GB2168311A

GB2168311A - Package handling apparatus

Info

Publication number: GB2168311A
Application number: GB08429377A
Authority: GB
Inventors: Kenneth Winston Franklin
Original assignee: Bishopbarn Ltd
Current assignee: Bishopbarn Ltd
Priority date: 1984-11-22
Filing date: 1984-11-22
Publication date: 1986-06-18
Also published as: GB8429377D0; GB2168311B; JPS61142102A

Abstract

Package handling apparatus for packages such as potato crisp packages is used to pack these packages in layers into a carton 46. The apparatus comprises a row receiving station based on an indexing conveyor 26 and packages are collated, one row at a time at the receiving station. A layer collating table 37 is offset from the row receiving station and a row transfer device 31-34 is arranged to transfer the rows of packages from the receiving station to the table and to deposit the rows thereon in such a position as to produce a layer of packages. The table, complete with a layer of packages is traversed to a position below a vertically movable loading head 41 having suction cups 42 for holding the layer of packages thereon. The table is withdrawn from under the head and the head lowered into a carton 46 to deposit the layer therein. Subsequently layers are collated and lowered into the carton in a similar way, with the downward strokes of the head being successively shortened. A control system employing PROM units permits the apparatus to handle various sized packages. The apparatus may be adjusted to provide overlap of packages within each layer or not. A leak-testing unit 19-23 and a weighing station is provided upstream of the conveyor 26. <IMAGE>

Description

SPECIFICATION Package handling apparatus The invention relates to package handling apparatus. The invention is concerned particularly but not exclusively with apparatus for packages such as potato crisps packs which have tapered edges and which are conveniently packed into cartons with the edges overlapping. The apparatus of the invention may also be used in connection with more regularly shaped packages which do not require overlapping but an attractive feature of the apparatus of the present invention is that it can easily be adapted for use with packages which do require an overlap.

In accordance with the present invention there is provided package handling apparatus for packing packages in layers into a carton comprising a row receiving station, means for collating rows of packages, one row at a time at the receiving station, a layer collating table, row transfer means for transferring the rows of packages from the receiving station to the table and depositing the rows thereon in such positions as to produce a layer of packages, a vertically movable loading head, means for traversing the table complete with layer of packages to a position below the loading head, means on the loading head for holding the layer of packages thereon, means for withdrawing the table from under the head and means for lowering the head into a carton to deposit the layer therein.

Preferably the row receiving station comprises a conveyor set to be driven in steps corresponding to the desired spacing of adjacent packages, and means for indexing the conveyor in response to sensing arrival of a package at an input location on the conveyor. The row receiving station may comprise a sensor for sensing the presence of a package at a position on the conveyor so spaced from the input location as to be indicative of the presence of a complete row and operation of this sensor may then activate the transfer means.

The transfer means may include at least one row of suction heads. When two rows of suction heads are provided side by side, the transfer means may be indexed laterally after one row of suction heads has collected a row of packages to enable the other row of suction heads to collect a row of packages.

The means on the loading head for holding a layer of packages may also comprise an array of suction heads.

Preferably the transfer means is operated in response to sensing a complete row of packages at the receiving station and after collecting the row of packages therefrom it is indexed laterally of the row through a distance controlled by a pre-programmed sequence to ensure movement through a suitable distance to build up a desired layer pattern.

The transfer means may be driven by an electric motor equipped with an encoder to signal the distance through which it has driven the transfer means such that the control system stops the mo tor after a desired rotation to control the move ment of the transfer means.

The loading head may be operated in response to arrival thereunder of the collating table and may then be lowered vertically through a distance controlled by a pre-programmed sequence to ensure movement through a suitable distance to deposit each successive layer above the immediately preceding layer.

The loading head may be driven by an electric motor equipped with an encoder to signal the distance through which it has driven the head such that the control system stops the motor after a desired rotation to control the movement of the head.

The individual packages and the rows may be collated into rows and layers in such a way that the packages and rows overlap each other.

An embodiment of the invention will now be described with reference to the accompanying drawing which is a pictorial view of a complete handling apparatus in accordance with the invention.

The apparatus shown incorporates a slightly modified version of the apparatus disclosed in our published UK Patent Application No. 2138150 and that part of the apparatus will be described only briefly. The invention will be described in relation to the handling of a series of packs of potato crisps but it should be understood that it could be used with packages of other products.

In general, the apparatus incorporates a conveying and testing section 11, a layer collating section 12 and a carton loading section 13.

Individual packs of crisps which have just been filled arrive one at a time at a pocket 14. A rotary transfer mechanism 15 incorporates three suction heads 16 which rotate in steps around a horizontal shaft 17 in steps in such a manner as to pick up individual packs of crisps and transfer them to a belt conveyor 18. Conveyor 18 passes under three probing stations 19, 21 and 22 at each of which a series of weighted probes are applied to the pack in such a way as to partially compress it if it incorporates a substantial air leak. The third probing station 22 incorporates a sensing element 23 which senses the distance through which the weighted probes descend on to the pack and provide a measure as to the airtightness of the pack. Further details of the arrangement just described can be obtained from UK Patent Specification 2138150.

