This invention relates to a packaging machine, which is especially suitable for processing beverage multipacks from blank to completed filled cartons. The machine is readily adjustable to accommodate various carton types, for example, wraparound type cartons and basket style carriers without undue time being taken to adapt the machine from running one type of carton to running a different type of carton.
The majority of known packaging machines are dedicated machines, which construct only one size of one type of carton. Therefore, modern bottling plants are required to use a plurality of packaging machines to package different carton types, each machine taking up considerable floor space and being expensive to both purchase and operate.
A limited number of packaging machines are capable of packaging different sizes of cartons for example, six, eight or twelve packs of a wrap around carton. All such machines require adjustment when switching from one size of carton to another. This adjustment includes the manual removal of all of the cartons within the packaging machine and possibly the mechanical adjustment of components in the machine. During this change over period, which can be thirty minutes or more, a machine cannot be used (known as "down time"), which is an expensive delay in a bottling plant. Such a delay may even result in down time for the entire bottling line, not just the packaging machine, if problems arise during the change over procedure.
In US 5,507,128 there is shown the use of two magazines for two different types of blanks, which are selectively withdrawn by a lug and conveyor assembly.
It is an object of the present invention to provide a packaging machine which overcomes the technical and commercial disadvantages of known packaging machines.
It is a further object of the present invention to provide a packaging machine which is capable of switching from one carton type or size to another with a minimal down time. The present invention seeks to overcome these commercial disadvantages by providing one machine which is able to set up and load more than one type of carton.
Further. the processing time of loading a wraparound carton is different than that of loading of basket type carrier. In order to maximise the efficiency of such a machine, it is necessary to decrease the set up time of a basket type carrier. The present invention seeks to overcome or at least mitigate these problems.
One aspect of the invention provides a method of switching a packaging machine from supplying and loading a first carton type with articles to supplying and loading a second carton type with articles comprising the steps of: placing a first feeder means and carton set up means for feeding and setting up one type of carton in an inoperative position, adjusting means for conveying the cartons downstream to feed the second type of carton, moving a second feeder means for feeding the second carton type into an operative position and commencing the feeding of the second type cartons.
A second aspect of the invention provides a packaging machine switchable between the supply and loading of cartons of the first and second types , comprising means for conveying articles through the machine, first feeder means sequentially to deliver successive cartons of the first type in a flat collapsed condition to a setting up station to separate side walls of the flat collapsed cartons. The setting up station delivers the cartons to a carton conveying means, the carton conveying means comprising support means adapted to be brought into contact with base panels of the carton during movement downstream such that the carton is held in the position required to be loaded by lowering said carton onto at least one article. In order to switch to the supply and loading of cartons of the second type, the first feeder means and setting up station become inoperative, and second feeder means is brought into an operative position to feed cartons of the second carton type, the support means being adjustable to engage the base panels of the second carton type.
According to an optional feature of the second aspect of the invention the carton conveying means may comprise a pair of chainsets.
According to another optional feature of the second aspect of the invention the support means may comprise a pair of oppositely disposed guide pins projecting from respective ones of the chainsets.
The chainsets may be moved apart to adjust to the second carton type.
A belt may be located so as to apply downward pressure onto successive cartons as the cartons are lowered onto the articles. Preferably, the belt may be adjustable vertically in its lowered position to engage and apply pressure to different carton types.
According to a further optional feature of the second aspect of the invention the successive cartons and articles may progress downstream to a panel locking station, a second vertically adjustable belt preventing unwanted vertical movement of the carton as the base panels are folded around to the underside of the carton and interconnected.
According to a still further optional feature of the second aspect of the invention the first and second feeder means may comprise rotary vacuum feeders supplying cartons from respective hoppers.
According to yet another optional feature of the second aspect of the invention a controller may control the switchover. Preferably, the controller may comprise a processor with a manual input.
According to yet another optional feature of the second aspect of the invention the first and second feeder means to provide carton blanks may further comprise a hopper to store blanks and a rotary feeder to transfer a blank from the hopper to the set up station. Preferably, regulating means may be provided to control the flow of articles on the article conveying means, the regulating means further comprising means to control the pressure of the articles into the machine and means to determine the correct number of articles for each carton.
