GB2079710A - Case packer - Google Patents

Abstract

The various operations of a case packer are synchronized in accordance with the continuous movement of a flight bar conveyor K. The conveyor K intermittently feeds empty cases to an elevator platform located below the loading area D. The flight bar pushes a case ahead of it along a section 48 of the conveyor which terminates adjacent the end of the platform so as to situate the case on the platform. The bar then travels along a looped "dwell" section 50 of the conveyor, remote from the platform, as the platform is raised for loading and lowered. The bar reaches the end of the dwell section as the platform motion ceases and, thereafter, travels along another section 54 of the conveyor above the platform to remove the loaded case therefrom. A bottle feed conveyor B moves a compliment of bottles into a loading area. The bottles are initially moved rapidly towards stops I at the end of the loading area and, thereafter, the movement thereof is slowed to reduce impact. The dual- speed drive is produced by an air cylinder connected to the conveyor through an overrunning clutch. The stops provided at the end of the loading area engage the tops of the bottles and, additionally, function to sense the presence of a full compliment of bottles in the loading area. <IMAGE>

Description

SPECIFICATION Case packer Background of the invention The present invention relates to materials handling equipment and, more particularly, to a case packer wherein the various operations are synchronized in conjunction with a continuously driven case feed conveyor designed to intermittently feed cases to, and remove cases from, an elevator platform, and certain other novel features, described in detail below.

In general, a case packer is a type of materials handling equipment which places a compliment of articles, such as bottles or the like, into cases or cartons. A wide variety of different case packers of varying sophistication have been known and used for a long time in the bottling industry and related endeavors.

In its most basic form, a case packer includes an article conveyor, such as an endless belt or the like, which conveys articles to a loading area. A gate is situated at the input end of the loading area, which is held opened until a full compliment of articles is situated in the loading area. When the loading area is fully loaded, the gate is closed to prevent additional bottles from entering until the previously loaded compliment of bottles is removed.

The loading area essentially comprises a platform with lane guides situated over a position displaceable grid which, in its normal or closed position, is located to support the bottles as they are loaded.

When ready, the grid is displaced such that the bottles are no longer supported and are gravity fed from the loading area. Immediately below the loading platform is situated a guide mechanism including a support and a number of pivotable downwardly extending fingers divided into sets. The fingers in each set are spring-loaded towards each other to converge, forming a funnel-shaped device which interacts with the case to align the interlocking partitions therein, as the case is vertically moved into loading position. The fingers also serve to guide each of the articles into the appropriate cell in the case when the articles are released from the loading platform.

An elevator platform is situated below the loading platform. An empty case is transferred along a case feed conveyor to the elevator platform when the platform is in its lower position. Once in place, the case is raised by the platform towards the guide mechanism. Once the elevator is in its uppermost position with the guide mechanism received therein, the displaceable grid in the loading platform is moved to a position where it no longer supports the articles. The articles are gravity-fed through the guide mechanism and into the individual cells in the case. Once the case is filled, the elevator platform is lowered and the loaded case removed therefrom by the case conveyor. The loading platform then receives the next compliment of articles. At the same time, an empty case is situated on the elevator platform which is then raised to the loading position.

From this brief explanation of the general functions which are performed by a case packer, it is clear that the individual operations thereof must function in a highly coordinated fashion in order for the apparatus to function reliably at high speed. A central control mechanism of some sort is therefore required to synchronize the various operations in order to provide smooth and efficient article and case flow.

In one aspect the present invention provides a simple electro-mechanical central control mechanism which will function reliably to synchronize the various operations of a case packet. This is accomplished by mounting a plurality of cams along a rotatable shaft. Each cam cooperates with a cam follower connected to operate a switch which controls one of the various operations of the case packer. In this simple manner, the actuation of the various individual operations of the case packer is determined in accordance with the position of a single rotating shaft.

The most basic operation of the case packer is the movement of the case feed conveyor. This would be the most natural operation upon which to base the timing and control of the remainder of the operations of the packer. The case feed conveyor feeds empty cases to the elevator platform and, thereafter, removes loaded cases therefrom. The platform must be raised and lowered between the feeding and removal operations for the case thereon to receive the gravity-fed articles. Since the case feed conveyor normally must function intermittently, the movement thereof cannot serve to determine the position of the control shaft, which must rotate continuously.

In other words, heretofore it has not been possible to drive the rotating control shaft by connecting same to be driven by the movement of the case feed conveyor because the case feed conveyor is operated intermittently, whereas the control shaft must be driven continuously.

Therefore, another aspect of the present invention provides a control system for a case packer wherein the various operations of the case packer are controlled in accordance with the movement of a continuously driven case feed conveyor, as the case feed conveyor functions to intermittently feed and remove cases from the elevator platform. This is accomplished by utilizing a flight bar-type conveyor of novel design as the case feed conveyor. The flight bar conveyor has three sections. As the flight bar moves along the first section, an empty carton is pushed ahead of the bar from the input end of the conveyor towards the elevator platform. As the flight bar approaches the front end of the platform, it pushes the case onto the platform.At a point near the front end of the platform, the flight bar abruptly changes direction and-enters a "dwell" section of the conveyor, which is a loop situated out of the way of the platform. The flight bar goes through a "dwell" period as it travels around the loop because it is out of contact with the case and remote from the platform. During this "dwell" time, the elevator is actuated to lift the case into position to be loaded, the articles are loaded therein, and the elevator is lowered to its original position. The operations are synchronized such that when the elevator returns to its original position, the flight bar has traversed the dwell loop and is again situated at the front end of the platform behind the case. The flight bar then abruptly changes direction again and enters another section of the conveyor which extends over the platform.Movement of the flight bar along this section serves to remove the loaded case from the platform.

In this manner, the case feed conveyor is continuously driven, although itfunctionsto intermittently place cases on, and remove cases from, the elevator platform. Since the case feed conveyor is continuously driven, it may serve as a timing mechanism for the control of the various other functions of the case packer. Thus, in the present invention, the rotating control shaft may be driven in accordance with the movement of the case feed conveyor, thereby greatly simplifying the entire control mechanism.

In designing a case packer, each individual operation is engineered to take place as efficiently, reliably, and quickly, as possible. For example, articles are fed to a ready station, prior to entrance thereof onto the loading platform, by an article feed conveyor which is driven continuously at a given speed, so as to move the articles towards the gate which precedes the loading platform. When the gate is opened, a compliment of articles is fed from the ready station to the loading platform by the movement of the conveyor. It is desirable to reduce the time which it takes to transfer the compliment of articles from the ready station to the loading platform in a manner which will not diminish the reliability of the machine.One method of accomplishing this is to speed up the article feed conveyor immediately after the gate has been opened such that the articles are transferred at a higher rate from the ready station to the loading platform. However, any increase in the article feed conveyor speed is severely limited by the fact that the articles being loaded, often bottles or jars made of glass, are fragile and must be handled gently. Thus, if the speed of the article feed conveyor were simply increased to reduce loading time, breakage would be unacceptably high as the lead articles crash into the stop abutment situated at the end of the loading platform.

Another aspect of the present invention provides a drive mechanism for the article feed conveyor wherein the compliment articles is fed rapidly to the loading platform for a first time period and, thereafter, driven at a decreased rate through a second period of time, until the leading articles abut the stops. In this manner, increased loading platform speed is obtained without causing damage or breakage of the articles. The dual-speed drive mechanism comprises a pneumatic cylinder connected to the conventional drive mechanism for the article feed conveyor by means of an over-running clutch. The operation of the pneumatic cylinder is carefully timed, such that when the gate to the loading platform is lifted, the cylinder is actuated to drive the conveyor, through the over-riding clutch, at a fasterthan-normal speed.As the articles approach the stops at the end of the loading platform, the pneumatic cylinder is deactuated such that, for the remainder of the length of travel, the articles decelerate and travel at the lower, normal motor speed, such that damage and breakage does not occur when the leading articles hit the stops.

