Field of the Invention

The present invention relates to packaging apparatus that is operable to convey articles in multiple streams. More particularly, though not exclusively, the present invention relates to such apparatus further being able to align articles of one stream, with articles of another stream, as those articles reach an end point of a conveyor upon which they are disposed.

Background to the Invention

In the field of packaging it is necessary for articles, initially disposed in a moving stream, to be combined with some form of carton or other form of packaging, so as to, for example, provide promotional advertising space, and to keep groups of articles together.

In order to speed up the rate at which the articles can be packaged, it is often desirable to have the articles initially in a first stream, and the cartons or packaging in a second stream, and then to bring the two together, in a correctly aligned relationship, such that the articles may be then quickly packaged.

If the two streams comprise regularly arranged articles/cartons, having identical pitches between each one, the two streams can be synchronised with one another such that each article from the first stream is aligned with the corresponding carton from the second stream. If, however, the pitch between the articles, or that between the cartons, is not perfectly regular, this becomes impossible.

For this reason, there is a need for an apparatus that is capable of overcoming irregular discrepancies in pitch between successive articles or cartons whilst maximising the throughput of the overall apparatus. Summary of the Invention

A first aspect of the present invention provides an apparatus for packaging articles, which apparatus comprises a first article conveyor for conveying a first stream of articles at a first speed, a second article conveyor for conveying a second stream of articles at a second speed and a drive means for driving each of the conveyors, which drive means is operable to alter the first and second speed relative to one another so as to align a given article of one stream with a corresponding article of the other of the streams and thereafter to convey those two articles in alignment with one another.

Preferably, the drive means is controllable to reduce said second speed to zero when a leading article of said second stream reaches a desired position, whilst said first speed is maintained so as to bring a leading article of said first stream into alignment with said leading article of said second stream.

Preferably, both leading articles, once aligned, are then conveyed in alignment with one another, downstream of said desired position.

Preferably, said first articles comprise tiered stacks of articles and wherein the apparatus is operable to convey said first stream with constant speed, and to adjust said second speed to ensure that each article of the second stream is aligned with a corresponding tiered stack of the first stream beyond a desired point in the stream.

Preferably, there further comprises a means for transferring promotional items into contact with the articles in at least one of the streams.

Preferably, there further comprises a package conveyor, onto which package conveyor articles from the second stream are conveyed, and wherein the articles in the first stream reach a terminal end of the first conveyor, in alignment on top of a corresponding article from the second stream, as that article is transferred onto the package conveyor. Preferably, the second conveyor comprises spaced belts driven in synchronicity with one another, across both of which belts the articles of the second stream are disposed, and wherein the package conveyor is disposed between those belts, at a terminal end of the second conveyor, and wherein the second conveyor inclines downwardly from the surface of the package conveyor at that terminal end, such that the articles so disposed across the spaced belts become disposed upon the package conveyor.

A second aspect of the present invention provides a method for packaging articles, which method comprises: conveying articles to form a first stream of articles at a first speed, and a second stream of articles, at a second speed, which streams are conveyed to an alignment point; and controlling the relative speeds of the two streams to align a given article of one stream and a corresponding article of the other of the streams, and thereafter to convey those two articles in alignment with one another.

Preferably, the method further comprises reducing said second speed to zero when a leading article of said second stream reaches a desired position, whilst said second speed is maintained so as to bring a leading article of said first stream into alignment with said leading article of said second stream.

Preferably, the method further comprises, once both leading articles, once aligned, conveying those leading articles in alignment with one another, downstream of said desired position.

Preferably, said first stream of articles comprises tiered stacks of articles and wherein method comprises conveying said first stream with constant speed, and adjusting said second speed to ensure that each article of the second stream is aligned with a corresponding tiered stack of the first stream, beyond a desired point in the stream.

Preferably, the method further comprises transferring promotional items into contact with the articles in at least one of the streams. Preferably, the method further comprises conveying articles from the second stream onto a package conveyor, and conveying articles in the first stream onto a corresponding article from the second stream, as that article is transferred onto the package conveyor.