Optionally, the regulating means to control the pressure of the articles may comprise an infeed star wheel.
A third aspect of the invention provides a control system for a packaging machine switchable between the supply of first and second type cartons, and the loading thereof with articles, the control system controlling the changeover from one carton type to the other according to the following steps: stopping a first feeder means feeding a first carton type and a set-up station for setting up the cartons, adjusting means for conveying the cartons downstream so as to feed the second carton type, moving a second feeder means for feeding cartons of the second type into an operative position and commencing the feeding of the cartons of the second type. Preferably, the control means may calculate the necessary adjustments required at changeover from carton parameter, data supplied via manual input means of the control means.
Embodiments of the invention will now be described by way of example, with reference to accompanying drawings in which:
The machine according to the present invention is capable of loading both wraparound and basket type cartons.
Referring to the drawings, and in particular Figures 1a and 1b thereof, carton 10 is a basket type carrier, shown in Figure 1b, in a set up condition ready for lowering onto articles. The carton 10 includes opposed side wall panels 12, 14 and opposed end wall panels 16, 18 hingably connected one to the next. The carton 10 further includes a handle structure 20 which interconnects end wall panels 16. 18 and comprises transverse partition panels 22 interconnecting each side wall panel 12, 14. Base panels 24, 26 are hingably connected to each side wall panel 12, 14 respectively.
As illustrated in Figures 2a and 2b, carton 30 is a wraparound type carton, shown in Figure 2a in its blank form. The carton blank 30 includes first base panel 32, side wall 34, top panel 36, second side panel 38 and base panel 40 hingably connected one to next. Top panel 36 comprises three pairs of apertures 42, 44 spaced between the side edges of top panel 36 and adapted to receive an upper portion of articles A, illustrated in Figure 2b.
It is envisaged that the cartons can vary depending upon the shape and/or quantity of articles to be packaged and accordingly, a machine in accordance with the present invention is adjustable in numerous respects so that it can process a wide variety of such cartons. The principal arrangements which are likely to be varied are shown in Figure 1a and 2b in which "H" is the overall height of the set up carton equivalent to the distance between the upper edge of the side wall and base panel, "L" is the overall length of the carton when the base panels are closed.
Referring now to Figure 3 of the drawings, there is shown a machine 50 for processing cartons 52 of the basket type outlined above. There is shown a packaging machine for continuously setting up and loading basket type cartons comprising opposed side 12, 14 and end walls 16, 18 which machine comprises article conveying means 46 for conveying articles through the machine, feed means 47 sequentially to deliver successive cartons from a supply in fiat collapsed condition to
a setting up station of the machine, means 48 to restrain a side wall of the carton relative to its opposed side wall thereof as it is moved downstream so as to separate the side and end walls to bring the carton into a set up condition, support means 49 adapted to be brought into contact with base panels of the carton during movement downstream so that the carton is maintained in a set up condition and is loaded by lowering said carton onto at least one article.
The upstream end of the machine includes a hopper 54 in which a multiplicity of cartons 52 in flat collapsed condition are held ready for processing. As shown in Figures 4 and 5, the cartons are removed from the hopper 54 sequentially by feed means 47 which in this embodiment is a rotary vacuum feeder 56. The vacuum feeder 56 comprises carton pick up means comprising four pairs of suction cups (not shown) each being interconnected to a drive shaft 58 by an elongated support rod 60. In one class of embodiments, the rods 60 are slidably mounted respectively on a collar structure 63 which collar structure is rigidly secured to main rotatable shaft 65. The drive shafts 58 are preferably connected to a cam track by a cam follower housed in a housing 62 which provide a uniform path for the suction cups when the drive shaft 58 is rotated.
The main drive shaft 65 is rotatable about a fixed axis X-X. The shaft 65 is generally supported at its end by a suitable bearing structure which is conventional and which is mounted to a side frame. Suitable driving mechanism, for example a servo motor 57, is provided to rotate the shaft 58.
