US20010050209A1 - Boxing system using conveyor apparatus - Google Patents
Boxing system using conveyor apparatus Download PDFInfo
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- US20010050209A1 US20010050209A1 US09/817,585 US81758501A US2001050209A1 US 20010050209 A1 US20010050209 A1 US 20010050209A1 US 81758501 A US81758501 A US 81758501A US 2001050209 A1 US2001050209 A1 US 2001050209A1
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- Prior art keywords
- packs
- fin
- fins
- holding
- articles
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G17/00—Conveyors having an endless traction element, e.g. a chain, transmitting movement to a continuous or substantially-continuous load-carrying surface or to a series of individual load-carriers; Endless-chain conveyors in which the chains form the load-carrying surface
- B65G17/30—Details; Auxiliary devices
- B65G17/38—Chains or like traction elements; Connections between traction elements and load-carriers
- B65G17/42—Attaching load carriers to traction elements
- B65G17/44—Attaching load carriers to traction elements by means excluding relative movements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B35/00—Supplying, feeding, arranging or orientating articles to be packaged
- B65B35/30—Arranging and feeding articles in groups
- B65B35/44—Arranging and feeding articles in groups by endless belts or chains
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B5/00—Packaging individual articles in containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, jars
- B65B5/06—Packaging groups of articles, the groups being treated as single articles
- B65B5/064—Potato chips
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B5/00—Packaging individual articles in containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, jars
- B65B5/10—Filling containers or receptacles progressively or in stages by introducing successive articles, or layers of articles
- B65B5/106—Filling containers or receptacles progressively or in stages by introducing successive articles, or layers of articles by pushers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
- B65G47/02—Devices for feeding articles or materials to conveyors
- B65G47/04—Devices for feeding articles or materials to conveyors for feeding articles
- B65G47/06—Devices for feeding articles or materials to conveyors for feeding articles from a single group of articles arranged in orderly pattern, e.g. workpieces in magazines
- B65G47/08—Devices for feeding articles or materials to conveyors for feeding articles from a single group of articles arranged in orderly pattern, e.g. workpieces in magazines spacing or grouping the articles during feeding
- B65G47/082—Devices for feeding articles or materials to conveyors for feeding articles from a single group of articles arranged in orderly pattern, e.g. workpieces in magazines spacing or grouping the articles during feeding grouping articles in rows
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2201/00—Indexing codes relating to handling devices, e.g. conveyors, characterised by the type of product or load being conveyed or handled
- B65G2201/02—Articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2201/00—Indexing codes relating to handling devices, e.g. conveyors, characterised by the type of product or load being conveyed or handled
- B65G2201/02—Articles
- B65G2201/0235—Containers
- B65G2201/0238—Bags
Abstract
A conveyor apparatus includes first and second groups of fins which are spaced along the conveying direction to provide spaces sufficient to hold packs therein. The fins in each group are divided into first and second sets. The first and second fin groups are mounted to first and second conveyor chain pairs, respectively, and moved through pack loading and unloading stations. Stepping motors drive the first and second chain pairs independently. A controller causes a fin set after being loaded or unloaded to be forwarded to the unloading or loading station at a speed higher than the speed at which the fin sets move through the loading station.
Description
- This application is a division of the application having Ser. No. 09/338,936, filed Jun. 23, 1999.
- This invention relates to a boxing system for putting articles, e.g. packs of food, such as potato chips, beans, pieces of candy and the likes, in boxes or cases, such as corrugated cardboard cases. This invention also relates to a conveyor apparatus useable with the boxing system.
- An example of prior art boxing system is shown in Japanese Unexamined Patent Publication (KOKAI) No. HEI 9-77003 published on Mar. 25, 1997. This prior art boxing system is used to put
packs 1 shown, for example, in FIG. 25(a) or boxes (not shown) in acase 2 shown, for example, in FIG. 25(c). Referring to FIG. 25(a),packs 1 conveyed on aninput conveyor 4 are put intospaces 6 formed between a plurality of adjacent ones of a plurality offins 5 planted on the conveying surface of analignment conveyor 3. One pack is put into onespace 6. Thus,packs 1 are aligned on the conveying surface of thealignment conveyor 3, standing erect. - When a predetermined number, five in the illustrated example, of
packs 1 are aligned on theconveyor 3, apusher plate 11 pushes five packs on theconveyor 3 to move on a U-shapedintermediate member 10 onto a predetermined position on gates 7-1 and 7-2 as shown in FIG. 25(b). Thepusher plate 11 has slits 12 therein to avoid interference with thefins 5 when it pushes five packs on thealignment conveyor 3. In the illustrated example, two sets of fivepacks 1 have been pushed onto the gates 7-1 and 7-2. - As shown in FIGS.25(c) and 25(d), after pushing five
packs 1 onto the predetermined position on the closed gates 7-1 and 7-2, thepusher plate 11 moves upward and returns to its original standby position (FIG. 25(a)) along a path above thealignment conveyor 3 in order to avoid interference with succeedingpacks 1 being conveyed and aligned on theconveyor 3. - Then, as shown in FIG. 25(b), the
packs 1 standing erect on the gates 7-1 and 7-2 are held by a pair of holding plates 9-1 and 9-2. - Thereafter, as shown in FIG. 25(c), the gates 7-1 and 7-2 are opened, and the
cardboard case 2 is moved upward from below the gates 7-1 and 7-2 So that the tenpacks 1 held between the holding plates 9-1 and 9-2 are put into thecardboard case 2. Thecardboard case 2 has been conveyed on a roller conveyor (not shown) to a predetermined position below the gates 7-1 and 7-2. Thecardboard case 2 has fourflaps 2 a-2 d. - Next, a
stuffing plate 13 disposed above the gates 7-1 and 7-2 is lowered, and, at the same time, the holding plates 9-1 and 9-2 are moved in the direction away from each other. In this manner,packs 1 are placed in thecardboard case 2, as shown in FIG. 25(c). - Then, the
cardboard case 2 withpacks 1 put therein is lowered, and the gates 7-1 and 7-2 are closed, so that the boxing system returns to the state shown in FIG. 25(a) to thereby complete one cycle of operation. This operation is repeated. - In the above-described prior art boxing system, the
alignment conveyor 3 must be stopped at the pushing position shown in FIG. 25(a) when thepusher plate 11 pushes fivepacks 1 on thealignment conveyor 3 onto theintermediate member 10. It disadvantageously preventspacks 1 conveyed by theinput conveyor 4 from being continuously supplied onto thealignment conveyor 3. Another problem is as follows. When one set of fivepacks 1 is pushed off thealignment conveyor 3, a next set of fivepacks 1 may have been already available. However, such new set cannot be brought to the pushing position at a high speed, since thealignment conveyor 3 should move at a speed low enough to receivepacks 1 supplied by theinput conveyor 4 without fail. These problems impede the improvement of the boxing efficiency of prior art systems. - For conveying and boxing thick packs in a case, the spacing between
adjacent fins 5 should be increased. Thefins 5 are screwed to the conveying surface of theconveyor 3. In order to widen thespaces 6, thefins 5 must be unscrewed, which requires time and labor. - As shown in FIG. 25(a), the holding plates 9-1 and 9-2 are arranged to advance by a predetermined stroke to press against a given number of
packs 1 between them. Accordingly, if each of the five alignedpacks 1 to be held is relatively thick, there is a danger that the holding plates 9-1 and 9-2 may crush items contained in thepacks 1. On the other hand, if the sum thickness of the fivepacks 1 is relatively small, they may slip off from between the holding plates 9-1 and 9-2. Accordingly, a predetermined number ofpacks 1 may not be boxed neatly. Thus, it is not always possible for the holding plates 9-1 and 9-2 of the prior art system to hold different sized packs with force appropriate for such packs. - Further, since the holding plates9-1 and 9-2
hold packs 1 by applying holding forces along the line on whichpacks 1 are aligned in a row, all or some of alignedpacks 1 may slip out from the row in the lateral direction.Such packs 1 may be caught by the upper edge of a side-wall of thecase 2, and, therefore, sometimes, proper boxing ofpacks 1 cannot be done. - Sometimes, a large number of
packs 1 may be in so long a row, being held between the holding plates 9-1 and 9-2, that one or more ofpacks 1 may slip off. If the force given by the holding plates 9-1 and 9-2 to the row ofpacks 1 is increased to prevent such slip-off of packs, the packs may be sometimes damaged. Accordingly, there is some limit on the holding force applied by the plates 9-1 and 9-2. - In prior art systems, in order for
packs 1 to be put into a case easily, the case should have a relatively large opening, which means that large-sized cases 2 are required. This necessitates a relatively large space for storing the packedcases 2. - An object of the present invention is to provide a boxing system in which a desired number of packs can be put into cases at a high rate without fail.
- Another object of the present invention is to provide a conveyor apparatus which can be used in the boxing system and which includes a plurality of easily detachable fins, between adjacent ones of which packs conveyed to be put into a case are disposed and supported.
- Still another object of the invention is to provide such fins between adjacent ones of which packs can be supported, standing erect without bend, so that the packs can be put into cases, being erected.
- According to a first aspect of the present invention, a conveyor apparatus is provided, which includes a group of first partitioning means mounted on first conveying means with spaces provided along a conveying direction between adjacent ones of the first partitioning means. Each of the spaces is sufficiently large to hold an article in it. The first partitioning means are adapted to pass through an article loading position where articles are put into respective ones of the spaces and an article unloading position where the articles held in the spaces are unloaded. The conveyor apparatus further includes a group of second partitioning means mounted on second conveying means with spaces provided along the conveying direction between adjacent ones of the second partitioning means. Each of the spaces is also sufficiently large to hold an article in it. The second partitioning means are also adapted to pass through the article loading position and the article unloading position. There are further provided driving means for driving the first and second conveying means independent from each other, and control means for causing the group of first or second partitioning means after being loaded or unloaded, to travel to the unloading or loading position at a speed higher than the speed at which the partitioning means pass through the loading position.
- The control means cause either one of the groups of first and second partitioning means to pass through the loading position at a predetermined article receiving speed, while causing the other group to be placed in the unloading position.
- The conveyor apparatus may be arranged so that while one of the groups of first and second partitioning means is being loaded in the loading position, the other group, after being unloaded, stands by for the loading at a position before the loading position. Alternatively, it may be so arranged that while one of the groups is being loaded in the loading position, the other group, after being loaded with articles, stands by for the unloading at a position before the unloading position.
- According to a second aspect of the invention, a conveyor apparatus includes conveying means, and a plurality of partitioning means mounted to the conveying means. Each of the partitioning means is detachably mounted to the conveying means by means of partitioning means mounting means, and is spaced from adjacent ones along a conveying direction to provide spaces therebetween sufficient to hold articles therein. Each of the partitioning means mounting means includes a through-hole formed in either of the conveying means and the partitioning means. The through-hole has wider and narrower openings communicating with each other. Each of the partitioning means further includes a partitioning means retainer mounted by an elongated member to the other of the conveying means and the partitioning means. The retainer is adapted to be inserted into the wider opening of the through-hole and, then, moved into the narrower opening to contact the periphery of the narrower opening. A spring is adapted to press the retainer in the narrower opening against the periphery of the narrower opening. The partitioning means further includes a detent for preventing the retainer pressed against the periphery of the narrower opening from moving into the wider opening.