Brief Description of the Accompanying Figures

Various embodiments and applications of the present invention will now be described, with reference to the accompanying Figures, in which:

Figures 1 to 4 show an infeed portion of an apparatus according to a preferred embodiment of the present invention;

Figures 5 to 7 show a more detailed view of the rotary picker of the preferred embodiment; Figures 8 and 9 show a more detailed view of the rotary arm of the preferred embodiment, placing promotional items on the cartons;

Figure 10 and 11 show the relative arrangement of the article and carton conveyors of the preferred embodiment;

Figure 12 shows an infeed end of the stack conveyor of the preferred embodiment; Figures 13 to 17 illustrate, sequentially, the movement of stacks of articles through the stack conveyor of the preferred embodiment;

Figure 19 shows a view of a terminal end of the carton conveyor of the preferred embodiment, as view as if the article conveyor had been removed; and

Figures 20 to 22 show the motion of the aligned cartons and stacks of articles, upon the package conveyor of the preferred embodiment, being conveyed to an outfeed end of the apparatus.

Detailed description of preferred embodiments

A packaging apparatus according to a preferred embodiment of the present invention is generally illustrated in Figures 1 - 4. The apparatus 10 comprises an article conveyor 2 that is driven by a drive means (not shown) and upon which articles A are deposited, so as to create a moving stream of articles A.

The articles A are initially disposed upon an infeed conveyor 6. In the illustrated embodiment, this infeed conveyor 6 is three lanes wide, which is to say that three parallel streams of articles are disposed thereupon. It may be that the infeed conveyor 6 actually comprises three separate belts that are parallel with one another, or all three parallel streams of articles A may be disposed upon one wide belt. It is further contemplated that any number of lanes may be used, including four lanes, using a wider or additional belt.

In the illustrated embodiment, the desired packaged output requires a single lane of stacks S of articles A, each comprising two tiers. Thus it is necessary that the articles A be manipulated such that from the original three streams of articles A disposed on the infeed conveyor 6, a single stream of stacks S, disposed on the article conveyor 2, be formed.

In the preferred embodiment, this manipulation of the articles A is achieved by robotic manipulators 8. The number of robots 8 required by the apparatus 10 is dependent upon the throughput of articles A entering the apparatus 10 at the infeed conveyor 6. In the illustrated embodiment, four such robots 8 are provided, each operating to engage with articles A on the infeed conveyor 6 and dispose them, in dual-tier stacks S, on the article conveyor 2. It is further contemplated that the articles A may be disposed in any number of tier stacks including one, two or three tier stacks.

Sufficient robotic manipulators 8 must be provided so that no articles A reach the terminal end of the infeed conveyor 6.

Each robot is controlled by a control unit (not shown) so that it is capable of locating an article A, whilst that article A is moving on the infeed conveyor 6, and once that article A has been located, of engaging that article A and transferring it to a detected "free space" on the article conveyor 2. The means of engaging the articles may be that of controllable suction heads, mechanical grippers or any other form of mechanism known in the field of robotic manipulators. Articles A, once so-engaged, are lifted upwardly off the surface of the infeed conveyor 6, so as to avoid interference with other articles A still disposed on that infeed conveyor 6. Once transferred into position above the article conveyor 2, the article A is deposited thereupon and the engagement is released.

This process can be implemented, using sufficiently accurate sensor and/or control logic, so that the articles A are all removed from the infeed conveyor 6, and disposed on the article conveyor 2, at a speed that provides the necessary throughput rate for the apparatus 10.

The throughput of the article conveyor 2 (that is to say, the number of articles passing a given point per unit of time) needs to at least match that of the infeed conveyor 6 if it is to be able to carry away all the articles transferred therefrom. If the arrangement of the articles A on the infeed conveyor 6 is such that, at identical speeds, the article conveyor 2 has a lower maximum throughput than the infeed conveyor, it is necessary to operate the two conveyors at different speeds so that the throughput rate of the article conveyor 2 is at least equal to that of the infeed conveyor 6.

Thus, in the illustrated embodiments, the article conveyor 2 is operated at a faster speed than the infeed conveyor 6.

