FIELD OF THE INVENTION

This invention relates in general to packaging machines and to methods of packaging articles into containers. More particularly, this invention relates to continuous motion packaging machines which form randomly ordered articles into groups of a predetermined

number of articles and article configurations using a flight-type selector wedge which also directs the groups of articles into a container, such a preformed sleeve-type carton or package

constructed of paperboard.

BACKGROUND OF THE INVENTION

Continuous motion packaging machines are known in the art. Continuous motion packaging machines, to include end loading machines, typically group a selected number of

articles, for example beverage containers, into a desired group size or configuration. Illustrative

examples of these configurations includes six packs of six beverage containers, half case lots of twelve beverage containers, and case lots of twenty-four beverage containers. Various product or article group sizes or configurations may be packaged depending on the packaging machine

being used, and the desired configuration of the articles.

In typical continuous motion packaging machine operations, the articles are supplied in a randomly ordered series to a selector device. The selector device then groups the articles into a predetermined configuration or pattern. The selector device generally is used in concert with

a lane divider/guide assembly for also moving the articles, either singularly, or as group, toward

and into the open end, or ends of a preformed sleeve-type carton or a package constructed of

paperboard.

Early continuous motion packaging machines preformed the article selection, grouping, and packaging functions in discrete steps which required interruption of the packaging process flow. This problem of process flow interruption was addressed in later packaging machines

which utilized guide rails to divide the articles into distinct flow paths or lanes, and selector

wedges or flights cooperating with the guide rails to move or rake a predetermined number of articles into a article group, and then transfer the group of articles into a container.

An early example of a continuous motion packaging machine which utilized selector

wedges or flights for forming groups of articles to package the articles without interruption of

the process flow is disclosed in the patent to Langen et al . U.S. Patent No. 3,778,959, issued

December 18, 1973. Langen et al. include a conveyor belt having a plurality of transversely extending spaced apart fence means, i.e., flights or selector wedges, mounted on a conveyor. The fences/ selector wedges of Langen et al. worked in concert with the movement of the

articles through a series of spaced and parallel guide rails for forming article groups of a predetermined size, and to move the articles in cooperation with the guide rails into the opened

end of sleeve-type container.

Although the invention of Langen et al. represented an improvement in continuous motion packaging machines which addressed the interruption of process flow formerly associated with packaging articles in discrete steps, the device of Langen et al. does not appear

to be readily adapted for forming groups of articles into a range or variety of predetermined

sizes in quick and economical fashion. Rather, it appears that the device of Langen et al. must be stopped, and the guide fences and selector wedges physically removed and replaced in order to accommodate different sized article groups, and/or articles of different sizes and

configurations.

It thus appears that Langen et al. is limited to processing articles of a specific diameter and a specific article group size. Considering that today a wide range of articles of varying dimension are packaged, this constitutes a serious limitation in the usefulness of the machine in

light of the current requirements of packaging operations handling large numbers of articles at high production rates.

A similar approach to forming predetermined group sizes of articles, and the passing of

articles into the open ends of cartons is disclosed in U.S. Patent No. 4,237, 673 to Calvert et aL, issued December 9, 1980, and in U.S. Patent No. 4,982,551 to Nigrelli, Sr.. issued January 8, 1991. ln both Calvert et al. and Nigrelli, Sr.. a conveyor belt having a spaced series of flights or selector wedges is passed through a pair of spaced guide lane assemblies having articles

formed thereby into discrete lanes or rows. The wedges of these inventions are moved into the

articles as aligned by the guide rails, and guide the articles as they are formed into groups into the spaced open ends of a sleeve-type carton.

Neither Calvert et al. nor Nigrelli, Sr.. however, apparently teach a device in which the

selector flight assembly of a continuous motion packaging machine may be readily changed to

handle articles of a different size, or differing packaging configurations, without the need to shut the machine down and manually change out the flights or selector wedges along the length of the conveyor belt to which they are attached. The inventions of Calvert et al. and Nigrelli, Sr..

do not therefore appear to respond to the need for flexibility in handling product sizes of varying configurations, as well as allowing for the packaging of a variety of predetermined article group

sizes on one packaging machine. Additional examples of continuous motion packaging

machines using flights or selectors wedges for forming articles into a predetermined group size,

and moving the articles along a path of travel on a packaging machine are disclosed in U.S.

Patent No. 5,036,644 to Lashyro et al.: U.S. Patent No. 4,936,077 to Langen et al : and U.S.

Patent No. 4,566,248 to Cooley.

While the continuous motion packaging machines described above have permitted

relatively high speed and uninterrupted packaging of articles, it appears that none of these machines is flexible in its ability to selectively package articles of differing dimensions, for example article diameters, as well as for packaging a variety of article groupings or configurations, to include differences in the pitch, or combination of pitches, of the articles being moved along the packaging machine during packaging operations This limitation has become

quite acute, and is even more of a disadvantage today since articles, for example bottled or canned beverages, are now marketed in an ever increasing range of sizes and different product configurations. For example, it is not uncommon for a beverage producer to package beverage containers in four packs, six packs, eight packs, twelve packs, and cases, and not only for one

size article, but for a variety of article sizes to include both beverage cans and bottles.

Accordingly, the known continuous motion packaging machines have required that either additional packaging machines be utilized for handling each distinct article size or product

configuration, or that the packaging machine be stopped, dismantled, and rebuilt, if possible, in

order to package articles of differing sizes and group configurations.