In the present embodiment, it is envisaged that a vacuum break is provided in the feeder mechanism 56 which is used in conjunction with a vacuum supply to set the vacuum connection and cut off points thereby determining when the carton is held by the feeder mechanism 56.
Whilst the use of a rotary vacuum feeder to supply cartons to the conveyor is preferred, it is envisaged that the present invention can be used with other types of feeder mechanisms without departing from the scope of the invention.
The hopper 54 is a "gravity feed" type whereby the carton blanks 52 are held in the hopper at an incline to provide a positive feed. In order for the blank to be transferred from this inclined position to a vertical plane, it is necessary to off-set the axis of rotation X-X of the rotary feeder from the vertical plane, as illustrated in Figure 4. The feed system is described in greater detail in parent application GB 9710639.7 and various other patent applications which depend therefrom for a priority date.
In use, the feeder mechanism 56 continuously and sequentially feeds cartons from the hopper to the infeed by the main shaft 65 rotating the pick up means in the direction indicated by the arrow "A", shown in Figure 4. As the pick up means rotates, the suction cups are moved in contact with side wall of carton 10. A vacuum is then applied to the set of suction cups by the vacuum supply. Thus, the carton 10 is withdrawn and then transferred to a belt 64. The vacuum is then maintained during this transfer stage so that the suction cups hold the side wall of the carton 10. When the carton is deposited at the belt 64, the vacuum break disconnects the vacuum supply from the suction cups to release the carton.
The blank is then placed between the nip end 66 of an infeed belt set shown generally at 64. The infeed belt set includes pairs of upper and lower receiving belts 70, 72 spaced apart so as to receive the handle portion 20 and base panels 24, 26 of a flat carton delivered by the rotary feeder 56. The belt sets 70, 72 maintain the position of the carton and move the carton downstream to a set up station shown generally at 74. It will be seen from Figures 4, 5 and 6 that as the rotary vacuum feeder rotates the cartons, they also undergo a translation about the path of the rotary movement from an inclined angle to a vertical plane.
The set up station 74 includes a pair of opening wheel units (or panel separating means) 76, 78 which are used to separate opposing panels and to assist in partly erecting the carton. The units 76, 78 are positioned either side of the carton of which the nearside unit 76 is adjustable relative to the far side unit 78 transversely to the machine to reflect the adjustments made to the type of carton. The wheel units are similar and hence only unit 76 is described in detail with reference to Figures 4, 6, 7. The apparatus used to separate opposing panels is described in more detail in parent application GB9710639.7 and various other applications which depend therefrom for a priority date.
As shown in Figure 7, the nearside unit 76 comprises a vacuum suction cup 79 connected via a drive rod 81 to the opening wheel 80. The opening wheel 80 is mounted onto a drive shaft 82 which is powered by a servo motor 84. The servo motor 84 is controlled by suitable control means, which can cause the rotational velocity of the opening wheel 80 to be varied and therefore, the suction cup 79.
The drive rod 81 is preferably connected to a cam track by a cam follower (not shown) contained in a housing 83 or to other suitable means to provide a uniform path for the suction cups when the drive shaft 82 is rotated. Thus, the suction cups and drive rod are moved under a guided linear motion "M" towards and away from the carton during one complete rotation "R" of the drive shaft.
In the present embodiment, it is envisaged that a vacuum break is provided in the housing 83 which is used in conjunction with a vacuum supply to set the vacuum connection and cut off points thereby determining when the carton is held by the panel separating means 76.
Likewise, the far side unit 78 shown in Figure 6 corresponds to the near side unit 76 and comprises a vacuum suction cup 79 connected via a drive rod 81 to the opening wheel 86. The opening wheel 86 is mounted onto a drive shaft 88 powered by a servo motor 90. The servo motor 90 is adapted to vary the rotational velocity of the opening wheel 86 and therefore, the suction cup.
