This invention relates to an indexing motion machine and method for producing discrete packages of articles, such as vacuum packaged food products or the like. More particularly, the invention disclosed and claimed by the continuation-in-part application is directed to a cross-cut assembly for use in an indexing motion packaging machine.

To produce discrete individual packages of food products such as frankfurters, sliced luncheon meat, cheese or the like, it has been known to employ packaging machines providing either continuous motion or indexing motion. Continuous motion machines typically provide a higher rate of package production than indexing machines. However, indexing machines have been in existence for a long time, and their design is well refined. Accordingly, indexing machines are reliable in operation.

The present invention has as its object to pro¬ vide an indexing motion package forming machine which is capable of producing packages at a rate equivalent to or greater than the rate at which packages can be produced on a continuous type machine. A further object of the inven¬ tion is to provide an indexing motion package forming machine utilizing motors- with programmable controls to control the movement of the various components of the package forming machine, to provide accurate positioning of the machine components and to provide variability in the package dimensions to accommodate packaging of different products.

In accordance with one aspect of the invention, a packaging machine includes a forming station in which a flexible web of packaging material is deformed so as to provide a cavity adapted to receive the product to be

packaged. Forming tooling defines the forming cavity, and the tooling is movable between a first position in which i engages the web of packaging material and acts on the web to form the web into the forming cavity, and a second position in which the tooling is moved away from web. The forming tooling is moved between its first and second positions by a motor having a rotatable output shaft and including a programmable controller associated therewith. A lifting and lowering system is interposed between the forming tooling and the motor output shaft for moving the forming tooling between its first and second positions in response to rotation of the motor output shaft. In a preferred embodiment, the lifting and lowering system includes a cam-type arrangement in which structure defining a cam slot is mounted to the forming tooling, and an arm is mounted to and rotatable with a rotatable member which is driven through a timing belt or the like in response to rotation of the motor output shaft. A roller member is mounted to the arm and is engaged within the cam slot, and alternating clockwise/counterclockwise rotation of the rotatable member causes back and forth movement of the roller within the cam slot to lift and lower the forming tooling.

This aspect of the invention further contemplates a method of forming a product cavity in a flexible web of packaging material, substantially in accordance with the foregoing summary.

In accordance with another aspect of the inven¬ tion, a packaging machine includes an indexing mechanism for supplying a flexible web of packaging material to the forming station of the packaging machine. A movable ad¬ vancement mechanism is provided for gripping the flexible web, and preferably comprises a pair of spaced chains. Each chain is preferably provided with a series of gripper members along its length, which grip the edges of the web.

A motor having a rotatable output shaft and having a pro¬ grammable controller associated therewith, is drivingly engaged with the pair of chains. Intermittent operation of the motor provides indexing advancement of the web to the forming station. The forming station includes forming tooling for deforming the flexible web to form a cavity adapted to receive product to be packaged.

The invention further contemplates a method of indexingly advancing a web of packaging material in a packaging apparatus, substantially in accordance with the foregoing summary.

In accordance with yet another aspect of the invention, a packaging machine includes a forming station in which a flexible web of packaging material is supplied to the forming station. A forming box is located at the forming station and includes an internal forming cavity. The forming box is movable to a forming position in which the web is located over the forming cavity. A vacuum mechanism provides negative air pressure to the forming cavity of the forming box when the forming box is in its forming position. A plug assist mechanism assists the web to conform to the contour of the forming cavity when the forming box is in its forming position. The plug assist mechanism comprises a plug member reciprocably movable between an operative position in which it engages the web and moves the web within the cavity to assist the web to conform to the cavity, and an inoperative position in which the plug member is withdrawn from the cavity. A motor having a rotatable output shaft and a programmable control- ler associated therewith is provided for reciprocably moving the plug member between its operative and inopera¬ tive positions in response to operation of the motor. In a preferred embodiment, the plug member is mounted to a frame assembly, and the plug member is reciprocably movable between its operative and inoperative positions by lowering

and raising the frame assembly in response to rotation of the motor output shaft, for moving the plug member between its operative and inoperative positions. In a particularly preferred embodiment, the frame assembly is lowered and raised by means of a linear actuator connected between the motor output shaft and the frame assembly for lowering and raising the frame assembly in response to alternating clockwise/counterclockwise rotation of the motor output shaft. This aspect of the invention further contemplates a method of assisting a flexible web of packaging material to conform to a forming cavity, substantially in accordance with the foregoing summary.

In accordance with yet another aspect of the invention, a packaging machine and method incorporates forming tooling, an indexing web drive, and a plug assist mechanism, each of which is independently driven by one or more motors having programmable controllers, so as to allow each component to be independently programmed and con- trol-led. This provides variability in the type of package which can be formed by the machine, as well as providing accurate control and adjustment of the various packaging components.

In each of the above-noted aspects of the inven- tion, the motor preferably comprises a programmable servo motor.