- According to a third aspect of the present invention, a boxing system for putting articles into a box is provided. The boxing system includes an article holding arrangement including holding members for holding a predetermined number of aligned articles to be put in a box. The holding arrangement includes a driving unit for moving the holding members toward and away from each other along a direction in which the articles are aligned. A force detecting unit detects forces with which the holding members press the aligned articles when the holding members are driven toward each other. The holding arrangement further includes means for stopping the driving unit from driving the holding members when the forces applied to the holding members as detected by the force detecting unit is greater than a predetermined value.
- According to a fourth aspect of the present invention, a boxing system for putting articles into a box is provided. The boxing system includes front and rear holding members for holding a predetermined number of aligned articles to b put in a box, by applying force to the aligned articles in the direction of alignment. The system further includes side holding members for holding the aligned articles held by the front and rear holding members, by applying force to the aligned articles in the direction perpendicular to the direction of alignment.
- According to a fifth aspect of the present invention, a boxing system for putting articles into a box is provided, which include holding members for holding a predetermined number of aligned articles, and a funnel-shaped guide into which the aligned articles held by the holding members are forced to thereby put the aligned articles into a box disposed at an outlet port of the funnel-shaped guide. The outlet port of the funnel-shaped guide includes guide plates which can be pushed outward by the articles passing therethrough and return to the original position when the articles have passed, and biasing means for biasing the guide plates to the original positions.
- According to a sixth aspect of the present invention a conveyor apparatus includes conveying means travelling in a loop including upper and lower paths with turning paths between the upper and lower paths, and a plurality of partitioning means mounted to the conveying means. Each of the partitioning means is detachably mounted to the conveying means by means of partitioning means mounting means, and is spaced along a conveying direction from adjacent ones to provide spaces therebetween sufficient to hold articles therein. Successive ones of the spaces are adapted to be loaded with articles when the partitioning means pass through a predetermined loading position in the turning path from the lower path to the upper path. Driving means drives the conveying means. Each of the partitioning means includes a partition standing erect and extending in the direction perpendicular to the conveying direction, and a base connected to the partition. Each of the partitioning means mounting means includes a mounting device secured to the base of the partitioning means, and an engaged device adapted to be engaged by an associated mounting device. The engaged devices are secured to the conveying means along the conveying direction with a fixed pitch. The engaged devices are arranged such that plural types of partitioning means with different distances between the mounting devices and the partitions can be mounted to the conveying means. The conveyor apparatus further includes control means for changing the amount by which the partitioning means are advanced to receive articles in the loading position, in accordance with the distance between the mounting devices of adjacent ones of the partitioning means.
- The number of different types of partitioning means may be two.
- Each of the partitioning means mounting means may include a through-hole formed in either of the conveying means and the partitioning means, which has wider and narrower openings communicating with each other, a partitioning means retainer mounted by an elongated member to the other of the conveying means and the partitioning means, which retainer is adapted to be inserted into the wider opening of the through-hole and, then, moved into the narrower opening to contact the periphery of the narrower opening. Each of the partitioning means mounting means further includes a spring adapted to press retainer in the narrower opening against the periphery of the narrower opening, and a detent for preventing the retainer pressed against the periphery of the narrower opening from moving into the wider opening.
- FIG. 1 is a front view of an alignment conveyor system used in a boxing system according to a first embodiment of the present invention.
- FIG. 2 is a plan view of the alignment conveyor system shown in FIG. 1.
- FIG. 3 is a plan view of the boxing system according to the first embodiment.
- FIG. 4 is a front view of the boxing apparatus shown in FIG. 3.
- FIG. 5 is a side view of the boxing system shown in FIG. 3.
- FIGS.6(a), 6(b) and 6(c) illustrate a fin-mounting arrangement for mounting fins to the alignment conveyor system shown in FIG. 1, in which
- FIG. 6(a) is an enlarged front view of a press-down limiting member contacting a fin-retainer together with a fin-mounting fitting,
- FIG. 6(b) is an enlarged front view of the press-down limiting member shifted upward away from the fin-retainer member, and
- FIG. 6(c) is an enlarged plan view of the fin-mounting fitting.
- FIGS.7(a) through 7(f) illustrate how the fin is mounted to the alignment conveyor system, in which
- FIG. 7(a) is a front view of the fin-mounting arrangement with the fin-retaining member inserted into a wider opening of a through-hole formed in the fin-mounting fitting,
- FIG. 7(b) is a partially cross-sectional view along a line B-B in FIG. 7(a),
- FIG. 7(c) is a front view of the fin-mounting arrangement with the fin-retainer slid into a narrow opening of the through-hole in the fin-mounting fitting,
- FIG. 7(d) is a partially cross-sectional view of along a line D-D in FIG. 7(c),
- FIG. 7(e) is a front view of the fin-mounting arrangement with the fin-retainer abutting the lower surface of the portion of the fin-mounting fitting around the narrow opening of the through-hole, and
- FIG. 7(f) is a partially cross-sectional view along a line F-F in FIG. 7(e).
- FIGS.8(a) and 8(b) are front and side views respectively of one of holding plate moving apparatuses for moving pack holding plates of the boxing system toward and away from each other.
- FIGS.9(a) and 9(b) are front and side views respectively of an example of a force detector other than the one used in the apparatus shown in FIGS. 8(a) and 8(b).
- FIGS.10(a), 10(b) and 10(c) are front, side and plan views respectively of a side holding plate driving arrangement of the boxing system shown in FIG. 1.
- FIG. 11 is a plan view of a guide used in the boxing system of the first embodiment.
- FIGS.12(a) and 12(b) are cross-sectional views of a part of the guide shown in FIG. 11, showing guide plates extending straight and guide plates pressed outward by packs, respectively.
- FIG. 13 is a cross-sectional view of the guide mounted in operational relation to the boxing system.
- FIGS.14(a) through 14(j) are perspective views illustrating how packs are put into a box, in which
- FIG. 14(a) shows packs being supplied to the alignment conveyor system,
- FIG. 14(b) shows the packs arranged on the alignment conveyor system,
- FIG. 14(c) shows a pusher plate pushes the packs out from the alignment conveyor system,
- FIG. 14(d) shows the pusher plate staying in front of the alignment conveyor system,
- FIG. 14(e) shows the pusher plate which has returned to its original position,
- FIG. 14(f) shows the packs held by the front and rear holding plates and a side holding plate,
- FIG. 14(g) shows the lifted case with gates opened,
- FIG. 14(h) shows a lowered stuffing plate with the front and rear holding plates moved away from the packs,
- FIG. 14(i) shows the packs pushed into the case, and
- FIG. 14(j) shows the gates moving to their closed position.
- FIG. 15 is a block diagram of electrical circuitry of the boxing system according to the first embodiment of the present invention.
- FIG. 16 is a flow chart illustrating the operation of the alignment conveyor system used in the first embodiment.
- FIGS.17(a) and 17(b) show a flow chart illustrating the operation of the front and rear holding plates and the side holding plate.
- FIG. 18 is a flow chart illustrating the operation of an alignment conveyor system used in a boxing system according to a second embodiment of the present invention, in which fins are mounted on the alignment conveyor system with the spacing of 2.5 inches disposed between adjacent fins.
- FIG. 19 is a flow chart illustrating the operation of the alignment conveyor system used in the boxing system according to the second embodiment of the present invention, in which fins are mounted on the alignment conveyor system with the spacing of 2 inches disposed between adjacent fins.
- FIG. 20 is a side view of the alignment conveyor system used in the boxing system according to the second embodiment, in which fins spaced by 2.5 inches are in the unloading position.
- FIGS.21(a) and 21(b) illustrate how the fins spaced by 2.5 inches are moved to the loading position by an amount varied for the respective fins, in which
- FIG. 21(a) shows the second fin receiving an pack, and
- FIG. 21(b) shows the third fin receiving an pack.
- FIGS.22(a) and 22(b) illustrate how the fins spaced by 2.5 inches are moved to the loading position by a fixed amount, in which
- FIG. 22(a) shows the second fin receiving an pack, and
- FIG. 22(b) shows the third fin receiving a pack.
- FIGS.23(a) and 23(b) illustrate how fins of the first embodiment spaced by 2 inches are moved to a loading position by a fixed amount, in which
- FIG. 23(a) shows the second fin receiving a pack, and
- FIG. 23(b) shows the third fin receiving a pack.
- FIG. 24 is a side view of the fins of the first embodiment spaced by 2 inches are in an unloading position.
- FIGS.25(a) through 25(d) are perspective views of a prior art boxing system illustrating how packs are put into a case, in which
- FIG. 25(a) shows packs aligned on an alignment conveyor system,
- FIG. 25(b) shows the packs pushed out of the alignment conveyor system by a pusher plate,
- FIG. 25(c) shows the case enclosing the packs, and
- FIG. 25(d) show the case containing the packs is removed from holding plates.
- Referring to the accompanying drawings, a boxing system according to a first embodiment of the present invention is described. FIGS.14(a) through 14(j) illustrate how packs are put into a cardboard box. The boxing system shown is used to put five (5) packs 1 into a corrugated cardboard box (hereinafter referred to simply as box) 2 as shown in FIG. 14(j). The
packs 1 are erected in thebox 2 with their bottoms down. Of course, the boxing system can be used to put smaller boxes in thebox 2. - An input conveyor or supply means4 is linked with an
alignment conveyor system 58 to supplypacks 1 onto thealignment conveyor system 58.Packs 1 are successively put one by one into respective ones ofpack receiving spaces 6 formed between adjacent ones of plural fins or partitioning means 5 mounted to the conveying surface of thealignment conveyor system 58.Respective packs 1 are put in the direction perpendicular to the conveyor surface so that they can erect upright in the respectivepack receiving spaces 6. Thealignment conveyor system 58 is driven by two steppingmotors motors fins 5 to advance in such a manner that one ofpacks 1 conveyed by theinput conveyor 4 is put input eachspace 6. Although not shown in FIGS. 14(a) through 14(j), two sets of sixfins 5, namely, a fin set 5-1 and a fin set 5-2, and two sets of sixfins 5′, namely a fin set 5′-1 and a fin set 5′-2, are mounted to fin-mountingfittings 33 secured to the alignment conveyor system 58 (FIG. 1). In the example shown in FIG. 1, the pitch of the fin-mountingfittings 33 is one (1) inch, and sixfins 5 are mounted to the respective ones of six successive pairs of fin-mountingfittings 33 so that adjacent fins are spaced by one inch. - The
motor 8 a drives two of the four fin sets, while themotor 8 b drives the remaining two fin sets.Packs 1 are successively conveyed to an unloadingstation 19 by thefins 5 of the four fin sets. - In this specification, the reference numeral “5” when used singly refers generally to one or all of the fins used. Similarly, the reference numeral “6” when used singly refers generally to one or all of the pack receiving spaces.