In order to bring the carton 52 into a set up condition the lower belt set terminates short of opening units 76, 78 and the carton is moved downstream by the upper belt unit only as shown in figures 4 and 5. The suction cup 79 of the far side opening wheel 86 is rotated and caused to engage the corresponding side panel 14 of the carton. The far side opening wheel 86 is accelerated by the control means relative to the moving blank so that the suction cup 79 is accelerated relative to the moving blank. The suction cup is also caused to move away from the carton by the cam effect of the opening wheel 86 so that side panel 14 and leading end panel 18 are separated and moved apart from the handle structure 20.
Likewise, the suction cup of the nearside opening wheel 80 is rotated and caused to engage the opposing side panel 12 of the carton blank. Vacuum is applied to the suction cup 79 mounted on the nearside opening wheel 80 and the electronic cam effect causes the suction cup to move away from the handle structure 20 thereby separating leading side panel 12 and trailing end panel 16 from the handle structure 20. Thus, the side panels 12, 14 are moved apart so that carton 52 is progressively brought into a set up condition (shown in Figure 1b). Preferably, the nearside opening wheel 80 is caused to decelerate so that the suction cup slows relative to the velocity of the carton as it moves through the set up station.
The preferred point of contact between the panel separating means 76. 78 and respective panels 12, 14 is in a central portion of the wall being separated. However, the position will vary according to the type of carton and in particular the dimensional variations of the side and end walls for each carton type and for different carton sizes. It is envisaged that the acceleration and/or deceleration can be altered according to the type of carton being processed through the machine and throughput times required by including manual input capability in the control means. Of course, the control means may be a dedicated processor or may be a control means for a packaging machine with which the apparatus of the invention is used. Alternatively, the control means may preferably be a known programmable servo control system.
Turning again to Figure 4, the end panels 16, 18 are maintained in a perpendicular relationship to the side panels 12, 14 by blocking lugs 92 mounted on a pair of side lug chain sets 94, 96. The base panels 24, 26 are then outwardly folded into a substantially perpendicular relationship with their respective side panels 12, 14 by guides 98 positioned either side of the carton 52.
After the cartons have been set up, they are transferred to the loading station 100 shown in Figure 3. Thus, the cartons leave engagement with the upper belt set and blocking lugs 92 and engagement is gradually transferred as the cartons move downstream to a pair of side lug chain sets 102, 104 shown in Figure 8. Each side lug chain 102, 104 set is of similar construction and includes endless chains 106 having a plurality of guide pin sets 108 which engage the opposed base panels 24, 26 of the carton in order to continue the downstream movement of the carton and to retain the base panels 24, 26, side panels 12, 14 and end panels 16, 18 in the set up condition illustrated in Figure 1b.
As illustrated in Figure 8, the set of three guide pins 110 are inserted into respective ones of apertures formed from each base panel 24, 26.
The endless chain sets 102, 104 are mounted on tables 112, 114 to provide additional support to the base panels 24, 26 and are downwardly inclined towards the loading station 100.
Articles such as bottles are fed into the machine by an infeed conveyor (not shown) and the line pressure of the bottles is controlled by an infeed star wheel (not shown), as is well known. The articles are separated into groups of the correct number per blank by means of a series of spaced metering bars (not shown) which also control the flow of the articles so that they can be introduced to the carton at the same rate as the carton blank flow.
At loading station 100 illustrated in Figure 9, the cartons are introduced to the group of articles from above as the carton and article group are moved forward in unison. The carton is lowered onto the articles due to the downward incline of the endless chains sets 102, 104. As illustrated in Figure 8, lateral movement of the carton 52 in the loading station 100 is controlled by a pair of guides 116, 118 positioned above each chain set 102, 104 and adapted to receive the free edges of each base panel 24, 26. Vertical movement of the carton is minimised by a pressure belt 119 shown in Figure 9 positioned above the endless chain sets 102, 104 and adapted to apply downward pressure to the handle structure. It is envisaged that in some embodiments, the pressure belt could be replaced by fixed guides or, where appropriate, vertically mounted endless chain and lug sets.
