BACKGROUND OF THE INVENTION

[0001] Embodiments of the invention relate to a method and apparatus for transferring and reorienting discrete articles, such as discrete web sections or discrete components used in the manufacture of wearable garments, as they advance along a production line.

[0002] In the production and manufacture of various types of wearable garments, it frequently becomes necessary to manufacture a component of the product in one orientation, and then to spin that component part to a predetermined angle, which is suitably oriented for use in another step in the production process. As an example, a typical article or web to be reoriented is an absorbent pad that is used in disposable products such as sanitary napkins or pants-type diapers. Existing transfer devices function to receive a pad, spin the pad to a predetermined angle, and transfer the pad for placement on a receiving surface. In the case of a diaper, for example, the pad may be an absorbent insert to be placed on a fluid impervious chassis. The transfer devices may further function to control a velocity and pitch between pads to achieve a desired placement pitch on the receiving surface, with the apparatuses receiving the pads at a first pitch and placing the pads onto the receiving surface at a different second pitch.

[0003] The transfer devices employed for transferring and reorienting discrete pads in the manufacture of absorbent articles are generally constructed to include a large wheel having a plurality of rotating article holding heads secured thereto that are selectively operable to provide the rotating and re-pitching of the pads. The wheel is driven and supported by a shaft extending from the drive side of the machine, with the article holding heads in turn being rotated along with the wheel. Additionally, each of the article holding heads functions to spin/turn about its own spin axis, so as to provide for turning (e.g., 90° turn) of the pads. The pucks function to pick up the pads at a receiving location, rotate the pads along a path of travel as the wheel rotates, and - as the pads are advanced along the path of travel from the receiving location to a placement location - re-pitch and spin the pucks to provide for turning of the pads into a desired orientation and placement of the pads onto the chassis at a desired pitch.

[0004] While existing transfer devices for the manufacturing of diapers perform adequately for rotating and re-pitching pads for placement on a receiving surface (e.g., a chassis), it is recognized that such transfer devices have several limitations. Primarily, existing transfer devices lack the flexibility desired in many manufacturing settings and implementations, including the ability to accommodate articles of a very large size. That is, in order for the transfer device to accommodate articles of different size, it is necessary for the transfer device to be operable at a plurality of different speed/velocity profiles and for the pitch range of the article holding heads to be modified. With existing transfer devices, such as the rotating puck wheel with rotating article holding heads as described above, there are limitations as to the maximum achievable pitch range of the article holding heads that makes the devices unsuitable for the transferring and reorienting of very large articles.

[0005] Therefore, it is desirable to provide an apparatus for transferring and reorienting discrete articles that is able to accommodate articles of larger size.

BRIEF DESCRIPTION OF THE INVENTION

[0006] Embodiments of the invention are expressed and characterized in the independent claims, while the dependent claims explain other characteristics and variants of the invention. The characteristics and variants described in the dependent claims may be used in combination with or in isolation from each other, according to embodiments of the invention.

[0007] In accordance with some embodiments, an apparatus for transferring and rotating a discrete article from a receiving location to a placement location is provided. The apparatus includes a main mover track defining a cyclical path of travel, an article holding head that translates along the main mover track about the cyclical path of travel, and a cam track offset from the main mover track and positioned to interact with the article holding head only when the article holding head traverses a sub-portion of the cyclical path of travel. The article holding head further includes an article carrying surface configured to retain the discrete article thereon and rotatable about a pivot axis between a first orientation and a second orientation, a biasing member configured to apply a biasing force that retains the article carrying surface in the first orientation, and a cam follower configured to engage the cam track when the article holding head traverses the sub-portion of the cyclical path of travel, wherein engaging of the cam follower with the cam track causes the article carrying surface to rotate from the first orientation to the second orientation by overcoming the biasing force.

[0008] In some embodiments, the article carrying surface rotates 90° from the first orientation to the second orientation.

[0009] In some embodiments, the cam follower includes a cam roller configured to roll along the cam track when the article holding head traverses the sub-portion of the cyclical path of travel, a pivot shaft rotatable about the pivot axis and coupled to the article carrying surface, and a connector arm having a first end coupled to the pivot shaft and a second end having the cam roller positioned thereon. Rolling of the cam roller along the cam track generates a rotational force that overcomes the biasing force and causes a resulting rotation of the connector arm that is transferred to the pivot shaft to cause the article carrying surface to rotate.

[0010] In some embodiments, the article holding head further includes a chassis frame member comprising a range limiting track formed therein and a pin fixed to the article carrying surface on a surface thereof facing the chassis frame member, the pin positioned within the range limiting track and configured to translate along the range limiting track responsive to rotation of the article carrying surface between the first orientation and the second orientation. The article holding head further includes a stop positioned at or near each of opposing ends of the range limiting track that is selectively positionable to define the first orientation and the second orientation.

[0011] In some embodiments, a catch feature is positioned adjacent the stop configured to retain the pin therein when the article carrying surface is in the first orientation.

[0012] In some embodiments, the biasing member of the article holding head comprises a tension spring.

[0013] In some embodiments, the cam track includes a linear region flanked by a first curved region and a second curved region. The cam follower engages the cam track to cause the article carrying surface to rotate in a first direction, from the first orientation to the second orientation, as the cam follower moves in a machine direction and along the first curved region to the linear region, and cause the article carrying surface to rotate in a second direction opposite the first direction, from the second orientation back to the first orientation, as the cam follower moves in the machine direction and along the curved surface from the linear region to the second curved region.

[0014] In some embodiments, the cam track is aligned with a conveyor that carries the discrete article to the receiving location such that the article carrying surface of the article holding head is caused to be in the second orientation when the discrete article is transferred from the conveyor to the article holding head at the receiving location.

[0015] In some embodiments, the main mover track has a perimeter defining the cyclical path of travel and the cam track is offset laterally outward from the perimeter.

[0016] In some embodiments, the perimeter of the main mover track has a generally rectangular-shaped perimeter with radiused comers and the cam track extends along all or a portion of one side of the generally rectangular-shaped perimeter.

[0017] In some embodiments, a retaining cam track section is positioned adjacent each of the radiused comers of the main mover track and offset therefrom. The cam follower engages a respective retaining cam track section as the article holding head traverses around the respective radiused corner of the main mover track, with engagement of the cam follower with the retaining cam track section retaining the article carrying surface in the first orientation.

[0018] In some embodiments, a vacuum system provides a vacuum to the article carrying surface of the article holding head, to retain the discrete article on the article carrying surface.

[0019] In some embodiments, the apparatus includes a plurality of additional article holding heads that translate along the main mover track about the cyclical path of travel, with the vacuum system configured to provide a vacuum to the article carrying surface of each of the article holding head and the plurality of additional article holding heads, to retain the discrete article on the article carrying surface. The vacuum system further includes a vacuum hub configured to provide the vacuum and a plurality of vacuum arms extending outwardly from the vacuum hub to transfer the vacuum from the vacuum hub to the article holding head and the plurality of additional article holding heads. The plurality of vacuum arms is rotatable about a central axis of the vacuum hub, with rotation of the plurality of vacuum arms tracking rotation of the article holding head and the plurality of additional article holding heads about the cyclical path of travel.

[0020] In some embodiments, a plurality of flexible tubes extend between the plurality of vacuum arms and the article holding head and the plurality of additional article holding heads.

[0021] In some embodiments, the article holding head and the plurality of additional article holding heads each include an arm guide including one or more openings therein that retain a respective flexible tube of the plurality of flexible tubes.

[0022] In accordance with other embodiments, a method for transferring and rotating a discrete article from a receiving location to a placement location is provided. The method includes advancing an article holding head in a machine direction along a main mover track that defines a cyclical path of travel for the article holding head, the article holding head comprising an article carrying surface configured to retain a discrete article thereon and that is rotatable between a first orientation into which the article carrying surface is biased and a second orientation. The method also includes engaging a cam follower of the article holding head with a cam track laterally offset from the main mover track upon the article holding head reaching a section of the main mover track that runs adjacent the cam track, rotating the article carrying surface from the first orientation to the second orientation while the cam follower is engaged with a first portion of the cam track, rotating the article carrying surface from the second orientation to the first orientation while the cam follower is engaged with a second portion of the cam track, and selectively utilizing vacuum to secure the discrete article on the article holding head at the receiving location with the article carrying surface in the second orientation and to release the discrete article at the placement location with the article carrying surface in the first orientation.

[0023] In some embodiments, the steps of engaging of the cam follower with the cam track and rotating the article carrying surface from the first orientation to the second orientation include rolling a cam roller along the cam track as the article holding head advances along the section of the main mover track that runs adjacent the cam track and rotating a connector arm of the article holding head, coupled between the cam roller and a pivot shaft connected to the article carrying surface, as the cam roller rolls along the cam track, to cause the article carrying surface to rotate from the first orientation to the second orientation.

[0024] In some embodiments, the rolling of the cam roller along the cam track generates a rotational force on the connector arm that overcomes a biasing force applied to the connector arm that maintains the article carrying surface in the first orientation.

[0025] In some embodiments, the biasing force is a spring force applied by a spring included in the article holding head.

[0026] In some embodiments, the method also includes locking the article carrying surface in the first orientation via a locking mechanism of the article holding head.

