PACKAGING SYSTEM

Abstract

The present invention provides a packing system for collecting together multiple articles and delivering them to a receptacle (50) such as a box and relates particularly to such a mechanism which can do so in a gentle manner, thereby reducing damage to said produce. The present invention may be used in the food packing industry where such damage is extremely undesirable but also lends itself to use in the packing of other products. In particular, the present invention provides a packing system (10) comprising a product accumulation station (12) and a filling point (14) having a lowering system (16), wherein said lowering system comprises a hinged lowering plate (16a) pivotally connected at a hinge (18) to said filling point (14) and being connected to an actuator (20) for actuation of said plate (16) between a first product receiving position (A) and a second product delivering position (B).

Description

The present invention relates to a packing system and relates particularly but not exclusively to a system for allowing food produce to be collected together and then delivered to a container for subsequent distribution.

Packing systems are well known and many forms thereof are used in many industries and they are particularly well known for use in food distribution, parts distribution, consumable goods distribution to name but three areas of use. The reader will appreciate from the below description that the present invention is of particular interest to the food packing and distribution industry because of the very gentle manner in which it handles what can be very delicate food products but the invention may be applied across the packing requirements of many industries.

In general, packing systems are used to collect together multiple individual articles, such as items of fruit, or groups of pre-packaged vegetables such as to form a larger group that can then be delivered to a packing container such as a box or tray which is then used to allow for easy handling and protection of multiple articles that may well be relatively easily damaged if handled individually. At present there is a problem associated with the final stage of the packing process in which the individual articles or groups of articles are placed into their final transportation container as this must either be done manually which is expensive or by some form of forced pusher system where the articles are physically dropped into their containers which can be very damaging of delicate food articles in particular. Alternative systems include the use of a robotic pick and place system which, whilst being faster can be expensive and do not necessarily lend themselves to use on all articles and generally requires the article being handled to include a smooth surface upon which the vacuum system associated therewith can work.

The present invention is aimed at providing a new approach to packing systems in which the articles to be packaged are first collected together and then gently lowered into the associated container. Accordingly, the present invention provides; a packing system comprising a product accumulation station and a filling point having a lowering system, wherein said lowering system comprises a hinged lowering plate pivotally connected at a hinge to said filling point and being connected to an actuator for actuation of said plate between a first product receiving position and a second product delivering position and further comprises a guide plate opposite an end of said lowering plate and extending downwardly and into a container to be filled.

In one arrangement said guide plate comprises a first introduction portion at a top thereof and being positioned to produce a reducing gap G¹ as the lowering plate opens and a second portion at a bottom thereof and being positioned for producing an increasing gap G² as the lowering plate is lowered to a fully lowered position.

In an alternative arrangement said guide plate comprises a second portion at a bottom thereof and being positioned for producing an increasing gap G² as the lowering plate is lowered to a fully lowered position.

Advantageously, said second portion is angled at an angle β relative to a vertical plane.

Advantageously, said first portion is angled at an angle θ relative to a vertical plane.

Preferably, the system includes a longitudinal conveying axis X and said hinge includes a longitudinal pivot axis extending substantially parallel to said conveying axis X.

Further, said lowering system may comprises a pair of lowering plates each of which includes a longitudinal pivot axis extending substantially parallel to said conveying axis X.

The system may also include a pair of actuators for moving said first and second lowering plates between said first and second positions.

The lowering plates may each be hinged along a central portion of said filling point and have otherwise free ends outward thereof or may be hinged at an outer portion and have otherwise free ends inwardly thereof.

Preferably, the surface of said plate or plates extend(s) substantially horizontally when said plate) is in said first position such as to receive product from said accumulation station and extends generally downwardly relative to said horizontal plane when in said delivering position.

Advantageously, said accumulation station includes a stopper plate and a pusher system for advancing accumulated product from said accumulation station to said filling point.

Preferably, said pusher system includes an actuator (38) for causing said pusher (34) to advance towards said filling point (14) in a first plane and return thereform in a second plane above said first plane.

Preferably, said pusher system includes a plurality of mobile fingers collectively forming a wall for engagement with product to be delivered and further including an actuation mechanism for advancing said fingers from a first retracted position to a second advanced position and any collected product towards said filling point.

