STATION FOR TRAYS FILLED WITH ROD-LIKE ARTICLES, APPARATUS AND METHOD FOR EMPTYING OF FOUR-WALL OR FIVE-WALL TRAY FILLED WITH ROD-LIKE ARTICLES OF THE TOBACCO INDUSTRY

Abstract

 A station (2) for trays filled with rod-like articles (R), in a tobacco industry apparatus provided with a receiving part (2A) to receive filled trays (3, 13); and a storage and conveying unit (2C) containing the filled trays (3, 13), provided with a conveyor (4) to convey the filled trays (3, 13) characterized in that the station (2) is additionally provided with a sensor (30, 31, 32, 33) for measuring weight of filled trays, this sensor (30, 31, 32, 33) for measuring the weight of filled trays is provided in the receiving part (2A), and a controller unit (40) adapted to compare the signal received from the sensor (30, 31, 32, 33) for the measurement of weight of filled trays with reference values for this type of rod-like articles, and adapted to generate an alarm signal if the measured value is outside the reference range. The object of the application is also an apparatus (1) for emptying as well as a method for emptying a four-wall or five-wall tray filled with the rod-like articles (R) of the tobacco industry.

Description

[0001] The object of the invention is a station for trays filled with rod-like articles, an apparatus for emptying and a method of emptying of four-wall and/or five-wall tray filled with rod-like articles of the tobacco industry.

[0002] Tobacco industry's factories manufacture various articles for smoking. Both finished and semi-finished products made at successive production stages may be jointly referred to as rod-like articles which may be transported on conveyors or in trays. Plastic trays which are used for all types of rod-like articles, among others for cigarettes, cigarillos, cigars and filter material rods, are commonly used in the tobacco industry. Plastic trays have the shape of a cuboid without two adjacent walls, i.e. these are trays having four walls. Plastic trays are rigid and are used for temporary storage and conveying of rod-like articles on the premises of tobacco factories. Generally, cardboard trays designed as five-wall trays are commonly used for the transport of filter rods outside the factory premises. Cardboard trays have thinner walls, are less rigid and easily deformable, with one swinging wall. The filling of a five-wall tray takes place after opening of a tray i.e. after swinging the swinging wall. After the filling, the tray must be closed i.e. the swinging wall must be turned to its original position. The same swinging wall is swung in order to empty the tray. For the transport, the filled tray is covered with a lid in order to protect the rods collected inside

[0003] Semi finished products, such as multi-segment filter rods are wrapped with protective material, which may be made of paper or plastic foil. Multi-segment filter rods may contain various types of segments, however, with thick or opaque protective material, it is not possible to differentiate between different rod types. As a result, there is a risk of accidentally introducing rods into the manufacturing machine that are inconsistent with the specification. The risk of mistaking different types of rod-like articles is present even if the trays are appropriately labeled. Such mistakes may lead to production losses as products inconsistent with the specification are to be discarded. A similar problem may also occur for other rod-like articles. Due to different types of materials used to produce the multi-segment rods, some types may be identified by checking their weight. Because it is not practical to weight a single rod, it is possible to take an approximate measure for a full tray with rods. The object of the invention is a machine enabling for the identification of various types of rod-like articles based on measured weight of a tray filled with rod-like articles.

[0004] The apparatus for emptying of five-wall cardboard trays is known from the patent document EP1118543B1. Furthermore, the apparatus for emptying of five-wall cardboard trays is known from the publication WO2015033264A1. Apparatuses for emptying four-wall trays are known from documents GB2043603A, EP1086628B1, US3759408A, EP1656841A1, US3298549. Current state of the art does not recognize known apparatuses adapted to empty four-wall and/or five-wall trays which are also weighing the trays that are delivered for emptying.

