The present invention relates to an apparatus for applying or stamping indicia on individual packages or packs held within a larger container or carton, and more particularly to the application of a tax stamp to one end of a cigarette pack of any size while positioned within a larger carton holding a plurality of cigarette packs.
Various tax stamping machines have been proposed in the past for providing a process of applying stamps to one end of a cigarette pack. However, each of these machines has been designed for a particular size of a cigarette pack, and can not be readily adapted or modified to handle cigarette packs of a different size. Therefore, it has been standard practice to manually hand stamp cigarette packs that are larger than the standard size pack. This is a very inefficient, costly and time consuming operation.
It would be desirable in the present invention to provide an automated apparatus capable of being readily adjusted for different size cigarette packs and cartons to allow for automated processing of the stamping operation for cigarettes of any size. It would be desirable to increase the efficiency of the stamping operation to provide a production rate on the order of 90 cartons per minute. It would be desirable in the present invention to provide an apparatus that was capable of operating on demand for production when the product to be stamped was present on a loading conveyor. It would be desirable in the present invention to provide an apparatus capable of detecting product jams along the transport path and automatically stopping further processing operations to eliminate damage or waste of tax stamps being improperly applied. It would be desirable in the present invention to provide an apparatus capable of automatically monitoring the operational temperature of the stamping head to prevent unsatisfactory operation due to temperatures being lower than desired, or temperatures being higher than desired. It would be desirable in the present invention to provide an apparatus with a temperature sensor for monitoring the temperature of hot glue to be applied to an open flap of the carton prior to resealing the carton after stamping. It would be desirable in the present invention to control operation of the apparatus to prevent processing of cartons or packages if the temperature range of one or more sensors is above or below the desired temperature range. It would be desirable in the present invention to provide an unloading mechanism with a sensor capable of stopping operation of the apparatus when the unloading mechanism is full. It would be desirable in the present invention to provide an apparatus capable of easy adjustment for different size cigarettes, including cigarettes of different lengths and widths. By way of example and not limitation, the apparatus should be capable of processing cigarette sizes corresponding to regular, king, 120's, slims, ultra long or the like. It would be desirable to provide a stamping apparatus having a computerized control system for monitoring processing and capable of being preprogrammed for different size packages to be stamped.
An apparatus for stamping a plurality of packages or packs positioned within a larger container or carton according to the present invention can include a loader mechanism for sensing the presence of a container or carton at a ready position and a pusher for moving the container or carton from the ready position. A transport conveyor receives the container or carton from the loader mechanism for movement along a predetermined transport path in a length wise orientation with respect to a longitudinal axis of the elongate container or carton in an upright or upside down orientation depending on which end of the packages or packs are to receive the stamp to be applied thereon. The transport path passes each container or carton through an opening station where an upper end of the container or carton is automatically opened as the container or carton continues to travel along the transport path. A sensor is positioned in proximity to the opening station to monitor whether a jam of the product in the transport conveyor occurs, and to send a corresponding signal if a jam is detected in order to cease further processing operations of the apparatus. The opened carton is then transported along the transport path to a stamping station. Sensors in proximity to the stamping station determine whether the flaps of the container or carton are in the opened position to expose one end of the plurality of packages or packs positioned within the larger container or carton. If the flaps are not open, a signal is sent to the control system indicating that the carton is not properly prepared for stamping and further processing is halted for operator intervention to correct the error. If both flaps of the container or carton are in the open position, the carton is stopped at an appropriate position along the transport path below the stamping head. The stamping head is reciprocated to engage a carrier sheet supporting a plurality of stamps, such as tax stamp indicia, and to drive the stamps simultaneously into engagement with the plurality of packages or packs positioned within the container or carton. A single reciprocal stroke applies a stamp to each of the packs within the carton. A temperature sensor continuously monitors the temperature of the stamp head to automatically cease operation of the apparatus in the event that the temperature falls below a predetermined value, or rises above a predetermined value. The carton containing the stamped packs then continues to move along the transport path through a closing station, where hot glue is applied to one of the flaps, and the flaps are folded over one another and pressed together to reseal the container or carton. A temperature sensor continuously monitors the temperature of the hot glue to be applied to the open flap. The temperature sensor is capable of sending an appropriate signal to the control system if the temperature of the glue falls below a predetermined temperature, or rises above a predetermined temperature. After resealing or closing of the container or carton, the transport conveyor discharges the resealed container to an unloader mechanism. The unloader mechanism accumulates resealed containers for repackaging into shipment boxes. The unloader mechanism preferably includes a sensor for monitoring whether the unloader mechanism is full of resealed containers. If the unloader mechanism becomes full of resealed containers or cartons, an appropriate signal is sent to the control system in order to cease further operation of the apparatus until the unloader mechanism has been cleared or the full signal condition no longer exists.
