IE920251A1

IE920251A1 - A method and a conveyor assembly for assembling components onto a base

Info

Publication number: IE920251A1
Application number: IE920251A
Authority: IE
Inventors: Edmond Joseph Heffernan
Original assignee: B G Res And Dev Ltd
Priority date: 1992-01-28
Filing date: 1992-01-28
Publication date: 1993-07-28
Also published as: GB2263679A; IE66383B1; BE1003960A7; GB9221289D0; GB2263679B

Abstract

A conveyor assembly (1) for assembling components onto carton bases (4) comprises an elongated main conveyor (10) (roller, belt, vibratory) for supporting the carton bases (4). Carrier means specifically carrier trolley(s) (45) for carrying containers (51) of components are provided on one/each side of the main conveyor (10). Each container (51) contains the exact number of identical components corresponding to the number of carton bases (4) on the conveyor (10). Guide track(s) (58) on one/each side of the main conveyor (10) guide the carrier trolley(s) (45) along the side(s) of the main conveyor (10). An operator pushes a carrier trolley (45) along the main conveyor (10) and sequentially assembles the components from the container (51) onto the carton bases (4). Secondary side conveyors (61) store containers (51). A framework (6) carries panels with display means (76-79) with information for operators. Weighing means weigh assembled bases to check correct assembly. Further control details are set forth.

Description

The present invention relates to a method and a conveyor assembly for assembling components onto a base, for example, for assembling components, such as, for example, hardware and software components, manuals and the like into a carton.

Where one wishes to assemble a plurality of components into a carton base, in general, the carton bases are placed on an assembly line which comprises an elongated conveyor. The cartons are conveyed along the assembly line past a plurality of assembly stations. At each assembly station an operator assembles one or more components into a carton base as it passes by the assembly station. When each carton base has reached the end of the assembly line each base should have one of each component assembled therein. All carton bases are inspected at the end of the assembly line, and a lid is then placed on the carton bases containing all the components, thus closing the cartons. This assembly technique suffers from a number of disadvantages. Firstly, the carton bases, and indeed, the components are subjected to an undesirable degree of handling. For example, each carton base must be moved along the assembly line from one assembly station to the other. Each movement of the carton base increases the risk of damage to the carton, and indeed, the component within the carton base. A second disadvantage is that because of the monotony of the assembly operation at each assembly station an operator can readily easily miss assembling a component onto to a carton base, and indeed, in certain cases it has been known for an operator to place two identical components in the one carton base where only one such component was required. This it will be appreciated is undesirable.

There is therefore a need for a method and a conveyor assembly which overcomes these problems.

The present invention is directed towards providing a method for assembling sets of components onto respective similar base means, and the invention also provides a conveyor assembly for carrying out the method.

According to the invention there is provided a method for assembling N sets of M components onto N respective similar base means, N being an integer greater than 1 and M being an integer from 1 upwards, the method comprising the steps placing the N base means onto a elongated main conveyor, the N base means being arranged one after the other longitudinally along the main conveyor, placing N sets of at least one of the M components onto a carrier means, the components being arranged on the carrier means in lots, each lot comprising N identical components, moving the carrier means longitudinally along the main conveyor, and assembling one of each identical component from one of the lots on the carrier means onto each base means as the carrier means passes a base means.

In one embodiment of the invention the method further comprises the step of returning the carrier means longitudinally along the main conveyor, and assembling one of each identical component from another one of the lots on the carrier means onto each base means as the carries means returns past a base means.

Preferably, each lot of N components are placed on the carrier means in the order in which each component is to be assembled onto the base means.

Advantageously, the base means are stationary on the main conveyor while the components are being assembled onto the base means. Preferably, the base means are stationary on the main conveyor until all M components have been assembled onto all N base means.

In one embodiment of the invention the base means are transferred from the main conveyor on the M components being assembled onto the base means. Preferably, each base means is weighed on being transferred from the main conveyor. Advantageously, the weight of each base means is compared with a reference weight, and on the weight of the base means comparing with the reference weight the base means is passed, otherwise the base means is rejected.

In another embodiment of the invention the method comprises the step of delivering the base means onto the main conveyor, and counting N base means onto the main conveyor.

In one embodiment of the invention each base means is a carton base, and the components comprise articles to be assembled onto the carton base. Advantageously, a lid is provided for each carton base.

