TECHNICAL FIELD

The present invention relates to the technical sector of automatic machines for packing articles in containers.

BACKGROUND ART In particular, the invention relates to a machine destined to insert a predetermined quantity of flat semi-rigid articles (for example cards, envelopes or the like) arranged side-by-side in tray containers, as well as to manipulate the filled containers in order to arranged them horizontally on a plane (or on a conveyor belt). The problems which emerge relate to various aspects, among which: supplying and counting the cards; supplying, configuring and arranging the into the tray containers in order to obtain an easy insertion of the cards; the need to obtain in outlet a horizontal positioning of the filled containers. The above problems also have to take account of certain special characteristics of some flat articles and the tray containers to be treated: in the case of the flat articles, when dealing with cardboard envelopes, there is an elastic central bulging in each of them which has to be dealt with in order to compact the row of articles; in the case of the tray containers, also made of semi-rigid cardboard, there is a decidedly oblong shape, so that the lateral walls at the long sides thereof provide poor resistance to flexion.

SUMMARY OF INVENTION The aim of the present invention is thus to provide a machine for packing batches of flat articles arranged flanked in relative tray containers and for discharge of the filled containers to a receiving station, conformed such as to optimally resolve the functional problems inherent to the supply and counting of cards, the supply, configuration and arrangement of tray containers in order to obtain easy insertion of the cards and the specific requirement of dispensing in outlet filled containers arranged horizontally.

A further aim of the invention is to make available a machine provided with constructional solutions that are effective according to the structural and dimensional characteristics of both the cards and the containers. A still further aim of the invention consists in obtaining a machine which offers at the same time high productivity and reliability, such as to be able to be combined downstream of another machine (for example of the fold and glue type for production of cardboard envelopes), thus improving the productive rhythm thereof.

A further aim of the invention relates to the desire to offer, however, a machine of simple conception and not excessive costs.

BRIEF DESCRIPTION OF THE DRAWINGS

The characteristics of the invention will emerge from the following description of a preferred embodiment of machine of the invention, in accordance with what is reported in the claims and with the aid of the accompanying tables of drawings, in which: figure 1 illustrates a schematic lateral view of the machine of the invention; figure 2 is a partial plan view of the machine of figure 1 ; figures 3A, 3B illustrate, in larger-scale, sections of a first station of the machine, obtained along plane Ill-Ill of figure 2, with the relative organs illustrated in successive operating stages; figures 4A, 4B, 4C, 4D illustrate, in larger scale, section of a second station of the machine, obtained along plane IV-IV of figure 2, with the relative organs illustrated in successive operating stages; figures 5A, 5B, 5C, illustrate, in larger scale, sections obtained along plane V-V of figure 4D, with the relative organs illustrated in successive operating stages; figure 6 illustrates, in larger scale, a section of a third station of the machine, obtained along plane VI-VI of figure 2, with the relative organs illustrated in a particular operating stage; figures 7A, 7B, 7C, 7D, 7E, 7F illustrate, in larger scale, sections of a fourth station of the machine obtained along plane VII-VII of figure 2, with the relative organs illustrated in successive operating stages: figure 8 illustrates a partial section along plane VIII-VIII of figure 7B; figures 9A, 9B illustrate other sections of the fourth station of the machine, relating to a first constructional variant of the relative organs; figures 10A, 10B, 10C illustrate further sections of the fourth station of the machine, relating to a second constructional variant of the relative organs.

BEST MODE FOR CARRYING OUT THE INVENTION

With reference to the above figures, M denotes the machine of the invention in its entirety. The machine M is destined to fill tray containers 1 with a predetermined quantity of flat semi-rigid articles 2, for example cards, envelopes, tubular blanks or the like, arranged flanked; in the description, for the sake of simplicity, the term card will be used with reference to any of the articles as wells as others of similar type.

The tray containers 1 considered are also made of semi-rigid card and exhibit an oblong shape, such that in as already mentioned in the foregoing, the lateral walls along the long sides will offer low resistance.

The machine M comprises, in a central position, a vertical-axis rotating turret 3 having a substantially truncoconical shape with the vertex at the top.

The turret 3, in a preferred embodiment, is peripherally provided with four radial heads 4, equal and angularly equi-distanced, arranged with the relative planes of symmetry inclined and intersecting the axis B of the turret 3 above the turret B.

Gripping means 5 are arranged in each of the radial heads 4, which gripping means 5 are destined to receive and retain one of the containers 1 , with the bottom 1A thereof facing towards the turret 3 and inclined with respect to the vertical in a way which is equal to the inclination of the lateral surface of the turret 3.

