GB2091198A - Buffer storage apparatus - Google Patents

Abstract

A buffer storage apparatus comprises means for removing a product travelling from one location to another, and an elongate reservoir belt movable in the direction of its elongation from a stowed position wound on a spool, past the removing means to receive the product and thereafter to a product storage position where the charged reservoir belt is wound on a further spool. When the reservoir belt is being wound round one spool the reservoir is being unwound from the other. The reservoir belt itself is preferably provided with pockets or dividers acting as means of separating articles and as distance pieces between layers of wound belt to prevent articles being compressed between layers of belt wound round the loaded conveyor spool. The system is designed to handle a variety of articles such as chocolate bars or cigarette packages, bottles, cigarettes, or tin cans. <IMAGE>

Description

SPECIFICATION Buffer storage apparatus The invention relates to a limited capacity buffer storage reservoir which may be sited between two stages of manufacture or process linked together by means of a conveyor band or the like, including means of diverting, holding and drawing articles, singly or in bulk.

Where two stages of manufacture or process are carried out on two separate machines linked in such a fashion, it is desirable to draw products off the direct link system if the second unit of manufacture (down line) stops for any reason thus enabling the first unit to continue operating. Conversely, if the first unit stops the second unit may continue operating if articles are introduced to the direct link conveyor.

The retrieval and feeding of articles from and to such conveyors may be carried out manually, with semi or fully automatic equipment. Articles removed from conveyors are placed into containers and, if need be, taken away to storage areas. Later they are returned to the feeding point and loaded onto the direct link system. Other, containerless, systems employ by-pass conveyors of varying lengths travelling over distances in straight lines, with returns, alongside or in tiers. Some are arranged at processing machine level, others are elevated and using combinations of horizontal, vertical and semicircular lengths of conveyor, in the main storage articles on lengths arranged horizontally. Articles, products, etc, are supported singly, in layers or in bulk, with or without the aid of additional chamber like side members.

According to the invention the buffer storage apparatus comprises means for removing a product travelling from one location to another, and an elongate reservoir movable in the direction of its elongation from a stowed position, past the removing means to receive the product and thereafter to a product storage position. Preferably the reservoir is stowed on a first core from which it is drawn when buffer storage is required, and is taken up on a second core in the product storage position i.e. the reservoir is coiled about the first core and is coiled about said second core as the reservoir is drawn off the first core, the product being encaptured between the turns of the reservoir on the second core.

This invention differs from other conveyor-based storage systems in that a long length of purpose made reservoir belt may be installed immediately above the point at which articles have to be removed from a direct link conveyor and returned thereto thus requiring little or no additional floor space. Two or more storage belts may be used side by side thus increasing total storage capacity. The reservoir may comprise a storage belt which when loaded is stored or contained in a small area by being wound or coiled around itself thus not requiring additional static supporting structures. This system consists, basically, of two spool-like drums, with or without side flanges, normally mounted one above the other, around which a length of reservoir belt is wound or coiled. One spool is employed to take up 'loaded' reservoir belt and the other 'empty' belt.When the reservoir belt is being wound round one spool the reservoir is being unwound from the other. The reservoir belt itself is preferably provided with pockets or dividers which apart from acting as means of separating articles serve as distance pieces between layers of wound belt thus eliminating the possibility of articles being compressed between layers of reservoir belt wound round the loaded.

reservoir conveyor spool/drum. The system is designed to handle a variety of sizes and shapes of articles such as rectangular products like chocolate bars or cigarette packages, bottles, cylindrical or rod-shaped articles such as cigarettes, tin cans, etc.