In accordance with yet another aspect of the invention, a cross-cut assembly is provided for transverse¬ ly severing the webs after the webs are sealed together about the product. The cross-cut assembly consists of a frame member mounted to the packaging machine for movement between a raised position and a lowered position. The frame member extends transversely across the packaging machine, and is mounted at one end for pivoting movement. An extendable and retractable cylinder assembly is inter-

posed between the other end of the frame member and the packaging machine, such that movement of the cylinder rod to its retracted position moves the frame member to its lowered position, and extension of the cylinder rod moves the frame member to its raised position. A traversing knife assembly is mounted to the frame member. The knife assembly consists of carriage having a pair of knife hold¬ ers, with the carriage being mounted to the movable output member of a rodless cylinder. The knife holders are adapt- ed to receive conventional utility knife blades, and pro¬ vide blade replacement without the need for employing tools to remove an existing blade and to mount a replacement blade. Each knife holder includes a slot having a width only slightly greater than that of the blade, to accommo- date placement of the blade therein. A magnetic retainer assembly is mounted to each holder, and includes one or more magnetic elements which maintain the blade within the slot. A utility knife blade typically includes a pair of notches along the non-sharpened edge of the blade, and each knife holder is provided with an upstanding peg which is adapted to be received within one of the notches, to pro¬ vide proper depth location of the blade when mounted to the blade holder.

Various other features, objects and advantages of the invention will become apparent from consideration of the following description taken together with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS The drawings illustrate the best mode presently contemplated of carrying out the invention. In the drawings:

Fig. 1 is an isometric view of a packaging ma¬ chine constructed according to the invention;

Fig. 2 is a side elevation view of the packaging machine of Fig. 1, with guards and covers removed to expos the components of the machine;

Fig. 3 is a schematic side view showing the web unwinding mechanism for supplying the lower web of pack¬ aging material;

Fig. 4 is a schematic view showing the steps involved in deforming the flexible web of packaging materi¬ al at the forming station to provide a product cavity adapted to receive product to be packaged;

Fig. 5 is an enlarged partial side view showing the forming tooling in its raised position;

Fig. 6 is a partial transverse sectional view illustrating the plug assist mechanism of the invention; Fig. 7 is a partial transverse sectional view showing a cutting assembly for transversely cutting the formed packages;

Fig. 8 is a schematic block diagram of control screen selections for controlling operation of the pack- aging machine;

Fig. 9 is a schematic block diagram of the con¬ trol and drive arrangement for the servo motors;

Fig. 10 is a partial side elevation view of the downstream portion of the packaging machine of Fig. 1; Fig. 11 is a partial transverse section taken generally along line 11-11 of Fig. 10, showing the cross¬ cut assembly;

Fig. 12 is an enlarged partial elevation view of a blade holder associated with the cross-cut assembly of Fig. 11;

Fig. 13 is a partial top plan view of the cross¬ cut assembly shown in Fig. 11; and

Fig. 14 is a partial section view taken generally along line 14-14 of Fig. 13.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Figs. 1 and 2 illustrate a packaging machine 10 constructed according to the invention. Packaging machine 10 generally includes a lower web supply station 12 for supplying a lower web 14 of flexible packaging material from a supply roll 16, a forming station 18, a loading station 20, an upper web supply station 22 for supplying a upper web of flexible packaging material from a supply rol 24, and a downstream station shown generally at 26. The operations performed at downstream station 26 will later b explained.

The various components of packaging machine 10 are mounted to and supported by a frame assembly (Fig. 2) including a pair of spaced parallel upper frame members 28, lower spaced frame members such as shown at 30, 32, and 34, and a series of vertical frame members extending between upper frame member 28 and lower frame members 30, 32 and 34. A series of legs 36 are provided for supporting ma¬ chine 10 above a floor 38. Lower web supply station 12 includes a roll support bracket 40 and an unwind shaft 42 extending from bracket 40. Supply roll 16 is rotatably mounted to shaft 42, which is stationarily mounted to bracket 40. An unwin motor 44 (Fig. 2) is mounted to a plate 46, and has its output shaft engaged with a gear box 48 which includes a horizontally oriented output shaft driven in response to rotation of the output shaft of motor 44. A pair of timin pulleys 50, 52 are fixed to a pair of shafts 54, 56, re¬ spectively, which extend through plate 46 and are fixed to a pair of driven steel rollers 58, 60 (Fig. 3) . A timing belt 62 is trained around timing pulleys 50, 52 and a timing pulley (not shown) engaged with the horizontal output shaft of gear box 48.

Referring to Fig. 3, a rubber surfaced nip roller 64 rests on top of driven rollers 58 and 60, forming a pair

of nips between roller 64 and rollers 58, 60. Lower web 14 is fed below driven roller 58, up and over nip roller 64, and below driven roller 60. Upon operation of motor 44, drive rollers 58 and 60 are driven in response to rotation of timing pulleys 50, 52, and lower web 14 is unwound from supply roll 16 by rotation of driven rollers 58, 60 and nip roller 64.

Motor 44 is a conventional variable speed DC motor, which provides variable speed unwinding of lower web 14 from supply roll 16 during its operation.

From driven roller 60, lower web 14 is trained around a dancer roller 66 rotatably mounted to a dancer arm 68, which is pivotably supported at its upper end on a shaft 70 extending between the sides of the machine frame. As noted previously, and as will be explained in greater detail, web 14 is advanced through machine 10 in an index¬ ing fashion. The dancer assembly, consisting of dancer arm 68 and dancer roller 66, acts as an actuator for switching unwind motor 44 on and off and for controlling its speed of operation, for providing unwinding of lower web 14 from supply roll 16 in response to indexing movement of lower web 14 through the stations downstream of the dancer assem¬ bly.

