US3694993A

US3694993A - Automatic bottle packing method and apparatus

Info

Publication number: US3694993A
Application number: US38974A
Authority: US
Inventors: Jerry L East
Original assignee: Simplimatic Engineering Co
Current assignee: Simplimatic Engineering Co
Priority date: 1970-05-20
Filing date: 1970-05-20
Publication date: 1972-10-03
Anticipated expiration: 1989-10-03
Also published as: FR2089185A5; NO130985C; BE765485A; NL7105178A; IE35827B1; NO130985B; DE2124984C3; ZA711158B; SE358605B; DE2124984A1; DE2124984B2; GB1302334A; CA944731A; IE35827L

Abstract

Apparatus and method for automatically packing bottles into a series of cases in a necks-down position. Means are provided for receiving the bottles in an upright position on a rotatable support, rotating the support to a position in which the bottles are held necks-down and releasing said bottles in such necks-down position into an elevated case. Guides and hold-back means are provided both for the cases and the bottles to insure properly timed automatic operation.

Description

United States Patent East [ AUTOMATIC BOTTLE PACKING METHOD AND APPARATUS [72] Inventor: Jerry L. East, Lynchburg, Va.

[73] Assignee: Simplimatic Lynchburg, Va.

22 Filed: May20, 1970 21 App1.No.: 38,974

Engineering Co.,

[52] US. Cl. ..53/26, 53/61, 53/161,

53/248, 214/1 BV [51] Int. Cl. ..B65b 21/06 [58] Field of Search ..53/26, 35, 61, 143,- 161, 162, 53/166, 247, 248, 249, 251, 159, 164, 242, 243; 214/1 BS, 1 BV, 6 FS; 294/64R [56] References Cited UNITED STATES PATENTS 3,443,355 5/1969 Birrell ..S3/161 2,249,201 7/1941 Ferguson 214/l BV [451 Oct. 3, 1972 Thayer ..53/251 X 3,353,331 11/1967 Rowekamp ..53/249 X 3,486,292 12/ 1 969 Ninneman ..53/161 X 3,589,094 6/1971 Pearson ..53/243 X FOREIGN PATENTS OR APPLICATIONS 1,162,757 2/1964 Germany ..5 3/247 Primary Examiner-Robert L. Spruill Attorney-James and Franklin ABSTRACT Apparatus and method for automatically packing bottles into a series of cases in a necks-down position. Means are provided for receiving the bottles in an upright position on a rotatable support, rotating the support to a position in which the bottles are held necks-down and releasing said bottles in such necksdown position into an elevated case. Guides and holdback means are provided both for the cases and the bottles to insure properly timed automatic operation.

29 Claims, 10 Drawing Figures PATENTEUnma m2 SHEET 2 0F 8 km T M x NVENTOR JERRY L. EAST )wM/M TTORNEYS PAIENIEnucra m2 3.694.993

SHEET 3 BF 8 INVENTOR JERRY L. EAST ATTORNEYS PATENTEDnm 3 I972 SHEET 0F 8 INVENTOR JERRY L. EAST BYI TTO R N EYS PATENTEDHBI 3 I972 SHEET 5 OF 8 Ill:

INVENTOR JERRYL.EA5T

ATTORNEYS PATENTEDum 3 I972 SHEET 6 OF 8 INVENTOR JERRY L. EAST BY) ATTORNEYS PATENTEDnm 3 m2 SHEET 7 OF 8 mm wt N WNQQQ INVENTOR JERRY L. EAST ATTORNEYS AUTOMATIC BOTTLE PACKING METHOD AND I APPARATUS The present invention pertains to apparatus for automatically loading or packing containers into a case. More particularly, the invention is designed for use with the packing operation generally associated with the bottled beverage industry.

The glass industry has in the past packed bottles, jars, and the like in the partitioned corrugated cases prior to their shipment to the product manufacturer for filling with the individual products. Quite often, these same corrugated cases are re-used by those who purchase the bottles or jars for shipping the product to market. Thus, the finished product is often shipped to the customer in the same cases in which the empty bottles are initially received.

The present invention is specifically designed to provide a packaging technique which considerably facilitates the handling of the containersby those who fill such containers with the final product. One of the first handling operations the glass companies customers perform is to remove the empty containers from the cases. The technique used in approximately half of the industries is to turn the case upside down and remove the case from its contents. It will be apparent that this technique is the most expeditious way of unpacking the empty containers from their cases. It will also be apparent, however, that this method is desirable and feasible with thin necked bottles only if the bottles are deposited in a necks-up position after the case is removed. Thus, the initialpacking of the case must necessarily be with the product in the neckdown position. By way 'of example, the whiskey industry universally requires that all their empty bottles be packed neck-down by the glass manufacturer.

Historically, this neck-down packing by the glass industry has been accomplished manually. This manual packing is extremely time consuming and, with the advent of high labor costs, increasingly expensive.

Accordingly, it is a primary object of the present invention to provide apparatus designed to automatically and expeditiously pack bottles in a necks-down position.

More specifically, it is an object of the present invention to provide a bottle packing apparatus characterized by means for sequentially conveying bottles and cases to a packing station in an orderly and properly time fashion, filling the cases with containers in a necksdown position and conveying such packed cases away from the packing station.

It is a further object of the present invention to provide apparatus of the type described which is adapted to receive containers in an upright position and discharge them into a case in a downturned position, all. in an extremely expeditious and safe fashion.

It is another object of the present invention to provide apparatus of the type described which is characterized by an automatic sequential operation providing safeguards against accidental handling out of sequence without the necessity of manual intervention.

