WO2010096111A1

WO2010096111A1 - Methods and apparatus for creating offset pack patterns

Info

Publication number: WO2010096111A1
Application number: PCT/US2009/062506
Authority: WO
Inventors: Irvan Leo Pazdernik; Eric Timmerman; Christopher Todd Davis; Simin Jiang
Original assignee: Douglas Machine Inc.
Priority date: 2008-10-29
Filing date: 2009-10-29
Publication date: 2010-08-26

Abstract

Product is conveyed as continuous streams between lane dividers (222) by metering conveyors (210-216) onto a transfer plate (32) and a transfer device (42) including first and second supports (42A, 42B). The transfer device (42) is movable between retracted and extended positions extending over a sweep conveyor (22) by securing its trailing and leading ends to flexible belts (106, 206) on opposite longitudinal sides of the sweep conveyor (22). Product is transferred from the second support (42B) to the sweep conveyor (22) and from the first support (42A) to the second support (42B) as the transfer device (42) moves from the extended position to the retracted position and is engaged by a metering bar (52B) which controls the product acceleration on the sweep conveyor (22) and by a metering bar (52A) which prevents unmetered product from tipping downstream. Sweep bars (62a, 62aa) collect the product on the sweep conveyor (22).

Description

METHODS AND APPARATUS FOR CREATING OFFSET PACK PATTERNS

BACKGROUND The present invention generally relates to methods and apparatus for creating a pattern having odd and even number of products in every other lane and, in the most preferred form, for creating offset pack patterns. Particularly, the present invention generally relates to apparatus and methods for metering product from continuous streams into an offset product group and/or pack pattern, particularly to metering apparatus and methods not requiring windows between product in the continuous stream, more particularly to metering apparatus and methods which are versatile to meter a wide variety of product such as cans, plastic bottles, jars, cartons, bundles, or trays, and specifically to metering apparatus and methods where product is metered by moving a transfer device from underneath a product group positioned above a sweeping conveyor. Offset pack patterns contain a staggered amount of products. Offset pack patterns provide greater strength and rigidity for palletizing. Specifically, offset pack patterns can be run unsupported without corrugate, thereby reducing or eliminating the cost for such corrugate.

Furthermore, the present invention relates to a metering bar mechanism for registering the leading edge of the product group on the transfer device, with such metering bar mechanism also preventing tipping of tall and/or unstable products. Also, the present invention relates to the metering bar mechanism abutting with the trailing edge of the offset product group moving onto a sweep conveyor.

In a typical packaging operation, product comes to a packaging machine in a continuous stream. It is necessary to separate product into groups so that they can be further processed such as being placed into a pack pattern and/or packed into a film overwrap or a corrugated wrap. U.S. Patent No. 6,843,360 represents one manner of metering product which has enjoyed considerable market success.

However, a need continues to exist for apparatus and methods for metering product and for creating offset pack patterns, which do not suffer from the deficiencies of prior metering apparatus and methods. SUMMARY OF THE INVENTION

The present invention solves this need and other problems in the field of metering products by providing, in a preferred first aspect, methods and apparatus for accelerating product in every other lane of product moving in a conveying direction onto a transfer device which is moved between a retracted position and an extended position to transfer product with a gap onto a sweep conveyor.

In another preferred aspect of the present invention, a pair of metering bars are simultaneously introduced into the gap created between product. The leading and trailing edges of product are abutted by the pair of metering bars when the transfer device is retracted to its retracted position, with the pair of metering bars independently moving along the same endless path relative to a conveyor and with the second metering bar being scalloped to match product in the offset arrangement.

In a preferred embodiment shown, the transfer device is in the form of first and second supports moveable between extended and retracted positions relative to the sweep conveyor, with the transfer device being moved independently of the sweep conveyor in the preferred form shown. Specifically, product previously on the second support are deposited on the sweep conveyor and product on the first support are deposited on the second support when the transfer device is moved from the extended position to the retracted position. By moving the second support faster towards the extended position, the gap is created between product on the second support and on the first support.

The present invention will become clearer in light of the following detailed description of illustrative embodiments of this invention described in connection with the drawings.

DESCRIPTION OF THE DRAWINGS The illustrative embodiments may best be described by reference to the accompanying drawings where:

Figure 1 shows a perspective view of an apparatus creating offset pack patterns according to the preferred methods of the present invention.

Figure IA shows an enlarged, perspective view of the apparatus of Figure 1 within the encircled area A of Figure 1. Figure IB shows an enlarged, perspective view of the apparatus of Figure 1 within the encircled area B of Figure 1.

Figure 2 shows a perspective view of the apparatus of Figure 1 with product and portions removed to show constructional details. All figures are drawn for ease of explanation of the basic teachings of the present invention only; the extensions of the figures with respect to number, position, relationship, and dimensions of the parts to form the preferred embodiments will be explained or will be within the skill of the art after the following description has been read and understood. Further, the exact dimensions and dimensional proportions to conform to specific force, weight, strength, and similar requirements will likewise be within the skill of the art after the following description has been read and understood.

