WO2022231440A1

WO2022231440A1 - Lidding device

Info

Publication number: WO2022231440A1
Application number: PCT/NZ2022/050049
Authority: WO
Inventors: Joseph Crawford MOFFETT
Original assignee: Moffett Orchards Limited
Priority date: 2021-04-29
Filing date: 2022-04-29
Publication date: 2022-11-03

Abstract

A lidding apparatus, comprising: a moveable carriage relative to a stationary packaging inner; a guide engaged to, or integral with, the carriage, wherein the guide is configured to interface between a bottom edge of a lid and an upper edge of the packaging inner during lid installation; a retainer configured to clamp and/or provide downward force on the lid as the lid is installed over the packaging inner.

Description

LIDDING DEVICE

FIELD

[0001] This relates to a lidding device.

BACKGROUND [0002] Most packaging of food produce is done using cardboard boxes. This has traditionally been done manually by workers packing produce into a packaging inner and installing a lid when the inner is full.

[0003] US6598375, titled "Lid applicator", includes an automated lidding system with hinged plates that slide between the lid and the box during the lidding process. This lid applicator raises a loaded inner up towards a stationary lid and is a separate process from any conveyor system.

SUMMARY

[0004] According to one example embodiment, there is provided a lidding apparatus, comprising: a moveable carriage relative to a stationary packaging inner; a guide engaged to, or integral with, the carriage, wherein the guide is configured to interface between a bottom edge of a lid and an upper edge of the packaging inner during lid installation; a retainer configured to clamp and/or provide downward force on the lid as the lid is installed over the packaging inner.

[0005] Embodiments may be implemented according to any one of the dependent claims 2 to 22.

BRIEF DESCRIPTION

[0006] The description is framed by way of example with reference to the drawings which show certain embodiments. However, these drawings are provided for illustration only, and do not exhaustively set out all embodiments. [0007] Figure 1 is a diagrammatic view of a conveyor and lidder system according to an example embodiment. [0008] Figure 2 is a side view of a conveyor system according to an example embodiment.

[0009] Figure 3 is a cross-sectional side view of the conveyor system of Figure 2.

[0010] Figure 4a is a top view of the conveyor system of Figure 2. [0011] Figure 4b is a perspective view of the conveyor system of Figure 2.

[0012] Figure 4c is a further cross-sectional side view of the conveyor system of Figure 2.

[0013] Figure 4d is a yet further cross-sectional view of the conveyor system of Figure 2. [0014] Figure 4e is a close-up view of an interface between a lid and an inner.

[0015] Figure 4f is a yet still further side view of the conveyor system of Figure 2.

[0016] Figure 5a is a first view of a lid dispenser according to an example embodiment.

[0017] Figure 5b is a second view of the lid dispenser of Figure 5a. [0018] Figure 5c is a third view of the lid dispenser of Figure 5a

[0019] Figure 5d is a fourth view of the lid dispenser of Figure 5a.

[0020] Figure 5e is a fifth view of the lid dispenser of Figure 5a.

[0021] Figure 6a is a first view of an inner stop according to an example embodiment. [0022] Figure 6b is a second view of the inner stop of Figure 6a.

[0023] Figure 6c is a third view of the inner stop of Figure 6a.

[0024] Figure 7a is a first perspective view of a carriage. [0025] Figure 7b is a second perspective view of a carriage.

[0026] Figure 8a is a first perspective view of the edge guides and the corner guides on a carriage.

[0027] Figure 8b is a second perspective view of the edge guides and the corner guides on a carriage.

[0028] Figure 9 shows a clamp for carriage.

[0029] Figure 10 is an example method for controlling the conveyor system of Figure 1.

[0030] Figure 11 is an example pneumatic system for a lidder system. DETAILED DESCRIPTION

[0031] In general terms a continuous inline conveyor system according to an example embodiment attaches a lid to a packaging inner to form a box. Each packaging inner (by that stage fully packed with goods) is conveyed along a conveyor. A supply of lids is located on top of a carriage above the conveyor. The lids are first conveyed to the lidding location and then dispensed into a lid chute by one or more lid dispensers. After a lid has been dispensed into a lid chute and retained at the top of the carriage with its bottom edges on a series of guides, a packaging inner is moved to a packaging position underneath the carriage. Clamps also engage and secure the lid, so it is in a fixed position on the carriage as it descends. As the carriage descends, with the help of the guides, the lid slides over the packaging inner. Once the lid is fully engaged on the packaging inner, the clamps release, the carriage continues its path downwards until it fully passes the packaging inner, and underneath the conveyor. Then the closed box continues on the conveyor, and the carriage rises back up to its top position. The process starts again with a new packaging inner passing underneath on the conveyor and with a new lid arriving at the lidding location. [0032] Figure 1 illustrates a packaging system 100 according to an example embodiment. The packaging system 100 may be provided at a 0-15° angle A to horizontal 101. The arrow also indicates the direction in which a packaging inner 104 travels in the packaging system 100. A lid chute 320 defined by a frame 173 is substantially perpendicular to the inner conveyor 102 and the lid dispensers 130,

132 and 134. Where there is provided a 0-15° elevation A, this means the lid chute 320 may be at a 90-105° to horizontal 101. The lid chute 320 may be configured so that as a lid descends the chute it substantially slides against a side of the chute (non-feed wall) distal the lid dispensers 130, 132 and 134. [0033] The inner conveyor 102 is fed with packaging inners 104 that is filled with produce earlier in the conveyor processing and is configured to move the packaging inners 104 to a packaging position 103. If there is an angular elevation A, the inner conveyor 102 may simply move the packaging inners 104 due to gravity, for example if the inner conveyor 102 is a static roller bed conveyor. Alternatively or additionally, the inner conveyor 102 may be powered by a separate power source. For example, the inner conveyor 102 may be driven by an electric motor.