Advantageously, the accumulation station further includes a plurality of fixed fingers positioned between said mobile fingers when said mobile fingers are in said retracted position and which in combination with said mobile fingers collectively form a sidewall.

Conveniently, said accumulation station includes a separate driven conveyor belt.

In one arrangement, the system further includes a product delivery mechanism for delivering product to said accumulation station. When provided, such a delivery mechanism may comprise a conveyor system of a production machine.

In one arrangement the system further includes a receptacle conveying mechanism for delivering and removing a receptacle to said filling point as and when required. When provided, said conveying mechanism includes a lateral conveyor and a vertical conveyor and wherein said mechanism is on an underside of said filling point and wherein said filling point is configured to lower product into a receptacle when so required. Advantageously, said lateral conveyer may comprise a conveyor belt and drive system. Advantageously, said vertical conveyer comprises a displaceable support platform and an actuation mechanism for displacing said receptacle substantially vertically between a first lower position in which it is engaged with said lateral conveyor and distal said filling point and a second higher position in which it is proximal said filling point and distal said lateral conveyer. The vertical conveyor may further include a connection rod and a rotatable crank mounted for rotation on an actuator shaft of an actuator and being operable to lift and lower said Platform upon rotation of said actuator.

Advantageously, the packing system further includes a control system operably connected to one or more actuators to operate said system. The system may further including sensors for determining the presence or otherwise of one or more of: a receptacle and on or more product.

The present invention will now be more particularly described by way of example with reference to the accompanying drawings, in which:

FIG. 1 is a general view of a packing system in accordance with aspects of the present invention;

FIG. 2 is a cross-sectional view taken in the direction of arrows G-G in FIG. 1 showing the lowering plates in a horizontal position;

FIG. 3 is a cross-sectional view taken in the direction of arrows G-G of FIG. 1 showing the lowering plates in a downward position;

FIG. 4 is a perspective view of a portion of FIG. 1 and shows some hidden detail associated with a system for raising and lowering a container up towards and down from a position in which it is to be filled by the articles in question;

FIG. 5 is a more detailed perspective view of the plates and actuation mechanism shown in FIG. 1;

FIGS. 6 to 9 illustrate the various stages in the loading of product into a tray or container; and

FIG. 10 is a schematic representation of an alternative form of the present invention.

Referring now to the drawings in general but particularly to FIG. 1, a packing system 10 comprises a product accumulation station 12 and a filling point 14 having a lowering system 16 associated therewith. The lowering system comprises a hinged lowering plate 16a pivotally connected at a hinge 18 to said filling point 14 and being connected to an actuator 20 for actuation of said plate 16 between a first product receiving position A and a second product delivering position B. As shown, the arrangement includes a pair of lowering plates 16a, 16b but it will be appreciated that they may be provided and used either individually or in multiples thereof. The system includes a longitudinal conveying axis X and the one or more plates 16a, 16b, include a hinge or other such arrangement 18 which extends generally along said axis X or substantially parallel and in close proximity thereto such as to provide a pivot axis 22. The pivot axis being centrally located between the extremities of a void 200 uncovered by the opening of the plates 16. One or more actuators 20a, 20b may be provided to cause the one or more plates 16a, 16b to be moved between said first and second positions A, B respectively and each may be directly or indirectly connected to an associated plate 16 by actuation rods 24. The actuators may be electro-activated systems, pneumatic actuated systems or geared actuation systems to name but three possible options but all such systems must be able to reproduce a periodic and controlled moving of plates 16 between positions A and B and should preferably be able to facilitate that movement in a smooth and gentle manner if the system is to be used on more delicate or easily damaged articles. Whilst the plates themselves can be arranged in a number of alternative positions, it is preferable that when two such plates 16 are provided that they be hinged along a central portion 26 of said filling point 14 such as to provide otherwise free ends 28, 30 of said plates outwardly thereof O on outer portions of the filling point 14, for reasons that will become apparent later herein. As shown, the surfaces 16s of the plates 16 extend generally horizontally H when said plate or plates are in said first position A and generally downwardly D relative to the horizontal plane H when in said delivering position B.

