Method and system for top loading of containers such as cartons, cases and trays, etc.

Abstract

A system comprises an item collating conveyor operable to form a plurality of items into a plurality of groups and transports each group of items in series in a first generally longitudinal direction to an item transfer station. The system also has a container delivery conveyor and a robotic device. The container delivery conveyor moves a plurality of containers from a container input station to the transfer station and then to a container output station. The robotic device has an end effector adapted to transfer each said group of items carried from the item collating conveyor into successive containers. Each item of the group of items is loaded together into each container by the robotic device while each container is moving in the second generally longitudinal direction. A controller controls the operation of the industrial robot. The tray conveyor can be configured with a three spaced chains, and a series of releasable and attachable lugs attached to the medial chain. The lugs can be configured to support the path of the medial chain.

Description

FIELD OF THE INVENTION

The present invention relates to the top loading of containers such as cases, trays, and other such containers having open tops, with one or more items.

BACKGROUND OF THE INVENTION

It is desirable in the packaging industry to be able to load items into a container such as a case or tray, having an open top (i.e. items can be loaded from above, downwards onto the base of the container). For example, in the battery industry, it is know to load several batteries or packages of batteries into a tray, which can then be wrapped and shipped to a retailer for sale of the batteries to consumers.

To be able to facilitate the loading of the open top containers, several items are typically first collated and then loaded as a group into an open topped container. Each item may comprise a group of individual units, such as a package of several batteries).

A known method of loading such containers provides a container moving in a longitudinal direction on a container conveyor which is brought into an adjacent position relative to an item loading conveyor also moving in the same longitudinal direction. If a container is brought into close proximity to the group of items, the items can be transferred transversely from the moving item loading conveyor into the moving container carried by the container conveyor.

Another known system for loading an open top container, is to bring the containers carried on a container conveyor to a stationary position for loading. The container can be loaded while stationary and then be moved again longitudinally by the container conveyor once the loading has taken place. However, a problem with this method is that if reasonably fast speeds are desired, to provide a high rate of container loading, there is a significant acceleration of the container out of the loading station once the container has been filled. Depending upon the type of items involved, this can result in the items becoming improperly configured in the container itself. Thus, this type of system has limits in terms of the type of items that can be loaded in this way and in terms of the maximum speeds and accelerations that can be imparted upon the loaded containers.

It is also known to employ robots having robot arms with one or more end effectors configured for picking up several items at once and then placing them into containers. The container conveyor can move continuously through the loading station as the end effector on the arm of the robot tracks the longitudinal movement of the container on the container conveyor and then release the items into the container, with zero relative longitudinal velocity.

However, current container loading systems have drawbacks. For example, the containers typically are carried on container conveyors comprising a pair of spaced, longitudinally oriented belts driven continuously by a conveyor drive mechansim. The belts support the containers directly thereon from underneath. Each of the belts is typically made from a continuous piece of a suitable material such as rubber, and each belt carries a plurality of spaced lugs. Each belt has a lug to contact a rear side of the container, to move it along the conveyor path through the item loading station. These lugs are typically fused directly to the belts. These belts will typically develop significant amounts of wear, particularly when the containers are carrying heavy items such as batteries. Additionally, such existing systems are not readily adaptable to provide for a quick system change over, to accommodate different sized containers.

Accordingly, it is desirable to have an improved method and system for loading containers having open tops with one or more items.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, there is provided a method of loading an open top container with one or more items comprising: a) forming a plurality items into a first group of items; b) moving the first group in a first generally longitudinal direction; c) moving a container in a second generally longitudinal direction transferring the first group into a container by a combination of generally lateral, longitudinal and vertical movements to load the items into the container while the container is moving in the second generally longitudinal direction.

According to another aspect of the present invention, there is provided a system for loading a plurality of groups of items in series into a plurality of open top containers, the system comprising: a) an item collating conveyor operable to form a plurality of items into a plurality of groups of items at an item loading station and transport each the group of items in series in a first generally longitudinal direction to an item transfer station; b) a container delivery conveyor moving a plurality of containers from a container input station to the item transfer station and then to a container output station; c) a robotic device having an end effector adapted to pick up and release the group of items, the robot operable to transfer each the group of items carried on the item collating conveyor with vertical, longitudinal and transverse movement from the item collating conveyor into successive containers of the plurality of containers, each of the group of items being loaded together into each the container by the robotic device while each the container is moving in the second generally longitudinal direction; d) a controller for controlling the operation of the industrial robot to effect the transfer of each of the groups of items.

According to another aspect of the present invention, there is provided a container delivery conveyor for moving a plurality of containers from a container input station to a container output station, the container delivery conveyor comprising at least one chain having a chain path, the chain comprising a plurality of interconnected chain links, at least some of the chain links having extended link pins extending on opposite sides of the links the system further comprising a chain drive mechanism for the chain operable to drive the chain, the chain also having a plurality of spaced lug members secured thereto, wherein successive lug members of the plurality of lug members can contact a rear surface of a respective container of the plurality of containers, to assist in moving the containers from the container input station, to the item transfer station and then to a container output station, wherein the lug members each comprise a base have a pair of forwardly directed arm portions each having a generally forwardly directed slotted opening, the base also having a pair of rearwardly directed arm portions each having a generally rearwardly directed slotted opening, only one of the pairs of forwardly and rearwardly directed arm portions having resilient jaw members for providing a releasable connection of pairs of arm portions to link pivot extension that restricts any translation movement of the pin in the respective slots, the other of the one of the pairs of forwardly and rearwardly directed arm portions having an open ended slot for providing permitting some translation movement of the pin in the slot, such that lug can accommodate travel along both generally straight and curved path portions.