[0034] The inner conveyor 102 comprises one or more gaps 231 near the packaging position 103 through which the carriage 108 can vertically pass. Between the gaps 231 is an inner support 170. The inner support 170 may be affixed to the frame 173. The inner support 170 may engage a packaging inner 104 with rows of wheels 177 (or roller bearings), which would allow a packaged box to easily move past the gap 231 distal the inner stop 602 and advance on the inner conveyor 102. In one example embodiment, there are two similar inner supports 170 disposed on opposing sides of the frame 173, as shown in Figure 3.

[0035] The packaging inners 104 can be retained on the inner conveyor 102 with an inner stop 602 near a waiting position 105. The operation of the inner stop 602 is described in more detail below. The inner stop 602 is configured to retract to allow a packaging inner 104 to pass and move to the transitional position 107 but is also configured to extend in time to retain the next packaging inner 104 at the waiting position 105.

[0036] A vertically translatable carriage 108 is controlled by pneumatic rams 110. The carriage 108 comprises a retainer 112 which retains a packaging inner 104 at the packaging position 103. A packaging inner 104 at the packaging position 103 is within the lid chute 320 and below the carriage 108 to allow a lid 118 to be installed onto itself. Linear bearings are attached to the carriage 108, which allows the carriage 108 to slide vertically along bearing rails.

[0037] The carriage 108 comprises a plurality of clamps 126 and a plurality of guides comprising cornerguides 124 and edge guides 114 (the distinction between the two types of guides is not clear in Figure 1 but will be described later). The clamps 126 help secure the lid 118 as it descends the lid chute 320 onto the packaging inner 104. The guides 114 and 124 allow for a smooth lidding process by providing an interface between the lid 118 and the packaging inner 104. The carriage 108 is described in more detail below.

[0038] The lids 118 may be provided to the carriage 108 using a lid dispenser 130, which may comprise a hopper or a sliding tray mechanism. In case of several variations of lids 118 (for different products or branded lids), multiple lid dispensers 130, 132 and 134 may be provided together. Each lid dispenser may operate independently of another lid dispenser. Multiple lid dispensers may operate at different elevations, meaning different lids 118 may be dispensed into the lid chute 320 at different heights. Each lid dispenser 130, 132 and 134 may comprise a respective dispenser pneumatic ram 136, 138 and 140.

[0039] The lids 118may arrive at the lid dispensers on multiple suitable lid conveyors at different elevations corresponding to the different elevations of the lid dispensers. Like the inner conveyor 102, the lid conveyors may also be at an angle A to the horizontal and so driven by gravity. Alternatively or additionally, motorised actuation of the lid conveyors may be provided. The lid conveyors are placed adjacent to the lid dispensers 130, 132, and 134, such that a lid 118 may be pushed off a conveyor onto an adjacent lid dispenser by a pneumatic ram as the lid 118 approaches the adjacent lid dispenser.

[0040] Alternatively, the lid dispensers may be part of the lid conveyors. That is, the lids 118 are dispensed into the lid chute 320 as a result of the conveying motion of the lid conveyors and are not pushed into the chute with a separate actuator e.g. a sliding tray. Such an arrangement may require a stop mechanism similar to the inner stop 602 paired with each lid dispenser. The conveying motion may be caused by gravity, motorised actuation, or a combination of both.

[0041] The lid dispensers 130, 132, and 134 and their operation are described in more detail below.

[0042] Figures 2, 3, 4a, 4b, 4c, 4d, 4e and 4f show a more realistic representation of the system 100. While not shown in Figure 1, the system 100 may preferably comprise a counterweight system 160 as shown most clearly in Figure 2. Key parts of the system 100 are individually described in more detail below. Lid Dispenser

[0043] A lid dispenser is shown in Figures 5a, 5b, 5c, 5d and 5e. This lid dispenser may be any one of the lid dispensers 130, 132 and 134. As mentioned above, the whole system 100 may be at an angle A to the horizontal 101. In addition, the lid dispensers 130, 132 and 134 may be at a further 0-15° angle to the rest of the system 100. This can be seen in Figures 2 and 4f, where the lid dispensers 130, 132 and 134 are shown to be at an angle relative to the inner conveyor 102.

[0044] As described above, the function of the lid dispenser is to dispense a lid 118 into the lid chute 320. The lid 118 may have been delivered to the lid dispenser via a separate lid conveyor (not shown) and subsequently received by a pusher tray cover 322. The dispensing is achieved by extending a pneumatic ram 310, which may be any one of the pneumatic rams 136, 138 and 140. When actuated, the pneumatic ram 310 moves in direction 312 towards the lid chute 320. Movement of the pneumatic ram 310 towards the lid chute 320 causes a pusher tray 314, carrying the lid 118, to also move in direction 312 towards the lid chute 320 in tandem. This transports the lid 118 into the lid chute 320. After the pneumatic ram 310 retracts, the lid 118 falls down the chute and is received by the carriage.

[0045] The lid dispenser is supported by a straight frame 302 that runs parallel to and above the inner conveyor 102. Referring to Figure 5b, the frame 302 has a substantially U-shaped cross section. Referring to the cross section of Figure 5a taken along a longitudinal axis of the lid dispenser, the frame 302 comprises cut outs 304 to receive rods 306. These rods 306 attach to one or more rigid structures in the vicinity and so support the lid dispenser structure. There may be two such cut outs 304 on each of the two opposing arms of the frame 302. As can be seen in Figure 4b, an example of such rigid structures may be panels 180. These panels 180 may be integral with or fastened to the frame 173. The cut outs 304 allow the position of the frame 302 to be adjusted vertically relative to the rods 306. Here, vertical refers to the direction that is substantially perpendicular to the movement direction 312 of the pusher tray 314.

