carton blanks from piles or magazines
- B65B43/20—Feeding individual bags or carton blanks from piles or magazines by reciprocating or oscillating pushers
- B65B43/205—Feeding individual bags or carton blanks from piles or magazines by reciprocating or oscillating pushers specially adapted for carton blanks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B43/00—Forming, feeding, opening or setting-up containers or receptacles in association with packaging
- B65B43/26—Opening or distending bags; Opening, erecting, or setting-up boxes, cartons, or carton blanks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H1/00—Supports or magazines for piles from which articles are to be separated
- B65H1/02—Supports or magazines for piles from which articles are to be separated adapted to support articles on edge
- B65H1/025—Supports or magazines for piles from which articles are to be separated adapted to support articles on edge with controlled positively-acting mechanical devices for advancing the pile to present the articles to the separating device
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H1/00—Supports or magazines for piles from which articles are to be separated
- B65H1/30—Supports or magazines for piles from which articles are to be separated with means for replenishing the pile during continuous separation of articles therefrom
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B43/00—Forming, feeding, opening or setting-up containers or receptacles in association with packaging
- B65B43/12—Feeding flexible bags or carton blanks in flat or collapsed state; Feeding flat bags connected to form a series or chain
- B65B43/126—Feeding carton blanks in flat or collapsed state
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2301/00—Handling processes for sheets or webs
- B65H2301/40—Type of handling process
- B65H2301/42—Piling, depiling, handling piles
- B65H2301/422—Handling piles, sets or stacks of articles
- B65H2301/4225—Handling piles, sets or stacks of articles in or on special supports
- B65H2301/42254—Boxes; Cassettes; Containers
- B65H2301/422542—Boxes; Cassettes; Containers emptying or unloading processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2701/00—Handled material; Storage means
- B65H2701/10—Handled articles or webs
- B65H2701/17—Nature of material
- B65H2701/176—Cardboard
Definitions
- the present invention generally relates to article packaging and handling systems, and in particular to a system for removing cartons and/or carton blanks from cases or other packaging for the cartons or carton blanks and transporting the removed cartons or carton blanks in stacks to a carton magazine for a packaging machine.
- articles such as cans, bottles, individually wrapped food-stuffs, etc.
- a product cartoning material such as a paperboard, cardboard or other, similar material.
- product cartons can be provided as a series of folded and glued carton sleeves that are open at their ends for insertion of the products therein, or can include substantially flat carton blanks that will be folded by the product packaging machine and wrapped about a group of articles or products placed thereon.
- the carton sleeves or carton blanks will be loaded into a carton magazine for the product packaging machine in stacks, which carton magazine then will feed individual carton sleeves or carton blanks into the packaging machine for loading with products or for wrapping about a series of product groups.
- US 5271710 A discloses a system according to preamble of claim 1 and teaches a system for dumping letters or other postal articles from bins with the letters stacked therein.
- the bins are moved onto a tipping trough of a coupling deck and are tilted to allow the letters held therein to slide out of the bins and onto a magazine platform.
- This system requires the operator to manually hold each bin on the pivotable coupling deck when tilting the bins to a downward sloping angle for enabling the materials to slide out while being "held back by the operator using the other hand" for placement onto the magazine.
- US 2002/146308 A1 also discloses a system that is specifically designed for high-speed unloading of mail from a series of bins or trays, wherein open-ended trays or bins having mail loaded therein are fed to a tray control module that rotates the trays into a position where they can be lifted off of a stack of mail by belts of tray removing module.
- the stack of mail is dumped onto a conveyor assembly.
- the tray control module includes a drum assembly formed with a series of spaced apart drum disks arranged in spaced configuration to enable tray holder members mounted thereon to pass between belts of a supply belt transport of the conveyor assembly as the mail is deposited thereon.
- the present invention generally relates to a system and method for automatically removing cartons or carton blanks from cases or other, similar containers in a stacked configuration such as for feeding into a magazine of a downstream product packaging machine.
- cases containing stacks of cartons such as, for example carton blanks or sleeves for packaging bottles, cans or other products in 2x6, 2x8, 2x12, 4x6 or other varying product configurations, will be loaded onto a carton infeed.
- the cases can be queued up along the carton infeed for presentation to an inverting assembly at the downstream end of the case infeed, and typically, will be loaded with the upper ends of the cases being open, and with notches or recesses also generally being formed in the upstream and downstream side walls of the cases.
- the cases initially are fed into the inverting assembly which includes an inverter head that is pivotally mounted on a support frame.
- the inverter head further generally includes a pair of adjustable side guides and a pair of top and bottom support guides that are vertically adjustable with respect to one another so as to define a receiving area therebetween for receiving a case of a predetermined or preselected size therein.
- the cases with the cartons stacked therein are correspondingly reoriented and are deposited on a downstream magazine or stacking conveyor, with the closed bottom end of each case generally being realigned in upwardly facing attitude or direction.
- the inverter head and magazine conveyor further are adjustable vertically to enable adjustment of the position of the cases with respect to an overhead case lifting mechanism, so as to accommodate different height or size cases as needed.
- the cases are initially deposited on a carton decasing assembly for removal of the case from the stack of cartons contained therein.
- the carton decasing assembly includes an adjustable framework having laterally adjustable side guide rails on which the cases are received and initially supported, and a series of containment rod mechanisms mounted on supports or holders that are moveable longitudinally with respect to the side guide rails so as to enable adjustment of the longitudinal position of the containment rod mechanisms.
- the adjustment of the side guide rails laterally, together with the longitudinal adjustment of the locations of the containment rod mechanisms enables the carton decasing assembly to be adjusted to accommodate varying length/depth and width cases.
- a series of gripping lugs which are also mounted on the longitudinally sliding supports or holders that carry the containment rod mechanisms, are pivoted into engagement with the cartons, typically moving or passing through the recesses or gaps formed in the cases so as to engage and compress the stack of cartons inwardly.
- the compression of the stack of cartons within the cases by the gripping lugs creates spacings/openings between the cartons and case walls in which the extensible containment rods can be received.
- the containment rods are inserted into and pass between the foremost and rearmost cartons of the stack of cartons and the front and rear side walls of their case so as to hold the cartons in a stacked configuration as the case is removed therefrom and prevent the walls of the case from frictionally engaging or otherwise dislodging cartons from the stack.
- each case is removed from its stack of cartons with the cartons being maintained in a stacked, substantially aligned configuration. Thereafter, the cartons are conveyed further along the magazine conveyor as the emptied cases are removed for disposal.
- the stack pusher assembly generally will include at least one stack pusher that, in one embodiment, can comprise a pair of extensible pusher rods each moved between extended and retracted positions by an actuator, such as a pneumatic or hydraulic cylinder, or other similar actuator.
- the pusher rods further can be carried by an overhead support linked to a drive system connected to the drive mechanism for the magazine conveyor so as to move with the forward movement of the magazine conveyor.
- the drive system of the stack pusher assembly also can be disconnected from the magazine conveyor so as to be independently driven for moving the stack pusher assembly to a retracted position as needed for engaging a next stack of cartons loaded on the magazine conveyor.
- the pusher rods will be retracted as the decasing assembly conveys the next stack of cartons into a combined, stacked arrangement against the prior loaded stack of cartons.
- the drive mechanism for the stack pusher assembly also can be disengaged from the magazine conveyor, and operated to retract the stack pusher assembly to a position behind the rearmost carton of the next stack of cartons being loaded, after which the pusher rods can be extended into an engaging position against the combined stack of cartons as the containment rods of the carton decasing assembly are retracted and the carton decasing assembly is moved back to its initial, loading position.
- the drive mechanism of the stack pusher assembly further can be reengaged with the magazine conveyor to continue its forward motion with its pusher rods engaging and supporting the combined stack of cartons as the cartons are fed to the discharge point of the magazine conveyor.
- Figs. 1-7D illustrate the automatic carton decasing system 10 and the operative assemblies thereof for removal of stacks of cartons 11 from cases or other containers 12 and for automatically loading such decased or removed carton stacks into a carton magazine 13 for feeding into a feeder assembly of a downstream packaging machine, as indicated in Fig. 1 .
- the cartons 12 can be received as stacks of flat carton blanks or as preformed carton sleeves, or in other configurations as needed or desired, and as will be understood by those skilled in the art, and will be oriented and removed from their cases in a stacked, substantially aligned configuration.
- the automatic carton decasing system further is designed to fit with and/or be operable with a variety of different type or size packaging machines.
- the automatic carton decasing system further can be designed for retrofitting to existing packaging machines in the field, and further is adapted to unload/remove and load a full range of carton sizes and/or configurations as well as different case proportions and materials.