According to another aspect of the present invention, there is provided a lug for use with a container delivery conveyor for moving a plurality of containers from a container input station to a container output station, the container delivery conveyor comprising at least one chain having a chain path, the chain comprising a plurality of interconnected chain links, at least some of the chain links having extended link pins extending on opposite sides of the links the system further comprising a chain drive mechanism for the chain operable to drive the chain, the chain also having a plurality of spaced lug members secured thereto, wherein the lug members each comprise a base have a pair of forwardly directed arm portions each having a generally forwardly directed slotted opening, the base also having a pair of rearwardly directed arm portions each having a generally rearwardly directed slotted opening, only one of the pairs of forwardly and rearwardly directed arm portions having resilient jaw members for providing a releasable connection of pairs of arm portions to link pin extension that restricts any translation movement of the pin in the respective slots, the other of the one of the pairs of forwardly and rearwardly directed arm portions having an open ended slot for providing permitting some translation movement of the pin in the slot, such that lug can accommodate travel along both generally straight and curved path portions.

According to another aspect of the present invention, there is provided a lug for use with a conveyor for moving an article, the conveyor comprising at least one continuous conveyor moving member having a path, the lug comprising a base and an upstanding flight member configured to engage the article, the lug being mountable to the moving member the base having at least one upwardly directed support device positioned transversely to the flight member.

According to another aspect of the present invention, there is provided a conveyor system comprising: a) at least one continuous conveyor moving member having a path; b) a lug for moving an article being mounted to the moving member, the lug comprising a base and an upstanding flight member configured to engage the article, and the base having at least one upwardly directed support device positioned transversely to the flight member; c) a track adapted to support the support device for movement thereon; wherein when the conveyor moving member is moving on a path such that the upstanding flight member is oriented downwards, the lug and the moving member are supported by the track and the support device.

According to another aspect of the present invention, there is provided a container conveyor systems for supporting and moving a plurality of containers comprising first, second and third, spaced continuous chains oriented generally parallel to each other in a longitudinal direction, the second chain being a medial chain positioned laterally between the first and second chains, the first, second and third chains each having an upper surface which are generally aligned in a common, transverse and longitudinally oriented plane, and the first, second and third chains having a generally common chain path on a forward run for transporting the containers, whereby the each of the plurality of containers can be carried by the upper surfaces of the first, second and third chains, the system further comprising a chain drive mechanism for the first, second and third chains operable to drive the first, second and third chains at substantially the same speed.

BRIEF DESCRIPTION OF THE DRAWINGS

In drawings which illustrate by way of example only, an embodiment of the invention:

FIG. 1 is a perspective view of components of a container loading system;

FIG. 2 is another perspective view of the system of FIG. 1;

FIG. 3 is a perspective view of the item in-feed conveyor, part of the system of FIG. 1;

FIG. 4 is a perspective view of the item collator, another part of the system of FIG. 1;

FIG. 5 is a perspective view of the container conveyor, another part of the system of FIG. 1;

FIG. 6 is an enlarged view of part of the container conveyor of FIG. 5 in a first operating position;

FIG. 7 is a view similar to FIG. 6, of the same part in a second operating position;

FIG. 8 is a view similar to FIG. 7, partially broken away;

FIG. 9 is an end perspective view of the same part of the conveyor as FIGS. 6 to 8;

FIG. 10 is top perspective view of the same part of the conveyor as FIGS. 6 to 9;

FIG. 11 is a top plan view of the same part of the conveyor as FIGS. 6 to 9;

FIG. 12 is a perspective view of the discharge end of the container conveyor of FIG. 5;

FIG. 13 is a vertical cross sectional view at 13-13 in FIG. 11;

FIGS. 14, 14A and 14B are an enlarged perspective and side views of part of the central conveyor chain with attached lug, comprising part of the container conveyor of FIG. 5;

FIG. 15 is a front perspective view of the loading station portion of the system of FIG. 1; and

FIG. 16 is a perspective schematic view of an industrial robot that could form part of the system of FIG. 1.

DETAILED DESCRIPTION

With reference to FIG. 1, a container loading system 10 is used to load containers/containers with items (not shown in FIG. 1). The items can be anything it is desired to package into an open top container. The containers may be any item retaining device and typically have a base portion, and a generally, but not necessarily completely, open top portion, through which items can be loaded onto the base.

Containers 17 like those shown in FIG. 2, will typically, but not necessarily have a base, and side walls upstanding all around, from the base. The side walls may be relatively high compared to the width and length of the base, or relatively shallow in comparison to the aforesaid width and length of the base, and in the general form of a tray. The base is sometimes, but not necessarily, generally flat. However, the base may be uneven, and could for example, also provide for slots or indentations or the like to retain items in the container.

The open portion at the top of the container may have a folding top panel, or some other type of closure device or lid, to enclose items loaded through the open top, in the container. The containers can be made of any type of suitable material for holding the items, including for example, plastics, relatively stiff paper material or cardboard.

As shown generally in FIG. 1, system 10 has several components, including an item input conveyor 12, an item collating device 14, an item transfer device 16, and a container delivery conveyor 18.

With particular reference to FIGS. 1, 2 and 3, item input conveyor 12 can be a continuous motion belt-driven conveyor having a pair of spaced continuous belts 30 supported by a series of pairs of pulleys generally designated 33, one or more of the pairs which will be driven by a conveyor motor 32, and can be constructed in a known manner. Item input conveyor 12 can be configured to continuously deliver items 11 singly in series to an collating station at which is located an item input for item collating device 14. In other example embodiments (not shown) it is possible to deliver items in stacks of two or more items. An item reject/blow off station generally designated 25 is also provided and constructed in a known manner. Station 25 ensures that the system can handle any problems downstream in the system by rejecting items. Also, it will function to reject an item 11, which may be too close to an earlier item. When station 25 is operational to reject items, items are not delivered to the collating device, if that device is not ready to receive the same. The operation of station 25 can be controlled by an overall system controller, as described hereinafter This can be accomplished by an electronic eye sensor which will sends signals to the controller as to when items pass by. If two signals are two closely spaced in time, the controller will operate the reject mechanism to reject the second item.