What is needed, therefore, but seemingly unavailable in the art, is a continuous motion

packaging machine which can readily be adapted to handle articles of differing sizes and product group configurations, to include varying article pitches, or combinations of pitches, and can do

so quickly and efficiently with minimal down time in packaging operations. Moreover, what is needed but unavailable in the art is a continuous motion packaging machine which will

automatically changeover from handling articles of one size and product grouping, to articles

of differing sizes and/or differing product groupings if so desired, to include the automatic

changeover of the machine's selector wedges, as well as having the ability to automatically space the selector wedges in a range of separate spaced series, dependent on packaging requirements, in order to satisfy the demand for flexibility and high production rates present in today's

packaging plants.

SUMMARY OF THE INVENTION

The present invention provides an improved automatic selector wedge changing assembly for use on a continuous motion packaging machine which overcomes some of the design deficiencies of other continuous motion packaging machines known in the art. The automatic

selector wedge changing assembly of this invention provides a highly flexible method and apparatus of automatically changing the selector wedges positioned in spaced series along the length of the selector belt, formed as a part of continuous motion packaging machine, which can be matched to the production needs of the packaging machine, and/or packaging operations

with which the method and apparatus of this invention are used Moreover, the concept of this

invention, as embodied in the disclosed structure and method of operation, can readily be adapted to the automated change-out of repetitive change machine parts, for example fill blocks or guide assemblies, used in automated continuous packaging machine operations

This invention, therefore, provides a much greater degree of flexibility than heretofore known in the art by permitting a packaging machine operator to package articles of a variety of

sizes, and differing article group configurations on a single continuous motion packaging machine constructed to automatically change the selector wedges positioned thereon, as well

as the spaced relationship of the selector wedges while providing a simple and efficient method and apparatus that is readily adapted for use in both high speed and low speed packaging operations, is well suited for use with virtually any type of article and/or article grouping or

configuration, and does so quickly and simply without the need for sophisticated machinery or

other devices.

This invention attains this high degree of flexibility while maintaining simplicity in design

and operation by teaching a method of automatically changing the selector wedges positioned

in spaced series along the length of a selector belt formed as a part of continuous motion

packaging machine. The novel method of this invention includes the steps of sequentially

removing the selector wedges of a first series of selector wedges attached to the selector belt, placing each selector wedge from the first series of selector wedges on a first wedge storage pallet positioned with respect to the selector belt, removing the selector wedges of a second

series of selector wedges positioned on second wedge storage pallet with respect to the selector

belt, and sequentially attaching each selector wedge of the second series of selector wedges to

the selector belt. This is done automatically, without any manual or physical handling of the first or second series of selector wedges being removed from, and attached to the selector belt of the machine.

The method also includes the steps of positioning the selector belt at a home position with respect to the first wedge storage pallet prior to removing the selector wedges of the first

series of selector wedges from the selector belt, and of indexing the selector belt from the home

position with respect to the first wedge storage pallet in response to removing a predetermined number of selector wedges from the selector belt. Similarly, the method of this invention also includes the steps of positioning the selector belt at a home position with respect to the second wedge storage pallet prior to removing the wedges of the second series of selector wedges

therefrom, and indexing the selector belt from the home position with respect to the second

wedge storage pallet in response to attaching a predetermined number of selector wedges to the selector belt.

Additionally, the method further comprises the steps of changing the position of a wedge

changing head, provided as a part of an automatic selector wedge changing assembly, with

respect to the first wedge storage pallet in response to placing a predetermined number of selector wedges thereon, as well as changing the position of the wedge changing head with

respect to the second wedge storage pallet in response to removing a predetermined number of selector wedges therefrom.

The sequential removal, i.e., the removal in series, of the selector wedges of the first

series of selector wedges attached to the selector belt, and the sequential attachment of the selector wedges of the second series of selector wedges to the selector belt is done so that each selector wedge of the first series of selector wedge is removed from the selector belt before the

first selector wedge of the second series of selector wedges is attached thereto. This allows not

only for changing the individual selector wedges themselves, but also allows for varying the

spacing of the selector wedges in series along the length of the selector belt for handling articles

of different product group configurations which has not heretofore been available in the art on an automatic, machine operated basis.

The novel automatic selector wedge changing assembly of this invention is well suited for use on continuous motion packaging machine having an infeed end and a spaced discharge

end, an infeed conveyor supplied with a randomly ordered series of articles, and a selector belt

adjacent to and parallel the infeed conveyor. The selector belt has a spaced series of removable selector wedges for forming the articles into groups of a predetermined size and for moving the groups of articles into an open ended sleeve-type carton carried on a carton transport conveyor

parallel to and adjacent the selector belt on the packaging machine. The automatic selector

wedge changing assembly of this invention includes a wedge changer positioned on the

framework with respect to the selector belt, a first wedge storage pallet positioned on the framework with respect to the wedge changer for receiving and storing a first series of selector

wedges removed from the selector belt thereon, and a second wedge storage pallet positioned

on the framework with respect to the wedge changer and storing a second series of selector wedges thereon. The automatic selector wedge changing assembly of this invention may also

include a third wedge storage pallet positioned on the framework with respect to the wedge changer and storing a third series of selector wedges thereon.

The wedge changer is constructed and arranged to sequentially engage and remove the

selector wedges of the first series of selector wedges from the selector belt, and place each selector wedge, in series, on the first wedge storage pallet. Thereafter, the first wedge storage

pallet is moved into a retracted position and the second wedge storage pallet is moved in

position with respect to the wedge changer. The wedge changer then sequentially removes the selector wedges of the second series of selector wedges from the second wedge storage pallet

and attaches each selector wedge, in series, to the selector belt in an identical spaced series, if

so desired, or a differing spaced series with respect to the spacing of the first series of selector wedges previously attached to the selector belt, if so desired.