In addition to the above, the accumulation station 12 includes an optional stopper plate or portion 32 and a pusher system 34 for advancing accumulated articles or produce towards the filling point 14 and plates 16 as and when desired. Whilst it will be appreciated that a number of different designs of accumulation system may be employed, it has been found that an arrangement of inter-leaved fingers, such as shown generally at 36 and 40 may be used to great advantage. In more detail, the fingers include mobile fingers 36 which, collectively, form a wall for engagement with articles or produce 37 to be packaged and further includes an actuation mechanism 38 shown as, for example, pneumatic cylinders and rods in FIGS. 1 to 3 which move the fingers 36 between a first retracted position RP to a second advanced position AP and then back again as and when desired. The movement between the positions being as marked by arrows R which indicate an advancing of the fingers in a lower plane such as to push any produce towards the doors 16 or filling position and then a retraction step including the vertical displacement of the fingers over into a second plane above the first plane and clear of any produce before the retraction is commenced by retracting the fingers over the produce and then lowering them back into the retracted position RP as shown in FIG. 1. Other forms of actuation mechanisms such as electro-mechanical systems, stepper motors and the like may used as alternatives so long as they are able to perform the function described in detail later herein. Interposed between said mobile fingers 36 are a plurality of fixed 40 which, in combination with said mobile fingers when in said retracted position RP collectively act to define or form a sidewall 42, the function of which will be described later herein. Associated with the accumulation station is one or more separate driven conveyors in the form of conveyor belt(s) 44 and associated drive mechanism 45 and an optional further product delivery mechanism 46 (not shown) which may be a conveyor belt, chute or other such device and may comprise a portion of an upstream conveying system not part of the present arrangement but provided for supplying produce to said accumulation system itself.

Also shown in FIGS. 2, 3 and 6 to 9 is an additional guide plate 17. This guide plate 17 may be provided on one or other or both sides of the lowering system 16. When provided, it preferably comprises two portions. The first of which comprises an introduction portion 17a towards a top thereof 17b and being angled and positioned relative to the end 16c, 16d of a plate 16 such as to produce a reducing gap G¹ as the plate moves from a closed to an open position. Such a gap G¹ being sufficient to provide clearance for the plate as it moves but insufficient to allow a product being lowered to pass through the gap G¹. In an alternative arrangement the gap G¹ may be kept generally constant by shaping the introduction portion 17a in a curved manner having a profile of curvature matching or closely corresponding to a the movement arc of the end(s) 16c, 16d. The second portion 17c is positioned at the bottom 17d of the guide plate 17 and extends generally downwardly from the first portion and is positioned and angled such as to provide a generally increasing gap G² between the end(s) 16c, 16d. This generally increasing gap G² is employed to allow any product being lowered to pass gently between the guide plate 17 and the end(s) 16c, 16d such that it is laid down gently into a container or receptacle 50 provided thereunder. The guide plate(s) 17 are each also positioned such as to extend into the confines of a receptacle 50 placed thereunder such as to provide a sidewall against which any product being lowered to slide against which is not the wall of the receptacle 50. This has the advantage of allowing for the guide plate(s) 17 being able to define a specific edge and position thereof which is independent of any receptacle and the gentle lowering of product is, therefore, independent of the receptacle and is consistent. This arrangement means that the shape and size and indeed position of the receptacle can vary or be varied without adversely affecting the gentle deposition of product into the receptacle. The arrangement of the present invention can, therefore, be used on a number of different shaped and positioned receptacles.

The skilled reader will appreciate that for some arrangements it will be possible to dispense with the introduction portion 17a and merely rely on the second portion 17c as the requirement is to define a separate sidewall against which products can slide as they are lowered into a receptacle rather than defining a reducing and then an increasing gap G¹, G². The skilled reader will also appreciate that the plate(s) may be hinged at the outer edge 200 of any aperture 202 through which the produce may be lowered rather than a central position, as shown in FIG. 1. Such an arrangement is shown diagrammatically in FIG. 10 which also includes an optional displaceable guide portion 217 which may be positioned centrally relative to the aperture 202 and extending generally along axis X such as to provide a guide against which product can be lowered (as shown in the dotted portion of the figure) in the sliding and gentle deposition manner described above with reference to FIGS. 6 to 9. The actuator 219 is provided for moving the guide portion 217 between its retracted 217a and its lowered position 217b. It will be appreciated that, in the retracted position 217a, the guide also acts as a divide which will prevent product pushed from one side of the system from being pushed too far over into the opposite side. This will help with even distribution of product into the receptacle 50 and help prevent jamming. It will also be appreciated that the arrangements of FIGS. 1 to 9 may also be provided with a retractable or a fixed divide shown at 220 and that such a divide would perform the same function in such an arrangement.