- the automatic carton decasing system of the present invention can be utilized with 2 x 2, 3 x 4, 4 x 6 or other carton sizes and can handle cartons of a variety of sizes and shapes, including long, short cases, substantially square cases and tall and wide cases, such as illustrated at 12A and 12B, respectively, in Figs. 3B-3C and 5A 5C .
- Fig. 1 generally illustrates one example embodiment of the automatic carton decasing system 10 according to the principles of the present invention, which generally includes an elongated frame 21, which frame generally can be adapted to match its parent packaging machine.
- a case infeed 23 At an upstream end or section 22 of the frame 21 comprises a case infeed 23.
- the case infeed 23 generally will comprise a conventional conveying system 24 such as a chain conveyor, belt conveyor or other known type of conveying mechanism including belts, slats, chains or other conveying elements 26 that are driven about a substantially continuous path in the direction of arrow 27 by a motor or similar drive mechanism (not shown).
- An operator can load the cases with cartons stacked therein on the upstream or first end of the case infeed conveyor 24, with the cases being queued in a line or supply arrangement.
- the cases 12 will be oriented on the case infeed conveyor 24 in an upstanding attitude and with a top or upper end 16 of the cases 12 being open and a series of recesses, cut-outs, gaps or similar features 17 formed in the leading and trailing side walls 18A/18B of the cases.
- the case infeed conveyor 24 will convey the cases in series to an inverting assembly 30, which inverts or otherwise reorients the cases so that the cases can be quickly and easily removed from the cartons while the cartons are maintained in a stacked configuration as illustrated in Figs. 2-3B .
- the cases can be conveyed or transported to the inverting assembly from a remote location or an automatic depalletizer.
- the case infeed conveyor further can be designed with respect to the inverting assembly 30 so that different length case infeed conveyors and/or extensions of the case infeed conveyor can be provided in either in-line or perpendicular arrangements to suit available space in a desired or required line layout.
- the cases 12 can be loaded onto a first, upstream section 28A of the case infeed conveyor, and can then be transferred to and/or reoriented on a second, downstream section 28B, which conveys the cases to the inverting assembly 30 at the downstream end thereof.
- the cases 12 with the cartons 11 stacked therein are conveyed to the downstream end of the case infeed conveyor and are brought into engagement/registration with the inverting assembly 30 positioned at the downstream end of the case infeed conveyor.
- the inverting assembly inverts or reorients the cases with the cartons contained therein and places them on a stacking or magazine conveyor 31 having a carton decasing assembly 32 initially located in a first or case receiving position adjacent an upstream end of the magazine conveyor, as indicated in Figs. 1 and 5A-5C .
- the inverting assembly thereafter will release each case, which will be moved with the decasing assembly along the magazine conveyor away from the inverting assembly and to a second or intermediate position for removal of the case as indicated in Fig. 1 .
- the inverting assembly 30 generally includes an inverter head 30A pivotally mounted on a pair of upstanding frame members or supports 33, and includes a pair of side guides or clamps 34 that are adjustable laterally so as to be repositionable as needed to engage different size cases.
- Each of the side guides 34 generally will include a rearwardly projecting plate or arm 36 typically having an outwardly flared first or guide portion 36A and a substantially flat body or second portion 36B mounted to an adjustable slide support 37.
- the slide supports 37 are movably mounted on a support rail 38 that extends laterally between a pair of vertical slides or supports 39, that further are mounted to a carrier or base frame member 41, which pivotally attaches and supports the inverter head 30A on frame members 33.
- the slide supports 37 can be moved laterally toward and away from each other, and can be fixed in place such as by set screws 42, or other, similar fasteners, to define a width for a receiving area 40 of the inverter head 30A in which the cases 12 are received, with the outwardly flared guide portions 36A of the side guides 34 helping to center and guide the cases into the receiving area.
- the side guides can be adjusted inwardly to accommodate the reduced width or thinner configuration of the cases.
- the inverter head 30A further includes top and bottom case support guides 44 and 46 that engage the top and bottom ends of the cases, for positively gripping and holding the cases during inversion or reorientation thereof to prevent the cartons from becoming dislodged or otherwise inadvertently released from the cases during inversion or reorientation thereof by the inverting assembly.
- the case support guides 44 and 46 generally are mounted to vertical slides or supports 39, with the positions of the case support guides being adjustable therealong, such as by cranks or handwheels 47 to define a height for the receiving area 40 of the inverter head.
- cranks or handwheels 47 to define a height for the receiving area 40 of the inverter head.
- the case supports further can include spaced forks, tines or plates 44A/46A, or can include other types of supports.
- the inverter head further can be connected to or engaged by a drive belt 48 or similar conveying mechanism driven by a motor such as indicated at 49 in Fig. 3A for controlling the rotary motion of the inverter head for lifting, inverting and depositing the cases onto the magazine conveyor 31 ( Fig. 2 ).
- case support guides 44 and 46 engage and lift and pivot the cases with the cartons stacked therein, as indicated by arrows 51 in Figs. 3B and 3C , so as to reorient the cases in an inverted or upside down configuration, with the open top portions 16 of the cases being placed in a substantially downwardly facing alignment on the magazine conveyor 31.
- the case support guides 44, 46 In their initial stack receiving position, the case support guides 44, 46 generally are separated by a gap that is greater than the case height. As the inverter head 30A inverts, the lower case support guide 46 can move toward the upper case support guide 44, which closes this gap and thus conforms the case support guides to the case height.
- the magazine conveyor 31 can be set at varying heights as needed depending upon the type of parent packaging machine and/or the type/configuration of cartons and cases being fed for decasing without affecting the operation of the inverting assembly 30.
- the geometry of the inverting assembly, and the adjustability and/or closing engagement of its side guides and case support guides with a case 12 during inversion and placement of the case on the magazine conveyor allows a fixed height case infeed conveyor 24 to be utilized with variable height magazine conveyors, with the case inverting assembly automatically adjusting for case size and placing the case on the correct magazine height for the packaging machine. For example, as shown in Fig.
- a tall case can be inverted and placed on the magazine conveyor, with the magazine conveyor adjusted and set at a lowered height, while for shorter or reduced height cases, as shown in Fig. 3C , the magazine conveyor 31 can be set at a higher level as needed for feeding the cartons into the magazine, without requiring reconfiguration or change-out of the inverting assembly 30.
- a simple adjustment of the positions of the side guides and case support guides so as to readjust the receiving area in which the cases are received and engaged can be made to ensure a secure lifting and reorientation of the cases.
- the carton decasing assembly 32 generally is initially located at the upstream or first end of the magazine conveyor 31 in a first, case receiving or loading position, indicated at 55, for receiving and engaging the cases after they are inverted by the inverting assembly.
- Figs. 4A-5C generally illustrate the carton decasing assembly 32, which is movable along the magazine conveyor 31 between its first loading position, a second, intermediate or case removal position, indicated at 56 in Fig. 7A , and a third, downstream or disengaging position indicated at 57 in Fig. 6 .
- the movement of the decasing assembly 32 is controlled by a drive mechanism 58 ( Fig. 4D ) that is independently operable from the magazine conveyor.
- each of the adjustable guide rails 62/63 is adjustable laterally along rails 71 to accommodate different size or configuration of cases, and the positions of the containment rods 60 further are adjustable longitudinally, such as by sliding movement of their supports 66 along guide rails 72 to further enable adjustment of the framework 61 of the carton decasing assembly to accommodate different size and/or configuration cases 12, as illustrated in Figs. 5A-5C .
- the positions of the containment rods 60 further are adjustable longitudinally, such as by sliding movement of their supports 66 along guide rails 72 to further enable adjustment of the framework 61 of the carton decasing assembly to accommodate different size and/or configuration cases 12, as illustrated in Figs. 5A-5C .
- an adjustment mechanism 73 here shown as a hand-wheel or crank, although it will be understood that other manual and automatic adjustment mechanisms also can be used, will be provided along the magazine conveyor 3 1 for adjustment of the width of the magazine conveyor, and with it the width of the carton decasing assembly, to accommodate different width/size cartons.
- a first side 74A of the magazine conveyor and the side guide rail (i.e., 63) associated therewith can remain fixed or stationary, with the opposite or second side 74B of the magazine conveyor being movable along laterally extending guide rails, such as shown at 75 in Fig. 4D , to adjust its position with respect to the first side 74A of the magazine conveyor, and with it, the position of side guide rail 62 with respect to side guide rail 63 of the carton decasing assembly.
