AUTOMATED LOADER

Abstract

A ramming mechanism to move material from one location to another is described. The ramming mechanism comprises a belt assembly comprising a belt driven over a plurality of pulleys, a ram carriage connected to the belt, and a ram cylinder mounted on the ram carriage.

Description

PRIORITY

This application claims priority from U.S. Provisional Patent Application Ser. No. 61/615,412, filed on Mar. 26, 2012, and from U.S. Provisional Patent Application No. 61/618,020, filed Mar. 30, 2012, the disclosures of both of which are incorporated by reference in their entireties.

FIELD OF THE INVENTION

The present invention relates generally to a device for moving material from one location to another. The invention relations more specifically to an automated device for loading material into a bag, net, or tube. More specifically, the invention relates to an improved ramming mechanism for loading material into a bag, net, or tube.

BACKGROUND OF THE INVENTION

Ramming mechanisms are conventionally used to move materials from one location to another. A ram is used in automated loaders, such as, for example, the automated poultry loader described in U.S. Pat. No. 7,178,310, Poly-stretch Bagger System with Hocking Pusher, the disclosure of which is incorporated herein. A whole dressed bird, such as a chicken, is presented adjacent two horns. The two horns move inside a plastic bag and hold the bag open while a ram forward strokes to push the chicken into the bag. The ram continues its forward stroke to push the now-bagged chicken through the space between the horns for the next processing step, such as clipping of the bag. The ram then reverse stroke to return to its original location.

Conventional rams use air cylinders to power the forward and reverse strokes. Air cylinders are easy to build and maintain and plant air supplies are common. Modern air cylinders use air actuation for both the forward stroke and the reverse stroke. These types of air cylinders, however, are slow, as it takes time to fill each cylinder with air. Some air cylinders use a spring for the reverse stroke and these types are slow as well. Additionally, the longer the length of a stroke, the more wear there is on the air cylinder and the more maintenance problems that result.

A faster ramming mechanism is attractive to manufacturers who have to move material from one place to another, in particular but not limited to those manufacturers who wish to move material into a bag, tube, and/or net. Additionally, devices that allow for the use of an air cylinder operating over a shorter distance will be attractive to these same users. The present invention addresses some of the issues of the prior art.

SUMMARY OF THE INVENTION

A ramming mechanism moves material from one location to another. A ram carriage is mounted on a belt conveyor and moves from a first location to a second location. An air cylinder is mounted on the ram carriage and a piston arm strokes in forward and reverse directions.

A BRIEF DESCRIPTION OF THE DRAWINGS

The organization and manner of the structure and operation of the invention, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings, wherein like reference numerals identify like elements in which:

FIG. 1 is a perspective view of an automated loader as known in the prior art.

FIG. 2 is a plan schematic view of another automated loader as known in the prior art.

FIG. 3 is a perspective view of a portion of the preferred embodiment of the automated loader of the present invention.

FIG. 4 is an elevation view of the automated loader of a preferred embodiment of the present invention.

FIG. 5 is another elevation view of the automated loader of FIG. 4.

FIG. 6 is another elevation view of the automated loader of FIG. 4.

FIG. 7 is another elevation view of the automated loader of FIG. 4.

FIG. 8A is a schematic view of an embodiment of the ram cylinder of the automated loader of FIG. 4 in a retracted position.

FIG. 8B is a schematic view of an embodiment of the ram cylinder of the automated loader of FIG. 4 in an extended position.

FIG. 9 is an elevation schematic view of the automated loader of another embodiment of the present invention.

FIG. 10 is another view of the automated loader of FIG. 9.

FIG. 11 is another view of the automated loader of FIG. 9.

FIG. 12 is another view of the automated loader of FIG. 9.

FIG. 13 is another view of the automated loader of FIG. 9.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

While the invention may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, specific embodiments with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that as illustrated and described herein. The embodiments of the present invention will be described as part of an automated ramming mechanism to be incorporated in an automated poultry loader. The present invention, however, can also be used on loaders for bagging and/or netting whole poultry, cut-up poultry, or whole muscle meat products, on other applications in which a material is enclosed in a casing, bag, or netting, such as sealants, adhesives, and explosives, or for any other application in which a ramming mechanism is needed to move material from a first position to a second position.

