The present invention relates to an improved pour spout fitment orientation device and method for using the same. In a known type of packaging machine, typically used in a dairy, particularly juice and other consumer fluid product form-fill-seal packaging machines, seals or pour spout fitments are applied to a product container at a high rate of speed. In typical packaging machines, caps (which means pour spout fitments comprising pour spouts and screw caps closing the spouts) are arranged in single file and various devices are employed to arrange the caps such that the top surfaces of the successive caps face in the same direction. These pre-arranged caps are then fed to a cap affixing system which applies each cap to a container. Pre-arranging the caps allows for a high throughput of containers and increases cycle time efficiency. A common problem with known capping machines is that caps having labels or embossments with logos, words, designs or the like on the top surface of the cap are not co-ordinated to a common orientation when the caps are fed to a cap affixing system. Therefore, when the caps are affixed to the containers by the capping mechanism, the orientation of the labels , or embossments are random. This condition is aesthetically displeasing since not only can the logo or the like on the top surface of the cap be positioned in an undesirable orientation, e.g., upside down with respect to the container, but also the cap orientation on the containers can vary from one container to the next. Accordingly, there exists a need for an improved apparatus to determine the cap orientation and rotate the cap when necessary such that labels, embossments, or the like on the top surfaces of the caps are uniformly positioned at a predetermined orientation when affixed to the containers. WO2008/139185A1 owned by the present Applicant discloses an orientating apparatus for a cap of which the pour spout has an annular flange.

The apparatus comprises a mounting device for supporting the cap, a follower, a drive arrangement arranged to produce relative rotary motion, about an axis, between the mounting device and the follower, a biassing device arranged to urge the follower towards the mounting device, and a detection device arranged to detect relative movement between the mounting device and the follower under the action of the biassing device and allowed by a notch in the flange and thereby to cause the drive arrangement to stop the relative rotary motion and to orientate the cap. The present invention is directed to an alternative to that apparatus and is applicable irrespective of whether a flange is notched.

According to one aspect of the present invention, there is provided apparatus for orientating a pour spout fitment, comprising: a loading chute for advancing pour spout fitments facing in the same direction as one another; an orientation area for receiving a pour spout fitment from said loading chute; a sensing and comparing system operable for determining an orientation of at least one surface of said fitment in said orientation area and comparing said orientation with a reference orientation; and a rotation mechanism operably connected to said system and having a drive member operable to rotate said fitment to substantially said reference orientation.

According to another aspect of the present invention, there is provided a method of orientating pour spout fitments, comprising: advancing pour spout fitments facing in the same direction as one another; advancing one of said fitments to an orientation area; sensing orientation of one or more surfaces of said one of said fitments; comparing said orientation with a reference orientation; and rotating said fitment to said reference orientation. In a preferred embodiment of the apparatus, a capping machine includes a cap orientation device comprising a system that can sense the rotational orientation of a cap and an orientation area with an associated rotation mechanism for rotating the cap to a predetermined, reference orientation. A linear loading chute successively delivers each cap to an orientation area and a slide lock maintains the cap in a laterally and axially fixed position while the rotation mechanism rotates the cap to bring a curved surface of the cap in mesh with a drive roller of the rotation mechanism. The system includes a camera or scanner which captures an image of the cap and the system translates and - A - compares the image with a reference image reflecting the desired predetermined orientation of the cap, e.g., predetermined orientation of a label or embossment having a logo, a word, a design or the like disposed on the top surface of the cap. If the captured image reflects an undesirable cap orientation, e.g., an upside down logo, this undesirable fault condition prompts the system to signal the rotation mechanism to rotate the drive roller to correct the fault. The cap orientation is corrected by rotating the cap until the desired predetermined orientation of the cap is substantially achieved. The cap is then pushed onto a spigot of a spigot assembly which brings the spigot to a position operably associated with a capping mechanism for affixing the cap to the container, e.g., a carton or a blow-molded container. The successive caps are thereby positioned at substantially the same predetermined orientation with respect to one another and the containers to which they are applied.