A plurality of items delivered by item conveyor 12 can be formed or collated into groups of items. For example, as shown in FIGS. 2 and 4, item collating conveyor 14 is a linear servo pak (LSP) device which has a first continuous conveyor belt 36 supported at either end by pulleys 35a, 35b and a second continuous conveyor belt 38, also supported by pulleys 35a, 35b. Belts 36 and 38 are mounted parallel in close but spaced relation to each other, and can be driven independently of each other by separate servo-motors 39, or other known conveyor belt driving mechanisms, and can be constructed in a known manner. Belts 36 and 38 can move independently of each other, and can move intermittently and at varying speeds. The movement of the belts is also controlled by the system controller, referenced above.

Also as shown in FIG. 4 (not FIG. 2), each belt 36, 38 can have a set of bucket devices 20, each bucket in the set being configured for receiving and holding an item 11 (see FIG. 1). In one embodiment, such as is shown in FIG. 4, the buckets of belt 38 are offset transversely so that they follow the identical path of the buckets of belt 36. Other arrangements are possible, such as for example, belts 36, 38 can directly support items 11 thereon, without the need for holding and separating devices like the buckets depicted in FIG. 4. Buckets 20 or other item holding devices can be mounted to the belts 36, 38 in conventional known ways. Each set of buckets 20 can be moved independently of the other set by their respective drive belts 36, 38. As shown in FIG. 4, a longitudinally extending rail member 33 is provided and at the item input end is flared outward at end 33a. Thus when items 11 are fed into the buckets 20, they have a tendency after hitting flared end 33a to bounce back into the bucket. However, some items may be in a position that extends transversely outward past the edge of the bucket. The rail 33 will thus serve to re-orient the item in the bucket as it is moved to the transfer station as described hereinafter.

When one of the belts 36, 38 is at the item in-feed station, generally designated 40, that belt will move intermittently, so that buckets in the bucket set of belt 36 are indexed through station 40. As each bucket is aligned at the output end of conveyor 12, an item 11 is fed into a bucket. A photo eye such as is available from Banner Engineering Corp. is positioned to detect when an item has been received in a bucket, so that the controller will activate the collator to index to the next bucket. Other methods and devices to load the buckets 20 of the collator could be employed as well.

Once each of the buckets in the set of buckets 20 at loading station 40 has been loaded, that set of buckets can be moved by its associated belt 36, 38 toward a discharge station area 42. At transfer station 42, the item transfer device 16 will pick up the items 11. The transfer of items from buckets 20 can be carried out in the illustrated embodiment while the belt continuously moves the buckets, so the items can be transferred by transfer device 16, to a container or containers carried by the tray conveyor 18, as described hereinafter.

The linear servo pak collating system 14 can operate so that while one of the belts 36, 38 has its set of buckets 20 being loaded with items 11 at station 40, the second belt will have the items in its set of buckets being unloaded at transfer station 42. The system may be configured in several different ways such as for example as follows: while the first set of buckets is still being loaded with items, the second set of buckets will have been emptied of items, will commence its return toward the item transfer station 42, and then will moved toward the loading position where it can receive items into its buckets. When the first set of buckets is filled, it will move from loading station 40 toward transfer station 42, to be replaced at loading station 40 by the second set of buckets carried on the other belt. Thereafter the cycle can be repeated, as the second set of buckets is loaded at station 40, the first set of buckets will proceed to transfer station 42.

In the illustrated embodiment, item transfer device 16 is utilized to transfer items from the item collating device 14 to the container conveyor 18. In this example embodiment, transfer device 16 is an industrial robot, such as the M-420IA series robot made by Fanuc Robotics America, Inc. of Rochester Hills, Mich., USA. Details of the M-420IA series robot can be found in the product data sheet available at www.fanucrobotics.com the contents of which are hereby incorporated by reference. The robot 16 is configured to be able to move an end effector 44 mounted on a movable arm 19, parallel to each of the three directions which are orthogonal to each other, namely longitudinal axis X, vertical axis Y and transverse axis Z, as shown in FIG. 15. This movement can be accomplished by rotational movements of the articulated arm link portions 19a, 19b, 19c of the robot around a total of four separate axes of rotation J1, J2, J3 and J4 (see FIG. 16). Other robotic devices can also be employed in other embodiments.

The movement of the robot 16 can be controlled by a programmable logic controller such as the Fanuc Robotics System R-J3iB Controller™ designated 100. Details of this controller can be found in the product data sheet also available at www.fanucrobotics.com the contents of which are hereby incorporated by reference. Controller 100 can be programmed to carry out the required movement sequence. In one embodiment the movement will comprise in the pick up phase, lifting items from the buckets 20 all at once, while the buckets are held at a stop position by the respective belt.

Robot 16 can thus pick up on product at a time, or several items at once and load them at the same time into a container 17. In some embodiments, only one load of items carried by end effector 44 will be sufficient to fill the container 17. In other embodiments, more than one load will be required.

The end effector 44 is mounted in a conventional manner to the free end of arm link 19c. End effector 44 will be specifically tooled and designed for the particular application and may include gripping devices. In this embodiment end effector 44 is constructed in this embodiment with a series of downwardly directed suction cups 46, which will be provided with a suction force provided by a vacuum source that can be turned on and off. The vacuum could be provided for each cup 46 by a plurality of vacuum generators associated with each suction cup, which are supplied by pipes, with pressurized air. See for example U.S. Pat. No. 5,997,458 issued to Guttinger et al. Dec. 7, 1999, the contents of which are hereby incorporated by reference. The control of the suction at each suction cup 46 can be controlled by one of more valves controlled by the system controller 100 or a separate control system. In another embodiment a single, combined vacuum generator can be provided for all suction cups. In yet another embodiment, an external vacuum source can be used. The suction is applied at each a suction cup 46 when it is desired to pick up an item, and is turned off when it is desired to release the item.

In one embodiment, the entire system 10 can be controlled by the same controller 100, including the movement of item collating conveyor device 14, robot 16 and container conveyor 18 so as to effect the operational movements described in greater detail below. Additionally, although item conveyor 12 and container conveyor 18 can be operated continuously at a constant speed, alternatively they can be driven at varying speeds and intermittently by for example servo-motors, with the movement being controlled by controller 100.