In one embodiment of the invention the components are manually assembled onto the base means.

Preferably, N is not less than 5, and advantageously, M is not less than 2.

Additionally the invention provides a conveyor assembly for carrying out the method of the invention, the conveyor assembly comprising an elongated main conveyor, a main conveying means for conveying the base means along the main conveyor, a carrier means for carrying the components to be assembled onto the base means, and guide means engagable with the carrier means for guiding the carrier means longitudinally along the main conveyor.

In one embodiment of the invention the guide means comprises an elongated guide track extending longitudinally along the main conveyor.

In another embodiment of the invention a guide roller is rotatably mounted on the carrier means for rollably engaging the guide means.

In a still further embodiment of the invention a pair of spaced apart guide rollers are rotatably mounted on the carrier means for engaging opposite sides of the guide means. Preferably two longitudinally spaced apart pairs of guide rollers are rotatably mounted on the carrier means for rollably engaging the guide means. Advantageously the guide rollers are rotatable about vertically disposed axes.

In one embodiment of the invention the carrier means comprises a framework supporting a platform for carrying the components. Preferably, the platform comprises conveying means for receiving components onto the platform. Advantageously, the conveying means comprises a roller track conveyor, the roller track conveyor forming the platform. Preferably, the carrier means is provided on one side of the main conveyor. In another embodiment of the invention the carrier means is provided on each side of the main conveyor, and respective guide means are provided on respective sides of the main conveyor.

In a further embodiment of the invention main drives means are provided for driving the main conveyor.

In another embodiment of the invention the main conveyor is provided in a plurality of longitudinal sections one after the other, each section being independently driveable relative to the other sections. Preferably, the main conveyor comprises a roller track conveyor, the main conveying means comprising a plurality of transversely disposed conveying rollers.

In another embodiment of the invention weighing means are provided at an output end of the main conveyor for weighing each base means as the base means is being transferred from the main conveyor. Preferably, comparing means are provided for comparing the weight of each base means with a reference weight.

Advantageously, diverting means are provided for diverting a base means whose weight does not compare with the reference weight.

In another embodiment of the invention delivery means are provided for delivering the base means onto the main conveyor at an input end thereof.

In a further embodiment of the invention counter means are provided adjacent the input end of the main conveyor for counting the base means being delivered onto the main conveyor.

In one embodiment of the invention a return conveying means is provided for returning empty containers from the carrier means, the return conveying means extending longitudinally relative to the main conveyor. Preferably, the return conveying means is mounted below the main conveyor. Advantageously, the main conveyor comprises a framework for accommodating the main conveying means and the return conveying means. Preferably, the return conveying means comprises a roller track conveyor.

Further the invention comprises a base means comprising a plurality of components assembled thereon, the components being assembled onto the base means using the method according to the invention.

Further the invention provides a base means comprising a plurality of components assembled thereon, the components being assembled onto the base means using the conveyor assembly.

The invention will be more clearly understood from the following description of a preferred embodiment thereof which is given by way of example only, with reference to the accompanying drawings in which: Fig. 1 is a side elevational view of a conveyor assembly according to the invention, Fig 2 is a plan view of the conveyor assembly of Fig. 1, Fig. 3 is a perspective view of portion of the conveyor assembly of Fig. 1, Fig. 4 is a perspective view of another portion of the conveyor assembly of Fig. 1, Fig. 5 is an end elevational view of a detail of 15 the conveyor assembly of Fig. 1, Fig. 6 is a perspective view of another detail of the conveyor assembly of Fig. 1, Fig. 7 is a perspective view of a further detail of another portion of the conveyor assembly of Fig. 1, and Fig 8. is a perspective view of portion of the conveyor assembly in use.