The stops themselves play an important part in the loading process because the stops must engage the leading article as the compliment of articles is rapidly fed to the loading platform and stop same in a manner which does not alter the position of the leading articles. In addition, some sort of sensing mechanism is required such that the gate at the input side of the loading platform is closed when a full compliment of articles is positioned on the loading platform.

Another aspect of the present invention combines these stop and sensing functions in a manner which permits the stop, as it is engaged by the top of the leading article, to simultaneously function as an abutment and a sensing means to determine when a full compliment of articles is present on the loading platform. This is accomplished through the use of a plurality of arms, one of which is provided for each lane of articles, which are pivotally mounted to a shaft situated above and transverse to the lanes, near the end of the loading platform. As the leading article in each lane approaches the end of the loading platform, the arm associated with that lane is engaged and pivoted by the article to a rotational position wherein it acts as a stop to prevent additional article movement.Aligned with each arm, but below same at a position only slightly above the level of the displaceable grid, are additional stops which engage the bottom of the leading article in each lane.

Each of the pivotal arms is provided with a flag portion having an opening. A light source is provided on one side of the set of arms, with a photoelectric signal generating means situated on the other side. When all of the arms are located in the appropriate position, reflecting the fact that a leading article is correctly positioned in each lane and, thus, a full compliment of articles is situated on the loading platform, the light from the light source travels along a path through the aligned flag openings in the pivotal arms and is sensed by the photoelectric signal generating means which, in turn, generates a signal signifying that a full compliment of articles is situated on the loading platform.

This signal permits the gate at the input side of the loading platform to be closed and the articles on the loading platform to be gravity-fed into an empty case, when the same is properly positioned there-' under.

In accordance with an embodiment of the present invention, a case packer is provided comprising means for loading an article into a case, means for feeding articles to the loading means, means for moving a case relative to the loading means such that the article may be loaded therein, means for conveying cases to and from the case moving means, means for continuously driving the case conveyor means, and means for synchronizing the actuation of the loading, article feeding, and case moving means with the movement of the conveying means. The synchronizing means comprises a shaft and means for operably connecting the shaft with the conveying means such that the shaft is rotated as the conveying means moves.A plurality of cams are fixedly mounted on the shaft and cooperate with an equal number of cam followers so as to synchronize and control the operation of the loading means, the article feeding means and the case moving means, respectively.

In accordance with another aspect of the present invention, the case packer comprises a case receiving station, such as an elevator platform, conveyor means having a case engaging part, such as a flight bar, for intermittently feeding cases to and removing cases from the station and means for continuously driving the conveyor means along a path. The path includes a first section, terminating in proximity to the station, along which a case is engaged by the case engaging part and moved into the station. In the second section of the path, the case engaging part passes through and away from the station such that the case in the station is engaged and removed therefrom. In a third section of the path, which is interposed between and operably connects the first and second sections, the case engaging means extends away and then back towards the station and is disengaged from the case.Thus, the third section of the path constitutes a "dwell" period during which the conveyor means operatively idles as the flight bar loops around a path which is remote from the station, such that it does not engage or otherwise interact with the case or limit the movement of the platform.

Means are provided for moving the platform relative to the second section of the path so as to bring the case into position underneath the loading area to situate same to receive the gravity-fed articles. Means are provided for actuating the moving means when the flight bar is in the third section of the path. Thus, the elevator platform is moved vertically during the time when the flight bar is in the "dwell" period, as it is moved along the third section of the path.

In accordance with another aspect of the present invention, the case packer includes an article accumulation platform and conveyor means for providing articles to the platform. The conveyor means comprises drive means including a first drive means in the form of a motor connected to a shaft to rotate same at a first relatively low speed. The shaft is connected through an overrunning clutch means to a spindle which supports the belt of the article conveyor. A second drive means, in the form of a pneumatic cylinder, is also connected to the clutch means. When actuated, the cylinder causes the clutch to overrun, causing the spindle and, thus, the belt to move at a second, faster speed.

The pneumatic cylinder is actuated when the product stop gate, situated at the input end of the loading platform, is opened such that the compliment of articles is transferred from the ready station to the loading platform at an increased rate. However, prior to the time when the leading articles of the compliment abut the stops at the far encl of the loading platform, the pneumatic cylinder is deactuated, such that the belt is driven by the motor through the clutch at a lower speed, causing the articles to decelerate prior to abutting the stops. In this manner, platform loading time is reduced without causing breakage or damage of the articles.

In accordance with another aspect of the present invention, the case packer includes a loading platform. Means are provided for conveying articles across the platform. Stop means are provided at the end of the platform for engaging the top of the leading article. The stop means comprises means for sensing the presence of the leading article at the end of the loading platform. In addition, second stop means are provided for engaging the bottom of the leading article at the end of the loading platform.

The first stop means comprises a support and an article engaging arm pivotally mounted on the support. The arm is movable relative to the support by the leading article as the article is moved towards the end of the loading platform, from a first position, wherein a portion of the arm is engaged by the leading article, to a second position, wherein further movement of the leading article along the platform is prevented.

The sensing means comprises means for detecting the second position of the arm. The detecting means comprises a light source and a photosensitive signal generating means located on opposite sides of the arm. The arm has a light transmissive part. The light transmissive part aligns with the source and the photo-sensitive signal generating means when the arm is in the second position. Thus, generation of a signal by the photosensitive signal generating means signifies the presence of a full compliment of articles and notifies the control section of the case packer that the subsequent operations relating to case loading may take place.

To these and such other objects which may hereinafter appear, the present invention relates to a case packer, as described in the following specification and recited in the annexed claims, taken together with the accompanying drawings, wherein like numerals refer to like parts, and in which: Figure 1A is an elevational view of one side of the case packer of the present invention; Figure 1B is a fragmentary view of the other side of the case packer, showing the rotating control shaft.

Figures 2A and 2B in combination, represent a top plan view of the upper level of the case packer of the present invention; Figures 3A and 3B in combination, represent a top plan view of the lower level of the case packer of the present invention; Figure 4 is a side plan view of a portion of the bottle feed conveyor drive and product gate at the input side of the loading platform and down bottle detector of the present invention; Figure 5 is a front elevational view, taken along line 5-5 of Figure 4; Figure 6 is a top plan view, taken along line 6-6 of Figure 5; Figure 7 is a top plan view of the displaceable grid of the loading platform of the present invention; Figure 8 is a view of the case packer of the present invention,taken along line 8-8 of Figure 1;; Figure 9 is a view of the case packer of the present invention, taken along line 9-9 of Figure 1; Figure 10 is a top plan view of the bottle feed conveyor drive mechanism of the present invention; Figure ii is a side elevational view of the drive mechanism shown in Figure 10; Figures 12 and 13 in combination, are a schematic diagram of the electrical portion of the control system of the present invention; Figure 14 is a graphical representation of the timing of the various functions of the case packer; and Figures 75A-15K respectively, schematically represent the operation of various components of the case packer at 30 intervals of angular rotation of the control shaft.

The case packer disclosed herein is designed for loading bottles or the like into cardboard cases.

However, the principles of operation disclosed herein are readily adaptable to equipment designed for loading other types of articles and to other types of equipment as well. Thus, the present invention is not limited to use on a case packer designed to load bottles and should not be construed as being so limited.

The overall operation of the case packer of the present invention can be best appreciated by referring to Figure 1A. The case packer includes a frame or support, generally designated A, consisting of vertical and horizontal support elements and having an upper level and a lower level. The upper level includes a bottle feed conveyor, generally designated B, and a drive mechanism therefor, generally designated C, which includes a conventional electric motor, a pneumatic cylinder, and an overrunning clutch assembly, described in detail below, designed to move bottles at two different speeds onto a loading platform, generally designated D.Situated along bottle feed conveyor B are an agitator assembly, generally designated E, an intermediate lane guide, generally designated F, down bottle detector means, generally designated G, and a product stop or gate means, generally designated H, the latter being situated between the output end of bottle feed conveyor B and the input end of loading platform D.

At the far end of loading platform SD is situated a bottle stop and detector means, generally designated I.