With reference now to FIGS. 2, 5, 11 and 13, container conveyor 18 comprises a frame generally designated 50, which includes two spaced, vertically oriented, longitudinally extending outer plate members 52a, 52b and corresponding spaced, vertically oriented, longitudinally extending inner plate members 52c, 52d. The upper guide channel portions of plates 51a, and 51b are flared relative to each other and provide a channel which narrows from the input end of the tray conveyor, to a width where a container situated therebetween and carried on the chain conveyor, has sides which are properly aligned. It should be noted that plate member 52b along with its associated chain conveyor mechanism are transversely displaceable, by sliding movement on shafts 50a, 50b which are supported on the frame 50. This permits the conveyor 18 to be readily modified to accommodate containers of differing widths.

Mounted for rotation between the plate members 52a, 52c and 52b, 52d are spaced pulleys 58a, 58b at a container input end 72, and drive wheels 60a, 60b at an opposite, container output end 72. Pulley 58a and drive wheel 61a define in part the path of continuous chain 61a. Likewise pulley 58b and drive wheel 61b define in part the path of continuous chain 61b. The top runs of chains 61a, 61b provide part of a support base for containers 17, and function in assisting to move trays from input end 70 to output end 72.

The upper longitudinal run of chain 61a is also defined by a longitudinally extending track member 63a that has an upwardly extending ridge portion 64a which is received between the link arms 80a of each chain link (See FIG. 9). Each cross link portion 82a rests and slides on ridge portion. A lower portion 65a is received into and held in a channel member 66a having inwardly facing channel arms that hold track member 63a in place. Channel member 66a is mounted to the frame 50 such as for example by bolts.

Likewise, the upper longitudinal run of chain 61b is also defined by a longitudinally extending track member 63b that has an upwardly extending ridge portion 64a which is received between the link arms 80b of each chain link (See FIG. 9). Each cross link portion 82b rests and slides on ridge portion. A lower portion 65a is received into and held in a channel member 66b having inwardly facing channel arms that hold track member 63b in place. Channel member 66b is mounted to the frame 50.

The lower longitudinal run of chain 61a is also defined by a longitudinally extending track member 163a that has an upwardly extending ridge portion 164a which is also received between the link arms 80a of each chain link (See FIG. 9). Each cross link portion 82a rests and slides on ridge portion. A lower portion 165a is received into and held in a channel member 166a having inwardly facing channel arms that hold track member 163a in place. Channel member 166a is mounted by way of an L plate member 167a to the frame 50.

Likewise, the lower path longitudinal run of chain 61b is also defined by a longitudinally extending track member 163b that has an upwardly extending ridge portion 164b which is also received between the link arms 80a of each chain link (See FIG. 9). Each cross link portion 82a rests and slides on ridge portion. A lower portion 165b is received into and held in a channel member 166b having inwardly facing channel arms that hold track member 163b in place. Channel member 166b is mounted by way of an L plate member 167b to the frame 50.

Mounted between chains 61a and 61b is a medial chain 261. The path of chain 261 is defined in part by a rotating end pulley 258 and opposite rotating drive wheel 260. Pulley 258 and wheel 260 are also mounted to in part define a path for chain 261 that has a top run which provide medial support for containers 17, and also assists chains 61a, 61b in moving trays from input end 70 to output end 72.

Like chains 61a, 61b, the upper longitudinal run of chain 261 is also defined by a longitudinally extending track member 263 that has an upwardly extending ridge portion 264a which is received between the link arms 280b of each chain link (See FIG. 14). Each cross link portion 282b rests and slides on ridge portion 264. A lower portion 265 is received into and held in a channel member 266 having inwardly facing channel arms that hold track member 263 in place. Channel member 266 is mounted to the frame 50 with a horizontal plate member 267 (FIG. 13).

The chain tracks supporting the upper and lower runs of the chains 61a, 61b and the upper run of chain 261 can be a commercially available chain track such as is manufactured by the company Solidur. They typically employ a slidable material to support the chain such as by way of example only UHMW polyethylene. However, other known tracks permitting movement of the chain could be provided.

The lower longitudinal run of endless chain 261 is, however, supported differently than the support of the upper run. In particular, because of the orientation of flight members 294 of the lugs 292 on the bottom run, the medial chain 261 can not be supported on the central link pins of the chain links.

Accordingly, the lugs have been designed to provide for laterally positioned upwardly (relative to the base) directed shoulder surfaces on both sides of flight members 294. The shoulder surfaces 293 are configured so that when the lug is mounted to chain 261, the shoulder surface provides a generally flat surface that runs parallel to the upper surface plane of the chain 261. Secured to the frame 50 are longitudinally extending rails 291 also which can be UHMW polyethylene which are positioned to engage and support for sliding movement, the surfaces 293 of lugs 292. Rails 291 are supported by channel members which are secured to the frame 50. In this way lugs 292, and thus chain 261, is supported for sliding movement during the lower return portion of the conveyor path. It should be noted that other moving mechanisms could be employed to take advantage of the basic support feature of the lugs, such as using a ball bearing connection support between the side portions of the lug and rails.

With reference to FIGS. 14, 14a and 14b, a portion of chain 261 is shown. A pair of link arms 280a join together cross link portions 282a which comprise extended link pins 290 passing therethrough. The extended link pins 290 provide members to secure lugs 292 in a particular longitudinal position and spacing on medial chain 261. Lugs can be made from any material which can provide for resilient jaw portions, such as a plastic like polyurethane. Other materials that might be suitable include ABS, or polycarbonate, by way of example only. Also, instead of a snap on connection between the arms 297 and pin 290a, other easily attachable and releasable, pivoting connections could be provided in other embodiments. Lugs 292 have a base portion 296 that when secured to chain 261 as shown, is oriented in generally longitudinal parallel alignment with the longitudinal axis of the chain. Extending upward from base 296 is a vertically oriented arm portion 294 which has a generally planar downstream directed face 294a, and which will engage a rear face of a container 17. The face 294a can be configured sufficiently wide so as to provide some degree of transverse leveling of the container when the rear face of the container is engaged by the face 294a.