Referring to the drawings there is illustrated a conveyor assembly according to the invention indicated generally by the reference numeral 1 for assembling components (not shown), such as, hardware, software and manuals into a plurality of base means, in this case carton bases 4 which may be of cardboard or expanded plastics material such as expanded polystyrene. Such packaging of hardware and software components into carton bases will be well known to those skilled in the art. In this particular embodiment of the invention the conveyor assembly 1 is for assembling N sets of M components into N respective similar cartons bases 4. N is a integer and may be any value from two upwards, typically N would be from five upwards. Normally, N would be a multiple of five. Where the carton bases are relatively small N could be as large as one hundred, where the carton bases are relatively large N may be as small as five. M is an integer and may be of any value from one upwards, but typically would be in the range of four to ten. For example, where a carton base is to contain a piece of hardware for attaching, for example, to a computer, the piece of hardware would be one component. The hardware component may require a cable for attaching to the computer. The cable would be another component. Software may be required which would be provided on one or more floppy and/or micro discs. A software manual would be provided, and an instruction manual may also be provided. In which case, the sum of components to be packed into a carton base is six namely, a piece of hardware, a floppy disc, a micro disc, a connecting cable, a software manual and an instruction manual. Thus, in this case M = 6. For the purpose of describing the method according to the invention, it is assumed that M is six and that there are ten carton bases namely, N is ten. The method for assembling the components into the carton bases 4 will be described after the conveyor assembly 1 has been described.

The conveyor assembly 1 comprises an elongated main framework 6 of box section steel comprising a plurality of upstanding member 7 joined by longitudinal side members 8 and transverse cross members 9. An elongated main conveyor 10 for supporting the carton bases 4 during assembly is supported on the cross members 9 of the framework 6. The main conveyor 10 extends longitudinally relative to the main framework 6 and comprises an input end 11 and an output end 12. A return conveying means, namely, a return conveyor 14 for a purpose to be described below is also mounted in the framework 6 and extends longitudinally thereof below the main conveyor . The main conveyor 10 is provided by roller track conveyor 16 comprising a pair of spaced apart side members 17 rotatably supporting a plurality of transversely extending conveying rollers 18 which act as main conveying means for conveying the carton bases 4 along the main conveyor 10. The main conveyor 10 is arranged in sections, in this embodiment of the invention three section 19 to 21 which are longitudinally arranged one after the other. The 10 conveying rollers 18 of each section 19, 20 and 21 are independently operable relative to the other sections 19, 20 and 21. This facilitates moving carton bases onto and off the main conveyer 10 as will be described below. Drive means comprising three drive motors 22 illustrated in block representation are mounted on the framework 6 for driving the conveying rollers 18 of the respective sections 19 to 21.

Delivery means comprising a delivery conveyor 24 supported on a delivery conveyor framework 25 at the input end 11 of the main conveyor 10 delivers carton bases 4 onto the main conveyor 10. The delivery framework is substantially similar in construction to the main framework 6. The delivery conveyor 24 is provided by roller track conveyor and comprises a pair of side members 26 which rotatably support conveying rollers 27. Drive means comprising a drive motor 28 illustrated in block representation is mounted in the delivery conveyor framework 25 for driving the conveying rollers 27. The delivery conveyor 24 is aligned with the main conveyor 10 and the height of the delivery conveyor 24 is similar to that of the main conveyor 10 to facilitate smooth transfer of carton bases 4 from the delivery conveyor 24 onto the main conveyor 10.

A counter means which comprises a light source 23 and a light sensor 29 are mounted at the input end 11 of the main conveyor 10 for counting carton bases onto the main conveyor 10. The light source 23 and the light sensor 29 are connected to an electronic control circuit (not shown) for controlling the apparatus as will be described below.

A discharge means, namely, a discharge conveyor 30 is provided at the output end 12 of the main conveyor 10 for conveying assembled carton bases 4 from the main conveyor 10 to a storage area (not shown). The discharge conveyor 30 is supported on a discharge conveyor framework 31 which is substantially similar in construction to the main framework 6. The discharge conveyor 30 is provided by roller track conveyor and comprises side members 33 rotatably supporting conveying rollers 34. A drive means, namely, a drive motor 35 illustrated in block representation, mounted in the framework 31 drives the conveying rollers 34. The discharge conveyor 30 is at a similar height to the main conveyor 10 and is aligned with the main conveyor 10 to provide smooth transfer of the assembled carton bases from the main conveyor 10 onto the discharge conveyor 30.