[0005] The object of the invention is a station for trays filled with rod-like articles, in a tobacco industry apparatus, provided with a receiving part to receive filled trays, a storage and conveying unit containing the filled trays, and provided with a conveyor to convey the filled trays. Moreover, the station according to the invention is further characterized in that the station is provided with a sensor for measuring weight of the tray, this sensor for tray weight measurement is located in the receiving section, as well as a controller system adapted to compare the signal from the sensor for weight measurement of filled trays with reference values for specific rod-like product types, and which is adapted to generate an alarm signal when the measured value is outside the reference scope.

[0006] The station according to the invention is further characterized in that the sensor for measuring the weight of filled tray is placed between bearing elements of the conveyor.

[0007] The station according to the invention is further characterized in that the sensor for measuring the weight of filled tray is placed outside bearing elements of the conveyor.

[0008] The station according to the invention is further characterized in that working surface of the sensor for measuring weight of filled trays is adapted to be moved above and below a surface of the bearing elements.

[0009] The station according to the invention is further characterized in that the weight measurement sensor for filled trays is provided with rollers adapted for carrying the weight of bottom walls of the trays.

[0010] The station according to the invention is further characterized in that the bearing elements of the conveyor are belt conveyors.

[0011] The station according to the invention is further characterized in that the bearing elements of the conveyor are chains with flat surfaced load bearing links.

[0012] Furthermore, the object of the invention is an apparatus for emptying of a four-wall and/or five-wall tray filled with the rod-like articles of the tobacco industry, whereas the upper wall of the five-wall tray is a swinging wall, provided with a filled tray station, a turning unit for turning the filled tray, a lifting unit for lifting the turning unit, a filled tray emptying station and an empty tray station. The apparatus according to the invention is further characterized in that the station is provided with a sensor for measuring weight of filled tray, furthermore, the apparatus is provided with a controller unit which compares the measured weight of a filled tray with the permissible range for given type of products, whereas the controller unit is adapted to generate an alarm signal when the measured value is outside the reference scope.

[0013] Furthermore, the object of the invention is a method for emptying of a four-wall tray or a five-wall tray filled with rod-like articles of the tobacco industry, whereas the upper wall of the five-wall tray is a swinging wall, in which a filled tray is placed on the filled tray station, the filled tray is conveyed along the filled tray station, the filled tray is gripped by a turning unit, the filled tray is lifted by a lifting unit, the filled tray is turned by the turning unit, the filled tray is placed in a filled tray emptying station, the empty tray is conveyed to an empty tray station, the empty tray is collected from the empty tray station. The method applied in the invention is further characterized in that after placing the filled tray on the filled tray station, a measurement of weight is carried out for the tray filled with rod-like articles, and subsequently if the measured weight of the tray filled with rod-like articles is outside a permissible range for given type of product, an alarm signal is generated.

[0014] The apparatus according to the invention enables checkup of each tray introduced for emptying and elimination of trays containing wrong product from manufacturing, moreover, it enables to recognize trays which are underfilled or otherwise not properly filled. The control unit may also recognize incidents in which the tray is damaged and therefore lighter, for example due to a broken off fragment of the bottom or side, which may affect correct gripping of the tray. For this reason, the apparatus according to the invention enables to eliminate the risk of feeding a damaged tray, which would cause a blockage in the apparatus and stoppage of the production line.

[0015] The object of the invention was shown in detail in a preferred embodiment in a drawing in which:

Fig. 1

shows a filled four-wall tray (of the second type) in a perspective view, the front side of the tray being visible;

Fig. 2

shows a filled five-wall tray (of the first type) in a perspective view, the front side of the tray being visible;

Fig. 2a

shows a filled five-wall tray (of the first type) in a configuration of the second type in a perspective view, the back side of the tray being visible;

Fig. 2b

shows a filled five-wall tray (of the first type) in a configuration of the second type in a perspective view, the front side of the tray being visible;

Fig. 3

shows an apparatus for emptying of trays for rod-like articles in a side view;

Fig. 4

shows a filled tray station in an upper view;

Fig. 5

shows a filled tray station in configuration with the sensor for measuring the weight of filled tray which contains the rolling elements in an upper view;