The wedge changer of this apparatus includes an elongate generally horizontal guide rail extending in the direction of the path of travel in substantial alignment with the selector belt, a

carriage assembly constructed and arranged for reciprocal movement along the horizontal guide rail, the carriage assembly including an integral and generally vertical guide rail supporting a wedge changing head for reciprocal movement thereon, the wedge changing head being

constructed and arranged to engage the selector wedges on the selector belt, and/or the wedge

storage pallets, for removing and attaching selector wedges to the selector belt.

The selector wedges of this invention have a generally elongate body and a pair of spaced mounting pins extending therefrom, the mounting pins being sized and shaped to be receiving within a pair of correspondingly spaced slotted openings defined in spaced selector plates, the

selector plates forming the selector belt. The mounting pins of the selector wedges are designed to fit through an enlarged portion of the slotted opening and then moved transversely within an

elongated locking slot with respect to the length of the selector belt for locking the shank of the

mounting pins, and thus the selector wedge, in position on the selector plate. The slotted openings formed in the selector belt occur in a first uniformly ordered series, and a second

recurrent series of slotted openings in which the slotted openings are progressively wider from

opening to opening within three adjacent selector belts, the recurrent series of slotted openings occurring in a regularly spaced series along the length of the selector belt.

The cooperation of the structural elements of this invention, as well as the method

practiced by this invention results in an automatic selector wedge changing assembly which

allows a single continuous motion packaging machine to be used with a variety of article sizes, as well as a variety of article configurations. Moreover, the method and apparatus of this invention provide for the automatic removal and placement of selector wedges in varying spaced

series along the length of the selector belt without the need for manual or physical intervention,

and do so quickly and efficiently. Accordingly, the objects of the present invention include the ability to quickly and automatically change the selector wedges of a continuous motion packaging machine in order to process articles of differing diameters or heights, and to permit various article configurations to be packaged on the machine with minimal production

downtime. The present invention accomplishes the above-stated objects while providing for flexible, efficient, and continuous high speed article packaging.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a perspective view of a packaging machine having a preferred embodiment of

the automatic selector wedge changing assembly positioned thereon.

Fig. 2 is a perspective view of a preferred embodiment of a selector wedge of this

invention, and of a spaced series of selector plates forming a part of the selector belt of a

continuous motion packaging machine.

Fig. 3 is a side elevational view along line 3-3 of Fig. 1.

Fig. 4 is an end elevational view along line 4-4 of Fig. 3. Fig. 5 is a top plan view of the automatic selector wedge changing assembly illustrated

in Fig. 3.

Figs. 6A and 6B are sequential and partial end elevational views illustrating the method of removing and attaching selector wedges of this invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, in which like reference characters indicate like parts

throughout the several views, numeral 5 of Fig. 1 illustrates a preferred embodiment of the automatic selector wedge changing assembly of this invention positioned on a continuous

motion packaging machine 7.

Continuous motion packaging machine 7 is provided with a support frame 8 of a type

known as a walk-in frame in which ready access of the components of the packaging machine

can be gained. Frame 8 has an infeed end 9, a spaced discharge end 11, and a path of travel "P"

extending from infeed end 9 toward discharge end 1 1. An endless infeed conveyor 12 is positioned at infeed end 9 of the packaging machine, and is supplied with a randomly ordered series of articles (not illustrated) which are moved toward a selector belt 13 positioned on frame

8, selector belt 13 being parallel to and adjacent at least a portion of the length of infeed conveyor 12

In fashion described in greater detail in U S application serial no 08/1 18,1 11, filed on

September 2, 1993, and entitled Packaging Machine and Method of Packaging Articles, which is incorporated by reference as if set forth fully herein, a guide rail assembly, (not illustrated)

comprised of a spaced series of generally parallel guide rails (not illustrated) is supported on

frame 8 above and with respect to infeed conveyor 12 and selector belt 13 for forming the

randomly ordered supply of articles into lanes or rows of articles Selector belt 13 has a spaced series of selector wedges (Fig 3) for forming the articles into groups of articles of a predetermined group size, and moving the articles along the guide rails toward the open end

(not illustrated) of a preformed sleeve-type carton (not illustrated) or paperboard carrier (not

illustrated) being moved on a carton transport conveyor 16 parallel to and adjacent at least a portion of the length of selector belt 13

Positioned at the infeed end of the packaging machine is a carton magazine assembly 17 provided with a supply of unopened carton blanks (not illustrated), which are passed in series

to a carton opening station 19 having a carton feed opening wheel assembly for opening the carton blanks into preformed cartons, and for passing the preformed cartons onto the carton transport conveyor Once the cartons (not illustrated) are filled with the predetermined groups

of articles (not illustrated), the cartons are moved along the carton transport conveyor toward,

and adjacent, a dual pocket loader wheel assembly 20 which seats the articles within the cartons

while simultaneously folding the flaps at the open end of the carton closed The carton is then

passed to a downstream glue application station (not illustrated) for applying glue to the flaps on the open end of the container, the container then having its flaps sealed in closed position by

being passed through compression and discharge section 21 supported at the discharge end 1 1

of packaging machine 7. As illustrated in Fig. 1, therefore, packaging machine 7 may include

the QUICKFLEX family of packaging machines manufactured by Riverwood International

Corporation of Atlanta, Georgia.