On either side of base 296 are a rearwardly directed arm portion 297, and a forwardly directed arm portion 299. It should be noted from FIG. 14 that slot 297a is rearwardly directed. Each rear arm portion 297 has a slot 297a which engages an extension of pin 290a with a resilient set of spaced jaws which can be opened to allow the pin to be snapped and held therein. In this embodiment slot 299a of forward arm 299 is generally oriented parallel to the longitudinal direction or axis of the chain 261. Each forward arm 299 engages an extension of pin 290d, but the pin is to some extent longitudinally slidable in slot 297a. As can be seen in FIGS. 14A and 14B, this permits for easier mounting of the lug on the chain, so that when releasing jaws 297a from engagement with pin 290a, by a downstream direction movement, pin 290d can slide to some extent in slot 299a sufficiently to allow jaws 297a to become engaged or disengaged from pin 290a. This configuration also provides for easier passage of the lug around a drive wheel, pulley or the like, with a reduced risk of dislodgment. It will be appreciated that by providing such a configuration, the links between pins 297a and 297d can be pivoted to some extent, and pin 290d is permitted to move within slot 299a, when the chain 261 travels around a sprocket or pulley. Lug 292 however, has enhanced stability in being mounted to link pins, which are spaced apart.

With reference now to FIG. 12, the drive mechanism for chains 61a, 61b and 261 is illustrated in detail. A drive shaft 300 is bearing mounted between plates 52a, 52b. Fixedly mounted on drive shaft 300 for rotation therewith, is drive wheel 60a for chain 61a, and drive wheel 60b for chain 61b. Also fixedly mounted on shaft 300 for rotation therewith is drive wheel 260 and a flywheel 304. Flywheel is interconnected by belt 302 to the motor drive wheel 308 of motor 310 mounted on motor drive shaft 318. Motor 310 is fixedly mounted to the frame 50. Thus operation of motor 310 will cause drive wheel 308 to turn, driving belt 302, causing shaft 300 to turn. The diameters of each of drive wheels/sprockets 60a, 60b and 260 are all the same, so that chains 61a, 61b, and 261 will all move at the same speed.

Motor 310 also has a secondary drive wheel 316 mounted to an opposite end extension of drive shaft 318. Drive wheel 316 drives a belt 312 which also engages the wheel of an encoder 314. Encoder 314 is configured to send signals to controller 100 indicative of the rotational position of each of drive wheels 61a, 61b, and 261. Thus, controller will be able to take into account these positions when to release the containers, when the lug passes by the trigger switch described hereinafter.

As can also be seen clearly in FIGS. 2 and 12, ramp members 320 with downward sloping surfaces are provided at the output end of conveyor 18. Complementing and attached to ramp members 320 are a series of pulleys, which help facilitate the transfer of containers 17 to another processing operation (not shown).

With reference now to FIGS. 8, 9, 10, 11 and 13, details of the construction of the container input mechanism are shown. Containers are delivered to container conveyor by a conventional devices, such as a standard infeed conveyor (not shown) delivering containers in series to the input station of conveyor 18. It will be noted in FIG. 8, that a trigger switch 400 is shown mounted in relation to pulley 258, such that the vertical wall portions 294 of lugs 292 will pass through the slot 401 in switch 400. Examples of switches 400 are proximity photo switches made by Omron. The passing of wall 294 through slot 401 results in an electronic signal being sent to controller 100. Thus, controller 100 knows that a lug is passed the ready position, and the controller can then operate the container release mechanism generally designated 410.

Container release mechanism 410 comprises a support frame 412 mounted to the main frame 50. Extending transversely above the chains and in relation to the chains 61a, 61b are a pair of longitudinally spaced shafts 414a, 414b. Shafts 414a are fixedly mounted in apertures in support 412.

Extending between shafts 414a, 414b, a pair of dual acting pneumatic cylinders 416a, 416b (such as the DSN series made by Festo) are mounted. The pneumatic cylinders 416a, 416b are each supplied with pressurized air through hoses 403, 404 to activate the pistons between both expanded and retracted positions. One end of each cylinder is attached to shaft 414b with a hinge pivot connection 409a, 409b to a respective mounting block 405a, 405b. The opposite end is attached by a pivot hinge connection 407a, 407b, to an arm of pivot member 418a, 418b. Pivot members 418a, 418b are pivotable on fixed shaft 414a. This could be accomplished by bearings for rotation. However the pivot member can be made from a suitable plastic material such as nylatron, which if the shaft is made from a suitable material such as stainless steel or another hard metal, will allow for pivoting rotation of the pivot members on the shaft. Positioning collars 409a, 409b and 409c are provided to ensure that the cylinders 416a, 416b and their respective pivot members 418a, 418b are appropriately transversely positioned.

As best shown in FIGS. 6, 7 and 8, extension of pistons 421a, 421b can be caused by supplying pressurized air through hoses 404, while first valves in the device are released and second valves are closed by electronic control from controller 100. (FIG. 8). To achieve retraction of pistons 421a, 421b pressurized air is supplied through hoses 403, while second valves in the device are released and the first valves are closed by electronic control from controller 100. In an embodiment, pressurized air can be only selectively and alternately supplied to one of the two pneumatic cylinders at a time. While one of the cylinders is being operated so that the fingers move between the generally horizontal release position, and the generally vertical container holding position and then back to the generally horizontal release position, the other cylinder will remain with its fingers in the horizontal release position, in a rest mode. Once one cylinder completes a cycle it will then go to a rest mode, and the other cylinder will then become operational and complete the same cycle. Thus the operation of the cylinders can be alternated, reducing the overall amount of cycling each cylinder does. The result is that in such embodiments, the life of the pneumatic cylinder unit as a whole is significantly increased, requiring less maintenance/repairs than if only a single cylinder is used.