In order that the invention may be clearly and completely disclosed, reference will now be made, by way of example, to the accompanying drawings, wherein:

Figure 1 is a perspective view of a capping machine;

Figure 2 is a sectional front view taken along line 2-2 of Figure 1 ;

Figure 3 is a rear perspective view of the capping machine; Figure 4 is a perspective view of a drive roller of the capping machine;

Figure 5 is a perspective view of a rotation mechanism and a push rod assembly of the capping machine; Figure 6a is a perspective view of a screw cap of a cap illustrating a first plane passing along a targeted image on a top surface of the cap prior to rotation of the cap;

Figure 6b is a perspective view of the screw cap of Figure 6a illustrating a second plane passing along the targeted image on the top surface of the cap after rotation to a predetermined orientation;

Figure 7 is a front view illustrating peripheral protrusions of a drive roller intermeshing with protrusions of a cap;

Figure 8a is a perspective view of a slide lock of the capping machine; Figure 8b is a rear view of the slide lock shown in phantom and illustrating a fixed plate in mechanical connection with the slide lock; and

Figure 9 is a schematic diagram illustrating an orientation method of the capping machine.

Referring to Figures 1 to 3, a capping machine is generally shown at 10, having two side-by-side loading chutes 12, orientation areas 14 and rotation mechanisms 16, a sensing and comparing system 18, and a spigot assembly 20.

Although in the preferred embodiment the system 18 is a single device serving both orientation areas 14, it may instead be in the form of two devices serving the respective areas 14. Each loading chute 12 receives caps 19 from a cap hopper that contains randomly oriented caps. Prior to entering the loading chute 12, the caps are arranged to face in the same direction such that the top surfaces 31 and the open ends of the caps enter the loading chute 12 facing the same respective directions. This is accomplished with an arrangement mechanism that can be a vibrational cap sorter, mechanical labyrinth, or other suitable device. Each loading chute 12 successively advances a single column of caps 19 to a respective orientation area 14. It is understood that while two side-by-side loading chutes 12 are depicted, the capping machine 10 can alternatively have more than two or a single loading chute 12, orientation area 14 and rotation mechanism 16.

Each loading chute 12 allows caps 19 to advance selectively, e.g., by gravity, to the respective orientation area 14. The cap 19 in the orientation area 14 is then manipulated in the orientation area 14, if necessary, before exiting to allow the next cap 19 to be fed to the orientation area 14. Each loading chute 12 has an escapement mechanism including at least a first and usually a second staging stopper 22,24 which slide in and out of the loading chute 12 in a reciprocating alternating pattern to control the advancing flow of caps 19 into the orientation area 14. Referring to Figures 1 , 2, 6a and 6b, the top surface 31 of the screw cap of the cap 19 can have a pre-printed, labeled, or embossed logo, word, mark, design, character, or the like. The cylindrical exterior curved surface 33 of the screw cap of the cap 19 has a plurality of protrusions 35, in this example ribs, but alternatively teeth, dimples, spirals, indented letters, logos, symbols, or the like, extending generally along a common axis of the top surface 31 and the open end of the cap 19. The curved surface 33 can alternatively be substantially smooth. The Figures generally illustrate a cap 19 having "ELOPAK" embossed on the top surface 31 ; however, any alternative words, designs, logos, physical features, or the like, or combinations thereof, can be used. One or more alternative surfaces can have pre-printed, labeled, or embossed logos, words, physical features, or the like.

Referring generally to Figures 1, 2 and 4 to 7, when the cap 19 is in the orientation area 14, the, say, embossed, top surface 31 of the cap 19 will generally face out toward the system 18, the curved surface 33 will rest on a drive roller 26 of the rotation mechanism 16, and the cap 19 will be gripped by a slide lock shown generally at 28. Referring more particularly to Figure 4, the drive roller 26 is formed with an outer surface 56 having generally parallelly spaced peripheral protrusions 30 projecting radially from the outer surface 56 and extending parallely to the axis of rotation of the drive roller 26. Referring more particularly to Figure 7, the peripheral protrusions 30 are formed to mesh with the opposedly disposed protrusions 35 of the screw cap of the cap 19. When the drive roller 26 is rotated, the intermeshing interface of the peripheral protrusions 30 of the drive roller 26 and the protrusions 35 of the cap 19 causes the cap 19 to rotate, in the clockwise sense R1 in Figure 5 (where the screw cap only is shown and not the pour spout carrying the screw cap), in response to rotation of the drive roller 26 in the counterclockwise sense R2. The peripheral protrusions 30 can be teeth, ribs, or the like for intermeshing with the curved surface 33.