A conventional poultry loader 20 as known in the prior art is shown in perspective view in FIG. 1. Loader 20 comprises in pertinent part a pair of horns 22, 24 mounted on a frame 26. A bag carriage assembly 28 is configured to slide under frame 26. A chicken 30 is presented between a first end 32 of horns 22, 24, either by manual placement or by automated delivery, such as by a conveyor belt. A stack of bags 34 is mounted to carriage assembly 28 and secured thereon by a wicket 36. An air blast slightly opens the top bag 34, enough to permit entry of horns 22, 24. Carriage assembly 28 slides under frame 26, pulling top bag 34 over horns 22, 24. Horn control mechanism 38 rotates horns 22, 24 to stretch bag 34. Ram 40, which is mounted on frame 26, forward strokes to push chicken 30 into bag 34, then continues to forward stroke to push chicken 30 against the bottom of bag 34, causing the now bagged-chicken 30 to move through horns 22, 24, causing bag 30 to tighten around chicken 30 as the combination bag-and-chicken come off horns 22, 24. Ram 40 reverse strokes to its first position and waits for another chicken 30 to be delivered. Controller 42 is an analogue or digital controller that controls operation of the various moving parts of loader 20 in proper sequence.

A similar loader 120 known in the art is shown in schematic plan view in FIG. 2. Loader 120 comprises in pertinent part a pair of horns 122, 124 mounted on a frame 126. A bag carriage assembly 128 is configured to slide under frame 126. A chicken 130 is presented between horns 122, 124 and adjacent ram 140, either by manual placement or by automated delivery, such as by a conveyor belt. A stack of bags 134 is mounted to carriage assembly 128 and secured thereon by a wicket 136. An air blast slightly opens the top bag 134, enough to permit entry of horns 122, 124. Carriage assembly 128 slides under frame 126, pulling top bag 134 over horns 122, 124. Horn control mechanism 138 moves horns 122, 124 laterally to stretch bag 134. Ram 140, which is mounted on loader 28, forward strokes to push chicken 130 into bag 134, then continues to forward stroke to push chicken 130 against the bottom of bag 134, causing the now bagged-chicken 130 to move through horns 122, 124, causing bag 130 to tighten around chicken 130 as the combination bag-and-chicken come off horns 122, 124. Ram 140 reverse strokes to its first position and waits for another chicken 130 to be delivered. Controller 142 is an analogue or digital controller that controls operation of the various moving parts of loader 120 in proper sequence.

The preferred embodiment of the present invention is a ramming mechanism 50 that replaces ram 40 in the above-described loader 20, replaces ram 140 in the above-described loader 120, or is used to any situation to move material from one location to another. Ramming mechanism 50 is shown in perspective view in FIG. 3 and in schematic, elevation view, as attached to an automated loader 20, in FIGS. 4 through 7. Ramming mechanism 50 comprises a ram carriage 52, a belt assembly 54, a ram cylinder 56, a tail pusher 58, and a hocking pusher 60.

Belt assembly 54 has a rear pulley 62, a forward pulley 64, and a belt 66. Preferably, forward pulley 64 is a drive pulley and rear pulley 62 is an idler pulley, but the drive could be on rear pulley 62 or on both pulleys 62, 64. Both pulleys 62, 64 are mounted to frame 26 by conventional means, such as axle mounts. While two pulleys 62, 64 are shown and described, more than two pulleys can be provided, in addition, non-driven pulleys or rollers (not shown) can be provided between pulleys 62, 64.

Belt 66 is a continuous loop made of rubber, plastic, metal or plastic mesh, or similar belt-type material, and rotates about pulleys 62, 64. The axle mounts can either be outboard of belt 66 or there can be two belts 66, with axle mounts between each belt. Forward drive pulley 64 is powered by an electric motor 68, such as a servo motor, which is itself mounted to frame 26. Motor 68 is coupled to controller 42, either by control wires or wirelessly.

Ram carriage 52 is affixed to belt 66 and is movable with belt 66. Motor 68 operates in a first direction to rotate belt 66 to move ram carriage 52 from a first position, remote from horns 22, 24, as shown in FIG. 6, to a second position, adjacent horns 22, 24, as shown in FIGS. 7 through 9. Motor 68 operates in second direction to rotate belt 66 to move ram carriage 52 back to the first position shown in FIG. 6.

Tail pusher 58 is a flat, elongated member mounted at its end distal to horns 22, 24 to the side of ram carriage 52 facing horns 22, 24. Tail pusher 58 has a dovetail cutout 70 in its end proximal to horns 22, 24, as shown in FIG. 3.

