ARTICLE ALIGNMENT APPARATUS

FIELD OF INVENTION

The present invention relates to apparatus for aligning articles. More specifically, though not exclusively, the present invention relates to apparatus that brings an alignment element into contact with articles in a stream and causes the or each article to rotate to align the label or advertising indicia applied to the article.

BACKGROUND OF THE INVENION

A common requirement of the packaging industry is to supply packs of multiple articles.

A problem associated with multiple article packaging is the orientation of advertising indicia or other printed material applied to the articles. In packages having a window or aperture through which the package contents are visible consumers prefer to view such indicia in a common orientation. There is, therefore a requirement for an apparatus that can orientate the articles during the packaging process, so that all the indicia are aligned within each group of articles or multi- packs. The present invention seeks to overcome or at least to mitigate the drawbacks of the prior art in providing an apparatus directed to the above requirement.

SUMMARY OF INVENTION

A first aspect of the invention provides an apparatus for aligning one or more articles in an array, which apparatus comprises a conveyor for conveying said array in a continuous forward movement, a detector for detecting the orientation of the or each article within the array, a controller for comparing the orientation of the or each article to a predetermined orientation and an article rotation means operably controllable for rotating the or each article to the predetermined orientation.

Preferably the article detection means comprises a sensor for detecting an indicia applied to the or each article.

Preferably, there comprises a plurality of sensors mounted to a conveyor, each sensor being adapted to determine the orientation of a respective article in the array during the rotation process.

An optional feature of this aspect of the invention provides the article rotating means comprises of plurality of grippers, each said gripper adapted to move between a rest position and a gripping position when the gripper makes contact with the article to cause it to rotate through a predetermined angle rotation and wherein there further comprises support means disposed opposite the grippers to support the or each article during rotation.

Preferably, the support means comprises one or more rollers mounted on a conveyor which rollers engage the article during its rotation.

Preferably the plurality of grippers is capable of rotating the/or each article by substantially 360°.

Preferably, the gripper comprises a gripping element which element comprises an elongate member which elongate member is sized to cause the article to rotate by up to around 120 .

Preferably, there comprises three grippers positioned sequentially adjacent the conveyor and oppositely disposed the support means.

Further preferably the or each gripper is controlled by a controller which causes the or each gripper to engage the article for a rotational distance determined by an input signal from the article detection means.

An optional feature of this aspect of the invention provides a controller for controlling the apparatus.

Preferably, the or each of said plurality of grippers is capable of sequentially engaging the or each article in said array.

A second aspect of the invention provides a method of aligning indicia applied to one or more articles in an array which method comprises: determining the orientation of each article within the array; calculating a first angle of rotation necessary to align a first article in the array in a first predetermined orientation; causing said first article to rotate through said first rotational distance;

Preferably said method further comprises calculating a second angle of rotation necessary to align a second adjacent article in the array in a second predetermined orientation, and causing the said adjacent article within the array to be rotated through a second rotational distance thereby to align said first and second articles in a pre-determined relationship to one another.

A third aspect of the present inventions provides a method of manufacturing a package in which an article is packaged in a carton having a display window, the method comprising determining the position of each article held within the package relative to the display window by checking the orientation of the or each article through access means provided by the carton, relative to a predetermined orientation of the article and automatically manipulating said article, if desired, to correct the orientation of the article thereby providing a package wherein an article held within the package is disposed in a predetermined position relative to the display window.

Preferably, wherein the predetermined position the articles are disposed such that they are each arranged to face uniformly outwardly from a display window of the package.

Preferably wherein the position of each article is determined by reading labeling graphics and/or surface decoration of the or each article.

A fourth aspect of the present invention provides an apparatus for ensuring correct alignment of articles held within a carton having a display window, the apparatus comprising a reading element for determining the orientation of each article held within the carton, a checking means for checking the orientation of the article relative to a predetermined orientation and manipulating means structured and arranged such that in response to the checking, the manipulating means, if desired, automatically manipulates each of said articles to alter the orientation of the articles such that they are disposed in a predetermined position relative to the display window.