The invention will now be described by way of example with reference to the accompanying drawings, in which: Figure lisa schematic elevation of the buffer storage apparatus arranged above a conveyor feeding cigarettes from a maker to a packer, Figure 2 is a part elevational view of the coiled elongate reservoir belt containing cigarettes, Figure 3 is a part elevational view of the pick-up and delivery drums and reservoir belt, Figure 4 is a part elevational view of a further embodiment in which the system is designed to convey packages (e.g. chocolate bars as shown), Figure 5 shows another buffer system in which the product is moved laterally of the conveyor to the reservoir belt, Figures 6a and 6b show elevation and plan views of a linked reservoir belt suitable for the system shown in Figure 5, Figure 7shows an arrangement for handling a bulk product, Figures 8a and 8b show elevation and plan views of a reservoir belt suitable for the system of Figure 7, Figure 9 is an elevation of another embodiment for handling a bulk product, Figures lOa and 10b show elevation and plan views of a reservoir belt suitable for the system of Figure 9 and other embodiments, Figure 11 is an end elevation of a buffer system in which two or more sets of reservoir belts (not shown) and drums and related equipment are arranged side by side, Figure 12 is a side elevation of the system shown in Figure 11, Figure 13 is a plan view of the system shown in Figure 11, Figure 14 is a section taken along the line A - A in Figure 12, on an enlarged scale, Figure 15 is a modified form of the system shown in Figure 1 in which the elongated reservoir is supplied from and taken up on endless tracks, Figure 76is an end elevation showing the reservoir belt and endless tracks only, and Figure 17 is an elevation of a further buffer system for cigarettes.

The preferred or basic arrangement for the buffer storage apparatues (see Figures 1 and 2) comprises an empty or 'take up' drum 11 mounted on a drive shaft 12 which in turn is supported by lateral members (not illustrated) on one or both sides of the drum. These members may rise from the ground, may be affixed to processing machinery or their direct linking conveyor systems, or hung from above. Below or to the side of the empty conveyor drum is a loaded belt drum 13 also mounted on a drive shaft 14 and supported by lateral members.

The drum shafts are rotated by variable speed, reversible, electric motors actuated by suitable electronic controls designed to keep the reservoir belt under constant and uniform tension. One end of a reservoir belt 15 is affixed to the drum 11 at a shoulder 16 and passes downwards around the outside of idlerwheels 17 and 18, beneath drum 13, and under and around a belt return wheel 19 (which may be driven). The other end of the reservoir belt 15 is affixed to the drum 13 at shoulder 20.

The arrangement of the two drums 11 and 13, the idlerwheels 17, 18 and wheel 19 are disposed above a conveyor band C which conveys cigarettes from a maker to a packer (not shown). The wheel 19 is positioned directly over a fluted pick-up drum 21 which when activated (i.e. when suction is applied in a manner well known in the art) picks up the cigarettes from the conveyor band C and passes them via a transfer drum 27 to the reservoir belt 15.

For the purpose of returning the cigarettes to the conveyor band a further fluted drum 28 is provided which cooperates with the pick up drum 21 on reversal of the latter.

The idlerwheels 17 and 18 may revolve freely or may be provided with variable speed motors for improved tension control. The return wheel 19 is also provided with a reversible drive motor, or mechanical gearing to synchronisethe rate of rotation to that of the pick up drum 21 feeding articles to point 22 on wheel 19.

In operation should the packer be stopped the buffer storage apparatus is actuated whereupon cigarettes are picked up and transferred by the fluted drum 21 to the belt 15 at point 22 which is wrapped up together with the cigarettes on the drum 13. The maker therefore does not stop. As soon as the packer recommences operation the buffer storage appar atus ceases to operate and retains the cigarettes fed to it during packer stoppage. Should the maker stop for any reason the buffer storage apparatus will once again operate but in the reverse direction thereby feeding cigarettes from the reservoir belt 15 to the conveyor band C.

The reservoir belt drum 13 is shown fully wound.

When the reservoir belt is commanded to unload articles, drum 13 rotates in a clockwise direction and gradually reduces in diameter. In turn, take-up drum 11 rotates in an anti-clockwise direction gradually increasing in diameter. If required, the loaded reservoir belt may be provided with support from below by a straight, or gradually curving, member (see Figure 9) which is raised and lowered.

A variety of patterns of reservoir belt may be used.

Whereas Figures 1 and 2 illustrate apparatus suitable for rod shaped articles such as cigarettes, the arrangement of Figure 4 is for rectangular box shaped articles such as chocolates. In the latter construction the articles are picked up by a series of arms 30 extending radially from a pick up drum 31.