[0046] An elbow 308 adjoins a pneumatic ram 310 and the frame 302. The pneumatic ram 310 may be any one of the pneumatic rams 136, 138 and 140. The dispenser pneumatic ram 310 may be about 500 mm long; it may have a diameter of about 20 mm and a stroke of about 400 mm. The dimensions may need to be adjusted for different sizes of inners.

[0047] The pusher tray 314 may comprise a two-piece structure. The first piece 315 and the second piece 316 may be fastened together with suitable fasteners 317. The second piece 316 comprises a folded pusher tab 318 that stands substantially upright. In an alternative embodiment, the pusher tab 318 is integral with the first piece 315, and there is no second piece 316. Movement of the pusher tray 314 is enabled by linear bearings 321 attached thereto, which slide in bearing rails 319 in response to actuation of the pneumatic ram 310. In one example embodiment, the length of the bearing rails 319 is about 500 mm, the ram 310 has a stroke of about 400 mm, and the linear bearings are about 100 mm long. [0048] The pusher tray cover 322 of the lid dispenser is a substantially rectangular frame mounted above the frame 302. Referring to Figure 5b, the pusher tray cover 322 also has a substantially U-shaped cross section. The pusher tray cover 322 and bearing rails 319 are adjoined via fasteners 324a. Pusher tray 314 and bearings 321 are adjoined via fasteners 324b. Bearings 321 slide inside and along bearing rails 319. As shown in Figure 5c, the pusher tray 322 is fastened with fastener 324a to bearing rail 319, which is in turn fastened to ramp 305. Ramp 305 is fastened with rods 306 to a panel 180 attached to frame 173. In use, the pusher tray cover 322 provides a contact surface for when a lid 118 is fed onto a lid dispenser. A lid 118 would first be disposed atop the pusher tray cover 322 and then slide and drop down in front of the pusher tab 318 as shown in Figure 5a.

[0049] While mostly concealed in Figure 5a due to the drawing being a middle cross section, the lid dispenser further comprises a ramp 305 on either side of the frame 302. The ramp 305 is not visible in Figure 5b because it does not span the whole length of the lid dispenser. The upper edge of the ramp 305 may be a narrow incline disposed on either side of the pusher tray 314. When viewed from the side such as in Figures 5c and 5d, the ramp 305 is substantially trapezoidal with the incline configured to support a lid, such that the end 325 of the ramp 305 proximate the lid chute 320 is raised relative to the end of the ramp 305 distal the chute. The incline may be at an angle of 0-15° relative to 312. One or more slots 323 for receiving rods 306 are provided along the bottom of the ramp 305. These slots 323 allow the position of the ramp 305 to be horizontally adjusted relative to the position of the rods 306. Here, horizontal refers to the direction that is substantially parallel to the movement direction 312 of the pusher tray 314. [0050] Figures 5c, 5d and 5e show the operation of the lid dispenser in more detail. The ramp 305 can be seen more clearly in these drawings: as mentioned above, the ramps 305 do not longitudinally overlap with the pusher tray covers 322 and are therefore not shown in the cross section view of Figure 5b. [0051] In Figure 5c, the lid 118 is retained by the ramp 305 and the pusher tab 318. As mentioned above, the lid dispenser may be at an angle A to horizontal 101.

[0052] In Figure 5d, the pneumatic ram 310 has been extended. Consequently, the pusher tray 314 carrying the lid 118 is extended into the lid chute 320. While not shown, the lid 118 is now above the carriage 108.

[0053] In Figure 5e, the pusher tray 314 is retracted out of the lid chute 320 by pneumatic ram 310. The lid dispenser is in the same position as that of Figure 5a. The lid 118, however, is still within the lid chute 320. The raised end 325 of the ramp 305 prevents the lid 118 from sliding back with the pusher tray 314. In the absence of a supporting force, the lid 118 will fall due to gravity and be received by the carriage 108. Figures 5c, 5d and 5e show the key stages of one lid dispensing operation. The lid dispenser as shown in Figure 5e is ready to receive and dispense the next lid.

Inner Stop [0054] As shown in Figure 6a, one or more inner stops 602 may be actuated by pneumatic ram 106 to allow or obstruct movement of a packaging inner 104 towards the transitional position 107 (see Figure 1). In one example embodiment (e.g. Figure 6b), there are two inner stops 602 disposed near two opposing ends of an inner stop bracket 604. The two inner stops 602 may be substantially identical in construction. An inner stop 602 may be removably connected to an inner stop bracket 604 via fasteners 606. Alternatively, an inner stop 602 may be integral with the inner stop bracket 604.

[0055] Inner stop bracket 604 may comprise a top platform 607 supported by at least two feet 609. In Figure 6b, there are two sections of feet 609 shown on each longitudinal side of the inner stop bracket 604. The two sections may be part of the same foot 609, that is, there may only be one foot 609 per longitudinal side.

Or the two sections may each be a foot 609, that is, there may be at least two feet 609 per longitudinal side. One or more inner stops 602 are fastened to the top platform 607, and the feet 609 are fastened to the rails of the inner conveyor 102. In this way, one or more inner stops 602 are connected to the inner conveyor 102 near the waiting position 105.