As noted previously, unwind motor 44 is a vari- able speed motor. Motor 44 is responsive to the position of dancer arm 68 which increases or decreases the motor speed as required to accommodate the indexing advancement of lower web 14 downstream of the dancer assembly. Motor 44 is normally off, and the dancer assembly selectively actuates motor 44 and controls its speed of operation.

Referring to Figs. 2 and 3, transducer-type proximity switch 74 is mounted to plate 46, and is inter¬ connected with unwind motor 44 through a motor drive 75. A cam-shaped switch actuator member 76 is mounted to dancer arm 68, for selectively actuating proximity

switch 74 .

Actuator member 76 provides a cam-shaped actuato surface, which acts on proximity switch 74 to control the speed of operation of motor 44. As noted previously, moto 44 is normally off. The cam shape of actuator member 76 provides gradual switching of motor 44 between its "on" an "off" modes.

When lower web 14 is pulled by the indexing driv mechanism, as will be explained, dancer arm 68 pivots counter-clockwise so as to bring actuator member 76 into proximity with switch 74. Proximity switch 74 then causes motor 44 to operate, first at a low speed and then at a higher speed as dancer arm 68 further pivots counter-clock wise, until motor 44 is operating at full speed, to unwind lower web 14 from supply roll 16. As the supply of lower web 14 from supply roll 16 catches up with the indexing advancement of lower web 14, dancer arm 68 pivots about shaft 70 in a clockwise direction. Actuator member 76 the causes proximity switch 74 to slow the speed of operation of motor 44. When the indexing advancement of lower web 1 ceases, motor 44 continues to supply lower web 14 to dance roller 66 and dancer arm 68 is pivoted clockwise until actuator member 76 is moved an amount sufficient to cut of power to motor 44 through proximity switch 74. Dancer arm 68 thus moves in an arcuate back and forth manner as long as actuator member 76 is maintained i proximity to proximity switch 74 during indexing advance¬ ment of web 14 downstream of the dancer assembly continues.

To advance lower web 14, a servo motor 78 is mounted to lower frame members 34, and includes an output shaft to which a timing pulley 80 is mounted. A timing belt 82 is trained around timing pulley 80, and also aroun a driven timing pulley 84 mounted to a driven shaft 86.

Driven shaft 86 is rotatably supported between the sides of the frame of packaging machine 10.

Referring briefly to Figs. 6 and 7, a pair of gripper chains shown generally at 88a and 88b, are provided on either side of the frame of packaging machine 10.

Gripper chains 88a and 88b provide upper runs 90a and 90b, respectively, and lower runs 92a and 92b, respectively. The upper and lower runs of chains 88a, 88b are mounted in inwardly facing slots formed in facing blocks 94a, 94b, located on either side of the frame of packaging machine

10. Blocks 94a, 94b are mounted to upper frame members 28, and provide sliding movement of gripper chains 88a, 88b along the length of packaging machine 10. Blocks 94a, 94b are formed of an ultra-high molecular weight polyethylene material.

Gripper chains 88a, 88b may be such as manufac¬ tured by Curwood, Inc. of Oshkosh, Wisconsin under its U.S. Pat. No. 4,915,283. This arrangement provides gripping of lower web 14 along its edges at upper runs 90a, 90b, of gripper chains 88a, 88b.

Driven shaft 86 (Fig. 2) , which is rotatable in response to rotation of the output shaft of indexing drive servo motor 78, has a pair of chain drive sprockets (not shown) connected thereto for engagement with gripper chains 88a, 88b. In this manner, intermittent operation of servo motor 78 provides indexing movement of gripper chains 88a, 88b, to indexingly advance lower web 14 through packaging machine 10.

Lower web 14 is gripped between upper runs 90a, 90b of gripper chains 88a, 88b downstream of the dancer assembly and upstream of forming station 18, and is there¬ after supplied to forming station 18 in an indexing fash¬ ion.

A web heater apparatus, shown generally at 96, is located immediately upstream of forming station 18 for

heating lower web 14 prior to forming of web 14 at forming station 18. The preheating of web 14 imparts increased flexibility to web 14 to assist in deforming web 14 at forming station 18. Forming tooling is provided at forming station 18 below web 14. As shown in Fig. 2, the forming tooling comprises a chilled forming box 98 mounted to a frame assembly 100. As will be explained, forming box 98 is movable between a raised position and a lowered position. In its raised position, forming box 98 acts on lower web 14 to deform web 14 downwardly to form a product cavity, and in its lowered position is moved away from web 14 so as to allow advancement of web 14 with the product cavity formed therein. Fig. 4 illustrates the series of steps which take place at forming station 18 in order to form a product cavity 102 in lower web 14. The forming arrangement shown in Fig. 4 is preferably employed when forming a relatively shallow product cavity 102 in lower web 14. At position A, forming box 98 is in its lowered position, and an unde- formed portion of web 14 is located over the open upper end of forming box 98. While web 14 is maintained stationary, forming box 98 is moved upwardly to position B, where the upper ends of the side walls of forming box 98 come into contact with the underside of web 14. Negative air pres¬ sure is then supplied to the interior of forming box 98 through a vacuum line 104 and a series of air passages formed in the bottom of forming box 98. At position C, a plug member 106 associated with a plug assist mechanism 108 moves downwardly under the influence of air pressure so as to come into contact with the upper surface of lower web 14, and to assist web 14 in deforming into the interior of forming box 98. At position D, plug member 106 is retract¬ ed to its upper position, and the negative air pressure supplied by vacuum line 104 deforms lower web 14 downwardly

into the interior of forming box 98 until the lower surface of web 14 is disposed against the bottom and sides of the interior of forming box 98. Product cavity 102 is thus formed. At position E, forming box 98 is moved downwardly an amount sufficient to allow formed web 14 to advance downstream from forming station 18, whereafter the de¬ scribed sequence of steps is repeated to again form another product cavity 102 in the upstream portion of lower web 14. The previously formed product cavity 102 is advanced to loading station 20, where product to be packaged is placed into product cavity 102.