- the adjustments of the side frame assemblies of the carton decasing assembly both laterally and longitudinally accordingly are part of the size change procedure for the automatic carton decasing system, with such longitudinal and lateral adjustments generally being controlled via manual drive mechanisms and sensors so as to match the spacing of the containment rods and gripper lugs to the particular size and/or configuration of the cases and accordingly the stacks of cartons contained therein.
- the positions of the containment rods will be adjusted to match the longitudinal size or thickness of the stacks of cartons, and to locate the containment rods approximately adjacent the fold or crease lines of the cartons to ensure stable and even engagement therewith as the cartons are conveyed along the magazine conveyor with the containment rods.
- the case will be lifted off of its stack of cartons by a lifting mechanism 80 ( Fig. 1 ) as the rods remain in a raised, engaging position for holding the stacks of cartons in place and as the case is removed therefrom.
- the containment rods will remain up for decasing and subsequent transfer of the carton load to the back of a carton magazine such as being combined with a prior loaded stack thereon, thus supporting the carton load until a stack pusher assembly 90 engages the stack of cartons and locates the stack of cartons against the back of previously loaded supply or stack of cartons within the magazine, as indicated in Figs. 7A-7C .
- a sensor 78 ( Fig.
- the containment rods of the carton decasing assembly can be retracted, releasing the cartons from engagement therewith, after which the carton decasing assembly can be moved back to its initial, loading or carton receiving position adjacent the upstream end of the magazine conveyor and the inverting assembly. Thereafter, as indicated in Fig. 7D , the stack pushers will continue to move forwardly with the forward motion of the magazine conveyor as the cartons are sequentially fed through the discharge point of the magazine conveyor and into a downstream packaging machine magazine.
- the inverter head further will be mounted on a carriage 201, which conveys the inverter head 30A about an extended, orbital path over and above a layer pad magazine access area or station 202 provided along the path of movement of the cases.
- This layer pad magazine access area 202 enables the operator to access the twin stack packaging machine PM ( Figs. 8 and 10 ) for loading of a stack or series layer pads into the layer pad magazine 203 of the twin stack packaging machine.
- Such access further is provided without disruption of the operation of the carton decasing system for removing stacks of cartons form their cases and feeding such stacks of cartons into a carton magazine 204 of the packaging machine.
- the drive motor 211 generally will be actuated to commence inverting of the case and cartons.
- the motor will pull the drive chain or other drive mechanism along the rails of the rail assembly 206, causing the carriage 201 to transport the inverter head 30A about its orbital path as shown by arrows 209, upwardly and over the layer pad magazine access area 202.
- the system further can be primed by loading a limited number of cartons initially within the feeder to create an initial stack against which later decased carton stacks will be placed, while the empty cases are dischargeable along a high level conveyor to help reduce the system footprint, and which further can be reconfigured to provide case discharge anywhere in an approximately 180° radius for discharging cases into a bin or baler or directing them to some other type of containment unit for collection and disposal or recycling.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Supplying Of Containers To The Packaging Station (AREA)
- Specific Conveyance Elements (AREA)
- Attitude Control For Articles On Conveyors (AREA)
- Sheets, Magazines, And Separation Thereof (AREA)
- Control And Other Processes For Unpacking Of Materials (AREA)
- Container Filling Or Packaging Operations (AREA)
Description
- The present invention generally relates to article packaging and handling systems, and in particular to a system for removing cartons and/or carton blanks from cases or other packaging for the cartons or carton blanks and transporting the removed cartons or carton blanks in stacks to a carton magazine for a packaging machine.
- In automated product packaging systems, articles such as cans, bottles, individually wrapped food-stuffs, etc., generally are fed into a product packaging machine where such articles can be grouped or otherwise sorted and thereafter placed within or wrapped with a product cartoning material such as a paperboard, cardboard or other, similar material. Such product cartons can be provided as a series of folded and glued carton sleeves that are open at their ends for insertion of the products therein, or can include substantially flat carton blanks that will be folded by the product packaging machine and wrapped about a group of articles or products placed thereon. Typically, the carton sleeves or carton blanks will be loaded into a carton magazine for the product packaging machine in stacks, which carton magazine then will feed individual carton sleeves or carton blanks into the packaging machine for loading with products or for wrapping about a series of product groups.
- The cartons, whether formed as carton sleeves or carton blanks, themselves typically are formed by outside vendors who ship the cartons in sleeve or blank form stacked in boxes or cases. Accordingly, before the cartons can be loaded into a carton magazine of a packaging machine, the cartons themselves first must be removed from their cases and thereafter stacked or loaded into the carton magazine. Even though automated carton stacking and loading systems have been developed for automatically loading stacks of cartons within the carton magazines of packaging machine or similar automated packaging equipment, it is still necessary to first remove the stacks of cartons from their containers or cases and thereafter load the stacks of cartons on the magazines or on automatic magazine loaders for feeding to the magazine for a packaging machine.
- In other technical fields than packaging technology, proposals for automated removal systems have been made. For example,
US 5271710 A discloses a system according to preamble ofclaim 1 and teaches a system for dumping letters or other postal articles from bins with the letters stacked therein. The bins are moved onto a tipping trough of a coupling deck and are tilted to allow the letters held therein to slide out of the bins and onto a magazine platform. This system requires the operator to manually hold each bin on the pivotable coupling deck when tilting the bins to a downward sloping angle for enabling the materials to slide out while being "held back by the operator using the other hand" for placement onto the magazine. -
US 2005/0077217 A1 discloses a carrier for mail or similar thin objects stacked side-by-side. The carrier comprises a floor upon which the stacked mail can be supported, a rear wall having spaces for receiving a mail stack pusher and a front wall movable between a mail stack retaining position and a mail stack releasing position. The mail stack can be moved by the pusher, sliding with respect to the floor and past the stacked mail retaining position. -
US 2002/146308 A1 also discloses a system that is specifically designed for high-speed unloading of mail from a series of bins or trays, wherein open-ended trays or bins having mail loaded therein are fed to a tray control module that rotates the trays into a position where they can be lifted off of a stack of mail by belts of tray removing module. The stack of mail is dumped onto a conveyor assembly. The tray control module includes a drum assembly formed with a series of spaced apart drum disks arranged in spaced configuration to enable tray holder members mounted thereon to pass between belts of a supply belt transport of the conveyor assembly as the mail is deposited thereon. - Generally, even though some automated removal systems have been developed, the removal of cartons from their boxes or cases typically has been a manual operation requiring an operator to manually remove the cases from about the cartons, and thereafter stack or restack the cartons, including in some cases inverting the cartons, and load them on a magazine loader or directly into the carton magazine of a packaging machine. Such manual operations can, however, cause repetitive strain injuries due to the repetitive handling of heavy carton loads by workers. In addition, when the cartons are removed from their cases, either manually or by current automated systems, it is often difficult to maintain the cartons in an ordered stack and prevent at least some of the cartons within the cases from being lifted with the case when the case is removed due to friction between the carton edges and case walls. As a result, workers often have to restack or remove portions of the stack of cartons from a case after the case has been removed, which takes additional time and can further contribute to repetitive strain injuries, or cause inefficiencies in operation.
- Accordingly, it can be seen that a need exists for a system and method for removal of stacked cartons from their cases or containers that addresses the foregoing and other related and unrelated problems in the art.
- The above object is achieved by the system for removing cartons from containers for loading into a product packaging machine, as defined in
claim 1. Moreover, the object set out above is achieved by the method of removing cartons of a case for feeding to a product packaging machine achieves, as defined inclaim 11. - Briefly described, the present invention generally relates to a system and method for automatically removing cartons or carton blanks from cases or other, similar containers in a stacked configuration such as for feeding into a magazine of a downstream product packaging machine. According to one example embodiment of the carton decasing system according to the principles of the present invention, cases containing stacks of cartons, such as, for example carton blanks or sleeves for packaging bottles, cans or other products in 2x6, 2x8, 2x12, 4x6 or other varying product configurations, will be loaded onto a carton infeed. The cases can be queued up along the carton infeed for presentation to an inverting assembly at the downstream end of the case infeed, and typically, will be loaded with the upper ends of the cases being open, and with notches or recesses also generally being formed in the upstream and downstream side walls of the cases.
- The cases initially are fed into the inverting assembly which includes an inverter head that is pivotally mounted on a support frame. The inverter head further generally includes a pair of adjustable side guides and a pair of top and bottom support guides that are vertically adjustable with respect to one another so as to define a receiving area therebetween for receiving a case of a predetermined or preselected size therein. As the inverter head is rotated or pivoted about its support frame, the cases with the cartons stacked therein are correspondingly reoriented and are deposited on a downstream magazine or stacking conveyor, with the closed bottom end of each case generally being realigned in upwardly facing attitude or direction. The inverter head and magazine conveyor further are adjustable vertically to enable adjustment of the position of the cases with respect to an overhead case lifting mechanism, so as to accommodate different height or size cases as needed.