Other applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings.
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
Referring now to
The loading station 16 can include a conveyor 28 for moving a plurality of containers 14 toward a ready position located in proximity to one end of the conveyor 28. When handling cigarette cartons having an elongate configuration along one axis, the cartons 14 are preferably moved along the conveyor 28 in a direction transverse to the longitudinal axis of the carton 14. A sensor 30 is provided in proximity to the ready position for generating an output signal corresponding to the presence of a container 14 at the ready position. In response to the signal generated by the sensor 30, the control system 26 activates a motor 32, such as a fluid operated cylinder to move a pusher arm from a first position 34 to a second position 36 to move the container 14 in the ready position of the loading station 16 along a transport path 38. The control system 26 and sensor 30 allow the loading station 16 to operate on demand when a container or carton 14 is at the ready position of the loading station 16.
A transport conveyor 40 receives the container or carton 14 pushed from the ready position of the loading station 16 by the motor or cylinder 32. The transport conveyor 40 includes an adjustable frame supporting the opening head 50, stamping head 64, and closing applicator elements at the closing station 22. Alternatively, adjustable shelf 42 can be provided to engage the bottom of the container or carton 14 as it moves along the transport path 38. The adjustable shelf can be moved vertically to configure the apparatus 10 according to the present invention for different length cigarette packages 12 positioned within the container or carton 14. The adjustment of the support frame or alternatively shelf 42 is programmed to respond to the operator selection of a particular size cigarette pack to be stamped. Alternatively, the control system 26 can automatically respond to appropriate input signals indicating the size of cartons to be processed and adjusting the elevation of the support frame or alternatively shelf 42 accordingly. By way of example and not limitation, preprogrammed settings can be provided in the control system 26 for regular size cigarettes, king size cigarettes, and ultra long cigarettes, sometimes referred to as 120 lengths. This configuration of the present invention permits the top of the particular container or carton 14 to be properly aligned with a common operational processing plane so that the top of each carton is operably engageable with the other processing elements as the carton travels along the transport path. The elements can include the opening head, the stamping head, and the closing station elements. This configuration permits a single adjustment of the support frame or alternatively shelf 42 without requiring individual adjustments of the various elements along the transport path 38. The transport conveyor 40 preferably includes a plurality of rollers 44 longitudinally spaced from one another on opposite sides of the transport path 38 to support counter rotating belts 46a, 46b engageable with opposite sides of the container or carton 14 for driving the container or carton 14 along the transport path 38 as the bottom of the container or carton 14 is supported on the adjustable support shelf 42. The programmable control system 26 can control the adjustable support frame or alternatively the shelf elevation 42 by sending an appropriate signal to motor 48 for adjusting the vertical position or elevation of the adjustable support frame or alternatively the shelf 42 for the particular size or dimensions of the containers or cartons 14 to be processed. The counter rotating belts 46a, 46b engage opposite sides of the container or carton 14 to slide the container or carton 14 along the transport path 38 while supported from beneath by the shelf 42. As the container or carton 14 passes through the opening station 18, an opening head 50 operably engages the upper flaps of the container or carton 14 and folds the flaps to an open position.