A preferred embodiment of selector wedge 23 used on selector belt 13 is disclosed in Fig. 2. Selector wedge 23 has an elongate wedge body 24 preferably made of an injection molded and low friction synthetic material such as nylon or plastic, although almost engineering polymer

will suffice so long as selector wedge 23 is provided as a durable and rigid selector wedge for use in handling a variety of articles on packaging machine 7. Selector wedge 23 has a leading

edge 26 which moves in the direction of the path of travel on selector belt 13 as it moves from

infeed end 9 toward discharge end 11 of the packaging machine. Selector wedge 23 includes a selector end 27 which first engages the articles positioned on infeed conveyor 12 and selector belt 13 for forming the articles into predetermined groups of articles as described in co-pending U.S. Application Serial No. 08/118, 1 1 1, filed on September 2, 1993, which has been earlier

incorporated by reference herein. Opposite selector end 27 of wedge body 24 is a tapered end 28 which is constructed and arranged to permit either one of the dual pocket loader wheels (not illustrated) of dual pocket loader wheel assembly 20 to be positioned thereabove and extending over selector wedge 23 so that one of the pocket loader wheels is positioned adjacent carton

transport conveyer 19 for seating the articles within the open ends (not illustrated) of the cartons

(not illustrated) being carried on carton transport conveyor 1 in the direction of the path of

travel.

Selector wedge 23 is provided with a pair of spaced mounting pins 30 which have a shank

31 extending from inside of wedge body 24 and away therefrom, the end of shank 31 extending

away from wedge body 24 having a tapered head 32 formed as a part thereof. Wedge body 24

is also provided with a pair of spaced openings 34 for being received on one of the wedge

selector pins 66 of wedge changing head 57 (Figs. 4-5), and a pair of spaced wedge rod openings 35 for being received on one of the pairs of spaced wedge rods 76 (Figs. 2-4) used for storing the various embodiments of selector wedge 23 on automatic selector wedge changing

assembly 5. Openings 34 and 35 extend through wedge body 24, although openings 34 need not necessarily extend all the way through the wedge body, but need only extend far enough to receive each of a spaced pair of wedge selector pins 66 (Fig. 5) of wedge changing head 57 therein, as described in greater detail below.

Still referring to Fig. 2, a portion of selector belt 13 is illustrated. Selector belt 13 is

comprised of a plurality of elongated and adjacent selector plates 36, each selector plate 36 being operably connected to three parallel and endless chain conveyors 15 (Fig. 4) extending along the length of selector belt 13, and moving selector belt 13 in the direction of the path of

travel. Certain spaced selector plates 36 are provided with pairs of slotted openings 37 defined therein. Slotted openings 37 are provided for receiving the mounting pins 30 of the various

embodiments of selector wedge 23 therein for removably fastening or attaching the selector wedges to the selector belt in spaced series along the length thereof. Therefore, each of slotted

openings 37 is provided with an enlarged portion 38 sized and shaped to receive tapered head 32 of mounting pins 30 therein, and an elongated locking slot 40 extending away therefrom, the locking slot being sized and shaped to receive shank 31 of mounting pins 30 therein and to lock

shanks 31 within slots 40 for holding wedges 23 in position on selector belt 13. Selector belt 13 includes, therefore, a first pair of slotted openings 41 defined in spaced series along the length of the selector belt. First pairs of slotted openings 41 form a first series

42 (Figs. 1 & 2) of pairs of slotted openings 41 extending along the length of selector belt 13.

It is anticipated that the first pairs of slotted openings 41 which comprise first series 42 of

slotted openings will be spaced on 7 1/2 inch centers from each adjacent pair of slotted openings

41 along the length of selector belt 13. This 7 1/2 inch spacing corresponds to the spacing of

the "split" pockets of carton transport conveyor 19, as disclosed in co-pending U.S. Application No. 08/118,111, and also corresponds to a "two-up" product configuration in which multiples of two articles are packaged within a single package, for example a four pack or six pack of

beverage containers.

Selector belt 13 is also provided with a second pair of slotted openings 43, a third pair

of slotted openings 44, and a fourth pair of slotted openings 45, the width between each pair

of slotted openings progressively increasing from second pair of slotted openings 43 to fourth

pair of slotted openings 45. In addition, the second, third, and fourth pair of slotted openings form a second series of recurrent slotted openings 48 (Figs. 1 & 2) along the length of selector belt 13. However, each of the pairs of slotted openings 43, 44, and 45 which comprise second

series of slotted openings 48 will be spaced on 15 inch centers from each corresponding and

spaced pair of slotted openings 43, 44 and 45 of the series along the length of selector belt 13. This spacing corresponds to a full pocket size for packaging "three-up" and "four-up" packages

of articles on packaging machine 7, as well as various configurations thereof.

Although a spacing, or "pitch," between each series of slotted openings (or selector

wedges, in this instance) of either 7 1/2 inches or 15 inches is described herein, it is anticipated that the automated selector wedge changing assembly of this invention may also be used with any number of desired ranges, ratios, or combinations of pitches, to include, for example, but

not being limited to, pitch combinations of 6 inches and 12 inches, 7 1/2 inches and 15 inches,

9 inches and 18 inches, and so on, as well as varying the ratio of the pitched series of slotted

openings with respect to one another, as desired. It will be equally apparent to those of ordinary

skill in the art, moreover, that more than two different pitch combinations may be present along

the length of the selector belt and used with the structure and method of the embodiments of

this invention, and that this device may be used for the automated changing of packaging machine components other than the selector wedges described hereinabove.