To these ends, the present invention comprises a bot- 4 tles are initially positioned on the support in the necksup position, they are adapted to drop through the grid onto the suction cups. The suction cups are adapted to hold the bottles while the support is rotated to position the bottles in a necks-down attitude. Cases are sequentially guided to the region directly below the rotatable support and elevated to a position directly thereunder. The bottles are then released. from the vacuum support and descend a small distance through guide means into the partitioned case in in a necksdown position. The loaded case is then lowered and carried off to be shipped. Both surfaces of the support are adapted to operatively engage bottles in this manner so that one group of bottles may be received on one surface as another group is released from the other surface. Automatic operation is insured by a series of limit switches responsive to the position of the various mechanisms and designed to actuate them in properly timed fashion. I

To the accomplishment of the above, and to such other objects as may hereinafter appear, the present invention relates to the construction of an automatic bottle packing apparatus as defined in the appended claims, and as described in this specification taken together with the accompanying drawings in which:

FIG. 1 is an exploded perspective view showing the operative features of the apparatus, including the bottle and case feeding mechanisms;

' FIG. 1A is an exploded enlarged perspective of the rotatable support showing the grid support;

FIG. 1B is a cross-sectional view of one support surface taken along the line lB-lB of FIG. 1A;

FIG. 2 is a side elevational view of the complete apparatus in its operative position showing the various mechanisms for handling the bottles and cases and sensing their positions;

FIG. 3 is a front elevational view taken along the line 3-3 of FIG. 2 and showing the rotatable bottle support and the case elevator with their associated actuating mechanisms; A

FIG. 4 is a cross-sectional view taken along the line 4-4 of FIG. 2 showing the rotatable support, including the vacuum means and the lower bottle guides with the bottle cut-off mechanism; I

FIG. 5 is a cross-sectional view along the line 5-5 of FIG. 4 showing the vacuum means and the bottle sensing mechanism; v

FIG. 6A is a schematic representation of the sequential operation of the bottle handling apparatus showing the relative positions of the various-actuating cylinders and associated limit switches; u

FIG. 6B is a schematic illustration of the case hane dling apparatus again showing the relative positions of the various actuating cylinders and associated limit switches; and

FIG. 7 is a schematic flow diagram showing the sequential operation of the apparatus.

Referring to FIGS. 1 and 2, the present invention generally comprises a suitable frame 8 (only partially shown) upon which is mounted a bottle guiding apparatus generally designated 10 for guiding and positioning the product (here bottles) to a packing station 11, bottle support apparatus generally designated 12 for supporting, rotating and releasing said bottles into a case at said packing station, and case handling apparatus generally designated 14 for guiding empty cases to a position beneath said bottle packing apparatus 12 and conveying filled cases away.

The drawings have been somewhat simplified to illustrate only those features of the apparatus which are relevant to the present invention, it being understood that all structure is mounted on frame 8 even when not so specifically described or illustrated.

The bottle guiding apparatus 10 is designed to convey a continuous stream of bottles 16 to a rotatable support generally designated 18. For this purpose there is provided a series of conveyor belts 20 mounted on appropriate rotatable means 22 and driven through shafts 23 by a suitable driving mechanism (not shown). Parallel vertical guide rails 24 serve to guide bottles 16 to the terminal conveyor belt 20a which is shown wider than belts 20. Flared guide rails 26 widen the flow area to accommodate three bottles across and are adapted to feed bottles 16 into three lanes 27 defined by four fixed guide rails 28 mounted above the upper surface of conveyor belt 20a. Rails 28 extend beyond belt 20a onto a platform 30 which is in the same plane as the .upper surface of conveyor belt 20a and provides a smooth transfer surface for conveying the bottle 16 from belt 20a onto the operative surface of support 18. Support 18, to be hereinafter described with more particularly, is provided with corresponding lower guides 32 aligned with rails 28 but slightly spaced therefrom and defining three corresponding lanes 31. The leading bottles 16 are guided along

conveyor belts

20 and 20a to platform 30 and deposited thereon inlanes 27. As successive bottles are so deposited the leading bottles 16 are pushed onto support 18 again into corresponding lanes 31.

An upper guide mechanism generally designated 34 is provided to help maintain the bottles in their respective lanes as they slide along support 18. It comprises a horizontally disposed plate 36 having four vertical guide rails 38 rigidly mounted thereon and downwardly extending therefrom. As bottles are pushed onto support 18, plate 36 is maintained slightly above the bottles 16, guide rails 38 extending from plate 36 a distance sufficient to straddle the side walls of bottles 16 below their neck-portions and thus prevent them from toppling sideways over lower guide rails 32 into an adjacent lane.

To allow the subsequent rotation of support 18 guide mechanism 34 must be retractable from this operative guide position. For this purpose plate 36 is mounted by suitable means generally designated 40 on one end of rods 42. As best shown in FIG. 3, mounting means 40 preferably comprises a rotatable mounting such as sleeve 41 rigidly connected to rod 42 and rotatable on a pin 43 mounted on a suitable fixture 44 attached to plate 36. Rods 42 are rigidly mounted on a plate 45 disposed parallel to and spaced from plate 36. Plate 45 is adapted for vertical reciprocal movement by means of a rod cylinder arrangement comprising rod 47 mounted at one end on plate 45 and at its other end with air cylinder A suitably mounted on frame 8. A pair of guide sleeves 46 are mounted onframe 8 in registration with apertures therein and are adapted to receive a pair of guide rods 39 which are rigidly attached to plate 45.

The upward stroke of cylinder A is adapted to retract upper guide mechanism 34 upwardly a distance sufficient to provide the necessary clearance for the rotation of support 18. The downward stroke is preferably adjustable so as to accommodate bottles of various heights directly below plate 36 in its operative guide position.

In the embodiment illustrated, support 18 is adapted to hold twelve bottles, four in each of the three lanes 31. Automatic operation of the bottle handling apparatus 12 begins when all three lanes 31 are full. Accordingly, a bottle sensing means generally designated 49 is provided at the left hand end of support 18 to sense when a sufficient number of bottles (here 12) have been conveyed to support 18, thereafter to begin automatic operation. Bottle sensor 49 comprises three vertically disposed flags 50 rotatably mounted on a horizontal shaft 51 and aligned respectively with the centers of the three lanes 31 (see FIG. 3).

As best shown in FIG. 5, shaft 51 is mounted on end supports 52 which in turn are mounted on a horizontally disposed plate 54 by means of angle bars 56. Secured to angle bar 56 by suitable means is a vertical plate 58 which, in its operative position (FIG. 5) serves as an end wall to prevent bottles from being pushed off the left hand end of support 18 (as viewed in FIG. 5). As best shown in FIG. 3, plate 58 is provided with three vertical slots 60 aligned respectively with flags 50 and adapted to receive them. Flags 50 are spring biased on rod 51 in a clockwise direction so that they normally extend at least partially through slots 60 into lanes 31 above support 18 in cantilevered fashion (broken line position of FIG. 5). As shown in FIG. 5, when a leading bottle 16 reaches the left-hand end of support 18, it engages the portion of the flag 50 overhanding its respective lane 31. Thus, as the leading bottleis pushed along a lane 31 by successive trailing bottles against end wall 58, the respective flag 50 is rotated counterclockwise out of lane 31 to the solid line position shown in FIG. 5.