Ram cylinder 56 is also affixed to ram carriage 52 and moves with ram carriage 52. Ram cylinder 56 is a conventional double-acting pneumatic cylinder, connected by plastic tubing 72 to a plant compressed air supply 74. Ram cylinder 56 has a cylinder body 76, a piston head 78, and a piston arm 80 connected to piston head 78. Piston head 78 and piston arm 80 are moveable within cylinder body 76. Ram cylinder 56 is shown in schematic view in FIG. 8A in a retracted position (and connected via tubing 72 to air supply 74) and in FIG. 8B in an extended position. Preferably, a hocking pusher 60 is mounted to the end of piston arm 78. Hocking pusher 60 is preferably a grabber assembly as described in U.S. Pat. No. 7,178,310.

For food-loading operations, it is preferable that as many components of ramming mechanism 50 as possible be made of stainless steel.

In operation, ram carriage 52 is in its first position and piston 76 and piston arm 80 are retracted within cylinder body 74, as shown in FIG. 4. A dressed chicken 30 is delivered to the space 84 between ram carriage 56 and horns 22, 24, either by a plant worker or by a delivery means, such as a conveyor belt. Dressed chicken 30 is placed with its severed neck facing horns 22, 24 and its tail facing ram carriage 52. Controller 42 causes motor 68 to rotate belt 66 to move ram carriage 52 forward from the first position to the second position, as shown in FIG. 5. This movement causes tail pusher 58 to contact the tail of chicken 30 and push the tail down, and to push chicken 30 from space 84 into the space 86 between horns 22, 24, where it will encounter bag 34 held on horns 22, 24, as shown in FIG. 5.

Controller 42 next causes ram cylinder 56 to actuate a forward stroke, as shown in FIG. 6. Piston arm 80 extends toward chicken 30 and hocking pusher 60 initially contacts the legs of chicken 30, as the tail has been pushed down. As piston arm 80 continues its forward stroke, chicken 30 is pushed between horns 22, 24 and fully into bag 34, until chicken 30 encounters the bottom of bag 34. As piston arm 80 continues its forward stroke, bag 34, now containing chicken 30, is pushed off horns 22, 24, as shown in FIG. 7. Bagged chicken 30 then proceeds for further processing, such as closing bag 34 with a clip. Controller 42 then causes piston arm 80 and piston head 78 to perform a reverse stroke to retract within cylinder body 76. At the same time, motor 68 reverses and rotates belt 66 to cause ram carriage 52 to move back to its first position.

Because the movement of ram carriage 52 from its first position to its second position is accomplished faster by electric motor than an air cylinder could move the same distance using pneumatic pressure, the entire operation moves more quickly. Additionally, since the distance that piston arm 80 has to move is smaller than if there was no ram carriage, a smaller air-actuated cylinder can be used, at lower expense and lower maintenance cost.

Ramming mechanism 50 can be used in a variety of food-loading applications, including by way of example and not by way of limitation, a bagging/netting system as described in U.S. Pat. No. 6,895,726; a bagging system as described in U.S. Pat. No. 6,883,297; a stuffer as described in U.S. Pat. No. 7,404,758; a netting machine as described in U.S. Pat. No. 7,124,553; a rack loader as described in U.S. Pat. No. 7,563,158; a breech loader as described in U.S. Pat. No. 7,284,359; a hybrid filling system as described in U.S. Pat. No. 7,544,118; a bagger as described in United States Published Patent Application No. 2008/0022636 A1; and a bagger as described in U.S. Pat. No. 8,096,097, the disclosures of each of which is incorporated herein by reference. Ramming mechanism 50 can also be used in non-food applications to load material into a bag, tube, or net, or for any other application in which material must be moved from a first location to a second location.

Another embodiment of the present invention is a ramming mechanism 250 that replaces ram 40 in the above-described loader 20, replaces ram 140 in the above-described loader 120, or is used to any situation to move material from one location to another. Ramming mechanism 250 is shown in schematic, elevation view in FIGS. 9 through 13. Ramming mechanism 250 comprises ram carriage 252, a belt assembly 254, an ram cylinder 256, a tail pusher 258, a hocking pusher 260, and a bottom plate assembly 200.