Referring to Fig. 2, each pair of slotted openings 41, 43, 44 and 45 are identically constructed to have an enlarged portion 38 for receiving tapered head 32 of mounting pin 30 therein, and an elongated locking slot 40 for locking shank 31 of mounting pins therein to secure

selector wedge 23 to selector belt 13. Although one embodiment of selector wedge 23 is shown

in Fig. 2, it is anticipated that continuous motion packaging machine 7 will be provided with several embodiments of selector wedges 23, as best illustrated in Fig 5, the embodiments of selector wedge 23 being constructed and arranged for forming predetermined group sizes of a

two-up, three-up, and four-up configuration, respectively This is described in greater detail below, as well as co-pending U.S Application Serial No 08/1 18, 1 1 1

Referring now to Figs 3-5, automatic selector wedge changing assembly 5 is illustrated in greater detail, and is shown positioned on frame 8 of packaging machine 7 (Fig. 1)

Automatic selector wedge changing assembly 5 includes a carriage assembly 51 supported on an elongated horizontal guide rail 52 by a linear bearing assembly 53 Horizontal guide rail 52

is substantially aligned with selector belt 13, as illustrated generally in Fig 1, and extends in the direction of the path of travel. Carriage assembly 51 is reciprocably driven on horizontal guide

rail 52 by servomotor 55, which powers a threaded rod (not illustrated) received within a ball

screw (not illustrated) formed as a part of carriage assembly 51 Servomotor 55 is mounted on frame 8, and moves carriage assembly 51 on horizontal guide rail 52 with respect to frame 8 as

well as with respect to selector belt 13.

Carriage assembly 51 includes an integral vertical guide rail 56 which supports wedge changing head 57 for reciprocal movement thereon Wedge changing head 57 is raised and

lowered on vertical guide rail 56 by servomotor 59 positioned on carriage assembly 51.

Servomotor 59 has a drive pulley 60 fastened thereto, with a corresponding drive pulley 61 driven by belt 63. Drive pulley 61 is fastened to an elongated threaded rod (not illustrated) housed within vertical guide rail 56, a ball screw (not illustrated) being formed as a part of wedge changing head 57. Servomotor 59 rotates drive pulley 60, and drive pulley 61 via drive

belt 63, which rotates the threaded rod to move wedge changing head 57 upward or downward

with respect to carriage assembly 51. Wedge changing head 57 is supported on vertical guide rail 56 of an elongated linear bearing assembly 64 (Figs. 6 A 6B).

Wedge changing head 57 is illustrated in Figs. 3-5, and includes a spaced pair of wedge

selector pins 66 which extend perpendicularly from the wedge changing head with respect to vertical guide rail 56, and along the length of horizontal guide rail 52. The wedge selector pins

are mounted on a support bracket 67, support bracket 67 being mounted on a linear actuator

68 which moves the support bracket and wedge selector pins transversely with respect to the

length of selector belt 13, and is used to lock selector wedges 23 to selector belt 13, and to unlock selector wedges 23 from selector belt 13 in the manner described in greater detail below. As shown in Fig. 5, wedge changing head 57 includes a vacuum suction cup 70 for

holding selector wedges 23 on wedge selector pins 66 when wedge changing head 57 is engaged with selector wedges 23 for removing and placing the selector wedges from and on selector belt 13. Vacuum suction cup 70 is a venturi vacuum pump which creates a suction pressure when

compressed air is passed through a venturi formed as a part of the vacuum pump. An example

of suction cup 70 is of the type of vacuum pumps manufactured by PIAB, Inc.

Referring now to Figs. 3 and 5, automatic selector wedge changing assembly 5 includes a first wedge storage pallet 71, a second wedge storage pallet 72, and a third wedge storage pallet 73. Each of the wedge storage pallets is supported on frame 8 of packaging machine 7,

and is positioned with respect to carriage assembly 51, and in particular to wedge changing head

57 thereof. Each of wedge storage pallets 71, 72, 73 has a generally quadrilateral bottom plate 75 supporting a series of spaced pairs of wedge rods 76 extending upwardly therefrom, and

being sized and shaped to be passed through wedge rod openings 35 defined in each of selector

wedges 23 for holding, i.e., storing, selector wedges 23 on the wedge storage pallets when not

in use. As shown in Figs. 3-5, when selector wedges 23 are stored on wedge rods 76, they are

positioned upside down so that their mounting pins 30 extend upwardly, each pair of mounting

pins being receiving within a corresponding spaced pair of pin storage openings 50 defined in each wedge body 24 so that selector wedges 23 lie adjacent each other on wedge rods 76. It

is anticipated that approximately 7 selector wedges 23 will be supported on each pair of wedge

rods 76, although this number may vary based upon the specific size and configuration of selector wedges 23, as well as the size of wedge storage pallets 71 through 73 and the control method employed in operating automatic selector wedge changing assembly 5. Here, however, it is anticipated that storage pallets 71-73, wedge rods 76, and selector wedges 23 are so sized

that seven (7) selector wedges will be stacked on each pair of wedge rods 76 mounted on base

plates 75, respectively.

Each of selector wedges 23 is constructed so that its spaced pair of openings 34 will be in substantial alignment with the spaced pair of wedge selector pins 66 formed as a part of

wedge changing head 57. In addition, each selector wedge 23 is so sized and shaped that its

spaced pair of wedge rod openings 35 received on wedge rods 76 will also act to center the

spaced pair of openings 34 with respect to wedge changing head 57 and its wedge selector pins

66 mounted thereon. Although not illustrated herein, the end of each wedge rod 76 extending

upward and away from bottom plate 75 is tapered so that each of selector wedges 23 can be easily received thereon and passed downward toward bottom plate 75 for being stored on each

respective wedge storage pallet.