One or more sensors 52 can be provided in proximity to the opening station 18 for verifying that the flaps have been moved to the open position and/or determining if a product jam has occurred by improper engagement of the opening head 50 with the container or carton 14. If the flaps have been moved to the open position, the container or carton 14 continues to travel along the transport path 38. If the flaps have not been moved into the open position, an error signal is sent to the control system 26 and operation of the apparatus 10 is temporarily halted for operator intervention to correct the error. If a product jam is sensed at the opening station 18, the transport conveyor 40 is temporarily halted for operator intervention to correct the error. The opposing rollers 44 supporting the counter rotating belts 46a, 46b can be adjusted toward and away from one another to adapt to different width containers or cartons 14 to be conveyed along the transport path 38. By way of example and not limitation, the programmable control system 26 can be preprogrammed for predefined container or carton dimensions corresponding to regular cigarettes, king size cigarettes, ultra long cigarettes, ultra thin cigarettes, or the like. An appropriate signal can be generated by the control system 26 to activate motor 54 to adjust the distance between opposing rollers 44 in accordance with a control program stored in memory of the control system 26. The control system 26 can control rotation of the counter rotating belts 46a, 46b by sending an appropriate signal to motor 56. Motor 56 operably drives the counter rotating belts 46a, 46b through transmission of rotary motion from the motor 56 to the drive rollers 58a, 58b respectively.
After successfully opening the flaps of the container or carton 14, the container or carton 14 continues along the transport path 38 driven by the transport conveyor 40 to the stamping station 20. Referring now to
The tax indicia are applied from two adjacent rows on the carrier film 62. The combination of reciprocating the stamping head 64 when in the first, second, and third positions 66a, 66b, 66c while the carrier sheet or film roll 62 is held stationary applies all of the stamps in the two adjacent rows to the corresponding first, second, and third cartons 14a, 14b, and 14c traveling sequentially down the transport path 38 of the apparatus 10 according to the present invention. When all of the stamps in the two adjacent rows have been applied as described above, a motor 68 is actuated by the control system 26 to index the carrier sheet or film roll 62 of tax indicia by two rows. The motor 68 can include a fluid operated cylinder and ratchet configuration if desired. After each reciprocal stamping operation of the stamping head 64, the appropriate stop 60a, or 60b is deenergized to return to the retracted position allowing the carton 14a, 14b, or 14c, to continue along the transport path 38. One or more sensors 70 can be provided for monitoring if the carrier sheet of tax indicia has been depleted. The sensor 70 can provide an appropriate signal to the control system 26 to indicate when the carrier sheet or film roll 62 of tax indicia has been depleted, so that the control system 26 can cease operation of the apparatus 10 for operator intervention to replace the depleted carrier sheet or film roll 62 with a new one.
The stamping head 64 can be mounted on one or more rails 72 for movement between the first, second, and third positions 66a, 66b, 66c. A motor 74 can be provided for moving a carriage 76 supported from the one or more rails 72 between the various positions in response to appropriate signals from the control system 26 in accordance with a control program stored in memory. A reciprocal motor 78 can be controlled by the control system 26 in accordance with the control program stored in memory for moving the stamping head 64 between the upper, raised position and the lowered, stamping position.
At least one temperature sensor 80 is preferably provided with respect to the stamping head 64 to monitor the current operating conditions of the stamping head 64. The temperature sensor 80 sends a signal corresponding to the temperature of the stamping head 64 to the control system 26. The control system 26 monitors the signal received from the sensor 80 in accordance with the control program stored in memory. If an abnormal temperature condition is sensed, either a temperature below a predetermined low temperature value, or above a predetermined high temperature value, the control system 26 can temporarily halt operation of the apparatus 10 for operator intervention to correct the error. One or more sensors 82 can be provided in proximity to the stamping station 20 to detect the presence of a container or carton 14 at the stamping station 20. The sensor 82 can provide an appropriate signal to the control system 26 in order to initiate the stamping operation when a carton, such as carton 14a, 14b, or 14c, is present at the stamping station 20. If a carton-present signal is not received from the sensor 82 within a predetermined time period, the control system 26 can provide an audible and/or visual signal indicating a malfunction requiring operator attention. It should be recognized that the sequential stamping operations can be modified corresponding to the number of stamps carried by the carrier sheet 62, the number of stamps applied with each reciprocal stamping stroke, and the size of the packages to receive the stamps without departing from the spirit and scope of the present invention.
Referring again to
The discharged container 14 is received by the unloading station 24. Preferably, the unloading station 24 includes a conveyor 94 for conveying and accumulating a predetermined number of resealed containers 14. A sensor 96 can be positioned in proximity to the unloading station 24 for monitoring the accumulation of the resealed containers 14 on the conveyor 94. If an excessive accumulation of resealed containers 14 occurs on the conveyor 94, an appropriate signal can be generated by sensor 96 to the control system 26 in order to temporarily halt operation of the apparatus 10 until the excessive accumulation condition is corrected.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.
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