Referring to Fig. 2, a servo lift motor 110 is mounted to lower frame members 30, and includes an output shaft 112 to which a drive timing pulley 114 is mounted. A timing belt 116 is trained around drive pulley 114 and a large driven pulley 118, which is mounted to a shaft 120 rotatably mounted between lower frame members 30. A small¬ er diameter lift pulley 124a is connected to shaft 120 on the inside surface of large timing pulley 118, and a timing belt 122 is trained around inside-mounted pulley 124a and around a second lift pulley 124b. Pulley 124b is keyed to a shaft 126, which is rotatably mounted to lower frame members 30. With this arrangement, the pair of lift pul¬ leys 124a and 124b are rotatable in response to operation of servo motor 110.

A pair of lift arms 128a and 128b are mounted to lift pulleys 124a and 124b. Lift arms 128a and 128b are fixed at their lower ends to shafts 120, 126, respectively, and therefore are pivotable with shafts 120, 126 in re- sponse to operation of lift servo motor 110.

As shown in Fig. 5, lift arm 128a is provided with an inwardly extending upper shaft 130 to which is mounted a roller member 132. Roller member 132 is mounted within a cam slot 134 formed in a cam member 136 which is connected to the underside of frame assembly 100. With

this arrangement, upon reciprocating clockwise and counter ^¬ clockwise movement of shaft 120 resulting from reciprocat¬ ing operation of lift servo motor 110, roller member 130 is caused to move back and forth in cam slot 134 to raise and lower frame assembly 100, to which forming box 98 is mount¬ ed. Referring to Fig. 2, a cam member 138 is mounted to the rear portion of frame assembly 100, and includes a cam slot similar to slot 134 formed in forward cam member 136. Rear lifting arm 128b is provided with a roller arrangement similar to that described with respect to arm 128a. Timing belt 122 trained around lift pulleys 124 provides simulta¬ neous lifting and lowering of lift arms 128a and 128b to raise and lower frame assembly 100. To ensure that lift arms 128a and 128b remain parallel to each other, a mechan- ical link (not shown) is connected between arms 128a and 128b.

In a preferred arrangement, a pair of forward cam members are mounted one on either side of the forward portion of frame 100, and a pair of forward lift arms 128a are connected to shaft 120. Similarly, a pair of cam members 138 are mounted one on either side of the rear portion of frame 100, and a pair of lift arms 128b are mounted to shaft 126.

As shown in Fig. 2, plastic bearing block 140 is mounted to the side of frame assembly 100, and a similar block is mounted to the opposite side of frame assembly 100. Bearing block 140 entraps the sides of a vertical shaft mounted to the inside of vertical frame member 144, and a similar arrangement is provided on a vertical frame member on the other side of machine 10. The bearing blocks, such as 140, provide vertical tracking of frame assembly 100 during lifting and lowering of lift arms 128a, 128b.

Referring to Fig. 5, forming box 98 is mounted to frame assembly 100 by means of a pair of side plates locat-

ed on either side of forming box 98, with one of the side plates being shown at 146. By loosening the side plates, forming box 98 can be moved to varying positions along the length of frame assembly 100, and thereafter fixed in a desired position by retightening the side plates. This provides accurate positioning of forming box 98 on frame assembly 100. In addition, forming box 98 can be complete¬ ly removed from frame assembly 100 and replaced with a different forming box providing a different configuration to the product cavity, to accommodate variations in the type of product being packaged. The mounting arrangement as shown and described may be replaced with any other satisfactory arrangement which provides adjustment and removal of forming box 98 relative to frame assembly 100. As shown in Fig. 2, a vacuum junction 148 is mounted to the frame of machine 10 for transferring nega¬ tive air pressure from a vacuum tube 150 to the interior of forming box 98 through vacuum line 104 (not shown in Fig. 2) , in accordance with known principles. Fig. 2 generally illustrates the location of plug assist mechanism 108 at forming station 18. Fig. 6 illus¬ trates plug assist mechanism 108 in greater detail. The arrangement of plug assist mechanism 108 shown in Fig. 6 is employed when forming a relatively deep product cavity in lower web 14, in contrast to the arrangement shown in Fig. 4. Referring to Fig. 6, plug assist mechanism 108 includes a frame assembly consisting of front and rear frame mem¬ bers, one of which is shown at 152. A pair of side plate members 154, 156 extend between the front and rear frame members. A pair of lugs 158, 160 are mounted to side frame members 154, 156, respectively.

A pair of linear actuator assemblies 162, 164 are provided one on either side of the frame of machine 10 and are mounted to the structural members of the frame. Actua- tor assembly 162 includes a.linearly movable output member

166 which is vertically movable relative to an actuator body 168. A servo motor 170 is mounted to actuator body 168, for providing rotary input power to actuator body 168 and to provide selective up-down movement of output member 166. Output member 166 is connected to plug assist frame lug 158.