Where used in the various figures of the drawings, the same numerals designate the same or similar parts. Furthermore, when the terms "side," "end," "bottom," "first," "second," "laterally," "longitudinally," "row," "column," and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawings as it would appear to a person viewing the drawings and are utilized only to facilitate describing the illustrative embodiments. DESCRIPTION OF THE PREFERRED EMBODIMENTS

An apparatus for metering product and in particular to apparatus which collates and separates groups of product in preparation for various types of packaging of the most preferred form is shown in the drawings and generally designated 10. Generally, apparatus 10 includes first and second product conveyance mechanisms which are independently driven for moving product in a conveying direction. In the most preferred form, the conveying direction of the first and second product conveyance mechanisms are colinear to each other, with the product being transferred from the first product conveyance mechanism where they are bunched together onto the second product conveyance mechanism where they are separated, typically into groups. However, it should be recognized that the first and second product conveyance mechanisms could have other arrangements including linearly parallel, perpendicular or at a nesting angle of offset product. In the most preferred form, the first product conveyance mechanism is shown as multiple metering conveyors 210-216 which are driven at variable, multiple speeds such as by servo motors. Each metering conveyor 210-216 corresponds to one lane of product which will form a column in the groups of product. In the preferred form, each multiple metering conveyor 210-216 includes an endless belt 14 including an upper run extending between and moving in the conveying direction from an upstream roller at an upstream end and a downstream roller 16 at a downstream end. The endless belt 14 also includes a lower run extending between and moving from the downstream end to the upstream end.

In the most preferred form, the second product conveyance mechanism is shown as a sweep conveyor 22 which is separately driven from conveyors 210-216 and typically in a continuous manner such as by a servo motor. In the preferred form, conveyor 22 includes an endless belt 24 including an upstream end and a downstream end and having an upper run extending between an upstream roller 26 defining the upstream end and a downstream roller. The upper run moves from the upstream end to the downstream end in the conveying direction, and the lower run moves from the downstream end to the upstream end, with at least a portion of the lower run being parallel to and spaced below the upper run. It should be realized that conveyor 22 can include one or more additional rollers, with one or more of the rollers 26 being rotated such as by a servo motor to cause movement of belt 24. In the most preferred form, the upper runs of belts 14 and 24 are in the same plane, and possibly the upper run of belt 24 being parallel to but slightly lower than the upper run of belts 14.

Due to the circular cross sections of rollers 16 and 26 in the most preferred form, a gap is created between belts 14 and 24. In the preferred form, a flat, stationary transfer plate 32 extends between the upper runs of belts 14 and 24 generally between the mid point of rollers 16 and 26. Thus, lead product is pushed by the continuous stream being advanced by conveyors 210-216 onto and past transfer plate 32 in a manner described hereinafter.

Lane dividers 222 extend in a spaced, parallel relation in the movement direction of metering conveyors 210-216 and conveyor 22 along conveyors 210-216 and along a substantial portion of the conveyor 22. The spacing between lane dividers 222 generally correspond to metering conveyors 210-216 and one lane of product. Apparatus 10 according to the teachings of the present invention includes a product transfer device 42 upon which product is supported and in the preferred form has an upper surface of a size upon which the bottom of the product is supported and in the most preferred form to receive product having multiple rows and multiple columns. Transfer device 42 is moveable relative to conveyor 22 between an extended position and a retracted position. Device 42 extends over conveyor 22 in the extended position and in the preferred form also extends over conveyor 22 beyond transfer plate 32 in the retracted position.

According to the teachings of the present invention, device 42 includes a first support 42 A which overlays a second support 42B, with second support 42B intermediate first support 42A and conveyor 22 and with the leading end of first support 42 A located intermediate the upstream end of conveyor 22 and the leading end of the second support 42B. In the most preferred form, first and second supports 42 A and 42B are in the form of thin pieces of flexible material such as a belt requiring external support to allow product to be supported thereon. Thus, in the preferred form, device 42 in the form of thin pieces of material engages and is supported by belt 24 to allow product to be supported upon device 42.