-19- As shown in Figs. 3 and 5, first and second wedge storage pallets 71 and 72 are

supported for movement on frame 8, and are constructed to be moved reciprocably into carriage assembly's 51 path of travel along horizontal guide rail 52. When extended, wedge storage pallets 71 and 72 are centered with respect to wedge changing head 57 and vertical guide rail

56. Accordingly, bottom plate 75 of first and second wedge storage pallets 71, 72 is supported

on a linear actuator 77, and a linear bearing assembly 79. Linear actuator 77 and linear bearing assembly 79 are spaced from, and are parallel to one another.

As shown in Figs. 4 and 5, linear bearing assembly 79 includes a guide rail 80 mounted on frame 8, and a slide block 81 mounted on bottom plate 75, slide block 81 being sized and shaped to be snugly fitted on guide rail 80 so that it cannot be removed upwardly therefrom, but yet travels freely along the length of the guide rail. Both linear actuator 77 and linear bearing

assembly 79 as shown in Figs. 3-5 are peφendicular to horizontal guide rail 52 so that the

wedge storage pallet is centered with respect to wedge changing head 57 when first and second wedge storage pallets 71, 72 are each respectively moved into carriage assembly's 51 path of travel along horizontal guide rail 52. It is anticipated that wedge storage pallets 71 and 72 will

be moved alternately into carriage assembly's 51 path of travel and will not both be extended

at the same time.

As shown in Fig. 5, a third wedge storage pallet 73 is fixed in position on frame 8, and is aligned with the longitudinal axis "A" passing through carriage assembly 51 and in particular wedge changing head 57. Each of base plates 75 of first through third wedge storage pallets

71-73 has a centrally defined cut-out portion 83 sized and shaped for receiving that portion of carriage assembly 51, and in particular vertical guide rail 56 on which wedge changing head 57

is positioned, when carriage assembly 51 is moved into base plate 75 of each respective wedge

changing pallet when selector wedges are being removed from, or added to, the wedge storage

pallets in the fashion described below.

Each of linear bearing assemblies 53, 64, and 79 is a conventional linear bearing assembly of the type manufactured by THK, Inc. and in particular may be THK's type SR... W (heavy-load type) linear bearing assemblies, each of which has an elongated guide rail, and a slide block having a retained series of ball bearings therein received on the guide rail of the bearing

assembly. Linear actuator 68 of wedge changing head 57, and linear actuators 77 of first and

second wedge storage pallets 71 and 72, respectively, are conventional band cylinders, among others, of the type manufactured by either TOL-O-MATIC or MOSIER, among others, which

offer the advantage of an extended range of movement in a space saving design well suited for

use on machinery of the type disclosed herein. Servomotors 55 and 59 are conventional servomotors, and may include those servomotors manufactured by INDRAMAT or PACIFIC

SCIENTIFIC, among others.

As shown in Figs. 3 and 5, packaging machine 7 is supplied with three distinct series of

selector wedges 23. A first series of selector wedges 91 is shown partially stored on first wedge storage pallet 71 in Fig. 3, the remainder of the first series of selector wedges being spaced

along the length of selector belt 13 as shown. A second series of selector wedges 92 is shown

stored on second wedge storage pallet 72 in Figs. 3 and 5, and a third series of selector wedges 93 is also shown stored on third wedge storage pallet 73 in Figs 3 and 5 As best shown in Fig. 5, each series of selector wedges 23 of 1 st through 3rd series 91 -93 of selector wedges are sized

and shaped differently. The first series of selector wedges 91 are those placed within the first

series of spaced openings 42 spaced along the length of selector belt 13, and are placed on 7 1/2

inch centers for forming product groups of a two-up configuration. The selector wedges of the second series of selector wedges 92 are used for forming article configurations of a four-up

configuration, and the third series of wedges 93 positioned on wedge storage pallet 73 are used for forming a three-up packaging configuration of articles, and are placed on fifteen inch centers within slotted openings 43-45 of the second series 48 of slotted openings in selector belt 13 Selector wedges 23 of the 1st through 3rd series of selector wedges 91-93 may be color

coded for visually identifying the type of selector wedge, and to ensure that the appropriate

selector wedge is positioned on selector belt 13 for the appropriate packaging requirements, i.e., selector wedges 23 of first series of selector wedges 91 are being used for two-up product configurations, rather than selector wedges 23 of third series of selector wedges 93, and so on

Additionally, and although the distance between each pair of spaced wedge rods 76 is shown

as being the same for each of three wedge storage pallets 71-73, it is anticipated that the spacing between each pair of wedge rods 76 could be varied so that only a specific type of selector wedge 23 could be positioned thereon in order to help ensure that the appropriate selector

wedges are stored on the correct wedge storage pallet.

Automatic selector wedge changing assembly 5 includes a pair of proximity switches (not

illustrated) positioned on horizontal guide rail 52 to ensure that carriage assembly 51 does not extend beyond the limits of the horizontal guide rail Similarly, each of wedge storage pallets 71 and 72 includes a pair of proximity switches mounted on frame 8 for detecting the position of the wedge changing storage pallet in either its extended or retracted position, the retracted position of wedge storage pallet 71 being shown in Fig 5, and the retracted position of wedge

storage pallet 72 also being shown in Fig 5

Lastly, wedge changing head 57 includes a photoelectric sensor (not illustrated) mounted on support bracket 67 adjacent the spaced pair of wedge selector pins 66 for detecting the presence of a selector wedge 23 adjacent the wedge changing head to ensure that a selector

wedge is in the appropriate position, either on selector belt 13, or on one of wedge storage

pallets 71-73, to begin the wedge changing sequence for that particular wedge

OPERATION

As described briefly above, automatic selector wedge changing assembly 5 will sequentially remove each selector wedge of the series of selector wedges positioned on selector

belt 13, place each selector wedge in series on the appropriate wedge storage pallet, remove the selector wedges in series, from another one of the wedge storage pallets, and sequentially place each one of the selector wedges of the second series of selector wedges on the selector belt in the appropriate pair of slotted openings defined therein, and spaced along the length of the

selector belt.