Flags 50 are each provided with an aperture 62. As best shown in FIG. 3, there is provided a conventional photoelectric sensing mechanism comprising a light source 64 at one sideof flags 50 and a photoelectric cell 66 on the opposite side of flags 50 and aligned with light source 64. In their normal spring biased position flags 50 serve to block the path of light rays emanating from source 64 and prevent them from reaching photoelectric cell 66. When all three flags have been rotated counterclockwise to the solid line position shown in FIG. 5, that is, when support 18 is filled to capacity with bottles 16, apertures 62 are aligned and provide a clear line of sight between source 64 and cell 66.

Cell 66 is operatively connected by suitable wiring to tion and its associated switching and circuitry is of a.

conventional nature and will therefore not be described with any great particularity. The switching and pneumatic and electrical operation is believed to be apparent to those skilled in the art from the sequence of operation schematically illustrated in block diagram in FIG. 7, and described in detail hereinafter.

When support 18 is filled to capacity a bottle cut-off mechanism generally designated 68 is actuated. As best illustrated in FIGS. 1, 4 and 5, bottle cut-off mechanism 68 comprises three gates 70 in the form of narrow plates vertically disposed to one side of each of three lanes 27 in the space between guide rails 28 and lower guides 32 on support 18. As best shown in FIG. 5,

gates 70 are rigidly mounted on and extend upwardly.

from shafts 72 which in turn are rotatably mounted on fixed bracket member 74 by means of collars 76. Bracket 74 extends laterally under plate 30 and is secured to frame 8 by suitable means (not shown). Plate 30 is provided with cut-out portions 80 (FIG. 4) receiving shafts 72.

As best illustrated in FIG. 4, a linkage mechanism generally designated 82 is provided for rotating shafts 72 and thus gates 70 on a vertical axis. Mechanism 82 comprises three arms 84 each rigidly fixed at one end to shafts 72 as by press fitting or welding and rotatably mounted at their other ends at spaced intervals along a horizontally extending bar 86 by means of pins 88. Bar 86 is in turn operatively, pivotally connected to a bifurcated member 90 by means of a stepped lever 92 (FIG. 3) pivotally mounted therein by means of pin 93. Bifurcated member 90 is mounted on one end of a shaft 94 the other end of which is mounted for reciprocating movement on air cylinder B by suitable means 97 (FIG. 4).

When cylinder B is in its extended position arms 84 and thus gates 70 are aligned with guide rails 28 and lower guides 32. Indeed gates 70 in this position serve to close the gap between rails 28 and guides 32. When all the lanes 31 on support 18 are full, apertures 62 on flags 48 align with the light beam emitted from light source 64 and photocell 66 is actuated. The actuation of photocell 66 is effective by means of suitable cireuitry to actuate cylinder B which retracts shaft 94 to the right as viewed in FIG. 1. Gates 70 are thus rotated clockwise to the position shown in FIG. 4 by means of bar 86 and arms 84. In this position gates 70 are efiective to block the passage of further bottles 16 to the left (as viewed in FIG. 4). Support 18 is therefore free to rotate with no possibility that bottles 16 will be pushed off the edge of plate 30. Bottles will, of course, continue to pile up in lanes 27 at cut-H gates 70 in anticipation of the next cycle of operation.

The method of holding bottles 16 on support 18 as it rotates will now be specifically described. As best shown in FIG. 5, support 18 comprises generally two identical support surfaces 100 and 100' in parallel back-to-back relationship, respectively.

To avoid repetition only the upwardly facing support surface 100 will be described specifically herein, the elements of downwardly facing support 100' being designated by like reference numerals, but with the addition of a prime. In the embodiment shown support surface 100 comprises two identical platens 102 disposed in contiguous end-to-end relationship (FIG. (the necessity for two platens rather than one will become apparent later in this specification). Each platen is provided with two parallel channels 104, extending laterally of lanes 31 (FIG. 4) and defining vacuum conduits 106. A series of apertures 108 are provided in the upper surfaces of platens 102 spaced along the registering with conduits 106. Suction cups 110 made of rubber or the like are fastened onto the upper surface of platens 102 in registration with apertures 108 in sealed relationship therewith by suitable means (not shown). As best shown in FIG. 4, conduits 106 are sealed at both ends and are provided with openings 112 along their lengths to enable a vacuum to be applied to cups 110. For this purpose a suitable pressure line comprising hosing 114 is provided on the underside of platens 100, the hosing being operatively connected to conduits 106 by means of suitable sealed connectors 116. I-Iosing 114 is connected to a small vacuum pump (not shown) disposed a sufficient distance from support 18 so as not interfere with its rotation. The portion of the housing extending out from platens 102 is sufficiently flexible to allow for such rotation with a minimum of disturbance to the apparatus. Suction cups 110 are arranged on platens 102 such that one cup is directly beneath each bottle 16 when support surface has been loaded to capacity.

Vacuum is continuously applied to cups through hosing 114 so that said cups are adapted to holdingly engage bottles 16 upon coming in contact therewith. However, it will be apparent that such contact must be delayed until support surface 100 is loaded to capacity with bottles 16 to provide for a smooth flow of bottles along lanes 31. Accordingly, the bottles are adapted to be loaded into lanes 31 on a grid arrangement generally designated 118 spaced above platens 102, best shown in FIG. 1A. Grid arrangement 118 comprises support plates 120, spaced from and secured to platens 102 respectively by suitable means 124. Each support plate 120 is provided with three elongated apertures 126, each of said apertures adapted to accommodate two bottles 16 in contiguous upstanding relationship. As best shown in FIG. 4, each aperture 126 is in registration with two underlying suction cups 110. Thelower guides 32 are secured directly to plates 120 in the region between adjacent apertures 126. Thus underlying each lane 31 there are two elongated apertures 126 each overlying two suction cups 110. A rectangular grid 128 is adapted to rest on plates 120 and provide a supporting surface for bottles 16 as they move along lanes 31. To this end grid 128 comprises a rectangular frame with three cross bars 130 of width W. During the period of loading of support 18 the three cross bars 130 are positioned respectively in lanes 31 centered directly above apertures 126 (see FIG. 1B). As best shown in FIG. 1A apertures 126 are slightly off center to the left in lanes 31, that is to say, they extend widthwise from their respective lefthand guide rails (as viewed in FIG. 1B) a distance less than the width of lanes 31 leaving a shoulder 133 of width W between an aperture 126 and its respective right hand guide rail. Each of the three right hand guide rails 32 is provided with a flange comprising a bar 134 also of width W secured to its respective rail spaced from shoulder 133 and extending into its respective lane. Grid 128 is movable to the right (as viewed in FIG. 18) by means of a scissor linkage 136 (see FIG. 4) actuated by air cylinder M. Scissor linkage 136 comprises two