The activation of the cylinder unit 416a, 416b will cause the corresponding fingers 419a, 419b to move from the vertically downward position in FIG. 7 to a horizontal orientation in FIG. 6 (which would release the container being held and supported on chains 61a, 61b). The chains 61a, 61b can, during normal operation, continue to move, while a container can be held at the input station, when fingers 419 are in a downward orientation.

As mentioned above, the containers can be delivered to the input station by a conveyor (not shown) which may includes an endless supported at either end by pulleys, one or more of which can be driven by a motor which may provide for continuous or intermittent movement and for a constant or varying speed. A plurality of containers 17 can thus be delivered, generally in serial abutment with each other. In some embodiments, containers can be delivered and handled by the system in batches.

Various sensors can be provided in the system and be interconnected to controller 100. Such sensors can be used to assist in ensuring the proper sequence of operation of the various components and also be configured to identify if there are certain types of problems with the operation of the system 10. For example, if a problem is identified somewhere in the system, item conveyor 12 can be stopped, to temporarily prevent the continuous feeding of items to the collating device 14.

By way of example, a sensor can be placed at item loading station 40 between in-feed conveyor 12 and collating conveyor 14. Such a sensor can be a beam sensor which emits a beam and so can, by interruption of the beam, sense if the gap between the in-feed conveyor 12 and collating conveyor 14 is blocked for an extended period of time. This beam sensor can be in communication with controller 100 and can be configured to provide a signal to controller 100 when the gap is blocked. It the gap is blocked for an improper period of time as measured by the controller 100 or other timing device, controller 100 can shut down the system.

Also an electronic eye sensor device (not shown) associated with the item in-feed location of collating conveyor 22, can be provided and be in electronic communication with controller 100. Such an electronic eye can detect the presence or absence of an item 11 positioned at the appropriate position in for example the bucket 20. Once a bucket 20 located at the in-feed location has been filled, the electronic eye can detect the same and send a signal to the controller 100. The controller 100 can then control the movement of collating conveyor 14, either to index belt 36 or 38 to the next cavity 41 if not all buckets 20 associated with that set of buckets has been filled, or if the controller recognizes that the count is such that all cavities are filled, move the respective belt 36 or 38 to transfer station 42.

Additionally, as shown in FIG. 9, another electronic eye 440 can be provided a little downstream of release mechanism, and the position where the lugs 292 attached to medial chain 261 will engage the rear face of the container 17. Electronic eye 440 such as is available at Banner, is set up with a beam passing from a transmitter on one side of the conveyor to a receiver on the other. It can detect the presence or absence of a container 17 positioned at the appropriate position being supported by chains 61a, 61b and 261. Also a second narrow beam is passed just in front of the lug position to ensure the tray is positioned right against the lug. When the eye detects a container 17 in the proper position, it will send a signal to controller 100, advising controller 100 that a container 17 is moving toward the transfer zone. The controller will then cause the robot device to continue with a movement sequence that will cause items 11 it has retrieved from collator 14, to be deposited into the container 17.

The operation of container loading system 10 will now be described. In this embodiment, items 11 are fed serially and continuously in turn by item input conveyor 12, into buckets 20 that are positioned at an item receiving location of item collating device 14. Items 11 would be positioned at an appropriate spacing on conveyor 12 for proper feeding to collating device 14. Sequentially, first all of the buckets 20 of one of belts 36 and 38 are filled in turn with an item 11. This is accomplished by indexing the respective belt 36, 38 carrying the buckets currently to be filled, so that each bucket receives a single item 11. Once one bucket is filled, the belt is indexed so the next bucket in the set is positioned ready to receive and then does receive an item 11. The flow of items needs to be controlled so items 11 are fed properly to collating conveyor 14. The use of a sensor to detect the filling of a cavity could be used in conjunction with controller 100 to ensure the proper movement of conveyor 12 and collating conveyor 14.

Once each of the buckets 20 on the belt being loaded has been filled, that set of buckets is moved by moving the appropriate belt 36 or 38 of collating conveyor 14, to transfer station 42. Typically, the belt will move to an unloading position where it stops to permit the removal of items. In another, more complex system, the buckets could continue to move through the transfer station at approximately a constant velocity with the robot to be programmed for appropriate movements to pick up the items from the buckets 20 “on the fly.

The movement of each of the belts 36, 38 can be coordinated so that while the set of buckets of one belt is being loaded with items 11 by conveyor 12, the other set of buckets in being unloaded by robot device 16 from the set of buckets associated with the other belt. The specific movement of robot 16 will be dependent upon the algorithm which operates the robot. The vacuum force will be being applied to the suction cups 46 when the cups are in the vicinity of the items 11. Depending upon the particular application, the cups may be brought either into close proximity to, to contact with, the items. The timing of the application of suction force can be tailored to the particular items 11.

Once the robot has picked up the items 11, it will move through a movement sequence to position itself to place or drop the items into a container 17, being carried along conveyor 18 on chains 61a, 61b and 261.

While the robot has acquired items, the tray conveyor 18 will be functioning to deliver containers 17 to the robot to receive the items. The chain 261 has a plurality of lugs 292, which are typically, but not necessarily arranged at a constant pitch. When each lug passes through the switch 400, it sends a signal to the controller, which then makes a record in a shift register memory in the controller to zero the encoder. Thereafter, as the encoder continues to send signals to the controller, the controller will know the position of that lug. This process is repeated for each lug, as a memory is formed for each lug.

The passing of the lug 292 through switch 400 and the associated signal to the controller 100 will also result in the controller sending a signal to the container release mechanism 410 to release a container to travel downstream to be engaged by the lug.

By knowing the position of each lug the system avoids requiring complex machine vision systems to be employed to aid the controller. The position of each lug is known, and the robot is programmed to respond to the movement of the container associated with that lug to deposit the items in the container. The end effector will be moved into position above container 17, and the vacuum will be cut off to release the items into the container, “on the fly”. The container will then carry on its path to the output end, where it can be passed for further processing.