[0027] In some embodiments, rotating the article carrying surface from the first orientation to the second orientation includes rotating the article carrying surface 90° in a first direction, and wherein rotating the article carrying surface from the second orientation to the first orientation comprises rotating the article carrying surface 90° in a second direction that is opposite the first direction.

[0028] In some embodiments, the method also includes supplying a vacuum to the article carrying surface of the article holding head via a vacuum system, wherein supplying the vacuum comprises, providing the vacuum from a vacuum hub positioned within an area defined by a perimeter of the main mover track, and transferring the vacuum from the vacuum hub to the article carrying surface of the article holding head through one or more vacuum arms and flexible tubes extending therebetween, wherein the one or more vacuum arms and flexible tubes rotate about a central axis of the vacuum hub in a manner that tracks the advancing of the article holding head about the cyclical path of travel. [0029] In accordance with other embodiments, an apparatus for transferring and rotating a discrete article from a receiving location to a placement location is provided. The apparatus includes a main mover track defining a cyclical path of travel and an article holding head that translates along the main mover track about the cyclical path of travel. The article holding head includes a chassis comprising a first chassis frame member and a second chassis frame member, the first chassis frame member movably coupled to the main mover track and the second chassis frame member coupled to the first chassis frame member. The article holding head also includes an article carrying surface configured to retain the discrete article thereon, the article carrying surface rotatable about a pivot axis between a first orientation and a second orientation. The article holding head further includes a stand-alone chassis frame member separate from the chassis and movably coupled to the main mover track and an actuating structure that rotatably couples the article carrying surface to the second chassis frame member and is configured to selectively rotate the article carrying surface between the first orientation and the second orientation, with the actuating structure including a pivot shaft comprising a first end coupled to the article carrying surface, a connector arm comprising a first arm end coupled to a second end of the pivot shaft, and a bridge member extending between a second arm end of the connector arm and the stand-alone chassis frame member so as to link the stand-alone chassis frame member to the chassis. The apparatus also includes a controller configured to independently control movement of each of the first chassis frame member and the stand-alone chassis frame member along the main mover track and thereby control a spacing between the first chassis frame member and the stand-alone chassis frame member, with a change in spacing between the first chassis frame member and the stand-alone chassis frame member causing the actuating structure to provide a corresponding rotation of the article carrying surface.

[0030] In some embodiments, the article holding head further includes a first mover element integrated with the first chassis frame member and configured to cause the chassis to move along the main mover track, and a second mover element integrated with the stand-alone chassis frame member and configured to cause the stand-alone chassis frame member to move along the main mover track. The controller is operably connected to one or more of the main mover track and the article holding head to control an interaction therebetween, thereby independently controlling movement of each of the first chassis frame member and the stand-alone chassis frame member along the main mover track.

[0031] These and other advantages and features will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The drawings illustrate embodiments presently contemplated for carrying out the invention.

[0033] In the drawings:

[0034] FIG. 1 is a block schematic diagram of an apparatus for transferring and reorienting discrete articles, along with arrangement thereof relative to input and output stations of a production line, according to an embodiment of the invention;

[0035] FIG. 2 is a front perspective view of an apparatus for transferring and reorienting discrete articles, according to an embodiment of the invention;

[0036] FIG. 3 is a top plan view of the apparatus of FIG. 2;

[0037] FIG. 4 is a closeup perspective view of the apparatus of FIG. 2;

[0038] FIGS. 5 and 6 are perspective views of an article holding head moving along a main mover track in the apparatus of FIG. 2;

[0039] FIG. 7 is a front perspective view of an article holding head included in the apparatus of FIG. 2;

[0040] FIG. 8 is a rear perspective view of an article holding head included in the apparatus of FIG. 2;

[0041] FIG. 9 is a top plan view of a portion of the apparatus of FIG. 2 showing an article holding head in a first position when engaging with a cam track of the apparatus;

[0042] FIG. 10 is a top plan view of a portion of the apparatus of FIG. 2 showing an article holding head in a second position when engaging with a cam track of the apparatus; [0043] FIG. 11 is a top plan view of a portion of the apparatus of FIG. 2 showing an article holding head in a third position when engaging with a cam track of the apparatus;

[0044] FIG. 12 is a top plan view of a portion of the apparatus of FIG. 2 showing an article holding head in a fourth position when engaging with a cam track of the apparatus;

[0045] FIG. 13 is a top plan view of a portion of the apparatus of FIG. 2 showing an article holding head in a fifth position when engaging with a cam track of the apparatus;

[0046] FIG. 14 is a flowchart of a method for transferring and reorienting discrete articles, according to an embodiment of the invention;

[0047] FIG. 15 is a top perspective view of an article holding head useable with an apparatus for transferring and reorienting discrete articles, according to an embodiment of the invention;

[0048] FIG. 16 is a top perspective view of an article holding head useable with an apparatus for transferring and reorienting discrete articles, according to an embodiment of the invention;

[0049] FIG. 17 is a top perspective view of an article holding head useable with an apparatus for transferring and reorienting discrete articles, according to an embodiment of the invention;

[0050] FIGS. 18 is a top view of an apparatus for transferring and reorienting discrete articles, according to another embodiment of the invention;

[0051] FIG. 19 is a perspective view of the apparatus of FIG. 18, with some features removed or phantomed in for clarity; [0052] FIGS. 20 and 21 are perspective views of an article holding head moving along a main mover track, according to another embodiment of the invention;

[0053] FIG. 22 is a front perspective view of the article holding head of FIGS. 20 and 21 in isolation; and

[0054] FIG. 23 is a rear perspective view of the article holding head of FIGS.

20 and 21 in isolation.

DETAILED DESCRIPTION

[0055] Embodiments of the invention are directed to a method and apparatus for transferring and reorienting discrete articles.

[0056] Referring to FIG. 1 , a block schematic diagram of an apparatus 10 for transferring and reorienting discrete articles 12 is shown, according to an embodiment. The apparatus 10 may form part of a larger production line for the manufacture of wearable garments, with the apparatus 10 receiving discrete articles 12 from one system or device of the production line (i.e. , an input station 14) and transferring the articles 12 to another system or device of the production line (i.e., an output station 16). While transferring the discrete articles 12, the apparatus 10 functions to reorient the articles 12 from an orientation in which they are received at the input station 14 to an orientation in which they are to be deposited or transferred at the output station 16.

[0057] In one embodiment, and as illustrated in FIG. 1 , the apparatus 10 may form part of a larger production line for the manufacture of multi-piece closed- back isolation gowns. The apparatus 10 receives a stream of incoming discrete articles 12 in the form of discrete torso web pieces (hereafter “discrete torso web pieces 12”) at the input station 14. The torso web pieces 12 may be formed from one or more continuous torso webs (not shown) that may be initially provided and subsequently folded, cut, and bonded, to form the discrete tubular torso web pieces 12 provided to the input station 14. The discrete torso web pieces 12 are transferred (and reoriented) by the apparatus 10 from the input station 14 to the output station 16, where a continuous web of shoulder web pieces 18 is provided. The discrete torso web pieces 12 are deposited from the apparatus 10 onto the continuous web of shoulder pieces 18 at the output station 16, whereafter the discrete torso web pieces 12 may be subsequently bonded to the continuous web of shoulder pieces 18 to form a stream of isolation gowns that may undergo further processing via additional downstream components in the production line. [0058] For transferring the discrete torso web pieces 12 and reorienting them from a first orientation at which they are received at the input station 14 to a second orientation at which they are deposited and transferred at the output station 16, a plurality of article holding heads 20 are provided in the apparatus 10. The article holding heads 20 rotate about a main mover track 22 of the apparatus 10 to traverse a cyclical path of travel 24. While moving about the cyclical path of travel 24, the article holding heads 20 pass a receiving location 26 at which they pick up discrete torso web pieces 12 from the input station 14 and then proceed in a machine direction 28 to a placement location 30 at which they deposit the discrete torso web pieces 12 onto the continuous web of shoulder web pieces 18 supplied via the output station 16. In the illustrated embodiment, each of the article holding heads 20 is fluidly coupled to a vacuum system 32 of the apparatus 10 that operates to selectively provide a vacuum to the article holding heads 20. The vacuum system 32 functions to supply a vacuum to the article holding heads 20 to pick up and retain the discrete torso web pieces 12 as they traverse between the receiving location 26 and the placement location 30 and then terminate the vacuum upon the article holding heads 20 reaching the placement location 30 to release the discrete torso web pieces 12.

[0059] While advancing along a sub-portion of the path of travel 24, the article holding heads 20 are caused to interact with a cam track 34 of the apparatus 10 that is laterally offset from the main mover track 22. The interaction between the article holding heads 20 and the cam track 34 causes a reorienting of an article carrying surface of the article holding heads 20. As will be explained in greater detail below, the article carrying surface of each article holding head 20 is biased into a first orientation for a majority of the path of travel 24 about which the article holding head 20 rotates, but the article carrying surface is caused to rotate to a second orientation responsive to the article holding head 20 interacting with the cam track 34. In this manner, the article holding heads 20 can reorient the discrete torso web pieces 12 for depositing onto the continuous web of shoulder web pieces 18. [0060] Referring now to FIGS. 2-8, various views of the apparatus 10 and of particular components therein are provided to better illustrate and describe aspects of the apparatus 10. As previously described, the main components of the apparatus 10 include article holding heads 20, a main mover track 22, a vacuum system 32, and a cam track 34. Also provided in the apparatus 10 is a base frame 36 that provides support to these different components. The base frame 36 may also, as in the present embodiment, provide for mounting of the input station 14 and the output station 16 thereto, such that the location and arrangement of the input station 14 and output station 16 are fixed relative to the apparatus 10.