links

140 and 141 pivotally connected to each other, link 140 being pivotally mounted on arm 142 extending from grid 128 and link 141, being pivotally mounted at oneend on frame 8 and at its other end on a piston rod 144 which is mounted in cylinder M for reciprical movement. As grid 128 is moved to the right cross bars 130 clear apertures 126 in plate 120 and bottles 16 are thus left unsupported above apertures 126. The bottles 16 are maintained centered over their respective aper tures during this movement by guide bars 134, which it will be recalled are of the same width as cross bars 130. Thus, when piston rod 144 has been fully retracted into cylinder M bottles 16 fall through their respective apertures 126 in plate 120 onto their respective suction cups 110. This drop is preferably a few inches and together with the vacuum continuously applied to cups 110 is effective to provide immediate holding engagement between cups 110 and their respective bottles 16. If desired the positive engagement between cups 110 and bottles 16 may be assured by various other means. Thus the bottles 16 may be positively compressed onto cups 110 until the desired engagement is complete. In the present embodiment this may be conveniently accomplished by adapting overhead bottle guide 34 to function as a bottle compressor to be actuated by a further extension of rod 47 from cylinder A subsequent to the retraction of cylinder M.

One further step is necessary before support 18 is adapted to rotate. It will be recalled thatfiags 50 of bottle sensor 49 overhand lanes 31 in their spring biased position (broken line position in FIG. It will be apparent that if bottle sensor 49 is maintained in its operative position (FIG. 5), flags 50 will interfere with bottles 16 as they move laterally past flags 50 during rotation of support 18. Accordingly, an actuating mechanism, generally designated 146 is provided for retracting bottle sensor 50 to the left (as viewed in FIG. 5) prior to the rotation of support 18.

As best illustrated in FIG. 5 mechanism 146 comprises a horizontally extending plate 148 mounted on frame 8. One end of a cantilevered trolley support 150 is adapted to be slidingly received on the upper surface of plate 148, the other end of said support being secured by bolts 152 to plate 54 on which the sensing mechanism is mounted as previously described. Accordingly, two L shaped rails 154 are mounted in spaced relation on the upper surface of plate 148 and provide a track or slot slidingly receiving trolley support 150. Support 150 andthe thus connected sensing mechanism 49 are retractable by means of air cylinder C through rod 158,

links

160 and 162 and coupling member 164 secured to support 150 by bolts 166. The retraction stroke of cylinder C is designed to move the bottle sensor 49 a sufficient distance to the left so as not to interfere with the rotation of support 18.

After support surface 100 has been filled to capacity (i.e. with 12 bottles), the entire support 18 is adapted to rotate 180, bottles 16 being holdingly engaged by suction cups 110 and shifted to a necks-down case loading position (see FIG. 5). As previously described support 18 comprises two operative back-to-back support surfaces 100 and 10 so that in the embodiment illustrated when one surface is in the case loading position the other surface is adapted to receive bottles from guiding apparatus 10. Accordingly, support 18 is adapted by means hereinafter described to rotate in increments of 180. It should be noted, however, that this embodiment is only by way of illustration, it being apparent that support 18 may comprise any number of operative surfaces, preferably in back-to-back pairs, the increment of rotation of support 18 being modified accordingly.

As best illustrated in FIG. 3, rotation of support 18 is accomplished through a support rotate assembly generally designated 168. Assembly 168 comprises an air cylinder D and a gear assembly 171. Air cylinder D is mounted on frame 8 and carries a rod 172 mounted thereon for reciprocal movement. Rod 172 drives rack 174 which engages pinion 184. Gear 176 is fast with pinion 184 and meshes with smaller gear 178. As best seen in FIG. 5, gear 178 is mounted on a shaft 186 car'- ried by a bearing assembly 188 and operatively connected to support 18 by coupling 190 and an air cylinder assembly 192, the purpose of which will be described hereinafter.

In order to rotate support 18 180 to the necks-down position, cylinder D is actuated and moves rod 172 to the right (as viewed in FIG. 3) a distance sufficient to rotate gear 176 through the engagement of pinion 184 with rack 174. Gear 178 will in turn be rotated 180. It will be apparent that support surfaces and 100+ may be alternately positioned to receive and dispense bottles 16 by alternately extending and retracting rod 172 in a sequence hereinafter to be described. Coupling 190 is designed to absorb some of the torque transmitted through shaft 186 to support 18 in a conventional manner.

After bottles 16 are received on the upward facing support surface 100, the four bottles in each lane 31 are dropped onto and held by suction cups in contiguous relationship (the leading bottles having been pushed into surface 100 by succeeding bottles). However, the cases in which bottles 16 are to be received are in a typical case (illustrated in FIG. 1) partitioned into two compartments each adapted to receive six bottles. Accordingly, it has been found necessary for a smooth loading operation to space the first two bottles in each lane from the last two bottles in that lane before releasing them into the case. The necessity of two contiguous platens 102 to form support'surface 100 will now be apparent. The two platens are connected and rigidly supported relative to each other (see FIG. 4) by means of support shafts 188 extending through platens 102 in either side thereof. The top and bottom supports 18 are bolted together attheir right hand ends (see FIG. 5) by a suitable shaft and bolt assembly 194 extending thropgh a spacer member 196 sandwiched between said supports at the bottle entrance end and from which extends a stub shaft 198. An L shaped bearing bracket 200 is mounted on frame 8 below bolt cut-off mechanism 68 and receives stub shaft 198 in rotatable supporting relationship. Coil springs 202 are mounted concentrically on each support shaft and received within the mating shoulders of bores 204 at the contiguous surfaces of platens 102. Springs 202 are adapted to bias the left hand platen 102 slightly away from its adjacent platen 102 as illustrated for support surface 100' in FIG.- 5. Accordingly, the left platen 102 is slidably mounted on support shafts 188. Prior to the loading of the support surface left platen 102 must be vey empty cases 210 in sequence to packing station 1 l,

elevate said cases to a position directly beneath support 18 to receive bottles 16 in the necks-down position, and lower and convey such loaded cases away from packing station 11. The time sequence of case handling operations is, of course, correlated with the time sequence of bottle handling operations in a suitable fashion to be described hereinafter.