The capacity of the system will be determined by the limits on the various components. In the example embodiments described herein in detail, items can be fed by the item in feed conveyor at a top rate of about 400-450 per min. and at a bottom rate of about 100 products per min. The collating device can deal with the items on a one-to-one relationship with the in-conveyor. The robotic device is capable of in the order of a maximum of 30 to 35 cycles per min, and thus the amount of items it picks up and drops in each cycle can be modified accordingly. Finally, the container conveyor can feed containers at a top rate of about 100 per minute.

This system is particularly adaptable for changeover for different items, containers and throughput. This can be facilitated in part, by the easy adjustment of the positioning/pitch of the lugs on the tray conveyor and the adjustment of the channel width in which the containers are held while being transported by conveyor 18. Additionally, the speeds of the item in-feed and tray conveyors can be varied. The rail 33 of collator 14 can also be adjusted to accommodate a different width item. The controller can have its programming easily adjusted to accommodate the different conveyor speeds and accommodate the other changes. Additionally, the position of sensors for the items in-feed and the container in-feed can be modified to suit different sized items, and particularly differently configured containers.

It is understood that the term “container” as used herein describes any container or holder with some kind of retaining wall(s) and an open top, such as an open-topped box. Although the invention has been described employing various specific components such as an item supply conveyor 12, transfer device 16, item collating conveyor 14 and conveyor 18, other types of apparatus can be employed to achieve the same movements and functions.

The foregoing described only preferred embodiments, and modifications and variations will readily become apparent to those of ordinary skill in the art without departing from the scope of the invention as defined by the claims hereinafter.

Claims

1. A method of loading an open top container with one or more items comprising:

a) forming a plurality items into a first group of items;

b) moving said first group in a first generally longitudinal direction;

c) moving a container in a second generally longitudinal direction

d) transferring the first group into a container by a combination of generally lateral, longitudinal and vertical movements to load said items into said container while said container is moving in said second generally longitudinal direction.

2. A method as claimed in claim 1 wherein said plurality of items are fed serially to an collating device adapted to form said plurality of items into said first group.

3. A method as claimed in claim 1 wherein a plurality of groups of items are formed in series, and a plurality of containers are fed in series in said second longitudinal direction, and wherein a group of said plurality of groups is each transferred into a different container of said groups of containers by a combination of generally lateral, longitudinal and vertical movements to load each of said items of said group into each said container while each said container is moving in said second generally longitudinal direction

4. A system for loading a plurality of groups of items in series into a plurality of open top containers, said system comprising:

a) an item collating conveyor operable to form a plurality of items into a plurality of groups of items at an item loading station and transport each said group of items in series in a first generally longitudinal direction to an item transfer station;

b) a container delivery conveyor moving a plurality of containers from a container input station to said item transfer station and then to a container output station;

c) a robotic device having an end effector adapted to pick up and release said group of items, said robot operable to transfer each said group of items carried on said item collating conveyor with vertical, longitudinal and transverse movement from said item collating conveyor into successive containers of said plurality of containers, each of said group of items being loaded together into each said container by said robotic device while each said container is moving in said second generally longitudinal direction;

d) a controller for controlling the operation of said industrial robot to effect said transfer of each of said groups of items.

5. A system as claimed in claim 4 further comprising an item input conveyor operable to deliver a plurality of containers in series to said collating conveyor.

6. A system as claimed in claim 5 further comprising an input conveyor operating continuously to deliver a plurality of containers in series to said container delivery conveyor, and further comprising a container restraining apparatus configured to restrain containers and to successively release containers on said container conveyor so that said container conveyor will deliver a series of containers to said transfer station and then to said output station.

7. A system as claimed in claim 4 wherein said container conveyor comprises first, second and third, spaced continuous chains oriented generally parallel to each other in said second direction, said second chain being a medial chain positioned laterally between said first and second chains, said first, second and third chains each having an upper surface on a forward run from said container input station to said item transfer station and to said output station which are generally aligned in a common, transverse and longitudinally oriented plane, and said first, second and third chains having a generally common chain path on said forward run, whereby said each of said plurality of containers can be carried by said upper surfaces of said first, second and third chains, said system further comprising a chain drive mechanism for said first, second and third chains operable to drive said first, second and third chains at substantially the same speed.

8. A system as claimed in claim 7 wherein said second chain has a plurality of spaced lug members secured thereto, wherein successive lug members of said plurality of lug members contact a rear surface of a respective container of said plurality of containers, to assist in moving said containers from said container input station, to said item transfer station and then to a container output station.

9. A system as claimed in claim 4 further comprising a system controller for controlling the movement items on said collating device and of containers on said container conveyor.

10. A system as claimed in claim 9 wherein said controller for said robotic device is operable to also function as said system controller.

11. A system as claimed in claim 10 further comprising an input conveyor operating continuously to deliver a plurality of containers to said container delivery conveyor, and further comprising a container restraining apparatus configured to restrain containers and to release a plurality of containers in series such that said container conveyor will deliver a series of containers to said transfer station at an appropriate time so as to be able to receive a group of said plurality of groups of items.

12. A system as claimed in claim 11 further comprising a container restraining apparatus configured to restrain containers and to release a container so that said container conveyor will deliver a container to said transfer station.

13. A system as claimed in claim 12 wherein said system controller is adapted to control the operation of said container constraining apparatus.

14. A system as claimed in claim 13 wherein said second chain has a plurality of spaced lug members secured thereto, wherein successive lug members of said plurality of lug members contact a rear surface of a respective container of said plurality of containers, to assist in moving said containers from said container input station, to said item transfer station and then to a container output station.

15. A system as claimed in claim 14 wherein each of said containers is carried along a first portion of said forward run only on said first and third chains, and wherein said second chain provides additional support for said container and said lug engages said rear of a container, after said first portion of said forward run.