Preferably, wherein the predetermined position the articles are disposed such that they are each arranged to face uniformly outwardly from a display window of the carton.

Preferably, wherein the position of each article is determined by reading means, reading labeling graphics and/or surface decoration of the or each article.

BRIEF DESCRIPTION OF THE FIGURES

Exemplary embodiments of the present invention will now be described, by way of example only, with reference to the following Figures in which:

FIGURE IA and IB illustrate a package comprising a carton and a group of articles in an array, which packages suitable for operating with an apparatus for aligning the articles, according to one aspect of the present invention;

FIGURE 2 illustrates an apparatus for aligning articles according to one aspect of the present invention;

FIGURES 3 and 4 illustrate the sequential operation of the apparatus as shown in FIGURE 2;

FIGURE 5 illustrates the support means of the apparatus shown in FIGURE 2; and

FIGURES 6A, 6B, 6C and 6D illustrate the alignment means of the apparatus of FIGURE 2, shown in plan view and illustrating the sequential alignment of three articles in an array.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a system for aligning the indicia applied to articles that are conveyed through the working reach of a packaging machine as shown in Figure 2.

One example of a package 12 comprising an article carrier 12, suitable for use with an article aligning apparatus 10 of the present invention, is illustrated in Figures IA and IB. The article carrier 12 is, in this embodiment, adapted to carry an array of three articles B (individually referred to as individual articles 14, 16, 18), for example bottles, arranged in a single row. It is desirable in such an article carrier 12 to have articles B in which the labels L or advertising indicia L are aligned to provide an aesthetic appearance and to help provide information to a consumer. Of course other types of article carriers can use the aligning apparatus 10 without departing from the scope of the invention.

In this embodiment, the article carrier 12 includes an aperture A adjacent each article B to receive a portion of an support means to be described in more detail below.

Figure 2 illustrates the article aligning apparatus 10 for aligning the indicia L applied to articles B such as those shown in Figure 1. The article aligning apparatus 10 comprises a conveyor 20 for conveying the package 12 in a continuous forward direction whilst the articles B are rotated by the article rotation means 30, described below.

Upstream of the conveyor 20 is article packaging apparatus (not shown) which packages an array of articles B in the article carrier 12. To transfer package 12

comprising the article carrier 12 and the array of articles B from the packaging apparatus to the aligning apparatus 10 there is provided an article outlet conveyor 22 having article support lug systems 24 and 26 which control the supply of article carriers 12 to the article aligning apparatus 10.

A input conveyor 28 transfers the package 12 comprising the array of articles B from the packaging apparatus to the conveyor 20. In some embodiments, the input conveyor 28 can accelerate or retard the forward velocity of the package 12 according to the throughput velocity of the article aligning apparatus 10.

The article aligning apparatus 10 further comprises article detection means (not shown) which in this embodiment is a colour sensor mounted on the support means 38, which sensor used to detect an edge of an indicia L on each individual article 14, 16, 18. The colour sensor transmits the relative position of the edge of the indicia to a controller (not illustrated) that controls the article rotation means 30.

In this embodiment, the article rotation means 30 comprises three grippers 32, 34, 36 mounted adjacent to conveyor 20. Preferably, the grippers 32, 34, 36 each comprise an elongate member 46, 48, 50 for engaging each of the articles B in each package 12. The elongate members 46, 48, 50 hereinafter referred to as first, second and third article engagement members 46, 48, 50 respectively are sized to cause an article B to rotate up to maximum defined angle, which in this embodiment each gripper 32, 34, 36 is capable of rotating an article B up to about 120°.

There further comprises support means 38, supporting the articles B during rotation. In this embodiment the support means 38 comprises one or more rollers 40, 42 mounted to a support 41. The support means 38 is coupled to a second conveyor 44 and the rollers 40, 42 engage each article B upstream of the rotation process.