[0061] As illustrated, the main mover track 22 is affixed to a top portion 38 of the base frame 36, with a footprint or perimeter 40 of the main mover track 22 and the base frame 36 being substantially similar in shape. In the present embodiment, the main mover track 22 is structured to define a generally rectangular-shaped perimeter 40 with radiused comers, although it is recognized that a main mover track 22 and base frame 36 having a differently shaped perimeter could alternatively be used in the apparatus 10 (e.g., a circular shaped perimeter). The perimeter 40 of the main mover track 22 defines the path of travel 24 of the article holding heads 20 as they advance in the machine direction 28 along the main mover track 22.

[0062] The cam track 34 is also affixed to the base frame 36 in a manner that fixes the cam track 34 relative to the main mover track 22. An extension arm structure 42 is provided to couple the cam track 34 to the base frame 36, with the extension arm structure 42 positioning the cam track 34 in a suspended arrangement relative to the base frame 36 and relative to the main mover track 22. As illustrated, the extension arm structure 42 is configured to position the cam track 34 in a laterally outward position from the perimeter 40 of the main mover track 22 and in vertical alignment with the main mover track 22 (i.e. , in generally a same horizontal plane). The cam track 34 is configured to extend along only a sub-portion 44 (FIG. 3) of the cyclical path of travel 24 defined by the main mover track 22. In the example embodiment, the cam track 34 is thus positioned adjacent only one side of the main mover track 22, with the cam track 34 sized to extend along only a portion of the side of the main mover track 22 (i.e. , the cam track 34 extends along only a portion of one side of the generally rectangularshaped perimeter 40 of the main mover track 22).

[0063] As shown, the side of the main mover track 22 adjacent to which the cam track 34 is positioned is the side at which the input station 14 is also positioned. The cam track 34 is thus aligned with the sub-portion 44 of the cyclical path of travel 24 of the article holding heads 20 that includes the receiving location 26 where the article holding heads 20 pick up discrete articles 12 from the input station 14. As will be explained in greater detail below, the cam track 34 interacts with the article holding heads 20 as they traverse this sub-portion 44 of the path of travel 24 in order to reorient an article carrying surface 46 of each article holding head 20. The article carrying surface 46 of each article holding head 20 is rotated into an orientation necessary for picking up a discrete article 12 at the receiving location 26 due to this interaction between the cam track 34 with the article holding head 20, with the interaction between the cam track 34 with the article holding head 20 then also causing the article carrying surface 46 to rotate back into an orientation appropriate for depositing the discrete article 12 at the placement location 30 at the output station 16.

[0064] Referring to FIGS. 5-8, the structure of the main mover track 22 and the article holding heads 20 are shown to better describe the interaction therebetween that enables movement of the article holding heads 20 along the main mover track 22.

[0065] As shown in FIGS. 5-8, the main mover track 22 generally includes a rail structure 48 and a conveyance surface 50 that collectively provide for mounting of the article holding heads 20 to the main mover track 22 and for conveyance of the article holding heads 20 along the main mover track 22. In the example embodiment, the rail structure 48 is formed to include a pair of upper rails 52 positioned on an upward facing surface and an outward facing surface of the main mover track 22 and a lower rail 54 positioned on a downward facing surface of the main mover track 22. The upper rails 52 and the lower rail 54 function as tracks along which the article holding heads 20 may translate, with the rails 52, 54 each following the perimeter 40 of the main mover track 22 to define the path of travel 24 of the article holding heads 20. The conveyance surface 50 is provided between the upper rails 52 and the lower rail 54 to form part of the outward facing surface of the main mover track 22. The conveyance surface 50 is formed as a generally planar, smooth surface that faces the article holding heads 20 when the article holding heads 20 are mounted on the main mover track 22, such that the article holding heads 20 may move freely along the main mover track 22.

[0066] As shown in FIGS. 5-8, an article holding head 20 generally includes a main body or chassis 56 and an article carrying surface 46 that is positioned on the chassis 56. The chassis 56 secures the article holding head 20 to the rail structure 48 of the main mover track 22 and provides for displacement of the article holding head 20 along the main mover track 22. The chassis 56 includes a pair of chassis frame members 58, 60 joined together, with the first chassis frame member 58 accommodating positioning of the rail structure 48 therebetween and the second chassis frame member 60 securing the article carrying surface 46 thereto in a manner that provides for rotation thereof.

[0067] The first chassis frame member 58 is structured as a generally C- shaped member having upper and lower protruding portions 62, 64 surrounding a center portion 66. A plurality of rollers 68 is coupled to the first chassis frame member 58 on or adjacent the upper and lower protruding portions 62, 64 in an arrangement that allows for the article holding head 20 to be secured onto the rail structure 48 and provides for translation of the article holding head 20 along the upper rails 52 and the lower rail 54. In one example, eight (8) upper rollers 68 and four (4) lower rollers 68 are provided on the upper and lower protruding portions 62, 64 of the first chassis frame member 58, with the eight upper rollers 68 positioned about and engaging the upper rails 52 and the four lower rollers 68 positioned about and engaging the lower rail 54. The center portion 66 of the first chassis frame member 58 is structured as a generally flat section that aligns with the conveyance surface 50 of the main mover track 22 when the article holding head 20 is mounted on the main mover track 22, such that the article holding head 20 may move freely along the main mover track 22.

[0068] Each of the article holding heads 20 includes a mover element 70 that advances the article holding head 20 along the main mover track 22. In one embodiment of the apparatus 10, the article holding heads 20 advance along the main mover track 22 via an electromotive force or electromagnetic propulsive force. In such a configuration, the mover element 70 is provided as one or more (permanent) magnets provided in the center portion 66 of the first chassis frame member 58, while the main mover track 22 is configured to generate an electromagnetic field that interacts with the mover element to cause the article holding heads 20 to move relative to the conductive track. That is, the main mover track 22 may include stator elements therein (not shown) adjacent/behind the conveyance surface 50 through which electrical current may be passed to generate an electromagnetic field. Magnetic fields generated by the mover element (i.e., magnet(s)) interact with this electromagnetic field to propel the article holding heads 20 along the main mover track 22. An electrical current may be passed through the conveyance surface 50 of the main mover track 22 that is used to either create an opposing magnetic field (from the magnetic field generated by the mover element 70), or to charge a field, which can then be repelled, to thereby cause the article holding head 20 to advance along the main mover track 22.

[0069] While not shown in the figures, an alternative embodiment of the apparatus 10 may utilize a mover element 70 in the form of one or more servo motors or other or actuators that drive rotation of the rollers 68 to advance the article holding heads 20 along the main mover track 22. The mover element 70 (that may include one or more servo motors) is provided in the center portion 66 of the first chassis frame member 58, such that the mover element 70 is positioned adjacent the conveyance surface 50 of the main mover track 22 when the article holding head 20 is mounted on the main mover track 22. In this configuration, the main mover track 22 functions as a conductive track that provides power to the article holding heads 20 and to the mover element 70 thereof. An electrical current may be passed through the conveyance surface 50 of the main mover track 22 to provide electromagnetic induction that powers the article holding heads 20, thereby driving the mover element 70 (servo motors) to rotate the rollers 68 and cause the article holding heads 20 to advance along the main mover track 22.

[0070] Referring still to FIGS. 5-8, the second chassis frame member 60 is shown as including a carrying surface mount 72 and a vacuum channel structure 74. The carrying surface mount 72 provides a lower surface or platform to which the article carrying surface 46 is positioned adjacent to. The carrying surface mount 72 includes an opening 77 formed therein that receives a pivot shaft 78 that is coupled to the article carrying surface 46 and that provides rotation thereto. The article carrying surface 46 is rotatable relative to the carrying surface mount 72 and may be selectively reoriented as desired during operation of the apparatus 10 to facilitate the transferring and reorienting of discrete articles 12 via the article holding heads 20.

[0071] The vacuum channel structure 74 of the second chassis frame member 60 is positioned on a side of the carrying surface mount 72 opposite from the article carrying surface 46. The vacuum channel structure 74 includes vacuum inputs 76 and internal vacuum channels (not shown) by which a vacuum can be provided to the article carrying surface 46. In the illustrated embodiment, a pair of vacuum inputs 76 are provided to provide a vacuum to the internal vacuum channels, although it is recognized the vacuum channel structure 74 could include a different number of vacuum inputs 76 (e.g., one input). In operation of an article holding head 20, a vacuum is drawn through the vacuum inputs 76 and through the internal vacuum channels, with the vacuum divided into multiple vacuum zones 79 at the article carrying surface 46 (FIG. 8). The orientation of the article carrying surface 46 may control which zones 79 are in fluid communication with the vacuum and whether the article holding heads 20 will pick up or release (i.e. , activate/deactivate the vacuum through the article holding head 20) a discrete article 12.