The above-mentioned gripping means 5 are constituted, for example, by a plate 50 orientated parallel to the plane of symmetry and the relative radial head 4, provided, at the bottom end, with a flap 51 arranged at right angles, facing externally of the turret 3 and destined to provide a rest for the lower head 1C of the container 1.

At least two shaped forks, respectively and upper 52A and a lower 52B are fixed at different heights to the plate 53, which forks face externally and are destined to laterally abut, with a slight interference, the flanks 1 B of the container 1 ; the upper fork 52A is developed in height such as to pass beyond the upper head 1 D of the container 1 , for reasons connected with the needs of some types of card 2.

The forks 52A, 52B are destined also to abut the bottom 1A of the container 1 , such that the container 1 is displaced from the plate 50, for reasons that will become more evident herein below. Also comprised in each of the radial heads 4 are movement organs 6, destined to raise and lower the gripping means 5, as well as the respective container 1 borne thereby.

The movement organs 6 are constituted, for example, by a double-slide 60 interposed between the plate 50 and the turret 3, activated by powering organs, not illustrated, able to vary the extension thereof in order to define the desired position of the plate 50, comprised between a maximum height H and a minimum height D.

The turret 3 is provided with motor organs, not illustrated, destined to activate it intermittently, in rotations of a predetermined angular amplitude, such that each of the radial heads 4 occupies in succession a series of four consecutive stations S1 , S2, S3, S4 arranged in a circle about the turret 3.

In the example of figure 2, the stations S1, S2, S3, S4 are angularly distanced by 90°, such that each rotation step of the turret 3 is of a corresponding value: with the presence of four radial heads 4, also located at 90° from one another, during the pause of the turret 3 there is a contemporary presence of each of them in a corresponding station.

Loading organs 10 are located in the first station S1, arranged externally of the turret 3 and destined to cyclically located a tray container 1, in which the upper head 1D is open, in the corresponding gripping means 5 of a radial head 4, in phase relation with the pause of the turret 3 .between one rotation step and another.

In the example of figure 3A, 3B, the container 1 is opened out and closed, apart from the upper head 1 D, in location, starting from a flat blank F; in this case, the loading organs 10 comprise a manipulator 11, for example having two axes, destined to singly pick up the flat blanks F from a store 12 (broken lines in figure 3A), then to push it to cross a forming hopper 13, before positioning the container 1 resulting in the seating defined by the gripping means 5 of the corresponding radial head 4, centred with respect to the hopper 13 (figure 3B). The closing of the flaps of the blank F is stabilised by hot-spraying of glue by means of suitable nozzles, not illustrated as of known type.

In a variant which is not illustrated, the containers 1 can be formed in another place and supplied to the first station S1 , where a specially-conformed manipulator picks them up one by one in order to insert them in the gripping means 5 as already described.

Supply organs 20 open into the second station S2, destined to convey the cards 2 internally of a corresponding container 1 engaged by relative gripping organs 5, in phase relation with the pause of the turret 3 and with the progressive lowering of the container 1 , as will be more fully described herein below.

The supply organs 20 are defined by conveyor belts 21 , 22, 23 24 arranged in series (figure 1), on which a machine located upstream (not illustrated) deposits the cards 2 produced in a line and partially superposed, one on a preceding one, like fish scales. In a known way, the first conveyor belt 21 is destined to direct eventual reject cards 2 towards an underlying collecting device 25 (figure 1).

Counting and separating means 30 are associated to the supply organs 20, which means 30 are destined to define batches, each made up of a predetermined number of cards 2, sufficient to fill one of the containers 1. The counting and separating means 30 are located between the third 23 and the fourth 24 of the conveyor belts and comprise sensors (of known type and not illustrated in detail) destined to detect the transit of the cards 2 and command organs destined to accelerate the fourth conveyor belt 24 after passage of the predetermined number of the cards 2, such that the batch is distanced from the following line (figure 1).

The fourth conveyor belt 24 exhibits the respective terminal portion 24T at the second station S2, as close as possible and centred with respect to the container 1 paused therein (figures 1 , 2, 4A). At the start of the introduction stage of the batch of cards 2, the plate 50 is raised in the maximum height position H thereof, together with the container 1 (figure 4A).

The plate 50 and the container 1 are progressively lowered, by means of the movement organs 6, in order to maintain the upper level of the pile of cards 2 at a constant level in the container 1 ; the pile being formed is kept abutting on the bottom thereof by action of a compacter 28, associated to the supply organs 20 below the terminal portion 24T (figures 4B, 4C).