[0056] An inner stop 602 comprises a pneumatic ram 106 and an arm 601 connected to pneumatic ram 106 at a joint 603 (see Figure 6c), e.g. by coupling an end of pneumatic ram 106 to arm 601. The other end of pneumatic ram 106 is coupled to an elbow 614, which is in turn affixed to the top platform 607 of the inner stop bracket 604. The pneumatic ram 106 moves substantially parallel to the inner conveyor 102 with a stroke of about 40 mm. Linear movement of pneumatic ram 106 actuates rotation of arm 601. [0057] Pneumatic ram 106 may be approximately 50 mm long and have a diameter of approximately 20 mm. The dimensions may need to be adjusted for different sizes of inners. Preferably, the length of the pneumatic ram 106 is about 20% the height of the inner, and the diameter of the pneumatic ram 106 is about 12.5% of the height of the inner. [0058] In a first position as shown in Figure 6c and 610 of Figure 6a, pneumatic ram 106 is substantially parallel to the inner conveyor 102. In the first position, arm 601 does not extend above inner conveyor 102, thereby allowing a packaging inner 104 to move past the waiting position 105 towards the transitional position 107.

In a second position as shown by 616 of Figure 6a, arm 601 is rotated about 45 in direction 605. In the second position, arm 601 extends above inner conveyor 102 and would retain a packaging inner 104 at the waiting position 105 if there were packaging inners 104 being conveyed as shown in Figure 6a. Preferably, an arm 601 is fitted with a wheel (which may be a roller bearing) at its tip 611 to allow smooth engagement of arm 601 with a packaging inner 104. Tip 611 of an arm 601 would slide up and down against a side of a packaging inner 104 and therefore likely not damage the packaging inner 104.

[0059] Rotational movement of arm 601 between the first and second positions is actuated by linear movement of pneumatic ram 106. Assuming arm 601 is in the first position, linear movement of pneumatic ram 106 in direction 613 would cause arm 601 to rotate in direction 605 about a pivot 615, since arm 601 is prohibited from linear movement due to being fastened to inner conveyor 102 at pivot 615.

As arm 601 rotates in direction 605, pneumatic ram 106 rotates in the opposite direction about joint 618, and inner stop 602 reaches the second position. In the second position, pneumatic ram 106 is still substantially parallel to conveyor 102 but is less parallel compared to when pneumatic ram 106 is in the first position. In one example embodiment, the pneumatic ram 106 rotates about 5° when moving between the first and second positions.

[0060] Conversely, linear movement of pneumatic ram 106 in the opposite direction to direction 613 would cause arm 601 to rotate in the opposite direction to direction 605 about pivot 615. As arm 601 rotates in in the opposite direction to direction 605, pneumatic ram 106 rotates in direction 605. This is how inner stop 602 would move from the second position to the first position.

Carriage [0061] Figures 7a and 7b show the carriage 108 in more detail. The carriage 108 comprises a substantially hollow rectangular body 113, a plurality of edge guides 114, a plurality of cornerguides 124, a plurality of clamps 126, and projections 135 for attaching the plurality of clamps 126 to the hollow rectangular body 113.

[0062] The top opening 246 of the carriage body 113 is substantially rectangular. The length and width of the top opening 246 are respectively greater than the length and width of a packaging inner 104 so that the packaging inner 104 may pass through the carriage body 113 during lid installation.

[0063] The front opening 248, complementary to the front plate 250, may preferably be substantially larger than the rear opening 247 complementary to the rear plate 251. The front opening 248 is what a packaging inner 104 would have to go through to reach the packaging position 103 if the carriage 108 were not raised completely above the packaging inner 104. Thus, the front opening 248 needs to be wider than the packaging inner 104. The height of the front opening 248 is preferably maximised so that the carriage 108 can be raised to a lower elevation and still allow a packaging inner 104 to pass through. This is advantageous since raising the carriage 108 to a higher elevation would cause the system 100 to expend more energy per packaging cycle.

[0064] The rear plate 251 needs to be substantially larger than the front plate 250 such that after a packaging inner 104 passes through the front opening 248, it is then retained within and beneath the carriage 108 at the packaging position 103.

In this way, the rear plate 251 may be the retainer 112 in the diagrammatic representation of Figure 1. If the height of the rear opening 247 were greater than the height of the packaging inner 104, then the packaging inner 104 might move past the packaging position 103 and advance on the conveyor 102; lid installation would not be possible.

[0065] In one example embodiment, the plurality of edge guides 114 consist of two guides corresponding to two opposing long edges of the carriage body 113 and two guides corresponding to two opposing short edges of the carriage body 113.

[0066] In one example embodiment, the plurality of corner guides 124 consist of four corner guides corresponding to four corners of the top opening 246 in the carriage body 113.

[0067] The guides 114 and 124 provide a retainer for a bottom edge 116 (see Figure 1) of the lid 118 and an interface between the bottom edge 116 and an upper edge 120 (see Figure 1) of the packaging inner 104 during lid installation. The edge guides 114 may also provide a retainer for any one or more other bottom edges of the lid 118. Similarly, the edge guides 114 may also provide an interface between anyone or more other bottom edges of the lid 118 and the corresponding one or more other upper edges of the packaging inner 104 during lid installation.

[0068] The edge guides 114 are configured to pivot relative to the carriage body 113. For example, this can be achieved by attaching the edge guides 114 to the carriage body 113 with butt hinges 115. The guides 114 may be hinged at IB electronically adjustable angles or at a fixed angle. Alternatively, the edge guides 114 and/or butt hinges 115 may be integrally formed with the carriage body 113.

[0069] The edge guides 114 may each be a substantially rectangular metal plate, preferably with rounded corners. In one example embodiment, the two edge guides 114 that correspond to the two opposing long edges of the carriage 108 are approximately 300 mm long and approximately 120 mm wide. In one example embodiment, the two edge guides 114 that correspond to the two opposing short edges of the carriage 108 are approximately 140 mm long and approximately 120 mm wide. The thickness of the edge guides 114 may preferably be about 1 mm. [0070] The edge guides 114 may be made of steel using cutting processes.