- Next, when a predetermined number, e.g. five, of
packs 1 put into fivepack receiving spaces 6 between thefins 5 on theconveyor system 58 are brought to the unloadingstation 19, being aligned with each other, a pusher plate (unloading means) 11 pushes the fivepacks 1 aligned on theconveyor system 58, as shown in FIG. 14(b). Thepusher plate 11 hasslits 12 therein through which thefins 5 can pass when thepusher plate 11 moves across thealignment conveyor system 58. - Then, as shown in FIG. 14(c), the five packs are pushed out of the
conveyor system 58 through a generallyU-shaped corridor 10 onto a pair ofgates 7. Thepusher plate 11 is driven to move laterally across and above thealignment conveyor system 58 by a later-described linear driver 55 (see, for example, FIGS. 3-5). Thus, thepusher plate 11 can push fivepacks 1 on thealignment conveyor system 58 to move through thecorridor 10 onto thegates 7 in the closed holding state. Astop plate 34 shown in FIG. 14(c) acts to prevent thepacks 1 from being pushed further on thegates 7 and also align the fivepacks 1 in a row. - The
pusher plate 11 is driven to move to pushpacks 1 out of thealignment conveyor system 58 when theconveyor system 58, which is intermittently driven to move, is temporarily stopped at a predetermined position. Depending on the width of the row of alignedpacks 1 and the number of rows ofpacks 1 to be put into thebox 2, the number of reciprocal movements and the stroke of respective movement of thepusher plate 11 may be changed appropriately. - After pushing
packs 1 to the predetermined position on thegates 7, thepusher plate 11 moves back in the opposite direction and temporarily stops at a location before thealignment conveyor system 58, as shown in FIG. 14(d), and, then, further moves across theconveyor system 58, without being interfered by thefins 5, to the original position to stand by for the next pushing operation, as shown in FIG. 14(e). - Then, a stuffing
plate 13 is lowered to a predetermined level to push down the top edges of the five packs on thegates 7 to thereby level the heights of therespective packs 1, as shown in FIG. 14(e). - Thereafter, as shown in FIGS.14(e) and 14(f), a
side holding plate 35, which has lain prone, is driven by a side holdingplate driving arrangement 107 to rotate to the vertical position, where it presses against the sides of the five packs on thegates 7 on the alignment conveyor side to make them align. At the same time, front and rear, upright holding plates 9-1 and 9-2 located at opposite ends of 11 a row of the fivepacks 1 on thegates 7 press against the front and rear ends of the row of thepacks 1. Thus, the fivepacks 1 on thegates 7 are held by the front and rear holding plates 9-1 and 9-2, thestop plate 34 and theside holding plate 35, which are pressed against the row ofpacks 1 from the four sides thereof. - Then, as shown in FIG. 14(g), the two
gates 7, which have been closed to support the fivepacks 1 thereon, are opened by a gate driver 106 (FIG. 3). Thebox 2 on a box rest 17 (see, e.g. FIG. 4) is lifted upward by a box lift 98 (see, e.g. FIG. 4) to locate below thepacks 1. Thebox 2 has been transported by aconveyor 96 shown in FIG. 4 and has stood by on thebox rest 17. Apack guide 90 guides thepacks 1 when they are put into thebox 2. - The front and rear holding plates9-1 and 9-2 are, then, moved slightly in the direction away from each other by respective holding plate drivers 16-1 and 16-2 (see FIG. 3) to reduce the pressure on the five
packs 1. The stuffingplate 13 is lowered to force the row ofpacks 1 into the bottom of thebox 2. See FIG. 14(h). Then, as shown on FIG. 14(i), theside holding plate 35 is rotated back to its original prone position. Thegates 7 are then closed by thegate driver 106, as shown in FIG. 14(j). - After that, the
rest 17 of thebox lift 98 with thebox 2 containing the fivepacks 1 resting on it is lowered to the original standby position, where thebox 2 is discharged to a discharge station. Then, anew box 2 is placed on therest 17 of thebox lift 98, the stuffingplate 13 returns to its original upward position, and the front and rear holding plates 9-1 and 9-2 return to their open positions. This completes one cycle of boxing operation. The same operation is repeated for putting another row of fivepacks 1 into thenew box 2. - Next, the
input conveyor 4, thealignment conveyor system 58 and thepusher plate 11 are described with respect to their structures and operations. -
Input Conveyor 4 andAlignment Conveyor System 58 - The
input conveyor 4 may be a belt conveyor of synthetic rubber and moves at a high speed to conveypacks 1. Thepacks 1 are supplied to theinput conveyor 4 at substantially constant intervals from a preceding packing machine (not shown) and fed to the succeedingalignment conveyor system 58. - However, due to some operating conditions of the packing machine, the intervals at which packs1 are fed to the
input conveyor 4 may vary. Anarticle sensor 20 disposed at the inlet end of thealignment conveyor system 58 senses packs 1 passing in front of thesensor 20, as shown in FIG. 1, which produces a pack representative signal when it senses apack 1. The first andsecond stepping motors alignment conveyor system 58 are actuated, in accordance with the pack representative signal, at such times that packs 1 are received in the respective ones of thepack receiving spaces 6 betweenadjacent fins 5, one for onespace 6. - The
alignment conveyor system 58 includes fourchain loops chain loops group chain loops first stepping motor 8 a, while the second group chain loops 21 a and 21 b are driven by thesecond stepping motor 8 b. Pairs of fin-mountingfittings 33 for holding thefins 5 are mounted to thechain loops fittings 33 is used to detachably mount onefin 5 to the firstgroup chain loops - As shown in FIGS. 1 and 2, the first
group chain loops fittings 33 with which at most twenty-onefins 5 can be mounted to the firstgroup chain loops fittings 33 with which at most twenty-onefins 5 can be mounted to thefirst chain loops fittings 33 is located halfway downstream from the first set. - The second group chain loops21 a and 21 b also have first and second sets each including twenty-one fin-mounting
fittings 33. The first and second sets are spaced by half the length of the loops as the first and second sets of fin-mountingfittings 33 of the firstgroup chain loops - Thus, as shown in FIG. 1, the
alignment conveyor system 58 includes a first set of fins 5-1 and a second set of fins 5-2 both of which belong to the first group and are driven by thefirst stepping motor 8 a, and a first set offins 5′-1 and a second set offins 5′-2 both of which belong to the second group and driven by thesecond stepping motor 8 b. - A first set of driving
sprocket wheel wheels first driving shaft 24 for rotation therewith and a second set of follower sprocket wheel wheels 22 c and 22 d freely rotatable with respect to theshaft 24 are disposed at the inlet end of thealignment conveyor system 58. Also, a second set of drivingsprocket wheel wheels second driving shaft 26 for rotation therewith and a first set of followersprocket wheel wheels shaft 26 are disposed at the outlet end of thealignment conveyor system 58. The firstgroup chain loop 18 a is looped around the drivingsprocket wheel wheels 22 a and the followersprocket wheel wheels 25 a, and the other firstgroup chain loop 18 b is looped around the drivingsprocket wheel wheels 22 b and the followersprocket wheel wheels 25 b. Similarly, the second group chain loops 21 a and 21 b are looped around the drivingsprocket wheel wheels 25 c and the follower sprocket wheel wheels 22 c and around the drivingsprocket wheel wheels 25 d and the follower sprocket wheels 22 d. The first andsecond driving shafts second stepping motors - As shown in FIG. 1, each
fin 5 is formed of a metal plate having an L-shaped cross-section and forms a pack receiving space 6 (6-1, 6′-1) withadjacent fins 5 as previously described. The length of eachpack receiving space 6 along the direction of travel of theconveyor system 58 is slightly larger than the thickness of eachpack 1 so that apack 1 can be held erect with some spacing left betweenadjacent fins 5. Thefins 5 extend radially in theloading station 43 at the inlet end of thealignment conveyor system 58 so thatpack inlet openings 23 are formed between adjacent ones of thefins 5. Each ofpacks 1 fed from theinput conveyor 4 slides into one of theopenings 23. -
Packs 1 are conveyed with their bottom facing forward on theinput conveyor 4 so that they can stand erect with their bottoms down in thepack receiving spaces 6. - The number of the
fins 5 in each set is six so that five packs, which thepusher plate 11 can push out of thealignment conveyor system 58 at a time, can be held. - Next, the electrical circuit of the boxing system is described with reference to FIG. 15.