[0072] As indicated above, the article holding head 20 is configured to provide for rotation of the article carrying surface 46 relative to the chassis 56 thereof. To enable this rotation of the article carrying surface 46, a spin cam follower structure 80 (hereafter “cam follower 80”) is included in the article holding head 20 that is configured to selectively rotate or “spin” the article carrying surface 46 during operation of the article holding head 20. In the example embodiment, the cam follower 80 includes a cam roller 82, pivot shaft 78, and connector arm 84. The cam roller 82 is positioned on one end of the connector arm 84, with the opposing end of the connector arm 84 coupled to the pivot shaft 78. The pivot shaft 78, in turn, is positioned within the opening 77 formed in the carrying surface mount 72 and extends therethrough to be coupled to the article carrying surface 46. According to this structure of the cam follower 80, any rotation of the connector arm 84 - such as may be caused by interaction of the cam roller 82 with an associated component (i.e., cam track 34) - is transferred to the pivot shaft 78, with the pivot shaft 78 rotating about a pivot axis 86 and causing the article carrying surface 46 to rotate in a like manner.

[0073] A biasing member 88 is included in the article holding head 20 that operates along with the cam follower 80 to control rotation of the article carrying surface 46 relative to the chassis. In particular, the biasing member 88 is configured to apply a biasing force to the connector arm 84 that retains the connector arm 84 in an initial position. This biasing of the connector arm 84 into the initial position, in turn, arranges or positions the article carrying surface 46 in a default (or first) orientation. In the example embodiment, the biasing member 88 is provided as a tension spring 88 (hereafter “tension spring 88”) that applies a biasing force (spring force) to the connector arm 84. The tension spring 88 is coupled at a first end to a spring mount 90 that is provided on the second chassis frame member 60 (e.g., on a top side of the carrying surface mount 72) and at a second end to the connector arm 84 (e.g., on an underside and near a mid-point of the connector arm 84). The tension spring 88 thus retains the connector arm 84 in an initial position relative to the chassis 56, with rotation of the connector arm 84 enabled only when a force is applied thereto that is opposite to and greater than the biasing force imposed by the tension spring 88.

[0074] As shown in FIGS. 5-8, the cam roller 82 (and connector arm 84) is positioned above the carrying surface mount 72 (opposite form the article carrying surface 46) and on a side of the article holding head 20 that is generally opposite from the first chassis frame member 58, such that the cam roller 82 is distal from the main mover track 22 along which the article holding head 20 is advanced. Positioning of the cam roller 82 on the side of the article holding head 20 that is generally opposite from the first chassis frame member 58 (and from the main mover track 22) allows the cam roller 82 to interact with the cam track 34 when the article holding head 20 is advanced along the sub-portion 44 of the path of travel 24 to which the cam track 34 is positioned adjacent. Thus, when the article holding head 20 is advanced into a position adjacent the cam track 34, the cam roller 82 comes into a rolling engagement with an edge or surface 92 (FIG. 3) of the cam track 34 facing the main mover track 22 and rolls along this edge 92 as the article holding head 20 continues to advance in the machine direction 28. As the cam roller 82 moves along the edge 92 of the cam track 34, a pushing force is applied onto the connector arm 84 that is opposite from the biasing force imposed on the connector arm 84 by the tension spring 88. The pushing force generated by interaction/movement of the cam roller 82 along the cam track 34 is large enough to overcome the biasing force and thereby causes the connector arm 84 to rotate, with rotation of the connector arm 84 being in the counterclockwise direction according to the illustrated embodiment. This rotation of the connector arm 84 is transferred to the pivot shaft 78 and causes the pivot shaft 78 to rotate about the pivot axis 86, with the rotation of the pivot shaft 78, in turn, rotating and reorienting the article carrying surface 46 of the article holding head 20. [0075] Referring now to FIGS. 9-13, the interaction between the cam follower 80 and the cam track 34 as the article holding head 20 advances in the machine direction 28 along the main mover track 22 is illustrated to better understand operation of the cam follower 80 and rotation of the article carrying surface 46. Initially, it is understood the interaction between the cam follower 80 and the cam track 34 results, at least in part, from the configuration and shape of the cam track 34. As seen in FIGS. 9-13, the cam track 34 is constructed such that the edge 92 thereof that interfaces with the cam roller 82 is presented as a non-linear (i.e., curved) surface. The edge 92 may generally be defined as including a central linear region 94 flanked by a first curved region 96 and a second curved region 98, with the first curved region 96 upstream in the machine direction 28 from the second curved region 98. Resulting from this non-linear edge 92 of the cam track 34, the advancement of the cam roller 82 along the edge 92 causes a movement and rotation of the connector arm 84 that, in turn, is transferred to the pivot shaft 78 and the article carrying surface 46 to cause reorientation of the article carrying surface 46.

[0076] Referring first to FIG. 9, an article holding head 20 is shown at a position P1 where it has advanced along the main mover track 22 to reach the sub-portion 44 of its path of travel 24 where the cam track 34 is located adjacent to (i.e., laterally offset from) the main mover track 22. As the article holding head 20 arrives at the position P1 , it is seen that the article carrying surface 46 thereof is positioned in a default (first) orientation 100 that, in the example embodiment, arranges the article carrying surface 46 in parallel with the machine direction 28 in which the article holding head 20 advances, although it is recognized that the default orientation 100 could instead position the article carrying surface 46 perpendicular to the machine direction 28 in an alternative embodiment. As previously described, the article carrying surface 46 is maintained in the default orientation 100 due to the tension spring 88 retaining the connector arm 84 of the cam follower 80 in an initial position 102, with the position of the connector arm 84 dictating the orientation of the article carrying surface 46 via its connection thereto by the pivot shaft 78. The article carrying surface 46 is maintained in the default orientation 100 for a majority of the path of travel 24 of the article holding head 20 about the main mover track 22, except for when the article holding head 20 reaches the sub-portion 44 of the path of travel 24 where the article holding head 20 interacts with the cam track 34.

[0077] Referring now to FIG. 10, the article holding head 20 is shown at a position P2 where it has advanced further along the main mover track 22 to a position where the cam roller 82 has begun to engage the first curved region 96 of the cam track 34. As the cam roller 82 advances along the first curved region 96 of the cam track 34, interaction of the cam roller 82 with the first curved region 96 applies a pushing force against the connector arm 84 that is opposite from the biasing force imposed on the connector arm 84 by the tension spring 88. The pushing force generated by movement of the cam roller 82 along the first curved region 96 is large enough to overcome the biasing force and thereby causes the connector arm 84 to begin to rotate in the counterclockwise direction. As shown in FIG. 10, as the connector arm 84 begins to rotate in the counterclockwise direction, the article carrying surface 46 of the article holding head 20 also is caused to rotate in the counterclockwise direction.

[0078] Referring now to FIG. 11 , the article holding head 20 is shown at a position P3 where it has advanced further along the main mover track 22 to a position where the cam roller 82 has now passed the first curved region 96 and has engaged the central linear region 94 of the cam track 34. In having advanced through the first curved region 96 of the cam track 34, the interaction of the cam roller 82 with the first curved region 96 has caused the connector arm 84 to fully rotate in the counterclockwise direction to a finished position 104 that is distal from its initial position 102. With the connector arm 84 being rotated to its finished position 104, the article carrying surface 46 of the article holding head 20 has, in turn, rotated in the counterclockwise direction to a turned (second) orientation 106. In the illustrated embodiment, the turned orientation 106 of the article carrying surface 46 is 90° from the default orientation 100, although it is recognized that the article carrying surface 46 could be rotated to other angular positions, including 180° from the default orientation 100, for example, or to 30°, 45°, or 60° from the default orientation 100, as additional examples. As the cam roller 82 continues to advance in the machine direction 28 along the central linear region 94 of the cam track 34, the connector arm 84 is held in the finished position 104 (due to the interaction of the cam roller 82 and the central linear region 94), with the article carrying surface 46 thus also being maintained in its turned orientation 106.

[0079] FIG. 11 also illustrates that the cam track 34 is positioned such that the central linear region 94 thereof is aligned (in the machine direction 28) with the sub-portion 44 of the path of travel 24 of the article holding head 20 that includes the receiving location 26, where the article holding head 20 picks up a discrete article 12 from the input station. Accordingly, when the article holding head 20 has advanced along the path of travel 24 to the receiving location 26, the article carrying surface 46 will have been rotated 90° to its turned orientation 106 responsive to the interaction of the cam follower 80 with the cam track 34 - i.e. , the cam roller 82 having advanced to the central linear region 94 and caused the connector arm 84 to rotate to its finished position 104.

[0080] Referring now to FIG. 12, the article holding head 20 is shown at a position P4 where it has advanced further along the main mover track 22, past the central linear region 94, and to a position where the cam roller 82 has begun to engage the second curved region 98 of the cam track 34. As the cam roller 82 advances along the second curved region 98 of the cam track 34, interaction of the cam roller 82 with the second curved region 98 causes the pushing force being applied against the connector arm 84 to be reduced. This reduction in the pushing force generated by movement of the cam roller 82 along the second curved region 98 allows the biasing force generated by the tension spring 88 to begin to rotate the connector arm 84 back in the clockwise direction, away from the finished position 104 and toward the initial position 102. As shown in FIG. 12, as the connector arm 84 begins to rotate in the clockwise direction, the article carrying surface 46 of the article holding head 20 also is caused to rotate in the clockwise direction.