The descent of the container 1 and the plate 50 proceeds up to complete insertion of the batch of cards 2; in the example of figure 4C it is hypothesised that the cards 2 are tubular blanks or envelope-type, such that each of them exhibits an elastic bulging which increases the height of the free pile.

At the end of the insertion the plate 50 is in its position of minimum height D and the upper part of the pile, exceeding the height of the container 1 , is contained by the upper fork 52A (see figure 4C once more).

In a preferred embodiment, a deflector 29 is associated to the supply organs 20, overlying the terminal portion 24T of the fourth belt 24 and mobile, by the action of the actuator organs, not illustrated, between an operating position K and a non- operating position N. In the operating position K (continuous line in figure 4A), the deflector 29 is partially inserted in the container 1 and facilitates the entry and the correct positioning of the cards 2 therein.

In the non-operating position N the deflector 29 is external of the container 1 and not interfering with the rotation of the turret 3. Figures 4B, 4C, 4D, 5A, 5B, 5C, 6 illustrate a preferred embodiment of the machine M, which comprises presser organs 40, associated to the turret 3, destined to act following the filling of a container 1 when the pile of cards 2 must be compacted in order to be housed internally thereof (see the example of figure 4D). The presser organs 40 comprise, for example, a jack 41 , positioned above the radial head 4 paused in the second station S2, inclined by the same angle as the head 4.

The cylinder of the jack 41 is supported by a horizontal carriage 42, in turn associated to a column 43, provided superiorly of the turret 3 and coaxially therewith; the carriage 42, by action of actuators (not illustrated), is destined to translate the jack 41 between two extreme positions, respectively an internal rest position R (figure 4B) and an external work position L (figures 4C, 4D).

The internal rest position R enables the movements of the plate 50 and the deflector 29; the deflector 29 is appropriately arranged in the non-operating position N thereof before displacing the jack 41 into the external work position L.

A plate 44 is fixed to the stem 41 A of the jack 41, which plate 44 is mobile between two positions, relatively a raised position X1 and a lowered position X2.

The presser organs 40 further comprise two groups 45A, 45B, symmetric and supported by the upper fork 52A with vertical regularity.

Each of the groups 45A, 45B is constituted by a horizontal guide 46 in which a cursor 47 is slidably engaged, destined to support an actuator 48 for moving a holding beam 49.

The cursors 47 are activated by powering organs (not illustrated) in synchrony along the respective guides 46 between a first position A1 in which they are mutually distanced (figure 5A) and a second A2 in which the cursors 47 are neared (figures 5B, 5C).

The actuators 48 are simultaneously commanded to activate the corresponding holding beams 49 between a retracted position C1 , in which they are external of the pile of cards 2 (figure 5A) and an advanced position C2 in which they are located above the pile (figure 5B).

When the container 1 in the second station S2 is filled and reaches its lowest position, the jack 41 is translated into the work position L thereof (figure 4C); the plate 44 which is initially in the raised position X1 is lowered into position X2 to superiorly abut the pile of cards 2, compacting downwards up to when the upper limit of the pile is lower than the upper head 1 D of the container 1 (figure 4D).

The cursors 47 are displaced in phase relation from the first position A1 (figure 5A) to the second A2 (figure 5B), and the actuators 48 are then activated to arrange the holding beams 49 in the relative advanced position C2 by a side of the plate 44 (see figure 5B once more).

In this situation the plate 44 can be raised to return it into position X1 , as the pile of cards 2 is kept compressed by the holding beams 49 (figure 5C). As soon as the plate 44 is out of the upper fork 52A, the turret 3 can be commanded to rotate such as to displace the radial head 4, which is in the second station S2, towards the third station S3 (figure 6).

Operating means 7 are further comprised in each radial head 4, destined to close the upper head 1D of the tray container 1 which is full of cards 2, in phase relation with the passage of the radial head 4 from the second S2 to the third S3 of the stations.

The operating means 7 comprise first and second folding means 71, 72, respective destined to act, in mutual phase relation, first on the lateral flaps (figure 5C) and then on the central flap (figure 6) of the upper head 1D; nozzles (not illustrated) are also comprised in the operating means 7, and are destined to hot- spray glue for blocking the flaps.

The first and second folders 71 , 72 are activated while maintaining the holding beams 49 in the advanced position C2, up to the end of the closing operations of the upper head 1D; successively the beams 49 are newly brought into the retracted position C1 thereof.