Weighing means for weighing each assembled carton base leaving the end 12 of the main conveyor 10 comprises a weigh platform 41 of roller track conveyor disposed between the main conveyor 10 and the discharge conveyor 30. A framework 42 supports the weigh platform 41 on load cells 43 for weighing the carton bases 4. A motor (not shown) on the framework 42 drives the rollers of the platform 41 for transferring carton bases onto and from the platform 41. The load cells 43 are connected to the electronic control circuit (not shown). The electronic control circuit (not shown) comprises a circuit (also not shown) for determining the weight of each carton base 4 from the signals for the load cells 43. Comparing means comprising a comparator (also not shown) in the electronic control circuits (not shown) compares the weight of each carton base 4 with a reference weight for determining if each carton base has been assembled with all the reguired components. A diverting means, comprising a pusher member 32 operated by a pneumatic ram 36 diverts any carton base 4 the weight of which does not compare accurately with the reference weight from the weigh platform 41 onto a reject conveyor 37 for further checking. The ram 36 is mounted on a support framework 52. The reject conveyor 37 is a roller track conveyor supported on a framework (not shown).

A pair of carrier means for carrying the components (not shown) to be assembled onto the carton bases 4 comprise a pair of carrier trollies 45 mounted one on each side of the main conveyor 10. Each trolley 45 comprises a framework 46 which rotatably carries four ground engaging wheels 48 so that the carrier trollies 45 are moveable along the ground adjacent opposite sides of the main conveyor 10. The framework 46 of each carrier trolley 45 supports conveying means, namely,a roller track conveyor 49 which defines a platform 50 for supporting containers 51 for carrying the components to be assembled onto the carton bases 4. Side members 53 of the roller track conveyor 49 rotatably support conveying rollers 55 for transferring the containers 51 to and from the platform 50. A stop bar 44 of the framework 46 of each trolley 45 engages a container 51 on the platform 50.

Guide means comprising a pair of elongated guide tracks 58 extend longitudinally on each side of the main conveyor 10 for guiding the carrier trollies 45 to move longitudinally relative to the main conveyor 10. Each guide track 58 is mounted on the main framework 6 by a plurality of mounting brackets 59 extending sidewardly outwardly of the main framework 6. Two longitudinally spaced apart pairs of guide rollers 60 are rotatably mounted about vertical axes on mounting brackets 62 extending from the framework 46 of each carrier trolley 45. The guide rollers 60 of each pair are spaced apart for engaging opposite sides of the guide track 58 for guiding each carrier trolley longitudinally along the side of the main conveyor 10. Transversally extending hand grip bars 64 extend at each end of each carrier trolley 45. The level of the platform 50 of each carrier trolley 45 is lower than the main conveyor 10 to provide easy access to the components in the containers 51 for an operator.

Secondary side conveyors 68 are provided on each side of the delivery conveyor 24 for storing containers 51 to be transferred onto the carrier trollies 45. Each secondary side conveyor 68 comprises a roller track conveyor 69 supported on a secondary framework 70.

The roller track conveyor 69 comprise side members 71 rotatably supporting conveying rollers 72. The roller track conveyors 69 are of a height similar to the platforms 50 of the respective carrier trollies 45 and are aligned therewith to provide smooth transfer of containers 51 from the secondary side conveyors 68 onto the carrier trollies 45. Drive means, namely, drive motors 73 illustrated in block representation are mounted in the framework 70 for driving the conveying rollers 72. Proximity sensors 90 on each secondary framework 70 co-operate with one of the hand grip bars 64 on each carrier trolley 45 for determining when a carrier trolley 45 is abutting its corresponding secondary conveyor 68 for the transfer of containers 51 onto the carrier trolley 45. Each proximity sensor 90 is connected to the electronic control circuit (not shown) for activating the appropriate motor 73 of the secondary side conveyor 68 for transferring one or more containers 51 from the secondary side conveyor 68 onto the carrier trolley 45.

An upper framework 74 mounted on and extending above the main framework 6 carries panels 75 which comprise display means in this case light emitting diode displays 76, 77, 78 and 79 for displaying information to operators operating on each side of the main conveyor 10. The light emitting diode displays 76 to 79 are powered and controlled by the electronic control circuit (not shown). The light emitting diode display 76 to 79 are double sided thereby giving relevant information to operators on each side of the main conveyor 10. The light emitting diode display 76 displays the time. The light emitting diode display 77 displays the standard time for carrying out an operation which the operator is carrying out. The light emitting diode display 78 displays the actual time taken by the operator to carry out the operation. The light emitting diode display 79 displays the identity of the component to be assembled next onto the carton bases 4.