16. A system as claimed in claim 4 wherein said container conveyor comprises a chain having a chain path, said system further comprising a chain drive mechanism for said chain operable to chain, said chain having a plurality of spaced lug members secured thereto, wherein successive lug members of said plurality of lug members contact a rear surface of a respective container of said plurality of containers, to assist in moving said containers from said container input station, to said item transfer station and then to a container output station.

17. A system as claimed in claim 16 further comprising a trigger switch device, operable to send a signal to said controller indicating a lug of said plurality of lugs is at a known position, prior to engagement with a container.

18. A system as claimed in claim 17 further comprising an encoder associated with said conveyor drive mechanism, said encoder operable to provide signals to said system controller indicative of the position of said chain as said chain moves around said conveyor path, said system controller configured to respond to said signal from said trigger switch device and said signals from said encoder to facilitate the operation of said container release mechanism and said robot so as to effect the loading of a group of items held by said robot into a container carried by said container conveyor.

19. A system as claimed in claim 16 wherein said chain comprises a plurality of interconnected chain links, at least some of said chain links having extended link pins extending on opposite sides of said links, and wherein each of said lugs has a pair of transversely spaced lug arms configured for releasable engagement with said link pins.

20. A system as claimed in claim 7 wherein each of said first, second and third chains comprises a plurality of chain links interconnected with link pins, at least said first and second chains being supported on a longitudinally extending chain track mounted to a frame.

21. A system as claimed in claim 20 wherein said chain track comprises a slidable member supported by a structural support member, said structural support member being mounted to said frame, said slidable member permitting said chain to slide over said slidable member.

22. A system as claimed in claim 21 wherein said slidable member is made from a UHMW polyethylene material.

23. A container delivery conveyor for moving a plurality of containers from a container input station to a container output station, said container delivery conveyor comprising at least one chain having a chain path, said chain comprising a plurality of interconnected chain links, at least some of said chain links having extended link pins extending on opposite sides of said links said system further comprising a chain drive mechanism for said chain operable to drive said chain, said chain also having a plurality of spaced lug members secured thereto, wherein successive lug members of said plurality of lug members can contact a rear surface of a respective container of said plurality of containers, to assist in moving said containers from said container input station, to said item transfer station and then to a container output station, wherein said lug members each comprise a base have a pair of forwardly directed arm portions each having a generally forwardly directed slotted opening, said base also having a pair of rearwardly directed arm portions each having a generally rearwardly directed slotted opening, only one of said pairs of forwardly and rearwardly directed arm portions having resilient jaw members for providing a releasable connection of pairs of arm portions to link pivot extension that restricts any translation movement of said pin in said respective slots, the other of said one of said pairs of forwardly and rearwardly directed arm portions having an open ended slot for providing permitting some translation movement of said pin in said slot, such that lug can accommodate travel along both generally straight and curved path portions.

24. A lug for use with a container delivery conveyor for moving a plurality of containers from a container input station to a container output station, said container delivery conveyor comprising at least one chain having a chain path, said chain comprising a plurality of interconnected chain links, at least some of said chain links having extended link pins extending on opposite sides of said links said system further comprising a chain drive mechanism for said chain operable to drive said chain, said chain also having a plurality of spaced lug members secured thereto, wherein said lug members each comprise a base have a pair of forwardly directed arm portions each having a generally forwardly directed slotted opening, said base also having a pair of rearwardly directed arm portions each having a generally rearwardly directed slotted opening, only one of said pairs of forwardly and rearwardly directed arm portions having resilient jaw members for providing a releasable connection of pairs of arm portions to link pin extension that restricts any translation movement of said pin in said respective slots, the other of said one of said pairs of forwardly and rearwardly directed arm portions having an open ended slot for providing permitting some translation movement of said pin in said slot, such that lug can accommodate travel along both generally straight and curved path portions.

25. A lug as claimed in claim 24 wherein said rearwardly directed arm portion has resilient jaw members for providing a releasable connection of its pairs of arm portions to the link pin extension.

26. A lug as claimed in claim 25 wherein at least one or both of said rearwardly and forwardly directed pairs arm portions provides a pair of opposed generally planar shoulder surfaces adapted to support said lug on a rail.

27. A lug for use with a conveyor for moving an article, said conveyor comprising at least one continuous conveyor moving member having a path, said lug comprising a base and an upstanding flight member configured to engage said article, said lug being mountable to said moving member said base having at least one upwardly directed support device positioned transversely to said flight member.

28. A lug as claimed in claim 27 wherein said support device is a support surface.

29. A conveyor system comprising:

a) at least one continuous conveyor moving member having a path;

b) a lug for moving an article being mounted to said moving member, said lug comprising a base and an upstanding flight member configured to engage said article, and said base having at least one upwardly directed support device positioned transversely to said flight member;

c) a track adapted to support said support device for movement thereon;

wherein when said conveyor moving member is moving on a path such that said upstanding flight member is oriented downwards, said lug and said moving member are supported by said track and said support device.

30. A system as claimed in claim 29 wherein said support device is a support surface.

31. A system as claimed in claim 29 wherein said support device is pair of support surfaces located transversely apart from each other on opposite sides of said upstanding flight member, and wherein said track supports said lug and said moving member on said pair of surfaces on said path.

32. A system as claimed in claim 29 wherein said moving member is a continuous conveyor chain.

33. A container conveyor systems for supporting and moving a plurality of containers comprising first, second and third, spaced continuous chains oriented generally parallel to each other in a longitudinal direction, said second chain being a medial chain positioned laterally between said first and second chains, said first, second and third chains each having an upper surface which are generally aligned in a common, transverse and longitudinally oriented plane, and said first, second and third chains having a generally common chain path on a forward run for transporting said containers, whereby said each of said plurality of containers can be carried by said upper surfaces of said first, second and third chains, said system further comprising a chain drive mechanism for said first, second and third chains operable to drive said first, second and third chains at substantially the same speed.

34. A system as claimed in claim 27 wherein said second chain has a plurality of spaced lug members secured thereto, wherein successive lug members of said plurality of lug members contact a rear surface of a respective container of said plurality of containers, to assist in moving said containers.