Patent Grant
8584436
The present invention relates to apparatus that can package and apply closure clips to materials that enclose products therein, and may be particularly suitable for clipping netting material about a desired product(s).
Certain types of commodity and/or industrial items can be packaged by placing the desired product(s) in a covering material and then applying a closure clip or clips to end portions of the covering material to secure the product(s) therein. For non-flowable piece goods, the piece goods can be held individually in a respective clipped package, or as a group of goods in a single package. The covering material can be any suitable material, typically a casing and/or netting material.
Generally described, when packaging a piece good product in netting, the product can be manually pushed through a netting chute. The product can include, by way of example, a non-flowable semi-solid and/or solid object such as a meat product including whole or half hams, turkey, chicken, and the like. The netting chute holds a length of a netting sleeve over the exterior thereof. A first downstream end portion of the netting is typically closed using a first clip. As the product exits the netting chute, it is covered with the netting. An operator can then orient the product inside the netting between the discharge end of the chute and the clipped first end portion of the netting. The operator can then pull the netting so that the netting is held relatively tight (typically stretched or in tension) over the product. The operator then uses his/her hands to compress or gather the open end of the netting (upstream of the product) and manually applies a clip to the netting, typically using a Tipper Tie® double clipper apparatus. A clip attachment apparatus or “clippers” are well known to those of skill in the art and include those available from Tipper Tie, Inc., of Apex, N.C., including product numbers Z3214, Z3202, and Z3200. Examples of clip attachment apparatus and/or packaging apparatus are described in U.S. Pat. Nos. 3,389,533; 3,499,259; 4,683,700; and 5,161,347, the contents of which are hereby incorporated by reference as if recited in full herein.
A double clipper can concurrently apply two clips to the netting proximate the open (upstream) end of the package. One clip defines the first end portion of the next package and the other defines the trailing or second end portion of the package then being closed. A cutting mechanism incorporated in the clipper apparatus can sever the two packages before the enclosed package is removed from the clipper apparatus. U.S. Pat. No. 4,766,713 describes a double clipper apparatus used to apply two clips to a casing covering. U.S. Pat. No. 5,495,701 proposes a clipper with a clip attachment mechanism configured to selectively fasten a single clip or two clips simultaneously. The mechanism has two punches, one of which is driven directly by a pneumatic cylinder and the other of which is connected to the first punch using a pin and key assembly. The pin and key assembly allows the punches to be coupled or decoupled to the pneumatic cylinder drive to apply one single clip or two clips simultaneously. U.S. Pat. No. 5,586,424 proposes an apparatus for movement of U-shaped clips along a rail. The apparatus includes a clip feed for advancing clips on a guide rail and the arm is reciprocally driven by a piston and cylinder arrangement. The contents of each of these patents are hereby incorporated by reference as if recited in full herein.
Other deices provide for semi-automated or automated clipping as described in U.S. patent Ser. No. 10/339,910 and co-pending, co-assigned U.S. Provisional Patent Application Ser. No. 60/508,659, the contents of which are also hereby incorporated by reference as if recited in full herein. For example, U.S. Pat. Ser. No. 10/339,910 describes a device with a chute that is configured to package a product, such as a vacuum-packed turkey, and can also form a handle in a tubular covering encasing the product.
Embodiments of the present invention provide apparatus, subassemblies and/or other devices, systems, methods and computer program products for packaging a product in a covering material and/or applying clips thereto.
In certain embodiments, the product can be manipulated and packaged so that at least one clip is automatically applied to enclose the product in the covering material. Particular embodiments (automatically) weigh, electronically transmit the weight to a printer, deliver an object into a predetermined travel path through a chute, and then package a discrete object or objects in netting as the object(s) exits the chute.
In certain embodiments, apparatus can be configured to enclose at least one product in a covering material. The apparatus include: (a) an elongate product chute having an outer surface and opposing receiving and discharge end portions with an interior cavity extending therethrough; and (b) a clipper mechanism disposed downstream of the product chute, the clipper mechanism configured to automatically apply at least one clip to a covering material that encloses a product after the product exits the product chute, wherein the clipper mechanism is configured with an automatic stroke cycle that comprises a first retracted home position, a second pre-clip dwell position, and a third clipping position.
In some embodiments, the clipper mechanism comprises a two-stroke actuation cylinder to pivotably and controllably serially advance from the first position, to the second position, and the third position, and then pivotably retract back to the first position. The second clipper mechanism position may be at least about 50% of the stroke distance between the first and third clipper mechanism positions.
Other embodiments are directed to an automated or semi-automated clipper mechanism for attaching at least one closure clip to a product held in netting. The mechanism includes a pivotable clipper mechanism having a clipper body configured to automatically deliver clips to a clip window and attach at least one clip to gathered netting. The clipper mechanism can have a predetermined automatic stroke cycle that comprises a first retracted home position, a second pre-clip dwell position, and a third clipping position.