[0071] The corner guides 124 may provide a retainer at a bottom vertex of the lid 118 and an interface between a vertical edge of the lid 118 and a corresponding vertical edge of the packaging inner 104 during lid installation. The corner guides 124 may also provide a retainer for any one or more other bottom vertices of the lid 118. Similarly, the corner guides 124 may also provide an interface between any one or more other vertical edges of the lid 118 and the corresponding one or more other vertical edges of the packaging inner 104 during lid installation.

[0072] Figures 4d and 4e show the corner guides 124 during lid installation. As can be seen most clearly in Figure 4e, the bottom portion of a corner guide 124 is in engagement with the packaging inner 104, while the top portion is in engagement with the lid 118. As the carriage 108 descends further, the corner guide 124 will be urged further to the upright position.

[0073] Like the edge guides 114, the corner guides 124 are configured to pivot relative to the carriage body 113. For example, this can be achieved by attaching the corner guides 124 to the carriage body 113 with corner butt hinges 121. The corner guides 124 may be hinged by unconstrained hinges, sprung loaded hinges or electronically adjustable angles or at a fixed angle. Alternatively, the corner guides 124 and/or corner butt hinges 121 may be integrally formed with the carriage body 113.

[0074] A corner guide 124 may form a substantially 90° angle. For example, two constituent metal plates may be formed separately and then assembled at about 90° into a corner guide 124. Alternatively, a single metal plate may be folded at about 90° into a corner guide 124. In one example embodiment, the two sides that form the substantially 90° angle are about 40 mm wide, and the height of the corner guides 124 is about 120 mm. The thickness of the corner guides 124 may be about 1 mm. [0075] Figures 8a and 8b show a more detailed view of the edge guides 114 and the corner guides 124. In Figure 8a, the edge guides 114 and the corner guides 124 would not be in engagement with the lid 118 or the packaging inner 104 in use. In this state, the edge guides 114 and the corner guides 124 are slanting. The edge guides 114 and the corner guides 124 may be spring loaded so that they are urged towards the slanting orientation shown in Figure 8a. Alternatively or additionally, the edge guides 114 and the corner guides 124 may be urged to the slanting orientation using a powered (e.g. pneumatic or electric) actuation means.

[0076] As the lid 118 descends onto the packaging inner 104, the upper edges of the packaging inner 104 urge the edge guides 114 and the corner guides 124 towards an upright orientation (see Figure 8b): the edge guides 114 and the corner guides 124 are rotated about the butt hinges 115 and the corner butt hinges 121, respectively. In use, the edge guides 114 and the corner guides 124 would be sandwiched between the lid 118 and the packaging inner 104 as the lid 118 descends the full height of the packaging inner 104. In embodiments where the edge guides 114 and the corner guides 124 are biased towards the slanting orientation, the force exerted by the upper edges of the packaging inner 104 must be sufficient to overcome this biasing force so as to move the edge guides 114 and the corner guides 124 to the upright orientation. [0077] In addition to functioning as hinge mechanisms, the butt hinges 115 and 121 also provide stable surfaces on which the lid 118 may be retained. Collectively, the butt hinges 115 and the corner butt hinges 121 allow the carriage 108 to receive the lid 118 by supporting its bottom edges. [0078] Further retention of the lid 118 is afforded by the plurality of clamps 126, which clamp and/or provide downward force on the top of the lid 118 as it is installed over the packaging inner 104. The plurality of clamps 126 are each controlled by a pneumatic ram 128. A clamp 126 is shown in more detail in Figure 9. [0079] A clamp 126 comprises a clamp bracket 127 and a curved arm 129. The clamp bracket 127 partially encloses pneumatic actuation means 141 including a pneumatic ram 128. Pneumatic connection means 157 (see Figures 7a and 7b) interface the pneumatic actuation means to a pneumatic system 1100 (described in more detail below). The clamp bracket 127 comprises flanges 131 and 143 having a hole 133 and openings 145 respectively. A fastener 149 affixes the curved arm 129 to the flange 131 through the hole 133, which makes 133 a pivot that enables rotation of the curved arm 129, as will be explained later. One or more fasteners (not shown) affix the flange 143 to a projection 135 (see Figures 7a and 7b) of the carriage 108 through one or more openings 145. The distal end 137 of curved arm 129 directly engages the top of a lid 118. Preferably, the distal end 137 is fitted with roller bearings 139. This may reduce friction and avoid damaging the top of the lid 118 when the clamp 126 is clamping and/or providing a downward force on the lid 118.

[0080] The curved arm 129 is configured to rotate about the pivot 133. The rotation is actuated by linear motion of the pneumatic ram 128, which is connected to the curved arm 129 at a joint 159. The joint 159 may comprise a clevis 161, which is attached to the pneumatic ram 128, and a fastener 163 that fastens the curved arm 129 and the clevis 161 together. [0081] As the pneumatic ram 128 moves in direction 147, it effects on the curved arm 129 a pulling force which results in rotation 158 of the curved arm 129, since the curved arm is prohibited from linear movement due to the fastener 149. Conversely, linear movement of the pneumatic ram 128 in the opposite direction to 147 effects on the curved arm 129 a pushing force which results in rotation opposite to the rotation 158 of the curved arm.