Cases 210 are conveyed and guided to packing station 11 along a conveying mechanism generally designated 212, comprising a series of narrow chain conveyor belts 214 mounted on suitable rotatable drive means 216. The drive means of the terminal belt (nearest packing station 11) is clutched by conveyor clutch 213 (FIGS. 2, 6B). If desired, a number of smooth conveyor belts 218, also driven by suitable means 220 may be mounted in spaced relation on either side of central belt 214 to provide additional support. A series of conveyer belts 215 are mounted on suitable rotatable drive means 217 at the left hand side of packing station 1 l for conveying loaded cases away. As best shown schematically in FIG. 6B, a case entering from the right transverses three positions designated

positions

1, 2, and 3 respectively, along conveyer mechanism 212. Each position is defined by a cylinder operated case holding mechanism here referred to as Accordingly, a flap opening mechanism generally designated 244 is provided for folding the flaps outwardly and downwardly. As best seen in FIG. 1 flap opening mechanism 244 comprises a front flap opener 246 disposed directly above position 2 on conveyor mechanism 212 and a side flap plow 247. Front flap opener 246 comprises a finger 248 actuated by air cylinder K and adapted to rotate counterclockwise and translate forwardly under the guidance of cam slot 252 in a vertically disposed plate 254, the entire arrangement being mounted on frame 8 by suitable means 256 (FIG. 2). As will be explained more fully hereinafter,

gates l, 2 and 3 respectively. Each gate is defined by two parallel L shaped members 222 adapted to be moved inwardly by means of air cylinders F, G and H for

gates

1, 2 and 3, respectively, to thereby grasp and hold a case 210 as it moves into such position. It should be noted that while

gates

1 and 2 are mounted on frame 8, gate 3 is mounted on the case elevator mechanism to be hereinafter described and is movable therewith. Two brake positions, one to the right of gate 1 and the other between gates l and 2 are designated, respectively, brake 1 and brake 2, and comprise fixed guide walls 226, against which a case 210 is adapted to be urged by movable vertical guides 228, pivotally mounted on linkages 230 and actuated by air cylinders I and J, for

brakes

1 and 2, respectively.

Position 3 in FIG. 68 corresponds to the loading position shown in FIG. 1. As there illustrated, a series of rollers 234 are mounted in sets on spaced shafts 236 spaced from the terminal conveyer belt 214 but having .an operative supporting surface in the same plane as folded along fold lines 242 provided for that purpose). l

flap opener 246 is adapted to open front flap 240F while the case is held by gate 2 and to open rear flap 240R as the case is released from gate 2 and on its way to loading position 3. A side flap plow 247 overhanging conveyer mechanism 212 between

positions

2 and 3 is provided and comprises a U shaped member 260 adapted to maintain the front flap 240E in a horizontal position as the case leaves position 2 (see FIG. 2) and two finger members 262 flared out from said U shaped member and adapted to operatively engage side flaps 2408 and fold them downwardly along fold lines 242 as case 210 tranverses below.

In operation a case 210 is conveyed via belts 214 and rollers 234 to the loading position 3 at which point it is held stationary by gate 3, ready for elevation to its loading position. For this purpose an elevator mechanism generally designated 264 is provided. Elevator 264 comprises a U shaped frame 266 parallel members of which are normally disposed below the supporting surfaces of rollers 234 between adjacent sets thereof. Frame 266 is mounted on a suitable support 268 which is slidably mounted on a pair of elevator guides 270 by means of parallel rollers 272 extending laterally therefrom. Support 268 and frame 266 are actuated by a vertically disposed air cylinder L and rod 276 operatively connected to said support at one end and mounted in said cylinder for reciprocal movement at its other end.

As best shown in FIG. 3, a case loading bottle guide 278 is mounted on a support 280 and is normally disposed below support 18 as illustrated. Support 280 is mounted on elevator guide 270 by means of rollers 282 in a manner similar to the mounting of support 268. In

this case, however, support 280 is freely slidable vertically and rests on a stop member 284 suitably mounted on frame 8. Bottle guide 278 comprises a rectangular frame 286 having a cross grid arrangement 288 from which 12 guide pockets 290 extend downwardly. Guide pockets 290 are preferably made of a flexible material such as rubber or elastic metal and are of a truncated conical shape, the diameter at the truncated end being slightly less than the diameter of bottles 16. Guide pockets 290 arethus adapted to slow the descent of bottles 16 as they drop into case 210. The lower surface of frame 286 presents a flange or shoulder which is adapted to engage the upper edges (defined by fold lines 242) of case 210, the guide pockets 290 being received within the open upper end of case 210. Thus, as a case 210, stillheld in gate 3, is elevated on frame 266 and support 268, it engages frame 286 and continues its upward travel while lifting said frame, which it will be recalled is vertically slidable on elevator guides 270. Bottles 16 are accordingly received within guide pockets 290. At this time roller drive mechanism 238 is disengaged by clutch 239 for reasons hereinafter discussed. The retraction stroke of cylinder L is preferably adapted to elevate case 210 to a position such that the bottom surface thereof is spaced only a few inches from the neck ends of bottles 16. The distance should be as small as possible without interfering with the positive release of bottles 16 from suction cup 110.

At this point it should be noted that there are various methods of releasing bottles 16 from cups 110 when disposed in their necks-down position over' an empty case, the preferred method here utilized involving a momentary blast of compressed air applied to cups 110 and effective to interrupt the suction thereof and positively blow bottles 16 off said cups. For this purpose a suitable valving means, (not shown) is disposed in the pressure line 114 and is adapted to momentarily con-v nect such line to a source of compressed air (also not shown).