- The cases are initially deposited on a carton decasing assembly for removal of the case from the stack of cartons contained therein. The carton decasing assembly includes an adjustable framework having laterally adjustable side guide rails on which the cases are received and initially supported, and a series of containment rod mechanisms mounted on supports or holders that are moveable longitudinally with respect to the side guide rails so as to enable adjustment of the longitudinal position of the containment rod mechanisms. The adjustment of the side guide rails laterally, together with the longitudinal adjustment of the locations of the containment rod mechanisms enables the carton decasing assembly to be adjusted to accommodate varying length/depth and width cases.
- Once deposited or located on the carton decasing assembly, a series of gripping lugs, which are also mounted on the longitudinally sliding supports or holders that carry the containment rod mechanisms, are pivoted into engagement with the cartons, typically moving or passing through the recesses or gaps formed in the cases so as to engage and compress the stack of cartons inwardly. The compression of the stack of cartons within the cases by the gripping lugs creates spacings/openings between the cartons and case walls in which the extensible containment rods can be received. The containment rods are inserted into and pass between the foremost and rearmost cartons of the stack of cartons and the front and rear side walls of their case so as to hold the cartons in a stacked configuration as the case is removed therefrom and prevent the walls of the case from frictionally engaging or otherwise dislodging cartons from the stack. As a result, each case is removed from its stack of cartons with the cartons being maintained in a stacked, substantially aligned configuration. Thereafter, the cartons are conveyed further along the magazine conveyor as the emptied cases are removed for disposal.
- As a stack of cartons is conveyed by the carton decasing assembly toward a discharge point or end of the magazine conveyor, and/or approaches a rearmost carton of a previously decased stack of cartons on the magazine conveyor, a stack pusher assembly will correspondingly engage the stack of cartons for urging the stack of cartons forwardly with the continued forward motion of the magazine conveyor. Thereafter, at about the same time, the containment rods can be disengaged from the stack of cartons and the carton decasing assembly retracted back to its initial, loading or case receiving position adjacent the inverting assembly. The stack pusher assembly generally will include at least one stack pusher that, in one embodiment, can comprise a pair of extensible pusher rods each moved between extended and retracted positions by an actuator, such as a pneumatic or hydraulic cylinder, or other similar actuator. The pusher rods further can be carried by an overhead support linked to a drive system connected to the drive mechanism for the magazine conveyor so as to move with the forward movement of the magazine conveyor.
- The drive system of the stack pusher assembly also can be disconnected from the magazine conveyor so as to be independently driven for moving the stack pusher assembly to a retracted position as needed for engaging a next stack of cartons loaded on the magazine conveyor. Thus, as the next loaded stack of cartons approaches a prior loaded stack of cartons, the pusher rods will be retracted as the decasing assembly conveys the next stack of cartons into a combined, stacked arrangement against the prior loaded stack of cartons. The drive mechanism for the stack pusher assembly also can be disengaged from the magazine conveyor, and operated to retract the stack pusher assembly to a position behind the rearmost carton of the next stack of cartons being loaded, after which the pusher rods can be extended into an engaging position against the combined stack of cartons as the containment rods of the carton decasing assembly are retracted and the carton decasing assembly is moved back to its initial, loading position. The drive mechanism of the stack pusher assembly further can be reengaged with the magazine conveyor to continue its forward motion with its pusher rods engaging and supporting the combined stack of cartons as the cartons are fed to the discharge point of the magazine conveyor.
- Various features, objects and advantages of the present invention will become apparent to those skilled in the art upon a review of the following detailed description, when taken in conjunction with the accompanying drawings.
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Fig. 1 is a perspective illustration of the automatic carton decasing system according to the principles of the present invention. -
Fig. 2 is a perspective view of the inverting assembly and stacking conveyor for receiving and inverting the packaged cartons for removal of the case therefrom. -
Fig. 3A is a perspective view of the inverting assembly with a case of stacked cartons received therein. -
Figs. 3B and 3C are side elevational views illustrating the inverting of the carton cases at different heights for different size or geometry cartons. -
Figs. 4A and4B are perspective illustrations of the carton decasing assembly with the containment rods thereof shown in retracted and raised positions. -
Fig. 4C is an end view of the extensive containment rods of the carton decasing assembly. -
Fig. 4D is a perspective view of the fore or proximal end of the stacking conveyor and the carton decasing assembly. -
Figs. 5A-5C are perspective illustrations showing the engagement of the grippers and containment rods of the carton decasing assembly for engagement and holding of a stack of cartons as the case is removed therefrom. -
Fig. 6 is a perspective view of the stacking conveyor, illustrating the stack pusher assembly and carton decasing assembly according to the principles of the present invention. -
Figs. 7A-7D are schematic illustrations of the operation of the stack pusher assembly for moving the stacks of cartons to a discharge point after removal of the cases therefrom. -
Fig. 8 is a perspective illustration of an alternative embodiment of the carton decasing system according to the principles of the present invention. -
Figs. 9A-9C are side elevational views schematically illustrating the extended orbital movement of the inverter head of the decasing system ofFig. 8 . -
Fig. 10 is a plan view of the decasing system ofFig. 8 . - Those skilled in the art will appreciate and understand that, according to common practice, the various features of the drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein.
- Referring now to the drawings in which like numerals indicate like parts throughout the several views,
Figs. 1-7D illustrate the automaticcarton decasing system 10 and the operative assemblies thereof for removal of stacks ofcartons 11 from cases orother containers 12 and for automatically loading such decased or removed carton stacks into acarton magazine 13 for feeding into a feeder assembly of a downstream packaging machine, as indicated inFig. 1 . Thecartons 12 can be received as stacks of flat carton blanks or as preformed carton sleeves, or in other configurations as needed or desired, and as will be understood by those skilled in the art, and will be oriented and removed from their cases in a stacked, substantially aligned configuration. The automatic carton decasing system further is designed to fit with and/or be operable with a variety of different type or size packaging machines. The automatic carton decasing system further can be designed for retrofitting to existing packaging machines in the field, and further is adapted to unload/remove and load a full range of carton sizes and/or configurations as well as different case proportions and materials. For example, the automatic carton decasing system of the present invention can be utilized with 2 x 2, 3 x 4, 4 x 6 or other carton sizes and can handle cartons of a variety of sizes and shapes, including long, short cases, substantially square cases and tall and wide cases, such as illustrated at 12A and 12B, respectively, inFigs. 3B-3C and5A 5C . -
Fig. 1 generally illustrates one example embodiment of the automaticcarton decasing system 10 according to the principles of the present invention, which generally includes anelongated frame 21, which frame generally can be adapted to match its parent packaging machine. At an upstream end orsection 22 of theframe 21 comprises acase infeed 23. The case infeed 23 generally will comprise a conventional conveyingsystem 24 such as a chain conveyor, belt conveyor or other known type of conveying mechanism including belts, slats, chains or other conveyingelements 26 that are driven about a substantially continuous path in the direction ofarrow 27 by a motor or similar drive mechanism (not shown). An operator can load the cases with cartons stacked therein on the upstream or first end of thecase infeed conveyor 24, with the cases being queued in a line or supply arrangement. - As indicated in
Fig. 1 , thecases 12 will be oriented on thecase infeed conveyor 24 in an upstanding attitude and with a top orupper end 16 of thecases 12 being open and a series of recesses, cut-outs, gaps orsimilar features 17 formed in the leading and trailingside walls 18A/18B of the cases. The case infeedconveyor 24 will convey the cases in series to an invertingassembly 30, which inverts or otherwise reorients the cases so that the cases can be quickly and easily removed from the cartons while the cartons are maintained in a stacked configuration as illustrated inFigs. 2-3B . Alternatively, the cases can be conveyed or transported to the inverting assembly from a remote location or an automatic depalletizer. As indicated inFig. 1 , the case infeed conveyor further can be designed with respect to the invertingassembly 30 so that different length case infeed conveyors and/or extensions of the case infeed conveyor can be provided in either in-line or perpendicular arrangements to suit available space in a desired or required line layout. For example, as shown inFig. 1 , thecases 12 can be loaded onto a first,upstream section 28A of the case infeed conveyor, and can then be transferred to and/or reoriented on a second,downstream section 28B, which conveys the cases to the invertingassembly 30 at the downstream end thereof. - As illustrated in