[0082] Reference 142 shows the curved arm 129 in an 'open' position. In the position, the curved arm 129 would not engage the top of the lid 118 in use. The clamps 126 are in the open position in Figure 2b. Contrastingly, position 144 is a 'closed' position, where the curved arm 129 would be clamping and/or providing a downward force on the top of a lid 118 e.g. during installation if said lid has been received by the carriage 108. The rotation of the curved arm 129 between the opening position and the closed position is about 45°.

[0083] The clamps 126 may be made of steel. The curved arm 129 may be manufactured using UHMWPE and cutting processes. In one example embodiment, the pneumatic rams 128 are about 20 mm long and have a diameter of approximately 15 mm. The pneumatic rams 128 have a stroke of 10 mm. In one example embodiment, the roller bearings 139 have a diameter of approximately 20 mm. In one example embodiment, the dimensions 201 and 203 of the curved arm 129 are about 60 mm and 100 mm respectively.

[0084] As described above, the carriage 108 is configured to move vertically within the lid chute 320. This is achieved by linear bearings 185 (see Figure 4c), which are attached to the carriage 108, vertically sliding on bearing rails 167 that are affixed to a rigid structure such as the frame 173 (e.g. at connections 169). A plurality of holes 234 are distributed on the bearing rail 167 across its height. One or more of the holes 234 may be used to fasten a bearing rail 167 to another rigid structure in the vicinity, in addition to the connections 169 joining the bearing rails 167 to the frame 173. In one example embodiment, there are two sets of actuation means, each set comprising a linear bearing 185, a bearing rail 167, and a pneumatic ram 110.

[0085] Upon actuating a pneumatic ram 110, a corresponding linear bearingl85 would move vertically up in its corresponding bearing rail 167. In this way, the carriage 108 can be moved up vertically in tandem in the lid chute 320. To keep the carriage elevated above its resting height, constant pressure would need to be applied in the pneumatic ram 110. Once the pneumatic ram 110 stops applying an upwards pushing force to the carriage 108, the carriage 108 would fall as a result of gravity. Counterweight

[0086] As most clearly shown in Figure 2a, the optional but preferable counterweight system 160 comprises multiple pulleys. Each pulley comprises a wheel 176 through which an axle 171 attaches it to a pulley mounting bracket 172, which is affixed to a frame 173. Suspended via a cable 174 fitted within a groove (not shown) of the wheel 176 is a counterweight 175. Collectively between all pulleys and counterweights 175 in the counterweight system 160, the total counterweight substantially matches the weight of the carriage 108, which is attached to the other end of each cable 174 of each pulley. Such a counterweight system can advantageously speed up the ascent of the carriage 108 and allow pneumatic ram 110 to do less work in raising the carriage 108. Preferably, the cable 174 is made of braided nylon. The cable 174 needs to be sufficiently long so as to not limit the carriage 108's range of movement. In one embodiment, the length of the cable 174 is greater than 500 mm.

[0087] Figure 2c shows an example counterweight system 160 having four pulleys. However, a different number of pulleys may be provided with the counterweight 175 of each pulley adjusted accordingly to achieve a desired total counterweight. In the example embodiment shown, the shape of the counterweight 175 is substantially a cylinder. However, in a different embodiment, the counterweight 175 may assume a different shape so long as it does not interfere with the operation of the other moving parts in the system 100. Preferably, all pulleys are well-matched.

Sensors

[0088] The lidding system 100 is fitted with multiple sensors (depicted as stars in Figure 1) installed at various locations. As will be explained below, these sensors are necessary for correct operation of the lidding system 100 according to a control algorithm.

[0089] A sensor 162 detects the absence or presence of a packaging inner 104 at the waiting position 105. [0090] A sensor 109 detects the absence or presence of a packaging inner 104 at a transitional position 107.

[0091] A sensor 146 detects the absence or presence of a packaging inner 104 at the packaging position 103 of the inner conveyor 102.

[0092] A sensor 148 detects the absence or presence of a lid 118 receivable at the top of the carriage 108.

[0093] A sensor 150 detects the position of the carriage 108 in the chute 320. In particular, sensor 150 is able to detect whether the carriage 108 is above the top of a packaging inner 104 in the packaging position 103 (whether the carriage 108 is in the 'up' position). When the carriage 108 is in the up position, a packaging inner 104 is able to move to the packaging position 103.

[0094] A sensor 151 is provided near the packaging position 103 and detects whether a lid 118 has been fully installed onto a packaging inner 104.

[0095] Sensor 152, 154, and 156 are provided near the lid dispensers 130, 132 and 134 respectively. Each sensor 152, 154, and 156 detects the presence or absence of a lid 118 at each respective lid dispenser. [0096] In one example embodiment, all sensors 162, 109, 146, 148, 150, 151, 152, 154, and 156 are photoelectric sensors. The photoelectric sensors may be through-beam or reflective. For through-beam sensors, an emitter and a receiver would need to be installed on opposing static structures such that the emitting and receiving elements are aligned. For reflective sensors, a single device emits light and also detects light reflected from a reflector; the device and the reflector are preferably aligned.

[0097] In some cases, it may be preferable to angle a sensor towards a positionable member that can be adjusted to protrude from a stationary structure by different distances. This would allow the sensing configuration to be changed by adjusting the position of the positionable member and accordingly re-angling the sensor to sense the repositioned positionable member.

[0098] As an example, sensor 151 could be configured to be angled away from the carriage 108 and towards a positionable member protruding from carriage. Consequently, sensor 151 would not necessarily be triggered by carriage 108 reaching the installation location of sensor 151.

[0099] Specifically, the photoelectric sensors may all be SICK's WTT2SL-2P3292 photoelectric sensor.