In the preferred form shown, apparatus 10 further includes a slip sheet drive 100. In particular, drive 100 includes first and second drive pulleys 102 on opposite sides of roller 26 and which are rotatable relative to roller 26. In this regard, roller 26 could be rotatable relative to a common axle defining the rotation axis of the semicircular portion of belt 24 of the upstream end whereas pulleys 102 could be rotatable relative to or rotatably fixed to the common axle, or pulleys 102 could be rotatable relative to the common axle whereas roller 26 could be rotatable relative to or rotatably fixed to the common axle. Drive 100 further includes a drive shaft 104 parallel to but spaced downstream of roller 26, pulleys 102, and their common axle, with drive shaft 104 located between the upper and lower runs of belt 24. First and second, flexible, gear belts 106 extend along an endless course between drive shaft 104 and pulleys 102 and on opposite longitudinal sides of sweep conveyor 22 and parallel to the conveying direction. It should be appreciated that either pulleys 102 or drive shaft 104 or both can be driven such as by a servo motor 108. The trailing and leading ends of first support 42A are suitably removably fixed at first and second leading points adjacent to the leading end and at first and second trailing points adjacent to the trailing end to gear belts 106, with the first and second leading points being spaced from the first and second trailing points and with the first and second longitudinal sides of conveyor 22 being intermediate the first and second leading points and intermediate the first and second trailing points. In the preferred form shown, each of gear belts 106 includes attachment plates including an array of protrusions extending outwardly thereof. The corners of the trailing and leading ends of first support 42 A includes an interconnect having a lower surface which removably receives one or more protrusions to secure first support 42 A to and between gear belts 106. It should be appreciated that both trailing and leading ends of first support 42 A are attached to gear belts 106 enabling positive movement both upstream and downstream.

Additionally, drive 100 includes first and second drive pulleys 202 on opposite sides of roller 26 and which are rotatable relative to roller 26. In this regard, roller 26 could be rotatable relative to a common axle defining the rotation axis of the semicircular portion of belt 24 of the upstream end whereas pulleys 202 could be rotatable relative to or rotatably fixed to the common axle, or pulleys 202 could be rotatable relative to the common axle whereas roller 26 could be rotatable relative to or rotatably fixed to the common axle. In the most preferred form shown, pulleys 202 are located intermediate roller 26 and pulleys 102. Drive 100 further includes a drive shaft 204 parallel to but spaced downstream of roller 26, pulleys 102, 202, and their common axle, with drive shaft 204 located between the upper and lower runs of belt 24. First and second, flexible, gear belts 206 extend along an endless course between drive shaft 204 and pulleys 202 and on opposite longitudinal sides of sweep conveyor 22 and parallel to the conveying direction. It should be appreciated that either pulleys 202 or drive shaft 204 or both can be driven such as by a servo motor 208.

The trailing and leading ends of second support 42B are suitably removably fixed at first and second leading points adjacent to the leading end and at first and second trailing points adjacent to the trailing end to gear belts 206, with the first and second leading points being spaced from the first and second trailing points and with the first and second longitudinal sides of conveyor 22 being intermediate the first and second leading points and intermediate the first and second trailing points. In the preferred form shown, each of gear belts 206 includes attachment plates including an array of protrusions extending outwardly thereof. The corners of the trailing and leading ends of second support 42B includes an interconnect having a lower surface which removably receives one or more protrusions to secure second support 42B to and between gear belts 206. It should be appreciated that both trailing and leading ends of second support 42B are attached to gear belts 206 enabling positive movement both upstream and downstream. Transfer device 42 is moved from its retracted position to its extended position with the leading ends of supports 42 A and 42B having a greater spacing from the upstream end of conveyor 22 in the extended position than in the retracted position.

Specifically, in the preferred form shown, transfer device 42 is moved independently of conveyor 22 by driving the upper runs of belts 106 and 206 in the same direction as the conveying directions of conveyors 210-216 and 22 to pull on the leading ends of first and second supports 42A and 42B. In the retracted position, the leading end of second support 42B is spaced in the conveying direction the length of one product pattern beyond the leading end of first support 42A. When transfer device 42 moves from its retracted position, first support 42A moves in the conveying direction of conveyors 210-216 and 22 and in the most preferred form generally at the speed of conveyors 210-216, while the second support 42B moves faster than first support 42A to create a gap between the leading edge of first support 42 A and the trailing edge of one product pattern supported upon second support 42B. Thus, the leading end of second support 42B is spaced in the conveying direction from the leading end of first support 42A in the extended position greater than the length in the retracted position. After the gap has been created, first and second supports 42A and 42B are retracted opposite to the conveying direction of conveyors 210-216 and 22, with second support 42B moving faster than first support 42A towards the retracted position such that the leading ends of first and second supports 42 A and 42B are spaced the length of one product pattern when transfer device 42 reaches its retracted position.

First and second supports 42A and 42B are moved from the extended position by driving the lower runs of belts 106 and 206 in the same direction as the conveying directions of conveyors 210-216 and 22 to pull on the trailing ends of first and second supports 42 A and 42B. The leading ends of first and second supports 42 A and 42B located in the conveying direction are at a greater spacing from the upstream end in the extended position than in the retracted position. It should be appreciated that although drive 100 of the preferred form shown is advantageous and produces synergistic results, it should be appreciated that transfer device 42 can be positively moved by securing the trailing and leading ends to drives of other forms and types according to the teachings of the present invention. Likewise, one or both of first and second supports 42A and 42B could be moved by pulling on the upstream ends thereof, such as by being wrapped around a roller and moving from the retracted position to the extended position as a result of friction.