FIG. 11 provides a little more detail with regards to the guide plate 17 shown in FIGS. 1 to 9 and from which it will be appreciated that the optional first portion 17a is angled backwardly and outwardly relative to the lowering system 16 at an angle θ from a vertical plane V. It will also be appreciated that the lower portion 17b is angled inwardly at an angle β relative to the vertical plane V. The magnitude of the angles θ and β may be selected such as to ensure that a gap is maintained between the lowering system 16 but that gap is preferably selected such as to allow for the maintenance of a minimum gap during the initial movement of the lowering system 16 and an increasing gap during at least the final movement of the lowering system 16. The increasing gap may be facilitated by having angle β set to zero but there is advantage in having a positive angle β as this allows for the generation of a gap which is not so large as to cause or facilitate premature dropping of any product being lowered. Angle θ may be set to zero so long as there is sufficient clearance between the lowering system 16 and the first portion 17a.

From the above, it will be appreciated that product to be placed within a receptacle 50 is first positioned on the top of the lowering system 16 before being lowered. The act of lowering causes the product to slide towards and then engage with the guide plate(s) 17 and against which it interacts as the lowering system moves downwardly. During this downward movement the product slides against both the guide plate 17 and the lowering mechanism 16 and is, therefore, relatively gently moved into the receptacle. The action is more similar to being moved by hand than being dropped, as is well known in the art. The final movement of the lowering system simply causes the lowering system to be removed from underneath of the product, a portion of which will already be in contact with the base of the receptacle or produce already loaded into said receptacle.

FIG. 9 illustrates the indexing downwardly of the receptacle 50 in the direction of arrow D and further illustrates three layers of product, two of which are shown in dotted lines. The first layer is deposited before the receptacle 50 is indexed downwardly such that the second layer is gently laid down on top of the first layer. This indexing step is repeated as many times as required in order to deposit the required number of layers.

A receptacle conveying mechanism, shown generally at 48 below the filling point 14 is provided for delivering and removing one or more receptacles 50 to said filling point 14, as and when required. Whilst a number of such conveying mechanisms may be used, a particularly advantageous arrangement comprises a lateral conveyor 52 and a vertical conveyor 54 provided on and underside US of said filling station 14 wherein said filling point is configured to lower produce into a receptacle 50 as and when one is suitably positioned. In more detail, the lateral conveyer 52 may compromise a conveyor belt 56 and a drive system 58. The vertical conveyor 54 may comprise a displaceable support platform 60 and an actuation mechanism for displacing said receptacle 50 substantially vertically between a first lower position L in which it is engaged with said lateral conveyor 52 and distal said filling point 14 and a second, higher, position H in which it is proximal said filling point 14 and distal said conveyor 52. In the particular example shown, the vertical conveyor 54 comprises a connection rod 62 and a rotatable crank 64 mounted for rotation on an actuator shaft 66 of an actuator 68 and being operable to lift and lower said platform 60.

In addition to the above, the present system includes a control system shown schematically at 70 for causing operation of one or more of the actuateable components in accordance with a desired routine such as to cause produce to be packaged as required and a plurality of sensors (not shown) positioned to detect the presence or absence of produce at appropriate portions of the system itself such as to allow the control system to initiate control of the system 10 and the packing process.

Operation of the above-described system will now be described by way of example only with reference to the drawings attached hereto.