Bottom plate assembly 200 is mounted to frame 26 and sits below belt assembly 54. Bottom plate assembly 200 has a bottom plate air cylinder 202, a bottom plate piston arm 204 part of bottom plate air cylinder 202, and a bottom plate 206 connected to bottom plate piston arm. Bottom plate air cylinder 202 is a conventional air cylinder, same as or similar to ram cylinder 56 described below and illustrated in FIGS. 8A and 8B. Bottom plate 206 is a flat, generally rectangular member preferably made of stainless steel. When bottom plate air cylinder 202 is retracted, bottom plate 206 is located in the space 84 between horns 224, 226 and belt assembly 254. When controller 242 actuates bottom plate air cylinder 202 to extend bottom plate piston arm 204, bottom plate 206 moves forward from its first position, as shown in FIG. 9, to its second position, inside stretched hag 32, as shown in FIG. 10. In use, then, a chicken 230 placed in space 284 will be on bottom plate 206 and will be conveyed into bag 232.

Belt assembly 254 has a rear pulley 262 and a forward pulley 264. Preferably, forward pulley 262 is a drive pulley and rear pulley 262 is an idler pulley, but the drive could be on rear pulley 262 or on both pulleys 262, 264. Both pulleys 262, 264 are mounted to frame 226 by conventional means, such as axle mounts. While two pulleys 262, 264 are shown and described, more than two pulleys can be provided. In addition, non-driven pulleys or rollers (not shown) can be provided between pulleys 262, 264.

Belt 266 is a continuous loop made of rubber, plastic, metal or plastic mesh, or similar belt-type material, and rotates about pulleys 262, 264. The axle mounts can either be outboard of belt 266 or there can be two belts 266, with axle mounts between each belt. Forward drive pulley 264 is powered by an electric motor 268, such as a servo motor, which is itself mounted to frame 226. Motor 268 is coupled to controller 242, either by control wires or wirelessly.

Ram carriage 252 is affixed to belt 266 and is movable with belt 266. Motor 268 operates in a first direction to rotate belt 266 to move ram carriage 252 from a first position, remote from horns 222, 224, as shown in FIGS. 9 and 10, to a second position, adjacent horns 222, 224, as shown in FIGS. 12 through 13. Motor 268 operates in second direction to rotate belt 266 to move ram carriage 252 back to the first position shown in FIG. 9.

Tail pusher 258 is a flat, elongated member mounted at its end distal to horns 222, 224 to the side of ram carriage 252 facing horns 222, 224. Tail pusher 258 has a dovetail cutout 270 in its end proximal to horns 222, 224, same as the dovetail cutout in tail pusher 58 shown in FIG. 3.

Ram cylinder 256 is also affixed to ram carriage 252. Ram cylinder 256 is identical to ram cylinder 56 illustrated in FIGS. 8A and 8B. Ram cylinder 256 is a conventional double-acting pneumatic cylinder, connected by plastic tubing 72 to a plant compressed air supply 74. Rain cylinder 256 has a cylinder body 76, a piston head 78, and a piston arm 80 connected to piston head 78. Piston head 78 and piston arm 80 are moveable within cylinder body 76. Preferably, a hocking pusher 260 is mounted to the end of piston arm 278. Hocking pusher 260 is preferably a grabber assembly as described in U.S. Pat. No. 7,178,310.

For food-loading operations, it is preferable that as many components of ramming mechanism 250 as possible be made of stainless steel.

In operation, ram carriage 252 is in its first position and piston 276 is retracted within cylinder body 274, as shown in FIG. 9. A dressed chicken 230 is delivered to the space 284 between ram carriage 256 and horns 222, 224, either by a plant worker or by a delivery means, such as a conveyor belt, and placed on bottom plate 2206. Horns 222, 224 are inserted into bag 232, preferably with the aid of an air nozzle, and rotated axially or in a plane to stretch bag 232. Dressed chicken 230 is placed with its severed neck facing horns 222, 224 and its tail facing ram carriage 252. Controller 242 first causes bottom plate air cylinder 202 to actuate to move bottom plate 206 and chicken 230 into bag 232 as shown in FIG. 10.

Next, motor 268 rotates belt 266 to move ram carriage 252 forward from the first position to the second position, as shown in FIG. 11. This movement causes tail pusher 258 to contact the tail of chicken 230 and push the tail down. Controller 242 next causes ram cylinder 256 to actuate a forward stroke, as shown in FIG. 12. Piston arm 280 extends toward chicken 230 and hocking pusher 260 initially contacts the legs of chicken 230, as the tail has been pushed down. As piston arm 280 continues its forward stroke, chicken 230 is pushed between horns 222, 224 and fully into bag 234, until chicken 230 encounters the bottom of bag 234. As piston arm 280 continues its forward stroke, bag 234, now containing chicken 230, is pushed off horns 222, 224, as shown in FIG. 13. Bagged chicken 230 then proceeds for further processing, such as dosing bag 234 with a clip. Controller 242 then causes piston arm 280 to perform a reverse stroke to retract piston 278 within cylinder body 276. At the same time, motor 268 reverses to rotate belt 266 to move ram carriage 252 back to its first position.