Apparatus 10 according to the teachings of the present invention further includes a control device for registering the leading edge of the product group on transfer device 42 in its extended position. In the most preferred form, the control device is in the form of a metering bar mechanism 52. Metering bar mechanism 52 generally includes a plurality of pairs of containment, metering bars 52 A and 52B extending laterally across sweep conveyor 22. At least one of the metering bars 52 A and 52B is scalloped (having different extents in the conveying direction corresponding to the lanes of product on conveyor 22 and the columns of the product groups) instead of straight (having the same extent in the conveying direction). The front containment, metering bar 52 A could be scalloped or straight, with straight being shown in the preferred form. It should be appreciated that although shown as formed from a bar including arcuate bends, scalloped, metering bars 52B could be formed in other manners including, but not limited to, a straight bar with blocks secured in alternate lanes of product on conveyor 22. Each pair of metering bars 52 A and 52B are carried along an endless path such as by belts, chains or other flexible transmission devices 52Aa and 52Ba extending over pulleys 52Ab and 52Bb and in the shape of the endless path parallel to the conveying direction. Conveyor 22 is located intermediate transmission devices 52Aa and 52Ba.

In the most preferred form shown, the plurality of pairs of metering bars 52A and 52B occupy the same operational footprint in apparatus 10. In particular, pulleys 52Ab and 52Bb include common axles 66 each defining an axis, with four such common axles 66 being shown defining a generally trapezoid cross sectional shaped endless path. In this regard, on one or more but not all of axles 66, pulleys 52Ab are rotatably fixed to the common axle 66 which is driven such as by a servo motor 52Ac, whereas pulleys 52Bb are rotatable with respect to such axle 66. Another one or more but not all of axles 66, pulleys 52Bb are rotatably fixed to the common axle 66 which is driven such as by a servo motor 52Bc, whereas pulleys 52Ab are rotatable with respect to such axle 66. In the preferred form, transmission device 52Aa and pulleys 52Ab are located inwardly of transmission device 52Ba and pulleys 52Bb. Metering bars 52A are connected between and driven by devices 52Aa but do not engage with or are connected to devices 52Ba. Bars 52B are connected between and driven by devices 52Ba and extend over devices 52Aa but are not connected to devices 52Aa. It should be appreciated that although the manner of moving bars 52A and 52B is believed to be advantageous and produces synergistic results, it should be appreciated that bars 52A and 52B can be moved in other manners according to the teachings of the present invention. Additionally, in a portion of the path, metering bars 52B move in the conveying direction of conveyor 22 at least initially at generally the conveyance speed of conveyors 210-216. Generally, the leading edge of product on transfer device 42 abuts against a respective metering bar 52B which may serve to prevent tipping of the product upon sweep conveyor 22 as well as to physically restrain product on transfer device 42. Likewise, in a portion of the path, metering bars 52 A move in the conveying direction of conveyor 22 at generally the conveyance speed of conveyors 210-216. Generally, the trailing edge of product on second support 42B abuts against a respective metering bar 52A which contains the pattern and positively positions the product pattern on the sweep conveyor 22.

In the preferred form shown, apparatus 10 further includes a mechanism 62 which collects product together and delivers the product to the next appropriate packaging function such as film overwrap or corrugated wrap in a finished form. In the most preferred form, mechanism 62 is a sweeping bar mechanism generally including a plurality of sweep bars 62a and 62aa extending laterally across sweep conveyor 22 and which are carried along endless paths such as by belts, chains or other flexible transmission devices 62ab and 62b extending over pulleys 62ac and 62c in the shape of the endless paths and independently of the plurality of pairs of metering bars 52A and 52B. Generally, sweep bar mechanism 62 introduces sweep bars 62a and 62aa between product on sweep conveyor 22 for abutting with the trailing and leading edges of product on sweep conveyor 22. Particularly, the rear containment sweep bar 62aa which is scalloped comes in behind the product at a faster rate of travel than the product group on sweep conveyor 22. As the rear containment sweep bar 62aa contacts the rear of the product group, the rear containment bar 62aa advances the long row of the product group until the entire pattern is staggered. The front containment bar 62a, which may or may not be scalloped, enters in front of the product group to stabilize the product group and travels at the same rate as the rear containment sweep bar 62aa. In the preferred form shown, lane dividers 222 end after bars 62a and 62aa are introduced, while only outer dividers 222a continue with decreasing spacing corresponding to the offset pack.

Now that the basic construction of apparatus 10 according to the preferred teachings of the present invention has been set forth, modes of operation and advantages of apparatus 10 can be explained. Generally, product is fed in a random basis to meter conveyors 210-216. In particular, metering conveyors 210-216 preferably run constantly at variable speed, and product is conveyed or pushed thereon. Products can be accumulated on and are conveyed by each metering conveyor 210-216 as a continuous stream in a lane including a single column and multiple rows in a conveying direction at a first conveyance speed.