Pneumatics [0100] In one example embodiment, all pneumatic rams 106, 110, 128 and 310

(lid dispenser pneumatic rams 136, 138 and 140) are double acting pneumatic cylinders. Pneumatic rams 106, 110, 128 and 310 may each require about 4 bars,

4.5 bars, 6 bars and 3 bars of working pressure, respectively. In use, pneumatic rams 106, 110, 128 and 310 may each apply about 126 N, 140 N, 47 N and 60 N of force, respectively.

[0101] Figure 11 illustrates a pneumatic system 1100 of the packaging system 100 according to an example embodiment. Pneumatic rams 106 are connected to valves 1106 comprising a solenoid valve and a pressure reducing valve; the solenoid valve may preferably be a 5-port, 2-way solenoid valve. Pneumatic rams 110 are connected to valves 1110 comprising a solenoid valve and a pressure reducing valve; the solenoid valve may preferably be a 5-port, 2-way solenoid valve. Pneumatic rams 128 are connected to valves 1128 comprising a solenoid valve and a pressure reducing valve; the solenoid valve may preferably be a 5-port, 2-way solenoid valve.

[0102] In an example embodiment with three independent lid dispensers, pneumatic rams 136 are connected to valves 1136 comprising a solenoid valve and a pressure reducing valve; the solenoid valve may preferably be a 5-port, 2-way solenoid valve. Further, pneumatic rams 138 are connected to valves 1138 comprising a solenoid valve and a pressure reducing valve; the solenoid valve may preferably be a 5-port, 2-way solenoid valve. And further still, pneumatic rams 140 are connected to valves 1140 comprising a solenoid valve and a pressure reducing valve; the solenoid valve may preferably be a 5-port, 2-way solenoid valve. [0103] A pneumatic manifold 1001 may enable installation of valves 1110, 1106,

1128, 1136, 1138 and 1140 in a centralised location where a single air supply 1103 and an exhaust port 1105 are shared among all valves. The pneumatic manifold 1001 may be configured for a mains pressure of 8 bars.

[0104] As can be seen in Figure 11, each pneumatic ram may be coupled to two flow restrictor valves. The pneumatic ram may be extended (push stroke) or retracted (pull stroke) by selectively opening one of the two valves to the air supply 1103 and the other to the exhaust port 1105. For example, to extend pneumatic ram 106, the air supply 1103 may be coupled to valve 1107 with valve 1108 coupled to the exhaust port 1105. And to retract pneumatic ram 106, the air supply 1103 may be coupled to valve 1108 with valve 1107 coupled to the exhaust port

1105. Alternatively, the retraction may be actuated by a biasing member such as a spring. Operation

[0105] Figure 10 illustrates a method 200 of controlling the system in Figure 1. This may be implemented on a programmable logic controller (PLC) such as a Schneider TM221, a microprocessor, or a computer network connected to a local or remote server. The PLC is in communication with every sensor 162, 109, 146, 148, 150, 151, 152, 154, and 156 in the packaging system 100.

[0106] Method 200 describes a full packaging cycle from start to finish.

[0107] At step 202, sensor 150 detects whether the carriage 108 is in the up position. Sensor 150 is repeatedly polled in the case of a negative output. [0108] At step 204, a sensor 152, 154, or 156 detects whether a lid 118 is ready to be dispensed into the lid chute 320 from the respective lid dispenser 130, 132, or 134. If a lid 118 is ready, the corresponding pneumatic ram 136, 138, or 140 is extended to push the lid 118 into the lid chute 320, which then guides the falling lid 118 onto the carriage 108 in the up position. This occurs at step 206. Sensor 152, 154, or 156 is repeatedly polled in the case of a negative output.

[0109] At step 208, sensor 148 detects whether the lid 118 has been received by the carriage 108. If the lid 118 has been received by the carriage 108, pneumatic rams 128 are extended at step 210 to close the clamps 126 onto the top of the lid 118, thereby clamping and/or providing a downward force on the lid 118. Sensor 148 is repeatedly polled in the case of a negative output.

[0110] At step 212, sensor 146 detects whether a packaging inner 104 is present at the packaging position 103 of the inner conveyor 102. If there is no packaging inner 104 at the packaging position 103, sensor 162 detects at step 214 whether a packaging inner 104 is waiting at the waiting position 105 of the inner conveyor 102. If there is a packaging inner 104 at the waiting position 105, pneumatic ram

106 of the inner stop 602 is retracted at step 216 to release the packaging inner 104, which will then begin to move towards sensor 109, either driven solely by gravity (if the inner conveyor 102 is angularly offset), or at least partially driven by a powered conveyor.

[0111] At step 218, sensor 109 detects whether the front side of the packaging inner 104 has reached the transitional position 107 of the inner conveyor 102. Once the sensor 109 has detected the presence of the packaging innerl04, pneumatic ram 106 is extended to rotate arm 601 of stop 602 towards the inners 104. This occurs at step 220 and prevents the next packaging inner 104 in the conveyor 102 from advancing past the waiting position 105. As the packaging inner 104 at the transitional position 107 would be raised by arm 601, step 220 should not be triggered so early as to cause the front side of the inner 104 to fall into gap 231. Once the packaging inner 104 arrives at the packaging position 103, it is stopped by the retainer 112 of the carriage 108.

[0112] Referring back to step 212: if there is a packaging inner 104 at the packaging position 103, then pneumatic ram 110 is actioned at step 222 to lower the carriage 108 and hence the lid 118 towards the packaging inner 104. At this stage of the lid installation cycle, lid 118, retained by clamps 126, is descending the lid chute 320 but has not yet engaged the packaging inner 104. As described above, the edge guides 114 and the corner guides 124 are slanting as they are not yet in engagement with the packaging inner 104. [0113] The carriage 108 carrying the lid 118 continues its descent in the lid chute

320. At some point the lid 118, retained by clamps 126, will have descended enough that the carriage 108 and the lid 118 are now in engagement with the packaging inner 104. As described above, the edge guides 114 and the corner guides 124 are in the upright position and provide interfaces between edges of the lid 118 and edges of the packaging inner 104.