Figs. 1 and2 , thecases 12 with thecartons 11 stacked therein are conveyed to the downstream end of the case infeed conveyor and are brought into engagement/registration with the invertingassembly 30 positioned at the downstream end of the case infeed conveyor. The inverting assembly inverts or reorients the cases with the cartons contained therein and places them on a stacking ormagazine conveyor 31 having acarton decasing assembly 32 initially located in a first or case receiving position adjacent an upstream end of the magazine conveyor, as indicated inFigs. 1 and5A-5C . The inverting assembly thereafter will release each case, which will be moved with the decasing assembly along the magazine conveyor away from the inverting assembly and to a second or intermediate position for removal of the case as indicated inFig. 1 . - As illustrated in
Figs. 2 and3A , the invertingassembly 30 generally includes aninverter head 30A pivotally mounted on a pair of upstanding frame members or supports 33, and includes a pair of side guides or clamps 34 that are adjustable laterally so as to be repositionable as needed to engage different size cases. Each of the side guides 34 generally will include a rearwardly projecting plate orarm 36 typically having an outwardly flared first or guideportion 36A and a substantially flat body orsecond portion 36B mounted to anadjustable slide support 37. The slide supports 37 are movably mounted on asupport rail 38 that extends laterally between a pair of vertical slides or supports 39, that further are mounted to a carrier orbase frame member 41, which pivotally attaches and supports theinverter head 30A onframe members 33. AsFig. 3A indicates, the slide supports 37 can be moved laterally toward and away from each other, and can be fixed in place such as byset screws 42, or other, similar fasteners, to define a width for a receivingarea 40 of theinverter head 30A in which thecases 12 are received, with the outwardly flaredguide portions 36A of the side guides 34 helping to center and guide the cases into the receiving area. For example, as indicated inFigs. 3A-3C , for taller, thinner cases, the side guides can be adjusted inwardly to accommodate the reduced width or thinner configuration of the cases. - The
inverter head 30A further includes top and bottom case support guides 44 and 46 that engage the top and bottom ends of the cases, for positively gripping and holding the cases during inversion or reorientation thereof to prevent the cartons from becoming dislodged or otherwise inadvertently released from the cases during inversion or reorientation thereof by the inverting assembly. As shown inFigs. 2 and3A , the case support guides 44 and 46 generally are mounted to vertical slides or supports 39, with the positions of the case support guides being adjustable therealong, such as by cranks orhandwheels 47 to define a height for the receivingarea 40 of the inverter head. As generally indicated inFig. 3A , the case supports further can include spaced forks, tines orplates 44A/46A, or can include other types of supports. The inverter head further can be connected to or engaged by adrive belt 48 or similar conveying mechanism driven by a motor such as indicated at 49 inFig. 3A for controlling the rotary motion of the inverter head for lifting, inverting and depositing the cases onto the magazine conveyor 31 (Fig. 2 ). - Accordingly, as the case support guides 44 and 46 engage and lift and pivot the cases with the cartons stacked therein, as indicated by
arrows 51 inFigs. 3B and 3C , so as to reorient the cases in an inverted or upside down configuration, with the opentop portions 16 of the cases being placed in a substantially downwardly facing alignment on themagazine conveyor 31. In their initial stack receiving position, the case support guides 44, 46 generally are separated by a gap that is greater than the case height. As theinverter head 30A inverts, the lowercase support guide 46 can move toward the uppercase support guide 44, which closes this gap and thus conforms the case support guides to the case height. As a result, when the case is inverted, the lower case support guide, which was below the case on the infeed side, is now engaging on top of the case to prevent the case from tipping, and holding it square and upright to facilitate insertion of case containment rods 60 (Figs. 4A-4C ) during a decasing operation (Figs. 5A-5C ). - As further illustrated in
Figs. 3B and 3C , themagazine conveyor 31 can be set at varying heights as needed depending upon the type of parent packaging machine and/or the type/configuration of cartons and cases being fed for decasing without affecting the operation of the invertingassembly 30. The geometry of the inverting assembly, and the adjustability and/or closing engagement of its side guides and case support guides with acase 12 during inversion and placement of the case on the magazine conveyor, allows a fixed heightcase infeed conveyor 24 to be utilized with variable height magazine conveyors, with the case inverting assembly automatically adjusting for case size and placing the case on the correct magazine height for the packaging machine. For example, as shown inFig. 3B , a tall case can be inverted and placed on the magazine conveyor, with the magazine conveyor adjusted and set at a lowered height, while for shorter or reduced height cases, as shown inFig. 3C , themagazine conveyor 31 can be set at a higher level as needed for feeding the cartons into the magazine, without requiring reconfiguration or change-out of the invertingassembly 30. Instead, a simple adjustment of the positions of the side guides and case support guides so as to readjust the receiving area in which the cases are received and engaged, can be made to ensure a secure lifting and reorientation of the cases. - As further indicated in
Figs. 1-2 , thecarton decasing assembly 32 generally is initially located at the upstream or first end of themagazine conveyor 31 in a first, case receiving or loading position, indicated at 55, for receiving and engaging the cases after they are inverted by the inverting assembly.Figs. 4A-5C generally illustrate thecarton decasing assembly 32, which is movable along themagazine conveyor 31 between its first loading position, a second, intermediate or case removal position, indicated at 56 inFig. 7A , and a third, downstream or disengaging position indicated at 57 inFig. 6 . The movement of thedecasing assembly 32 is controlled by a drive mechanism 58 (Fig. 4D ) that is independently operable from the magazine conveyor. - The carton decasing assembly 32 (
Figs. 4A-4B ) includes an adjustable framework orsled 61 including laterally adjustableside guide rails containment rod mechanisms 64. Each containment rod mechanism includes a vertically extensiblecase containment rod 60, which is extensible between a lowered, resting or non-engaging position (Fig. 4A ) and a raised, engaging position (Fig. 4B ) by operation of anactuator 66, such as a pneumatic or hydraulic cylinder or other, similar actuator. Each of the containment rod mechanisms further is carried on adjustable supports orholders 67 to enable variation of the longitudinal positions of the containment rod mechanisms as needed to accommodate varying depth or length cases. A series ofgripping lugs 68 also are pivotally mounted to thesupports 66 for the containment rod mechanisms, and are extensible/pivotable by actuators, as indicated at 69, so as to move through the recesses or gaps 17 (Figs. 5A-5C ) formed in the leading and trailing side walls of thecases 12 and into engagement with the cartons within the cases for gripping and applying pressure to the stacked cartons, as illustrated inFigs. 5A 5C . - As further illustrated in
Figs. 4A ,4B and4C , each of theadjustable guide rails 62/63 is adjustable laterally alongrails 71 to accommodate different size or configuration of cases, and the positions of thecontainment rods 60 further are adjustable longitudinally, such as by sliding movement of theirsupports 66 alongguide rails 72 to further enable adjustment of theframework 61 of the carton decasing assembly to accommodate different size and/orconfiguration cases 12, as illustrated inFigs. 5A-5C . As indicated inFig. 2 , anadjustment mechanism 73, here shown as a hand-wheel or crank, although it will be understood that other manual and automatic adjustment mechanisms also can be used, will be provided along the magazine conveyor 3 1 for adjustment of the width of the magazine conveyor, and with it the width of the carton decasing assembly, to accommodate different width/size cartons. Preferably, afirst side 74A of the magazine conveyor and the side guide rail (i.e., 63) associated therewith can remain fixed or stationary, with the opposite orsecond side 74B of the magazine conveyor being movable along laterally extending guide rails, such as shown at 75 inFig. 4D , to adjust its position with respect to thefirst side 74A of the magazine conveyor, and with it, the position ofside guide rail 62 with respect toside guide rail 63 of the carton decasing assembly. - The adjustments of the magazine conveyor, and with it, the carton decasing system, to accommodate varying size and/or configuration cartons and their cases generally will be made with respect to the parent packaging machine into which the cartons are to be fed. The parent machine generally will act on a fixed score line date based on a crease or fold line about which the cartons are folded to provide a reference axis or line (indicated at
phantom line 76 inFig. 1 ) for the X-Y-Z adjustments of the magazine conveyor and carton decasing assembly. The adjustments of the side frame assemblies of the carton decasing assembly both laterally and longitudinally accordingly are part of the size change procedure for the automatic carton decasing system, with such longitudinal and lateral adjustments generally being controlled via manual drive mechanisms and sensors so as to match the spacing of the containment rods and gripper lugs to the particular size and/or configuration of the cases and accordingly the stacks of cartons contained therein. Typically, the positions of the containment rods will be adjusted to match the longitudinal size or thickness of the stacks of cartons, and to locate the containment rods approximately adjacent the fold or crease lines of the cartons to ensure stable and even engagement therewith as the cartons are conveyed along the magazine conveyor with the containment rods. -