This speed difference, however, sometimes leads to gaps 12 being introduced into the stream of articles A on the article conveyor 2. These gaps 12 will arise whenever the last robotic manipulator 8 in the sequence of robotic manipulators has insufficient articles A within its working reach on the infeed conveyor 6 to fill the space on the article conveyor 2. One aspect of the present invention provides a means by which those gaps 12 may be overcome, without them disrupting the continuous output of the packaging line.

Disposed substantially beneath the article conveyor 2 is a carton conveyor 4. Disposed upon this carton conveyor 4 is a stream of cartons C (which assume the form of flat blanks prior to application to the articles), that are placed, with a regular pitch, on the carton conveyor 4 by a rotary picker 16, from a magazine 14 (as best shown in Figures 5 to 7). As the rotary picker 16 rotates about a pivot point 24, in a direction Dl, numerous arms 17 of the rotary picker 16 move in a reciprocal manner along a radial path about that pivot point 24. A controller (not shown) synchronises this radial movement of the arms 17 with the rotation of the picker 16 as a whole, so that suction cups 19 mounted along points on the surface of each arm 17, radially distal from the pivot point 24, are brought into contact with successive endmost cartons C in the magazine 14. Once such contact is made, the vacuum cups 19 of the arm 17 in question are operated to form a vacuum seal with the carton C, thereby engaging the arm 17 with it. Either rotation of the picker 16, or radial movement of the arm toward the pivot point 24, or both, pulls the carton C free of the magazine 14. Rotation of the picker 16 in the direction of Dl then positions that carton C over portion of the surface of the carton conveyor 4. If necessary, radial movement of the arm 17 away from the pivot point can be utilised to bring the carton C closer to the surface of the carton conveyor belt 4, before the vacuum cups 19 are operated to release the vacuum seal with the carton C and hence deposit that carton C upon the carton conveyor 4 so that it can be conveyed away from the magazine in a direction shown in Figure 7 as D2. Preferably, each arm is pivotally mounted adjacent a peripheral edge of the rotary picker 26.

In the preferred embodiment, the carton conveyor 4 comprises spaced parallel belts 20a, 20b, driven synchronously with one another by either a single drive means or by dual synchronised drive means. On each belt is mounted a plurality of lugs 22 that contact a trailing edge of the cartons C that are disposed on the belts 20a, 20b, and thereby convey those cartons C. The lugs 22 on each of the parallel belts 20a, 20b are aligned with each other, so that each carton C is in contact with a lug 22 from each belt 20a, 20b.

The cartons C, disposed upon carton conveyor 4, are thereby formed into a stream of cartons C having a constant pitch between successive cartons C, by the placement of the lugs 22. These cartons C are conveyed in the same direction as the articles A on the article conveyor 2.

A rotary arm 26 (shown in Figures 8 and 9) is positioned over the path of the cartons C as they are conveyed by the carton conveyor 4. The rotation of this arm 26, in the direction D3 indicated in Figure 9, is synchronised with the movement of the carton conveyor 4 in the direction D2 such that as each successive carton C passes beneath the rotary arm 26, the rotary arm 26 can deposit a promotional item P, fed from a hopper, on the carton C.

In the present embodiment, the rotary arm 26 has one or more suction heads and is controlled such that the suction heads may be controlled independently, thus allowing one promotional item to be disengaged from one suction head whilst another suction head is engaging with a successive promotional item fed to the rotary arm 26. In the preferred embodiment, the promotional item P is a promotional magnet (such as a fridge magnet), though any kind of promotional item suitable for attachment to the surface of a carton C may be used.

Figures 10 and 11 illustrate the cartons C disposed upon the carton conveyor 4 once the promotional items P have been attached thereto. As is best viewed in Figure 11, the two belts 20a, 20b of the carton conveyor 4 may be disposed either side of the article conveyor 2, albeit vertically offset below.

A stack conveyor 28 (best shown in Figures 12 to 18) is positioned at a down stream of the direction of travel of the stacks S of articles A disposed on the article conveyor 2. The stacks S are conveyed into the stack conveyor 28 by the article conveyor 2, and the stack conveyor 28 then acts to convey those stacks S onward and off a terminal end of the article conveyor 2.