The fourth station S4 exhibits extraction and orientation organs 80, destined to act in cooperation with the gripping means 5 and movement organs 6, for unloading the relative filled container 1 from the corresponding radial head 4 and for positioning the container 1 horizontally on a horizontal plane 100. ln a first embodiment, illustrated in figures from 7A to 7F, the extracting and orientation organs 80 are constituted by two groups 81 , 82 activated in phase relation.

The first group 81 is defined by a pliers extractor 810 comprising two lateral tines 81 1 and a lower tine 812, activated by relative actuators, not illustrated, destined to open and close them simultaneously.

The pliers extractor 810 is made mobile perpendicular to the container 1 paused in the fourth station S4, by action of an actuator 813, between a first retracted position W1 , a second advanced position W2 and a third intermediate position W3.

The second group 82 is defined by an elevator 820 in which an openable external platform 821 and an upper presser 822 are provided.

The elevator 820 is borne by a support 823 by means of a horizontal-axis hinge 824, which makes is oscillatable on the vertical plane of translation of the first group 81 ; powering organs (not illustrated) are interposed between the elevator 820 and the support 823, for defining two angular positions Z1 , Z2 of the elevator 820, in the first of which it is inclined parallel to the bottom 1A of the container 1 paused in the fourth station S4 (figures 7A, 7B) while in the second it is horizontal (figure 7F). The elevator 820 is provided with actuators, not illustrated, destined to command the elevator 820 to run between a raised position Q1 (figure 7A) and a lowered position Q2 (figure 7C) when the elevator 820 is in the inclined angular position Z1 ; a further actuator, also not illustrated, is destined to move the pusher 822 in nearing or distancing motion with respect to the openable lower platform 821 , as will be more precisely explained in the following.

The horizontal plane 100, defined for example by a conveyor line, is situated at a height established on the basis of the horizontal position Z2 of the elevator 820.

On arrival of the filled container 1 in the fourth station S4, the first group 81 is in the first retracted position W1 , while in the second group 82 the elevator 820 is in -lithe angular position Z1 , raised into the position Q1 (figure 7A).

The translation of the pliers extractor 810 is commanded in phase relation into its advanced position W2, with the relative tines 811 , 812 open.

At end of run, the tines 811 , 812 are closed, such as to engage the container 1 (figures 7B, 8); the teeth of the tines can posteriorly grasp the bottom 1A of the container 1 thanks to the fact that the forks 52 keep it displaced from the plate 50 (see in particular figure 8).

The pliers extractor 810 is newly brought into the retracted position W1 , bringing the container 1 with it, which thus exits from the gripping organs 5; thereafter the elevator 820 is lowered into its position Q2 (figure 7C).

At this point the pliers extractor 810 is brought into the intermediate position W3, together with the container 1 , which is thus located in the elevator 820; the tines 81 1 , 812 are opened in suitable phase relation and the pusher 822 is lowered up to abutting the upper head 1 D of the container 1 , which consequently disengages from the extractor 810 and is encountered by the elevator 820, held between the pusher 822 and the external platform 821 (figure 7D).

The pliers extractor 810 is returned into the retracted position W1 and in phase relation the elevator 820 is raised into the position Q1 , together with the container 1 (figure 7E); thereafter the elevator 820 - container 1 group is rotated into a horizontal position Z2 (broken lines in figure 7E).

The lowering of the openable external platform 821 and the movement towards it by the pusher 822 enable transferring the container 1 , horizontally-disposed, onto the horizontal plane 100 (figure 7F).

In a second embodiment, illustrated in figures 9A, 9B, the extraction and orientation organs 80 are constituted, in each radial head 4, by a roto-translating carriage 83, interposed between the movement organs 6 and the turret 3, engaged via upper rollers 831 and lower rollers 832 in a first guide 833 made solid to the turret 3 with an inclination which conforms with the inclination of the turret 3 and inferiorly open. The roto-translating carriage 83 is associated to relative manoeuvring means, not illustrated, destined to maintain it against the turret 3, and thus parallel to the first guide 833, up to when the respective radial head 4 reaches the fourth station S4, where a second horizontal guide 834 is provided coming into alignment with the lower end of the first guide during the paused stage.

The manoeuvring means are then activated to move the roto-translating carriage 832 downwards, the trim of which is modified due to the fact that the lower rollers 832 exit from the first guide 833 and enter the second horizontal guide 834 (broken lines in figure 9A). When the upper rollers 831 of the roto-translating carriage 83 arrive at the bottom of the first guide 833, the carriage and thus the container 1 are arranged horizontally (figure 9B).

In this embodiment, the flap 51 of the gripping means 5 is mobile in order to open and enable the exit of the container 1 (see figure 9B once more). The transfer of the container 1 towards a horizontal plane arranged at the same level, not illustrated, is realised by translating means, also not illustrated.