The outer surface 56 of the drive roller 26 can be any surface suitable for causing the cap 19 to rotate, e.g., a substantially smooth, soft, rubber surface which causes rotation of the cap 19 through frictional engagement. Preferably, in the alternative shown, where the drive roller 26 is manufactured such that peripheral protrusions 30 and protrusions 35 of the cap mesh with each other, the meshing is with, say, 1.30 degrees of backlash. The depth and the shape of the peripheral protrusions 30 can vary and depend upon the curved surface 33 of the cap 19 with which they must engage. While it is preferred that the top surface 31 generally faces out toward the system 18, the top surface 31 can alternatively face in any direction suitable for allowing the system 18 to view one or more surfaces of the cap 19.

Referring to Figures 1, 2, 8a and 8b, the slide lock 28 is arranged to engage the curved surfaces 33 of two caps 19 on respective, substantially opposing sides of the caps 19. While the drive rollers 26 rotate the caps 19, the slide lock 28 maintains the two caps 19 in respective, desired lateral and axial positions and prevents the two caps 19 from jumping out of the orientation areas 14 and from becoming out of mesh with the drive rollers 26. Typically, the slide lock 28 has a fixed pad 23 disposed in a fixed location on one side of each of the orientation areas 14, a sliding pad 25 disposed on the opposite side of that orientation area 14, a cam 27, and an air cylinder 29, and is operably connected to a control system. The sliding pad 25 has a leading end formed as a surface oblique to the vertical. The air cylinder 29 can move the cam 27 vertically up and down. The cam 27 is in mechanical connection with a fixed plate 5. The fixed plate 5 is associated with the orientation areas 14 and has at least one recess 7 formed to receive slidably the sliding pads 25 and at least one elongate horizontal aperture 9. Respective ends of two pins 11 are slidably disposed within respective slots 13 formed on the cam 27. The pins 11 also extend through the elongate horizontal aperture(s) 9 of the fixed plate 5 and are connected at respective second ends to the respective sliding pads 25. Each sliding pad 25 is slidably disposed within recess 7 of the fixed plate 5 such that it can slide horizontally in the recess 7. Figure 8(a) depicts one of the sliding pads 25 in phantom and illustrates in full lines its pin 11 slidably disposed at one end within its slot 13.

Figure 8b illustrates the slide lock 28, the cam 27 in particular in phantom in mechanical connection with the fixed plate 5. As illustrated in that Figure, the cam 27 has not been moved vertically down by the air cylinder 29. The slots 13 are angled such that, when the cam 27 is moved up and down by the air cylinder 29, the pins 11 are translated horizontally by their engagement with the slots 13 of the cam 27 which moves vertically with respect to the pins 11. Preferably, the slots 13 are angled such that the upper ends 15 of the slots 13 are disposed outboard on the cam 27 and the lower ends 17 are disposed inboard. During relative movement between the pins 11 and the slots 13, the pins 11 can also slide substantially horizontally within the elongate horizontal aperture(s) 9 of the fixed plate 5 to allow the pins 11 to slide along the angles of the slots 13. Preferably, when the cam 27 is moved down, the pins 11 slide outboard toward the upper ends 15 of the slots 13 and the sliding pads 25 slide in the recess(es) 7 toward the outer edge of the fixed plate 5 and at least partly into the orientation areas 14 to engage the curved surfaces 33 of the caps 19. When the cam 27 is moved up, the pins 11 slide inboard toward the lower ends 17 of the slots 13 and the sliding pads 25 slide inboard in the recess(es) 7 to disengage from the caps 19 and slide out of the orientation areas 14.

The cam 27 moves vertically upward contemporaneously with the sliding of the second staging stopper 24 out of the loading chute 12. This clears the way for the next cap 19 to advance downward into the orientation area 14.