The stack conveyor 28 preferably comprises two vertically mounted belt arrangements, each of which comprises a number of individual belts 30 that span between vertical rotational shafts 32 at either end. In the illustrated embodiment three such belts 30 are provided for each such arrangement 28, each belt 30 being vertically offset from the others.

Each belt 30 comprises a plurality of lugs 36 mounted along the length thereof, which lugs 36 are brought into contact with a trailing edge or surface of a given stack S in the stack conveyor 28, such that conveyance of that stack S may be passed from the article conveyor 2 to the stack conveyor 28, by bringing the belt lugs 36 into abutment with a trailing end of each stack S. A second set of belts 34 (as best shown in figures 13 to 18), mechanically linked to the first set, is optionally provided over some portion of the length of the stack conveyor 26. Each of these secondary belts 34 has a plurality of lugs 38 that give additional support to the articles A forming each of the stacks S as they are carried through the stack conveyor 26, and guard against misalignment between the two tiers of articles A.

As the stack conveyor 28 conveys successive stacks S, the carton conveyor 4 rises at an incline to bring the cartons C disposed thereupon directly beneath the stacks S. At this point it may be that the stacks S and the cartons C are not properly aligned with one another, or that a carton C is substantially aligned beneath a gap 12 in the stream of stacks S.

As the stacks S approach an alignment point 48 along the stack conveyor 28, a control sensor detects whether the closest upstream stack S is correctly aligned over a carton C and, if necessary, a controller (not shown) controls the drive means of the carton conveyor 4 to reduce the speed of the carton conveyor in the direction D2 to zero, thereby entirely stopping all of the cartons C disposed thereupon. Once the stack S in question has moved forward sufficiently so as to become correctly aligned over a carton C, the speed of the carton conveyor is returned to its original value and the carton C below the aligned stack S, moves off upon a package conveyor 40 that is disposed at a terminal end of the carton conveyor 4 and article conveyor 2.

The package conveyor 40 (best shown in Figures 18 and 19) is preferably some form of belt conveyor that supports a base panel of the carton C, upon which base panel is disposed the stack S. The package conveyor 40 may be a number of parallel belts, as is the case in the illustrated embodiment, or it may alternatively be a single wide belt, such as the illustrated infeed conveyor 6. The commencing end of the package conveyor 40 sits between the terminal ends of the belts 20a, 20b forming the carton conveyor 4, such that before the cartons C move off the end of the carton conveyor 4, they are already disposed upon the package conveyor 40. During such a period as the speed of the carton conveyor 4 has been reduced to zero, the suction cups 19 mounted on the arms 17 of the rotary picker 16, are simultaneously controlled not to deposit any further cartons C on the carton conveyor 4, so as to avoid a build up of cartons C being deposited whilst the carton conveyor 4 is stationary. By controlling the suction cups 19 in this manner rather that entirely shutting down the rotary picker 16, the time taken to recommence picking and placing of the cartons C is reduced. Thus a gap in the stream of stacks S is overcome with a minimum of impact upon the continuous throughput of the apparatus 10, and the carton stream can recommence movement once the correct alignment is achieved within a minimum of time, thus maximising the mean throughput of the apparatus 10 as a whole.

Figures 13 to 17 sequentially exemplify the operation of the apparatus 10 where a gap 12 in the stream of stacks S is detected at the alignment point 48. The stream of stacks S passed through the stack conveyor 26 at a constant rate, as does the stream of cartons C upon the carton conveyor 4 below. However, in Figure 14, it is shown that a gap 12 exists in the stream, which gap 12 reaches the alignment point 48 in Figure 15. The speed V2 of the stream of cartons C on carton conveyor 4 is immediately reduced to zero, as the closest upstream carton C (best shown in Figure 15) reaches the alignment point 48. The speed of the stack conveyor 28 remains unaltered, and the speed V2 remains at zero until the closest upstream stack S' also reaches the alignment point 48.

Figure 16 shows the aforesaid closest stack S' reaching the alignment point 48, at which moment the speed to V2 is returned to its original value, and the carton C and the stack S' are conveyed together, in vertical alignment, through to a terminal end of the stack conveyor 28 (as shown in Figure 17).