Push button switches 80 are provided at the input end 11 and the output 12 of the main conveyor 10. The button switches 80 are connected to the electronic control circuit (not shown) so that an operator by depressing an appropriate button switch 80 can indicate that a pass of the carrier trolley 45 from one end 11 to the other end 12 or visa versa of the main conveyor 10 has been completed. This thus indicates to the control circuit (not shown) that all the components which were to have been assembled onto the carton bases 4 on that pass have been assembled.

The control circuit (not shown) than changes the display on the light emitting diode display 79 to indicate to the operator the next component to be assembled onto the carton bases 4. Push button switches 81 are also placed along the main conveyor 10 at the end of each section 19 and 20. The push button switches 81 are connected to the electronic control circuit (not shown) to enable an operator by depressing the appropriate push button switch 81 to indicate that a pass of the carrier trolley 45 has been completed if only one or two sections 19 or 20, as the case may be, of the main conveyor 10 are being used in an assembly operation.

The return conveyor 14 is for receiving empty containers 51 which may are transferred from the carrier trollies 45 by an operator for return to a central collection point at the input end 11 of the main framework 6. The return conveyor 14 comprises a side members 92 which rotatably carry conveying rollers 93 which are driven by an electrically powered motor (not shown) mounted in the main framework 6.

The motor (not shown) is driven under the control of the electronic control circuit (not shown).

All the drive motors of the conveyor assembly 1 are electrically powered and controlled by the electronic control circuit (not shown). The motors of the delivery conveyor 24, the main conveyor 10 and the discharge conveyor 30 as well as the motor for the weight platform 41 are controlled by the electronic control circuit for delivering carton bases onto the main conveyor 10 and for conveying the assembled carton bases from the main conveyor 10. On the desired number of carton bases having been counted onto the main conveyor 10, the electronic control circuit (not shown) deactivates the motors driving the main conveyor 10.

In use, carton bases 4 onto which components are to be assembled are delivered and counted onto the main conveyor 10 as will be described below. Components to be assembled onto the carton bases 4 are arranged in lots of identical components in the containers 51 which are placed on the secondary side conveyors 68.

In general, one lot of identical components will be provided in each container 51. As required the containers 51 are transferred onto the carrier trollies 45. In general, two containers 51 are transferred each time onto a carrier trolley 45. One container comprising one lot of components to be assembled onto the carton bases 4 as the carrier trolley 45 moves from one end 11 to the other end 12 of the main conveyor 10 in an outward pass, and the other container 51 comprising the lot of components to be assembled onto the carton bases 4 as the carrier trolley 45 makes a return pass from the end 12 to the end 11 of the main conveyor 10. On the appropriate number of containers 51 being delivered onto the platform 50 of the carrier trolley 45, the container 51 or one of the containers 51 engages the stop bar 44 of the carrier trolley 45, and further conveying action of the secondary side conveyor 68 pushes the carrier trolley 45 away from the secondary side conveyor 68. This causes the carrier trolley 45 to disengage the proximity switch 90 thereby deactivating the secondary side conveyor 68. An operator pushes the carrier trolley 45 along the main conveyor 10. As the operator passes each carton base 4 the operator places a component from the appropriate lot from the carrier trolley 45 into the carton base 4. On completing one pass of the carrier trolley 45 from the input end 11 to the output end 12 of the main conveyor the operator then returns with the carrier trolley from the output end 12 to the input end 11, and assembles the next lot of components from the carrier trolley 45 onto the carton bases 4. On completing one pass of the carrier trolley 45 from the input end 11 or 12 to the other end 11 or 12 of the main conveyor 10, the operator pushes the appropriate push button switch 80 or 81 as the case may be, thereby indicating to the electronic control circuit (not shown) that a pass has been completed. The electronic control circuit (not shown) changes the data displayed on the displays 76 to 79 accordingly. On the return of each carrier trolley 45 to the secondary side conveyor 68, the proximity switch 90 activates the corresponding secondary side conveyor 68 for the transfer of the next one or two containers 51 to the carrier trolley 45. On all components being assembled onto all the carton bases 4, the main conveyor 10 is activated and transfers the assembled carton bases 4 onto the discharge conveyor 30. As each carton base 4 passes over the weigh platform 41 between the main conveyor 10 and the discharge conveyor 30 the carton base 4 is weighed. Carton bases 4 of the correct weight are passed by the weigh platform 41 onto the discharge conveyor 30 for conveying to the storage area (not shown). Carton bases 4 of incorrect weight are diverted onto the reject conveyor 37 for further checking.

