TUMBLE PACKING APPARATUS
United States Patent 3788029
Tumble packing apparatus for filling a case with containers such as damageable, liquid-filled, lightweight plastic containers and the like including: apparatus for discharging containers in a free fall path of travel to a container case, and a cushioning pad which is selectively movable from a removed position into the path of initially charged, free falling containers to temporarily interrupt and cushion the free fall travel of the initial charge of containers before they impact the container case. Mechanism is provided to remove the pad, after a predetermined number of containers have been cushioned, to permit the initial charge of containers to move to a final position within the case and cushion the immediately following containers which fall to fill the case.
US Patent References:
Nail packaging dribbler
Odell - February 1966 - 3235052
GUIDE WITH ENERGY-ABSORBING BAFFLES
Adrian - July 1971 - 3590981
GRAVITY CONVEYOR
Ross et al. - February 1972 - 3640366
Bottle packing machine
Wimmer - August 1954 - 2686623
Package collector for coin package machine
Watts - May 1960 - 2934871
Nail packaging dribbler
Odell - February 1966 - 3235052
GUIDE WITH ENERGY-ABSORBING BAFFLES
Adrian - July 1971 - 3590981
GRAVITY CONVEYOR
Ross et al. - February 1972 - 3640366
Bottle packing machine
Wimmer - August 1954 - 2686623
Package collector for coin package machine
Watts - May 1960 - 2934871
Application Number:
05/276068
Publication Date:
01/29/1974
Filing Date:
07/28/1972
View Patent Images:
Export Citation:
Assignee:
Koehring Company (Milwaukee, WI)
Primary Class:
Other Classes:
53/248
International Classes:
B65B5/10; B65B57/06; B65B5/00
Field of Search:
53/35,59,67,248 193/7,32 198/26,36,37
US Patent References:
| 3021656 | Device for use in filling a container with fruit | February 1962 | Vries |
Primary Examiner:
Spruill, Robert L.
Attorney, Agent or Firm:
Learman & McCulloch
Claims:
What is claimed is
1. Apparatus for tumble packing articles, such as liquid-filled containers, in article cases and the like, comprising:
2. Apparatus as set forth in claim 1 wherein said interrupting means comprises:
3. The apparatus set forth in claim 2 wherein said carriage moves in a vertically inclined path of travel.
4. Apparatus for tumble packing articles, such as liquid-filled containers, in article cases and the like, comprising:
5. The apparatus set forth in claim 4 including means responsive to an additional predetermined number of articles being forwarded toward said case to render said article conveying means inoperable until another case is positioned at the case filling station.
1. Apparatus for tumble packing articles, such as liquid-filled containers, in article cases and the like, comprising:
2. Apparatus as set forth in claim 1 wherein said interrupting means comprises:
3. The apparatus set forth in claim 2 wherein said carriage moves in a vertically inclined path of travel.
4. Apparatus for tumble packing articles, such as liquid-filled containers, in article cases and the like, comprising:
5. The apparatus set forth in claim 4 including means responsive to an additional predetermined number of articles being forwarded toward said case to render said article conveying means inoperable until another case is positioned at the case filling station.
Description:
BACKGROUND OF THE INVENTION
This invention relates to apparatus for, and a method of, tumble packing containers in cases, and more particularly to apparatus for, and a method of, reducing the impact effect on containers dropped into a container case by cushioning the fall of containers tumble packed into a container case to eliminate container damage.
Fruit juice, milk, and other liquid products are frequently stored in thin-walled deformable plastic containers having removable closure members sealed thereto. The containers are frequently randomly packed, or tumble packed, in container cases for subsequent storage and transportation.
Tumble packing filled containers in cases typically involves moving a standard size dairy or fruit juice case beneath container discharge mechanism which releases free falling containers. Although dairy standards permit the use of flat-bottom cases for tumble packing, such cases are not practical in the dairy and fruit juice industries since such cases are not as quickly and economically cleaned. The cases utilized have side and bottom panels incorporating wire or plastic grids so that water, debris, and spilled container contents can be readily washed therethrough. Each of the grids or grills has protruding edges which constitute blunt "knife edges" and, when free falling containers strike such edges, the impact energy sometimes causes penetration of the containers and the closure members or cracking of the containers, resulting in what are known as "leakers". It has been discovered that damage generally occurs to only the first few containers inasmuch as succeeding containers are protected because they land on the initial charge of deformable containers already lining the bottom of the case.