On the lower level is situated an endless belt case feed conveyor, generally designated J, which includes case stop means and case brake means, and a flight bar conveyor, generally designated K, designed to transport empty cases from case feed conveyor J and intermittently feed same to an elevator mechanism, generally designated L, which serves to lift an empty case to position same directly under loading platform D such that the bottles, gravity-fed from loading platform B, may be received therein. Flight bar conveyor K also serves to intermittently remove loaded cases from elevator mechanism Land to convey same to the output end of the case packer where the loaded cases are removed, the top flaps thereof sealed, and the cases sent for storage or shipping.

Figures B shows the reverse side of the case packer and, particularly, the mechanical portion of the control system. A rotating shaft 11 is provided, one end of which is connected through a chain 17, a second shaft 19, and a gear box 21,the latter being operably connected to the pully for the dwell section of conveyor K, such that shaft 11 rotates in accordance with the movement of continuously driven flight bar conveyor K. Fixedly mounted on shaft 11 are a plurality of cams 13, each of which has a special contour corresponding to the actuation time of a different one of the operations of the packer.

Associated with each cam 13 is a cam follower 15 connected to control the state of a cam switch CS which, in turn, operates a solenoid valve. The valve, when actuated, connects a pneumatic cylinder to a source of compressed air so as to actuate one of the operations of the case packer. The detailed operation of the control means is described below, after the general description of the various operations of the case packer.

Figures 2A and 2B, collectively, show a plan view of the upper level of the case packer. From the input side of bottle feed conveyor B (right, as seen in the drawings), extend a pair of upstanding bottle side guide rails 10, 12, provided to guide the incoming flow of bottles to the intermediate portion of the case packer wherein upstanding lane guides 14,16,18,20 and 22 serve to divide the incoming flow of bottles into four distinct lanes. As the bottles are divided up into lanes, same pass under agitator assembly E of conventional design. Agitator assembly E causes the lane guides to vibrate slightly in a direction transverse to the direction of bottle flow, so as to insure an even flow of bottles into the lanes, without jamming.

As the bottles travel further along bottle feed conveyor B, they pass underneath the intermediate lane guide F, which serves to support and properly maintain the position of upstanding lane guides 14, 16, 18,20,22. Thereafter, the bottles pass beneath down bottle detector means G, which detects any bottles which are not correctly situated in an upstanding position. After passing through means G, the bottles are conveyed to a ready station, immediately preceding product stop or gate means H.

Means H serves to prevent additional bottles from entering loading platform D, until same is ready to receive the next compliment of bottles.

Loading platform D comprises a displaceable grid 24, located beneath lane guides 14, 16, 18,20,22, which, in turn, is connected to a grid drive 36, such as a pneumatic cylinder or the like. Grid 24 comprises four runners 26,28,30,32, one of which is provided for each lane. In the position shown in Figure 2A, each runner 26, 28, 30, 32 serves to support one lane of bottles, defined by guides 14, 16, 18,20 and 22. When a case is in position underneath loading platform D, cylinder 36 is actuated, moving grid 24 with respect to the lane guides such that the bottles, formerly supported by the runners of grid 24, are no longer supported thereby and are, thus, gravity-fed to a case waiting below.

At the end (left, as seen in Figure 2A) of loading platform D is situated bottle stop and detector means I. Means I comprises four pivotal detector arms (not shown in Figure 2A), one for each lane, designed to engage the top of the leading bottle in each lane, such that the arm is pivoted by the bottle as the bottle is moved towards the end of the loading platform. The pivotal arms are mechanically connected, such that they can be pivoted by the tops of the bottles only to a certain rotational point and, thereafter, will act as a stop, preventing further movement of the bottle. In addition, the arms are each provided with an opening or hole. At one side of the arms is located a light source 38 and, at the other side of the arms is located a photoelectric signal generating means 40.When all of the arms are in the proper position such that the openings therein align, indicating that a full compliment of bottles is present in loading platform D, the photoelectric signal generating means 40 will sense the light from light source 38 and generate a signal to close a switch, permitting the product stop or gate means H to close, thereby preventing additional bottles from entering loading platform D.

Figures 3A and 3B, collectively, constitute a plan view of the lower level of the case packer. At the input end of the lower level (right, as seen in the drawings), is an endless belt case feed conveyor J which functions in conjunction with case brakes 42 and case stops 44 to feed empty cases, one at a time, to flight bar conveyor K at predetermined intervals.

Case brakes 42 comprise a pair of pneumatic cylinders with extendable rods which can be moved into and out of the path of movement of the cases so as to permit or prevent the leading case on conveyor J from being picked up by the flight bar conveyor K.

Brakes 42 are situated on either side of the position of the second case on conveyor J and, when actuated, serve to hold the second and all subsequent cases back as the leading case is released by stops 44, such that only a single case is fed to conveyor K at a time. Brakes 42 may be enlarged pressure pads or the like connected to extendable rods of pneumatic cylinders located on either side of conveyor J.

Cases are picked up, one at a time, from conveyor J by the flight bars orflight bar conveyor K which transports each empty case to an elevator platform 46 located near the end of the lower level and immediately beneath loading platform D. As explained in detail below, the unique structure of flight bar conveyor K permits same to be continuously driven, although it functions to intermittently position empty cases on platform 46 and remove full cases from platform 46. This permits the timing of each of the operations of the case packer to be based on the movement of flight bar conveyor K, through the use of a central electro-mechanical control system, described in detail below.

The path of movement of the flight bars of conveyor K comprises three sections. The first section 48 comprises a planar portion extending from a point adjacent the output end of case feed conveyorJ to a point immediately adjacent the input side (right, as seen in the drawings) of elevator platform 46. The flight bars traverse the first section no the ninth nt S IPVPI sliahtlv above the level of conveyor J and platform 46, when the latter is in its lowest position. As a flight bar travels along the path defined by section 48, it moves a single empty case from case feed conveyor J and pushes same ahead of it until it is situated on elevator platform 46.It should be noted that even though the path of movement along section 48 terminates just prior to the front end of elevator platform 46, the case is situated on platform 46 at the end of section 48 because the case is pushed ahead of the flight bar.

After movement along section 48, the flight bar changes direction abruptly and travels downwardly, around a pully 106, and then upwardly, along a loop-like path, defining section 50 of flight bar conveyor K. As the flight bar moves along section 50, which is spaced from the plane of section 48, the case on the platform is no longer engaged thereby and, thus, the movement of the flight bar along looped section 50 does not affect the position of the case. Moreover, in section 50, the flight bar does not interfere with the movement of the elevator platform 46.The time which it takes the flight bar to traverse section 50 of conveyor K is "dwell" time, which is required to permit elevator L to be actuated to cause platform 46 to move upwardly into engagement with the downwardly extending fingers 52, which constitute a part of the bottle guide mechanism situated immediately below loading platform D and, after the bottles are gravity-fed into the cells in the case, to move platform 46 downward until it reaches its original position. The movement of elevator L is timed such that it will reach its downward position prior to the time when the flight bar completes it path of movement along section 50 of conveyor K.

At this point, the flight bar again abruptly changes position and enters the third section 54 of conveyor K, which is another planar path, coplanar with section 48. Section 54 passes over the surface of platform 46, when same is in its lowermost position.

As the flight bar traverses section 54, the loaded case resting on platform 46 is engaged at its rear and removed from platform 46. After traversing section 54, the flight bar is returned to the beginning of the section 48 of the path of conveyor K.

It will now be appreciated that, due to the novel structure of flight bar conveyor K, it is possible to continuously drive conveyor K, by means of an electric motor 56 or the like, and still intermittently feed empty cases to and remove loaded cases from elevator platform 46. Since the position of a case is the most basic factor in the timing of the various operations of the device, it is now possible to synchronize all of the operations of the case packer in accordance with the position of flight bar conveyor K, because same is driven continuously.

Clearly, this would not be possible if the conveyor feeding cases to the elevator and removing cases from the elevator were driven intermittently, as in prior art devices.

Motor 56 is connected to conveyor K through an air clutch 57. As long as clutch 57 is actuated, conveyor K will be operational. However, when clutch 57 is deactuated, conveyor K will stop. Since the operation of the entire packer is based on the movement of conveyor K, deactuating clutch 57 will cause the entire machine to stop. This will occur if a problem occurs on the line, such as the presence of a down bottle, a lack of empty cases, a full case back-up, etc.

