GB2522239A

GB2522239A - Method of inserting a tray into a box

Info

Publication number: GB2522239A
Application number: GB1400854.4A
Authority: GB
Inventors: Elton Jeremy Nunes
Original assignee: Individual
Current assignee: Individual
Priority date: 2014-01-19
Filing date: 2014-01-19
Publication date: 2015-07-22
Also published as: GB201400854D0

Abstract

Two conveyors 7-9 are vertically disposed and inclined to converge towards each other at their downstream ends. Items 2 on the upper conveyor 8 can enter containers 1 on the second conveyor 8, 9 at an angle so that the front of the item contacts the interior surface of the front of the container wall first. Ideally the container is an open box 1 and the item is a tray of confectionary 2. Prior to insertion, an item and its corresponding box can both be conveyed by a single pusher 11. Ideally the pusher has two surfaces at different angles so that one surface is perpendicular to the direction of travel of the item 2, the other being perpendicular to the direction of travel of the box 1. Ideally the pushers are mounted on a continuous belt 22. The items on the upper conveyor may move faster than those on the lower conveyor. It can be the lower conveyor which is sloped 9.

Description

Method of Inserting a Tray into a Box

Field of the Invention

This invention relates to a method and apparatus to place a first object onto or into a second object and has particular but not exclusive application to inserting a tray into a box. It has further particular but not specific application to inserting, e.g. a confectionary tray, into an open-topped box.

Background

in the confectionary industry, it is known to provide confectionary items such as chocolates into a flexible tray, which is then placed into a box. Currently trays filled with chocolates and such like are inserted manually into a box. Although the human can readily place the filled tray into a box accurately using sight, this obviously requires extra personnel on a production line to implement this task.

It is an object of the invention to provide an automated method of inserting trays into boxes which is robust, quick and accurate.

Statement of the invention

In a first aspect is provided a method of inserting a first object onto or into a second generally planar object comprising arranging said first object generally above said the second object, and conveying said first object in a generally horizontal direction to a confluence with said second object wherein on contact the second object is inclined in a vertical plane at an angle a to the direction of movement of the first object.

Additionally or alternatively on contact the second object is inclined in a vertical plane at an angle a to the orientation of the first object when the first object is also a substantially planar object.

The method may include conveying the second object at the point of contact in the same direction in a horizontal plane as the first object and at a relative vertical angle a.

The second object may have generally an open box form including a front wall and arranged such that on contact, the front end of the first object abuts/contacts the front inner wall of the second component.

The method may comprise conveying the first object along a first platform and conveying a second object along a second platform in the same general horizontal direction, the first platform being disposed above the second platform and being co-aligned in the horizontal plane, wherein one or more of the platforms have an inclined/sloped portion at its distal end to form said confluence.

The horizontal component of speed of travel of said first object may be greater than the horizontal component of speed of travel of said second component.

Preferably the lower platform has a portion, which is sloped upwards at an angle a.

Preferably the objects are conveyed to said confluence by a common pushing element.

The common pushing element may comprise one or more pushing arms, said pushing arms have a contact portion which includes at least one substantially perpendicular portion and/or a profiled portion.

As the first or second object are transported along said sloped portion(s), said profiled portion of the pusher arm preferably engages with a correspondingly formed side of the first or second object to provide substantially intimate contact therebetween.

The profiled portion may be sloped, adapted to be engaged with a substantially straight perpendicular side of the second object.

Preferably the sloped portion is at an angle to the non-sloped portion substantially the same as angle a.

Preferably said pusher element or arm(s) is arranged on a continuous belt system.

The first object may be a confectionary tray.

In a second aspect is provided an apparatus for placing a first object onto or into a second generally planar object comprising a first platform and a second lower platform said first platform being arranged generally above said second platform, and means to convey said first object along said first platform in a direction towards a confluence with the second object such at the confluence the second object is inclined vertically at an angle a to the direction of movement of the first object.

The apparatus may include means to convey the second object in the same direction in a horizontal plane as the first object and at a relative vertical angle a.

The apparatus may be adapted to convey the first object along a first platform and conveying a second object along a second platform in the same general direction, the first platform being disposed above the second platform and having a common axis, wherein one or more of the platforms have an inclined/sloped portion at its distal end to form said confluence.

The lower platform may have a portion which is sloped upwards at an angle a.

The apparatus may have means to convey the objects to a confluence by a common pushing element.

The pushing element may comprise one or more pushing arms, said pushing arms have at least one substantially perpendicular portion and/or a profiled portion.