The method for using the conveyor assembly 1 to assemble components onto the carton bases will now be described. Although the main conveyor 10 has been described as having carrier trollies 45 on two sides, namely, on sides A and B (see Fig. 2), for convenience in the description of the method all assembly of components onto the carton bases 4 will be carried out from the side A only. In other words, the carrier trolley 45 and secondary side conveyor 68 on the side A only will be used. However, in many cases it is envisaged that the carrier trollies 45 on both side A and side B will be used. In which case, the operators on the sides A and B will assemble different components into the carton bases 4, and, in general, it is envisaged that one operator would continuously follow the other operator. As already discussed, for the purpose of explanation it is being assumed that ten carton bases 4 are to be assembled with six components. On all assembled carton bases 4 having been conveyed from the main conveyor 10 the next batch of ten empty carton bases 4 are delivered by the delivery conveyor 24 onto the main conveyor 10. The light sensor 29 under the control of the electronic control circuit (not shown) counts ten carton bases 4 onto the main conveyor 10. Depending on the length of the main conveyor 10 which will be occupied by the ten carton bases 4, one or all sections 19, 20 and 21 of the main conveyor 10 are operated for conveying the carton bases 4 along the main conveyor 10. To save assembly time, the ten carton bases 4 are aligned one after the other longitudinally along the main conveyor relatively closely to each other, with the last of the carton bases 4 adjacent to the input end 11 of the main conveyor 10. The components are arranged in lots of identical components, each lot comprising ten identical components, one for each carton base 4.

Each lot of identical components is placed in a container 51. The containers 51 are placed on the secondary side conveyor 68 on the side A in the order in which they are to be assemble onto the carton bases 4. Accordingly, the first component to be assembled onto a carton bases 4 is in the container 51 which is first to be transferred from the secondary side conveyor 68 to the carrier trolley 45. The carrier trolley 45 on the side A is moved up to the input end of the main conveyor 10 to abut the secondary side conveyor 68. On the carrier trolley 45 activating the proximity switch 90, two containers 51 comprising the two lots of components which are to be assembled firstly and secondly, respectively, onto the carton bases 4 are transferred onto the platform 50 of the carrier trolley 45. The operator pushes the carrier trolley 45 along the main conveyor 10 on an outward pass from the input end 11 to the output end 12. The operator on passing each carton base assembles a component from the container 51 which comprises the components to be first assembled onto each carton base 4. On the operator reaching the output end 12 of the main conveyor 10 or an end of a section 19 or 20, as the case may be, the outward pass having been complete, the operator depresses the appropriate push butter switch 80 or 81 indicating to the electronic control circuit (not shown) that the outward pass has been completed. The operator removes the empty container 51 and places it on the return conveyor 14 where it is returned to a collection point for removal. The operator then commences the return pass pushing the carrier trolley 45 towards the input end 11 of the main conveyor 10 and assembles the second component to be assembled onto the carton bases 4. On arriving at the input end 11 of the main conveyor 10 the empty container 51 is removed from the carrier trolley 45. The operator depresses the button switch 80 at the input end of the main conveyor 10 indicating to the electronic control circuit (not shown) that the return pass has been completed. The proximity switch 90 on being engaged by the carrier trolley 45 activates the secondary side conveyor 68 for transfer of the next two containers 51 onto the carrier trolley 45. The assembly operation is repeated until all six components have been assembled onto all ten carton bases 4. On assembly of the carton bases being completed the main conveyor 10 and the discharge conveyor 30 are activated for transfer of the carton bases 4 from the main conveyor. The carton bases 4 are weighed on the weigh platform 41 as they are being transferred onto the discharge conveyor 30. Rejects are diverted onto the reject conveyor 37 by the pusher member 32. On the main conveyor 10 being cleared of assembled carton bases the next batch of ten carton bases 4 are delivered onto the main conveyor 10 by the delivery conveyor 24 and the next batch of containers 51 with components are placed on the secondary side conveyor 68 for the next batch to be assembled.