Figure 4 shows a side view of down bottle detector means G and product stop or gate means H. Down bottle detector means G comprises a pair of upstanding supports 59 mounted to frame A at either side of bottle feed conveyor B. Connected between supports 59 is a shaft 58, situated in a position transverse to the bottle lanes and spaced from the surface of bottle conveyor B by a distance greater than the height of the bottles. Pivotally mounted on spaced portions of shaft 58 are detector arms 60, each of which is aligned with a different one of the bottle lanes. Each arm 60 comprises an engaging part 62 and a flag part 64. The arms 60 are spring-loaded on shaft 58 so as to rotate in a counterclockwise direction, as seen in Figure 4, towards a substantially vertical position.

As the bottles are conveyed along the line beneath down bottle detector means G, each bottle in each lane, in turn, will engage portion 62 of arm 60 and, as long as the bottles are in the correct vertical position, will maintain portion 62 and, thus, flag portion 64 of arm 60 in the non-vertical position shown in Figure 4. However, should a bottle in one of the lanes fall down and, thus, be in the wrong position, that is, not upstanding, the top thereof will now engage portion 62 of arm 60 associated with the lane of the down bottle, thereby permitting the arm 60 associated with that lane to pivot to a point where flag section 64 thereof is approximately vertical.A light source 61 and a photosensitive signal generating means 63 (neither of which are shown in Figure 4) are located at either side of bottle feed conveyor B such that the light source normally generates light to the photosensitive signal generating means along a path which is interrupted by an arm 60 with its flag portion 64 in the vertical position. Thus, when arm 60 swings to its vertical position, indicating the presence of a down bottle in one of the lanes, the light path between the light source and the photosensitive signal generating means is interrupted and the photosensitive signal generating means generates a signal to the control mechanism.

From down bottle detector means G, bottle feed conveyor B transfers the bottles to a ready station 65 which is a platform immediately adjacent the end of conveyor B underneath product stop or gate means H. As best seen in Figures 4 and 5, product stop or gate means H comprises a pair of upstanding supports 66, located on frame A, at either side of bottle conveyor B. Located between upstanding supports 66 is a position adjustable assembly 68, the vertical position of which is adjustable by a standard mechanical linkage controlled by wheel 70, to accommodate bottles of different height. Located on assembly 68 are provided four separate stop mechanisms 72 of identical structure, one of which is provided for each lane of bottles. Structures 72 each comprise an air cylinder with an extendable piston rod connected to a vertically movable pad 74.When actuated, cylinders 72 serve to move pad 74 vertically downwardly to retain the bottles below same between it and platform 65 and, thus, prevent the engaged and all subsequent bottles from being moved forward onto loading platform D. The actuation of cylinders 72 is controlled by the control mechanism in conjunction with the bottle stop and detector means I, which determines when a full compliment of bottles is situated on loading platform D. Thus, product stop or gate means H will be closed when a full compliment of bottles is detected on loading platform D and will not be opened until the compliment of bottles present on loading platform D is gravity-fed into a waiting case, and support grid 24 has returned to its normal position, such that incoming bottles are properly supported.

Figure 6 is a top view of product stop and gate means H. This figure shows the cylinder mounting bar 76 which forms a portion of assembly 68 and its position with respect to lane guides 14,16,18,20,22, which are not shown in Figure 5. The lane guides are mounted on a lane guide rod 77 which extends across and above conveyor B, prior to means H.

Figure 7 shows a plan view of the displaceable loading grid 24. Grid 24 comprises a rectangular frame 78 mounted on support A so as to be displaceable with respect thereto in a direction transverse to the bottle movement. Runners 26, 28, 30 and 32 are situated to support the bottles in each lane formed by guides 14, 16, 18, 20, 22 when frame 78 is in its normal or supporting position. Interposed along each lane at the end thereof are a plurality of upstanding bottle stops 90, mounted on crossbar 92.

When frame 78 is in its normal supporting position, upstanding bottle stops 90 serve to engage the bottom of the leading bottle in each lane and prevent further movement thereof. Frame 78 is provided with a bracket 94 for connection with grid drive cylinder 36 (see Figure 2A) which has an extendable piston rod and serves to move frame 78 relative to support A such that the runners 26, 28,30, 32 no longersupportthe bottles in each lane, and bottom bottle stops 90 do not interfere with the gravity feed of the bottles into the waiting empty case.

Figures 8 and 9 are front and partial side views, respectively, of the loading platform D showing the top bottle stop and detector means I. Means I consists of four spring-loaded pivotal arms 96, one for each lane, which are pivotally connected at 97 on a rod or shaft 98, extending in a direction transverse to the path of bottle movement. In its normal position (shown in phantom in Figure 9), each arm 96 extends downwardly and forwardly towards the bottles as same enter platform D. As the leading bottle in each lane approaches the end of the loadirig platform D, the top of the body thereof engages one of the arms 96 and pivots same to a position (shown in solid in Figure 9) wherein same cannot be further rotated with respect to shaft 98 because of an internal mechanical stop mechanism (not shown).

Arms 96 are located and designed such that the movement of the bottle pivots the arm to its farthest extent and, thereafter, further movement of the bottle is prevented. In this position, the bottom of the leading bottle abuts the bottom bottle stop 90, and the top of the bottle abuts arm 96.

As best seen by Figure 9, each of the arms 96 is provided with an opening 100 which, when the arm has been pivoted as far as possible by the bottle, align along a path along which a light source 38 generates a beam of light. When all of the openings 100 are properly aligned, the light beam from source 38 will be detected by photosensitive signal generating means 40 which may be a photoelectric cell or the equivalent. Thus, the light beam is interrupted until the leading bottle in each land is pushed against the top and bottom bottle stops, indicating that a full compliment of bottles is present on the loading platform D.At this point, photosensitive signal generating means 40 generates a signal permitting product stop or gate means H to close and indicating that cylinder 36, which displaces support grid 24, may be actuated to displace the support grid when the empty case is correctly positioned.

Figures 10 and 11 illustrate the drive mechanisms for flight bar conveyor K and case feed conveyor B.

As best seen in Figure 11, the drive mechanism for flight bar conveyor K comprises an electric motor 56 operably connected to drive a sprocket 102. Sprocket 102 is, in turn, connected to a second sprocket 104 by a chain 103 or the like. Second sprocket 104 is connected, through air clutch 57 (not seen in Figure 10), to drive a pully 106, around which the flight bars of conveyor K move along the dwell section 50 of their path of movement. As described above, motor 56 is normally actuated and serves to continuously drive conveyor K, except when air clutch 57 is deactuated because of a problem at one part of the machine, the correction of which requires that operations of the machine be temporarily terminated.

Located above the drive mechanism for conveyor K is the drive mechanism C for conveyor B. Mechanism C comprises an electric motor 108 connected through a euro-drive reducer 110 to a sprocket 112.

Sprocket 112 is, in turn, connected to a second sprocket 114, by means of a chain 113 orthe like.

Sprocket 114 is fixedly mounted to a rotatable shaft 116 which is connected through a clutch 122 of the overrunning variety to a spindle or the like 118, about which endless belt B travels.

Motor 108 drives belt B art a normal, relatively low constant speed, for example, 60 feet/minute. Conveyor B is run at this speed to convey the bottles from the input end thereof (right, as seen in Figure 1) up to product stop means H. When product stop means H is opened, such that the next compliment of bottles is ready to be situated on loading platform D, it is desired to move the new compliment of bottles onto loading platform D as rapidly as possible without causing breakage thereof. This is accomplished by means of an air cylinder 120 acting in conjunction with clutch 122. Cylinder 120 is mounted to frame A by a mounting bracket 124. Cylinder 120 has an extendable piston rod 126, upon which a rack is situated. The rack engages a pinion on a shaft 117 connected to clutch 122.When cylinder 120 is actuated, shaft 117 is rapidly rotated, thus rotating spindle 118, through clutch 122. Thus, when cylinder 120 is actuated, spindle 118 is moved more rapidly + n ;o to/^1 hvB h\r mntnr ln C.Iiitrh 19 permits shaft 117 and, thus, spindle 118 to rotate more quickly than sprocket 114 or shaft 116 because of the overrunning feature of the clutch.