- The boxing system includes a controller or
CPU 27. TheCPU 27 executes various arithmetic operations in accordance with programs stored in amemory 28 to drive the first andsecond stepping motors third stepping motor 8 c for operating thepusher plate 11, and other driving units. - A
setting display unit 30 is connected to the controller (CPU) 27, and is used to set, for example, the speeds of thechain loops fins pack receiving spaces input conveyor 4 at theloading station 43, and the speeds of thefins station 43 and the unloadingstation 19. Theunit 30 is also used to set operation timings in various processing steps, and other settings. Such settings may be displayed by thedisplay unit 30. - The speed at which the
fins station loading station pack receiving spaces packs 1 fed by theinput conveyor 4. It should be noted that since, in the illustrated example, thefins fins pack receiving spaces - The
CPU 27 operates to cause one of the first and second groups offins pack receiving spaces packs 1 properly from the input conveyor 4 (FIG. 14(a)). At the same time, theCPU 27 causes the other of the first and second groups offins station 19 whilepacks 1 in thepack receiving spaces conveyor system 58 by the pusher plate 11 (FIG. 14(b)). - The
CPU 27 can be also arranged to operate in accordance with programs stored in thememory 28 to cause one set of fins (5-2 in the example shown in FIG. 1) of one of the first and second fin groups 5-1, 5-2 and 5′-1, 5′-2 to stand by at a location immediately before the loading station, while one set of fins (5′-1 in the illustrated example) of the other fin group are in theloading station 43 for loading the pack receiving spaces (6′-1) withpacks 1. TheCPU 27 may also be arranged to operate to cause the other, loaded fin set (5-1) of the one fin group to stand by immediately before the unloadingstation 19, while the one fin set (5′-1) of the other fin group are being loaded withpacks 1. Both or either one of the described standby operations may be employed. - To realize it, the length of the
chain loops alignment conveyor system 58 is such that after, for example, the first fin set (5-1) of the first group is unloaded, the second fin set (5-2) of the first group can be in the standby position indicated in phantom before theloading station 43, and that the loaded first fin set (5′-1) can be in the standby position indicated by phantom before the unloadingstation 19. It should be note that in FIGS. 14(a)-14(e), theconveyor system 58 is shown schematically, and, therefore, the length of the chain loops are shown shorter for simplicity of explanation. - Also, connected to the CPU (controller)27 are an unloading
station sensor 31, thearticle sensor 20 and apusher sensor 42, which will be described later in greater detail. Also,pulse generators CPU 27 to provide pulses to be applied todrivers stepping motors - The unloading
station sensor 31 senses a set offins 5 with a predetermined number, e.g. five, ofpacks 1 received in the associatedspaces 6 when they arrived at the unloadingstation 19, and make the sensed fin set stop at the unloadingstation 19. - The
article sensor 20 senses apack 1 when it is received in onepack receiving space 6 from theinput conveyor 4 as shown in FIG. 1, and produces a pack representative signal in response to which the chain loops are driven to bring the nextpack receiving space 6 to the loading position. - The
pusher sensor 42 senses thepusher plate 11 when it is in its original position as shown in FIG. 14(b). When thepusher plate 11 in the original position is sensed, thepacks 1 in thepack receiving spaces 6 in the unloading station can be unloaded. - The
pulse generators controller 27 and supply the generated pulses to thedrivers drivers respective stepping motors drivers - The operation of the
alignment conveyor system 58 of the boxing system with the above-described arrangement is now described with reference to the flow chart shown in FIG. 16. When one fin set moves to theloading station 43, theCPU 27 makes a judgment as to whether apack 1 is put into the first or leading one of the pack receiving spaces 6 (Step S100). If apack 1 is in thefirst space 6, the steppingmotor second space 6 comes to the loading position where anext pack 1 is put into the second space 6 (Step S102). Each time apack receiving space 6 is loaded with apack 1, theCPU 27 makes a judgment as to whether or not all of a predetermined number, five in the illustrated example, ofspaces 6 have been loaded with packs 1 (Step S104). If the judgment is negative, Step S100 and Step S102 are repeated until all thespaces 6 are loaded withpacks 1. When it is judged that all of the fivespaces 6 have been filled withpacks 1, the fin set is moved to the unloadingstation 19 wherepacks 1 in thespaces 6 are to be taken out (Step S106). In this case, the speed of the fin set moving from theloading station 43 to the unloadingstation 19 is higher than the speed of the fin set when they move in theloading station 43. In the unloadingstation 19, therespective packs 1 in thespaces 6 are pushed out of thealignment conveyor system 58 by thepusher plate 11. Then, the fin set is intermittently driven to move in such a manner as to stop at a plurality of preset positions (Step S108). After that, the fin set is moved to theloading station 43 at a higher speed than it is moved in theloading station 43. It is arranged such that the fin sets do not interfere or contact with the preceding fin set. - Since the speed of the
fins 5 travelling between the loadingstation 43 and the unloadingstation 19 is higher than the speed in theloading station 43, the traveling time can be reduced, which results in reduction of time required for loading and unloading of the alignment conveyor system withpacks 1. Thus, according to the present invention, the efficiency of the boxing system can be improved. - Since the first and second fin groups are driven independently, packs conveyed by one fin set of one of the two fin groups can be taken off at the unloading
station 19 where they are stopping or moving at a low speed, while thefins 5 of a fin set of the other group are in theloading station 43 where they are intermittently moved for receiving packs in the respectivepack receiving spaces 6 at a predetermined speed. - Thus, it is not necessary to delay loading or unloading one fin group until other fin group has been unloaded or loaded, which results in reduction of the time required for one cycle of the loading and unloading of the
alignment conveyor system 58. - As described previously, one fin set of one fin group shown in phantom in FIG. 1, which have been unloaded, can stand by for the loading at the standby position immediately before the
loading station 43, and a fin set of one fin group shown in phantom in FIG. 1, which are carryingpacks 1, can stand by for the unloading at the standby position immediately before the unloading station, while a fin set of the other fin group are being loaded withpacks 1. - Thus, with the above-described arrangement, the loading and unloading of the
alignment conveyor system 58 can be done continuously, which results in improvement of the efficiency of the boxing system - Next, referring to FIGS.2, 6(a)-6(c) and 7(a)-7(f), an
arrangement 44 for mounting thefins 5 to thechain loops - The fin-mounting
arrangement 44 is for detachably mounting thefins 5 to fin-mountingfittings 33 which are fixed to the firstgroup chain loops group chain loops fittings 33 fixed to the other of the first group chain loops to form a pair for mounting onefin 5. Similarly, each fitting 33 fixed to one of the second group chain loops 21 a and 21 b face one of thefittings 33 fixed to the other of the second group chain loops to form a pair for mounting onefin 5′. In the illustrated example, twenty-one pairs of fin-mountingfittings 33 are used for each of the first and second fin groups. - Since all of the
fins 5 are mounted to the chain loops in the same manner, the fin-mountingarrangement 44 is described only for onefin 5 for simplicity of explanation. - As shown in FIGS.6(a)-6(c) and 7(a)-7(f), each of a pair of fin-mounting
fittings 33 fixed to the respective ones of thechain loops hole 45. Eachfin 5 includes apartition 5 a and abase 5 b. - A
retainer 46 is attached to thefin 5 on each of the opposing sides thereof. - Each fin-mounting
fitting 33 is a generally rectangular plate and fixed to one of thechain loops coupling member 49. - Each of the through-
holes 45 has a generally roundwider opening 47 and a generally ellipticnarrow opening 48, which are joined together. - Each of the
retainer 46 is disc-shaped and is secured by anut 51 to the bottom end of each of a pair ofshanks 50, which are spaced from each other and extend downward from thebase 5 b of thefin 5. The outer diameter of theretainer 46 is smaller than the inner diameter of thewider opening 47 of the through-hole 45, but it is larger than the inner diameter of thenarrow opening 48. Accordingly, when theretainer 46 is inserted into thewider opening 47 of the through-hole 45 and moved to thenarrow opening 48, the upper surface of theretainer 46 can contact the bottom surface of theperiphery 48 a of thenarrow opening 48. - Each
shank 50 is disposed to extend through a bore through a shortercylindrical member 52. Thecylindrical member 52 supports alarger diameter flange 52 a joined to the bottom end thereof. Thecylindrical member 52 and theflange 52 a are movable together along the length of theshank 50. - A
coil spring 53 is mounted on themember 52. The bottom end of thecoil spring 53 is in contact with theflange 52 a so as to press theflange 52 a against the retainer 46 (FIG. 6(a)). FIG. 6(b) shows thecylindrical member 52 with theflange 52 a slid upward against the spring force of thecoil spring 53. - The
retainer 46, theshank 50, thenut 51, thecylindrical member 52, theflange 52 a and thecoil spring 53 form a mountingdevice 59 on the fin side. - As shown in FIGS.6(a) and 7(a), a
short columnar detent 54 projects downward from the bottom end of one of a pair of fin-mountingfittings 33. Thedetent 54 is on the right-hand side fitting 33 in the example shown in FIGS. 6(a) and 7(a). Thedetent 54 is engaged by theretainer 46, which is pressed by thespring 53 against the bottom surface of theperiphery 48 a of the narrow through-hole portion 48, as shown in FIGS. 7(e) and 7(d), so that theretainer 46 cannot move into thewider opening 47, whereby thefin 5 does not slip off from the pair of fin-mountingfittings 33. When theretainer 46 is in engagement with thedetent 54, theshank 50 is in contact with the inner periphery of thenarrow opening 48 of the through-hole 45. Thus, thedetent 54 acts also to position thefin 5 with respect to the pair offittings 33. - With the above-described arrangement of the fin-mounting
arrangement 44, thefins 5 can be detachably mounted on respective pairs of fin-mountingfittings 33. For mounting afin 5 to a pair offittings 33, thefin 5 is placed with the free edge of thebase 5 b of the L-shaped fin facing forward. Then, as shown in FIGS. 7(a) and 7(b), a pair ofretainers 46 of thefin 5 are forced into thewider openings 47 of the through-holes 45 in therespective fittings 33 against the force of thesprings 53. As the fin is pressed down, the lower surfaces of theflanges 52 a abut against the upper surfaces of the peripheries of the respectivewider openings 47, and, therefore, thefin 5 receives a force tending to lift it upward. After that, as shown in FIGS. 7(c) and 7(d), thefin 5, being pressed down with theretainers 46 placed in thewider openings 47, is moved rightward (in FIGS. 7(c) and 7(d)) until theshanks 50 contact the right portion of the inner peripheries of the respectivenarrower portions 48. Since thefin 5 is pressed downward, theretainer 46 on the right side portion of thefin 5 can move over thedetent 54. Then, the force to press down thefin 5 is removed so that theretainers 46 are pressed against the bottom surface of the portion of thefittings 33 around theperipheries 48 a of thenarrower portions 48 by thesprings 53. In these positions, theretainers 46 are prevented from moving into thewider openings 47 by thedetent 54, and, therefore, thefin 5 does not come off from the fin-mountingfittings 33. - For dismounting the
fin 5 from the fin-mountingfittings 33, the above-described procedures are followed in the opposite direction. Specifically, thefin 5 is pressed downward against the spring force given by thesprings 53 so that theretainers 46 are removed from the bottom surfaces of theperipheries 48 a of thenarrower portions 48 of the through-holes 45. With theretainers 46 kept off from the bottom surfaces of thefittings 33, thefin 5 is moved leftward into thewider openings 47. Since theright retainer 47 is off the bottom surface of theright fitting 33, it can move over or below thedetent 54. In this position, thefin 5 can be removed from the fin-mountingfittings 33, by pulling theretainers 46 off from thewider openings 47 of the respective through-holes 45. - For
accommodating packs 1 of a different thickness, the width of thepack receiving spaces 6, i.e. the dimension of thespaces 6 in the traveling direction of thefins 5, must be changed, which requires to change the locations where therespective fins 5 are mounted to thealignment conveyor system 58. As is understood from the above-description, with the fin-mountingarrangement 44 of the present invention, such change in location of thefins 5 can be done easily without resort to any tools, and the fins, after such changes in location, can be held in place by thedetents 54 during the operation of theconveyor system 58. Also, it is easy to add or reduce the number of thefins 5 attached to thealignment conveyor system 58, which would be required for accommodating a different number of packs to be put in a box. -
Pusher Plate 11 and Arrangement for Operating It - As best shown, for example, in FIGS.3-5 and 14(b), the
pusher plate 11 formed of metal includes a number ofslits 12 therein for avoiding interference with thefins 5. Accordingly, for different numbers of thefins 5 in each fin set and for different widths of thespaces 6,different pusher plates 11 should be prepared. - The
pusher plate 11 is driven by thelinear driver 55. In FIG. 5, the side elevation of thelinear driver 55 is shown. Thelinear driver 55 is mounted on aframe 37 of the boxing system and includes a reciprocating table 56, which moves on rails (not shown) along a path extending in parallel with the conveyor surface of thealignment conveyer system 58 and transverse to the travelingdirection 57 of thealignment conveyor system 58. The reciprocating table 56 is adapted to move along the path over a distance of S1 shown in FIGS. 3 and 5. Thepusher plate 11 is fixed to the reciprocating table 56 for movement with the table 56. - The movement of the
pusher plate 11 by the distance S1 from the original position shown in FIG. 5 across theconveyor system 58 makes fivepacks 1 aligned on thealignment conveyor system 58 are pushed to the position between the front and rear holding plates 9-1 and 9-2. - The reciprocating table56 is driven by a
third stepping motor 8 c, which, in turn, is controlled by theCPU 27. Thus, the operation of thepusher plate 11 is controlled by theCPU 27. - Being controlled by the
CPU 27, thepusher plate 11 moves along a predetermined substantially horizontal path extending above and across thechain loops alignment conveyor system 58 from the original position beside theconveyor system 58, when one of the four sets offins 5 is in theunloading position 19, as shown in FIG. 14(b). As a result, fivepacks 1 held in thespaces 6 betweenadjacent fins 5 are pushed onto the position on thegates 7 between the front and rear holding plates 9-1 and 9-2. Thepusher plate 11 is arranged to return to its original position, moving along the predetermined path in the opposite direction, without interfering with the unloadedfins 5. - Pack Holding Arrangement
- As shown in FIG. 14(f), the five
packs 1 pushed by thepusher plate 11 and aligned on thegates 7 are held in place by thestop plate 34, the front and rear holding plates 9-1 and 9-2, and theside holding plate 35. The front and rear holding plates 9-1 and 9-2 and theside holding plate 35 are driven by a pack holding arrangement. The pack holding arrangement includes the front and rear holding plate drivers 16-1 and 16-2 and the side holdingplate driving arrangement 107 shown in FIG. 3. - As previously described, the front and rear holding plate drivers16-1 and 16-2 drive the front and rear holding plates 9-1 and 9-2 toward and away from each other, respectively. Since the two drivers 16-1 and 16-2 have the same arrangement, only one of them is described. Accordingly, in this specification, the reference numeral “16” used alone denotes generally the holding plate drivers 16-1 and 16-2, and, similarly, the reference numeral “9” used alone denotes generally the front and rear holding plates 9-1 and 9-2.