Such container damage is vexatious, since filled container cases are generally stacked four to five high and leaking containers in upper cases will contaminate the cases and containers below, the cooler storage area and other floors over which the cases are transported, and container display cases.
Accordingly, it is a primary object of the present invention to provide a tumble packing apparatus and method which minimizes or eliminates damage to tumble packed containers which free fall into such cases.
It is another object of the present invention to provide a new and improved method of tumble packing cases by cushioning the free fall of the containers into the cases.
It is another object of the present invention to provide tumble packing apparatus which incorporates a fall-breaking pad in, or adjacent, a case being filled for cushioning initially charged free falling containers from full impact with the grill edges of standard dairy and fruit industry cases.
It is still another object of the present invention to provide a tumble packing system which automatically, at proper times, positions a resilient pad in, and withdraws the pad from, the path of containers being discharged into a case.
Other objects and advantages of the present invention will become apparent to those of ordinary skill in the art as the description thereof proceeds.
SUMMARY OF THE INVENTION
Apparatus for tumble packing articles, such as liquid-filled plastic containers, in article cases and the like, comprising: frame support means; apparatus thereon for supporting an article case at a case filling station; conveying means on the frame support means for supplying a line of articles to a higher level than a case at the case filling station and releasing them in a free fall path of travel to the case; means on the frame support means movable in a to-and-fro path of travel between a removed position out of the path of the free falling articles, and an operative position in the path of the free falling articles for interrupting the free fall of at least a portion of them to prevent them from striking sharp edges on the case in their free fall path of travel; and means on the frame support means for moving the interrupting means in said to-and-fro path between the operative position and the removed position to permit the interrupted containers to finally settle in the case.
The present invention may more readily be understood by reference to the accompanying drawings, in which:
FIG. 1 is an end elevational view of tumble packing apparatus constructed according to the present invention, taken along the line 1--1 of FIG. 2;
FIG. 2 is a top plan view of the tumble packing apparatus illustrated in FIG. 1;
FIG. 3 is an enlarged, perspective plan view of a typical container case turned on its side to illustrate its grid-like bottom; and
FIG. 4 is a schematic diagram of a control circuit for controlling the operation of the apparatus illustrated in FIGS. 1 and 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to FIGS. 1 and 2, tumble packing apparatus constructed according to the present invention includes a framework, generally designated F, having longitudinally and laterally spaced pairs of upstanding support rails 10 and 12, spanned respectively by vertically spaced rails 14 and 15. Side rails 17 and 18, respectively connect the inner posts 10 and 12. Supported on the side rails 17 and 18 between the upstanding frame rails 10 and 12 is a container case conveyor, generally designated 16, including a pair of frame supported endless link chains, schematically designated 22, continuously endlessly driven by a motor M (FIG. 4), for forwardly conveying, in the direction of the arrow a, container cases or receptacles, generally designated R. Channel guide members 20 are mounted on the side rails 18 for laterally guiding the container cases R moved forwardly by the chains 22, to a conveyor case filling station, generally designated 24, where forward movement of the container cases R on the chains 22 is temporarily interrupted by a stop bar 26 pivotally mounted on the side frame member 18 by a pivot pin 28. The stop 26 is moved between the non-blocking position, illustrated in solid lines in FIG. 1, and a case blocking position, illustrated in chain lines in FIG. 1, by a double-acting, solenoid actuated, fluid operated cylinder 30 pivotally mounted on a frame supported pivot pin 31 and having a piston rod 32, pivotally connected with the stop bar 26 by a pivot pin 33.