In this manner, when it is desired to move the compliment of bottles onto loading platform D, air cylinder 120 is actuated. Motor 108 would normally rotate endless belt B at approximately 60 feet per minute. However, the actuation of air cylinder 120, acting through overrunning clutch 122, causes belt B to move more quickly, for example, 120 feetiminute, during the actuation thereof.

However, bottles moving at the rate of 120 feeti minute would crash against bottle stops 90 and 96, causing damage to, and possibly breakage of, the leading bottles. In orderto eliminate this problem, air cylinder 120 is actuated only for a limited time and is deactuated at a point in time where the leading bottles in each row on the leading platform are still spaced from the bottle stops. When air cylinder 120 is deactuated, belt B slows to its normal speed, that is, 60 ft./minute, decelerating the bottles as the bottles abut the bottle stops. Thus, the compliment of bottles is first rapidly moved onto the loading platform and then the movement thereof is slowed, immediately prior to contact with the bottle stops, in order to eliminate damage to, or breakage of the bottles.

Figures 12 and 13, in combination, schematically represent the electrical portion of the control system of the present invention. For ease of reference, each horizontal line of the schematic diagram is denoted by a number, 1 through 37, listed in the left margin.

A three-phase power source or the like (not shown) is connected at lines 1,2 and 3 through circuit breakers 130 to bottle feed conveyor drive motor 108 and flight bar conveyor drive motor 56, through normally opened relay contacts M, and M2, respectively. A transformer 132 is connected between power lines 1 and 2, respectively, and line 7 of the control circuitry, to power the latter. At line 8 is situated a "power on" indicator lamp 134. Immediately below indicator 134 is a connection for a test probe 136 and a test probe indicator lamp 138. Lines 11 and 12, respectively, are energizing circuits for a photoelectric detector means 140 and a photoelectric detector means 142. Photoelectric detector means 140 is located downstream of case feed conveyor J and functions to detect a shortage of incoming empty cases.Photoelectric detector means 142 is located upstream of section 54 of conveyor K and functions to detect a back-up of loaded cartons.

Located at line 14 is a relay M1 which, when actuated, causes relay contacts M1 on lines 1,2 and 3 to close, actuating bottle feed conveyor drive motor 108. Located at line 13 is the bottle feed conveyor drive motor indicator lamp 144. Also located at line 13 is a normally open start switch 146, a normally closed stop switch 148, and a normally closed emergency stop switch 150. Prior to emergency stop switch 150, a pair of normally opened safety gate switches LS1 and LS2 are connected in series. Limit switches LS1 and LS2 are associated with gates upstream of bottle feed conveyor B which, when closed, prevent bottles from entering the conveyor.

When these aates are opened, limit switches LS1 and LS2 are closed, permitting bottle feed conveyor B to be actuated. With switches LS1 and LS2 closed, emergency stop switch 150 closed, and stop switch 148 closed, start switch 146 is depressed to energize relay M1 and, thus, motor 108. When switch 146 is released, relay M1 will remain energized because relay contacts M1 at line 15 are closed, as are normally closed relay contacts R1 at line 14. Normally closed relay contacts R1 on line 14 are controlled by relay R1, at line 15, which constitutes the down bottle memory, and serves to de-energize motor 108 until a down bottle is cleared. LS1, LS2 and switch 150 all must be closed to energize the remainder of the control circuit.

Also at line 15 is a normally opened switch 152 connected in series with the contacts 154 of a relay controlled by the down bottle photoelectric sensor 63, utilized in conjunction with the down bottle detector means G. Relay contacts 154 are normally closed, indicating the presence of a down bottle, but are held open when no down bottles are detected.

When a down bottle is detected, contacts 154 close and down bottle memory relay R1 is energized, causing alarm 156, connected in parallel therewith at line 16, to sound until normally closed alarm reset button 158 is depressed. When relay R1 at line 15 is energized, normally opened relay contacts R1 at line 16 are closed, such that, even if the down bottle passes detector means G, alarm 156 will continue to sound. When the operator corrects the position of the down bottle, alarm reset button 158 is depressed, deactivating relay R, and alarm 156, and permitting motor 108 to be restarted.

A pair of normally closed limit switches LS17 and LS18, situated in parallel at lines 17 and 18, are situated upstream of agitator assembly E along bottle feed conveyor B and, when closed, indicate a sufficient flow of bottles to agitator assembly E.

When bottle feed conveyor drive motor 108 is actuated, contacts M1 at line 17 are closed, such that a time delay circuit 160 is energized. Circuit 160 periodically actuates solenoid 162 of agitator assembly E so as to agitate the lane dividers. A surge suppressor 164 is located at line 17, in parallel with solenoid 162, to protect same.

At line 20 is located relay M2 which, when actuated, closes contacts M2 at lines 4, 5 and 6 so as to energize motor 56 which is the drive for flight bar conveyor K. Located in parallel with relay M2, at line 19, is an indicator lamp for motor 156. Also at line 19 are located a normally opened start switch 166 and a normally closed stop switch 168. Assuming switch 168 to be closed, depression of switch 166 actuates motor 56 as long as normally closed relay contacts R2 at line 20 remain closed, indicating the lack of a jam. Even after start switch 166 is released, motor 56 will remain energized because normally opened relay contacts M2 at line 20 will now be closed.

Relay R2, located at line 22, constitutes the jam memory relay and has an indicator lamp 170 connected in parallel thereto at line 21. Also at line 21 are a normally opened limit switch LS28 and a normally closed reset switch 172. Limit switch LS28 is located adjacent bottle feed conveyor B and is closed when a bottle jam occurs thereon. The closing of LS28 causes relay R2 to be energized, energizing indicator lamp 170, closing normally opened relay contact R2 at line 22, and opening contacts R2 at line 20, so as to de-energize motor 56. Thus, even if LS28 is opened prior to the depression of reset switch 172, lamp 170 and relay R2 will remain energized.

At line 23 is a normally opened switch 174 which is controlled by photoelectric sensing means 140 located at line 11. Closing of switch 174 energizes indicator lamp 176, denoting a lack of cases being - fed to case feed conveyor J. At line 24 is located a normally closed switch 178 which is connected to the photosensitive detector means 142 at line 12 and, when closed, serves to energize indicator lamp 180, indicating afull carton backup beyond section 54 of flight bar conveyor K.

At line 25 is situated another pair of relay contacts M2 which are normally opened but are closed when motor 56 is actuated. Thus, lines 25 through 37 are not energized unless motor 56 is driving flight bar conveyor K. As mentioned above, the operations of the various portions of the case packer of the present invention are controlled by a rotating shaft 11, driven by the movement of conveyor K. On this rotating shaft are fixedly mounted a plurality of cams 13, each of which cooperates with a cam follower 15.

Each cam follower 15 is connected to actuate or deactuate a cam switch CS which controls a solenoid valve. Each solenoid controls one of the operations of the packer. These cam switches are shown at lines 25-31,33 and 36.

At line 25 is situated normally closed cam switch CS-1A. When closed, cam switch CS-1A energizes solenoid 182 to cause elevator Lto move platform 46 upwardly towards loading platform D, as long as limit switch LS8, located adjacent platform 46, is closed, indicating the presence of a case on platform 46.

Located at line 26 is a normally closed cam switch CS-2A which, when closed, actuates a solenoid 184 to cause elevator L to move platform 46 from its uppermost vertical position to its lowermost vertical position. Located at line 27 is a normally closed cam switch CS-3A which, when closed, actuates a solenoid 186 to close product stop or gate H. Located at line 28 is a normally opened cam switch CS-3B which, when closed, serves to actuate a solenoid 188 to open the product stop or gate H, as long as limit switch LS13 is closed, indicating that grid 24 is in the closed or support position. Located at line 29 is a normally open cam switch CS-4B which, when closed, energizes solenoid 190 to actuate air cylinder 36 so as to displace or open grid 24 when limit switch LS10, located adjacent the uppermost position of elevator L, is closed, indicating that the elevator is in its uppermost position.