[0081] Referring now to FIG. 13, the article holding head 20 is shown at a position P5 where it has advanced further along the main mover track 22 to a location past the second curved region 98 of the cam track 34. In having advanced past the second curved region 98 of the cam track 34, the interaction of the cam roller 82 with the second curved region 98 has ended such that there is no longer any pushing force being generated by movement of the cam roller 82 along the second curved region 98. The biasing force generated by the tension spring 88 thus causes the connector arm 84 to fully rotate back in the clockwise direction to its initial position 102. As the article holding head 20 arrives at the position P5, it is thus seen that the article carrying surface 46 thereof is again positioned in the default orientation 100, so as to be in parallel with the machine direction 28 in which the article holding head 20 advances. The article carrying surface 46 is maintained in the default orientation 100 as the article holding head 20 exits the sub-portion 44 of the path of travel 24 in which it is adjacent the cam track 34, and as it continues to advance in the machine direction 28 along the main mover track 22.

[0082] While the interaction the article holding head 20 and cam track 34 is shown and described in FIGS. 9-13 as being based on a positioning of the cam track 34 in a laterally outward position from the perimeter 40 of the main mover track 22 and the cam follower 80 being arranged accordingly to interact with the edge 92 of the cam track 34, it is recognized that additional embodiments could have the cam track 34 positioned in alternative locations and the article holding head 20 reconfigured accordingly to interact with such alternatively positioned cam track 34. Thus, for example, the cam track 34 could be positioned inside the perimeter 40 of the main mover track 22 or above/below the main mover track 22, with the cam follower 80 of the article holding head 20 being arranged accordingly in a location and orientation that allows for interaction and engagement of the cam follower 80 (cam roller 82) with the repositioned cam track 34.

[0083] In one embodiment, additional features are provided on the article holding head 20 that function to limit the range of rotation of the article carrying surface 46 and selectively retain or “lock” the article carrying surface 46 in its default orientation 100. As best shown in FIG. 7, a range limiting track 107 is formed in the second chassis frame member 60 (i.e., through carrying surface mount 72) that interacts with a pin 108 extending up from, and fixed to, a top side of the article carrying surface 46. The pin 108 is engaged with the track 107 and moves within the track 107 as the article carrying surface 46 is rotated between its default orientation 100 and its turned orientation 106. Stops 109 are provided at either end of the track 107 to limit the path of travel of the pin 108 within the track 107 and thereby correspondingly limit the range of rotation of the article carrying surface 46. As previously described, in one embodiment the article carrying surface 46 may desirably be enabled to rotate 90° from the default orientation 100 to the turned orientation 106, and the stops 109 may be positioned to accommodate such 90° rotation. In other embodiments, the positioning of the stops 109 along the track 107 may be altered to shorten or lengthen the allowable travel of the pin 108 within the track 107, thereby also altering the range of rotation of the article carrying surface 46 to more than or less than 90°.

[0084] In one embodiment, a catch feature 110 may be included as part of one or more of the stops 109, with the catch feature 110 acting as a locking mechanism that retains the article carrying surface 46 in its present orientation. In the illustrated embodiment, the catch feature 110 is included only on the stop

109 that defines the position for the default orientation 100 of the article carrying surface 46, which is the left-side stop 109 in FIGS. 6 and 7. The catch feature

110 is configured to engage and retain the pin 108 therein to prevent the pin 108 from moving (and the article carrying surface 46 from rotating) as the article holding head 20 rotates about the main mover track 22, with a notch included in the catch feature 110 that mates with the pin 108 to retain it therein. In operation of the apparatus 10, the pin 108 would thus be retained by the catch feature 110 for all parts of the path of travel 24 of the article holding head 20 except when traversing the sub-portion 44 where the article holding head 20 interacts with the cam track 34. As previously described, interaction of the cam follower 80 (cam roller 82) of the article holding head 20 with the cam track 34 causes the connector arm 84 to rotate from its initial position 102 to its finished position 104 (overcoming the biasing force provided by the tension spring 88), and this rotation of the connector arm 84 is transferred to the article carrying surface 46 to cause the article carrying surface 46 to also rotate from its default orientation 100 to its turned orientation 106. With the cam follower 80 interacting with the cam track 34 to cause rotation of the article carrying surface 46 away from its default orientation 100, the force with which the pin 108 is retained in the catch feature 110 is overcome and the pin 108 therefore releases from the catch feature 110 and slides within the track 107 as the article carrying surface 46 rotates.

[0085] Thus, as described above, interaction of the catch feature 110 with the pin 108 may prevent unwanted rotation of article carrying surface 46 away from the default orientation 100, while also selectively allowing rotation of the article carrying surface 46 to its turned orientation when the article holding head 20 is in the sub-portion 44 of its path of travel 24. As one example, it is recognized that forces acting on the article holding head 20 as it rotates about the path of travel 24, such as centrifugal forces generated as the article holding head 20 advances around the radiused corners of the perimeter 40, may overcome the biasing force provided by the tension spring 88 and cause the connector arm 84 to rotate. The catch feature 110 may prevent such an occurrence due to the force with which the pin 108 is retained in the catch feature 110 being greater than such centrifugal forces.

[0086] While not shown in FIGS. 6 and 7, it is recognized that other locking mechanisms could be provided in the article holding head 20 that function to selectively retain the article carrying surface 46 in its default orientation 100. As one example, an electromagnetic lock may be positioned beneath a connector arm 84 formed of a ferrous material, such that the connector arm 84 is attracted to the electromagnetic lock upon the lock being powered to generate a magnetic field. In another embodiment, a solenoid pin lock may be positioned adjacent the connector arm 84 or the pivot shaft 78, with the solenoid pin lock extending out to mate with the connector arm 84 or the pivot shaft 78 upon power being provided thereto, thereby locking the connector arm 84 or the pivot shaft 78 in position.

[0087] Referring again now to FIGS. 2-4, the vacuum system 32 of the apparatus 10 is described in greater detail, including the operation thereof to selectively provide a vacuum to the article holding heads 20 to retain discrete articles 12 thereon and release discrete articles 12 therefrom. As best shown in FIGS. 2 and 4, the vacuum system 32 is generally composed of a vacuum hub 112 and a plurality of vacuum arms 114. The vacuum hub 112 functions as a vacuum source for the vacuum system 32 and for the apparatus 10. The vacuum hub 112 is secured to the base frame 36 at a location inward from the perimeter 40 of the base frame 36. An arrangement or “tree” of vacuum arms 114 is coupled to the vacuum hub 112 to provide a fluid path between the vacuum hub 112 and the article holding heads 20. The vacuum arms 114 extend upward from a vacuum manifold 116 (rotatably coupled to the vacuum hub 112) and to an upper frame 118, with the vacuum arms 114 then branching outwardly from the upper frame 118 before being routed back down to mate with the vacuum inputs 76 of the article holding heads 20. In the illustrated embodiment, a pair of vacuum arms 114 may extend out to each of the article holding heads 20 to mate with the vacuum inputs 76, but it is recognized that only a single vacuum arm could be provided to each article holding head 20 in an alternative embodiment.

[0088] In operation of the vacuum system 32, the arrangement of vacuum arms 114 is caused to rotate about a central axis 120 of the vacuum hub 112, such that the vacuum arms 114 may remain coupled to their respective article holding heads 20 to provide a vacuum thereto. A servo motor (not shown) or other actuator is provided in the vacuum system 32 that drives rotation of the vacuum manifold 116 and the vacuum arms 114 coupled thereto, with the speed of rotation of the vacuum manifold 116 and the vacuum arms 114 tracking the speed at which the respective article holding heads 20 are advanced along the main mover track 22. In one embodiment, to account for the rectangular-shaped perimeter 40 of the path of travel 24 of the article holding heads 20, flexible tubes 121 (e.g., rubber or plastic tubes) are included in the vacuum system 32 to couple the vacuum arms 114 to the respective article holding heads 20. The range of motion provided by the flexible tubes 121 accommodates the irregular (i.e. , noncircular) path of travel 24 of the article holding heads 20 relative to the central axis 120. That is, the positioning and orientation of the flexible tubes 121 may change during operation to accommodate any discrepancies in movement between the rotational movement of the rotating vacuum arms 114 and the movement of the article holding heads 20 along the main mover track 22, thereby allowing the vacuum arms 114 to remain connected to the article holding heads 20 and provide a vacuum thereto.

[0089] In one embodiment, each of the article holding heads 20 may include an arm guide 124 that aids in securing respective flexible tubes 121 to the vacuum inputs 76 of the article holding head 20. As best shown in FIGS. 5-8, the arm guide 124 is coupled to the first chassis frame member 58 on the upper protruding portion thereof. The arm guide 124 is constructed to define a pair of openings 126 therein that are vertically aligned with the vacuum inputs 76 of the article holding head 20. Accordingly, in providing a vacuum to an article holding head 20, a set of flexible tubes 121 may extend down from the vacuum arms 114 and be routed downwardly through the openings 126 in the arm guide 124 before being coupled to the vacuum inputs 76 of the article holding head 20. In this manner, the flexible tubes 121 routed to each article holding head 20 can be retained securely in place and operate to provide a vacuum thereto.

[0090] Referring now to FIG. 14, and with continued reference to FIGS. 1 -13, a flowchart is provided that illustrates a method 130 for transferring and rotating a discrete article 12 from a receiving location 26 to a placement location 30. The method 130 begins at STEP 132 with advancing an article holding head 20 in a machine direction 28 along the main mover track 22 that defines the cyclical path of travel 24 for the article holding head 20. While the article holding head 20 advances in the machine direction 28, the article carrying surface 46 thereof is retained in a biased default (first) orientation that, in one embodiment, is parallel to the machine direction 28.