Conveyor 18 is of course arranged to index the individual packs in steps and thus the packs leave the probing station 22 one at a time.

From conveyor 18 each individual pack is transferred to a short upwardly inclined conveyor 24 and the conveyors are operated in such a way that the pack comes to rest on this conveyor. Conveyor 24 is then pivotted downward to leave the pack supported on a weighing platform 25 at which it is checked whether the pack lies within prescribed weight limits. Any pack which is found to be unsatisfactory, either due to leakage or due to having the wrong weight, is ejected laterally from the apparatus by means not shown.

In the layer collating section 12, a further con veyor 26 is the primary element in a row receiving station. Each pack leaves the conveyor 24 in its elevated condition as shown and is discharged onto the conveyor 26 which at this stage is stationary.

As a further pack arrives at the weighing station, namely on conveyor 24, this is signalled by a sensor 27. The combination of the arrival of a pack at the weighing station and checking that it has the correct weight, causes the control system to index the conveyor 26 through a distance equivalent to the required distance between adjacent packs in a row of such packs to be loaded into a carton. Almost simultaneously, the new checked pack on the conveyor 24 is moved forward onto the conveyor 26 immediately behind the preceding pack. When an overlap is required, the indexing distance of conveyor 26 should be less than the width of a pack by the required overlap distance so that the new pack will overlap the preceding pack as it is discharged onto the conveyor 26.The elevation of conveyor 24 enables the new pack to be deposited partially above the preceding pack in an orderly manner without pushing it forward.

This process continues until the required number of packs has been built up on the conveyor 26 to form a complete row. In this example, four packs are required for each row. A sensor 28 senses when the first pack to arrive on conveyor 26 has indexed three times, thereby indicating that a total of four packs have been collated to form a complete row on the conveyor 26.

A row transfer means 29 incorporates a carriage 31 capable of traversing laterally in parallel guides 32 and 33. In this example, the carriage incorporates two longitudinal rows of four suction heads 34. Each row of suction heads can be operated separately from its own supply. Carriage 31 is driven along guides 32 and 33 from an electric motor 35 through a toothed belt 36. The shaft of the motor 35 carries an encoder (not shown) which measures the rotation of the motor to enable the control system for the apparatus to stop the motor after a predetermined rotation and thus after a predetermined distance of travel of the carriage 31. A brake for the motor ensures that it is stopped accurately in its desired position.The carriage 31 can be traversed from a position over the conveyor 26 constituting the row receiving station to a layer collating table 37 which will be described subsequently in greater detail.

The row transfer means operates as follows.

When sensor 28 indicates the presence of a complete row of packs on conveyor 26, the row of suction heads 34 shown nearer the front of the drawing are operated to cause them to pick up the row. In response to this operation, the carriage 31 is indexed laterally to bring the second row of suction heads directly over the conveyor 26. Meanwhile, a second row of packs is being built up on the conveyor 26. On completion of the second row, sensor 28 causes the second row of suction heads to be operated to pick up the second row. With both rows of packs supported on the suction heads 34, the carriage 31 is traversed to a position directly over the collating table 37 and release of suction allows the packs to be deposited on the table. An angled guide 38 helps to define the area of the table in which the layer of packs is to be deposited and helps to hold the packs in position.

A high degree of flexibility is available for the number and position of packs in a layer. For example, when three rows are required, the spacing between the two rows of suction heads 34 may be such as to provide for the two outer rows. Then, in a subsequent traverse, only one row of suction heads 34 is used to pick up one row of packs and this row of packs is deposited between the two extreme layers, overlapping to a desired extent depending on the initial spacing chosen. Similarly, a total of four layers could be achieved by two traverses each with both rows of suction heads 34 occupied by packs. Furthermore, it would be possible to provide a single row of suction heads 34 and to deposit two or three or more rows to build up the required layer. The angled guide 38 is of course removable or movable to take account of the pattern required for the layer.Similarly, the number of suction heads in each row and the spacing thereof may be adjusted to cater for packs of different lengths or for different required overlaps within a particular row. Of course, the distance indexed by conveyor 26 on arrival of each pack would also have to be adjusted correspondingly. This wide degree of flexibility with regard to dimensions and spacing of packs renders the apparatus particularly versatile and flexible. For example, with an electronic control system it is possible to employ a single PROM unit incorporating all the required data for a given kind of pack. In that case, all that is needed to change the equipment from one kind of pack to another is to change over from one PROM to another.In addition to controlling the movement and operation of the row transfer means, the PROM unit may also carry information such as the acceptable range of weights of pack to be allowed past the weighing platform 25.

After the sequence of operation of the row transfer means 29 has been completed to indicate that a complete layer of packs has been built up on the table 37, the table is traversed (to the left in the drawing) to a position where the layer of packs thereon lies directly underneath a loading head 41.

The loading head carries an array of suction heads 42 in such numbers and positions as to be capable of supporting all the packs in the layer on table 37.