Located at line 30 is a normally closed cam switch CS-5Awhich, when closed, actuates a solenoid 192 which, in turn, actuates the air cylinder 120, forming a portion of the bottle feed conveyor drive C, which causes a compliment of bottles to be rapidly fed to the loading platform D. Located at line 31 is a normally closed cam switch CS-6A which, when closed, will actuate a solenoid 194 to open case stops 44, as long as limit switch LS3, located along side case feed conveyor J upstream of case stop 44, is closed, indicating the presence of a case immediately upstream of case stop 44. At line 32, is another switch 196 which acts in conjunction with limit switch LS3, but in the opposite direction, such that when one is closed, the other is opened.When switch 196 is closed, indicating that no carton is present immediately upstream of case stop 44, solenoid 198 is energized so as to close case stops 44.

Lines 33-36 include circuitry which, if a portion of the machine is not functioning correctly, will deactuate a solenoid 200 which controls air clutch 57 between conveyor K (and, thus, shaft 11) and motor 56, such that the operation of the packer terminates.

For solenoid 200 to be energized, one of the lines 33 or 34 must be a complete circuit and either CS-8B or LS7 must be closed.

CS-7B is normally open, but is held closed except for a short period prior to the closing of CS-4B (opening the grid in platform D). If the contacts on line 34 are not all closed at this time, solenoid 200 is deactuated. Line 34 contains contacts 206 (closed only when a full compliment of bottles is present on platform D as sensed by bottle stop and sensing means 1), contacts R1 (closed as long as down bottle memory relay R1 if off), LS-17, LS-18 and LS-24 (located upstream of product stop or gate H and closed when an adequate supply of bottles is present on conveyor B), contacts 210 (controlled by photoelectric sensing means 142 and opened when a lack of incoming cases is detected), contacts 212 (open by photoelectric sensing means 140 when a full case back-up is detected), and switch 214 which is closed to start the control cycle.LS-17, LS-18 and LS-24 may be bypassed by closing normally opened switch 208 to start up the machine before a sufficient number of bottles is on conveyor B.

Normally opened CS-8B is held closed, except for a short period prior to the elevator down dwell period. If the elevator is not in the correct position (down) to receive an empty case (and, thus, keep LS-7 closed), solenoid 200 will be de-energized.

A normally open switch 204 on line 36 is connected in series with an indicator lamp 202. If the case feed is not functioning properly, switch 204 will close, energizing lamp 202.

The lowermost portion of Figure 13 shows the wiring diagram for the photoelectric sensing means 63, 40 and relay 207. Photoelectric sensing means 63 corresponds to the down bottle detector sensing means G and operates relay contacts 154 at line 15.

Photoelectric sensing means 40 constitutes the sensing means for the bottle detector and stop means I, and serves to operate relay 207 and, thus, contacts 206 at line 34.

The sequence of operation of the various portions of the case packer of the present invention is graphically illustrated by Figure 14which, ate top thereof, has a scale from 0 to 360 , indicating the angular position of the rotating control shaft 11. The packer goes through a complete operational cycle for each 3603 rotation of the control shaft. The synchronization of the various operations of the case ar onn hart hA InnrFliRtC?T1 with reference to Figure 14,swell asto Figures 15A-15K,which schematically show the various operations in sequence.

At the start of the cycle, as shown in Figure 15A, that is, with the angular position of the rotating shaft 11 at 0 , elevator L is down, having just completed a dwell period during which an empty case has been positioned thereon, closing LS-8. Switch CS-1A now closes causing elevator Lto move upwardly, as long as LS-8 is closed, indicating the presence of an empty case on platform 46. Switch CS-2A is open.

Product stop or gate H is open, permitting bottles to enter loading platform D. Switch CS-3A is open and CS-3B, as well as LS-13 (indicating that support grid 24 is in the support position) are closed. CS-4B is open keeping the grid in platform D in the closed or support position. None of the flight bars from flight bar conveyor K is located on top of platform 46 of elevator L, but the flight bar which pushes the empty case onto platform 46 is about to leave section 48 and enter section 50 of conveyor K. Normally open switch CS-5A is open such that air cylinder 120 is deactuated and the bottle conveyor B is operating at its lower speed (indicated by short arrow 220) as the compliment of bottles nears the end of loading platform D. Case stops 44 are in and case brake 42 is off, because switch CS-6A is opened, preventing the next empty case from entering conveyor K.

As seen in Figure 15B, which shows the case packer when the rotating control shaft 11 is at 30 , switch CS-1A is still closed, causing elevator platform 46 to continue to move upwardly. Switch CS-2A remains open, preventing the elevator from moving downwardly. Product stop or gate H remains open with switch CS-3A opened and switch CS-3B closed. Switch CS-4B remains closed such that the grid in platform D remains in the support position.

The flight bars of conveyor K are positioned so as not to interfere with the elevator movement. CS-5A remains open, such that the bottles are moving along conveyor B towards the end of platform D at a relatively slow speed. Switch CS-6A has been closed such that case stops 44 open and case brake 42 is on.

Thus, the leading carton on case feed conveyor J is moved to a position with respect to flight bar conveyor K such that same is engaged by a flight bar and placed on conveyor K to commence its path of travel along section 48 of conveyor K towards elevator L. The next empty case is held by brake 42.

Figure 15C shows the packer at 60 rotational position of the control shaft. At this point, elevator L has raised to its uppermost position and switch CS-1A is opened, causing the elevator to dwell in the uppermost position, such that bcttles can be gravityfed thereto. Switch CS-2A remains open to prevent the elevator platform from moving downwardly.

Bottle stop or gate H is still open as switch CS-3B is closed, whereas switch CS-3A is opened. Conveyor K is positioned such that no flight bar is situated in the vertical path of elevator platform 46, but the empty case is being moved towards elevator L. The grid in platform D remains closed as switch CS-4B has not yet been closed. Switch CS-5A is still open, keeping cylinder 120 deactuated. Switch CS-6A remains closed such that case stops 44 are out and case brake 42 is on.

At this point, normally open CS-8B is permitted to open briefly, for about 10 of rotation. This is done to test for the presence of a full compliment of bottles on platform D, the absence of down bottles, sufficient bottles being fed along conveyor B, sufficient empty cases being fed to conveyor, and the lack of a full case back-up. If any of these conditions is not met, solenoid 200 is deactuated and air clutch 57 disconnects motor 567 from conveyor K, shutting down the packer until the problem is corrected.

Figure 15D shows the case packer when the control shaft is at 900. Switch CS-1A has opened, causing elevator platform 46 to dwell in its uppermost position to receive bottles. Switch CS-2A remains open, preventing the downward movement of the elevator. Switch CS-3B is now closed, such that product stop or gate H has closed, preventing further bottles from being positioned on loading platform D. Switch CS-4B has closed, such that the grid 24 in the loading platform is displaced, causing the bottles previously supported thereby to be gravity-fed to the waiting case. Conveyor K is still in a position such that no flight bar is in the path of movement of the elevator, but the empty case on section 48 of the conveyor continues to move towards the elevator. Switch CS-5A remains opened, such that cylinder 120 is off.Switch CS-6A is closed, such that case stops 44 remain out and case brake 42 remains on.

Figure 15E shows the machine at a point 1200 in the rotation of the control shaft. At this point, elevator platform 46 continues to dwell in the up position, CS-1A and CS-2A being open. Product stop and gate H is closed, with CS-3A on and CS-3B off.

The grid in loading platform D is closed with CS-4B being opened. No flight bar on flight bar conveyor K is in the path of movement of the elevator, but the case on section 48 of flight bar conveyor K has been moved further towards the elevator. CS-SA is opened, such that cylinder 120 is deactuated. Case stops 44 are out, but case brakes 42 are on, CS-6A being closed.