Turning now to Figures 3 to 6 which illustrate the progress of the package 12 through the article aligning apparatus 10. The article carrier 12 comprising the individual articles 14, 16, 18 is fed into the article aligning apparatus 10 by the input conveyor 28 and onto the conveyor 20. In Figure 3, the articles B

progressively come into contact with a pair of rollers 40, 42 of a support 41 coupled to the support means 38, this occurs upstream of the article rotating means 30, shown more clearly in Figure 5. As the conveyor 20 moves the package 12 forward, a support 41 is brought into registry with each article B in the package 12. It is envisaged that a colour sensor may be mounted on each support 41. In alternative embodiments a single colour sensor may be provided which determines the position of every article B as it passes. The colour sensor determines the position of the indicia L on each article B. This information is transmitted to a controller (not shown), which compares the actual position of the article to a desired position of the article in order to place them in the desired orientation. The controller then determines the degree of rotation to be applied to each article B. The controller then effects the rotation of each article B by sending instructions to the grippers 32, 34, 36 to move forward to engage each article B requiring rotation for a defined period of time, thereby causing the engaged articles B to rotate, as shown in Figure 4 and described in more detail below. As the articles B are rotated the article support means 38 holds the respective article B stable and without hindering rotation because each article B is in abutment with a pair of the rollers 40 and 42. In alternative embodiments rollers 40, 42 or support 41 may facilitate rotation of the article B.

Once the articles B have been rotated to the desired position, they move to the outfeed end of the article aligning apparatus 10.

Figure 5 illustrates the progressive engagement and disengagement of the support means 38 through the working reach of the article aligning apparatus 10.

Turning in detail to the configuration of the article rotation means 30, reference is made to Figure 6 A to 6D.

In the embodiment illustrated in Figure 6 A, the leading article Bl is required to move in excess of three quarters of a full rotation, in other words by more than 270°. This degree of rotation is achieved by employing all three grippers 32, 34, 36 to sequentially engage the article Bl. Furthermore in the preferred embodiment it requires the use of all three grippers 32, 34, 36 since in the preferred embodiment

each gripper 32, 34, 36 individually is capable of a maximum angle of rotation of 120°. The reason for this it that the length of each gripper 32, 34, 36 is equal to one third of the circumference of the articles B. Thus the article Bl is engaged by the first engagement member 46 to rotate it through 120°. As the article Bl moves forward it is engaged by the second engagement member 48, shown in Figure 6B to cause the article Bl to rotate through a further 120°. As the article Bl passes the third engagement member 50 the engagement member 50 engages with the article for a shorter period of time, thus to effects a smaller degree of rotation. In doing so the angle of rotation achieved by the third engagement member 50 is smaller than 120° in order to bring the indicia L to the desired position shown in Figure 6D.

The second article B2 is already aligned in the desired orientation so as the second article B2 passes each of grippers 32, 34, 36 the first, second and third engagement members 46, 48 and 50 are sequentially withdrawn to their rest positions whilst the second article B2 passes, shown in Figures 6B, 6C and 6D.

The third article B3 is required to rotate through an approximately quarter turn, 90°, the first engagement member 46 is instructed to engage the article B3 for a period of time sufficient to rotate the indicia L into the desired orientation after which it is withdrawn to its rest position. Thereafter the second and third gripping elements 48 and 50 remain in their rest position as the indicia L is now positioned in its desired orientation. In alternative embodiments the required degree of rotation may be effect by utilizing all three gripper 32, 34, 36 each to effect one third of the required angle of rotation.

In this embodiment, the first second and third engagement members 46, 48, 50 are actuated forwards and backwards, in a direction transverse to the direction of article flow, by a pneumatic piston although it is envisaged that other electrical or electro mechanical means can be applied without departing from the scope of the inventions.

Furthermore, in the preferred embodiment three grippers 32, 34, 36 are provided and each gripping element can rotate the article by up to about 120° in order to provide up to 360° rotation.

It is envisaged that the number of degrees of rotation provided by each gripper 32, 34, 36 can be varied by changing the length of the engagement members 46, 48, 50, for example if the article B had a low co-efficient of friction, then it would be desirable for each gripper 32, 34, 36 to rotate the article B through a smaller angle of rotation, in which case a fourth gripper could be provided with each gripper in the series providing up to 90° rotation.