As illustrated in the Figures, if two side-by-side orientation areas 14 are used, a slide lock 28 having two mirror image sliding pads 25, recesses 7, and slots 13 is disposed between the two orientation areas 14 to enter the respective orientation areas 14 simultaneously. The fixed and sliding pads 23 and 25 can have respective soft pad, roller, bearing or the like surfaces for engaging the caps 19 and for deterring scratching and damaging of the caps, e.g. can be formed of plastics capped with rubber tips or the like.

Referring to the Figures in general, and specifically to Figures 1 and 3, the system shown generally at 18 has a camera (or scanner) 32 to capture images of the top surfaces 31 of the caps 19 in the orientation areas 14, a light source, and a processor to translate and compare images. The camera 32 is mechanically connected to a mount assembly 37 such that the camera 32 is disposed at some distance apart from and generally in front of the top surfaces

31 of the caps 19 in the side-by-side orientation areas 14. Preferably, the camera is angled at 40° with respect to the axes (extending from the top surfaces

31 to the open ends) of the caps 19 in the orientation areas 14.

The system 18 notes that a cap 19 has entered one of the orientation areas 14 and the camera 32 captures an image of at least part of the top surface 31 of the cap 19 for evaluation. Typically, the system 18 is selectively trained to recognize a particular targeted image from the captured image for evaluation, e.g., a blue letter of an otherwise substantially symmetrical word, a logo, part of a logo, an entire word mark, a physical feature, or the like. Preferably, the system 18 recognizes or picks up at least 60 percent of the targeted image for evaluation. The processor, e.g., microprocessor and microcontroller, translates and compares the captured image with a predetermined image reflecting the desired predetermined orientation of the cap 19. If the orientation of the captured image of the top surface 31 under evaluation differs from the predetermined orientation, the system 18 transmits a command signal to the relevant rotation mechanism 16, which rotates its drive roller 26, thereby to rotate the cap 19 to correct the fault condition. Typically, the system 18 is in communication with the rotation mechanism 16 to transmit and receive signals therebetween. Preferably, the system 18 to which the rotation mechanism 16 is connected, e.g., by hardwire or wireless connection, includes a control system to transmit and receive signals with respect to the mechanism 16, e.g., a Profinet control system by Siemens AG, Munich, Germany. Preferably, the camera 32 is a Cognex 5400 vision system provided by Cognex Corporation, headquartered in Natick,

Massachusetts, United States of America. As a way of non-limiting example, an algorithm can be used in the processor to provide a translation of the captured image under evaluation relative to the desired predetermined orientation to determine the position and orientation of the logo, word, physical feature, or the like on the top surface 31 of the cap 19 under evaluation. If a fault condition is present, e.g., the logo orientation on the top surface 31 does not significantly match that of the predetermined orientation, the system 18 signals the rotation mechanism 16 to rotate the drive roller 26 until the top surface 31 matches the predetermined orientation. Thus, the interface between the system 18 and the rotation mechanism 16 is operable to recognize and clear the fault condition. Preferably, the orientation of the top surface 31 of the cap 19 will thereby be corrected to be within about zero to three degrees of the predetermined orientation.

Alternatively, more than one surface of the cap 19 can be evaluated and orientated to the predetermined orientation. The surface of the cap 19 evaluated can be any surface suitable for evaluation and orientation to the predetermined orientation. One or more physical features of the cap 19, e.g., tabs, shapes, dimensions, asymmetrical planar shapes, orientable shapes or features, or the like, can alternatively be evaluated and orientation to the predetermined orientation effected.