Fig. 6

shows a filled tray station in a side view, all trays being situated on a bearing element of the conveyor;

Fig. 7

shows a filled tray station in a side view, the first tray being situated on a bearing element of the conveyor and the other trays being lifted;

[0016] In this description, the invention will be described with reference to a four-wall tray 3 shown in a simplified way in Fig. 1 and to a five-wall tray 13 shown in Fig. 2. Both trays 3, 13 were shown as filled in upright position, i.e. in such position in which the filled trays 3, 13 are placed on the filled tray station 2 of an apparatus 1 for emptying filled tray shown in Fig. 3. The filled space of the trays 3, 13 shown in Figs. 1 and 2 was marked by hatching, with only several example rod like articles R lying on the bottom of the trays 3, 13. In such upright position, the filled trays 3, 13 are placed by the operator onto the filled tray station 2, whereas the operator holds the tray by the sidewalls with the inside of the tray being directed towards him. Such expressions as upper, bottom, lateral, front and back will refer to the position of trays 3, 13 shown in Figs. 1 and 2, with the front side, left lateral side and upper side of each of the trays 3, 13 being visible therein. The four-wall tray 3 has a bottom wall 3B on which its stands, a back wall 3A and two lateral walls, a left lateral wall 3L and a right lateral wall 3R, whereas the designation of the sides refers to the position in which the tray 3 can be seen by the operator putting a filled tray onto the filled tray station, with the open front side 3G of the trays 3 being directed towards him. The filling and the emptying of the tray 3 takes place through the open side 3T. The four-wall trays may be made of plastic or other suitable material ensuring an adequate rigidity and are usually designed for multiple uses.

[0017] The five-wall tray 13 has a bottom wall 13B on which it stands, a back wall 13A and two lateral walls, a left lateral wall 13L and a right lateral wall 13R. The five-wall tray 13 has a hinged upper wall 13T' which is designated as swinging relative to the back wall 13A of the tray 13 with which it is connected along the edge 13E. The upper wall 13T' has two swinging flaps, a left swinging flap 13FL and a right swinging flap 13FR, which are inserted for the time of transport into the slots in the corresponding lateral walls 13L and 13R. After putting the filled five-wall tray 13 onto the filled tray station 2, the operator lifts the upper wall 13T' so that the swinging flaps 13FL and 13FR pull out of the walls 13L and 13R and loosely hang down on the side outside the lateral walls 13L and 13R. Figs. 2a and 2b show the five-wall tray 13 at a later stage of the emptying cycle of the five-wall tray 13. The upper wall 13T' is swung so as to enable to empty the five-wall tray 13 through the upper open side 13T of the five-wall tray. The filling of the five-wall tray 13 also takes place through the upper side 13T. Similar to the four-wall tray 3, the operator puts the five-wall tray 13 onto the filled tray station while holding the five-wall tray 13 with the open side 13G directed towards him. Five-wall trays 13 may be made of cardboard or other cheap material, are usually less rigid than the four-wall trays and are most often designed for a single use.