- The
driver 16 includes, as shown in FIGS. 8(a) and 8(b), a holding platelinear driver 63 for reciprocally moving the holdingplate 9, aforce detector 64 for measuring the force by which theplate 9 presses the row ofpacks 1, and plate stopping means for stopping the holdingplate 9 provided by the control of theCPU 27 as represented by Steps S214 and S216 in the flow chart shown in FIGS. 17(a) and 17(b) which will be described later. - The holding plate
linear driver 63 includes atiming belt 65 as shown in FIG. 8(a). A table 66 is connected to thetiming belt 65 and is reciprocally movable on alinear guide rail 67. Thetiming belt 65 is looped around afollower timing pulley 68 a and adriving timing pulley 68 b secured to a rotary shaft of afourth stepping motor 8 d. Thefourth stepping motor 8 d when rotating in forward and reverse directions reciprocally moves the table 66. With the reciprocal motion of the table 66, the holdingplate 9 moves back and forth. Thefourth stepping motor 8 d, thelinear guide rail 67, thefollower timing pulley 68 a and thedriving timing pulley 68 b are secured to theframe 37. - It should be noted, however, in place of the timing belt type
linear driver 63, any other suitable driving arrangement may be used to drive the holdingplate 9. - The
force detector 64 includes, as shown in FIGS. 8(a) and 8(b), a pair ofsprings 69 and apressing force sensor 70. When theplate 9 abuts and presses against the front orrear end pack 1 aligned on thegates 7 as it is driven forward by thedriver 63, thesprings 69 are compressed. Thepressing force sensor 70 detects when thesprings 69 are compressed to a predetermined length, which means a predetermined force is applied to thepack 1. Then, thesensor 70 produces a detection signal and applies it to the controller (CPU) 27. - As shown in FIGS.8(a) and 8(b), two
parallel support rods 71 are coupled to the back surface of the holdingplate 9 and are supported bybearings 72 so as to axially slide therein. Thebearings 72 are secured to an L-shapedmember 73, which, in turn, is coupled to the reciprocating table 66 by a slidingshaft 74. Theshaft 74 is slidably supported by abearing 105. Thesprings 69 are mounted over therespective support rods 71 and bias the holdingplate 9 toward thepacks 1 on thegates 7. -
Stoppers 15 are provided at the proximal ends of the twosupport rods 71 opposite to the holdingplate 9, for preventing therods 71 from slipping off from thebearings 72. Theforce sensor 70 is secured to one, the upper one in the example shown in FIG. 8(a), of thestoppers 15 or the proximal ends of thesupport rod 71. Theforce sensor 70 includes a photosensor, which generates a signal when light incident on it is blocked by ashield 76. The signal generated by theforce sensor 70 is applied to theCPU 27, which causes the rotation of thefourth stepping motor 8 d and, hence, the movement of the holdingplate 9 to stop. - The
shield 76 is attached to the horizontal portion of the L-shapedmember 73 by means of aposition adjusting arrangement 77 so as to be adjustable in position. Theposition adjusting arrangement 77 includes aguide shaft 78 secured to the L-shapedmember 73 in parallel with theshaft 74, and a bolt 79 a and anut 79 b for fixing theshield 76 to the L-shapedmember 73 by fastening thenut 79 b. - The position of the
shield 76 relative to the quiescent or original position of thesensor 70 shown in FIG. 8(a) can be changed by unfastening thenut 79 b and moving theshield 76 on theguide shaft 78. After theshield 76 is brought to a desired position, thenut 79 b is fastened. - In operation of the front and rear holding plate drivers16-1 and 16-2, when packs 1 are pushed out from the
alignment conveyor system 58 onto thegates 7 as shown in FIG. 14(d), thefourth stepping motor 8 d and afifth stepping motor 8 e, which drives the rear holding plate driver 16-2, are rotated in the forward direction to drive the front and rear holding plates 9-1 and 9-2 forward, i.e. toward each other. The forward rotation of thestepping motors packs 1, i.e. the front end pack and the rear end pack, on thegates 7. It causes the respective L-shapedmembers 73 coupled to the reciprocating tables 66 to compress therespective springs 69, so that the distances between the L-shapedmembers 73 and the associated holding plates 9-1 and 9-2 decrease. Then, the holding plates 9-1 and 9-2 press a predetermined number, five in the illustrated example, of alignedpacks 1 with a preset force by virtue of the compressed springs 69. The position of theshields 76 relative to theforce sensors 70 is such that theshields 76 block thesensors 70 from incident light when thesprings 69 are compressed to give the preset force to the holding plates 9-1 and 9-2. Theforce sensors 70, when shielded, produce the sensor signals which cause the fourth andfifth stepping motors gates 7 with a preset force. TheCPU 27 detects this fact and proceeds to the next step. - With the above-described arrangement, packs1 are not crushed even when the length of the row of aligned
packs 1 is relatively large. Also, even when the length of the rows of alignedpacks 1 is relatively short, packs 1 will not slip off from between the holding plates 9-1 and 9-2 since an appropriate force is given to them. - Sometimes, packs1 are filled with gas, e.g. inert gas, which results in variations in thickness among
packs 1. The above-described holding arrangement can reliably hold a row of such packs with an appropriate force by the holding plates 9-1 and 9-2. - The maximum amount of feed, X1, by which the holding plates 9-1 and 9-2 are fed forward, can be preset through the
setting display unit 30 connected to the controller (CPU) 27 (FIG. 15). The maximum amount of feed is such an amount that even when the holding platelinear driver 63 forwards tables 66 by that amount, thesensors 70 are not shielded by theshields 76 if the number ofpacks 1 on thegates 7 is smaller than the predetermined number. Whether the tables 66 have been fed by the maximum amount or not can be determined by measuring the angle of rotation of the steppingmotor 8 d and/or the steppingmotor 8 e, or counting the number of pulses supplied to the stepping motors. TheCPU 27 is arranged to cause the fourth andfifth stepping motors CPU 27, then, may activate an alarm (not shown) to notify an operator that a smaller number ofpacks 1 have been supplied onto thegates 7 and may stop the operation of the boxing system. - As shown in FIGS.10(a) and 10(b), the side holding
plate driving arrangement 107 operates to hold the lateral sides of the row of alignedpacks 1 of which the front and rear end are held by the front and rear holding plates 9-1 and 9-2. The lateral sides are held by theside holding plate 35 and thestop plate 34. Thestop plate 34 is secured to theframe 37, and theside holding plate 35 is driven to swing by asixth stepping motor 8 f. - The
side holding plate 35 is rectangular in shape and secured to ashaft 81 by a mountingplate 80 as shown in FIG. 10(a). Theshaft 81 is rotatably supported bybearings 82 at its opposite ends. Thebearings 82 are secured to abase 83. Thesixth stepping motor 8 f is mounted on the upper surface of thebase 83 for swinging theside holding plate 35 about theshaft 81. A drivingpulley 84 is mounted on the rotary shaft of themotor 8 f, and afollower pulley 85 is fixed to theshaft 81. Atiming belt 86 is looped around the drive and follower pulleys 84 and 85. - As shown in FIG. 10(b), a
swing position sensor 87 is disposed on thebase 83, which senses the original position of theside holding plate 35. Theswing position sensor 87 senses a slit 88 a in adisc plate 88 fixed to theshaft 81 to sense the original position of theside holding plate 35. The original position of theside holding plate 35 is indicated in phantom in FIG. 10(b), which is substantially a horizontal position. When theside holding plate 35 is driven to swing to the vertical position indicated by solid lines, it can hold, together with thestop plate 34, the lateral sides ofpacks 1 on thegates 7. - The side holding
plate driving arrangement 107 is fixed to theframe 37 by securing the base 83 torods 89 that are secured to theframe 37 as shown in FIG. 5. FIG. 10(c) is a plan view of the side holdingplate driving arrangement 107. - When five packs on the
alignment conveyor system 58 are pushed to thegates 7 and aligned on them by thepusher plate 11, theside holding plate 35 in the horizontal position (FIG. 14(e)) is driven to swing to the vertical position (FIG. 14(f)) to thereby laterally hold the sides of the five packs in a row on thegates 7 between theplates plate 35 to the vertical position can also align the sides of therespective packs 1. After the lateral sides ofpacks 1 are held by theside holding plate 35 and thestop plate 34, the front and rear ends of the row of thepacks 1 are held between the front and rear holding plates 9-1 and 9-2. Thus, packs 1 on thegates 7 can be put into thebox 2 without their edges and corners being caught by theflaps 2 a and/or upper edges of the sides of thebox 2. Thus, packs 1 can be placed neat in thebox 2. - With the above-described pack holding arrangement, even when the length of the row of aligned
packs 1 is long or the total weight of alignedpacks 1 is heavy, packs 1 can be reliably held between the pack holding plates 9-1, 9-2 and 35 and thestop plate 34 with such a small force that will not damagepacks 1, so that a number of packs can be reliably and neatly put into thebox 2. - Next, the