Apparatus, generally designated 25, for supplying liquid-filled containers c, typically comprising spin-welded hollow, plastic bodies 32, sealed by cap closure members 34, to the container cases R at the case filling station 24 includes a flat (table) top conveyor assembly 35, of the type disclosed in U.S. Pat. No. 1,966,659, supported by longitudinal side rails 13 spanning the upper ends of the vertical rails 12. The conveyor assembly 35 includes an endless conveyor member generally designated 35c continuously driven by the motor M (FIG. 4) and having upper and lower runs 35a and 35b. The containers c are fed on the upper run 35a of conveyor 35c between a pair of parallel guide rails 36, which are supported on the frame rails 13 by mounting bars 37, to a container discharge station 33. The container guide rails 36 include curvilinear forward end portions 36a for directing the containers c sidewisely off the flat top conveyor run 35a to a deflector pad 38 mounted on one of the side rails 13 for deflecting the released containers c laterally away from the conveyor assembly 35 in a downward path of travel, represented by the arrow d (FIG. 1) toward a case R at the case filling station 24. Apparatus is provided for controlling the discharge of liquid-filled containers c from the conveyor 35, and includes a normally braked star wheel assembly, generally designated 40, including a star wheel plate 46 mounted on a vertical shaft 42, journaled in frame supported bearings 44, and having peripherally spaced pockets 46a spaced to receive successive containers c moving on the conveyor run 35a.
Apparatus is provided for normally braking rotation of the star wheel shaft 42 and may comprise a shaft 47 journaled in frame supported bearings 48 and mounting, at its upper end, a gear 49 drivingly connected with a gear 50 fixed to the lower end of the star wheel supporting shaft 42. A brake drum 54 may be provided on the shaft 47 and a frame supported brake shoe 55 may be normally biased into engagement therewith by a pair of springs 56 mounted on the frame F. An electrically energizable, control solenoid 58 is provided for moving the brake shoe 55 to a removed, inoperative position, permitting the free-wheeling of the shaft 47 and the star wheel assembly 40 to permit containers c to be moved forwardly on the conveyor run 35a into the case R at the case filling station 24. When the solenoid 58 is deenergized, the star wheel assembly 40 is braked and prevents the further discharge of containers c to the container case R. When the brake solenoid 58 is deenergized, the star wheel assembly 40 is free to be turned by the advancing containers c to index a conventional, commerically available frame supported "double register" electronic counter CR. The counter typically may be the Model 49800-405 (49803 prewarn) counter manufactured by Durant Instruments Division of Cutler Hammer, Inc., of Watertown, Wisconsin, which is mechanically linked to the shaft 47 and is operatively connected in the control circuit (FIG. 4 to control the energization of the brake solenoid 58 and the release of containers c from the container discharge station 33.
A typical industry container case R (FIG. 3) includes side walls 63 and a bottom wall 61 which is made up of plastic grill or grid members 65 with exposed blunt edge portions 67 which may penetrate a container c dropped thereagainst in an uninterrupted free fall path of travel from the conveyor run 35a. To prevent the containers c from being damaged, apparatus is provided for interrupting or cushioning the free fall of the initial charge of containers c into each case R at the case filling station 24 and comprises a vertically inclined base frame member 60 supported by the vertical frame rails 10 and mounting a pair of upstanding carriage-supporting plates 63, spanned by transverse, guide rods 62 on which a pad supporting carriage 64 is freely slidably movable between a lowered, operative position, illustrated in solid lines in FIG. 1, and a raised, removed position, illustrated in chain lines in FIG. 1. Resiliently mounted on the carriage 64 is a resilient pad 66 of soft rubber material, preferably in the 40 - 50 durometer range, which has sufficient strength to support itself in the position in which it is shown in FIG. 1. The pad 66 will "give" or be deflected slightly downwardly each time it interrupts the fall of one of the containers c.
Apparatus for reciprocating the carriage 64 and cushioning pad 66 between the lowered and raised positions, illustrated in solid and chain lines respectively in FIG. 1, comprises a pressure fluid-operated, double acting, solenoid actuated cylinder 68 mounted on a pair of longitudinal cross members 67 provided on the plate 60. The cylinder 63 includes a piston rod 70 extending through one of the upstanding carriage supporting plates 63 and connected to the pad mounting carriage 64.