Selector belt 13 is shown in its home position in Fig 3, in which spaced selector plates of belt 13 carry a selector wedge 23 thereon, positioned with respect to carriage assembly 51, and in particular wedge changing head 57 thereof In Fig 3 selector belt 13 is also shown

positioned with respect to first wedge storage pallet 71 As selector wedges 23 are removed from selector belt 13, they are stacked, in series, starting at the rearmost pair of wedge rods 76

and extending upward until seven selector wedges have been placed thereon, whereupon

carriage assembly 51 is moved with respect to first wedge storage pallet 71, i.e., it is moved or

indexed backward out of the wedge storage pallet withm cut-out portion 83 defined therein, and the next seven selector wedges are stacked in series on the second pair of wedge rods 76 This process continues until all of the selector wedges of the first series of selector wedges 91 has

been removed from selector belt 13 When the first selector wedge 23 is being removed from selector belt 13, selector belt 13 is first positioned at its home position, as shown in Fig 3, and then indexed backward with respect to the pair of wedge rods 76 in the rearmost position of

first wedge storage pallet 71 with respect to carriage assembly 51, so that as selector wedge 23 is removed from the pair of slotted openings in which mounting pins 30 are received, the selector wedge is moved vertically downward onto wedge rods 76, the wedge rods extending

upward through the spaced pair of wedge rod openings 35 defined in wedge body 24 of each

selector wedge.

The process of removing selector wedges 23 from selector belt 12 involves the first step of positioning wedge changing head 57 with servomotors 55 and 59 in an approach position

adjacent the selector wedge to be removed from the selector belt. The position of wedge changing head 57 with respect to selector belt 12 is programmed into a control processor (not

illustrated) which operates the servomotors to move wedge changing head 57 vertically toward and away, and moves carriage assembly 51 horizontally toward and away from selector wedges

23 on selector belt 13 and wedge rods 76 on wedges plate 75. Once the photoelectric sensor (not illustrated) provided as part of the wedge changing head detects that a selector wedge is

adjacent the wedge changing head, carriage assembly 51 is moved forward so that the spaced

pair of wedge selector pins 66 is received within spaced openings 34 defined in wedge body 24

(Fig. 2). Prior to doing so, however, linear actuator 68 is fired by the control processor to move pins 66 into their lock/release position (Figs. 4, 6 A) for being properly positioned with respect to openings 34 of selector wedge 23 in its locked position on belt 13 (Fig. 6A). Once selector

wedge 23 is received on selector pins 66, vacuum cup 70 is fired to create a vacuum force

against the selector wedge to hold it in position on wedge changing head 57.

Once the selector pins 66 of the wedge changing head have been moved into selector wedge 25 (Fig. 5), a data signal is emitted by the encoder (not illustrated) provided as a part of

servomotor 55 to the control processor, whereupon a control signal is sent to linear actuator

68 to move support brackets 67 and wedge selector pins 66 transversely with respect to the

length of selector belt 13 (Fig. 6A) to its home position (Fig. 6B) for unlocking shanks 31 of

mounting pins 30 from elongated locking slots 40 of slotted openings 37. The selector wedge

23 to be removed from selector belt 13 will be moved within elongated locking slot 40 to enlarged portion 38 by linear actuator 68. Thereafter, a control signal is emitted from the control processor to servomotor 59, whereupon wedge changing head 57 is lowered vertically

downward (Fig. 6B) on linear bearing assemblies 64 so that the spaced pair of wedge rod openings 35 defined in wedge body 24 are received on the appropriate spaced pair of wedge

rods 76 on first wedge storage pallet 71. Due to the use of a digitally encoded servomotor, wedge changing head 57, in communication with the control processor, will constantly know

it vertical position with respect to the bottom plate 75 of the wedge storage pallets, and with respect to the bottom surface of selector belt 13, at all times. Accordingly, wedge changing

head 57 thus moves selector wedge 23 vertically downward onto wedge rods 76 until the

selector wedge is in its appropriate position either on the bottom plate, or stacked on others of

the selector wedges previously removed from the selector belt Thereafter, a signal is sent to suction cup 70 to release selector wedge 23, and to

servomotor 55 whereupon carriage assembly 51 is backed out of the selector wedge now

positioned on the wedge storage pallet. The wedge changing head is then moved vertically

upward back into its approach position with respect to the next sequential selector wedge to be removed from the selector belt. The selector belt is moved in the direction of the arrow shown in Fig. 3 after each selector wedge has been removed so that the next sequential selector wedge

to be removed therefrom is moved into the home position with respect to wedge changing head 57 and first wedge storage pallet 71. Once again the control processor fires linear actuator 68

to its lock/release position prior to placing selector pins 66 within the next sequential selector

wedge.

This process is repeated until all of the selector wedges of first series of selector wedges 91 have been removed from selector belt 13. Thereafter, first wedge storage pallet 71 is moved into its retracted position with respect to carriage assembly 51 (Fig. 5) by retracting linear

actuator 77, the position of the wedge storage pallet being determined by the pair of proximity

switches (not illustrated) positioned on frame 8 with respect to the wedge storage pallet. The

control processor then emits a signal to linear actuator 77 of second wedge storage pallet 72, which extends it into alignment with carriage assembly 51 and with wedge changing head 57,

as shown for first wedge storage pallet 71 in Fig. 5.