In the embodiment, the colour sensors may be located on the each support 41 and continuously monitor the position of the indicia L relative the desired location whilst rotation is being effected thereby providing real time monitoring of the orientation of the article B during the rotation process.

In other embodiments, it is envisaged that articles B within the package 12 could be rotated by providing a support means 38 and grippers 32, 34 and 36 on both sides of the conveyor 20, without departing from the scope of invention. Furthermore in such an embodiment it is envisaged that a plurality of articles B may be pointed in an array comprising two rows, and that the articles in both rows may be aligned by a respective engagement member.

In an alternative embodiment the articles B are provided with both front L and rear labels R. The following method is equally applicable to articles other than bottles having either one or more directly affixed labels and/or wrapping and/or other graphics printed directly to the article/bottle. The purpose of the graphic labeling is to provide stand-out to the consumer, for aesthetic and marketing appeal and for advertising and branding purposes and as such has a correct orientation. The following method sets out how the randomly orientated articles B of Figure 3A are uniformly aligned to produce the package of Figure 3B.

The assembled package 12 with randomly orientated graphic labeling or indicia L is moved into an apparatus (not shown) comprising a conveyer for moving the package 12 in front of a sensor which 'reads' the label. By reading it is meant any form of interpretation of the graphic labeling for example, colour and/or character recognition

of the matter printed on the label, detection of the outline of the label and other automated means for registering the current location of the labeling graphics.

The sensed and registered location of the graphic labeling is checked against a desired correct position. In this example a central axis of the affixed label L is to be disposed in line with a notional line running between the centre of a neck aperture and the centre of the base aperture, as shown in Figure 3B. This desired orientation or correct orientation of the indicia L is known or predetermined by a control means coupled to the sensor which can calculate the number of degrees the bottle needs to be rotated in order for the central axis of the indicia L to fall on the notional line.

The article alignment apparatus 10 is provided with a manipulation element (or series thereof) such as those described above which is coupled to a reading sensor such that the manipulation element can carry out the manipulation i.e. rotation of the articles B to adjust the position of each article by a required movement i.e. the number of degrees rotation required in order to align the central axis of the indicia L with the notional line. In this way each article B in a package 12 is oriented correctly regarding the display of the indicia L of the article B.

It can be appreciated that various changes may be made without departing from the scope of the present invention, for example, the size and shape of the panels may be adjusted to accommodate articles of differing size or shape. In another embodiment, the articles do not have labels affixed thereto but may have graphics printed thereon. It is envisaged that only one or more articles may be contained in the carton and that bottles may be substituted for any other kind of article without departing from the scope of the present invention.

In one embodiment the indicia or label L is read by a laser based sensor disposed in front of the front panel 22, 24, 26, 28 of the package 12 and the manipulation element is also disposed in front of the package 12 and aligned to contact the or each article B at a location below the graphic labeling L to ensure that the manipulation element does not damage the graphic labeling L. In this embodiment the aperture A is provided to receive a rearside conveyor which stabilises the bottle during rotatory manipulation. In an alternative embodiment there is no rearside conveyor and the

aperture A is used to provide access to the article B for reading the graphic labeling by the sensor. In yet a further alternative embodiment, the aperture A is provided to receive the article manipulation element.

The embodiments of the system herein described above are exemplary in nature and it is contemplated that the implementation of the various features as described above may be altered within the scope of the invention as set up in the attached claims. As noted herein above the conveyor means 20 which is illustrated as a conveyor belt may be in any other form a conveyor means capable of driving the packages 12 along a path suitable for achieving the alignment operation as described above. Additionally, the mechanical implementation of the connection between the conveyor means 20 and the articles B may also be adapted to include one or more alignment elements. The alignment elements of the present invention are not limited to those disclosed in the embodiment described above.

The exemplary embodiments as illustrated show operation in a horizontal plane although it is contemplated that the same technique can be used to align articles B in some other orientation, without departing from the scope of the invention.