For the sake of explanation, it will be assumed that device 42 is in its retracted position and product has been advanced by metering conveyors 210-216 to the free edge of second support 42B. Device 42 is moved from its retracted position to its extended position such as by moving gear belts 106 and 206 such that first and second supports 42A and 42B move in the conveying direction of conveyor 22 in the most preferred form at a speed which is less than the speed of conveyor 22. Simultaneously, while device 42 is moving to its extended position, metering conveyors 210-216 are actuated to move belts 14 to push and thereby transfer product from belts 14 onto transfer plate 32 and onto first support 42A. Additionally, as both supports 42A and 42B start to extend, every other metering conveyor 210, 212, 214 and 216 is accelerated to deposit one or more extra product(s) in those lanes onto the lower support 42B. Since second support 42B is moving from the retracted position faster than first support 42 A, a gap is created between product supported upon second support 42B and the leading edge of first support 42 A. After a gap is created, a pair of metering bars 52 A and 52B are simultaneously introduced in an introduction position of the endless path of transmission devices 52Aa and 52Ba into the gap, with first and second bars 52 A and 52B being closely adjacent and having an extent in the conveying direction less than the gap. After introduction, metering bars 52 A and 52B move from the introduction position to a metering position of the endless path of transmission devices 52Aa and 52Ba. Specifically, bar 52B is slowed such that the leading edge of product upon support 42 A engages with bar 52B, with bar 52B moving in the conveying direction initially to generally match the conveying speed of metering conveyors 210-216 in the most preferred form. Also, after introduction, bar 52 A is accelerated to engage with the trailing edge of product upon support 42B. The reason for scalloping the rear containment bar 52A is to contain the offset alignment that the product is in while on the second, lower support 42B. Thus, the extent of metering bars 52A and 52B in the conveying direction is less in the introduction position than in the metering position. It should be appreciated that as support 42B is accelerated to create the gap, bar 52B of the previous cycle is simultaneously accelerated to maintain contact with the product upon support 42B. After bar 52 A engages with the trailing edge of product upon support 42B, bar 52A engaging with the trailing edge and bar 52B engaging the leading edge are simultaneously accelerated to match the conveying speed of conveyor 22. While metering bars 52 A and 52B are being accelerated to match the conveying speed of conveyor 22, transfer device 42 is retracted and moves opposite to the conveying direction such that product previously on support 42B are deposited upon conveyor 22 traveling at the conveying speed of conveyor 22. It should also be appreciated that metering bar 52A contains the pattern and positively positions the product pattern on conveyor 22. As transfer device 42 is being retracted, the product group is still contained with front and rear containment along with lane dividers 222 which keep each lane of the product group separated. Thus, the product is removed from support 42A by sliding from support 42 A onto support 42B as the upstream product on conveyors 210-216 and transfer plate 32 abut with the continuous stream of product upon support 42 A and thereby prevent product on support 42 A from moving in an upstream direction with support 42A as transfer device 42 moves from the extended position to its retracted position. It should be noted that the distance moved should generally be equal to the length of the desired product pattern and specifically a distance so that the last product(s) in the desired group of product are located sufficiently upon support 42B such that they will travel with support 42B and thereby are repositioned relative to support 42A by support 42B. It should be appreciated that the leading edge of support 42 A should be located between product groups such as electronically by controlling transfer by metering conveyors 210-216 and/or by controlling drive 100 on the amount that support 42A is moved. It should be appreciated that bar 52B prevents tipping of product onto support 42B when transfer device 42 is retracted to deposit product upon support 42B as well as when transfer device 42 moves from its retracted position.

After product transfer device 42 has reached its retracted position, this operation is repeated. In the most preferred form, sweep conveyor 22 is moving in the same conveying direction as but at a higher velocity than metering conveyors 210-216 such that the product pattern is accelerated when moved from device 42 onto sweep conveyor 22 to create the physical separation between the product patterns and the contiguous stream of products on metering conveyors 210-216. This is beneficial as the velocity of metering conveyors 211, 213 and 215 can approach being constant if device 42 can be moved from its extended position to its retracted position and again move towards its extended position as the leading product(s) in the continuous stream of product pass from transfer plate 32 after the previous product has passed onto belt 24.

Once product groups have been placed onto sweep conveyor 22 with physical separations between them, the product in the groups can be collected together and placed in a desired pack pattern, if not already so, such as by the use of sweep bar mechanism 62 and such as but not limited to shrink-packing (film only, film and pad, and/or film and tray), tray loading, cartoning, sleeving or case packing.

It should be appreciated that apparatus 10 according to the teachings of the present invention is advantageous for several reasons. First, it is not necessary for the product to have windows between them in the continuous stream as was necessary with pin type metering. Particularly, apparatus 10 of the present invention can be utilized with product which have windows such as but not limited to cylindrical product, such as but not limited to cans, plastic bottles, and jars, product which do not have windows such as but not limited to rectangular parallelepipeds, such as in cartons and boxes, as well as product in the form of bundles or trays. Thus, apparatus 10 is able to function with many types of product.