Figs. 5A-5C generally illustrate the operation of thedecasing assembly 32. Initially, after the case has been inverted and placed on top of the magazine conveyor and moved into registration or otherwise located for engagement by thecarton decasing assembly 32, the gripper lugs 68 andcontainment rods 60 are generally in their retracted, non-engaging positions. Typically, the cases will have been formed with cutouts 17 (Fig. 2 ) that enable access therethrough by the gripper lugs 68 for engaging and holding the cartons (Figs. 5A-5C ). Initially, the gripper lugs will be engaged to first centralize the carton load and at least partially compress the stacks of cartons inwardly. This engagement/compression of the stacks of cartons further will create spaced gaps or openings along the sides of the cartons to facilitate and/or enable entry of thecontainment rods 60, between the cartons and the leading and trailing side walls of the cases, as indicated inFig. 5B . Additionally, as the cartons and cases are moved along the magazine conveyor, they will engage and ride along a slopedcenter guide 77 that assists in supporting the cartons and cases and in keeping them in a substantially square attitude or alignment as the containment rods are inserted. - Thereafter, as illustrated in
Fig. 5C , with the cartons being held by the containment rods, the case will be lifted off of its stack of cartons by a lifting mechanism 80 (Fig. 1 ) as the rods remain in a raised, engaging position for holding the stacks of cartons in place and as the case is removed therefrom. The containment rods will remain up for decasing and subsequent transfer of the carton load to the back of a carton magazine such as being combined with a prior loaded stack thereon, thus supporting the carton load until astack pusher assembly 90 engages the stack of cartons and locates the stack of cartons against the back of previously loaded supply or stack of cartons within the magazine, as indicated inFigs. 7A-7C . A sensor 78 (Fig. 4D ) generally can be provided at an upstream end of the adjustable frame/sled 61, which can be engaged by the prior loaded stack of cartons, as the sled approaches the stack. The activation of thissensor 78 signals the activation of the pusher assembly and retraction of the carton decasing assembly. At the same time, the gripper lugs generally will release the cartons from engagement as the case is lifted off of the stack of cartons as shown byFig. 5C , which gripper lugs will further be retracted below the cartons as indicated inFig. 5A . - As illustrated in
Figs. 1 ,2 ,6 and7A-7D , thestack pusher assembly 90 generally is located along themagazine conveyor 31, downstream from thecarton decasing assembly 32. Thestack pusher assembly 90 can include one ormore stack pushers 91 movable along the length of the magazine conveyor, which stack pushers will engage the stacks of cartons after they are removed from their cases and will hold a final or rearmost carton at the back of a stack of cartons being fed into thedischarge point 92 of the magazine conveyor. In one embodiment, the at least onestack pusher 91 can comprise a pivoting arm, indicated atphantom lines 94 inFig. 2 , having apusher plate 96, and which is adapted to be pivotable into and out of the path of travel of the stacks of cartons, which is movable with the operation of the magazine conveyor to maintain the stacks of cartons at an upright, stacked attitude. - Alternatively, as illustrated in
Figs. 2 ,6 and7A-7D , in another embodiment, these stack pushers can include a pair of extensiblepusher rod assemblies 100/101 mounted above the magazine conveyor and movable along a parallel path of travel therewith. Thepusher rod assemblies 100/101 generally will be spaced apart along a laterally extending support rail, with the lateral position or location of the pusher rod assemblies along thesupport rail 102 being adjustable with respect to one another to accommodate different size cartons. For example, the lateral positions of the pusher rod assemblies can be adjusted with respect to a centerline of the parent packaging machine to align theirpusher rods 106 with creases or fold lines of the cartons. Typically, the pusher rod assemblies each will include anactuator 104, such as a hydraulic or pneumatic cylinder, and apusher rod 106 which is extensible to a lowered, engaging position and can be retracted upwardly to a non-engaging or retracted position out of engagement with the cartons. - The
pusher rods 106 can be provided with a length sufficient to engage a variety of different height cartons, or alternatively, the position of thesupport rail 102 can be adjusted vertically alongguide arm 107 to further adjust the vertical position of thepusher assemblies 100/101. Thus, the height of the pusher assemblies can be further adjusted as needed to accommodate variations in size of the cases. As also indicated inFigs. 2 and6 , thesupport rail 102 is slidable along anupper guide rail 108, which helps control and maintain consistent movement of the pusher assemblies in a substantially parallel path of travel to the path of travel P of the cartons along the magazine conveyor. Thevertical support 107 also connects thesupport rail 102 and thus thepusher assemblies 100/101 mounted therealong to anindependent drive system 110. - As indicated in
Figs. 6-7D , theindependent drive system 110 of the stack pusher assembly is disengagably connected to the magazine conveyor drive mechanism orsystem 111 so as to generally be moved therewith as the cartons are fed along the magazine conveyor with the pusher rods of the stack pushers in engagement therewith. However, thedrive system 110 for the stack pusher assembly further is separably operable as needed to permit the stack pusher assembly to be moved longitudinally, upstream and downstream, independently of the movement of the magazine conveyor as needed to retract and/or reposition the stack pusher assembly as indicated inFigs. 7A-7D . Thereafter, the stack pusher assembly can be re-synced with the movement of the magazine conveyor to maintain the stack pusher assembly in engagement with the stacks of cartons being fed along the magazine conveyor into thedownstream magazine 13. Thus, when the stack pusher is operated with the magazine conveyor, its motor is at rest and the stack pusher sprocket is engaged with the chain with the stack pusher(s) engaging the carton stack as the whole assembly moves in concert. However, when the stack pushers need to move upstream to go behind a new stack of cartons, its stack pusher motor drives the stack pusher assembly upstream, along its chain and along the magazine conveyor, whether the magazine is stationary or indexing to feed a next carton. - The operation of the stack pusher assembly is generally illustrated in
Figs. 7A-7D . After the cases have been removed from the cartons, the cartons are conveyed in a stacked configuration by thecarton decasing assembly 32 along their path of travel P along themagazine conveyor 31 toward the discharge end or point of the magazine conveyor. As indicated inFig. 7A , after the initial startup and loading of a first stack of cartons on the magazine conveyor, the next stack of cartons being conveyed or moved along the magazine conveyor by the carton decasing assembly will approach a previously loaded stack ofcartons 11, which stack of cartons is maintained in a substantially upright, or slightly forward leaning attitude by the engagement of the stack pusher assembly therewith. - As the next stack of cartons 11' approaches the previously loaded stack of
cartons 11, the sensor 78 (Fig. 4D ) at the upstream end of thesled 61 of thecarton decasing assembly 32 will be engaged, such as by contacting a rearmost carton (Fig. 7B ) of the previously loaded stack of cartons. Upon engagement and activation of the sensor 78 (Fig. 4D ), as indicated inFigs. 7B and7C , the activation of the sensor by the approach of the next stack of cartons being carried by the carton decasing assembly towards the rearmost carton of the preceding loaded stack of cartons will cause the disengagement of the stack pusher assembly. Upon a disengagement signal being sent to the stack pusher assembly, thepusher rods 106 will be retracted, as indicated inFig. 7B , and thedrive system 110 for the stack pusher assembly will be disengaged from the magazine conveyor. Thereafter, as indicated inFig. 7C , the stack pusher assembly drive mechanism will be independently operated so as to move the stack pushers rearwardly, in the direction ofarrow 115, to a retracted position behind the rearmost carton of the stack of cartons on the carton decasing assembly. - Once the stack pushers have been retracted to their rearward position, as indicated in
Fig. 7D , the pusher rods will be extended into engagement with the rearmost carton of the combined stack of cartons and the drive system for the stack pusher assembly will be reengaged with the drive system or drive mechanism of the magazine conveyor. Additionally, as indicated inFigs. 6 and7B-7C , as the stack pushers are moved to their retracted position, a pair ofshoes 116 can engage and pass over the top edges of the cartons to ensure that the cartons will not be caught or otherwise engaged by the pusher rods. These shoes also can be linked to a sensor to signal a fault condition if movement of the shoes along the cartons is disrupted or interfered with during retraction of the stack pushers. After the pusher rods of the stack pushers have been engaged with the rearmost carton of the combined stack of cartons, the containment rods of the carton decasing assembly can be retracted, releasing the cartons from engagement therewith, after which the carton decasing assembly can be moved back to its initial, loading or carton receiving position adjacent the upstream end of the magazine conveyor and the inverting assembly. Thereafter, as indicated inFig. 7D , the stack pushers will continue to move forwardly with the forward motion of the magazine conveyor as the cartons are sequentially fed through the discharge point of the magazine conveyor and into a downstream packaging machine magazine. - An additional embodiment of the