Because the movement of ram carriage 252 from its first position to its second position is accomplished faster by electric motor than an air cylinder could move the same distance using pneumatic pressure, the entire ramming operation moves more quickly. Additionally, since the distance piston arm 280 has to move is smaller than if there was no ram carriage, a smaller air actuated cylinder can be used, at lower expense and lower maintenance cost. Because chicken 230 is moved into bag 232 on bottom plate 206, the problem of tearing the plastic of bag 232 as chicken 230 is rammed over it is ameliorated.

Ramming mechanism 250 can be used in a variety of food-loading applications, including by way of example and not by way of limitation, a bagging/netting system as described in U.S. Pat. No. 6,895,726; a bagging system as described in U.S. Pat. No. 6,883,297; stuffer as described in U.S. Pat. No. 7,404,758; a netting machine as described in U.S. Pat. No. 7,124,553; a rack loader as described in U.S. Pat. No. 7,563,158; breech loader as described in U.S. Pat. No. 7,284,359; a hybrid filling system as described in U.S. Pat. No. 7,544,118; a bagger as described in United States Published Patent Application No. 2008/0022636 A1; and a bagger as described in U.S. Pat. No. 8,096,097, the disclosures of each of which is incorporated herein by reference. Ramming mechanism 250 can also be used in non-food applications to load material into a bag, tube, or net, or for any other application in which material must be moved from a first location to a second location.

While preferred embodiments of the present invention are shown and described, it is envisioned that those skilled in the art may devise various modifications of the present invention without departing from the spirit and scope of the appended claims.

Claims

1. A ramming mechanism for pushing material through stuffing horns, the mechanism comprising:

a belt assembly comprising a belt driven over a plurality of pulleys;

a ram carriage connected to the belt;

tail pusher mounted to the ram carriage; and

a ram cylinder mounted on the ram carriage.

2. (canceled)

3. The ramming mechanism of claim 1, wherein the tail pusher comprises a cutout.

4. The ramming mechanism of claim 1, further comprising a hocking pusher on the ram cylinder.

5. The ramming mechanism of claim 1, wherein the belt assembly is driven by an electric motor.

6. An automated loader comprising the ramming mechanism of claim 1.

7. The ramming mechanism of claim 1, further comprising a bottom plate assembly located below the belt assembly, the bottom plate assembly comprising an air cylinder, a piston arm having a first end and a second end, the first end connected to a bottom plate and the second end connected to the air cylinder, the bottom plate and piston arm being actuated by the air cylinder to move from a first position adjacent the belt assembly to a second position remote from the belt assembly and between the horns.

8. An automated loader comprising:

a frame;

a pair of stuffing horns mounted on the frame;

a belt assembly comprising a belt rotating over a plurality of pulleys, the belt comprising a continuous loop, the belt assembly mounted on the frame and having a first end adjacent the pair of stuffing horns and a second end remote from the pair of stuffing horns;

a ram carriage connected to the belt;

a ram cylinder mounted on the ram carriage;

a tail pusher comprising an elongated member having a first end and a second end, the second end mounted to the ram carriage and the first end extending toward the pair of stuffing horns; and

a motor driving at least one of the plurality of pulleys to rotate the belt to move the ram carriage and ram cylinder from a first position adjacent the pair of stuffing horns and to a second position remote from the pair of stuffing horns.

9. The loader of claim 8, wherein the tail pusher has a dovetail cutout at the first end.

10. The loader of claim 8, further comprising a hocking pusher on the ram cylinder.

11. An automated loader comprising the ramming mechanism of claim 8.

12. The ramming mechanism of claim 8, further comprising:

a bottom plate assembly mounted to the frame below the belt assembly, the bottom plate assembly comprising an air cylinder, a piston arm having a first end and a second end, the first end connected to a bottom plate and the second end connected to the air cylinder, the bottom plate and piston arm being actuated by the air cylinder to move from a first position adjacent the belt assembly to a second position remote from the belt assembly and between the horns.

13. The loader of claim 12, wherein the tail pusher has a dovetail cutout at the first end.

14. The loader of claim 12, further comprising a hocking pusher on the ram cylinder.

15. An automated loader comprising the ramming mechanism of claim 12.