The articles are transferred to the reservoir belt 15 and in order to orientate the articles for return grippers at the ends of the arms 30 are arranged to rotate by means well known. The rectangular shaped objects are thereby transferred to the reservoir belt in such a fashion to ensure that when returned to the direct link conveyor, they are still face upwards. In this arrangement articles are rotated 180 between the time they are picked off the direct link conveyor and transferred to belt 15. When articles are being conveyed directly between two stages of manufac ture the wheel 19 is raised sufficiently to allow free passage of the articles on the conveyor band or, the conveyor band itself is lowered.

The arrangement shown in Figures 8 and 10 are designed to accommodate rod-shaped articles in bulk. Other shaped articles, singly or in bulk may be carried or contained as illustrated or altered to suit other and irregular shaped objects.

Articles being carried upwards to the loaded reservoir belt drum 13 (Figure 1) are held in place by gravity. However, as an additional precaution wires, bars or plates may be fitted (see guide 23 in Figure 1). Once articles reach the point on the drum where the belt starts to wind they are contained in place by the reverse face of the belt already wound on the drum. Articles are prevented from being compressed by reservoir belt dividers 39 (Figure 2). Additional protection may be provided by feeding a web of flexible material 24 (Figure 1) between layers of belt would round the drum, the end of this interleaf web being fixed at the shoulder 10 (Figure 1). The interleaf web is fed from a reel 25 provided with a winding motor and appropriate control (not shown).

Articles being transported by direct link conveyor between two stages of manufacure or process may be diverted to the buffer system by a number of means. Figure 3 illustrates rod shaped products 36 being transferred by the drum 21 to the reservoir belt 15 travelling around the return wheel 19. The drum 21 is provided with internal vacuum chambers 41 actuated in such a fashion that articles adhere to suction ports 42 at point 43 and are released at point 44. At this point the articles are transferred to the reservoir belt 15 and are held in place by stationary wires or plates 23. When the reservoir belt is required to return articles to the direct link conveyor they are transferred at point 44 held by suction to point 46, transferred to suction drum 27 and released at point 48. Alternatively, where the first stage of manufacture is fitted with a delivery suction drum 50 (shown in chain lines), the suction drums 21 and 27 may be dispensed with, the transfer of articles to the direct link conveyor taking place at point 44.

Figure 5 illustrates a system where articles are being conveyed in pockets on a direct link conveyor C. The reservoir belt of the arrangement of Figure 5 (but also of any other example) may comprise links 49 capable of containing multiples of rod shaped articles or single rectangular products (see Figures 6a and 6b).

When articles reach the run 52 of the belt 15 they are transferred by pushers represented schematically at 56 into the pockets in the reservoir belt 15 and taken to the loaded reservoir drum 13. When return ing articles to the direct link conveyor, the belt 15, shown in interrupted lines, is lowered by wheels 50 on levers 54 so that the run 52 coincides with the direct link conveyor band at point 55 and articles are transferred by pushers 57.

Another arrangement of the storage buffer is shown in Figure 7 in which products are discharged into an intermediate hopper 71 and then released onto a direct link conveyor band C. The reservoir belt 15 is drawn off the drum 11 and passes over idler rollers 78,79 to a run 73, between rollers 74, aligned with the conveyor band C. The articles are transferred sideways into the reservoir belt 15 and taken up to the loaded belt drum 13. When required to return articles, the reservoir belt 15 is reversed thus returning articles around wheel 70 to the hopper 71 at point X and from there discharges the products onto the conveyor band C to point 76 where they are discharged into hopper 77.

Figure 8 illustrates a suitable reservoir belt with upright dividers 81, the leading edges of which are shaped in a mannerto prevent articles from colliding, or jamming, at the moment of transfer.

In the example of Figure 9 the products are conveyed between bands 91,92 and plates 93. The reservoir belt 15 is accommodated as described above on two drums 11, 13. When articles are to be loaded or diverted to the reservoir belt 15 the band 92 stops and the articles are routed upwards between bands 94 and are transferred to reservoir belt pockets travelling around drum 99 at point 95. A limited drum 96 with flaps or bushes regulates the quantity of articles to be carried in the pockets of the reservoir belt 15. To return articles to the direct link conveyor 91, 92 the system is reversed, band 91 stopping and band 92 starting.To minimise compression of articles in the storage belt as it is wound round the loaded reservoir drum, the reservoir belt 15 may be fitted with portions 100 and flexible hammock-like pieces of material 101 (Figure 10) which deform towards the corners of the pockets as the belt curves.