In a third embodiment, illustrated in figures 10A, 10B, 10C, the extraction and orientation organs 80 comprise a base 84, situated coaxially below the turret 3, having a truncoconical shape which is complementary to that of the turret 3, provided at the fourth station S4 with a roto-translating carriage 85 similar to the previously-described one with reference to the second embodiment, which therefore underlies the radial head 4 paused in the fourth station S4.

The roto-translating carriage 85 is engaged by means of upper rollers 851 and lower rollers 852 in a first inclined guide 853 provided in the base 84, open inferiorly, which connects with a second horizontal guide 854.

The roto-translating carriage 85 is associated to the relative manoeuvring means, not illustrated, destined to maintain it against the base 84, and thus parallel to the first guide 853, and is provided with a plate 86, mobile longitudinally to the carriage 85 by means of an actuator (not illustrated) destined to be positioned upwards in order to restingly receive the container 1 released by the opening of the flap 51 of the gripping means 5 (figure 10A).

The plate 86 is lowered, accompanying the descent of the container 1 , which thus disengages from the gripping organs 5. When the plate 86 has reached its lower endrun (figure 0B), the manoeuvring means are activated to move the roto-translating carriage 85 downwards, in an entirely similar way to what has already been described; the lower rollers 852 then exit from the first guide 853 and enter the second horizontal guide 854 (broken lines in figure 10B). When the upper rollers 851 of the roto-translating carriage 85 arrive at the end of the first guide 853, the carriage and the container 1 are arranged horizontally (figure 10C).

The plate 86 is brought into a non-interfering position, for example by tilting it (position represented in a broken-line in figure 10C), and a pusher 87 internal of the base 84 is activated (see figure 10C once more) which intercepts the container 1 and displaces from the carriage 85 to a horizontal plane which is appropriately arranged at a flank thereof (not illustrated).

As is evident, the extraction and orientation organs 80, in all described embodiments, are advantageously conformed such that the full container 1 is brought from the inclined position, in which it is in the radial head 4, and in the position arranged horizontally on the horizontal plane without subjecting it to flexion stress which, as mentioned hereinabove, it is not able to support without deforming due to the structural and dimensional characteristics thereof.

Optionally a labelling group for the container 1 can be included in the machine, positioned externally of the turret 3.

In the machine M as described, independently of embodiment adopted for the extraction and orientation organs 80, a radial head 4 is present in each of the stations S1 , S2, S3, S4 is contemporaneously present, such that the operating stages occur at the same time. With the described first and third embodiments of the extraction and orientation organs 80 the arrival of a successive full container 1 in the fourth station S4 can be anticipated, by means of a rotation shift of the turret 3 (see in particular figures 7F and 10C), even if the stages of unloading onto the horizontal plane of the preceding container 1 has not yet been completed.

As the cadence of the intermittent rotation of the turret 3 with multiple radial heads 4 depends on the longest operating stage from among those realised in stations S1 , S2, S3, S4, this cross-over of stages can be advantageous in increasing the productivity of the machine M in a case in which the unloading of the filled container 1 is the stage requiring the longest time.

Variant realisations are comprised, not illustrated, with a greater or lesser number of radial heads 4 and stations arranged at angles different to 90° with respect to one another.

From the above it is clear that the machine of the invention is able to fully achieve all the set aims, in particular in order to obtain a rapid, easy and reliable insertion of the cards into the containers, arranged inclined in the truncoconical turret, and in order to organise the containers, once filed, in the desired horizontal position without subjecting them to undesired flexion stresses.

The machine of the invention is advantageously provided with auxiliary devices, such as the deflector 29 and the presser organs 40, especially useful, the first for optimising the insertion of the cards into the containers and the second for compressing and holding the pile of cards during the closure of the upper head thereof.

The rotating turret with multiple radial heads, representing the heart of the machine, enables a high productivity to be attained together with high levels of reliability, such as to make it suitable for working in line with a machine for producing cards, for example of the fold-and-glue type.

The functional characteristics of the described machine are obtained with relatively simple technical solutions, in which the movements of the various organs are powered by actuators mostly constituted by pneumatic jacks, easily obtainable on the market, easy to install and power and, last but not least, easily manageable by an electronic control unit which is not particularly complex, with evident benefits in containing realisation costs. The above is intended to be by way of non-limiting example, as any eventual modifications which might be introduced to the operating organs for technical and/or functional reasons are considered henceforth to fall within the ambit of protection defined by the following claims.