Assuming that the present system 10 is provided in conjunction with the end of an associated packing line (not shown) it is highly likely that the packaged articles provided thereby will be supplies at irregular intervals and must then be collected together before being packaged in bulk. The accumulation station 12 is used to accumulate multiple articles supplied thereto as the conveyor 56 acts to receive said produce/articles individually and the stopper plate 32 acts to prevent them passing past the belt itself. For this purpose, it is advantageous if the upper surface of the conveyor comprises a smooth and slippery surface such that the conveyor may continue to rotate whilst any collected produce/articles remain thereon whilst being collected. Once a desired number of articles have been supplied to the accumulation station 12 a sensor (not shown) detects the presence of sufficient articles stationary within the station 12 then actuator mechanism 38 is activated such as to deploy the pusher system 34 and advance the mobile fingers 36 such that they engage with and then slide the articles in the direction of arrows R and towards and into the lowering system portion 16 such that the articles in question are on top of the lowering plate or plates 16. Once the articles are in this position the fingers 36 may be retracted back to their previous position and made ready for subsequent use. Once the articles are placed above plates 16 they are ready to be lowered into a packing receptacle 50 as and when desired. Before the articles can be lowered one must ensure that a suitable container has been placed under the plates 16 and this is achieved by actuating the horizontal conveyer 52 such as to ensure a receptacle 50 is in position and then raising said receptacle by activating the vertical conveyor 54 such as to place a receptacle immediately below plates 16. Once the receptacle is sensed as being in position the plate(s) 16 may be opened by activating actuators 20 and at this point any articles or produce on the plates is then gently lowered into the receptacle rather than dropped therein such as to reduce the level of impact that the articles experience. This reduction in impact is particularly important with fragile or easily damaged articles such as fruit, vegetables, glass articles and the like. Once the articles are conveniently placed within the receptacle 50 it is then lowered back down onto the conveyers 52 for subsequent passage in the direction of arrows Z to be distributed to the wholesaler or customer as a packaged article.

The above process may be repeated as and when necessary such as to ensure the continuous supply of packaged produce/articles to be dispatched from the packing company. It will be appreciated that modifications and amendments to the above-described system and method may be made without materially departing from the scope of the present invention. In particular, it will be appreciated that one or more plates 16 may be provided. Further, it will be appreciated that the one or more plates 16 may be hinged at a point on the outer side of the filling point rather than an inner portion thereof such that the otherwise free ends 28, 30 are on an inner portion of the filling point 14 or simply confronting each other.

Still further it will be appreciated that the system can be used to pack product into trays and boxes or any other holding media or receptacle and the above description should be interpreted accordingly. In addition, it will be appreciated that the media to be filled may be raised and lowered by a programmable device that can stop at any given position and that the apparatus includes a top mechanism for achieving this desire. The packs may be lowered into the tray/box, the tray/box may then lowered and a second layer is placed on top. This may be repeated for as many layers as required. Finally, it will also be appreciated that the trap doors can also be pivoted from the outside edges should that prove desirable, as discussed above.

Claims

1. A packing system (10) comprising a product accumulation station (12) and a filling point (14) having a lowering system (16), wherein said lowering system comprises a hinged lowering plate (16a) pivotally connected at a hinge (18) to said filling point (14) and being connected to an actuator (20) for actuation of said plate (16) between a first product receiving position (A) and a second product delivering position (B) and further comprises a guide plate (17) opposite an end of said lowering plate (16a) and extending downwardly and into a container (50) to be filled.

2. A packaging system (10) as claimed in claim 1 wherein said guide plate (17) comprises a first introduction portion (17a) at a top (17b) thereof and being positioned to produce a reducing gap G1 as the lowering plate (16a) opens and a second portion (17c) at a bottom (17d) thereof and being positioned for producing an increasing gap G2 as the lowering plate (16a) is lowered to a fully lowered position.

3. A packaging system (10) as claimed in claim 1 wherein said guide plate (17) comprises a second portion (17c) at a bottom (17d) thereof and being positioned for producing an increasing gap G2 as the lowering plate (16a) is lowered to a fully lowered position.

4. A packaging system (10) as claimed in claim 2 or claim 3 wherein said second portion (17c) is angled at an angle β relative to a vertical plane.

5. A packaging system as claimed in any one of claims 2 to 4 wherein said first portion is angled at an angle θ relative to a vertical plane.