Referring now more particularly to FIG. 4, a control circuit for operating the apparatus disclosed in FIGS. 1 and 2 is schematically illustrated and includes a pair of lines L1 and L2 connected across a suitable source of power, such as 110 volt, 60 cycle, current. Connected across the lines L1 and L2 in line L3 is an electrical motor M for continuously driving the flat table-top conveyor 35 to forwardly deliver containers c to the star wheel assembly 40 and the container discharge station 33. Connected across the lines L1 and L2 in line L4 is the pad lowering solenoid 68a for causing fluid to be directed to the pad lowering cylinder 68 in such a manner as to lower the resilient cushioning pad 66 to the cushioning position, illustrated in FIG. 1 in the path of the free falling containers c. Also connected in line L4 is a set of limit switch contacts LS-1a which are closed when a limit switch LS-1, mounted on the pivotal case stop bar 26 is engaged by a container case R engaging the pivotal stop bar 26 at the case filling station 24. Connected in series with the pad lowering solenoid 68a and the limit switch contacts LS-1a are the normally closed contacts 68b1 which are opened when a pad raising solenoid 68b connected in line L5 is energized. The pad raising solenoid 68b (line L5), when energized, will direct fluid to the cushioning pad control cylinder 68 in such a direction as to cause the resilient pad 66 to be withdrawn to the raised position illustrated in chain lines in FIG. 1. Serially connected with the pad raising solenoid 68b are the normally open contacts CR1 which are closed when a sufficient number of containers c have passed the star wheel 40 to line the bottom of the case R and the counter CR connected in line L6 across the lines L1 and L2 is incrementally indexed an identical number of times.
Connected in line L7 across the lines L1 and L2 are the normally open limit switch contacts LS-1b, which are closed when the limit switch LS-1 on the pivotal case stop bar 26 is actuated by a case R arriving at the case loading station 24, the brake actuating solenoid 58a for withdrawing the brake 58 to permit the star wheel assembly 40 to be rotated by the containers c moving on the conveyor 35, and the normally closed counter contacts CR3 which open when the counter CR has been indexed a sufficient number of times to indicate that the case R is full.
Connected in line L8 across the lines L1 and L2 is a stop bar control cylinder 30a for moving the pivotal stop bar 26 to the case interrupting position illustrated in chain lines in FIG. 1 and the normally closed contacts 30b1 which are open when the solenoid 30b (line L9) is energized. The solenoid 30b (line L9) is energized to retract the pivotal stop bar 26 to the non-blocking position illustrated in solid lines in FIG. 3. Connected in series with the solenoid 30b in line L9 are the normally closed limit switch contacts LS-2a which are closed when a limit switch LS-2 downstream of the case filling station 24 is energized by a case moving away from the case filling station 24, and the normally open counter contacts CR2 which close when a predetermined number of containers have been deposited in the case R to fill the case.
THE OPERATION
The containers c are formed, filled, and sealed by apparatus such as that disclosed in United States patent application Ser. No. 154,058, filed June 17, 1971, and now U.S. Pat. No. 3,744,212 which is assigned to the assignee of the present invention.