[0091] As the article holding head 20 is advanced along the main mover track 22, the article holding head 20 reaches a section of the main mover track 22 (or sub-portion 44 of the path of travel 24) where the cam track 34 runs adjacent to (but offset outwardly from) the main mover track 22. Upon reaching this location, a cam follower 80 (i.e. , cam roller 82) of the article holding head 20 engages the cam track 34, as indicated at STEP 134. With the cam follower 80 engaged with the cam track 34, the article holding head 20 continues to advance in the machine direction 28 and, as the article holding head 20 advances, the cam follower 80 becomes engaged with a first curved region 96 of the cam track 34. The engagement and advancement of the cam follower 80 along this first curved region 96 of the cam track 34 causes the article carrying surface 46 to rotate at STEP 136, with the article carrying surface 46 rotating from the default orientation 100 to the turned (second) orientation as the cam follower 80 traverses from the beginning of the first curved region 96 to the end of the first curved region 96. Specifically, advancement of the cam roller 82 along this first curved region 96 applies a pushing force onto the connector arm 84 of the cam follower 80 sufficient to overcome a biasing force that maintains the connector arm 84 in its initial position 102, thereby causing the connector arm 84 of the cam follower 80 to rotate. This rotation of the connector arm 84 is transferred to the article carrying surface 46 via a pivot shaft 78 coupled between the connector arm 84 and the article carrying surface 46. In one embodiment, the article carrying surface 46 rotates 90° from the default orientation 100 to the turned orientation 106.

[0092] With the article carrying surface 46 in the turned orientation 106, the article holding head 20 operates to receive and secure a discrete article 12 thereto at STEP 138. That is, a vacuum from the vacuum system 32 is selectively provided to the article carrying surface 46 after it has been reoriented to the turned orientation 106 and as it approaches the receiving location 26 to enable the article holding head 20 to receive and secure a discrete article 12 thereto.

[0093] Upon securing a discrete article 12 on the article carrying surface 46 at the receiving location 26, and with the cam follower 80 still engaged with the cam track 34, the article holding head 20 continues to advance in the machine direction 28 and, as the article holding head 20 advances, the cam follower 80 becomes engaged with a second curved region 98 of the cam track 34. The engagement and advancement of the cam follower 80 along this second curved region 98 of the cam track 34 causes the article carrying surface 46 to rotate at STEP 140, with the article carrying surface 46 rotating from the turned orientation 106 back to the default orientation 100 as the cam follower 80 traverses from the beginning of the second curved region 98 to the end of the second curved region 98. Specifically, advancement of the cam roller 82 along this second curved region 98 reduces the pushing force applied to the connector arm 84 of the cam follower 80 such that the biasing force on the connector arm 84 begins to overcome the pushing force, thereby causing the connector arm 84 of the cam follower 80 to be drawn/rotated back. This rotation of the connector arm 84 is transferred to the article carrying surface 46 via the pivot shaft 78, with the article carrying surface 46 rotating 90° in the opposite direction from the turned orientation 106 back to the default orientation 100.

[0094] Upon the article holding head 20 advancing past the second curved region 98, the cam follower 80 disengages the cam track 34 and the article holding head 20 continues to advance along the main mover track 22 in the machine direction 28, as indicated at STEP 142. While the article holding head 20 continues to advance in the machine direction 28 at STEP 142, the article carrying surface 46 thereof is retained in the default orientation 100. As the article holding head 20 is advanced along the main mover track 22, the article holding head 20 reaches a placement location 30 where the discrete article 12 is to be transferred off of the article holding head 20, such as onto another moving web of material. Thus, upon reaching the placement location 30, the article holding head 20 operates to release the discrete article 12 therefrom at STEP 144. To release the article, the vacuum that was being applied to the to the article carrying surface 46 is terminated, thereby causing the discrete article 12 to be released from the article holding head 20.

[0095] For the apparatus 10 shown and described in FIGS. 1 -13 and the accompanying method of operation thereof shown and described in FIG. 14, it is recognized that numerous variations regarding the structure, arrangement, and/or operating method thereof are envisioned according to additional embodiments. For example, in reorienting the discrete articles 12, the apparatus 10 and article holding heads 20 may be configured such that the article carrying surface 46 of the article holding heads 20 reorient the discrete articles 12 by rotating in the opposite direction from that shown and described in FIGS. 9-13, i.e., clockwise vs. counterclockwise. As another example, the apparatus 10 and article holding heads 20 may be configured to rotate the discrete articles 12 to different orientations other than the 90° rotation shown and described in FIGS. 9- 13, such as 30°, 60°, or 180° as other non-limiting examples. As another example, the apparatus 10 and article holding heads 20 may be configured to deposit the discrete articles 12 at any of a number of locations along the main mover track 22 other than just the output station 16. As still another example, the apparatus 10 may be arranged in other orientations from that shown in FIG. 2 for example, i.e., with the with article carrying surface 46 of the article holding heads 20 facing down and acquiring discrete articles 12 from a horizontal conveyor). That is, it envisioned that the apparatus 10 could be flipped so that the article carrying surface 46 of the article holding heads 20 faces up and acquires discrete articles 12 from an inverted conveyor arrangement or that the apparatus 10 could be arranged on its side (i.e., rotated 90 degrees from the orientation of FIG. 2) so that a vertical acquisition and handoff of discrete articles 12 is performed by the article holding heads 20. [0096] Referring now to FIGS. 15-17, additional embodiments of article holding heads useable in an apparatus for transferring and reorienting discrete articles 12 are provided. The article holding heads may be substantially similar to the article holding heads 20 included in the apparatus 10 regarding the structure and interaction thereof with a main mover track 22 and regarding the general arrangement of vacuum inputs 76 and an article carrying surface 46, and thus common elements between the article holding heads 20 and the additional article holding head embodiments are not described in detail below. However, the article holding heads of FIGS. 15-17 differ regarding the mechanism(s) included thereon that provide for reorientation of the article carrying surface 46 of the article holding heads. In particular, the article holding heads according to the embodiments described here below function to reorient the article carrying surface 46 without any interaction between a cam follower 80 and a cam track 34, with it thus being recognized that the article holding heads would be implemented with an apparatus for transferring and reorienting discrete articles 12 that does not include a cam track 34 as shown and described in the previous embodiment.

[0097] Referring first to FIG. 15, an article holding head 146 is shown that includes an actuator 148 coupled directly to a connector arm 84 to cause rotation thereof. The actuator 148 may be positioned on and secured to the second chassis frame member 60 (e.g., on a top side of the carrying surface mount 72) at a location adjacent the connector arm 84. According to embodiments, the actuator 148 may be configured as a pneumatic or electric actuator that is coupled to the connector arm 84 and provides a rotational force thereto. The rotational force selectively causes the connector arm 84 to rotate between an initial position 102 and a finished position 104. Rotation of the connector arm 84 causes a corresponding rotation of the pivot shaft 78 coupled to the connector arm 84, with rotation of the pivot shaft 78, in turn, causing the article carrying surface 46 of the article holding head to reorient. That is, with the connector arm 84 in its initial position 102, the article carrying surface 46 is in its default orientation 100 (see FIG. 9, for example), and as the connector rotates to its finished position 104, the article carrying surface 46 is also caused to rotate to its turned orientation 106 (see FIG. 1 1 , for example). In one embodiment, the turned orientation 106 may be rotated 90° from the default orientation 100. In addition to providing for rotation of the connector arm 84 of the article holding head, the actuator 148 may also perform a locking function that retains the connector arm 84 in place. That is, when the actuator 148 is not operating to rotate the connector arm 84, the actuator 148 may instead remain in a locked condition that prevents the connector arm 84 from rotating, thereby retaining the connector arm 84 in its initial position 102 and the article carrying surface 46 in its default orientation 100, for example.

[0098] Referring now to FIG. 16, an article holding head 150 is shown that includes an actuator 152 coupled directly to a pivot shaft 78 (with no connector arm present) to cause rotation thereof. The actuator 152 may be positioned on and secured to the second chassis frame member 60 (e.g., on a top side of the carrying surface mount 72) at a location adjacent the pivot shaft 78. According to embodiments, the actuator 152 may be configured as a servo motor or a stepper motor that directly drives rotation of the pivot shaft 78. The rotational force provided by the actuator 152 causes the pivot shaft 78 to rotate. That rotation, in turn, causes the article carrying surface 46 of the article holding head '50 to reorient. In one embodiment, rotation of the pivot shaft 78 may cause the article carrying surface 46 to rotate 90° from a default orientation 100 (see FIG. 9, for example) to a turned orientation 106 (see FIG. 11 , for example). In addition to providing for rotation of the pivot shaft 78, the actuator 152 may also perform a locking function that retains the pivot shaft 78 in place. That is, when the actuator 152 is not operating to rotate the pivot shaft 78, the actuator 152 may instead remain in a locked condition that prevents the pivot shaft 78 from rotating, thereby retaining the article carrying surface 46 in its default orientation 100, for example.