pack guide 90 shown in FIGS. 14(g)-14(i) is described. Thepack guide 90 facilitates the putting ofpacks 1, held by the holding plates 9-1, 9-2 and 35 and thestop plate 34, into thebox 2 by the stuffingplate 13. As shown in FIG. 14(g), thepack guide 90 is disposed horizontally below thegates 7 and above the upper edges of theflaps 2 a of thebox 2. - The
guide 90 is shown in greater detail in FIGS. 11, 12(a) and 12(b). Thepack guide 90 includes aguide frame 91, fourguide plates 97 and coil springs (not shown) attached to the respective ones of theguide plates 97. - The
guide frame 91 is a rigid metal frame and is formed by four trapezoidalplanar plates guide frame 91 has arectangular outlet port 92 b (FIG. 12(a)) which is substantially the same size as the inlet opening of thebox 2, and has arectangular inlet port 92 a larger than theoutlet port 92 b, which facilitates the putting of thepacks 1 held by the holding plates 9-1 and 9-2 into theguide 90. - The four
guide plates 97 are hinged byrespective shafts 99 and biased by the respective coil springs to assume the innermost positions (FIG. 12(a)) in which they extend diagonally downward from the lower ends of theplates 91 a-91 d in the planes in which theplates 91 a-91 d lie. The lower edges of theplates 91 a-91 d form theoutlet port edges 101 a-101-d of the funnel-shapedguide frame 91. The fourguide plates 97 cannot swing inward of the innermost positions, but they can swing outward by about 90°. FIG. 12(b) shows one of the fourguide plates 97 pushed outward bypacks 1. In this position, the fourguide plates 97 press thepacks 1 inward. Therectangular outlet port 94 defined by the fourguide plates 97 is slightly smaller than the opening of thebox 2 so that the upper edges of the four substantiallyupright flaps 2 a of thebox 2 can be outside the fourguide plates 97, as shown in FIG. 12(a). - As shown in FIGS.11, 12(a) and 12(b),
support plates plates 91 a and 91 c and are provided with mountingmembers 95, which are used to secure thepack guide 90 to theframe 37. - The aligned packs1 held by the holding plates 9-1 and 9-2 are pushed into the relatively
large inlet port 92 a of thepack guide 90 by the stuffingplate 13, as shown in FIG. 13. The stuffingplate 13 pushes thepacks 1 further down into thebox 2 below thepack guide 90 through the relativelysmall outlet port 94 of theguide 90. When thepacks 1 pass through theoutlet port 94, they push the fourguide plates 97 outward, as shown in FIG. 12(b), so that the row of thepacks 1 are pressed inward by the recovery force of theplates 97 given by the coil springs. - Because of the funnel shape of the
pack guide 90, edges, such as heat-sealed portions, and corners ofpacks 1 do not contact the upper edges of thebox 2, and, therefore, packs 1 can be put into thebox 2 without leaving empty spaces. - Also, since the
guide plates 97 can swing outward or inward to an extent for accommodating various sizes of alignedpacks 1, packs 1 of various sizes can be put into abox 2 without being caught by the upper edges of thebox 2. This makes it possible to useboxes 2 of smaller sizes than conventionally used ones, which, in turn, makes it possible to use a smaller area for storing the packedboxes 2. - Further, as shown in FIG. 13, the upper edges of the four
flaps 2 a of thebox 2 when it is lifted to a position beneath theguide 90 are pressed outward by being guided along the outer surfaces of thecorresponding guide plates 97. Thus, packs 1 do not contact the upper edges of theflaps 2 a when they are put into the box and, therefore, are not damaged. - In accordance with programs stored in the
memory 28, the controller (CPU) 27 controls the operation of the fourth andfifth stepping motors sixth stepping motor 8 f which drives theside holding plate 35 to swing. - The number of
packs 1 to be pushed out from thealignment conveyor system 58 can be set through thesetting display unit 30 connected to theCPU 27. Thesetting display unit 30 is also used for setting timing for operating various drivers including the above-described ones as well as quantities of such operations. - The
pressing force sensors 70, theswing position sensor 87, andpulse generators CPU 27. Thepulse generators drivers motors drivers respective pulse generators CPU 27. - The operation of the above-described pack holding arrangement is described with reference to the flow chart shown in FIGS.17(a) and 17(b). The processing shown in FIGS. 17(a) and 17(b) is executed by the
CPU 27 in accordance with the programs stored in thememory 28. - First, a predetermined number, five in the illustrated example, of
packs 1 are supplied to a set offins 5 of thealignment conveyor system 58. In Step S200, whether or not the fin set withpacks 1 is in the unloadingstation 19 shown in FIG. 14(b) is judged. If it is (i.e. the answer is YES), thepusher plate 11 is driven forward (Step S202), so that the fivepacks 1 held by thefins 5 are pushed onto thegates 7. Whether thepusher plate 11 has returned to the original position or not is then judged (Step S204), and, if it has returned to the original position, a judgment is made as to whether or not thepusher plate 11 has pushed five packs 1 a predetermined number of times, once in the example illustrated in FIGS. 14(a) through 14(j) (Step S206). - If two rows of
packs 1 are to be put in abox 2, as in the case shown in FIGS. 25(a)-25(d), thepusher plate 11 operates successively twice in one operating cycle to push out fivepacks 1 twice. - A judgment is made as to whether or not the
pusher plate 11 has been in a predetermined position in the return path to the original position (Step S208). If thepusher plate 11 is in the predetermined intermediate position, thesixth stepping motor 8 f is driven to move theside holding plate 35 in the horizontal position shown in FIG. 14(e) to the vertical position shown in FIG. 14(f) (Step S210). Thus, the fivepacks 1 are aligned on thegates 7 and held between theside holding plate 35 and thestop plate 34. - The
side holding plate 35 is moved from the horizontal position to the vertical position after thepusher plate 11 is in the predetermined intermediate position in order to avoid collision of thepusher plate 11 returning to its original position with theside holding plate 35 swinging toward the vertical position. - Then, the fourth and
fifth stepping motors force sensors 70 have been blocked by theshields 76 and generated the representative signal, is judged (Step S214). If theforce sensors 70 have generated the respective signals, the fourth andfifth stepping motors gates 7 are held between the front and rear holding plates 9-1 and 9-2 by an appropriate force. - If the
force sensors 70 are judged not to have generated the representative signals, a judgment is made in Step S218 as to whether the fourth andfifth stepping motors 8 d and Se have operated to forward the the table 66 (FIG. 8(a)) by the preset amount X1. If the determination in Step S218 is YES, i.e. if the fourth andfifth stepping motors 8 d and Se have forwarded the respective holding plates 9-1 and 9-2 by X1, the steppingmotors 8 d and Se and, hence, the holding plates 9-1 and 9-2 are stopped (Step S220). Then, the boxing system is stopped operating, and an alarm signal is generated (Step S222). This situation indicates that the number ofpacks 1 on thegates 7 is less than the predetermined number, or the total thickness of thepacks 1 on thegates 7 has been reduced due to, for example, breakage in one or more packs. - An operator should press an acknowledgment switch on the setting display unit30 (Step S224), which results in the returning of the
side holding plate 35 to the horizontal position (Step S226). The operator then takes steps to place the boxing system in the proper operating condition, by , for example, removing thepacks 1 on thegates 7 and placing a predetermined number ofnew packs 1 between the front and rear holding plates 9-1 and 9-2 on thegates 7 manually or by any appropriate means (Step S228), and press the acknowledgment switch again (Step S230). This causes theside holding plate 35 to swing to the vertical position to hold thenew packs 1 on the gates 7 (Step S232). - After Step S216 or Step S232, the
gates 7 are opened (Step S234). The stuffingplate 13 is lowered to place the fivepacks 1 into abox 2 which has been lifted to a position beneath thegates 7, and thereafter, the stuffingplate 13 is raised (Step S236). Theside holding plate 35 is returned to the horizontal position, thegates 7 are closed, the front and rear holding plates 9-1 and 9-2 are returned to their respective retracted positions, and thebox 2 withpacks 1 put therein is lowered and outputted (Step S238). In Step S240, whether or not thepusher plate 11 is in the original position is judged. If thepusher plate 11 is in its original position, the processing returns to Step S200, and the operation described above is repeated. - If it is judged that the
pusher plate 11 is not in the original position in Step S240, Step S240 is repeated until theplate 11 returns to its original position, and, then, Step S200 is executed. - A boxing system according to a second embodiment of the present invention is now described with reference to FIGS.18-24. The boxing system of the second embodiment differs only in an alignment conveyor system from the boxing system of the first embodiment. Therefore, detailed description of the remaining portions will not be given.