carton decasing system 200 according to the principles of the present invention is generally illustrated inFigs. 8-10 . The embodiment of thedecasing system 200 shown inFigs. 8-10 is designed to enable access to the packaging machine PM, as needed, such as for loading additional materials, clearing jams, etc. For example, the decasing system can be adapted for use with "twin stack" type packaging systems and equipment wherein a first stack or layer of products, such as bottles or cans or other similar product, are placed upon a carton, after which a layer pad is placed over the first or lower stack of products placed on the carton, after which a second layer or stack of products is placed on top of the layer pad and the carton folded thereabout to form a "twin stack" product package. The layer pads typically are inserted between the stacks of products at an intermediate point along the path of travel of the products through the twin stack packaging machine and thus access must be provided to the layer pad magazine for loading of additional layer pads therein. Thedecasing system 200 according to the present embodiment is adapted to provide the automated decasing features of the present invention for use with such a twin stack or other style packaging machines while also enabling access to the layer pad magazine and/or other areas of the packaging machine by an operator, without requiring reconfiguration of the packaging machine and/or without substantial disruption in the decasing of the cartons for feeding into the carton magazine of the packaging machine. - As illustrated in
Figs. 8-10 , thecases 12 with thecartons 11 stacked therein will be fed along thecase infeed conveyor 24 to the invertingassembly 30 where the cases are engaged by theinverter head 30A thereof. The case infeed conveyor andinverter head 30A generally will have substantially the same construction as discussed above with reference toFigs. 1-3C . Thus, as with the embodiment of the carton decasing system illustrated inFigs. 1-3C , the inverter head will generally be mounted on adjustable frame members or supports 33 and generally will include side guides or clamps 34 that are adjustable laterally to receive cases of different sizes and/or configurations, as well as top and bottom case support guides 44 and 46 (Figs. 9A-9B ) that likewise are vertically adjustable along the frame members of the inverter head to accommodate different size and/or configuration cases. - In the present embodiment of the
carton decasing system 200, the inverter head further will be mounted on acarriage 201, which conveys theinverter head 30A about an extended, orbital path over and above a layer pad magazine access area orstation 202 provided along the path of movement of the cases. This layer padmagazine access area 202 enables the operator to access the twin stack packaging machine PM (Figs. 8 and10 ) for loading of a stack or series layer pads into thelayer pad magazine 203 of the twin stack packaging machine. Such access further is provided without disruption of the operation of the carton decasing system for removing stacks of cartons form their cases and feeding such stacks of cartons into acarton magazine 204 of the packaging machine. - As illustrated in
Figs. 8-9C , thecarriage 201, on which theinverter head 30A of thecarton decasing system 200 is supported, is mounted on a radially extending track orrail assembly 206. As shown in the figures, thisrail assembly 206 extends along an orbital path, upwardly and over the layer padmagazine access area 202, from the downstream end of the case infeed conveyor to theupstream magazine conveyor 31. Therail assembly 206 generally will include one ormore rails 207, which could include V-rails, box rails, or other configuration rails, and which can further include a series of rollers mounted therealong for supporting the carriage as it is moved along the rails. Therails 207 are supported over the layer pad magazine access area by anorbital frame 208. - The
carriage 201 of theinverter head 30A generally will engage and ride along the rails of therail assembly 206 and will be moved about its orbital path, indicated byarrows 209 inFig. 9B , for transporting a case with the stacked cartons therein over the operator and layer padmagazine access area 202 for depositing the case in an inverted position onto themagazine conveyor 31. Adrive system 210 will control the orbital movement of thecarriage 201 along therail assembly 206. Thedrive system 210 generally will include a reversible, variable speed motor, such as shown at 211, and a drive mechanism or means, illustrated byphantom lines 212 inFig. 8 , that transports thecarriage 201 along its orbital path as shown inFigs. 9A-9C . Thedrive motor 211 generally will be a variable speed, reversible motor sized for a duty cycle and load to accommodate varying size and weight cases containing varying size cartons stacked therein. The motors also can include a reducer so as to increase the torque of the motor to accommodate varying size/weight loads of cartons and can be operated at cycle rates of approximately 30-45 seconds per operational cycle, although greater or lesser cycle rates also can be used. Thedrive mechanism 212 further can include one or more chains, cables, belts, or a combination of chains, belts and/or cables (shown inphantom lines 214 inFig. 8 ) that are received within and moves along therails 207 of therail assembly 206 in a reversible, back and forth motion under operation of thedrive motor 211. Also, the drive mechanism could include an orbital rack and pinion, with a pinion gear being driven by a motor mounted to the inverter head. - As illustrated in
Figs. 9A-9C , once acase 12 with a stack of cartons therein has been engaged and contained within theinverter head 30A of the invertingassembly 30 by the side guides and bottom case support guides (the top support guide generally floating over and conforming to the top of the case as the case is inverted), thedrive motor 211 generally will be actuated to commence inverting of the case and cartons. As indicated inFig. 9B , the motor will pull the drive chain or other drive mechanism along the rails of therail assembly 206, causing thecarriage 201 to transport theinverter head 30A about its orbital path as shown byarrows 209, upwardly and over the layer padmagazine access area 202. The inverter head thus will be moved about its expanded, orbital path for inversion of the case, and will place the inverted case on themagazine conveyor 31 as discussed with respect to the prior embodiment ofFigs. 1-6 . Thereafter, a carton decasing operation can be commenced, as discussed above with respect to the prior embodiment and as illustrated inFigs. 6-7D , for removal of the cases from the stacks of cartons, after which the cases can be removed from the carton decasing system and packaging machine along their overhead conveyor, while the stacks of cartons are fed into thecarton magazine 204 for the packaging machine PM. As the cartons are fed to the carton magazine, thedrive motor 211 of thedrive system 210 also can be reversed, pulling the drive chain(s) 214 of the drive mechanism 212 (Fig. 8 ) rearwardly so as to transport the inverter head in a reverse direction along its orbital path, back to its initial, home position at the downstream end of the case infeed conveyor for receiving a next case with a stack of cartons therein. - The embodiment of the
carton decasing system 200 illustrated inFigs. 8-10 thus enables the use of the carton decasing system according to the principles of the present invention with additional types of packaging machines, such as twin-stack type packaging machines, by providing an operator with walk-in access to the layer pad magazine of the packaging machine for loading of additional layer pads and/or for providing access to the packaging machine as needed for clearing of jams, etc. As further illustrated inFigs. 8-10 , theaccess area 202 defined within thecarton decasing system 200 generally will include a series of protective panels or barriers, generally indicated at 215 forming a protective housing orcage 216 beneath therail assembly 206 along which thecarriage 201 is conveyed during a case inverting operation.Such barriers 215 can include Plexiglas or safety glass panels supported byframe members 217, which panels orbarriers 215 can further be removable or otherwise pivotally mounted to the frame member so as to enable access to therail assembly 206 as needed for maintenance or repair/replacement or other adjustments thereof. Additionally, other panels or barriers also can be used, including the formation of a wire cage or similar protective housing, so that the operator can be provided with substantially safe/protected access to the layer pad magazine or other areas of the packaging machine during operation of the invertingassembly 30 of thecarton decasing system 200. - The automatic carton decasing system of the present invention thus is designed to maximize the use of space by utilizing the smallest footprint possible, while maintaining front guard line and maintenance side clearance as needed for the infeed conveyors. Additionally, as noted, the case infeed conveyor is provided with an in-line layout enabling extensions of the case infeed conveyor as needed. The automatic carton decasing system further is provided with open access for each of the operative assemblies for ease of changeover and maintenance, and is generally adapted to be a self-contained unit to enable magazine loading and unloading with or without decasing functionality so that the system can be utilized in various configurations and as a retrofit or upgrade to existing packaging systems. The system further can be primed by loading a limited number of cartons initially within the feeder to create an initial stack against which later decased carton stacks will be placed, while the empty cases are dischargeable along a high level conveyor to help reduce the system footprint, and which further can be reconfigured to provide case discharge anywhere in an approximately 180° radius for discharging cases into a bin or baler or directing them to some other type of containment unit for collection and disposal or recycling.
- The foregoing description generally illustrates and describes various embodiments of the present invention. It will, however, be understood by those skilled in the art that various changes and modifications can be made to the above-discussed construction of the present invention without departing from the spirit and scope of the invention as disclosed herein, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense.