Figure 15F shows the case packer when the control shaft is at 180". At this point, the bottles have been loaded into the case on elevator platform 46, and switch CS-2A has been closed such that the elevator platform begins moving downwardly. Product stop or gate H continues to be closed, CS-3B being on.

The grid 24 of platform D remains in the closed position, with CS-4B opened. None of the flight bars on conveyor K are in the path of movement of elevator L, but the case on section 48 of conveyor K is approaching the elevator. CS-SA continues to be open, such that cylinder 120 is deactuated. Case stops 44 continue to be out, and case brake 42 continues to be on, as CS-6A is closed.

Figure 15G shows the case packer with the control shaft at 210 . CS-2A is closed, causing elevator L to continue its downward movement, CS-4B remains closed, such that the support grid in platform D is in the support position and product stop or gate H has been opened as switch CS-3B is closed. CS-5A has been closed, energizing the air cylinder 120 to rapidly move the bottles on conveyor B onto loading platform D (long arrow 220). The case on section 48 of flight bar conveyor K has almost reached the position wherein it will be pushed onto the elevator.

CS-6A has been opened, causing the case stops 44to be in and the case brake 42 to be off, so as to set up the next empty carton for feeding onto flight bar conveyor K.

At 230 , normally open CS-8B is held opened for a brief period of about 10 . If LS-7 is not closed at this point, indicating that the elevator platform 46 is down, solenoid 200 is de-energized, causing clutch 57 to be deactuated and the movement of conveyor K to cease. Thus, an empty case cannot be fed to the elevator unless the elevator is down.

Figure 15H shows the case packer when the control shaft is at the 240 position. At this point, CS-2A has been opened as the elevator platform 46 is down and the elevator enters the down dwell period. One flight bar on conveyor K has reached the end of its dwell section 50 and will now pass over the platform 46, which is in its downmost position, so as to remove the loaded case therefrom. In addition, the case moving along section 48 of flight bar conveyor K is now in position to be situated on elevator platform 46. CS-3B continues to be off such that product stop or gate H is opened. The grid is in the closed or support position as CS-4B is opened.

CS-SA is closed, such that the bottle conveyor drive continues at its relatively high speed, so as to rapidly move the next compliment of bottles onto loading platform D. Case stops 44 remain in with case brake 42 off, CS-6A being opened.

Figure 151 shows the case packer when the control shaft is at 270". At this time, elevator L is still down, CS-2A being open. Product stop or gate H remains open, because CS-3B is open, to permit bottles to enter the platform. The grid in loading platform D remains closed because CS-4B is open. CS-5A is closed, such that the bottles are still rapidly being moved onto loading platform D. Case stops 44 are in and case brake 42 is off because CS-6A is open. One flight bar is now removing a full case from elevator platform 46 as another flight bar is pushing an empty case onto the elevator platform.

Figure 15J shows the case packer at 300 in the rotation of the control shaft. Switches CS-1A and CS-2A remain open such that elevator platform 46 dwells at its lowermost position. CS-3A is open and CS-3B is closed, such that product stop or gate H is open. CS-4B is opened such that the grid in platform D is in the support position. The flight bars of flight bar conveyor K are positioned such that one has almost completed pushing a full case off the elevator platform as another continues to push an empty case thereon. CS-SA continues to be closed, such that bottles are moved rapidly onto loading platform D. CS-6A continues to be open, such that case stops 44 are in and case brake 42 is off.

Figure 15K shows the case packer when the control shaft is at 330". CS-1A and CS-2A continue to be opened such that the elevator remains in the down dwell position. Product stop and gate H is opened as CS-3B is closed. The grid in loading platform D continues to be closed, CS-4B being opened. CS-5A is now opened, causing air cylinder 120 to be deactuated. Since the bottle conveyor drive motor 108 remains energized, bottles on the loading platform are slowed to normal (lower) speed as the leading bottles approach the product stop at the extreme end of the platform (short arrow 220).

CS-6A continues to be open, such that case stops 44 are in and case brake 42 is off. At this point, the full case has been completely removed from the elevator platform 46 and the empty case is almost fully positioned thereon. The flight bar pushing the empty case is approaching the very end of section 48 of flight bar conveyor K and will thereafter enter into dwell section 50, through which it will travel while elevator L is moved upwardly to receive bottles from loading platform D and, thereafter, move downwardly to its lowermost position. When it reaches its lowermost position, the flight bar will enter section 54 of the path of movement of flight bar conveyor K at which time it will travel over platform 46 and remove the loaded case therefrom.

It will now be appreciated that the present invention relates to a case packer with a control system for synchronizing the various operations of the case packer in accordance with the movement of a continuously driven case feed conveyor as the case feed conveyor functions to intermittently feed and remove cases from the elevator platform. This is achieved by connecting the rotating control shaft to be driven by the continuously driven case feed conveyor and having a dwell portion in the path of the conveyor such that the conveyor goes through a dwell period between the time an empty case is loaded onto the platform and a full case is removed therefrom, during which time the elevator is moved upwardly, bottles are loaded into the case, and the elevator is moved downwardly.

In addition, a drive mechanism for the article feed conveyor is provided wherein a compliment of bottles is fed rapidly to the loading platform for a first time period and, thereafter, driven art a decreased rate through a second period of time, until the leading bottles abut the bottle stops at the extreme end of the platform. In this manner, increased loading platform speed is attained without increasing the risk of damage or breakage of the bottles. This dual speed drive mechanism includes a pneumatic cylinder connected to a conventional drive mechanism for the bottle feed conveyor by means of an overrunning clutch. The operation of the cylinder is timed such that when the gate to the loading platform is lifted, the cylinder is actuated to drive the conveyor through the overrunning clutch at a faster-than-normal speed.As the bottles approach the stops, at the end of the loading platform, the cylinder is deactuated such that for the remainder of the length of travel the article is decelerated, reducing damage and breakage.

Moreover, the bottle stop and sensing functions are combined. A plurality of pivotable arms, one of which is provided for each lane of bottles, acts as a stop for the top of the bottle, when pivoted into the stop position by the movement of the bottle and, additionally, when in the stop position, indicates that the lane of bottles is full.

uL:'- la r rr n;la nrfnrrPTI amhnrliment nf the present invention has been disclosed herein for purposes of illustration, it is obvious that many modifications and variations could be made thereto.

It is intended to cover all of these variations and modifications which fall within the scope of the present invention, as defined by the following

Claims (38)

claims: CLAIMS

1. Acase packer comprising a case-receiving station (46) and conveyor means (K) having a case engaging part for intermittently feeding cases to and removing cases from said station (46); said case packer being characterized by means (56) for continuously driving said conveyor means along a path comprising: a first section (48), terminating in proximity to said station (46), along which a case is engaged by said part and moved into said station (46); a second section (54), passing through and away from said station (46), along which a case is engaged by said part and moved into said station (46); a second section (54), passing through and away from said station (46), along which a case is engaged by said part and removed from said station (46); and a third section (50), interposed between and operably connecting said first (48) and second (54) sections, and extending away from and back towards said station (46), along which said part is disengaged from the case.

2. The case packer of Claim 1, further characterized by means (L) for moving said case out of, and back to, said station, and means 182, 184 for actuating said moving means when said part is in said third path section.

3. The case packer of Claim 2, characterized in that said case moving means (L) moves said case from a first position, adjacent said second path section (54), to a second position, remote from said second path section (54), and back to said first position, while said part is in said third path section (50).

4. A case packer comprising a platform (46) and conveyor means (K) having a case engaging part for intermittently feeding cases to and removing cases from said platform; said case packer being characterized by means (56) for continuously driving said conveyor means (K) along a path comprising: a first section (48), leading up to said platform (46), along which a case is engaged by said part and moved onto said platform (46); a second section (54) passing along and away from said platform (46), along which a case is engaged by said part and removed from said platform (46); and a third section (50), interposed between and operably connecting said first (48) and second (54) sections, extending away from and back towards said platform (46) along which said part is disengaged from the case.

5. The case packer of Claim 4, further characterized by means (L) for moving said platform (46) and means (182,184) for actuating said moving means (L) when said part is in said third path section (50).