In the first place, the conveyor chains 22 are driven to move a case R against the pivotal stop bar 26 extending into the path of a case R at the case filling station 24, and this activates limit switch LS-1. When the limit switch LS-1 is actuated, the contacts LS-1a (line L4) close to energize the cushioning pad advance solenoid 68a to lower the cushioning pad 66 in a downwardly inclined path of travel into the container case R at the case filling station 24 to the position illustrated in FIG. 1. At the same time, the contacts LS-1b (line L7) are closed to energize the brake retract solenoid 58 for retracting the brake 55 and permitting the star wheel assembly 40 to be freely driven by containers c moving on the conveyor 35. After enough containers c (e.g. 8 - 10) to line the bottom of the case R pass the star wheel assembly 40 and fall into the container case R, the electronic counter CR signals for retraction of the cushioning pad 66 by closing the contacts CR1 (line L5) to energize the pad retract solenoid 68b which retracts the cushioning pad 66 to the inoperative position illustrated in chain lines in FIG. 1. The filled containers c continue to flow into the container case Rutilizing the initial charge of containers c as a cushioning layer which now lines the bottom wall 68 of the container case R during the remainder of the filling operation for that particular case. When the case is filled with a predetermined number of filled containers c, the electronic counter CR will have been actuated a predetermined additional number of times so that the normally closed counter contacts CR3 (line L7) open to deenergize the brake solenoid which releases the brake 55 into engagement with the brake drum 54 and prevents the containers c from turning the star wheel assembly 40 and thus prohibits the further passage of containers c on the conveyor 35. When the counter CR has counted the full complement of containers which are to be delivered to the case R, the contacts CR2 (line L9) also close to energize the retract solenoid 30b (line L9) which retracts the pivotal case stop 26 to the solid line position illustrated in FIG. 1 so that the filled container case R may be moved by the conveyor chains 22 forwardly in the direction of the arrow a. Upon exit from the case filling station 24, the container case R trips the limit switch LS-2 to open the limit switch contacts LS-2a (line L9) and deenergize the stop retract solenoid 30b. This closes the contacts 30b1 (line L8) and permits the stop advance solenoid 30a to again be energized to laterally position the pivotal case stop 26 in the path of the next succeeding container case R moved to the container filling station 24. The electronic counter CR will have been reset and the cycle will again repeat itself when the limit switch LS-1 is again actuated by a succeeding case R arriving at the case filling station 24.
It is to be understood that the drawings and descriptive matter are in all cases to be interpreted as merely illustrative of the principles of the invention, rather than as limiting the same in any way, since it is contemplated that various changes may be made in various elements to achieve like results without departing from the spirit of the invention or the scope of the appended claims.
This invention relates to apparatus for, and a method of, tumble packing containers in cases, and more particularly to apparatus for, and a method of, reducing the impact effect on containers dropped into a container case by cushioning the fall of containers tumble packed into a container case to eliminate container damage.
Fruit juice, milk, and other liquid products are frequently stored in thin-walled deformable plastic containers having removable closure members sealed thereto. The containers are frequently randomly packed, or tumble packed, in container cases for subsequent storage and transportation.
Tumble packing filled containers in cases typically involves moving a standard size dairy or fruit juice case beneath container discharge mechanism which releases free falling containers. Although dairy standards permit the use of flat-bottom cases for tumble packing, such cases are not practical in the dairy and fruit juice industries since such cases are not as quickly and economically cleaned. The cases utilized have side and bottom panels incorporating wire or plastic grids so that water, debris, and spilled container contents can be readily washed therethrough. Each of the grids or grills has protruding edges which constitute blunt "knife edges" and, when free falling containers strike such edges, the impact energy sometimes causes penetration of the containers and the closure members or cracking of the containers, resulting in what are known as "leakers". It has been discovered that damage generally occurs to only the first few containers inasmuch as succeeding containers are protected because they land on the initial charge of deformable containers already lining the bottom of the case.
Such container damage is vexatious, since filled container cases are generally stacked four to five high and leaking containers in upper cases will contaminate the cases and containers below, the cooler storage area and other floors over which the cases are transported, and container display cases.
Accordingly, it is a primary object of the present invention to provide a tumble packing apparatus and method which minimizes or eliminates damage to tumble packed containers which free fall into such cases.
It is another object of the present invention to provide a new and improved method of tumble packing cases by cushioning the free fall of the containers into the cases.
It is another object of the present invention to provide tumble packing apparatus which incorporates a fall-breaking pad in, or adjacent, a case being filled for cushioning initially charged free falling containers from full impact with the grill edges of standard dairy and fruit industry cases.
It is still another object of the present invention to provide a tumble packing system which automatically, at proper times, positions a resilient pad in, and withdraws the pad from, the path of containers being discharged into a case.
Other objects and advantages of the present invention will become apparent to those of ordinary skill in the art as the description thereof proceeds.