The advantages of the invention are many. One of the main advantages of the invention is that by virtue of the fact that the carton bases remain stationary during assembly movement of the carton bases is reduced to a minimum and therefore the risk of damage to the carton bases or components therein is minimised. Furthermore, by virtue of the fact that the carton bases are counted onto the main conveyor and that the components are arranged in lots of identical components, and each lot comprises the same number of components as carton bases the risk of a carton base being assembled without a component or with two of the same component is virtually eliminated. At the end of a pass if an operator has one or more components too many or is short of one or more components, then immediately the operator is aware of the fact that one of the carton bases on the main conveyor is missing a component, or alternately, has one component too many. Thus a quick check of the number of carton bases on the main conveyor enables the operator to immediately determine which carton base has been incorrectly assembled. The incorrectly assembled carton base can then be rectified and assembly can continue. It will therefore be appreciated that it is advantageous to keep the number of carton bases in each batch relatively low. Ten to one hundred carton bases is believed to be optimum. While more carton bases can be assembled in each batch, it will be appreciated that should an error occur the time required to determine where the error has occurred is longer.

It is envisaged in certain cases that a camera may be mounted on the upper framework 74 which would be moveable longitudinally along the main conveyor 10 for scanning the carton bases as the assembly method is in operation.

While the conveyors in all cases have been described as comprising roller track conveyors, other types of conveyors may be used, for example, belt type conveyors, vibratory type conveyors, or the like. It will of course be appreciated that a mix of different types of conveyors may be used. It will also be appreciated that the secondary side conveyors may be dispensed with as indeed may one of the carrier trollies .

Needless to say any other suitable shape and construction of frameworks may be provided and other guide means and guide roller arrangements may be provided.

The upper framework may also be dispensed with if desired. While it is preferable that the assembled carton bases should be weighed, this is not essential and in such cases where it is not required the weighing means may be dispensed with. Also, the diverting means may be dispensed with if desired.

While it is preferable it is not essential that counting means for counting the carton bases onto the main conveyor be provided.

It will of course be appreciated that while the conveyor assembly has been described for assembling components into carton bases, the conveyor assembly may be used for assembling any type of components onto any type of base means.

Claims

1. A method for assembling N sets of M components onto N respective similar base means, N being an integer greater than 1 and M being an integer from 1 5 upwards, the method comprising the steps placing the N base means onto a elongated main conveyor, the N base means being arranged one after the other longitudinally along the main conveyor, placing N sets of at least one of the M components onto a carrier 10 means, the components being arranged on the carrier means in lots, each lot comprising N identical components, moving the carrier means longitudinally along the main conveyor, and assembling one of each identical component from one of the lots on the 15 carrier means onto each base means as the carrier means passes a base means.

2. A method as claimed in claim 1 in which the method further comprises the step of returning the carrier means longitudinally along the main conveyor, 20 and assembling one of each identical component from another one of the lots on the carrier means onto each base means as the carries means returns past a base means .

3. A method as claimed in claim 1 or 2 in which each 25 lot of N components are placed on the carrier means in the order in which each component is to be assembled onto the base means.

4. A method as claimed in any preceding claim in which the base means are stationary on the main conveyor while the components are being assembled onto 5. The base means .

5. A method as claimed in claim 4 in which the base means are stationary on the main conveyor until all M components have been assembled onto all N base means.

6. A method as claimed in any preceding claim in 10 which the base means are transferred from the main conveyor on the M components being assembled onto the base means.

7. A method as claimed in any preceding claim in which each base means is weighed on being transferred 15 from the main conveyor.

8. A method as claimed in claim 7 in which the weight of each base means is compared with a reference weight, and on the weight of the base means comparing with the reference weight the base means is passed, 20 otherwise the base means is rejected.

9. A method as claimed in any preceding claim in which the method comprises the step of delivering the base means onto the main conveyor, and counting N base means onto the main conveyor.

10. A method as claimed in any preceding claim in which each base means is a carton base, and the 5 components comprise articles to be assembled onto the carton base.