An apparatus may be adapted so as to convey said first or second object along said sloped portion(s), during which said profiled portion(s) of the pusher arm is adapted to engages with a correspondingly formed side of the first and/or second object to provide substantially intimate contact therebetween.

The sloped portion may be at an angle to the non-sloped portion substantially the same as angle a.

The pusher element may be arranged on a continuous belt system.

The term "generally horizontal direction" does not necessarily mean substantially horizontal but having the major component of travel in a horizontal direction.

Brief Description of Drawings

The invention will now be described by way of examples and with reference to the following figures of which: Figure 1 illustrates a basic embodiment of the invention; Figure 2 shows a view of the embodiment of figure 1 at the point where a conveyed tray and box make contact; Figure 3 illustrates a further basic embodiment of the invention; Figures 4a and b show an advanced embodiment of the invention, and specifically show a plan view and side view respectively; Figure 4c shows the side view of a pusher element/arm according to one aspect; Figure 5a and Sb are similar to figures 4a and b but include also the framework for the components of the figure 4 arrangement; Figure 6a and b show an end elevation and plan views respectively according to one embodiment which shows the tray and box support platforms and illustrates an example of a pusher arrangement; Figure 6c shows schematically how the tray may be arranged on a tray support platform additionally guided by guide rails; Figures 7a and b show schematic plan and sectional side views of an alternative arrangement according to an alternative embodiment; Figure 8 is a side view showing schematically an alternative embodiment.

Detailed Description of the Invention

Figure 1 shows basic embodiment of the invention. A box 1, adapted to receive a tray 2, is brought into a correctly aligned position, along a sloped bench/support or conveyor belt 3. The box may be brought to this the correct position by any suitable method known in the art, such as by a pusher mechanism or by a conveyor belt. Control of the positioning may be provided by appropriate programming and the use of positional detectors also known in the art.

A tray is arranged vertically above the box by transporting it (conveying the tray) so as to bring the tray into contact with, and on top of the box. Again, the tray may be moved towards the box by conveyor means 4 such as a belt or pusher mechanism. The sloped bench support/conveyor 3 is aligned at an angle a to the conveyor/support 4 and thus arranges the box at the same angle.

Fignre 2 shows the position of the tray and the box just before contact. By arranging the tray to be located above the box and arranged to move relatively to the box in a generally horizontal directional, and wherein the box is arranged on a slope (such that there is an angle between the plane of the box and the tray), provides a way in which the tray is received into the box and the front end of the tray pushes against the inner wall of the box. After contact the tray will push against the inner wall of the box and thus the tray and box move together in the later direction as shown by the arrow during a which process the tray will drop into the box gently. The slope/ angle a provides said initial contact between the outer tray wall and inner box thus ensuring alignment so that the rest of the tray will slip into the box. The box may be further conveyed at any time and in particular especially at the time point of contact so that the tray and box move together onwards as the tray falls into the box.

Figure 3 shows an alternative arrangement where the above referenced effect is provided by arranging the box and tray to be brought together by respective conveyor belts 5 and 6, which are aligned at an angle a between each other in the vertical plane.

Preferably the (horizontal component of) speed on the tray is greater than that of the box.

Such embodiments ensure that a tray can be inserted into a box with a degree of reliability and alignment. Tn some of such embodiments there may be needed further positional control. In further advanced embodiments as will be described hereinafter, reliability is further ensured by increasing the alignment and positioning reliability via robust, effective and relatively simple means without the need for several sensors and/or careful speed/positioning control.

Figures 4a arid b shows such an advanced embodiment of the invention, and specifically shows a plan view and side view respectively of an apparatus to insert trays into boxes in a quick reliable fashion. As can be seen from the side elevation, the basic feature of the mechanism provides a tray support platform 7 which is arranged vertically above and in alignment when viewed from plan view with a box support platform 8. During the production process, the tray 2 is brought onto the tray support platform and the box 1 onto the box support platform (arranged underneath the tray platform). Tt would be clear to the skilled person how this could be achieved i.e. by conveyor belts or other mechanisms.

As can be seen from the elevation view, the lower box support platform has an inclined portion 9. Again similar to the previous embodiments this provides an angle a between the orientation of the box and tray in the vertical plane. In operation both the box and the tray are transported/conveyed in the direction of the arrows by means which will be explained in greater detail hereinafter. This could be by the platforms being conveyor belts or pushing (actuation) elements.

As the tray and box are propelled in the direction of the arrow, the box rises up at an angle a along the inclined portion of the box platform. Similar to the figure 1 embodiment, the relative angle between the general plane of the tray and box ensures that they come together in a gentle fashion such that the tray does not simply fall into the box, but is gradually inserted into the box by gravity and in a gentle fashion which due to the said relative angle between the tray and the box, ensure the tray is correctly inserted into the box.