Once the cartons have been loaded with articles, they are transferred by means of the article conveyor and/or pressure belt 119 to a further set of endless chains with side lugs 120, 122 which are used to transfer the carton to the outfeed end of the machine shown in Figure 10.
During this stage, the base panels 24, 26 are folded around to the underside of the carton and are interconnected by a locking mechanism 124 known in the art. Optionally, where the basket carrier is provided with apertures to receive and retain the articles, folding mechanism 126 is provided prior to constructing the base, as is known in the art. A second pressure belt 128 is provided above the handle structure to prevent unwanted upward movement of the carrier. The completed carton is transferred to the outfeed end of the machine.
Turning to the construction of wraparound type cartons, as illustrated in Figures 2a and 2b, the machine 10 must first be adjusted to receive cartons of this type. Thus, the pair of downwardly inclined chain sets 102, 104 and tables 112, 114 are mounted on platforms which can be adjusted in both vertical and horizontal planes by computer controlled servo motors 130. Likewise, the first and second pressure belts 119, 128 are also mounted on units 132, 134 which are adjustable in a vertical plane by computer controlled servo motors 136, 138.
In order to modify the machine to receive wraparound cartons shown in Figures 11 and 12, the downwardly inclined chain sets are moved apart to increase the width between the chain sets 102, 104 and a second hopper 140 and rotary vacuum feeder 142 brought into position of use. The hopper 140 holds a multiplicity of carton blanks 30 illustrated in Figure 2 which are held ready for processing. The blanks 30 are then removed sequentially by the rotary vacuum feeder 142. The vacuum feeder 142 is mounted horizontally and is similar in construction to the feeder 56 outlined above. A blank is removed from the hopper 140 and is fed one at a time to the paper feed chain sets 102, 104 so that the base panels 32 and 40 and side panels 34, 38 are supported. The carton is transferred to the set up station by the endless chains 102, 104 and guide pins 110. The chain is downwardly inclined so that the carton can be introduced to a group of articles from above during forward movement as illustrated in Figure 11. It is often the case that the angle of incline will differ for different carton types and therefore the chain sets 102, 104 and tables 112, 114 can be adjusted vertically to alter the angle of incline by suitable control means.
The articles are introduced to the loading station 100 by the article conveyor in the same way as described above.
At the loading station 100, upper portions of the articles are inserted through apertures 42, 44 by lowering the cartons. This is achieved by the first pressure belt 119 which is positioned in a central region to lower the top panel and enable the neck portions of the articles to pass through the apertures.
As illustrated in Figure 11, the side panels are folded into a perpendicular relationship with top panel by fixed guides (not shown) and the partly erected carton is transferred to the second set of endless chains 120, 122 which transfer the carton to the outfeed end of the machine. In this embodiment, the second pressure belt 128 is raised to a position of non-use and where appropriate, the second set of endless chains are moved apart or brought closer together by means of horizontal adjustment which are controlled and powered by servo motors (not shown). The bottom is constructed and, where appropriate, article retaining means is formed by the same method as described above. Thus, the carton is secured to complete the packaging operation.
By pre-programming the control system, the adjustments to the machine required to change from packaging one carton type to another carton type can be preset, thus reducing the amount of down time when interchanging carton types or styles. According to this invention, the speed of operation of the apparatus is improved as well as its efficiency and durability. An advantage of the present invention is the flexibility offered by the system.
While the preferred embodiment described herein is for loading bottles into cartons, it will be recognised that the invention is not limited to cartons for bottles. The invention may be used with machines for packaging cans, paperboard "bricks" and other containers into cartons.
Moreover, while the preferred embodiment described herein is shown as part of a machine for loading containers into basket type cartons, the invention is not limited to cartons of this type. As will be recognised by those skilled in the art, the invention may be used with wrap-around or end-loaded cartons.
It will be understood that the carton erecting mechanism of the invention has been illustrated with reference to a specific embodiment and that numerous modifications are possible within the scope of the invention. The carton erecting mechanism is able to process cartons comprising numerous configurations of groups of articles covering a range of carton size and shape, for example, four, six, eight and twelve bottles without undue time being spent in adjusting the mechanism.