SUMMARY OF THE INVENTION
Apparatus for tumble packing articles, such as liquid-filled plastic containers, in article cases and the like, comprising: frame support means; apparatus thereon for supporting an article case at a case filling station; conveying means on the frame support means for supplying a line of articles to a higher level than a case at the case filling station and releasing them in a free fall path of travel to the case; means on the frame support means movable in a to-and-fro path of travel between a removed position out of the path of the free falling articles, and an operative position in the path of the free falling articles for interrupting the free fall of at least a portion of them to prevent them from striking sharp edges on the case in their free fall path of travel; and means on the frame support means for moving the interrupting means in said to-and-fro path between the operative position and the removed position to permit the interrupted containers to finally settle in the case.
The present invention may more readily be understood by reference to the accompanying drawings, in which:
FIG. 1 is an end elevational view of tumble packing apparatus constructed according to the present invention, taken along the line 1--1 of FIG. 2;
FIG. 2 is a top plan view of the tumble packing apparatus illustrated in FIG. 1;
FIG. 3 is an enlarged, perspective plan view of a typical container case turned on its side to illustrate its grid-like bottom; and
FIG. 4 is a schematic diagram of a control circuit for controlling the operation of the apparatus illustrated in FIGS. 1 and 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to FIGS. 1 and 2, tumble packing apparatus constructed according to the present invention includes a framework, generally designated F, having longitudinally and laterally spaced pairs of upstanding support rails 10 and 12, spanned respectively by vertically spaced rails 14 and 15. Side rails 17 and 18, respectively connect the inner posts 10 and 12. Supported on the side rails 17 and 18 between the upstanding frame rails 10 and 12 is a container case conveyor, generally designated 16, including a pair of frame supported endless link chains, schematically designated 22, continuously endlessly driven by a motor M (FIG. 4), for forwardly conveying, in the direction of the arrow a, container cases or receptacles, generally designated R. Channel guide members 20 are mounted on the side rails 18 for laterally guiding the container cases R moved forwardly by the chains 22, to a conveyor case filling station, generally designated 24, where forward movement of the container cases R on the chains 22 is temporarily interrupted by a stop bar 26 pivotally mounted on the side frame member 18 by a pivot pin 28. The stop 26 is moved between the non-blocking position, illustrated in solid lines in FIG. 1, and a case blocking position, illustrated in chain lines in FIG. 1, by a double-acting, solenoid actuated, fluid operated cylinder 30 pivotally mounted on a frame supported pivot pin 31 and having a piston rod 32, pivotally connected with the stop bar 26 by a pivot pin 33.
Apparatus, generally designated 25, for supplying liquid-filled containers c, typically comprising spin-welded hollow, plastic bodies 32, sealed by cap closure members 34, to the container cases R at the case filling station 24 includes a flat (table) top conveyor assembly 35, of the type disclosed in U.S. Pat. No. 1,966,659, supported by longitudinal side rails 13 spanning the upper ends of the vertical rails 12. The conveyor assembly 35 includes an endless conveyor member generally designated 35c continuously driven by the motor M (FIG. 4) and having upper and lower runs 35a and 35b. The containers c are fed on the upper run 35a of conveyor 35c between a pair of parallel guide rails 36, which are supported on the frame rails 13 by mounting bars 37, to a container discharge station 33. The container guide rails 36 include curvilinear forward end portions 36a for directing the containers c sidewisely off the flat top conveyor run 35a to a deflector pad 38 mounted on one of the side rails 13 for deflecting the released containers c laterally away from the conveyor assembly 35 in a downward path of travel, represented by the arrow d (FIG. 1) toward a case R at the case filling station 24. Apparatus is provided for controlling the discharge of liquid-filled containers c from the conveyor 35, and includes a normally braked star wheel assembly, generally designated 40, including a star wheel plate 46 mounted on a vertical shaft 42, journaled in frame supported bearings 44, and having peripherally spaced pockets 46a spaced to receive successive containers c moving on the conveyor run 35a.