The reservoir belt 15 may be supported by a pivoted guide 97 raised and lowered by mechanism 98.

In Figures 11,12, 13 and 14 two or more sets of storage and take-up drums and other related equipment are shown installed side by side, and for the sake of clarity reservoir belt 15 are only shown in Figure 12. Vertical side frames 111, mounted on the floor, on machinery or from above the direct link system between two stages of process or manufacture, are spaced to contain, say, three sets of loaded drums 112, take up drums 113 and return wheels 114, each set separated by upright dividing plates 115. Sufficient space between the upright frames is left to enable the three sets of drums and wheels to be indexed sideways as shown in interrupted lines on Figures 11 and 13. Articles are transferred to a reservoir belt at point 116.

When a loaded reservoir drum is fully wound and incapable of taking in any more articles or, conversely, when drums are fully unloaded and articles are still available in one or both of the other storage drums, all three sets of drums and wheels are indexed laterally by pusher rods 117 passing through the side frames. The three sets of loaded, take up drums and pick up wheels, reservoir belts and ancillary equipment are mounted on three composite shafts also mounted on the side frames.

Each of these shafts consist of a rotating inner drive shaft 118 and outer bearings 119. The bearings 119 are static and affixed to the side frames. Splined gears, or wheels, or electro-magnetic couplings 110 are fitted at the mid-point of the drive shafts 118.

which rotate one set of loaded drum, take up drum and pick up wheel. The bores of all the drums and wheels are also splined, or contain magnetic couplings. By these means only the drums and wheel of the set in action rotate, the other two sets remaining idle. Actuating mechanisms (not shown) are fitted to pusher rods 117, causing them to traverse, thus indexing all three sets of drums and wheels at the same time. The drive shafts 118 are rotated by reversible and variable speed drive motors actuated, or controlled, by sensors arranged at point 116 at direct-link conveyor level or combinations thereof.

The transfer of articles at point 116 is momentarily interrupted when change overs take place. To facilitate the change over action, a portion of each belt 15 at the end thereof is smooth on both sides whereby during lateral translation the articles sustain no damage which could otherwise result if dividers were present and additional stationary or movable fingers, plates or wheels and conveyor belts may be arranged at this point 116.

The arrangement illustrated in Figures 15 and 16 is based on the same principle of winding cigarette reservoir belt round a loaded conveyor drum and a take up drum.

Whereas the earlier described arrangements have two single spaced apart drums, the modification of Figures 15 and 16 has a flexible or linked track or band extending between two drums. The flexible track 131 is supported by a fixed plate 132 and a movable suppot plate 135 which rises and falls as necessary. The track is driven by a sprocket wheel 134 and passes around an idler sprocket 136. The extreme end of the reservoir belt is attached to the track at a shoulder 135. The empty reservoir is wound round a similar pair of sprockets 136 also carrying a track similar to 131. This second set of sprockets and track may be arranged at the side of the loaded reservoir drums and track as illustrated in Figure 16 or on top. Empty, or take up drums of the example shown in Figure 1 may also be arranged alongside take up drums in order to reduce the total height of the system.

Alternatively the tracks could be arranged one above the other.

The bulk buffer storage arrangement shown in Figure 17 is arranged in the region of a packer hopper 140. A delivery conveyor band 141 passes over a pulley 142 which is mounted for horizontal movement towards and away from a reservoir belt 15. As described above, the latter can be stowed on a drum 11 and can be withdrawn therefrom when buffer storage is required. The storage is effected by winding the reservoir belt 15 around a take-up drum 13.

To accommodate the change in length of the conveyor 141, a loop 150 passing around idler pulleys 146, 147 and 148 is provided.

If the packet stops the pulley 142 traverses to the right to cut off the feed to the hopper and instead deliver the product to the reservoir belt 143. On start up the pulley 142 retracts to the left. If the maker stops then the reservoir belt reverses and feeds the buffered product to the hopper.