[0099] Referring now to FIG. 17, an article holding 154 head is shown that is similar to the article holding head 150 of FIG. 16, except that instead of being coupled directly to a pivot shaft 78, an actuator 152 is provided that is coupled to the pivot shaft 78 via a belt drive 156. The actuator 152 may be positioned on and secured to the second chassis frame member 60 (e.g., on a top side of the carrying surface mount 72), with the drive belt extending between the actuator and the pivot shaft 78. According to embodiments, the actuator 152 may be configured as a servo motor or a stepper motor. The rotational force provided by the actuator 152 is transferred to the pivot shaft 78 via the drive belt 156, thereby causing the pivot shaft 78 to rotate. That rotation, in turn, causes the article carrying surface 46 of the article holding head 154 to reorient. In one embodiment, rotation of the pivot shaft 78 may cause the article carrying surface 46 to rotate 90° from a default orientation 100 (see FIG. 9, for example) to a turned orientation 106 (see FIG. 11 , for example). In addition to providing for rotation of the pivot shaft 78, the actuator 152 may also perform a locking function that retains the pivot shaft 78 in place. That is, when the actuator 152 is not operating to rotate the pivot shaft 78, the actuator 152 may instead remain in a locked condition that prevents the pivot shaft 78 from rotating, thereby retaining the article carrying surface 46 in its default orientation 100, for example.

[00100] For each of the article holding heads 146, 150, 154 described above, the respective actuator 148, 152 included therein may be operated via an associated controller 158 that determines the timing and amount of any rotation provided by the actuator 148, 152. That is, as opposed to an article holding head where a mechanical interaction between a cam follower and cam track causes rotation and reorienting of the article carrying surface, the article holding heads 146, 150, 154 operate according to a control scheme implemented by the controller 158 that controls the tim ing and amount of rotation of the article carrying surface 46. The control scheme could cause the article carrying surface 46 to be reoriented into the turned orientation 106 when the article holding head 146, 150, 154 comes into proximity to the receiving location 26, with the control scheme then causing the article carrying surface 46 to be reoriented back into the default orientation 100 at a point of the path of travel 24 somewhere between the receiving location 26 and the placement location 30. [00101] Referring now to FIGS. 18 and 19, another embodiment of an apparatus 160 is illustrated that varies from the apparatus 10 shown in FIG. 2 only in the inclusion of additional cam track sections therein. That is, rather than including only cam track 34 that interacts with the article holding head 20 as the article holding heads 20 traverse the sub-portion 44 of its path of travel 24, apparatus 160 also includes additional retaining cam track sections 162 positioned at locations along the path of travel 24 where the article holding heads 20 traverse around corners of the main mover track 22. That is, a retaining cam track section 162 is positioned at each of the four radiused comers of the main mover track 22. The retaining cam track sections 162 are configured as arc-shaped members having a curvature that generally corresponds to the curvature of the radiused corners of main mover track 22. In the illustrated embodiment, an extension arm structure 164 couple the retaining cam track sections 162 to the base frame 36, with the extension arm structure 164 positioning the retaining cam track sections 162 in a suspended arrangement relative to the base frame 36 and relative to the main mover track 22. As illustrated, the extension arm structure 164 is configured to position the retaining cam track sections 162 in a laterally outward position from the perimeter 40 of the main mover track 22 and in vertical alignment with the main mover track 22 (i.e. , in generally a same horizontal plane).

[00102] As previously described, it is recognized that forces may act on the article holding head 20 as it rotates about the path of travel 24, such as centrifugal forces generated as the article holding head 20 advances around the radiused corners of the perimeter 40. These (centrifugal) forces may overcome the biasing force provided by the tension spring 88 and cause the connector arm 84 to rotate (see FIG. 7, for example), such that the article carrying surface 46 of the article holding head 20 may also rotate. Positioning of the retaining cam track sections 162 adjacent the radiused corners of the perimeter 40 of the main mover track 22 may act against such centrifugal forces and prevent the article carrying surface 46 from rotating as the article holding head 20 advances around the radiused corners of the perimeter 40. That is, with the retaining cam track sections 162 positioned adjacent to (and laterally outward from) the radiused corners of the main mover track 22, the cam follower 80 (see FIG. 7, for example) of the article holding head 20 will engage with a respective retaining cam track section 162 as the article holding head 20 translates around the corner. This engagement and interaction of the cam follower 80 with the retaining cam track section 162 counteracts the centrifugal forces acting on the article holding head 20 to help maintain the article carrying surface 46 in its default orientation 100 as the article holding head 20 turns the corner of the main mover track 22. Thus, each retaining cam track section 162 functions to “lock” the article carrying surface 46 in its default orientation 100 as the article holding head 20 turns a respective corner of the main mover track 22.

[00103] As shown in FIGS. 18 and 19, a pair of the retaining cam track sections 162 on one side of the base frame 36 are positioned and constructed so as to abut the cam track 34 on opposing side thereof, thereby forming a continuous cam track arrangement 166 on one side of the base frame 36. The retaining cam track sections 162 may be coupled to the cam track 34 via connecting plates 168 to provide a continuous face or track between the respective retaining cam track sections 162 and the cam track 34. The continuous cam track arrangement 166 formed by the retaining cam track sections 162 and the cam track 34 allow for the cam follower 80 (i.e., cam roller 82) of an article holding head 20 to stay in constant contact and engagement with the arrangement 166 - with the article holding head 20 translating around the radiused corner of the main mover track 22 and engaging with a retaining cam track section 162, moving toward and through the sub-portion 44 of the path of travel 24 while engaging with the cam track 34, and then exiting the cam track 34 and continuing to translate around the opposite radiused corner of the main mover track 22 and engaging with the other retaining cam track section 162.

[00104] FIGS. 20-23 illustrates an article holding head 170 according to another embodiment. The article holding head 170 includes a number of identical components to the article holding head 20 shown and described in FIGS. 5-8, and thus like components included in each of the article holding heads 170, 20 are numbered the same in FIG. 20. As described below, the article holding head 170 is configured to provide for rotation of the article carrying surface 46 thereof. The rotation of the article carrying surface 46 provided by the article holding head 170 is achieved without the use of an accompanying cam track 34, as is required with the article holding head 20, but instead may be achieved only by way of the article holding head 170 itself.

[00105] As shown in FIGS. 20-23, the article holding head 170 generally includes a chassis 56 and an article carrying surface 46 that is positioned on the chassis 56. The chassis 56 secures the article holding head 170 to the rail structure 48 of the main mover track 22 and provides for displacement of the article holding head 170 along the main mover track 22. The chassis 56 includes a pair of chassis frame members 58, 60 joined together, with the first chassis frame member 58 accommodating positioning of the rail structure 48 therebetween and the second chassis frame member 60 securing the article carrying surface 46 thereto in a manner that provides for rotation thereof.

[00106] The article holding head 170 is configured to provide for rotation of the article carrying surface 46 relative to the chassis 56 thereof. To enable this rotation of the article carrying surface 46, a rotational actuating structure 172 (hereafter “actuating structure 172”) is included in the article holding head 170 that is configured to selectively rotate or “spin” the article carrying surface 46 during operation of the article holding head 170. The actuating structure 172 includes a pivot shaft 78, a connector arm 84, a stand-alone chassis frame member 174 (and mover element 70 associated therewith), and a bridge member 176. The pivot shaft 78 is positioned within an opening 77 formed in an carrying surface mount 72 of the second chassis frame member 60 and extends therethrough to be coupled to the article carrying surface 46 on one end thereof. The opposite end of the pivot shaft 78 is connected to the connector arm 84 in a fixed manner such that the pivot shaft 78 and connector arm 84 rotate in unison. The connector arm 84, on the end thereof opposite the pivot shaft 78, is coupled to the bridge member 176. The bridge member 176 extends between the connector arm 84 and the stand-alone chassis frame member 174 and thereby links the stand-alone chassis frame member 174 to the chassis 56. According to this arrangement of the actuating structure 172, any rotation of the connector arm 84 - such as may be caused by movement of the bridge member 176 attached thereto - is transferred to the pivot shaft 78, with the pivot shaft 78 rotating about a pivot axis 86 and causing the article carrying surface 46 to rotate in a like manner.

[00107] In operation of the actuating structure 172, rotation of the connector arm 84 - and thus rotation of the article carrying surface 46 - is accomplished by varying a spacing of the stand-alone chassis frame member 174 and the chassis 56 (i.e. , first chassis frame member 58) along the main mover track 22. That is, a variation in the positioning of the stand-alone chassis frame member 174 relative to the chassis 56 along the main mover track 22 causes a movement of the bridge member 176, with movement of the bridge member 176 in turn causing rotation of the connector arm 84, which is transferred via the pivot shaft 78 to the article carrying surface 46. By controlling the spacing between the stand-alone chassis frame member 174 and the chassis 56, the connector arm 84 may be controllably rotated between an initial position 102 (where the article carrying surface 46 is in a corresponding default (or first) orientation 100) and a finished position 104 (where the article carrying surface 46 is in a corresponding turned (or second) orientation 106). According to embodiments, the angular range over which the article carrying surface 46 can be turned can vary based on the operation and system with which the article holding head 170 is to be employed. In one embodiment, the article carrying surface 46 can rotate between a 0° default orientation 100 and a 90° turned orientation 106 and can be stopped or held at any specific angle therebetween. In other embodiments, the angular range can be greater than or less than 90°.