Head 41 is movable vertically with respect to a guiding support 43. An electric motor 44 drives the head 41 up and down vertically through a mechanism such; as a rack and pinion which is not shown. Motor 44 is equipped with an encoder and brake to enable the displacement of the loading head 41 to be monitored and controlled.

The table 37 can be traversed horizontally by means of a cylinder 45 between the position shown and a position where the layer of packs thereon lies directly below the suction heads 42 of the loading head 41. Operation of the suction heads 42 causes the complete layer of packs to be supported on the loading head 41. The collating table 37 is then retracted by means of the cylinder 45 to the position shown ready to receive the next row or rows of packs.

A carton 46 (shown in ghost) is in position immediately below the loading head 41. The complete layer of packs supported on the loading head 41 is then lowered into the carton 46, almost to the bottom of the carton. Suction is then withdrawn from heads 42 and the complete layer is released in an orderly manner in the bottom of the carton.

The loading head 41 is then retracted by motor 44.

A second layer which has meanwhile been building up on the table 37 is then transferred to the loading head 41 in the same manner as for the first layer and this second layer is lowered into the carton to such a depth that the second layer is positioned immediately above the first layer. This second layer is then released. The whole process is repeated with successively shorter down strokes for the loading head 41 until such time as a carton has been filled. The same PROM unit as is used for controlling the row transfer means may also incorporate the necessary variables to control the depth to which the loading head is lowered on each successive occasion.

The apparatus also incorporates a carton loading section by virtue of which empty cartons are delivered to a station 51 on a gravity roller conveyor.

Short rollers 52 are retracted when a carton is required so that the carton drops down on to a carton platform 53. When the carton immediately below the loading head 41 has been filled, an arm 54 causes it to be traversed laterally. After retraction of arm 54, an empty carton on the platform 53 is driven into the position immediately below the loading head by means of a pusher 55. A microswitch 56 senses when the carton is in position and by this means allows the loading head to be lowered again to start filling the new carton. Full cartons are then pushed away from the apparatus by means not shown to a conveyor or other source for distributing the completed cartons.

The apparatus thus constitutes a simple and effective package handling apparatus for loading packages such as potato crisp packs into cartons. A high degree of flexibility is available as to the size of pack which can be handled by the apparatus and adaptability of the apparatus from one kind of product to another of different dimensions is very simple and quick.

Claims

1. Package handling apparatus for packing packages in layers into a carton comprising a row receiving station, means for collating rows of packages, one row at a time at the receiving station, a layer collating table, row transfer means for transferring the rows of packages from the receiving station to the table and depositing the rows thereon in such positions as to produce a layer of packages, a vertically movable loading head, means for traversing the table complete with layer of packages to a position below the loading head, means on the loading head for holding the layer of packages thereon, means for withdrawing the table from under the head and means for lowering the head into a carton to deposit the layer therein.

2. Package handling apparatus as claimed in claim 1 wherein the row receiving station comprises a conveyor set to be driven in steps corresponding to the desired spacing of adjacent packages, and means for indexing the conveyor in response to sensing arrival of a package at an input location on the conveyor.

3. Package handling apparatus as claimed in claim 2 wherein the row receiving station comprises a sensor for sensing the presence of a package at a position on the conveyor so spaced from the input location as to be indicative of the presence of a complete row and wherein operation of this sensor activates the transfer means.

4. Package handling apparatus as claimed in any one of the preceding claims wherein the transfer means includes at least one row of suction heads.

5. Package handling apparatus as claimed in claim 4 wherein two rows of suction heads are provided side by side and wherein the transfer means is indexed laterally after one row of suction heads has collected a row of packages to enable the other row of suction heads to collect a row of packages.

6. Package handling apparatus as claimed in any one of the preceding claims wherein the means on the loading head for holding a layer of packages comprises an array of suction heads.

7. Package handling apparatus as claimed in any one of the preceding claims wherein the transfer means is operated in response to sensing a complete row of packages at the receiving station and after collecting the row of packages therefrom is indexed laterally of the row through a distance controlled by a pre-programmed sequence to ensure movement through a suitable distance to build up a desired layer pattern.

8. Package handling apparatus as claimed in claim 7 wherein the transfer means is driven by an electric motor equipped with an encoder to signal the distance through which it has driven the transfer means and wherein the control system stops the motor after a desired rotation to control the movement of the transfer means.

9. Package handling apparatus as claimed in any one of the preceding claims wherein the loading head is operated in response to arrival thereunder of the collating table and is lowered vertically through a distance controlled by a preprogrammed sequence to ensure movement through a suitable distance to deposit each successive layer above the immediately preceding layer.

10. Package handling apparatus as claimed in claim 9 wherein the loading head is driven by an electric motor equipped with an encoder to signal the distance through which it has driven the head and wherein the control system stops the motor after a desired rotation to control the movement of the head.

11. Apparatus as claimed in any one of the preceding claims wherein the individual packages are collated into such a way that the packages overlap each other.

12. Package handling apparatus as claimed in any one of the preceding claims wherein the individual rows are built into a layer in such a way that the packages of one row overlap packages of another row.

13. Package handling apparatus substantially as described with reference to and as illustrated by the accompanying drawing.