[0018] The tray 3, 13 emptying apparatus 1 described below, being a tray unloader, is adapted to empty both four-wall trays 3 and five-wall trays 13. For the sake of simplicity, the units belonging to the tray emptying apparatus 1 according to the invention were shown in Fig. 3 in simplified terms without the drive mechanisms; the outer contour of the body of the apparatus 1 was shown with a dashed line. The tray emptying apparatus 1 is provided with a filled tray station 2 onto which the filled four-wall trays 3 or five-wall trays 13 are placed by the operator for unloading. From the filled tray station 2 the filled trays 3, 13 are fed one filled first tray 3', 13' at a time to the lifting unit 6, whereas a plurality of filled trays 3, 13 is collected on the filled tray station 2. The lifting unit 6 for raising filled trays 3, 13 is provided with a multi-part support 7A, 7B, 7C and 7D as shown on Fig. 4, whereas this support may be inclined towards the front of the front part 1A of tray emptying apparatus 1. The lifting of the tray 3, 13 by the lifting unit 6 may be accomplished by means of any linear movement mechanism with electric or pneumatic drive. The lifting unit 6 lifts the filled tray 3, 13 to a height at which the turning unit 10 shown in Fig. 4 may grip the filled tray 3, 13. The turning unit 10 is adapted to turn the filled tray 3, 13 before unloading it at the filled tray emptying station 23. The turning unit 10 is attached to a rotating shaft 12 with the axis of rotation 12A on a slide 11A of the lifting unit 11. The turning unit 10 and the lifting unit 11 constitute a handling unit 19. During the tray 3, 13 emptying cycle, the tray 3, 13 is lifted, turned and moved away from the axis of rotation 12A. The tray emptying apparatus 1 is provided with a filled tray emptying station 23 (Fig. 3) in the front part 1A of the apparatus 1 underneath which is situated a discharging conveyor 24 receiving the rod like articles R unloaded from the trays 3, 13. In the back part 1B of the tray emptying apparatus 1, an empty tray station 25 is situated. The tray emptying apparatus 1 was described in detail in the patent application P.417941 belonging to the applicant. The tray emptying apparatus 1 is provided with a controller unit 40 shown in Fig. 3 connected with individual units of the apparatus 1.

[0019] The filled tray station 2 is provided with a receiving part 2A, on which trays 3, 13 are placed by the operator, and delivering unit 2B, from which trays 3, 13 are taken away by any type of collecting unit. In the presented example realization of the apparatus, the collecting unit constitutes the lifting unit 6 of tray emptying apparatus 1, however, any type of tray conveyor can be utilized as a receiving unit. Between the receiving part 2A and the delivering unit 2B, there is a storage and conveying unit 2C. The storage and conveying unit 2C is provided with conveyor 4 which possesses two bearing elements 4D (Fig. 4), being for example, belts or flat surfaced load bearing links. Trays 3, 13 may be transported using any flat surfaced load bearing elements. Conveyor is adapted to transport trays 3, 13 in such a manner, that the trays rest on one another, or are conveyed one at a time. Moreover, the storage and conveying unit 2C is provided with a tray separation mechanism 4A, in the embodiment, first tray 3', 13' is separated from trays collected on conveyor 4. The 4A tray separation mechanism is provided with lifting bars 51 attached by means of joints 51A, 51 B on levers 52, 53, which are pivotally attached to joints 52A and 53A (Fig. 6). The swinging motion of lever 53, and resulting up-down motion of bars 51, is mechanically coupled with the motion of swinging limiter 4B installed on axis 54, whereas the coupling may be achieved by means of four-bar linkage 55 or another mechanism. Fig. 6 shows an arrangement in which all trays 3, 13 gathered on conveyor 4 are halted by the limiter 4B, whereas the bearing elements 4D may be actuated and stopped. Fig. 7 shows a situation in which the first tray 3', 13' is moved towards the 2B delivering unit, whereas all other trays 3, 13 are lifted, so that their bottom sides 3B, 13B are not in contact with bearing elements 4D.The lifting of trays 3, 13 via bars 51 may be achieved by servomotor 49. Bars 51 may also be located outside belts 4D. Trays 3, 13 may be lifted by plate type components placed between bearing elements 4D as well as outside the bearing elements 4D.