Apparatus is provided for normally braking rotation of the star wheel shaft 42 and may comprise a shaft 47 journaled in frame supported bearings 48 and mounting, at its upper end, a gear 49 drivingly connected with a gear 50 fixed to the lower end of the star wheel supporting shaft 42. A brake drum 54 may be provided on the shaft 47 and a frame supported brake shoe 55 may be normally biased into engagement therewith by a pair of springs 56 mounted on the frame F. An electrically energizable, control solenoid 58 is provided for moving the brake shoe 55 to a removed, inoperative position, permitting the free-wheeling of the shaft 47 and the star wheel assembly 40 to permit containers c to be moved forwardly on the conveyor run 35a into the case R at the case filling station 24. When the solenoid 58 is deenergized, the star wheel assembly 40 is braked and prevents the further discharge of containers c to the container case R. When the brake solenoid 58 is deenergized, the star wheel assembly 40 is free to be turned by the advancing containers c to index a conventional, commerically available frame supported "double register" electronic counter CR. The counter typically may be the Model 49800-405 (49803 prewarn) counter manufactured by Durant Instruments Division of Cutler Hammer, Inc., of Watertown, Wisconsin, which is mechanically linked to the shaft 47 and is operatively connected in the control circuit (FIG. 4 to control the energization of the brake solenoid 58 and the release of containers c from the container discharge station 33.
A typical industry container case R (FIG. 3) includes side walls 63 and a bottom wall 61 which is made up of plastic grill or grid members 65 with exposed blunt edge portions 67 which may penetrate a container c dropped thereagainst in an uninterrupted free fall path of travel from the conveyor run 35a. To prevent the containers c from being damaged, apparatus is provided for interrupting or cushioning the free fall of the initial charge of containers c into each case R at the case filling station 24 and comprises a vertically inclined base frame member 60 supported by the vertical frame rails 10 and mounting a pair of upstanding carriage-supporting plates 63, spanned by transverse, guide rods 62 on which a pad supporting carriage 64 is freely slidably movable between a lowered, operative position, illustrated in solid lines in FIG. 1, and a raised, removed position, illustrated in chain lines in FIG. 1. Resiliently mounted on the carriage 64 is a resilient pad 66 of soft rubber material, preferably in the 40 - 50 durometer range, which has sufficient strength to support itself in the position in which it is shown in FIG. 1. The pad 66 will "give" or be deflected slightly downwardly each time it interrupts the fall of one of the containers c.
Apparatus for reciprocating the carriage 64 and cushioning pad 66 between the lowered and raised positions, illustrated in solid and chain lines respectively in FIG. 1, comprises a pressure fluid-operated, double acting, solenoid actuated cylinder 68 mounted on a pair of longitudinal cross members 67 provided on the plate 60. The cylinder 63 includes a piston rod 70 extending through one of the upstanding carriage supporting plates 63 and connected to the pad mounting carriage 64.
Referring now more particularly to FIG. 4, a control circuit for operating the apparatus disclosed in FIGS. 1 and 2 is schematically illustrated and includes a pair of lines L1 and L2 connected across a suitable source of power, such as 110 volt, 60 cycle, current. Connected across the lines L1 and L2 in line L3 is an electrical motor M for continuously driving the flat table-top conveyor 35 to forwardly deliver containers c to the star wheel assembly 40 and the container discharge station 33. Connected across the lines L1 and L2 in line L4 is the pad lowering solenoid 68a for causing fluid to be directed to the pad lowering cylinder 68 in such a manner as to lower the resilient cushioning pad 66 to the cushioning position, illustrated in FIG. 1 in the path of the free falling containers c. Also connected in line L4 is a set of limit switch contacts LS-1a which are closed when a limit switch LS-1, mounted on the pivotal case stop bar 26 is engaged by a container case R engaging the pivotal stop bar 26 at the case filling station 24. Connected in series with the pad lowering solenoid 68a and the limit switch contacts LS-1a are the normally closed contacts 68b1 which are opened when a pad raising solenoid 68b connected in line L5 is energized. The pad raising solenoid 68b (line L5), when energized, will direct fluid to the cushioning pad control cylinder 68 in such a direction as to cause the resilient pad 66 to be withdrawn to the raised position illustrated in chain lines in FIG. 1. Serially connected with the pad raising solenoid 68b are the normally open contacts CR1 which are closed when a sufficient number of containers c have passed the star wheel 40 to line the bottom of the case R and the counter CR connected in line L6 across the lines L1 and L2 is incrementally indexed an identical number of times.