Linear actuator assembly 164 is similarly con¬ structed, providing a vertically movable output member 172, a linear actuator body 174 and a servo motor 176. Output member 172 is connected to frame lug 160.

Linear actuator assemblies 162, 164 are prefer¬ ably those such as manufactured under U.S. Pat. No. 4,137,784.

With the described arrangement, operation of servo motors 170, 176 results in rotary input power being provided to linear actuator bodies 168, 174, to provide vertical movement of linear actuator output members 166, 172, and thereby lifting and lower of the plug assist frame assembly relative to the frame of packaging machine 10. An upper plate 178 extends between the front and rear frame members of the plug assist assembly. In the illustrated embodiment, forming box 98 provides a pair of internal cavities to form lower web 14 so as to provide a pair of side-by-side product cavities. A pair of plug assist members, shown generally at 180, 182, are mounted to the underside of upper plate 178 for assisting lower web 14 in conforming to the contour of the internal cavities provided by forming box 98. Plug assist member 180 in¬ cludes a vertical post 184 and a lower forming member 186 connected to the lower end of post 184. Similarly, plug assist member 182 includes a vertical post 188 connected to the underside of upper plate 178, and a forming member 190 mounted to the lower end of post 188.

Forming members 186, 190 are dimensioned so as to fit within the internal cavity provided in forming box 98

with which each is aligned. Preferably, each edge of forming members 186, 190 is located approximately 1/2 inch inwardly from the side wall of the cavity to which it is adjacent. Forming members 186, 190 are preferably moved downwardly within the respective forming cavities to a lowermost position in which the bottom of each of forming members 186, 190 is at approximately three quarters of the depth of the cavity.

A pair of vertical guide posts 192, 194 are mounted to the frame of packaging machine 10. Post 192 is received within an opening 193 defined by structure ex¬ tending between the front and rear frame members of plug assist assembly 108, with the opening having a cross sec¬ tion corresponding to and slightly larger than the cross section of post 192. Similarly, post 194 is received within an opening 195 defined by structure extending be¬ tween the front and rear frame members of plug assist assembly 108, with the opening providing a cross section corresponding to and slightly larger than the cross section of post 194. With this arrangement, posts 192 and 194 ensure vertical movement of plug assist assembly 108 during operation of linear actuator assemblies 162, 164 in re¬ sponse to operation of servo motors 170, 176. It is under¬ stood that any other satisfactory arrangement could be employed for this purpose, e.g. a mating channel and pro¬ jection type system.

Forming members 186, 190 are shown in their lowermost position in solid lines in Fig. 6. Forming member 190 is shown in its raised position in phantom. In accordance with known principles, forming members 186, 190 engage lower web 14 and move lower web 14 downwardly, to assist it in conforming to the forming cavities of forming box 98.

Referring to Figs. 1 and 2, after the formed lower web is discharged from forming station 18 where it is

deformed to provide side-by-side product cavities, the product, shown at P in Fig. 1, is loaded into the product cavities at loading station 20. Product P may be loaded in any satisfactory manner, such as by hand or by an automated loading system. Product P as illustrated in Fig. 1 com¬ prises hotdogs, but it is understood that product P could be any product which is satisfactorily packaged in the manner disclosed, such as ham, bacon, sliced luncheon meat, cheese, pharmaceuticals, or the like. After the product cavities are loaded with prod¬ uct P, the formed and loaded lower web is moved to upper web supply station 22.

Upper web supply station 22 (Fig. 2) is arranged similarly to lower web supply station 12, and functions in a similar manner. Upper web supply roll 24 is rotatably supported on a shaft 196 stationarily mounted to a bracket assembly 198. A pair of vertical frame members 200, 202 extend upwardly from upper frame members 28 of packaging machine 10, for supporting upper web supply station 22. An unwinding drive assembly, shown generally at

204, is mounted to the frame of upper web supply station 22 for unwinding upper web material from supply roll 24. The components of unwind drive assembly 204 are the same as those described previously with respect to lower web supply station 12, and function in the same manner as such compo¬ nents. Upper web supply station 22 further includes a dancer assembly 206 which functions in the same manner as the dancer assembly located at lower web supply station 12, for providing selective unwinding of upper web material from supply roll 24 by unwind drive assembly 204 in re¬ sponse to indexing movement of the upper web along with the formed and loaded lower web.

At downstream station 26, a vacuum box 208 is mounted to a frame 210, and is operable in accordance with known vacuum packaging principles to evacuate the product

cavities while the upper and lower webs are sealed togeth¬ er, to provide a vacuum package of product P. A heating assembly 212 is located at downstream station 26 to acti¬ vate sealant on the upper web and lower web 14. Frame 210 is movable between a raised and lowered position in the same manner as frame assembly 100 located at forming station 18. A lift servo motor 214 is provided for imparting selective lifting and lowering of a pair of lift arms, one of which is shown at 216, through a timing belt and pulley arrangement similar to that described previously at forming station 18.

After the product cavities are evacuated and the upper and lower webs are bonded together to provide a vacuum package for product P, the bonded upper and lower webs are advanced to a cutting station, shown generally in Fig. 2 at 218. As the webs exit cutting station 218, a centrally located cutting blade severs the webs longitudi¬ nally to separate the two lanes of formed packages. Prior thereto, a cross-cut mechanism, shown in Fig. 7 generally at 220, then severs the webs transversely.