While the above descriptions portray systems placed above points between two stages of process, reservoir drums may be sited below direct link conveyors and/or at unlimited distances and the runs of reservoir belt itself may follow an infinite variety of routes. By using reservoir belts capabie of being articulated in more than one direction they may be arranged to turn at right angles thus enabling drums to be mounted at right angles to each other or face to face.

Claims (15)

1. A buffer storage apparatus for receiving a product normally travelling along a path from one location to another, comprising an elongate reservoir movable in the direction of its elongation from a stowed position, past a predetermined region to receive the product and thereafter to a product storage position.

2. A buffer storage apparatus as claimed in claim 1, including a first core for stowing said elongate reservoir from which core said reservoir is drawn when buffer storage is required.

3. A buffer storage apparatus as claimed in claim 2, including a second core in the product storage position onto which core the reservoir belt winds when buffer storage is required.

4. A buffer storage apparatus as claimed in claim 1,2 or 3, including a pick up drum for location adjacent the path of travel from one location to another, and a belt return wheel disposed at a transfer region between said pick up drum and a portion of said belt between the stowed position and the storage position.

5. A buffer storage apparatus as claimed in claim 4, including a return drum adjacent said pick up drum whereby on reversal of said reservoir belt direction when supply from said buffer storage is required the pick up drum feeds the return drum from which the product is returned to the path of travel.

6. A buffer storage apparatus as claimed in claim 1,2 or3, including a pair of wheels over which the elongate reservoir passes and between which there exists a linear transfer region which is arranged to align with the forward feed product path of a product conveyor during buffer storage demand, and pusher means at said transfer region for moving the product laterally in relation to said reservoir belt to transfer the product from the conveyor to the reservoir belt during buffer storage demand.

7. A buffer storage apparatus as claimed in claim 6, wherein levers are provided to support said pair of wheels and to shift said wheels from said transfer region to a return region whereby the linear transfer region of the belt is aligned with the return run of the conveyor, and further pusher means for moving said product laterally from the linear transfer region of said reservoir belt to said conveyor.

8. A buffer storage apparatus as claimed in claim 1, 2 or 3, including a conveyor belt for conveying said articles between said locations, a pair of wheels over which the elongate reservoir belt passes between which wheels there exists a linear transfer region which is arranged to align with a forward feed path during buffer storage demand, pusher means adjacent said transfer region and a reservoir belt return wheel around which said belt passes to form a loop, whereby on buffer storage demand the product is transferred from the forward run of the conveyor to the reservoir belt and on reversal of the belt the articles are transferred from the belt to the forward run of the conveyor via the loop.

9. A buffer storage apparatus as claimed in claim 1,2 or 3, including a pair of conveyor belts disposed substantially vertically above said path of travel between the latter and the reservoir belt, forming between them a lifting channel which delivers the product to the reservoir belt on buffer storage demand.

10. A buffer storage apparatus as claimed in claim 3, wherein a plurality of reservoir storage belts are provided side by side on pairs of stowage and take up drums, means being provided to feed said belts sequentially during buffer storage demand in accordance with the extent of the demand.

11. A buffer storage apparatus as claimed in any one of claims 1 to 10, wherein the reservoir belt comprises a series of linked compartments for receiving groups of cigarettes or individual articles or packages.

12. A buffer apparatus as claimed in any one of claims 1 to 10, wherein the reservoir belt comprises a series of partitions providing separate compartments along the belt and for spacing the turns of the belt to prevent crushing of the product.

13. A buffer storage apparatus as claimed in claim 1, 2 or 3, including a conveyor belt horizontally disposed for feeding the product to a hopper of a packer, and a roller for supporting one end of the conveyor belt, said roller being movable in the horizontal direction towards and away from said removing means whereby on buffer storage demand the conveyor extends beyond the hopper to deliver the product to the reservoir belt.

14. A buffer storage apparatus as claimed in any one of the preceding claims when appended to claim 3, wherein one or both cores comprises a flexible or linked trade extending between two drums.

15. A buffer storage apparatus substantially as described herein with reference to the accompanying drawings.