In this regard, it may be desired to manufacture support 42A to have a leading edge which is scalloped to have a shape representing the actual shape of the leading bottom edges of the offset pattern of product to be appropriately deposited onto support 42B, with the leading bottom edge of product not being linearly straight such as being circular as in the case of many cans, bottles, jars or the like. The advantage of such a scalloped shape is that the leading edge follows the following edge of the last row of the product group and the leading edge of the continuous stream as the following edge has a forward extent forward of the rearward extent of the leading edge due to the offset arrangement which could result in product being haphazardly released from or carried by support 42A if its leading edge were not scalloped. Although it would be necessary to have support 42 A scalloped to each of the potential offset patterns of products desired to be metered, support 42 A can be a replacement part which is especially inexpensive when formed of belting or similar thin, flexible material. Additionally, leading edge of support 42 A could have other shapes to help removal of product as support 42 A moves from its extended position.

Likewise, to change over to product groups having different group depths such as to change between groups having different product sizes or groups having a different number of rows, it is only necessary to adjust the distance that device 42 moves between its extended and retracted position such as by changing the controls to drive 100 in the preferred form, to attach device 42 at a different length to gear belts 106 and 206, or to utilize a different device 42 which can be a relatively inexpensive replacement part. Thus, apparatus 10 according to the teachings of the present invention can be rapidly changed between product and pack pattern type and size.

As can be appreciated, a major desire in the field is product throughput. Prior apparatus including but not limited to U.S. Patent No. 6,843,360 included a transfer device formed by a single element where the product is transferred from that single element directly onto the sweep conveyor. The limiting factor on speed of such prior apparatus is often the amount of friction between the sweep conveyor and the product. Since the sweep conveyor is initially traveling faster than the product, the acting force that pulls the product to move with the sweep conveyor is kinetic friction. According to the preferred teachings of the present invention, the coefficient of friction of supports 42 A and 42B is higher than that of belt 24 of sweep conveyor 22. The acting friction on the bottom of the product for metering in apparatus 10 of the present invention is static friction, which is always greater than kinetic friction. This greater friction allows faster metering speeds according to the preferred teachings of the present invention. The faster metering speeds of the present invention is one of the reasons that metering bars 52B are utilized in the preferred form shown according to the teachings of the present invention. It should be appreciated that apparatus 10 according to the teachings of the present invention is formed of relatively few moving parts, and the only part which would be subjected to wear is device 42, which in the preferred form is a relatively inexpensive replacement part. In particular, conveyors 210-216 and 22 and metering bar mechanism 52, if utilized, are low wear and maintenance especially in comparison to the pin metering conveying mechanisms. Additionally, product is open from the top and generally open from the sides during the metering function of apparatus 10 according to the teachings of the present invention to allow easy access to product on conveyors 210- 216 and/or 22. Likewise, apparatus 10 only requires drive 100 in the preferred form within conveyor 22 (and servo motors to the side) for easy access to the bottom for maintenance and cleaning.

In the most preferred form, conveyor 22 moves at a higher velocity than metering conveyors 210, 212, 214 and 216 so that the product group accelerates from the continuous stream once they are supported directly on conveyor 22. This is advantageous because metering conveyors 210, 212, 214 and 216 can continuously operate without stopping even during the removal of product from transfer device 42 by moving in a direction opposite to the conveying direction of metering conveyors 210-216. However, it is possible to have metering conveyors 210-216 surge in velocity to transfer product onto device 42 and then decelerate to cause the separation between the metered product group and the continuous stream of product. Likewise, separation could be caused by other techniques including but not limited to combinations of the above. Acceleration of metering conveyors 210, 212, 214 and 216 relative to conveyors 211, 213 and 215 moves product generally equal to the length of product in the conveying direction. Thus, apparatus 10 according to the teachings of the present invention allows nesting in the continuous stream which is very desirable. Thus, when separated into groups, product will be offset or will not be in the same physical relationships to each other as when they were in the continuous stream. As a result, the product in group will slide on conveyor 22 (possibly with the help of lane dividers 222) relative to each other so that they will be located in an arranged pack pattern suitable for further packaging functions when engaged by sweep bars 62a and 62aa. Now that the basic teachings of the present invention have been explained, many extensions and variations will be obvious to one having ordinary skill in the art. For example, although apparatus 10 of the most preferred form includes the combination of several, unique features believed to obtain synergistic results, apparatus could be constructed according to the teachings of the present invention including such features singly or in other combinations.

Additionally, it can be appreciated that conveyor 22 could be arranged to receive a tray or a pad before transfer device 42 is extended thereover or product transferred onto conveyor 22 according to the teachings of the present invention.