Cross-cut mechanism 220 includes a frame assembly including an upper frame member 222 and a bracket member 224, which is pivotably mounted to a support member 226 mounted to upper frame member 28 of packaging machine 10. A bracket member 228 is located at the other end of upper frame member 222, and is connected to the extendable and retractable output member 230 of a cylinder assembly shown generally at 232. A bracket 234 connects the lower end of cylinder assembly 232 to a support member 236, which is interconnected with frame member 28 of packaging machine 10.

Cylinder assembly 232 may be any satisfactory assembly for raising and lowering output member 230, such as a pneumatic or hydraulic cylinder, or a solenoid-type arrangement. With this construction, upper frame member

222 is movable between a lowered position as shown in Fig. 7, and a raised position.

A rodless pneumatic cylinder 238 is mounted to the underside of upper frame member 222, and a carriage 240 is connected to the movable output member of rodless cylin¬ der 238. A pair of blade holder assemblies 242, 244 are mounted to the ends of carriage 240, and retain a pair of knife blades 246, 248.

Operation of rodless cylinder 238 provides a cutting stroke to carriage 240 for drawing blades 246, 248 rightwardly through the upper and lower webs, to trans¬ versely sever the webs. The output member of rodless cylinder 238 is first moved to its leftwardmost position, so that blade 246 is disposed leftwardly of the leftward edges of the upper and lower webs, and blade 248 is located in the area between the two lanes of formed packages. Output member 230 of cylinder assembly 232 is then retract¬ ed, so that the points of blades 246, 248 pierce the upper and lower webs. Rodless cylinder 238 is then operated to move carriage 240 rightwardly, and blades 246, 248 cut through the upper and lower webs to completely sever the webs. Upon a full cutting stroke of rodless cylinder 238, blade 246 is moved rightwardly an amount sufficient to sever the webs up to the point where blade 248 initially pierced the webs. Blade 248 is moved completely through the webs to clear the rightward edges of the webs. Output member 230 of cylinder 232 is then extended to raise blades 246, 248 above the webs, and the output member of rodless cylinder 238 is then moved leftwardly to bring the blades back to their original position, whereafter output member 230 is again retracted to bring blades 246, 248 into con¬ tact with the webs.

Blades 246, 248 are conventional blades as used in a utility knife or the like, and therefore are rela- tively inexpensive and are readily available. This reduces

an operator's costs, since blades must often be replaced during operation of packaging machine 10.

Blade holder assemblies 242, 244 are constructed so as to provide quick and.easy interchangeability of blades 246, 248, thus minimizing downtime of packaging machine 10 for blade replacement.

Referring again to Fig. 1, a control module 250 is mounted to an arm 252, which is pivotably connected to the upper end of the frame of upper web supply station 22. Control module 250 can be moved to varying positions by the operator of machine 10, who normally is positioned at loading station 20.

Control module 250 includes a touch screen 254 for controlling the operation of servo motors 78, 110, 170, 176 and 214. In accordance with known technology, the operation of the servo motors is controlled by programmable controllers, thereby providing very fine control of the position of the servo motor output shafts, and thereby of the packaging machine components driven by the servo mo- tors. This is in marked contrast to prior art indexing- type packaging machines, which typically employ pneumatic cylinders for providing up and down movement of the plug assist members and the forming and evacuating boxes, and a continuously operating motor with a Geneva drive system for providing indexing advancement of the packaging webs. The servo motors are programmed so as to provide smooth and even acceleration and deceleration of the driven components and rapid intermediate movement for moving the components from one position to another. In this manner, the servo motor driven components of packaging machine 10 can be operated at a very high rate of speed, providing a dramati¬ cally increased rate of package production over convention¬ al indexing-type machines, as well as an increased rate of production relative to continuous motion-type machines.

Another advantage offered by the use of servo motors in machine 10 is that the operating parameters can be varied by changing the program which controls the opera¬ tion of the servo motors. The operating parameters are varied by use of the operator interactive touch screen 25 . For example, chains 88a and 88b lengthen slightly over time due to wear of the links. In a conventional indexing-type machine, this problem is addressed by changing the position of the forming box. With the packaging machine of the invention, the operator simply changes the operating param¬ eters to shorten the length of the indexing web repeat, thus minimizing machine down time.

Fig. 8 illustrates the various modes of operation selectible on touch screen 254. On start-up of machine 10, a start-up screen 256 appears, and the operator can touch one of areas 258, 260, 262 or 264 to select one of screens 266, 268, 270 or 272, which respectively comprise an auto¬ matic run operator screen, a recipe select screen, a clean¬ up screen and a maintenance menu screen. Maintenance menu screen 272 can only be selected upon entry of a maintenance password, represented at 274. After the various parameters are set on the appropriate screen, the operator pushes the "start" button associated with a button panel 276 (Fig. 1) , to commence operation of machine 10. As also shown in Fig. 1, an enclosure 278 con¬ tains the componentry which controls the operation of the servo motors associated with packaging machine 10. Refer¬ ring to Fig. 9, enclosure 278 houses a programmable motion control computer 280, which is interconnected with the operator interface control module 250. Computer 280 pro¬ vides output signals to control amplifiers, such as shown at 282, 284, 286 and 288. Amplifiers 282, 284, 286 and 288 provide control signals to servo motors 78, 170, 176, 110 and 214, respectively, to control the operation of the motors and therefore the position of the respective motor

output shafts. Servo motors 78, 170, 176, 110 and 214 include position sensors and feedbacks 290, 292, 294, 296 and 298, respectively, for conveying to computer 280 the actual positions of the motor output shafts. In this manner, the actual shaft position is compared with the programmed shaft position, and the motor speed is adjusted to move the motor shafts to the appropriate positions.