After bottles 16 are released and drop into case 210 the case is lowered onto rollers 234 by elevator mechanism 264, guide mechanism 278 coming to rest on stop member 284. The roller drive mechanism 238 is again engaged by clutch 239 and loaded case 210 is conveyed onto conveyer belt 215 so that the upper flaps may be closed and secured for delivery to the product manufacturer.

Sequential actuation of the various mechanisms heretofore disclosed will now be specifically described with respect to the schematic diagrams of FIGS. 6A,.

6B, and FIG. 7. It should be noted that each operation, unless otherwise noted, is actuated by means of conventional limit switches which are tripped or untripped depending upon the position of the air cylinder involved or, with respect to some of the case handling apparatus the position of a case. It is believed that the associated circuitry operatively connecting such switches to the cylinders to be actuated will be apparent to those skilled in the art. The circuitry will, therefore, not be described herein. It will be further noted that the oval enclosures in the flow diagram of FIG. 7 represents schematically the appropriate air cylinders associated with the mechanism designated and, where noted, certain limit switches.

A cycle begins when the photoelectric cell 66 is actuated by means of flags 50 of bottle sensor 49. At this time support 18 has been filled with 12 bottles.

Bottle cut-off cylinder B is accordingly retracted in response to the signal at cell 66 and serves to prevent the further flow of bottles toward support .18.

The retraction of cylinder B trips a limit switch LSB which is adapted to actuate the grid mechanism 136 shown in FIG. 1A.

Grid cylinder M is retracted, moving cross bars 130 clear of apertures 126 in supporting surface 120. Accordingly bottles 16 drop through apertures 126 onto suction cups 110. Vacuum is continually applied to suction cups 110 via hosing 114. As bottles 16 operatively sealingly engage suction cups 1 10, the pressure in vacuum line 114 drops considerably since there is no further air flow through the line. A vacuum detecting mechanism (not shown) is disposed in the flow line and is adapted to trip a switch (also not shown) in response to the pressure drop associated with the sealing engagement of bottles 16 to cups 110. Such switch is adapted by such cylinders. Thus, support 18 will not be rotated unless elevator mechanism 264 has started its descent untripping or releasing switch LSL (FIG. 6D), bottle sensor 49 has been fully retracted tripping switch LSC (FIG. 6A) and overhead guide 34 has begun its ascent releasing switch LSA (FIG. 6A). It should be noted at this point that support rotate cylinder D is actuated in both directions (extension and retraction) by the same signals since the extension and retraction strokes are equivalent for the purpose of rotating support 18 1 The left hand platen 102 is shifted to the left relative to the right hand platen by cylinder E at this point in response to the tripping of bottle sensor switch LSC (see FIG. 6A).

Elevator cylinder L is responsive to the switch LS3 associated with gate 3 (FIG. 6B) the operation of which will be more fully described hereafter. Suffice it to say at this point that limit switch 3 is tripped when a case enters position 3 (the loading position) on case conveyer mechanism 212. Thus a case 210 will be elevated only if (1) the support 18 has completed its rotation and (2) a case is in position 3 ready to be loaded.

When limit switch LSL (FIG. 63) associated with the up position of elevator 264 is tripped two things happen a subsequent case loading sequence is started and a new bottle loading sequence is begun on the upper support surface:

NEW CASE LOADING SEQUENCE The actuation of switch LSL causes the bottles 16 to be blown off from suction cups in the mannerpreviously described. Elevator cylinder L, in the up or retracted position and platen shift cylinders E are responsive again through suitable switching and circuitryto the decrease in pressure in vacuum flow line 114 associated with the release of bottles 16 from suction cups 110. Thus, a loaded case is lowered onto' rollers 234 and the lower left platen is moved into contiguous relation with its associated right platen at this time.

As illustrated in FIG. 7, the drive mechanism for rollers 234 is engaged as the elevator support begins its descent releasing limit switch LSL.

NEW BOTTLE LOADING SEQUENCE ing cross bars into their operative supporting posi-f tion to receive a flow of bottles 16 in lanes 31. Finally, overhead guide cylinder A (also responsive to switch LSC) is extended lowering upper guides 38 into their operative guide position.

Referring to the lower portion of the flow diagram of FIG. 7, the

gate

1, 2 and 3,

brakes

1 and 2 and flap opener designations schematically represent the associated air cylinders, the designation open corresponding to a retracted position and close corresponding to an extended position of said cylinders. The

position

1, 2 and 3 designations represent the limit switches (listed in parenthesis) associated with the respective positions. Switch LS1, LS2 or LS3 is tripped when a case 210 enters

position

1, 2 or 3, respectively, and is not released until the trailing edge of the case passes through that position. The designations loaded and unloaded for each position refers to the tripped and released positions respectively of the associated limit switches.

A case handling cycle begins with no cases in any of the positions, all gates closed, brake 1 open, brake 2 closed, front flap opener 248 closed and the conveyer clutch 213 de-energized. As a case 210 passes open brake 1 and is loaded into position 1, switch LS1 is tripped actuating cylinders F and l. Accordingly, gate 1 is opened and brake l is closed, holding back subsequent cases. Case 210 is thus allowed to move out of position 1. As limit switch 1 is released by the trailing edge of case 210, cylinders F extend closing gate 1 and cylinder l retracts opening brake 1 to allow a second case 210' to enter position 1. When case 210 reaches position 2 (position 2 loaded) switch LS2 is tripped, cylinder K is extended opening the front flap of case 210, cylinder J is extended closing brake 2, cylinder G is extended opening gate 2 and the conveyer clutch 213 is energized moving case 210 toward position 3. It should be noted, however, that gate 2 will not open and conveyer clutch 213 will not be energized until switch LSK is tripped by the extension of flap opener 248. Moreover, another condition for the opening of gate 2 is the releasing of switch LS3 by the unloading of position 3. Thus position 3 must be clear before gate 2 will open.

At the same time a new cycle is started. As case 210' reaches position 1, switch LS1 is tripped opening gate 1 and closing brake 1. Case 210 accordingly moves out of position .1. However, since brake 2 was closed as a result of the loading of case 210 into position 2, case 210 will be held at brake 2 during this period. As the trailing edge of case 210 passes position 2, limit switch LS2 will be released (position 2 unloaded) closing gate 2, retracting flap opener cylinder K, and de-energizing clutch 213. It will be noted that when the trailing edge of a case releases limit switch LS2, its leading edge has already entered onto rollers 234. Thus, case 210 will continue to move into position 3 under the influence of rollers 234 despite the de-energization of clutch 213.