Claims (15)
- A system (10/200) for removing cartons (11) from containers (12) for loading into a product packaging machine, comprising:a case infeed (23) along which the containers (12) are fed in series to a magazine conveyor (31);an inverting assembly (30) receiving the containers (12) from the case infeed (23), the containers (12) are engaged by an inverter head (30A) of the inverting assembly (30), the inverter head (30A) is mounted on a carriage (201) and transports the containers (12) about an extended, orbital path over and above a layer pad magazine access area (202) along the path of movement of the container (12) and places the containers (12) with the cartons (11) stacked therein in an inverted position on the magazine conveyor (31);a stack pusher assembly (90) for engaging and supporting the cartons (11) in their stacked configuration as the cartons are moved along the magazine conveyor (31) toward the discharge (92) of the magazine conveyor (31) for feeding the cartons (11) to a magazine for the packaging machine;a decasing assembly (32) movable along the magazine conveyor (31) between a loading position adjacent the case infeed (23) and a case removal position, characterized by:
the decasing assembly (32) including an adjustable frame (61) with a plurality of adjustable guide rails (62, 63) that are adjustable along rails (71) and are movable to configure the decasing assembly (32) to receive containers (12) having different sizes and/or configurations with the cartons (11) stacked therein, the decasing assembly (32) further including a series of containment rod mechanisms (64) each including a vertically extensible containment rod (60), the containment rod mechanisms (64) being carried on adjustable supports or holders (67) to enable variation of the longitudinal positions of the containment rod mechanisms (64) as needed to accommodate varying depth or length containers and being configurable to substantially match the sizes and/or configurations of the cartons (11) received as needed to substantially contain and maintain the cartons (11) in a stacked configuration as the cartons (11) are removed from the containers (12) and moved along the magazine conveyor (31) toward a discharge (92) thereof; - The system (10/200) of claim 1, wherein the containment rods (60) are extensible into the containers (12) between the cartons (11) and at least one side wall (18A/B) of the containers (12) to facilitate removal of the cartons (11) from the containers (12).
- The system (10/200) of claim 1, wherein the position of the inverted containers (12) being placed on the magazine conveyor (31) by the inverting assembly (30) is automatically adjusted to substantially match an elevation of the magazine conveyor (31).
- The system (200) of claim 3, wherein the inverter head (30A) has top and bottom case support guides (44/46) and is mounted on the carriage (201) that is movable along the extended, orbital path over the access area (202) as the containers (12) are moved to their inverted position.
- The system (200) of claim 4, wherein the access area (202) is of a size sufficient to enable access to a portion of the packaging machine by an operator without interfering with movement of the containers (12) along their extended, orbital path from the case infeed (23) to the magazine conveyor (31).
- The system (10) of claim 3, wherein the inverter head (30A) is rotatable and has adjustable side rails (33) and top and bottom case support guides (37) defining a receiving area (40) for receiving and supporting the containers (12) of varying sizes with the cartons (11) stacked therein, as the containers (12) are reoriented and deposited onto the magazine conveyor (31) for removal of the container (12).
- The system (10/200) of claim 1 and wherein the decasing assembly (32) further comprises a lifting mechanism (80) for removing the containers (12) from about the cartons (11), with the cartons (11) maintained in their stacked configuration.
- The system (10/200) of claim 1, wherein the series of containment rods (60) are movable into the containers (12) to facilitate removal of the containers (12) from the cartons (11), and the decasing assembly further comprises grippers (68) adapted to move into an engaging position for engaging the cartons (11) within their containers (12) to create a spacing for entry of the containment rods (60) into the containers (12).
- The system (10/200) of claim 1 and wherein the stack pusher assembly (90) includes at least one stack pusher (91) carried by a drive system (110), the drive system (110) engageable with a conveying mechanism (111) for the magazine conveyor (31) so as to move the at least one stack pusher (91) therewith during feeding of a carton stack (11), and being selectively disengageable from the conveying mechanism (111) of the magazine conveyor (31) so as to be operable independently of the conveying mechanism (111) of the magazine conveyor (31) for repositioning of the at least one stack pusher (91) with respect to a new stack of cartons (11) loaded on the magazine conveyor (31).
- The system of claim 9, wherein the at least one stack pusher (91) comprises a pair of extensible pusher rods (100/101) positioned above the magazine conveyor (31) and moveable therealong, each of the pusher rods (100/101) connected to an actuator (104) for controlling retraction and extension of the pusher rods (100/101) between a retracted, non-engaging position and an extended, engaging position for contacting and supporting the stacks of cartons (11) as the stacks of cartons (11) are moved along the magazine conveyor (31) toward the discharge (92).
- A method of removing cartons (11) from a case (12) for feeding to a product packaging machine, comprising:moving the case (12) with a stack of cartons (11) therein along a path of travel;transporting the case (12) with the stack of cartons (11) therein about an extended, orbital path at least partially over and above a layer pad magazine access area (202) provided along the path of movement of the case (12) with an inverting assembly (30) having an inverter head (30A) mounted on a carriage (201), and transferring the case (12) with the stack of cartons (11) therein to a decasing assembly (32) movable along a magazine conveyor (31), wherein the decasing assembly (32) includes an adjustable frame (61) with a plurality of adjustable guide rails (62, 63) that are adjustable along rails (71) and are movable to configure the decasing assembly (32) to receive cases (12) having different sizes and/or configurations, and a series of containment rod mechanisms (64) each including a vertically extensible containment rod (60), the containment rod mechanisms (64) being carried on adjustable supports or holders (67) to enable variation of the longitudinal positions of the containment rod mechanisms (64) as needed to accommodate varying depth or length cases and being configurable to substantially match the sizes and/or configurations of the cartons (11);moving the containment mechanisms (60) into positions adjacent foremost and rearmost cartons (11) of the stack of cartons (11) received by the decasing assembly (32);moving the decasing assembly (32) along the magazine conveyor (31) while holding the cartons (11) in a stacked configuration with the decasing assembly (32) and removing the case (12) from the stack of cartons (11);engaging the stack of cartons (11) with a stack pusher assembly (90) comprising at least one stack pusher (91); andcontinuing movement of the stack of cartons (11) along their path of travel along the magazine conveyor (31) toward a discharge point (92) as the case (12) is moved away from the stacked cartons (11).
- The method of claim 11, wherein transferring the case (12) with the stack of cartons (11) thereon to the decasing assembly (32) comprises receiving the case (12) on a carriage (61), engaging the stack of cartons (11) within the case (12) with a series of gripping fingers (68) to create a gap between the cartons (11) and at least one side wall of the case (12), and inserting the containment rod mechanisms (60) into the case (12), adjacent upstream and downstream sides of the stack of cartons (11) and in contact therewith.
- The method of claim 11, further comprising moving an additional stack of cartons (11) toward a prior stack of cartons (11) being urged toward the discharge point (92) by the at least one stack pusher (91), as the additional stack of cartons (11) approaches the prior stack of cartons (11), retracting the at least one stack pusher (91) out of engagement therewith and moving the at least one stack pusher (91) to a position behind the additional stack of cartons (11), urging the additional stack of cartons (11) against the prior stack of cartons (11), and moving the combined stack of cartons (11) forwardly with the at least one stack pusher (91).
- The method of claim 11, further comprising moving the case (12) with the cartons (11) stacked therein into the inverting assembly (30), engaging at least lower and side edge portions of the case (12) with case support guides (44/45), and transporting the case (12) from a first position on a case infeed conveyor (24) to an inverted position on the magazine conveyor (31).
- The method of claim 14 and wherein moving the case (12) to an inverted position comprises transporting the case (12) along the extended, orbital path upwardly and over the operator access area (202) as the case (12) is inverted, and placing the case (12) on the magazine conveyor (31) in its inverted position.
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US201261656715P | 2012-06-07 | 2012-06-07 | |
PCT/US2013/040730 WO2013184295A1 (en) | 2012-06-07 | 2013-05-13 | Carton decasing system |
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- 2013-05-13 WO PCT/US2013/040730 patent/WO2013184295A1/en active Application Filing
- 2013-05-13 CN CN201380029713.4A patent/CN104349980B/en active Active
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MX356335B (en) | 2018-05-23 |
WO2013184295A1 (en) | 2013-12-12 |
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AU2013272120B2 (en) | 2016-07-07 |
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CN104349980A (en) | 2015-02-11 |
BR112014027930A2 (en) | 2017-06-27 |
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EP2858907A1 (en) | 2015-04-15 |
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EP2858907A4 (en) | 2016-03-23 |
AU2013272120A1 (en) | 2014-10-16 |
CA2869017C (en) | 2018-02-13 |
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