A power supply 300 provides power for operating the servo motors through control amplifiers 282-288, re- spectively.

The servo motors are preferably such as manu¬ factured by the Gettys Corporation of Racine, Wisconsin under catalog number M324-P70A-1001. The motors provide rotary output power to cycloidal type gear reducers, of conventional technology. Suitable reducers are those such as manufactured under the trademark "SM-Cyclo" by Sumitomo Machinery Corporation of America, under Model No. H3105HS. The control amplifiers employed with the servo motors are preferably such as manufactured by Gould, Inc./Motion Control Division of Racine, Wisconsin under Model No. A700. The programmable motion control computer 280 may be such as manufactured by Giddings & Lewis Electronics under its Model No. PiC49.

Reference is now made to Figs. 10-14, which illustrate cutting station 218 of packaging machine 10 in greater detail. As shown in Fig. 11, which is somewhat similar to Fig. 7, cross-cut assembly 220 includes upper frame member 222, bracket 224 and support member 226, which cooperate to pivotably mount one end of frame member 222 to packaging machine frame member 28. Bracket 228 is located at the other end of frame member 222 and is connected to the extendable and retractable rod 230 of pneumatic cylin¬ der assembly 232, which is interconnected with the left- hand frame member 28 of packaging machine 10 through brack- et 234 and support member 236. Cylinder assembly 232 is

operable to move frame member 222 between a lowered posi¬ tion, shown in solid lines in Fig. 11, and a raised posi¬ tion, shown in phantom. Movement of frame member 222 to its lowered position prepares cross-cut assembly 220 for a cutting stroke, and a return stroke is provided upon move¬ ment of frame member 222 to its raised position.

Rodless cylinder 238, which is mounted to the underside of frame member 222 by means of a pair of brack¬ ets 300, 302, comprises a magnetic cylinder assembly such as manufactured by SMC Pneumatics, Inc. of Indianapolis,

Indiana, under its designation Series NCY1, which includes an internal reciprocating piston coupled by magnetic force to an output member. The output member of rodless cylinder 238 is encased within a UHMW polyethylene block 306. Carriage member 240, which is constructed of stainless steel, is secured by bolts or the like through the lower portion of nylon block 306 to the output member of cylinder 238, so as to be movable therewith during movement of the output member. Blade holder assemblies 242, 244 are formed at the ends of carriage member 240, and knife blades 246, 248 are mounted to blade holder assemblies 242, 244, re¬ spectively in a manner as will be explained.

When frame member 222 is moved to its lowered position, in which a cutting stroke of blades 246, 248 is provided, frame member 222 is oriented at an angle of approximately 3° to horizontal, as is cylinder 238 and carriage member 240. With this arrangement, blade holder assemblies 242, 244 and blades 246, 248 travel slightly uphill during the cutting stroke of cross-cut assembly 220. Reference is now made to Fig. 12 for a detailed description of blade holder assembly 242. It is to be understood that blade holder assembly 244 is constructed in a manner similar to that of blade holder assembly 242, and that the following description applies with equal force to blade holder assembly 244.

As noted previously, blades 246, 248 are conven¬ tional blades as used in a utility knife, which are rela¬ tively inexpensive and are readily available. The particu¬ lar blade illustrated in Fig. 12 is that such as manufac- tured and sold by The Stanley Works of New Britain, Con¬ necticut, as a replacement blade for a Stanley utility knife. The edge of blade 246 parallel and opposite to the sharpened edge is provided with a pair of notches, shown at 308, 310. Notches 308, 310 are located one on either side of the center of blade 246, and are intended to be received within a projection associated with a blade-receiving portion of a conventional utility knife, to determine the amount of projection of the sharpened edge of blade 246 from the front end of the utility knife. Blade holder assembly 242 essentially consists of a block having a groove 312 formed in its front face. Groove 312 has a depth of approximately 1/8 inch to 3/16 inch, which is sufficient to receive the entire thickness of blade 246 therewithin. Groove 312 has a width only slightly greater than the width of blade 246 from its sharpened edge to its non-sharpened edge. Groove 312 is oriented such that the sharpened edge of blade 246 is disposed at an angle of approximately 28° to vertical when blade 246 is received within groove 312. Blade 246 is maintained within slot 312 by means of a series of magnets, shown in Fig. 12 at 314, 316. Magnets 314, 316 are mounted in a bore 318 formed in the front face of blade holder 242. A magnet holder member 320 is provided with openings which receive magnets 314, 316 therewithin, and is adapted for placement within bore 318 so as to firmly and securely retain magnets 314, 316 on magnet holder assembly 242 in bore 318. The forward faces of magnets 314, 316 are flush with the bottom surface of groove 312.

A peg 322 is mounted to blade holder assembly 242 adjacent the edge of groove 312 against which the non- sharpened edge of blade 246 is placed. Peg 322 is adapted to be received within one of the notches 308, 310 when blade 246 is mounted within groove 312 of blade holder assembly 242.