Furthermore such an arrangement allows the front outer end of the tray to abut (make initial contact) against the inner front wall of the box, again ensuring alignment in an automatic fashion without requiring complex control or additional sensors. As mentioned this ensures that firstly the tray is gently "dropped" (inserted) into the box and also ensures that the box and tray do not have to be accurately positioned.

The figure also shows one or more guiding rails or guide walls lOa, lOb for the box and the tray respectively to ensure correct alignment in vertical plan of the box and tray.

The tray and box support platforms may comprise conveyor belts, these belts may be tightly controlled along with positional detection means (e.g. optical sensors) to ensure correct and accurate lateral alignment; particularly at the time/point of contact of the box and tray.

Alternatively a pusher member/element 11 including two (or any number of) arms 12 may be utilised to transport/propel the boxes forward in the direction of the arrow rather than via a conveyor belt.

Although such advance embodiments provide advantages over the figure 1 and 3 embodiments, the reliability and cost of the alignment systems can be improved according to further preferred embodiments, which will be described hereinafter, so as to provide an accurate, robust and quick method of correctly aligning the tray and box without the need for tight control and detection sensors.

In such advanced embodiments, this is provided by the use of a common pusher element 11. The common pusher element is arranged to convey both box and tray together, at the same time, thus ensuring the box and tray are appropriately aligned as they are conveyed together towards the confluence by the front surface of the pusher element abutting (coming into contact with) the end of the tray and the end of the box. The pusher element may include one or more pusher arms 12 as shown in figure 4a. The pusher element/pusher arms 11/12 are generally aligned vertically and abut against both the box and the tray at the same time and move them both together; by having a common pusher element the lateral alignment of the box and tray is ensured.

The pusher element (pusher arms) is adapted to be able to move the box and tray in the direction of the arrows. It may comprise a mechanism such as pneumatic mechanism to move the pusher backwards and forwards in translational reciprocating movement.

However in a preferred embodiment as will be described in more detail, the pusher element is arranged along a conveyor belt type and moves around in conveyor belt type fashion. The pusher element (pusher arms) may be arranged on either (or both sides) of the platforms or in a (e.g. central) slot form in the platforms.

In yet a frirther refinement, as shown in figure 4e, the pusher element/pusher arms advantageously has contact surfaces which includes a vertical portion 13 at the top where it comes into contact with the side of the tray when the tray is transported along the first platform, and a similar small perpendicular vertical portion 14 (perpendicular to the horizontal axis) toward the bottom portion. The pusher element includes a sloped or profiled portion 15, which is generally at the same angle as the angle of incline of the inclined portion of the box support platform. As can be seen from figure 4b this inclined portion ensures intimate (good) contact with the outside of the box as it is propelled upwards along the inclined portion of the box support. The profiled portion may be any shape that corresponds to the side wall of the object (e.g. box) transported along the bottom platform.

Figure Sa and Sb are similar to figures 4a and b but include also the framework 22 and support guides 23 for the components of the figure 4 arrangement.

Figure 6a shows an end elevation according to one embodiment which shows how the tray and boxes are brought onto the tray and box support platforms and illustrates an example of a pusher arrangement. Guide walls 16 are disposed either side of the tray and box support platforms 7 and 8. The pusher clement here comprises two pusher arms 12 located between the guide walls and the tray and box support platforms shown in figure 6b. Of course in alternative embodiments, one or more pusher arms may be arranged in a (e.g. central) slot in both platforms. The guide walls may include guide rails 17; these are useful and can be used to support a tray which may have a lip 18 as shown in figure 6c. The box and tray may be brought onto the respective support platforms by conveyor belt means 19 disposed in a direction which is perpendicular to the direction of movement of the box and tray in the support platforms in the horizontal plane, this has advantages in terms of spatial arrangement as shown in figure ób.

Figure 6b shows the schematic plan view of the arrangement showing one embodiment of the arrangement of the pusher arms. The tray platform is disposed vertically above the box platform shown.

The guide walls 16 are disposed generally on either side of the platforms. The guide walls may include cut out sections to allow the box and tray to be loaded onto the respective platforms. The two pusher arms 12 are located on two belts drives 22, the belts are driven as shown by the rotational arrows such as to make contact with the box and tray on the platforms. Both the guide rails and/or the pushers arms ensure the box and tray are correctly aligned during forward movement in the direction of arrow A plan and so providing a robust system where the box and tray only have to be roughly aligned on the platforms as they come off their supply conveyors (e.g. belts).