- As shown in FIG. 24, the
alignment conveyor system 58 according to the first embodiment uses a plurality offins fins base 5 b and spaced by a distance “a” from thepartition 5 a. All thefins fins fittings 33, which, in turn, are secured to the pairs ofchain loops chain loop 18 a is shown. As shown in FIGS. 23(a) and 23(b), the chain loop pair with thefins devices 59. This pitch P1 is equal to an integral multiple of the pitch F of the fin-mountingfittings 33. In the example shown in FIGS. 23(a), 23(b) and 24, the pitch P1 is equal to two (2) inches. Thus, theadjacent partitions 5 a are spaced by 2 inches for accommodating apack 1 having a thickness of more or less smaller than 2 inches. This successively places the tip ends of thefins loading position 40 in theloading station 43 to receive apack 1 fed from theinput conveyor 4. - According to the second embodiment, the
alignment conveyor system 58 is so arranged that fins can be mounted not only with the spacing E therebetween being equal to an integral multiple of the pitch F of the fin-mountingfittings 33, but also with the spacing E being equal to a non-integral multiple of the pitch F. The fin spacing is changed in order to accommodate packs of various thicknesses D. For this purpose, the distance E between adjacent fins or partitions which is different from an integral multiple of the pitch F (=1 inch) of the fin-mountingfittings 33 is employed. In the illustrated example, the distance E is 2.5 inches. The illustrated example is arranged to conveypacks 1 having a thickness of, for example, 2.2 inch. - The illustrated example shown in FIG. 20 uses the first, third and
fifth fins device 59 spaced by the distance “a” from thepartition 5 a and second, fourth and sixth fins 60 2, 60 4, and 60 6 each having asimilar mounting device 59 secured to itsbase 60 b and spaced by a different distance “b” from its partition 60 a. The different distances “a” and “b” are used because the spacing E between adjacent partitions is not an integral multiple of the pitch F of the fin-mountingfittings 33. Because of different distances “a” and “b” employed between the mountingdevice 59 and the partition, the distance between adjacent mountingdevices 59 are such that the distance between the mountingdevices 59 of thefirst fin 5 1 and the second fin fins 60 2 is P1 (=2 inches), the distance between the mountingdevices 59 of the second fin fins 60 2 and thethird fin 5 3 is P2 (=3 inches), the distance between the mountingdevices 59 of thethird fin 5 3 and the fourth fin 60 4 is P1, the distance between the mountingdevices 59 of the fourth fin 60 4 and thefifth fin 5 5 is P2, and the distance between the mountingdevices 59 of thefifth fin 5 5 and the sixth fin 60 6 is P1. The values “a” and “b” are determined by the distance E between adjacent partitions (or the thickness of packs), the pitch F of the fin-mountingfittings 33, the radius of curvature of the turning path in the receivingstation 43, etc. In the illustrated example, the value “b” is larger than “a” by 0.5 inches. - As shown in FIGS.21(a) and 21(b), after a
pack 1 is received on the second fin 60 2 at theloading position 40, the chain loops are forwarded by the pitch P2. This places the tip end of thethird fin 5 3 at a loading position 41 (FIG. 21(b)) in theloading station 43 so that anext pack 1 can be received on thethird fin 5 3. Then, the chain loops are fed by the pitch P1, which places the tip end of the fourth fin 60 4 at theloading position 40, so that anotherpack 1 can be received on the fourth fin 60 4 from theinput conveyor 4. In this way, the pitch by which therespective fins 5 and 60 are moved alternates between P2 and P1. The same procedures are repeated to load the fin set with fivepacks 1. - The loading positions41 and 40 in the
loading station 43 are such that the tip ends of thefins 5 and 60 can properly receive apack 1 in a straight position without causing thepack 1 to be bent, as shown in FIGS. 21(a) and 21(b), and FIGS. 23(a) and 23(b). - Now, the reason why the tip ends of the
fins - The
alignment conveyor system 58 and theinput conveyor 4 are in such positional relation that, as shown in FIGS. 23(a) and 23(b), the tip ends of the second throughsixth fins 5 can be properly placed in theloading position 40 when the distance “a” between the mountingdevice 59 and thepartition 5 a is employed for allfins 5 and the pitch by which the chain loops are intermittently moved is an integral multiple of the pitch F of the fin-mountingfittings 33. - FIG. 21(a) illustrates the second fin 60 2 with its tip end positioned at a
loading position 40 in theloading station 43 in the turning path when thefirst fin 5 1 is in the position forward by P1 (=2 inches) from theloading position 40. (It is so programmed that thefirst fin 5 1 does not stop at theloading position 40 because it is the fin 60 2 that first receives a pack.) - Since the distance E between the
partition 5 1 a of thefin 5 1 and the partition 60 2 a of the fin 60 2 is 2.5 inches, the chain loops or thefin 5 1 should have been moved by 2.5 inches, and therefore, thefin 5 1 should be further moved by a shortage of 0.5 inches. However, since the distance between the mountingdevice 59 and the partition 60 2 a of the fin 60 2 is “b” for adaptation of the mountingdevice 59 for the fin-mountingfittings 33, the tip end of the fin 60 2 can be in a position advanced from the position the tip end would assume when the distance “a” is employed, by the difference between “b” and “a”, i.e. (b−a)=0.5 inches. In other words, by shifting forward the position of the mountingdevice 59 of the fin 60 2 by (b−a), the tip end of the fin 60 2 in the arcuate turning path is lifted upward to compensate for the shortage of 0.5 inches, so that the tip end can be positioned properly at theloading position 40. - FIG. 21(b) shows the second fin 60 2 in the position it assumes when the chain loops advance by P2 (=3 inches) from the position where the tip end of the second fin 60 2 was in the
loading position 40. In this state, the tip end of thethird fin 5 3 is at aloading position 41 in theloading station 43, where the chain loops have advanced from the position where the tip end of thefirst fin 5 1 is in theloading position 40 by just the twice the distance E between the partitions of adjacent fins, which is an integral multiple (five times) of the pitch F of the fin-mountingfittings 33. The tip end of thethird fin 5 3 can be positioned properly at theloading position 41 because the distance of thepartition 5 3 a and its mountingdevice 59 is “a”. - In the same manner, the tip ends of the fourth and sixth fins60 4 and 60 6 can stop at the
loading position 40 shown in FIG. 21(a), and thefifth fin 5 5 can stop at theloading position 41 shown in FIG. 21(b), where they can properly receive packs 1. - FIGS.22(a) and 22(b) show the positions where the six
fins loading station 43 if the chain loops were intermittently moved by 2.5 inches. It should be noted that only three of the six fins, namely, thefins fifth fins loading position 41′ shown in FIG. 22(b), and the tip ends of the second, fourth and sixth fins 60 2, 60 4 and 60 6 stop at theloading position 40 shown in FIG. 22(a). Thefirst fin 5 1 passes both loading positions as in the case illustrated in FIGS. 21(a) and 21(b). - If the system is so arranged that the tip ends of the even-numbered fins60 2, 60 4 and 60 6 are placed at the substantially
appropriate loading position 40 as shown in FIG. 22(a), the tip ends of the odd-numberedfins position 41′ shown in FIG. 22(b), which is lower by a relatively large distance than the output end of theinput conveyor 4. Atsuch loading position 41′, packs 1 fed by theinput conveyor 4 cannot be properly received on thefins fins - As is understood from the above description, if the chain loops are moved by a step of 2.5 inches even when the distance E between adjacent partitions of fins is 2.5 inches, packs1 cannot properly be received on the respective fins, as shown in FIGS. 22(a) and 22(b). Accordingly, the amount by which the
chain loops devices 59. - Although only one fin set has been described with reference to FIGS. 20 through 24, the same is applicable to the remaining fin set.
- According to the second embodiment, the fins of each set are mounted to the chain loops with the distance E between adjacent partitions determined in accordance with the thickness D of packs1 (FIG. 20). For example, when the thickness of the
packs 1 is about 2.2 inches, thefins 5 and 60 are alternately mounted to the fin-mountingfittings 33 with the distance E set to 2.5 inches. In this case, a value of 2.5 is set through thesetting display unit 30, which is coupled to theCPU 27. By this setting, the first and second sets offins 5 and 60 of the first and second groups can be advanced intermittently so as to properly receivepacks 1 successively from theinput conveyor 4, as illustrated in FIGS. 21(a) and 21(b). - In the example shown in FIG. 24, the thickness D of the
packs 1 is about 1.7 inches, and thefins 5 are mounted to thefittings 33 with the distance E of 2.0 inches. In this case, a value of 2.0 is set through thesetting display unit 30, so that the chain loops are moved intermittently to properly receive packs having the thickness D of about 1.7 inches successively fed from theinput conveyor 4, as shown in FIGS. 23(a) and 23(b). - Now, the operation of the
alignment conveyor system 58 according to the second embodiment is described with reference to the flow chart shown in FIG. 18. The flow chart is for the system in which the thickness D ofpacks 1 is about 2.2 inches, a set of fins mounted to the fin-mountingfittings 33 include sixfins fittings 33 of each of thechain loop pair conveyor system 5 can be achieved by setting a value of 2.5 through thesetting display unit 30. Thus, the distance E between thepartitions 5 a and 60 a ofadjacent fins 5 and 60, which is equal to 2.5 inches, is 2.5 times the pitch F (=1 inch) of the fin-mountingfittings 33. - First, the controller (CPU)27 causes the second fin 60 2, in one of the two fin sets of a predetermined one of the first and second fin groups to advance to the
loading position 40 in theloading station 43 as shown in FIG. 21(a) (Step S300). Then, theCPU 27 makes a judgment as to whether apack 1 has been put into thespace 6 formed between thepartitions 5 1 a and 60 2 a of thefins 5 1 and 60 2 (Step S302). If apack 1 has been received, it is judged whether that fin set has been stopped in theloading station 43 an odd number of times (Step S304). Since it is the first time, i.e. or an odd-numbered time, that that fin set has stopped in theloading station 43, the associatedchain loop pair motor 8 a. It places the tip end of thethird fin 5 3 in theloading position 41 as shown in FIG. 21(b) (Step S306). Next, a judgment is made as to whether that fin set has stopped a predetermined number, five in the illustrated embodiment, in the loading station 43 (Step S308). In other words, theCPU 27 makes a judgement as to whether a predetermined number, five in the illustrated example, ofpacks 1 have been put into therespective spaces 6 formed betweenadjacent fins third fin 5 3 has been brought to theloading position 41, the process returns to Step S302, and Steps S302 and S304 are repeated. This time, however, the answer to the query made in Step S304 is NO, the associated steppingmotor 8 a is driven to advance thechain loops loading position 40 shown in FIG. 21(a). After that, theCPU 27 makes a judgment as to whether that fin set has stopped five times in theloading station 43, i.e. whether fivepacks 1 have been put into the respective ones of the five spaces 6 (Step S308). Steps S302, S304 and S306 or S310 are repeated if the answer to the query made in Step S308 is NO. When that fin set has stopped the fifth time in theloading station 43, and all of the fivespaces 6 have been loaded withpacks 1, the answer to the judgment made in Step S308 becomes YES, that set offins packs 1 held in thespaces 6 between adjacent ones of the six fins are pushed out of thechain loops alignment conveyor system 58 by thepusher plate 11, and that fin set is forward to the next position (Step S314). - After that, the next fin set is forward to the
loading station 43 until the tip end of the second fin 60 2 is in theloading position 40 shown in FIG. 21(a), and the same processing as described above is repeated. - The forwarding of each fin set is controlled in such a manner that it does not interfere or contact with the preceding one.