[00108] The structure of the stand-alone chassis frame member 174 is similar to that of the first chassis frame member 58, with each of the chassis frame members 58, 174 including frame portions 62, 64, 66 and rollers 68 in an arrangement that secures the respective chassis frame members 58, 174 onto the rail structure 48 and provides for translation of the article holding head 170 along the upper rails 52 and the lower rail 54 of the main mover track 22. A center portion 66 of the chassis frame members 58, 174 is structured as a generally flat section that aligns with the conveyance surface 50 of the main mover track 22 when the article holding head 20 is mounted on the main mover track 22. A mover element 70 associated with each of the chassis frame members 58, 174 operates to enable advancement of its respective chassis frame member 58, 174 along the main mover track 22. According to embodiments, the mover element 70 may be attached to the chassis frame members 58, 174 or integrated therein.

[00109] In one embodiment, the mover element 70 associated with each of the chassis frame members 58, 174 is provided as a magnet structure (e.g., one or more permanent magnets) that is attached to or integrated in the center portion 66 of each of the chassis frame members 58, 174. Magnetic fields generated by the magnet structure interact with a conductive main mover track 22 that includes stator elements (not shown) therein to propel the article holding heads 20 along the main mover track 22. That is, an electrical current may be passed through the conveyance surface 50 of the main mover track 22 that is used to either create an opposing magnetic field (from the magnetic field generated by the magnet structure), or to charge a field, which can then be repelled, to thereby cause the chassis frame members 58, 174 to advance along the main mover track 22. According to embodiments, currents provided to the main mover track 22 (i.e. , to stator(s) in the main mover track 22) and the creation of opposing magnetic fields to that created by the magnet structure may be selectively controlled to provide for independent advancement and positioning of the stand-alone chassis frame member 174 and the first chassis frame member 58. The independent controlling of the stand-alone chassis frame member 174 positioning relative to the first chassis frame member 58 is limited by the length of the bridge member 176 and the range of rotation of the connector arm 84, with the bridge member 176 and the range of rotation of the connector arm 84 defining a maximum and minimum separation distance between the stand-alone chassis frame member 174 and the first chassis frame member 58 along the main mover track 22.

[00110] In another embodiment, the mover element 70 associated with each of the chassis frame members 58, 174 may be provided as a servo motor or other actuator that drives rotation of the rollers 68 to advance the chassis frame members 58, 174 along the main mover track 22. The selective operation of the servo motors associated with each of the chassis frame members 58, 174 allows for independent advancement and positioning of the stand-alone chassis frame member 174 and the first chassis frame member 58. Again, the independent controlling of the stand-alone chassis frame member 174 positioning relative to the first chassis frame member 58 is limited by the length of the bridge member 176 and the range of rotation of the connector arm 84, with the bridge member 176 and the range of rotation of the connector arm 84 defining a maximum and minimum separation distance between the stand-alone chassis frame member 174 and the first chassis frame member 58 along the main mover track 22.

[00111] In operation of the article holding head 170, the positioning of the standalone chassis frame member 174 relative to the first chassis frame member 58 (of chassis 56) is selectively controlled to provide a desired rotation of the article carrying surface 46. A controller 178 (FIG. 21 ) may be provided for implementing a desired control scheme that controls movement and positioning of one or both of the stand-alone chassis frame member 174 and the first chassis frame member 58 along the main mover track 22. According to an embodiment where the mover element 70 is provided as a magnet structure and the chassis frame members 58, 174 are translated via a magnetic interaction between the mover element 70 and the main mover track 22, the controller 178 may selectively control a supply of current to sections of the main mover track 22 to independently control movement of the chassis frame members 58, 174 along the main mover track 22. According to an embodiment where the mover element 70 is provided as servo motors and the chassis frame members 58, 174 are translated via the servo motors causing rotation of rollers 68, the controller 178 may selectively control operation of the mover element 70 associated with each of the chassis frame members 58, 174 to independently control movement of the chassis frame members 58, 174 along the main mover track 22.

[00112] By controlling the movement of one or both of the stand-alone chassis frame member 174 and the first chassis frame member 58 along the main mover track 22, the separation between the stand-alone chassis frame member 174 and the first chassis frame member 58 can be set to a desired distance. The separation between the stand-alone chassis frame member 174 and the first chassis frame member 58, in turn, determines and controls the rotational position of the connector arm 84 due to the coupling between the connector arm 84 and the stand-alone chassis frame member 174 via the bridge member 176. At a closest positioning between the stand-alone chassis frame member 174 and the first chassis frame member 58 (as determined by the length of the bridge member 176 and/or the range of rotation of the connector arm 84), the connector arm 84 is at its initial position 102. With the connector arm 84 at its initial position 102, the article carrying surface 46 is in a corresponding default orientation 100. As the stand-alone chassis frame member 174 begins to separate further from the first chassis frame member 58 along the main mover track 22, the connector arm 84 rotates away from its initial position 102 toward a finished position 104, which causes the article carrying surface 46 to rotate away from its default orientation 100 toward a turned orientation 106. As the stand-alone chassis frame member 174 moves to a farthest allowed position from the first chassis frame member 58 (as determined by the length of the bridge member 176 and/or the range of rotation of the connector arm 84), the connector arm 84 is at its finished position 104. With the connector arm 84 at its finished position 104, the article carrying surface 46 is in its corresponding turned orientation 106 that, in one embodiment, is 90° from the default orientation 100.

[00113] By controlling the movement of one or both of the stand-alone chassis frame member 174 and the first chassis frame member 58 along the main mover track 22, the rotational position of the article carrying surface 46 can also be locked at its existing orientation. As a first example, the stand-alone chassis frame member 174 can be maintained at a closest positioning relative to the first chassis frame member 58 (via controls implemented by the controller) so as to maintain or hold the connector arm 84 at its initial position 102. With the connector arm 84 held at its initial position 102, the article carrying surface 46 is effectively “locked” at its default orientation and prevented from rotating. As another example, the stand-alone chassis frame member 174 can be maintained at a farthest positioning relative to the first chassis frame member 58 (via controls implemented by the controller) so as to maintain or hold the connector arm 84 at its finished position 104. With the connector arm 84 held at its finished position 104, the article carrying surface 46 is effectively “locked” at its turned orientation and prevented from rotating.

[00114] Beneficially, embodiments of the invention thus provide a method and apparatus for transferring and reorienting discrete articles. The method and apparatus are able to accommodate the transferring and reorienting of articles of larger size, such as torso sections of an isolation gown, for example, thereby providing flexibility in the manufacturing of a large variety of wearable garments.

[00115] Therefore, according to one embodiment of the invention, an apparatus for transferring and rotating a discrete article from a receiving location to a placement location is provided. The apparatus includes a main mover track defining a cyclical path of travel, an article holding head that translates along the main mover track about the cyclical path of travel, and a cam track offset from the main mover track and positioned to interact with the article holding head only when the article holding head traverses a sub-portion of the cyclical path of travel. The article holding head further includes an article carrying surface configured to retain the discrete article thereon and rotatable about a pivot axis between a first orientation and a second orientation, a biasing member configured to apply a biasing force that retains the article carrying surface in the first orientation, and a cam follower configured to engage the cam track when the article holding head traverses the sub-portion of the cyclical path of travel, wherein engaging of the cam follower with the cam track causes the article carrying surface to rotate from the first orientation to the second orientation by overcoming the biasing force.

[00116] According to another embodiment of the invention, a method for transferring and rotating a discrete article from a receiving location to a placement location is provided. The method includes advancing an article holding head in a machine direction along a main mover track that defines a cyclical path of travel for the article holding head, the article holding head comprising an article carrying surface configured to retain a discrete article thereon and that is rotatable between a first orientation into which the article carrying surface is biased and a second orientation. The method also includes engaging a cam follower of the article holding head with a cam track laterally offset from the main mover track upon the article holding head reaching a section of the main mover track that runs adjacent the cam track, rotating the article carrying surface from the first orientation to the second orientation while the cam follower is engaged with a first portion of the cam track, rotating the article carrying surface from the second orientation to the first orientation while the cam follower is engaged with a second portion of the cam track, and selectively utilizing vacuum to secure the discrete article on the article holding head at the receiving location with the article carrying surface in the second orientation and to release the discrete article at the placement location with the article carrying surface in the first orientation.

[00117] According to another embodiment of the invention, an apparatus for transferring and rotating a discrete article from a receiving location to a placement location is provided. The apparatus includes a main mover track defining a cyclical path of travel and an article holding head that translates along the main mover track about the cyclical path of travel. The article holding head includes a chassis comprising a first chassis frame member and a second chassis frame member, the first chassis frame member movably coupled to the main mover track and the second chassis frame member coupled to the first chassis frame member. The article holding head also includes an article carrying surface configured to retain the discrete article thereon, the article carrying surface rotatable about a pivot axis between a first orientation and a second orientation. The article holding head further includes a stand-alone chassis frame member separate from the chassis and movably coupled to the main mover track and an actuating structure that rotatably couples the article carrying surface to the second chassis frame member and is configured to selectively rotate the article carrying surface between the first orientation and the second orientation, with the actuating structure including a pivot shaft comprising a first end coupled to the article carrying surface, a connector arm comprising a first arm end coupled to a second end of the pivot shaft, and a bridge member extending between a second arm end of the connector arm and the stand-alone chassis frame member so as to link the stand-alone chassis frame member to the chassis. The apparatus also includes a controller configured to independently control movement of each of the first chassis frame member and the stand-alone chassis frame member along the main mover track and thereby control a spacing between the first chassis frame member and the stand-alone chassis frame member, with a change in spacing between the first chassis frame member and the stand-alone chassis frame member causing the actuating structure to provide a corresponding rotation of the article carrying surface.

[00118] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.