In order to free the cartons C from the carton conveyor 4, such that they may then be conveyed by the package conveyor 40, the belts 20a, 20b of the carton conveyor 4 are inclined downwards, away from the stack S, whilst the carton C upon which the stack is situated is supported by an upstream end of the package conveyor 40. As the carton C moves further along the package conveyor 40, it moves away from the surface of the belts 20a, 20b of the carton conveyor 4, such that the lugs 22 of the carton conveyor 4 no longer contact the trailing edge of the carton C, and thereby freeing the carton C from the carton conveyor 4 (as best shown in Figures 18 and 19).

Until such a point as the carton C in question has been freed from the carton conveyor 4, the stack conveyor 28 continues to convey the stack S disposed upon that carton C, so as to maintain the alignment between the two.

Figure 19 shows an illustrative view of the terminal end of the carton conveyor 4 and the commencing end of the package conveyor 40, and best illustrates the relative positioning of that commencement end relative to the downward incline of the carton conveyor 4 at that point. The article conveyor 2 is not illustrated in Figure 19.

Figures 20 to 22 illustrate the stacks S, having exited the stack conveyor 28 (not shown in Figure 20), and disposed upon cartons C on the package conveyor 40, being conveyed to an outfeed end of the apparatus 10. As the cartons C are conveyed, the side walls thereof pass over an upper surface of a fold guide 42, the incline of which serves to increasingly fold those side wall panels of the carton C upwardly relative to a base panels thereof upon which the stack S is disposed. This is mirrored either side of the carton C such that opposed side walls are formed either side of the stack S.

A rotary folder 46 is position in the direction of travel of one or both side wall panels of the cartons C. This rotary folder 46 rotates to come into abutment with a top panel of the carton C, hinged to an end of the side wall. As the rotary folder 46 continues to rotate, the top panel is folded over the top of the stack S to partially complete the package. The rotary folder 46 may take any number of different forms to fulfil this function, but the illustrated example comprises a rotary head, mounted on a pivot and driven by a belt 44 that links it to a drive means (not shown).

Further down the stream of partially completed packages, a gluing station is provided (not shown) overhead the stacks S, which gluing station applies glue, or alternatively some form of mechanical fastener or tape to the upper free edges of the carton C, thereby securing the carton C in a closed condition around the stack S. This completes the packages, which are then conveyed, by the package conveyor 40, to an outfeed of the apparatus 10.

The above description of a preferred embodiment of the invention is intended to exemplify the underlying principle of the invention. One skilled in the art would be aware that there are many options for achieving the sub-functions details above. For example, there are many ways of conveying articles in a stream - a belt conveyor such as the carton conveyor 4 shown in the Figures being only one such option.

Whilst the Figures specifically shown an embodiment wherein the alignment is to be achieved between a carton and an article, or stack of articles, the invention is not limited to being applied in such a way. It is envisaged that any kind of article may be disposed on either of the conveyors, such that they can be aligned with one another. In particular, the nature of the carton illustrated in the Figures is not limiting, and it is envisaged that there are many different for of carton that one would wish to disposes articles upon, whether the cartons are, as is the case in the Figures, initially planar, or are alternatively partially or fully erected before the alignment takes place.

The use of directional references, such as "above, "below", "upwardly" and the like, are included for clarity only and are not limiting to the scope of the invention. It is envisaged that the exact geometry and relative positioning of the component of the apparatus may be substantially altered without departing from the scope of the invention as defined by the attached claims.

It is contemplated that the apparatus 10 described above may be modified to accommodate different desired throughput rates and stack configurations. As indicated above, the infeed conveyor 6 may have any number of article lanes thereon, and it is contemplated that the number of robotic manipulators 8 would be altered in order to transfer articles A from the infeed conveyor 6 at the desired throughput. Also described above is the possible variation of the number of tiers of articles A in each stack S; this will impact upon the required speed of the article conveyor 2, carton conveyor 4 and stack conveyor 28. Additional tiers of articles A in each stack S are preferably transferred by a variant of the illustrated stack conveyor 28, having additional belts 30, 34 for each additional tier.

Various carton formats may be used in the apparatus 10, and it is contemplated that additional folding procedures may be employed to form a completed package around each stack S.