[0114] At step 224, sensor 151 detects whether the carriage 108 has descended enough to have completed the lid installation. Once the lid 118 has been substantially installed onto the packaging inner 104, the clamps 126 retract at step 226 so that the carriage 108 may continue its descent past the packaging inner 104. Step 224 repeats until sensor 151 outputs a positive result.

[0115] Although the lid 118 has been installed, the lid installation cycle is not yet complete. If the carriage 108 were to rise now, it would remove the lid 118 from the packaging inner 104. To avoid this, the carriage 108 continues its descent through the gaps 231 until it has fully descended past the inner conveyor 102, so that the carriage 108 is low enough to allow the packaging inner 104, now fitted with a lid 118, to advance past the packaging position 103 on the inner conveyor 102 with the retainer 112 no longer in engagement with the packaging inner 104. In the absence of retention provided by the retainer 112, the packaging inner 104 and the lid 118 may simply move past the packaging position 103 under the effect of gravity without requiring an additional sensorto signal that the carriage 108 has fully descended past the inner conveyor 102.

[0116] At step 228, sensor 146 detects whether the packaging inner 104 (and the lid 118) has moved past the packaging position 103. If sensor 146 detects the absence of a packaging inner 104, pneumatic ram 110 is retracted at step 230 to raise the carriage 108 back to its up position through gaps 231. This concludes the lid installation cycle. The lid installation starts again with a new packing inner 104 being delivered on the inner conveyor 102 and a new lid 118 being dispensed onto the carriage 108 in the up position.

Interpretation

[0117] Where an approach has been described as being implemented by a controller, this may comprise a plurality of controllers. That is, at least in the case of controllers, the singular should be interpreted as including the plural. Where a method comprises multiple steps, different steps or different parts of a step may be performed by different controllers.

[0118] The term "comprises" and other grammatical forms is intended to have an inclusive meaning unless otherwise noted. That is, they should be taken to mean an inclusion of the listed components, and possibly of other non-specified components or elements.

[0119] Reference to any document in this specification does not constitute an admission that it is prior art, validly combinable with other documents or that it forms part of the common general knowledge.

[0120] While the present invention has been explained by the description of certain embodiments, the invention is not restricted to these embodiments. It is possible to modify these embodiments without departing from the spirit or scope of the invention.

Claims

1. A lidding apparatus, comprising: a moveable carriage relative to a stationary packaging inner; a guide engaged with, or integral with, the carriage, wherein the guide is configured to interface between a bottom edge of a lid and an upper edge of the packaging inner during lid installation; and a retainer configured to clamp and/or provide downward force on the lid as the lid is installed over the packaging inner.

2. The lidding apparatus of claim 1 further comprising a conveyor configured to convey a packaging inner.

3. The lidding apparatus of claim 2, wherein the lid passes over the packaging inner and the carriage continues its passage downwards until the retainer is below the packaging inner and/or the conveyor.

4. The lidding apparatus of any one of claims 1 to 3, wherein the carriage is vertically moveable.

5. The lidding apparatus of any one of claims 1 to 4, wherein the guide is a plurality of plates on the sides and/or the corners of the packaging inner.

6. The lidding apparatus of claim 2, wherein the lid is dispensed through a lid chute so that it lands on top of the guide.

7. The lidding apparatus of claim 6, further comprising one or more lid conveyors to dispense one or more lids into the lid chute.

8. The lidding apparatus of claim 7, wherein the conveyor and lid sliding tray are mounted at an angle from 0° to 15° from horizontal, and the lid chute is mounted at an angle from 90 to 105^° from horizontal.

9. The lidding apparatus of claim 8, wherein the lid chute is configured so that as a lid descends the chute the lid substantially slides against a non-feed wall of the chute.

10. The lidding apparatus of claim 9, wherein a plurality of different lids in separate conveyors are dispensed according to the designation of the goods in each packaging inner.

11. The lidding apparatus of claim 1, wherein the guide comprises a plurality of hinged guides.

12. The lidding apparatus of claim 11, wherein the hinged guides are powered.

13. The lidding apparatus of claim 11, wherein the hinged guides are non- powered.

14. The lidding apparatus of claim 11, wherein the guide further comprises a plurality of hinged edge guides and a plurality of hinged corner guides.

15. The lidding apparatus of claim 2, wherein the conveyor comprises gaps through which the carriage can vertically pass.

16. The lidding apparatus of claim 2, wherein the carriage installs the lid onto the packaging inner and passes down through the conveyor, then the box is conveyed outwards, and the carriage passes back up through conveyor to receive a new lid.

17. The lidding apparatus of any one of claims 1 to 16, wherein the packaging inner is fed by gravity along a static roller bed conveyor.

18. The lidding apparatus of any one of claims 1 to 16, wherein the packaging inner is fed by a powered conveyor.

19. The lidding apparatus of any one of claims 1 to 16, comprising a plurality of pneumatic rams to control the movement of the packaging inner, the carriage and/or the retainer.

20. The lidding apparatus of claim 19, wherein a programmable logic controller (PLC) controls the plurality of pneumatic rams based on the outputs of the plurality of sensors.

21. The lidding apparatus of any one of claims 1 to 20, comprising a plurality of sensors are configured to detect location of the packaging inner, the carriage and/or the lid.

22. The lidding apparatus of claim 1, wherein the carriage is counterweighted.