6. A packing system (10) as claimed in claim 1 wherein said system (10) includes a longitudinal conveying axis X and said hinge (18) includes a longitudinal pivot axis (22) extending substantially parallel to said conveying axis X.

7. A packing system (10) as claimed in claim 1 wherein said system (10) includes a longitudinal conveying axis X and said lowering system (16) comprises a pair of lowering plates (16a, 16b) each of which includes a longitudinal pivot axis (22) extending substantially parallel to said conveying axis X.

8. A packing system (10) as claimed in claim 3 and including a pair of actuators ((20a, 20b) for moving said first and second lowering plates (16a, 16b) between said first and second positions (A,B).

9. A packing system as claimed in claim 3 or claim 4 wherein said lowering plates (16a, 16b) are each hinged along a central portion (26) of said filling point (14) and have otherwise free ends (28, 30) outward (0) thereof.

10. A packing system (10) as claimed in any one of claims 1 to 5 wherein a surface (26) of said plate (16) extends substantially horizontally (H) when said plate (16) is in said first position (A) such as to receive product from said accumulation station (12) and extends generally downwardly (D) relative to said horizontal plane (H) when in said delivering position (B).

11. A packing system (10) as claimed in any one of claims 1 to 4 wherein said accumulation station (12) includes a stopper plate (32) and a pusher system (34) for advancing accumulated product from said accumulation station (12) to said filling point (14).

12. A packaging system (10) as claimed in claim 11 wherein said pusher system includes an actuator (38) for causing said pusher (34) to advance towards said filling point (14) in a first plane and return thereform in a second plane above said first plane.

13. A packing system (10) as claimed in claim 7 wherein said pusher system (34) includes a plurality of mobile fingers (36) collectively forming a wall for engagement with product to be delivered and further including an actuation mechanism (38) for advancing said fingers from a first retracted position (RP) to a second advanced position (AP) and any collected product towards said filling point (14).

14. A packing system (10) as claimed in claim 8 wherein the accumulation station (12) further includes a plurality of fixed fingers (40) positioned between said mobile fingers (36) when said mobile fingers are in said retracted position and which in combination with said mobile fingers (36) collectively form a sidewall (42).

15. A packing system (10) as claimed in any one of claims 1 to 9 wherein said accumulation station (12) includes a separate driven conveyor belt (44).

16. A packing system (10) as claimed in any one of claims 1 to 10 and further including a product delivery mechanism (46) for delivering product to said accumulation station (12).

17. A packing system (10) as claimed in claim 11 wherein said delivery mechanism (46) comprises a conveyor system of a production machine.

18. A packing system (10) as claimed in any one of claims 1 to 12 and further including a receptacle conveying mechanism (48) for delivering and removing a receptacle (50) to said filling point (14) as and when required.

19. A packing system (10) as claimed in claim 13 wherein said conveying mechanism (48) includes a lateral conveyor (52) and a vertical conveyor (54) and wherein said mechanism (48) is on an underside (US) of said filling point (14) and wherein said filling point is configured to lower product into a receptacle (50) when so required.

20. A packing system (10) as claimed in claim 14 wherein said lateral conveyer (52) comprises a conveyor belt (56) and drive system (58).

21. A packing system (10) as claimed in claim 14 or claim 15 wherein said vertical conveyer (54) comprises a displaceable support platform (60) and an actuation mechanism for displacing said receptacle (50) substantially vertically between a first lower position (L) in which it is engaged with said lateral conveyor (52) and distal said filling point (24) and a second higher position (H) in which it is proximal said filling point (14) and distal said lateral conveyer (52).

22. A packing system as claimed in claim 16 wherein said vertical conveyor (54) further includes a connection rod (54) and a rotatable crank (56) mounted for rotation on an actuator shaft (58) of an actuator (60) and being operable to lift and lower said Platform (60) upon rotation of said actuator (60).

23. A packing system as claimed in any one of claims 1 to 17 and further including a control system (62) operably connected to one or more actuators (WW,XX, YY, ZZ) to operate said system (10).

24. A packing system as claimed in any one of claims 1 to 18 and further including sensors for determining the presence or otherwise of one or more of: a receptacle and one or more product.