Figures 6a and 6b show an example of rotation of the cap 19 in response to the orientation of a targeted, captured image differing from a predetermined orientation. Referring to Figure 6a, line 3 illustrates a first plane passing along the targeted image prior to rotation. Referring to Figure 6b, line 4 illustrates a second plane passing along the targeted image after rotation to the predetermined orientation. For example, the angle "x" in Figure 6a may be 45 degrees and reflect the amount of clockwise rotation of the cap 19 by the drive roller 26 required to orientate the cap 19 to the predetermined orientation. Referring to Figures 1 and 3, the system 18 has a light source to illuminate the top surface 31 of the cap 19 in the field of view of the camera 32. An auxiliary light can also be employed to ensure that no other light sources, e.g., other lights around the capping machine 10, interfere with capturing an adequate image of the cap 19. Preferably, the light source illuminates an area that is about 3.50 inches (about 9 cm.) in diameter relative to the cap 19. Alternatively, the light source can be backlighting or be a ring of a plurality of lights normal to the top surface 31 of the cap 19. Backlighting is particularly desirable when the cap 19 under evaluation has a translucent wall which has an embossment the orientation of which is to be detected, in order to ensure that an image of the embossed logo, words, or the like can be captured by the camera 32.

The system 18 can comprise a single or dual camera 32 arrangement to capture simultaneously images of caps 19 in both side-by-side orientation areas 14 and can contemporaneously translate both captured images and simultaneously signal both rotation mechanisms 16 to actuate the respective drive rollers 26 if necessary. The system 18 associated with the side-by-side orientation areas 14 can be contained in a single housing. The system 18 can also detect when a lens of the camera 32 is damaged or dirty, to prevent inaccurate images. By way of non-limiting example, an image can be an engraving mark on the lens that should not change under normal operating conditions. If the image changes, the system 18 alerts a capping machine operator of the irregularity, e.g., by lighting an LED (light emitting diode), to indicate that there may be a problem with the lens of the camera 32.

Referring generally to Figures 1 to 3, 4 and 5, the rotation mechanism

14 has a motor 34, an output shaft 36, and the drive roller 26. The output shaft 36 is connected to and extends horizontally from one end of the motor 34 and rotates about its longitudinal axis. The opposite end of the output shaft 36 is connected into a central aperture 38 of the drive roller 26. The motor 34 is in communication with the system 18 such that the motor 34 produces rotation of the output shaft 36 in response to control signals received from the system 18. Typically, the output shaft 36 has a turning angle that is about +180 degrees to about -180 degrees and can rotate selectively clockwise or counterclockwise.

Preferably, the output shaft 36 is rotated only counterclockwise, to help prevent the screw cap of the cap 19 from being loosened during rotation of the drive roller

26. Typically, the motor 34 is a servo motor, preferably a Servo Motor AKM22- An by Danaher Corporation, Washington, District of Columbia, United States of

America.

Each orientation area 14 further has a rear opening 40 sized to allow the cap 19 to exit from the back of the orientation area 14 once the cap 19 is orientated to the predetermined orientation. An optional plate 42 or stop, shown in Figure 3, can be used at the rear of the orientation area 14 to help prevent the cap 19 from exiting the orientation area 14 prematurely. The plate 42 moves upward from the rear opening 40 only after the cap 19 is orientated to the predetermined orientation. Referring to Figures 1 to 3, the spigot assembly 20 comprises spaced apart arms 46 having a spigot 44 disposed at the end of each arm 46 to receive and retain a cap 19. The spigot assembly 20 rotates to align a spigot 44 selectively with the rear opening 40 of the orientation area 14. The spigot assembly 20 then advances forward so that the spigot 44 extends through the rear opening 40 into the orientation area 14. The spigot 44, e.g., a plug, is formed to fit at least partly through the open end of the cap 19 and not scratch or damage the cap 19, e.g., formed of plastics, cast polyurethane, capped with rubber, or the like. The arms 46 are spaced such that respective spigots 44 can be disposed in two side-by-side orientation areas 14 simultaneously, shown in

Figure 2. This allows a cap 19 in each orientation area 14 to be removed through the rear opening 40 simultaneously thereby increasing cap throughput of the capping machine 10.

Referring generally to Figures 1 and 5, a push rod assembly shown generally at 48 has an actuator 50, support brace 52, and pushing member 54 disposed in front of the top surface 31 of the cap 19 when the cap 19 is in the orientation area 14. The actuator 50 is connected to a control system and pushing member 54. The pushing member 54 pushes the cap 19, once the cap

19 has been orientated to the predetermined orientation, onto the spigot 44. The spigot assembly 20 then withdraws the spigot 44 back out of the rear opening 40 and rotates to a position associated with a capping mechanism for affixing the cap 19 to the container. The actuator 50 can be an electric actuator, an hydraulic actuator, a pneumatic actuator, or some other suitable device controlled by the control system in operable communication with the sensor system 18. The pushing member 54 is formed so as not to scratch or damage the top surface 31 of the cap 19, e.g., formed with a rubber end, plastics, or the like.