[0020] The feeding of first filled tray 3', 13' out of all filled trays 3, 13 in station 2 is carried out after lifting all the filled trays 3, 13 from conveyor 4, with exception of the first tray 3', 13', which is transported on the bearing elements 4D of conveyor 4 to the 2B delivering unit. After moving the first filled tray 3', 13' to the delivering unit 2B, bars 51 are lowered, and trays 3,13 that were lifted earlier are placed on bearing elements 4D, at the same time, the limiter 4B is being raised. The filled tray station 2 may be provided with lateral guides 4C placed on the two sides of trays 3, 13 transported along the filled tray station 2. Lateral guides 4C are positioned convergently in the feeding direction, i.e. from the rear part constituting the receiving part 2A, towards front part 2B constituting the delivering unit, whereas the convergence of lateral guides 4C may be adjusted depending on the type of tray 3, 13, for example on the rigidity of the tray. The filled tray station 2 may be provided with an adjustable limiter 5, the limiter 5 is adjustable to ensure that a filled tray 3', 13' can be stopped in a location where it is possible to easily collect it or lift by the lifting unit 6. Fig. 4 and 5 shows a multi-part support consisting of items 7A, 7B, 7C and 7D being part of the lifting unit 6, which carries out the upwards and downwards motion along guide 8.

[0021] Fig. 4 shows an example implementation of sensor 30 for measuring the weight of a filled tray in the receiving part 2A of filled tray station 2. Sensor 30 for measuring the weight of a filled tray is located between the bearing elements 4D. The shown tray 3 is in position as if it would be placed by an operator on station 2 for filled trays. Sensor 30 for measuring weight of a filled tray may be installed in stationary variant, in which the bottom side 3B, 13B of tray 3, 13 slides over it. Sensor 30 for measuring weight of a filled tray may be installed in mobile variant, in which the working surface 35 slides over the load bearing surface of bearing elements 4D, whereas after making the weight measurement the working surface 35 is lowered and raised once again if the presence of the subsequently fed tray is detected by sensor 37. Any type of drive component, for example servomotor 38, can be used to raise sensor 30 for measuring weight of a filled tray. The weight measurement of a filled tray can be carried out in two points by two sensors 31 and 32 for measuring weight of a filled tray. Fig. 5 shows an embodiment of sensor 33 for measuring weight of a filled tray, which consists of rolling components, for example rollers 34, on which the filled tray 3, 13 will be placed (the illustration does not show the bearing alignment of rollers 34). Sensor 33 for measuring the weight of filled tray containing rollers 34 may also be located so that the filled tray 3 is placed on bearing elements 4D and exerts pressure on rollers 34 while moving, enabling to measure the weight of the tray. Sensor 30, 31, 32, 33 for measuring the weight of filled tray and sensor 37 to detect tray presence is connected to the control system 40, signaling the measurement taken and established value.

[0022] Filled tray 3 is placed by the operator in the rear part of filled tray station 2, which at the same time acts as the receiving part 2A of the filled tray station 2. Sensor 30, 31, 32, 33 measures the weight of filled trays 3, 13, and subsequently generates a signal confirming the measurement and transfers the result of the measurement to the controller unit 40. The controller unit 40 stores reference limit weight values for properly filled trays 3, 13, i.e., when the tray is filled with proper articles for ongoing production. The limit values must permit for proper weight tolerance for single articles depending on the used process technology as well as the amount of rod-like articles R gathered in the tray 3, 13, additionally it is required to allow in the tolerance for the weight of the tray 3, 13 itself, as well as all the carried rod-like articles R. If proper weight for filled tray 3, 13 is read for a given specification of fed rod-like articles R, the controller unit 40 registers the measured weight and may signal correct weight for the fed 3, 13 tray. If the measured weight of the filled tray 3, 13 is outside the reference range, the control unit 40 identifies that a problem has occurred and generates an alarm signal. The operator is informed that the fed tray 3, 13 does not have proper weight i.e. the actual weight is outside the reference range. Alternatively, the control unit 40 may lock filled tray station 2 or switch off apparatus 1. The operator must remove the tray, confirm that the wrong 3, 13 tray is removed and restart the filled tray station 2. Exceeding the maximum permissible weight of tray 3, 13 may indicate that the fed tray contains rod-like articles R which are inconsistent with the required specification, or that the tray is filled over the allowable limit for rod-like articles R. Measuring the actual weight of tray 3, 13 that is lower than the allowable weight for trays 3, 13 may indicate that the filed tray 3, 13 contains rod-like articles R which are inconsistent with the required specification, or that the tray 3, 13 is damaged. The cause for too low weight of filled tray 3, 13 may also be not enough amount of rod-like articles R present on the tray 3, 13.