- Now, the operation of the
alignment conveyor 58 is described with reference to the flow chart shown in FIG. 19. The flow chart shown in FIG. 19 is for explaining the operation of theconveyor system 58 shown in FIG. 24, in which the thickness D of eachpack 1 is about 1.7 inches and two fin sets each including sixfins fittings 33 mounted to each of the chain loop pairs 18 a and 18 b and 21 a and 21 b. The operation can be achieved by setting a value of “2.0” through thesetting display unit 30. The distance E betweenpartitions 5 a of adjacent ones of the sixfins 5 is equal to 2 inches, which is twice the pitch F (=1 inch) of the fin-mountingfittings 33 attached to thechain loops - First, the controller (CPU)27 causes one of two sets in one of the four groups of fins to be brought into the
loading station 43, where the tip end of thesecond fin 5 2 is placed in theloading position 40 as shown in FIG. 23(a) (Step S400). Whether apack 1 is put into thespacing 6 between the first andsecond fins space 6 is loaded with apack 1, the associatedchain loop pair motor 8 a, so that the tip end of thethird fin 5 3 is brought in theloading position 40 as shown in FIG. 23(b) (Step S404). Then, a judgment is made as to whether that fin set has been stopped in the loading station 43 a predetermined number, five in the illustrated example, of times (Step S406). Since it is the second stop of that fin set that the tip end of thethird fin 5 3 stops, which is less than the predetermined number of times, the processing in the respective Steps S402-S406 is repeated. When the fin set has stopped five times in theloading station 43 so that fivepacks 1 have been put into therespective spaces 6, the fin set is forwarded to the unloading station 19 (Step S408). Then, thepusher plates 11 pushes out the fivepacks 1 in the fivespaces 6 out of thealignment conveyor system 58, and the fin set is forwarded to the next position (Step S410). After that, the tip end of thesecond fin 5 2 of the next fin set which belongs to the other fin group is brought to theloading station 40 shown in FIG. 23(a), and the processing in Steps S400-S410 is executed in the manner as described above. - As described above, the amount by which the chain loop pair is forwarded in one step of the intermittent forwarding of the
alignment conveyor system 58 according to the second embodiment depends on whether the distance E between the partitions of adjacent fins is an integral multiple (e.g. 1, 2, 3, . . . ) or a multiple with a decimal (e.g. 1.1, 1.2, 1.3, . . . ) of the pitch F of the fin-mountingfittings 33 on thechain loop pair - If, as shown in FIG. 20, the thickness D (e.g. 2.2 inches) of the
packs 1 to be handled is slightly less than a predetermined multiple (e.g. 2.5), which is greater than one and has a decimal portion, of the pitch F (e.g. 1 inch) of the fin-mountingfittings 33, the distance E between adjacent partitions of, for example, thefins 5 1 and 60 2, can be the predetermined multiple, i.e. 2.5 times the pitch F of thefittings 33. Accordingly, it is necessary to alternately mount to the fin-mountingfittings 33, a plurality, two in this case, of different types offins 5 and 60 having the distances “a” and “b”, respectively, between the mountingdevice 59 and thepartitions 5 a and 60 a. In this case, the mountingdevices 59 of the first and second fins are spaced by the distance P1, the mountingdevices 59 of the second and third fins are spaced by the distance P2, and the mountingdevices 59 of the third and fourth fins are spaced by the distance P1. In this manner, the distance between theadjacent mounting devices 59 alternates between P1 and P2. The chain loop pair is then advances intermittently by P1 and P2, alternately. This makes the tip ends of thefins 60 and 5 be placed in the respective loading positions 40 and 41 in the turning path, wherepacks 1 can be properly received in the respectivepack receiving spaces 6. - The thickness D (e.g. 1.7 inches) of
packs 1 to be handled may be slightly less than a multiple (e.g. two) of the pitch F (e.g. 1 inch) of the fin-mountingfittings 33, as in the case shown in FIG. 24. In this case, the distance E betweenadjacent partitions 5 a of the respective fins 5 1-5 6 can be an integral multiple (e.g. two) of the pitch F of the fin-mountingfittings 33. Accordingly, it is possible to use a plurality, e.g. six in the illustrated example, of fins of the same structure with the distance “a” between the mountingdevice 59 and thepartition 5 a. Thus, the mountingdevices 59 of thefins respective fittings 33 with the same pitch (e.g. 2F). In this case, the fin set is advanced stepwise by a fixed pitch (=2F=2 inches in the illustrated embodiment), and the tip ends of therespective fins loading position 40 in the turning path shown in FIGS. 23(a) and 23(b). - As described above, according to the second embodiment, independent of the mounting pitch F of the fin-mounting
fittings 33, the tip ends of the fins can be placed in the loading position in the loading station appropriate for receiving apack 1, by using eitherfins 5 orfins 5 and 60, dependent on the thickness of thepacks 1 to be handled, and advancing the fins by a predetermined fixed amount as shown in FIGS. 23(a), 23(b) and 24, or alternately by predetermined different pitches (e.g. 2F and 3F) as shown in FIGS. 20, 21(a) and 21(b). With this arrangement, as shown in FIGS. 20 and 24, packs 1 can be held adjacent to each other and conveyed, and they can be pushed out from thealignment conveyor system 58 onto thegates 7, without being bent sincepacks 1 can be held with little gap between adjacent ones. Then, the front and rear holding plates 9-1 and 9-2 can hold, without fail, thepacks 1 which are closely spaced and erected on thegates 7, and can put them into thebox 2. - As described above, packs having a thickness less than an integer, one or greater, plus 0.5 times the pitch of the fin-mounting
fittings 33 can be handled by using only two types of fins,e.g. fins 5 and 60, having different distances between the mountingdevices 59 and the partitions. Thus, the number of types of fins to be prepared can be small, two in the illustrated examples, and, therefore, the manufacturing of the fins is easy. Also, the number of the types of fins to be stocked can be small. - The length of the
bases 5 b (60 b) on which packs are placed should be slightly less than the distance E betweenadjacent partitions 5 a (60 a). - In the above-described embodiments, the number of fins used is six, but a different number of fins may be used to convey a different number of packs in a time.
- Also, the system of the present invention can put two or more rows of packs in a
box 2, as in the prior art shown in FIGS. 25(a) through 25(d). Also, a row or rows of packs may be stacked in abox 2. For these and other modifications, the shape of thepusher plate 11, the shape and distance of the front and rear plates 9-1 and 9-2, the timing of the lowering and lifting the stuffingplate 13, etc. may have to be modified, but such modifications are within the scope of the invention. - In the descried embodiments, packs1 are supplied to the
alignment conveyor system 58 one by one in a row. Although not shown, however, two ormore packs 1 may be fed side by side from theinput conveyor 4 into each of thepack receiving spaces 6 on thealignment conveyor system 58. In such a case, packs are pushed out from thealignment conveyor system 58 in two or more rows onto thegates 7. In this case, too, the shape of thepusher plate 11, the shape of the front and rear plates 9-1 and 9-2, the timing of the lowering and lifting the stuffingplate 13 etc. may have to be modified, but such modifications are within the scope of the invention. -
Packs 1 can be put in abox 2 with one lateral side down. - In the described embodiments, each of the first and second groups of fins includes two sets of fins, but it may include only one set.
- The controller (CPU)27 may be arranged to control the system in such a manner that when one fin set of one of the first and second fin groups is in the unloading
station 19, one fin set of the other fin group loaded with a predetermined number ofpacks 1 can stand by for the unloading immediately before the unloadingstation 19, which results in improvement of the boxing efficiency of the boxing system. - The
force sensors 70 may have a structure shown in FIGS. 9(a) and 9(b), instead of the structure shown in FIGS. 8(a) and 8(b). FIGS. 9(a) and 9(b) are front and side views of one of theforce sensors 70. This alternative structure includes aload cell 100 for detecting the magnitude of the force with which the associated holdingplate 9 presses the row ofpacks 1 and generating a magnitude-representative signal. Theload cell 100 is coupled between the slidingshaft 74 and the holdingplate 9. The holdingplate 9 is driven by the holding platelinear driver 63 to forward to continuously press theend pack 1. Thecontroller 27 stops the driving of the holding platelinear driver 63 in response to the magnitude representative signal theload cell 100 generates when the holdingplate 9 presses thepack 1 with a preset force. In place of theload cell 100, a piezoelectric device may be used. Alternatively, a pressure sensor may be used in place of theload cell 100, together with a piston and a cylinder filled with a fluid. One of the piston and the cylinder is coupled to the slidingshaft 74 and the other to the holdingplate 9. The pressure sensor is connected in such a manner as to be able to sense the pressure applied to the fluid. - The fins used in the described embodiments are the fins5-1, 5-2, 5′-1 and 5′-2 for one inch for the distance E between adjacent partitions of 1 inch (FIGS. 1 and 2), the
fins 5 for two inches for E of two inches (FIG. 24), and thefins 5 and 60 for 2.5 inches for E of 2.5 inches (FIG. 20), but fins for 3, 4, 1.3 or 2.8 inches, for example, may be used for the distance E of 3, 4, 1.3 or 2.8 inches may be used instead for receiving, from theinput conveyor 4, packs 1 having a corresponding thickness. In this case, the amount of intermittent movement of the fins in the standby position before theloading station 43 to place them in the loading station is set to a value equal to or approximately equal to the distance between the mountingdevice 59 of the fin in the loading station and the mountingdevice 59 of the immediately succeeding fin. - Further, in the described embodiments, one or more of fin sets are put in a standby position before the loading station or the unloading station. However, the present invention can be also applicable to an alignment conveyor system in which fin sets do not stand by for the unloading or loading before the unloading or loading station.
- The above-described arrangement, in which fins with a variable spacing between adjacent mounting
devices 59 with the fins intermittently forwarded with a corresponding variable pitch, can be also applied to a conveying system having only one chain conveyor. - As various changes could be made in the above without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
Claims (9)
1. A boxing system including an article holding arrangement including holding members for holding a predetermined number of aligned articles to be put in a box, said holding arrangement comprising:
a driving unit for moving said holding members toward and away from each other along a direction in which said articles are aligned, said holding members being engageable with at least some of said articles to press said aligned articles together;
a force detecting unit for detecting forces with which said holding members press said aligned articles together when said holding members are driven toward each other; and
means for stopping said driving unit from driving said holding members when the forces applied to said holding members as detected by said force detecting unit is greater than a predetermined value.
2. A boxing system as set forth in wherein said driving unit includes at least one linearly movable member connected to a holding member, and a motor for actuating said movable member.
claim 1
3. A boxing system as set forth in wherein said means for stopping said driving unit comprises a CPU of a control unit.
claim 1
4. A boxing system comprising:
front and rear holding members for holding a predetermined number of aligned articles to be put in a box, by applying force to said aligned articles in the direction of alignment; and
side holding members for holding said aligned articles held by said front and rear holding members, by applying force to said aligned articles in the direction perpendicular to said direction of alignment.
5. A boxing system comprising:
holding members for holding a predetermined number of aligned articles; and
a funnel-shaped guide into which said aligned articles held by said holding members are forced to thereby put said aligned articles into a box disposed at an outlet port of said funnel-shaped guide;
wherein said outlet port of said funnel-shaped guide comprises guide members which can be pushed outward from an original position by said articles passing through said outlet port, said guide members returning to the original position when said articles have passed through said outlet port, and biasing means for biasing said guide members toward said original position.
6. A boxing system as set forth in wherein said outlet port of the funnel-shaped guide is rectangular.
claim 5
7. A boxing system as set forth in wherein said funnel-shaped guide has an inlet port for receiving said aligned articles.
claim 5
8. A boxing system as set forth in wherein said inlet port is rectangular.
claim 7
9. A boxing system as set forth in further comprising a movable pushing device for pushing said aligned articles from a position held by said holding members through the funnel-shaped guide and into said box.
claim 5
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US09/817,585 US6382401B2 (en) | 1998-06-25 | 2001-03-26 | Boxing system using conveyor apparatus |
Applications Claiming Priority (9)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP10-179132 | 1998-06-25 | ||
JPHEI10-179132 | 1998-06-25 | ||
JP17913298A JP2000006910A (en) | 1998-06-25 | 1998-06-25 | Transfer apparatus and boxing apparatus |
JP10211227A JP2000043806A (en) | 1998-07-27 | 1998-07-27 | Casing apparatus |
JP10-211227 | 1998-07-27 | ||
JP10-331256 | 1998-11-20 | ||
JP33125698A JP4124530B2 (en) | 1998-11-20 | 1998-11-20 | Transport device |
US09/338,936 US6260689B1 (en) | 1998-06-25 | 1999-06-23 | Conveyor apparatus and boxing system using conveyor apparatus |
US09/817,585 US6382401B2 (en) | 1998-06-25 | 2001-03-26 | Boxing system using conveyor apparatus |
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US09/338,936 Division US6260689B1 (en) | 1998-06-25 | 1999-06-23 | Conveyor apparatus and boxing system using conveyor apparatus |
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US20010050209A1 true US20010050209A1 (en) | 2001-12-13 |
US6382401B2 US6382401B2 (en) | 2002-05-07 |
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US09/817,585 Expired - Lifetime US6382401B2 (en) | 1998-06-25 | 2001-03-26 | Boxing system using conveyor apparatus |
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WO2012034591A1 (en) * | 2010-09-15 | 2012-03-22 | Sigma Engineering B.V. | A device and a method for packaging substantially flat products in a box |
WO2016200753A1 (en) * | 2015-06-09 | 2016-12-15 | The Procter & Gamble Company | Drive mechanism and methods of grouping articles |
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