The function of plate 32 is to allow product to be transferred from metering conveyors 210-216 to conveyor 22. However, it can be appreciated that this function can be accomplished in other manners as well known in the packaging art including but not limited to by the use of roller mechanisms, reshaping conveyors 210-216 and/or 22, or by utilizing other manners of product conveyance mechanisms. As an example, another possibility is using a moving conveyor transfer that consists of the tail shaft of sweep conveyor 22 and the head shaft of metering conveyors 210-216 having a fixed relationship to each other and which can laterally position itself (such as via a servo motor) underneath the appropriate product separation point and then in combination with metering bars 52A and 52B advance the desired arrangement of product to conveyor 22. Although metering bar mechanism 52 and sweep bar mechanism 62 are separately provided in the preferred form shown which provides advantages including higher speed operation, greater flexibility to allow apparatus 10 to meter product of varying configurations and types, ease of operation control and the like, mechanisms 52 and 62 could be incorporated in a single mechanism with metering bars 52B providing the function and result of sweep bars 62a according to the teachings of the present invention. Thus since the invention disclosed herein may be embodied in other specific forms without departing from the spirit or general characteristics thereof, some of which forms have been indicated, the embodiments described herein are to be considered in all respects illustrative and not restrictive. The scope of the invention is to be indicated by the appended claims, rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.

Claims

1. Apparatus for metering product comprising, in combination: a sweep conveyor having an upstream end and a downstream end and including an upper run moving from the upstream end to the downstream end in a conveying direction and a lower run moving from the downstream end to the upstream end; first and second metering conveyors each having an upper run moving in the conveying direction; and a transfer device moveable relative to the sweep conveyor between an extended position and a retracted position, with product being transferred from the upper run of the first and second metering conveyors into the transfer device and from the transfer device onto the upper run of the sweep conveyor, with the second metering conveyor being separately driven to accelerate relative to the first metering conveyor.

2. The apparatus of claim 1 further comprising, in combination: first and second metering bars moveable between an introduction position and a metering position, with the first and second metering bars having an extent in the conveying direction, with the extent of the metering bars in the introduction position being less than the gap and less than the extent of the metering bars in the metering position, with the second metering bar being scalloped to match product in an offset arrangement.

3. The apparatus of claim 2 further comprising, in combination: first and second, flexible, metering transmission devices parallel to the conveying direction, with the conveyor located intermediate the first and second, flexible, metering transmission devices, with the first metering bar secured to and extending between the first and second, flexible, metering transmission devices; and third and fourth, flexible, metering transmission devices parallel to the conveying direction, with the conveyor located intermediate the third and fourth, flexible, metering transmission devices, with the second metering bar secured to and extending between the third and fourth, flexible, metering transmission devices.

4. The apparatus of claim 3 further comprising, in combination: a plurality of axles each defining an axis, with each axle including first and second metering pulleys rotatable about the axis and receiving the first and second, flexible metering transmission devices, with the conveyor located intermediate the first and second metering pulleys, with each axle further including third and fourth metering pulleys rotatable about the axis and receiving the third and fourth, flexible, metering transmission devices, with the conveyor located intermediate the third and fourth metering pulleys.

5. The apparatus of any one of claims 2-4 further comprising, in combination: first and second sweep bars moving independently from the first and second metering bars, with the second sweep bar being scalloped to match product in the offset arrangement.

6. The apparatus of any preceding claim wherein the transfer device comprises a first support having a leading end and a second support having a leading end, with the second support intermediate the first support and the upper run of the conveyor, with the leading end of the first support being intermediate the upstream end and the leading end of the second support, with the leading ends of the first and second supports located in the conveying direction at a greater spacing from the upstream end in the extended position than in the retracted position, with the leading end of the second support being spaced in the conveying direction from the leading end of the first support in the retracted position for a length generally equal to the product in the conveying direction, with the leading end of the second support being spaced in the conveying direction from the leading end of the first support in the extended position greater than the length to define a gap downstream of the leading edge of first support, with the transfer device moving from the extended position to the retracted position opposite to the conveying direction.

7. The apparatus of claim 6 wherein the conveyor includes first and second longitudinal sides extending parallel to the conveying direction; and with the apparatus further comprising, in combination: a drive secured to the first support at first and second leading points adjacent to the leading end of the first support and secured at first and second leading points adjacent to the leading end of the second support, with the first and second longitudinal sides being intermediate the first and second leading points of the first support and being intermediate the first and second leading points of the second support.

8. The apparatus of claim 7 wherein the first and second supports each include a trailing end, with the drive secured to the first support at first and second trailing points adjacent to the trailing end of the first support, with the drive secured to the second support at first and second trailing points adjacent to the trailing end of the second support.

9. The apparatus of claim 8 wherein the drive includes first, second, third and fourth flexible belts parallel to the conveying direction, with the first leading and trailing points of the first support being on the first flexible belt, with the second leading and trailing points of the first support being on the second flexible belt, with the first leading and trailing points of the second support being on the third flexible belt, and with the second leading and trailing points of the second support being on the fourth flexible belt.