To mount blade 246 to blade holder assembly 242, the operator simply inserts the blade into groove 312 such that the sharpened edge of blade 246 is positioned adjacent one of the side walls of groove 312, and the non-sharpened edge is positioned adjacent the other side wall of groove 312. The lowermost of notches 308, 310 is positioned so as to receive peg 322 therewithin, and magnets 314, 316 then magnetically retain blade 246 within position in groove 312. The engagement of peg 322 within notch 308 fixes the vertical position of blade 246 relative to blade holder assembly 242. After blade 246 is positioned within groove 312, with peg 322 engaged within notch 308, the engagement of the edges of blade 246 with the side walls of groove 312 prevents movement of blade 246 during operation of cross¬ cut assembly 220.

When the lower portion of blade 246 becomes dull by use, the operator can manually remove blade 246 from groove 312 by pulling outwardly on blade 246, and flip blade 246 end for end to expose an unused portion of the sharpened edge of blade 246. The operator positions blade 246 such that peg 322 is engaged within notch 310, to once again provide proper vertical positioning of blade 246. After both ends of blade 246 have been used and dulled, the operator replaces blade 246 in a manner as described previ¬ ously, by manually removing blade 246 and positioning a replacement blade within groove 312.

With the arrangement as shown and described, blade replacement is extremely quick and simple, and re- quires no tools. In the past, blades have been held in

place by inserting a screw through an opening formed in the blade, and engaging the screw with a threaded opening formed in the blade holder assembly. The blade holder as shown and described eliminates this step, and constitutes a significant improvement over the prior art.

Referring to Fig. 13, a pair of identical cross¬ cut assemblies 220 are provided at cutting station 218. Downstream of cross-cut assemblies 220 is located a longi¬ tudinal slitting mechanism, shown generally at 330, for slitting the transversely cut webs to provide discrete product packages. Slitting mechanism 330 includes a rotat¬ ing bar 332 having a series of slitters mounted thereto. Each slitter consists of a hub 334 and a blade 336. A series of slitter blocks 338 are mounted below slitting mechanism 330, and each includes a groove within which slitting blade 336 is located. Slitting blocks 338 are narrow enough to fit between the formed packages, and each includes a sloped leading surface.

Referring to Figs. 10, 11 and 14, a pair of cross-cut platens 340 are disposed below cross-cut assem¬ blies 220. Platens 340 consist of UHMW polyethylene blocks mounted to a cross-member 342, which is supported at its ends by a pair of upright members 344, 346. Upright mem¬ bers 344, 346 are secured to frame 210, which is movable between a raised and lowered position as described previ¬ ously, in response to operation of lift servo motor 214 and a pair of lift arms, one of which is shown at 216. Platens 340 are narrow enough to fit between the formed product cavities, and are located at an elevation which, when frame 210 is moved to its raised position, causes engagement of the upper surface of platens 340 with the underside of lower web 14, to lift webs 14 and 24 and to introduce tension therein during the cross-cut operation. Platens 340 are provided with a longitudinal slot which receives blades 246, 248 therewithin when cross-cut assembly 220 is

moved to its lowered position. Alternatively, the material of platens 340 on one side of the slot may be removed, forming a shoulder against which the blade is positioned. To perform the cross-cut operation, cylinder 232 is operated to move frame member 222 to its raised posi¬ tion, and frame 210 is moved to its lowered position so as to move platens 340 out of the path of webs 14, 24 which have been formed into packages. The webs are then index- ingly advanced forward, and frame assembly 210 is then moved to its raised position to bring platens 340 into engagement with the underside of web 14 and to introduce tension into the webs. Simultaneously, cylinder assembly 232 is operated to retract its rod 230, and to move frame member 222 to its lowered position. This causes piercing of webs 14, 24 by blades 246, 248. Air pressure is then introduced into cylinder 238 to move its output member rightwardly, and along with block 306, resulting in a cutting stroke of cross-cut assembly 220. During the cutting stroke, the slight angle of inclination of cylinder 238 results in blades 246, 248 traveling uphill, thus utilizing more than a single point of the sharpened edge of blades 246, 248 to perform the cutting of webs 14, 24. Blade 246 initially pierces webs 14, 24 outwardly of the formed product cavity, and blade 248 pierces the webs substantially at the center of the central product cavity. During the cutting stroke, blade 246 is moved rightwardly so as to sever webs 14, 24 up to the point of piercing of the webs by blade 248. Simultaneously, blade 248 is moved rightwardly past the outer edge of the rightwardmost prod- uct package. In this manner, webs 14, 24 are severed substantially across their entire width, excepting the portion of webs 14, 24 which is engaged by the clip chains 88a, 88b.

After the cutting stroke of cross-cut assembly 220 is completed, cylinder 232 is operated to move frame

member 222 to its raised position, thus withdrawing blades 246, 248 above webs 14, 24. Platens 340 are simultaneousl withdrawn from below webs 14, 24 by lowering of frame assembly 210, and the webs are moved to slitting mechanism 330. Slitter blades 336 then longitudinally sever webs 14, 24 into discrete product packages. The outer portion of webs 14, 24 is retained by the clip chains, and is eventu¬ ally discharged therefrom and discarded as waste.

Various alternatives and embodiments are con- templated as being within the scope of the following par¬ ticularly pointing out and distinctly claiming the subject matter regarded as the invention.