As case 210 enters position 3 (position 3 loaded), switch LS3 is tripped retracting elevator cylinder L to thus elevate case 210 into its loading position. In addition, cylinder J is extended opening brake 2 if flap opener 248 has been fully retracted. It will be apparent that for proper operation front flap opener 248 should be in its up (retracted) position prior to the loading of a case into position 2. Thus in the event flap opener 248 has not fully retracted (switch LSK released) by the time case 210 reaches position 3, the opening of brake 2 will delayed until such time as said fiap opener 248 is fully retracted (e.g. both the tripping of switch LS3 and the release of limit switch LSK are preconditions for the retraction of cylinder J).

When case 210 reaches its fully elevated position (LSL tripped), the valve in pressure line 1 14 is momentarily actuated and bottles 16 are blown off suction cups and fall through bottle guide 278 into the case. At the time gate 3 is opened by the retraction of cylinder H so that any slight misalignment between case 210 and bottles 16 will be corrected by lateral movement of case 210 on elevator support 280 as the bottles drop into the case. Finally, and as previously noted, the roller clutch 239 is deactuated at this time as a safety precaution in the unlikely event any of bottles 16 drop onto the case conveyor mechanism 212.

As previously noted, elevator cylinder L is caused to be extended (down) in response to the pressure decrease in pressure line 114 associated with the release of bottles 16 from cups 110. As elevator support 280 begins its descent, limit switch LSL is released and roller clutch 239 is again actuated. Case 210 is thus deposited on rollers 234 and conveyed away by said rollers and conveyors 215.

As the trailing edge of case 210 passes position 3, switch LS3 is released (position 3 unloaded) and the second cycle is continued, gate 2 opening to allow case 210 to move to position 3, etc.

The apparatus described herein provides a completely automated means of performing an extremely cumbersome process packing bottles in a necks-down position. Moreover, the apparatusis adapted to perform such operation in an extremely rapid manner, several cases and groups of bottles being acted on simultaneously. By providing two operative loading surfaces on support 18 the loading of bottles onto support 18 in a necks-up position may be carried out simultaneously with the loading of bottles into a case 210 in the necks-down position. The switching associated with the various operations insures that all operations take place expeditiously in proper sequence.

1 Finally, the apparatus is relatively inexpensive as compared to the labor costs involved in manual packing at the same rate of speed.

While only one embodiment of the present invention has been specifically disclosed herein, it will be apparent that many variations may be made therein, all within the scope of the invention as defined in the following claims.

I claim:

1. An apparatus for automatically packing a plurality of containers into a case at a packing station, comprising: conveyer means for conveying a continuous supply of containers in an upturned position in a given direction to 'said packing station; a support at said packing station aligned with said conveyer means and adapted, in a first position, to receive said containers from said conveyer means and to support same in an upturned position in a plurality of closely spaced rows and columns, said support comprising means on an operative support surface thereof, active on the bottom surfaces of said containers and adapted to positively hold said containers on said operative surface, means for shifting said support to a second position in which said containers are held by said holding means in a downtumed position, and releasing means operatively connected to said holding means for releasing said container from said holding means, whereby said containers are adapted to enter said case.

2. The apparatus of claim 1, further comprising means for feeding a supply of cases to said packing station substantially in said given direction and means for elevating a case to a position directly beneath said containers after said holding means has been shifted, means for lowering said case after said containers have been released from said holding means into said case, and means for conveying a thus loaded case away from said packing station.

3. The apparatus of claim 2, in which said shifting means comprises means to rotate said support about an axis substantially parallel to said given direction.

4. The apparatus of claim 1, wherein said holding means is provided with at least first and second differently facing operative surfaces each of said surfaces effective to hold a plurality of containers at said packing station, said means for shifting said holding means being adapted to shift each of said first and second operative surfaces of said holding means from saidfirst to said second position.

5. The apparatus of claim 4, wherein said containers are received at one side of said support in a plurality of rows, means at the other side of said support adapted to engage the leading containers in each row for sensing when a designated number of containers is positioned on said support, and cut-off means operatively connected to said sensing means for cutting off the flow of containers to said support when a designated number .of containers is positioned on said support.

6. The apparatus of claim 4, in which said holding means comprises suction means, and said releasing means comprises means for disabling said suction means.

7. The apparatus of claim 1, wherein said containers are received at one side of said support in a plurality of rows, means at the other side of said support adapted to engage the leading containers in each row for sensing when a designated number of containers is positioned on said support, and cut-off means operatively connected to said sensing means for cutting off the flow of containers to said support when a designated number of containers is positioned on said support.

8. The apparatus of claim 7, in which said holding means comprises suction means, and said releasing means comprises means for disabling said suction means.

9. The apparatus of claim 8, comprising means responsive to said sensing means and said cut ofi means for urging said containers against said suction means after the flow of containers to said holding means is cut off.

10. The apparatus of claim 7, comprising means- 12. The apparatus of claim 11, further comprising grid means adapted to support said containers directly above and spaced from said holding means, and wherein said urging means comprises means for shifting said grid means out of its operative supporting position to enable said containers to drop onto said holding means.

13. The apparatus of claim 12, further comprising guiding means comprising a plurality of guide rails disposed above said holding means and defining a plurality of lanes each adapted to receive a single row of containers.

14. The apparatus of claim 13, wherein said grid means comprises a frame, a plurality of supporting cross bars operatively connected to said frame, each disposed in its operative supporting position in one of said lanes overlying said holding means.

15. The apparatus of claim 14- further comprising a plurality of guide bars each extending from one of said guide rails into one of said lanes spaced above said support surface and adapted to operatively engage said containers and wherein said supporting cross bars are adapted to shift to a position underlying said guide bars whereby said containers are prevented from shifting with said supporting cross bars.

16. The apparatus of claim 15 wherein said guiding means further comprises a support surface underlying said grid means and wherein said plurality of guide rails are mounted on said support surface, said support surface having apertures adapted to allow said containers to drop onto said holding means.

17. The apparatus of claim 1, further comprising means for moving said case towards said containers when said containers are in said downtumed position, whereby said containers drop only a small distance into said case when released from said holding means.