10. The apparatus of claim 9 wherein the first, second, third and fourth flexible belts are each arranged along an endless course.

11. The apparatus of claim 9 or 10 further comprising, in combination: first and second shafts extending between the upper and lower runs, with the first and second flexible belts extending around the first shaft, with the third and fourth belts extending around the second shaft, with the upstream end and the first and second shafts being spaced and parallel, with the first shaft being intermediate the upstream end and the second shaft.

12. The apparatus of any one of claims 6-11 wherein each of the first and second supports is in the form of a thin piece of flexible material.

13. Method for metering products comprising: transferring products in a conveying direction in first and second continuous streams into a transfer device in a retracted position; moving the transfer device from the retracted position in the conveying direction to an extended position; moving the transfer device opposite to the conveying direction from the extended position to the retracted position to transfer product from the transfer device to a sweep conveyor with a gap created between product on the transfer device and on the sweep conveyor; and after moving from the retracted position and before moving from the extended position, accelerating the second continuous stream in the conveying direction relative to the first stream for an offset distance.

14. The method of claim 13 further comprising: simultaneously introducing first and second metering bars into the gap before the transfer device moves opposite to the conveying direction; abutting the introduced second metering bar with a leading edge of the products located on the transfer device while the transfer device moves opposite to the conveying direction; and abutting the introduced first metering bar having a scallop corresponding to the nesting distance with a trailing edge of the products on the sweep conveyor while the transfer device moves opposite to the conveying direction.

15. The method of claim 14 wherein simultaneously introducing the first and second metering bars comprises: moving first and second, flexible, metering transmission devices parallel to the conveying direction, with the product located intermediate the first and second, flexible, metering transmission devices, with the first metering bar secured to and extending between the first and second, flexible, metering transmission devices; and moving third and fourth, flexible, metering transmission devices parallel to the conveying direction, with the product located intermediate the third and fourth, flexible, metering transmission devices, with the second metering bar secured to and extending between the third and fourth, flexible, metering transmission devices.

16. The method of claim 15 further comprising: providing a plurality of axles each defining an axis, with each axle including first and second metering pulleys rotatable about the axis and receiving the first and second, flexible metering transmission devices, with the sweep conveyor located intermediate the first and second metering pulleys, with each axle further including third and fourth metering pulleys rotatable about the axis and receiving the third and fourth, flexible, metering transmission devices, with the sweep conveyor located intermediate the third and fourth metering pulleys.

17. The method of any one of claims 13-16 further comprising: abutting the trailing edge of transferred product being conveyed with a sweep bar having a scallop corresponding to the nesting distance.

18. The method of any one of claims 13-17 wherein transferring product onto the transfer device comprises: transferring products onto first and second supports in the retracted position, with each of the first and second supports having a leading end, with the leading end of the second support being spaced a length in the conveying direction of one of the products from the leading end of the first support in the retracted position; wherein moving the transfer device comprises moving the first and second supports from the retracted position in the conveying direction with the second support moving faster than the first support to create a gap between the one of the products on the second support and the leading end of the first support; wherein moving the transfer device from the extended position comprises moving the first and second supports opposite to the conveying direction after the gap is created and to the retracted position with the second support moving faster than the first support, with moving the first and second supports opposite to the conveying direction including transferring the one of the products from the second support onto the sweep conveyor and transferring another of the products from the first support onto the second support.

19. The method of claim 18 wherein moving the first and second supports comprises moving a drive secured to the first support at first and second leading points adjacent the leading end of the first support and secured at first and second leading points adjacent the leading end of the second support, with the conveyor including first and second longitudinal sides extending parallel to the conveying direction, with the first and second longitudinal sides being intermediate the first and second leading points of the first support and being intermediate the first and second leading points of the second support.

20. The method of claim 19 wherein moving the drive comprises moving a drive secured to the first support at first and second trailing points adjacent a trailing end of the first support and secured to the second support at first and second trailing points adjacent a trailing end of the second support.

21. The method of claim 20 wherein moving the drive comprises moving first, second, third and fourth flexible belts parallel to the conveying direction, with the first leading and trailing points of the first support being on the first flexible belt and with the second leading and trailing points of the first support being on the second flexible belt, with the first leading and trailing points of the second support being on the third flexible belt, and with the second leading and trailing points of the second support being on the fourth flexible belt.

22. The method of claim 21 wherein moving the first, second, third and fourth flexible belts comprises moving the first, second, third and fourth flexible belts along an endless course.

23. The method of claim 21 or 22 wherein moving the first, second, third and fourth belts comprises moving the first and second belts around a first shaft and moving the third and fourth belts around a second shaft spaced in the conveying direction from and parallel to the first shaft.

24. The method of any one of claims 18-23 with moving the first and second supports comprising moving the first and second supports each in the form of a thin piece of flexible material.