11. A method as claimed in claim 10 in which a lid is provided for each carton base.

12. A method as claimed in any preceding claim in 10 which the components are manually assembled onto the base means .

13. A method as claimed in any preceding claim in which N is not less than 5.

14. A method as claimed in any preceding claim in 15 which M is not less than 2.

15. A method for assembling N sets of M components onto N respective similar base means, the method being substantially as described herein with reference to and as illustrated in the accompanying drawings. 20

16. A conveyor assembly for carrying out the method of any of claims 1 to 15, the conveyor assembly comprising an elongated main conveyor, a main conveying means for conveying the base means along the main conveyor, a carrier means for carrying the components to be assembled onto the base means, and 5 guide means engagable with the carrier means for guiding the carrier means longitudinally along the main conveyor.

17. A conveyor assembly as claimed in claim 16 in which the guide means comprises an elongated guide 10 track extending longitudinally along the main conveyor.

18. A conveyor assembly as claimed in claim 16 or 17 in which a guide roller is rotatably mounted on the carrier means for rollably engaging the guide means. 15

19. A conveyor assembly as claimed in claim 18 in which a pair of spaced apart guide rollers are rotatably mounted on the carrier means for engaging opposite sides of the guide means.

20. A conveyor assembly as claimed in any of claims 20 16 to 19 in which two longitudinally spaced apart pairs of guide rollers are rotatably mounted on the carrier means for rollably engaging the guide means.

21. A conveyor assembly as claimed in any of claims 16. To 20 in which the guide rollers are rotatable about vertically disposed axes.

22. A conveyor assembly as claimed in any of claims 16 to 21 in which the carrier means comprises a 5 framework supporting a platform for carrying the components .

23. A conveyor assembly as claimed in claim 22 in which the platform comprises conveying means for receiving components onto the platform. 10

24. A conveyor assembly as claimed in claim 23 in which the conveying means comprises a roller track conveyor, the roller track conveyor forming the platform.

25. A conveyor assembly as claimed in any of claims 15 16 to 24 in which the carrier means is provided on one side of the main conveyor.

26. A conveyor assembly as claimed in any of claims 16 to 25 in which the carrier means is provided on each side of the main conveyor, and respective guide 17. 20 means are provided on respective sides of the main conveyor.

27. A conveyor assembly as claimed in any of claims 16 to 26 in which main drives means are provided for driving the main conveyor.

28. A conveyor assembly as claimed in any of claim 16 to 27 in which the main conveyor is provided in a 5 plurality of longitudinal sections one after the other, each section being independently driveable relative to the other sections.

29. A conveyor assembly as claimed in any of claims 16 to 28 in which the main conveyor comprises a roller 10 track conveyor, the main conveying means comprising a plurality of transversely disposed conveying rollers.

30. A conveyor assembly as claimed in any of claims 16 to 29 in which weighing means are provided at an output end of the main conveyor for weighing each base 15 means as the base means is being transferred from the main conveyor.

31. A conveyor assembly as claimed in any of claims 16 to 30 in which comparing means are provided for comparing the weight of each base means with a 20 reference weight.

32. A conveyor assembly as claimed in claim 31 in which diverting means are provided for diverting a base means whose weight does not compare with the reference weight.

33. A conveyor assembly as claimed in any of claims 16 to 32 in which delivery means are provided for delivering the base means onto the main conveyor at an 5 input end thereof .

34. A conveyor assembly as claimed in claim 33 in which counter means are provided adjacent the input end of the main conveyor for counting the base means being delivered onto the main conveyor. 10

35. A conveyor assembly as claimed in any of claims 16 to 34 in which a return conveying means is provided for returning empty containers from the carrier means, the return conveying means extending longitudinally relative to the main conveyor. 15

36. A conveyor assembly as claimed in any of claims 16 to 35 in which the return conveying means is mounted below the main conveyor.

37. A conveyor assembly as claimed in claim 36 in which the main conveyor comprises a framework for 20 accommodating the main conveying means and the return conveying means .

38. A conveyor assembly as claimed in any of claims 35 to 37 in which the return conveying means comprises a roller track conveyor.

39. A conveyor assembly substantially as described herein with reference to and as illustrated in the 5 accompanying drawings .

40. A base means comprising a plurality of components assembled thereon, the components being assembled onto the base means using the method of any claims 1 to 15. ,w

41. A base means as claimed in claimAk^in which the components are assembled onto the base means using the conveyor assembly of any of claims 16 to 39.