Connected in line L7 across the lines L1 and L2 are the normally open limit switch contacts LS-1b, which are closed when the limit switch LS-1 on the pivotal case stop bar 26 is actuated by a case R arriving at the case loading station 24, the brake actuating solenoid 58a for withdrawing the brake 58 to permit the star wheel assembly 40 to be rotated by the containers c moving on the conveyor 35, and the normally closed counter contacts CR3 which open when the counter CR has been indexed a sufficient number of times to indicate that the case R is full.
Connected in line L8 across the lines L1 and L2 is a stop bar control cylinder 30a for moving the pivotal stop bar 26 to the case interrupting position illustrated in chain lines in FIG. 1 and the normally closed contacts 30b1 which are open when the solenoid 30b (line L9) is energized. The solenoid 30b (line L9) is energized to retract the pivotal stop bar 26 to the non-blocking position illustrated in solid lines in FIG. 3. Connected in series with the solenoid 30b in line L9 are the normally closed limit switch contacts LS-2a which are closed when a limit switch LS-2 downstream of the case filling station 24 is energized by a case moving away from the case filling station 24, and the normally open counter contacts CR2 which close when a predetermined number of containers have been deposited in the case R to fill the case.
THE OPERATION
The containers c are formed, filled, and sealed by apparatus such as that disclosed in United States patent application Ser. No. 154,058, filed June 17, 1971, and now U.S. Pat. No. 3,744,212 which is assigned to the assignee of the present invention.
In the first place, the conveyor chains 22 are driven to move a case R against the pivotal stop bar 26 extending into the path of a case R at the case filling station 24, and this activates limit switch LS-1. When the limit switch LS-1 is actuated, the contacts LS-1a (line L4) close to energize the cushioning pad advance solenoid 68a to lower the cushioning pad 66 in a downwardly inclined path of travel into the container case R at the case filling station 24 to the position illustrated in FIG. 1. At the same time, the contacts LS-1b (line L7) are closed to energize the brake retract solenoid 58 for retracting the brake 55 and permitting the star wheel assembly 40 to be freely driven by containers c moving on the conveyor 35. After enough containers c (e.g. 8 - 10) to line the bottom of the case R pass the star wheel assembly 40 and fall into the container case R, the electronic counter CR signals for retraction of the cushioning pad 66 by closing the contacts CR1 (line L5) to energize the pad retract solenoid 68b which retracts the cushioning pad 66 to the inoperative position illustrated in chain lines in FIG. 1. The filled containers c continue to flow into the container case Rutilizing the initial charge of containers c as a cushioning layer which now lines the bottom wall 68 of the container case R during the remainder of the filling operation for that particular case. When the case is filled with a predetermined number of filled containers c, the electronic counter CR will have been actuated a predetermined additional number of times so that the normally closed counter contacts CR3 (line L7) open to deenergize the brake solenoid which releases the brake 55 into engagement with the brake drum 54 and prevents the containers c from turning the star wheel assembly 40 and thus prohibits the further passage of containers c on the conveyor 35. When the counter CR has counted the full complement of containers which are to be delivered to the case R, the contacts CR2 (line L9) also close to energize the retract solenoid 30b (line L9) which retracts the pivotal case stop 26 to the solid line position illustrated in FIG. 1 so that the filled container case R may be moved by the conveyor chains 22 forwardly in the direction of the arrow a. Upon exit from the case filling station 24, the container case R trips the limit switch LS-2 to open the limit switch contacts LS-2a (line L9) and deenergize the stop retract solenoid 30b. This closes the contacts 30b1 (line L8) and permits the stop advance solenoid 30a to again be energized to laterally position the pivotal case stop 26 in the path of the next succeeding container case R moved to the container filling station 24. The electronic counter CR will have been reset and the cycle will again repeat itself when the limit switch LS-1 is again actuated by a succeeding case R arriving at the case filling station 24.
It is to be understood that the drawings and descriptive matter are in all cases to be interpreted as merely illustrative of the principles of the invention, rather than as limiting the same in any way, since it is contemplated that various changes may be made in various elements to achieve like results without departing from the spirit of the invention or the scope of the appended claims.