6. The case packer of Claim 5, characterized in that said platform moving means (L) moves said platform (46) from a first position, adjacent said second path section (54), to a second position, remote from said second path section (54), and back to said first position, while said part is in said third path section (50).

7. The case packer of Claims 1 - 6, characterized in that said third path section (50) forms a loop.

8. The case packer of Claims 1 - 7, characterized in that said first and second path sections (48, 54) are substantially coplanar.

9. The case packer of Claim 8, characterized in that said third path section (50) generally extends in a direction away from the plane in which said first and second path sections (48, 54) are situated.

10. The case packer of Claims 8 or 9, characterized in that said conveyor means (K} comprises a flight bar conveyor, the flight bar of which comprises said case engaging part.

11. A case packer comprising conveyor means, said conveyor means comprising a belt (B) and means (108, 120) for driving said belt (B), said belt drive means (108,120) comprising first drive means (108) for moving said belt (B) at a first speed, and second drive means (120) for moving said belt (B) at a second, higher speed; said case packer being characterized by overrunning clutch means (122), operably interposed between said first (108) and said second (120) drive means, on the one hand, and said belt (B), on the other hand, said clutch means (122) comprising first (114) and second (117) input shafts operably connected to said first (108) and second (120) drive means, respectively, and an output shaft (118) operably connected to said belt (B) to drive same, said clutch means (122) normally connecting said first input shaft (114) to said output shaft (118) to move said belt (B) at said first speed and being effective, upon actuation of said second drive means (120), to connect said second input shaft (117) to said output shaft (119) to move said belt (B) at said second speed.

12. The case packer of Claim 11, further characterized by an article accumulation platform (D) having a first end, adjacent said belt (B) onto which articles are loaded as said belt (B) is moved and a second end comprising article stop means (I) and further comprising means (M,) for actuating said second drive means (120) to move said belt (B) until an article is spaced a given distance from said stop means (I).

13. The case packer of Claims 11 or 12, characterized in that said second drive means (120) comprises a pneumatic cylinder (120) with an extendable piston rod (126) and means for operably connecting said rod to said second input shaft (117).

14. The case packer of Claim 13, characterized in that said rod connecting means comprises a pinion on said second input shaft (117) and a rack on said rod, said rack engaging said pinion to rotate said second input shaft (117) when said cylinder (120) is actuated to extend said rod.

15. The case packer of any of Claims 11-14, characterized in that said first drive means (108) is continuously actuated.

16. The case packer of any of Claims 11-15, characterized in that said first drive means (108) comprises a motor (108) and means (112) for operably connecting said motor to said first input shaft (114).

17. The case packer of any of Claims 11-16, further characterized by gate means (H) operably situated between said belt (B) and said first end, means (72) for opening said gate means (H) and wherein said means (M1) for actuating said second drive means (120) is actuated as said gate opening means (72) is actuated.

18. The case packer of Claim 17, characterized in that said stop means (I) comprises means (96) for sensing an article at said second end and further comprising means (40) for deactuating said gate opening means (72) when an article is sensed at said second end.

19. A case packer comprising a loading platform (D) having an end, means (B) for conveying an article across said platform towards said end, and stop means (I) at said end for engaging the article; said case packer being characterized by said stop means (I) comprising means (96) for sensing the presence of the article at said end.

20. The case packer of Claim 19, characterized in that said stop means (I) engages the top of said article and further comprising second stop means (90) at said end for engaging the bottom of said article.

21. The case packer of Claim 20, characterized in that both of said stop means (I, 90) engage the leading article substantially simultaneously.

22. The case packer of any of Claims 19-21, characterized in that said stop means (I) comprises a support (98) and an article engaging arm (96) pivotally mounted on said support (98), said arm (96) being moved relative to the support (98) by said article, as said article moves towards said end, from a first position, wherein a portion thereof is engaged by said article, to a second position, wherein further movement of said article along the platform (D) is prevented.

23. The case packer of Claim 22, characterized in that said sensing means (96) comprises means (38, 40) for detecting said second position of said arm (96).

24. The case packer of Claim 23, characterized in that said detecting means (38,40) comprises a light source (38) and photosensitive signal generating means (40) located on opposite sides of said arm (96), said arm (96) having a Iighttransmissive part (100), said lighttransmissive part (100) aligning With said source (38) and said signal generating means (40) when said arm (96) is in said second position.

25. The case packer of any of Claims 22-24, further characterized by spring means for urging said arm (96) towards said first position.

26. A case packer comprising means (D) for loading an article into a case, means (B) for feeding articles to said loading means (D), means (L) for moving a case relative to said loading means (D) such that the article may be loaded into the case, and means (K) for conveying cases to and from said case moving means (L), said case packer being characterized by means (56) for continuously driving said case conveying means (K) and means (11, 13, Cs) for synchronizing the actuation of said loading means (D), article feeding means (B), and case moving means (L) with the movement of said conveying means (K).

27. The case packer of Claim 26, characterized in that said synchronizing means (11,13,15, Cs) comprises a shaft 11, means (102,57,21,19,17) for operably connecting said shaft (11) with said conveying means (K) such that said shaft (11) is rotated as said conveying means (K) moves, first, second and third cams (Cs) fixedly mounted on said shaft (11) and first second and third cam followers (15) engaging said first, second and third cams (Cs), respectively, said first, second and third cam follower (15) controlling the actuation of said loading means (D), said article feeding means (B) and said case moving means (L), respectively.

28. A case packer comprising means (D) effective, when actuated, to load articles into a case, means (B) effective, when actuated, to feed articles to said loading means (D), means (L) effective, when actuated, to move a case relative to said loading means (D), such that the article may be loaded into the case, said case packer being characterized by means (K) for conveying cases to said case moving means (L), operatively idling for a given period and, thereafter, removing cases from said case moving means (L), means (56) for continuously driving said case conveying means (K), and means for synchronizing (11,13, 15, Cs) the actuation of said loading means (D), feeding means (K), and moving means (L) in accordance with the movement of said conveying means (K).

29. The case packer of Claim 28, characterized in that said moving means (L) is actuated during said given period.

30. The case packer of any of Claims 26-29, characterized in that said synchronizing means (11, 13,15, Cs) comprises first, second and third control means (Cs) for, respectively, actuating said loading means (D), article feeding means (B), and said case moving means (L), in accordance with the move mentofsaid conveying means (K).

31. The case packer of any of Claims 28-30 characterized in that said moving means (L) comprises an elevator (46).

32. The case packer of any of Claims 28-31 characterized in that said conveying means (K) comprises a first section (48) leading up to said moving means (L), along which a case is engaged and moved onto said moving means, a second section (54) passing along and away from said moving means (L), along which a case is engaged and removed from said moving means and a third section (50), interposed between said first and second sections (48, 54), along which the case is disengaged so as to permit said conveying means to operatively idle.

33. The case packer of Claim 32, characterized in that said third path section (50) extends away and back towards said moving means (L).

34. The case packer of any of Claims 28-33 characterized in that said moving means (L) is actuated during said given period.

35. The case packer of any of Claims 31-34 rh,,rnrserized in that said conveying means (K) comprises a first section (48) leading up to said elevator (46), along which a case is engaged and moved onto said elevator, a second section (54) passing along and away from said elevator (46), along which a case is engaged and removed from said elevator and a third section (50), interposed between said first and second sections (48, 54), along which the case is disengaged so as to permit said conveying means to operatively idle.

36. The case packer of Claim 35, characterized in that said third path section (50) extends away and back towards said elevator means (L).

37. The case packer of any of Claims 31-36 characterized in that said synchronizing means (11, 13,15, Cs) comprises first, second and third control means (Cs) for, respectively, actuating said loading means (D), article feeding means (B), said case moving means (L), in accordance with the movement of said conveying means (K).

38. The case packer of any of Claims 35-37 characterized in that said synchronizing means (11, 13, 15, Cs) comprises, first, second and third control means (Cs) for, respectively, actuating said loading means (D), article feeding means (B), and said elevator means (L), in accordance with the move mentofsaid conveying means (K).