The present embodiment of the invention can be used on caps 19 having various top surface logos, embossments, labels, or the like. At least the system 18 of the present embodiment can be trained or adjusted to translate and compare images as set forth based on the particular top surface logo or the like that is under evaluation.

Referring to the Figures in general, and more particularly to Figure 9, the method of orientating a cap 19 in a capping machine is generally shown at

100. As the cap hopper feeds a cap 19 to the loading chute 12, an arrangement mechanism positions the cap 19 in a uniform direction such that the top surface

31 of the cap 19 faces generally in a predetermined direction, preferably generally facing the system 18, shown at first step 102. The first staging stopper 22 of the loading chute 12 is selectively slid out of the loading chute 12 to allow the single column of caps 19 to advance, e.g., by gravity, down to the second staging stopper 24, shown at second step 104. The second staging stopper 24 is slid out of the loading chute 12 contemporaneously with the first staging stopper

22 sliding into the loading chute 12, thereby allowing a single cap 19 to advance down to the orientation area 14 and, with its curved surface 33, to come to rest on the outer surface 56 of the drive roller 26, shown at third step 106. The air cylinder 29 moves the cam 27 down to slide the sliding pad 25 into the orientation area 14 such that the curved surface 33 of the cap 19 is engaged on one side by the sliding pad 25 and on the other side by the fixed pad 23.

If the outer surface 56 of the drive roller 26 has peripheral protrusions

30, it is possible for the curved surface 33 of the cap 19 to come to rest on the drive roller 26 and yet not be in mesh with the peripheral protrusions 30. To ensure that the protrusions 35 of the cap 19 and the peripheral protrusions 30 of the drive roller 26 are in mesh, once the cap 19 comes to rest in the orientation area 14, and before an image is captured, the drive roller 26 is pulsed or rotated a predetermined extent, shown at fourth step 108. Preferably, the drive roller 26 is rotated 10° in one direction, preferably clockwise, to ensure that the curved surface 33 of the cap 19 is in mesh with the outer surface 56 of the drive roller

26.

The system 18 notes that the cap 19 has entered the orientation area 14 and the camera 32 captures an image of at least part of the top surface 31 of the cap 19 for evaluation, shown at fifth step 110. At decision 112, the processor, e.g., microprocessor and microcontroller, translates and compares the orientation of the cap 19 with a predetermined image reflecting the desired predetermined orientation of the cap 19. If the cap 19 is oriented at the predetermined orientation, the cap 19 is pushed onto a spigot assembly 40, shown at step 116. If the orientation of the captured image differs from the desired predetermined orientation, the system 18 transmits a command signal to the rotation mechanism 16, e.g., via a control system, which causes rotation of the drive roller 26 to rotate the cap 19 to the predetermined orientation, shown at sixth step 114. An alternative surface or more than one surface can be evaluated and orientated to the predetermined orientation.

The spigot assembly 20 rotates to align one of the spigots 44 selectively with the rear opening 40 of the orientation area 14 substantially contemporaneously with the cap 19 being rotated to the predetermined orientation. The spigot assembly 20 advances forward such that the spigot 44 passes through the rear opening 40 and is disposed in the orientation area 14 relative to the open end of the cap 19. A connected control system commands the actuator 50 of the push rod assembly 48 to advance the pushing member 54, thereby to push the cap 19 onto the spigot 44, shown at step 116. The spigot assembly 20 withdraws the spigot 44 back out of the rear opening 40 and rotates to a position operably associated with a capping mechanism for affixing the cap 19 to the container. The orientation of labels, embossments, physical features or the like on the top surfaces 31 of the caps 19 are thereby substantially uniformly orientated at the predetermined orientation when affixed to the containers.