Once second wedge storage pallet 72 has been moved into its extended position, carriage assembly 51 is moved along horizontal guide rail 52 until it is positioned adjacent the first of

selector wedges 23 positioned at the top of the stack of selector wedges closest to the carriage

assembly, and supported on wedge rods 76. Once carriage assembly 51 has been driven into position adjacent wedge storage pallet 72, wedge changing head 57 is moved vertically into its approach position by servomotor 59, whereupon the photoelectric eye (not illustrated)

positioned on the wedge changing head looks for a selector wedge to verify the correct

positioning of wedge changing head 57 with respect to selector wedge 23 on pallet 72. Thereafter, a signal is emitted to servomotor 55 whereupon carriage assembly 51 and wedge changing head 57 are moved forward so that selector pins 66 engage the spaced pair of openings 34 defined in wedge body 24 of selector wedge 23. Here, and unlike removing the

wedges, linear actuator 68 is in its home position so that pins 66 will be aligned with openings

34 in wedge body 24.

Once the wedge changing head is engaged with the selector wedge to be placed on the selector belt, vacuum suction cup 70 is activated for creating a vacuum force to hold selector

wedge 23 on pins 66. Thereafter, a signal is emitted to servomotor 59 for vertically raising

wedge changing head 57 upward off of wedge rods 76 toward selector belt 13, whereupon the

pair of mounting pins 30 extending upwardly from the bottom of selector wedge 23 are passed into enlarged portion 38 of slotted opening 37, at which point a position data signal is emitted

from the servomotor to the control processor, the control processor then emitting a control signal to linear actuator 68 to move into its lock/release position which fires and moves selector

wedge 23 transversely with respect to the length of the selector belt (Fig. 4) for guiding shank 31 of mounting pin 30 within elongated locking slot 40, the elongated locking slot locking shank 31 therein, and thus securing selector wedge 23 to selector belt 13.

Thereafter, a signal is emitted to servomotor 55 which backs carriage assembly 51 away

from the selector wedge now positioned on the selector belt, a signal is emitted to linear actuator 68 so that the spaced pair of wedge selector pins 66 on the changing head are returned to their home position, and the wedge changing head is lowered on vertical guide rail 56 by a control signal given to servomotor 59, the wedge changing head moving into an approach

position with respect to the next sequential selector wedge to be removed from the second wedge storage pallet and placed within its appropriate pair of spaced openings 42, 44 or 45 within selector belt 12.

This process is repeated from top to bottom, front to back, so that each selector wedge

stored on the second wedge storage pallet is sequentially removed and placed on the selector belt. After the removal or placement of seven selector wedges from or on the selector belt,

respectively, the selector belt is moved with respect to the wedge changing head and the pairs of wedge rods on the wedge storage pallets so that the next pair of slotted openings defined in

selector belt 13 is properly positioned with respect to the selector wedge, and wedge rods therefor, being removed from or attached to selector belt 13.

Thus, once the wedge changing head has removed the first seven selector wedges from the second wedge storage pallet, the carriage assembly is driven inward toward the next stack of seven wedges supported on the wedge storage pallet, a signal is emitted to the servomotor

(not illustrated) which drives selector belt 13 so that selector belt 13's home position is indexed

with respect to the horizontal movement of carriage 51 and wedge changing head 57 so that as the second seven selector wedges are lifted off of wedge rod 76, they are moved straight upward into the enlarged portion 38 of slotted opening 37 for each respective selector wedge

to be spaced in series along the length of selector belt 1 .

Second wedge storage pallet 72 remains in its extended position until such time as the selector wedges of the second series of wedges 92 are removed from selector belt 13. The

selector wedges of the second series of wedges are removed from selector belt 13 in the same

fashion as were the first series of selector wedges, described above.

When and if it is desired to place the third series of selector wedges 93 stored on third wedge storage pallet 73 on the selector belt, both wedge storage plates 71 and 72 are moved

into their retracted position so that carriage assembly 51 is driven along the length of horizontal

guide rail 52 so that carriage assembly 51 and wedge changing head 57 are positioned with respect to the top most selector wedge at the first stack of wedges positioned on third wedge storage pallet 73, and the process of removing the wedges from the third wedge storage pallet

and placing them on selector belt 13 is repeated as it was for the second series of selector

wedges described above.

Although only three wedge storage pallets are illustrated in Figs. 3-6B, it is anticipated that a greater or lesser number of wedge storage pallets could be provided as a part of automatic

selector wedge changing assembly 5 based on the needs of the packaging machine operator, as

well as the size of the machine. If, for example, selector belt 13 had a length relatively greater

than that shown in Fig. 1 , then several movable wedge storage pallets could be positioned in series, and adjacent one another, along frame 8 of packaging machine 7 with an elongated

horizontal guide rail 52 extending along the length thereof and a final wedge storage pallet positioned in a fixed positioned on the frame as is third wedge storage pallet 73 shown in Fig.

5.

While a preferred embodiment of the invention has been disclosed in the foregoing specification, it is understood by those skilled in the art that variations and modifications thereof can be made without departing from the spirit and scope of the invention as set forth in the

following claims. In addition, the corresponding structures, materials, acts, and equivalents of

all means or step plus function elements in the claims below are intended to include any structure, material, or acts for performing the functions in combination with other claimed elements as specifically claimed herein.