Claims

1. A station (2) for trays filled with rod-like articles (R), in a tobacco industry apparatus, provided with

a receiving part (2A) to feed filled trays (3, 13); and

a storage and conveying unit (2C) containing the filled trays (3, 13) and provided with a conveyor (4) to convey the filled trays (3, 13)

characterized in that the station (2) is further provided

with a sensor (30, 31, 32, 33) for measuring weight of the tray, this sensor (30, 31, 32, 33) for measuring the weight of the filled tray is provided in the receiving part (2A), of the apparatus and

a controller unit (40) adapted to compare a signal from the sensor (30, 31, 32, 33) for measuring weight of a filled tray with the reference values for the particular type of rod-like articles, and is furthermore adapted to generate an alarm signal when the measured value is outside the reference value range.

2. The station (2) as in claim 1 characterized in that the sensor (30, 33) for measuring the weight of filled tray is placed between bearing elements (4D) of the conveyor (4).

3. The station (2) as in claim 1 characterized in that the sensor (31, 32) for measuring the weight of filled tray is placed outside bearing elements (4D) of the conveyor (4).

4. The station (2) as in claim 1 characterized in that an operating surface (35) of the sensor (30) for measuring the weight of filled tray is adapted to be moved above and below a surface of bearing elements (4D).

5. The station (2) as in claim 1 characterized in that the sensor (33) for measuring the weight of the filled tray is provided with rollers (34) adapted to bear the weight of bottom walls (3B, 13B) of trays (3, 13).

6. The station (2) as in any of the previous claims from 1 to 5 characterized in that the load bearing elements (4D) of the conveyor (4) are belt conveyors.

7. The station (2) as in any of the previous claims from 1 to 5 characterized in that the load bearing elements (4D) of the conveyor (4) are chains with flat surfaced bearing links.

8. An apparatus (1) for emptying of a four-wall (3) and/or five-wall (13) tray filled with rod-like articles (R) for the tobacco industry, whereas the upper wall (13T') of the five-wall tray (13) is a swinging wall, provided with

a filled tray station (2),

a turning unit (10) for turning filled trays (3, 13),

a lifting unit (11) for lifting the turning unit (10),

a filled tray (3, 13) emptying station (23), and

an empty tray station (25),

characterized in that
the filled tray station (2) is provided with a sensor (30, 31, 32, 33) for measuring weight of filled tray (3, 13), and furthermore the apparatus (1) is provided with a controller unit (40) which compares the measured weight of a filled tray (3, 13) with permissible weight range for given type of products, whereas the controller unit (40) is adapted to generate an alarm signal if the measured weight of tray (3, 13) filled with rod-like articles (R) is outside the permissible range for given type of product.

9. A method for emptying of a four-wall tray (3) and/or five-wall tray (13) filled with rod-like articles (R) for the tobacco industry, whereas the upper wall (13T') of the five-wall tray (13) is a swinging wall, in which

the filled tray (3, 13) is placed on a filled tray station (2),

the filled tray is conveyed (3, 13) along the filled tray station (2),

the filled tray (3, 13) is gripped by a turning unit (10),

the filled tray (3,13) is lifted by a lifting unit (11),

the filled tray (3,13) is turned by the turning unit (10),

the filled tray (3, 13) is placed in a filled tray emptying station (23),

the empty tray (3, 13) is conveyed to an empty tray station (25),

the empty tray (3, 13) is collected from the empty tray station (25)

characterized in that

after placing the filled tray (3,13) on the filled tray station (2), a measurement of weight is carried out for the tray (3, 13) filled with rod-like articles (R) and subsequently if the measured weight of the tray (3, 13) filled with rod-like articles (R) is outside a permissible range for given type of product, an alarm signal is generated.

Drawing