18. The apparatus of claim 1, in which said holding means comprises suction means, and said releasing means comprises means for disabling said suction at said suction means.

19. The apparatus of claim 18, further comprising means for urging said containers against said suction means.

20. The apparatus of claim 1, further comprising means for urging said containers against said holding means.

21. A method of automatically packing a group of containers in a case at a packing station comprising: guiding a group of containers to said packing station; supporting said group of containers in an upturned position on a support; applying suction to said containers in a direction drawing said containers to said support, shifting said support to a position in which said group of containers is holdingly retained by said suction on said support in a downtumed position above said case; and releasing said suction thereby to release said group of containers from said support while in said downtumed position, whereby said group of containers enters said case.

22. The method of claim 21, wherein said support is adapted to hold and retain said containers on first and means for urging said containers against said holding means.

second differently facing operative surfaces thereof, and comprising the further steps of guiding a second group of containers to said second surface of said support while said first mentioned group of containers is held and retained on said first surface of said support; holding said second group of containers on said second surface of said support by applying suction thereto while shifting said support to a position in which said second group of containers is held and retained on said second surface of said support in a downtumed position above said case, and releasing said suction on said second group of containers thereby to release same from said second surface of said support, whereby said second group of containers enters said case.

23. The method of claim 22, in which said first and second surfaces are on opposing sides of said support whereby said second surface of said support is adapted to receive said second group of containers when said support is in position to retain said first group of containers on said first surface of said support in a downtumed position.

24. The method of claim 22, comprising the step of urging said containers against said suction applying means prior to shifting said support.

25. The apparatus of claim 22, wherein said containers are received at one side of said support in a plurality or rows, means at the other side of said support adapted to engage the leading containers in each row for sensing when a designated number of containers is positioned on said support, and cut-off means operatively connected to said sensing means for cutting off the flow of containers tosaid support when a designated number of containers is positioned on said support.

26. The method of claim 21, comprising the step of urging said containers against said suction applying means prior to shifting said support.

27. The method of claim 21, further comprising conveying a supply of cases to said packing station in a given direction, and wherein said step of shifting said support comprises rotating said support about an axis substantially parallel to said given direction.

28. In a packing apparatus for packing a plurality of objects into a case at a packing station, support means at said packing station, means on said support means for gripping a plurality of said objects, means for guiding a supply of said objects to said support means at said packing station, grid means adapted to support said plurality of objects directly above and spaced from said gripping means, and means for shifting said grid means out of its operative supporting position to enable said objects to drop onto said gripping means.

29. The apparatus of claim 28, wherein said gripping means comprises suction means.

Claims

1. An apparatus foR automatically packing a plurality of containers into a case at a packing station, comprising: conveyer means for conveying a continuous supply of containers in an upturned position in a given direction to said packing station; a support at said packing station aligned with said conveyer means and adapted, in a first position, to receive said containers from said conveyer means and to support same in an upturned position in a plurality of closely spaced rows and columns, said support comprising means on an operative support surface thereof, active on the bottom surfaces of said containers and adapted to positively hold said containers on said operative surface, means for shifting said support to a second position in which said containers are held by said holding means in a downturned position, and releasing means operatively connected to said holding means for releasing said container from said holding means, whereby said containers are adapted to enter said case.

4. The apparatus of claim 1, wherein said holding means is provided with at least first and second differently facing operative surfaces each of said surfaces effective to hold a plurality of containers at said packing station, said means for shifting said holding means being adapted to shift each of said first and second operative surfaces of said holding means from said first to said second position.

5. The apparatus of claim 4, wherein said containers are received at one side of said support in a plurality of rows, means at the other side of said support adapted to engage the leading containers in each row for sensing when a designated number of containers is positioned on said support, and cut-off means operatively connected to said sensing means for cutting off the flow of containers to said support when a designated number of containers is positioned on said support.

9. The apparatus of claim 8, comprising means responsive to said sensing means and said cut off means for urging said containers against said suction means after the flow of containers to said holding means is cut off.

10. The apparatus of claim 7, comprising means responsive to said sensing means and said cutoff means for urging said containers against said holding means after the flow of containers to said holding means is cut off.

11. The apparatus of claim 1, further comprising means for urging said containers against said holding means.

12. The apparatus of claim 11, further comprising grid means adapted to support said containers directly above and spaced from said holding means, and wherein said urging means comprises means for shifting said Grid means out of its operative supporting position to enable said containers to drop onto said holding means.

15. The apparatus of claim 14 further comprising a plurality of guide bars each extending from one of said guide rails into one of said lanes spaced above said support surface and adapted to operatively engage said containers and wherein said supporting cross bars are adapted to shift to a position underlying said guide bars whereby said containers are prevented from shifting with said supporting cross bars.

17. The apparatus of claim 1, further comprising means for moving said case towards said containers when said containers are in said downturned position, whereby said containers drop only a small distance into said case when released from said holding means.

21. A method of automatically packing a group of containers in a case at a packing station comprising: guiding a group of containers to said packing station; supporting said group of containers in an upturned position on a support; applying suction to said containers in a direction drawing said containers to said support, shifting said support to a position in which said group of containers is holdingly retained by said suction on said support in a downturned position above said case; and releasing said suction thereby to release said group of containers from said support while in said downturned position, whereby said group of containers enters said case.

22. The method of claim 21, wherein said support is adapted to hold and retain said containers on first and second differently facing operative surfaces thereof, and comprising the further steps of guiding a second group of containers to said second surface of said support while said first mentioned group of containers is held and retained on said first surface of said support; holding said second group of containers on said second surface of said support by applying suction thereto while shifting said support to a position in which said second group of containers is held and retained on said second surface of said support in a downturned position above said case, and releasing said suction on said second group of containers thereby to release same from said second surface of said support, whereby said second group of containers enters said case.

23. The method of claim 22, in which said first and second surfaces are on opposing sides of said support whereby said second surface of said support is adapted to receive said second group of containers when said support is in position to retain said first group of containers on said first surface of said support in a downturned position.

25. The apparatus of claim 22, wherein said containers are received at one side of said support in a plurality or rows, means at the other side of said support adapted to engage the leading containers in each row for sensing when a designated number of containers is positioned on said support, and cut-off means operatively connected to said sensing means for cutting off the flow of containers to said support when a designated number of containers is positioned on said support.