Of course the invention is not limited to such embodiments. Figure 7a and 7b shows an alternative arrangement showing schematic plan and side views respectively wherein there is a single pusher element/ arm 11/12 which is arranged to move in a slot 20 cut in the tray and box platforms 7/8. The pusher element is again located along a drive belt 22, the belt drive wheels being located perpendicular to the platforms underneath them.

In the above embodiments, the box platform has an inclined portion such that the tray and box come into contact the general plane axis of the tray is at an angle to the planar axis of the box.

Of course in alternative embodiments the tray platform 7 may have a portion 21, which slopes downwards instead of the box platform 8 as shown in figure 8.

Claims

Claims 1. A method of inserting a first object onto or into a second generally planar object comprising arranging said first object generally above said second object, and conveying said first object in a generally horizontal direction to a confluence with said second object wherein on contact the second object is inclined in a vertical plane at an angle a to the direction of movement of the first object.
2. A method as claimed in claim 1 including conveying the second object at the point of contact in the same direction in a horizontal plane as the first object and at a relative vertical angle a.
3. A method as claimed in claims 1 or 2 wherein said second object has generally an open box form including a front wall and arranged such that on contact, the front end of the first object abuts/contacts the front inner wall of the second object.
4. A method as claimed in claims 2 to 3 comprising conveying the first object along a first platform and conveying a second object along a second platform in the same general horizontal direction, the first platform being disposed above the second platform and being co-aligned in the horizontal plane, wherein one or more of the platforms have an inclined/sloped portion at its distal end to form said confluence.
5. A method as claimed in claims 1 to 4 wherein the absolute or horizontal component of speed of travel of said first object is greater than the absolute or horizontal component of speed of travel of said second component.
6. A method as claimed in claims 1 to 5 wherein the lower platform has a portion which is sloped upwards at an angle a.
7. A method as claimed in any preceding claim wherein the objects are conveyed to said confluence by a common pushing element.
8. A method as claimed in claim 7 wherein said common pushing element comprises one or more pushing arms, said pushing arms have a contact portion which includes at least one substantially perpendicular portion and/or a profiled portion.
9. A method as claim in claim 8 wherein when said first or second object is being transported along said sloped portion(s), said profiled portion of the pusher arm engages with a correspondingly formed side of the first or second object to provide substantially intimate contact therebetween.
10. A method as claimed in claim 9 or 10 wherein said profiled portion is sloped, adapted to be engaged with a substantially straight perpendicular side of the second object.
11. A method as claimed in claim 10 wherein said sloped portion is at an angle to the non-sloped portion substantially the same as angle a.
12. A method as claimed in claimed in claims 7 to 11 wherein said pusher element or arm(s) is arranged on a continuous belt system.
13. A method as claimed in claims Ito 12 wherein said first object is a confectionary tray.
14. Apparatus to for placing a first object onto or into a second generally planar object comprising a first platform and a second lower platform said first platform being arranged generally above said second platform, and means to convey said first object along said first platform in a direction towards a confluence with the second object such at the confluence the second object is inclined vertically at an angle a to the direction of movement of the first object.15. An apparatus as claimed in claim 14 including means to convey the second object in the same direction in a horizontal plane as the first object and at a relative vertical angle a.
15. An apparatus as claimed in claim 15 adapted to convey the first object along a first platform and conveying a second object along a second platform in the same general direction, the first platform being disposed above the second platform and having a common axis, wherein one or more of the platforms have an inclined/sloped portion at its distal end to form said confluence.
16. An apparatus as claimed in claim 14 to 16 wherein the lower platform has a portion which is sloped upwards at an angle u.
17. An apparatus as claimed in claim 14 to 17 having means to convey the objects to a confluence by a common pushing element.
18. An apparatus as claimed in claims 14 to 18 wherein said pushing element comprises one or more pushing arms, said pushing arms have at least one substantially perpendicular portion and/or a profiled portion.
19. An apparatus as claimed adapted so as to convey said first or second object along said sloped portion(s), during which said profiled portion(s) of the pusher arm is adapted to engage with a correspondingly formed side of the first and/or second object to provide substantially intimate contact therebetween.
20. An apparatus as claimed 20 wherein said profiled portion is sloped, adapted to be engaged with a substantially straight perpendicular side of the second object.
21. An apparatus as claimed in claim 21 wherein said sloped portion is at an angle to the non-sloped portion substantially the same as angle a.
22. An apparatus as claimed in claim pusher element is arranged on a continuous belt system.