In some embodiments, the clipper mechanism can also include: (a) a clipper body; (b) a curvilinear clip rail attached to the clipper body having opposing top and bottom end portions and defining a generally downwardly extending clip feed direction; (c) a clip entry window in communication with the bottom end portion of the clip rail and a clip closure delivery path in communication with a punch mechanism that is adapted to wrap a clip from the clip rail about covering encasing a target product; (d) a clip pusher configured to selectively engage with clips held on the clip rail to force the clips in the feed direction; (e) a first gathering plate disposed on a first side of the clip entry window, the first clipper gathering plate configured to extend a distance below the clip rail and generally outwardly therefrom toward the covering; and (f) a second clipper gathering plate disposed on an opposing side of the clip entry window downstream of the first clipper gathering plate so as to be spaced apart from the first clipper gathering plate, the second clipper gathering plate configured to extend a distance below the clip rail and generally outwardly therefrom toward the target covering material. In operation, the first and second clipper gathering plates move in concert with the clipper mechanism.
Other embodiments are directed to clipper apparatus that include: (a) a mounting frame; (b) a clipper mechanism attached to the mounting frame so as to be able to travel to advance and retract relative to a product travel path, the clipper mechanism having a clipper body configured to automatically attach at least one clip to a portion of gathered target covering material, wherein the clipper mechanism has an automatic stroke cycle that comprises a retracted home position and a clipping position; and (c) a discharge tray held downstream of the clipper mechanism, the tray having first and second spaced apart upwardly extending flaps that automatically pivot laterally inward to reside closer together to trap a forwardmost position of a respective product in a clip location, then pivot away from each other to allow the clipped product to pass.
The apparatus may also include first and second longitudinally extending laterally spaced apart slots. The first and second pivotable flaps can each have a leg that extends downwardly through a respective slot, the legs configured to advance and retract in the respective slots to thereby position the flaps at longitudinally adjustable distances. In some embodiments, an underside of the tray comprises a four bar linkage with a center link and opposing first and second side links attached to the center link. The side links have opposing first and second end portions. One leg is attached to a first end portion of the first side link and the other leg is attached to a first end portion of the second side link. The center link may also include a slot on opposing end portions thereof. The second end portion of the first side link can travel in one of the center link slots and the second end portion of the second side link can travel in the other center link slot.
Some embodiments include clipper apparatus that include: (a) a mounting frame having opposing first and second upstanding sides residing on opposing sides of a product flow path; (b) a clipper mechanism attached to the first side of the mounting frame, the clipper mechanism configured to automatically deliver clips to a clip window, attach at least one clip to a portion of gathered target covering material, wherein the clipper mechanism has an automatic stroke cycle that comprises a retracted home position and a clipping position; and (c) a printer platform holding a printer thereon, the printer platform pivotably mounted to the mounting frame and configured with a generally planar top member configured to allow the printer to slide for loading of consumable items. The printer platform has an operative position that aligns a printer output port of the printer with a label feed window in the product flow path and a re-load position. The printer platform pivots laterally outward and the printer top member slides in a predetermined direction. The printer platform can provide increased precision re-alignment with the feed window upon repositioning in the operative position.
The apparatus can be configured with a frame that can accommodate modular interchangeable subassembly components that can be selectively mounted at different positions on the frame to thereby provide increased manufacturing build options and/or selectable purchaser options without requiring custom designed equipment. The flexible mounting arrangements and/or modular sub-assembly selections can reduce inventory, build-times, and provide greater customer options.
Some embodiments are directed to packaging apparatus for packaging at least one discrete product in a netting material. The apparatus includes a clipper mechanism and a support platform disposed downstream of the clipper mechanism. The support platform includes longitudinally extending laterally spaced apart first and second slots with first and second pivotable flaps, each flap having a generally downwardly extending leg extending through a respective one of said slots. In operation, a free end of each of the flaps move to reside closer together, the flaps then move upstream to trap a target product while the netting material is being clipped by the clipper mechanism, then the flaps automatically pivot outwardly to open to allow the enclosed netted product to travel downstream thereof.
Still other embodiments are directed to methods of packaging a product in netting. The methods include: (a) weighing a packaged whole bird product having encased protruding legs; (b) conveying the whole bird product on a first conveyor along a first travel direction with the legs positioned substantially orthogonal to the conveying direction; (c) conveying the product in a primary travel path on a second conveyor, the primary travel path being substantially orthogonal to the product first travel direction with the product held on the second conveyor with its legs facing downstream; (d) automatically wrapping the product in netting as it exits a netting product chute; and (e) clipping an end portion of the netting to enclose the product therein.
Other embodiments are directed to methods of operating an automated or semi-automated packaging apparatus that includes a clipper mechanism and a product chute with a supply of covering material held thereon. The methods, include: (a) weighing a product; (b) directing the product to travel through the product chute to automatically encase the product in the covering material as the product exits the product chute; (c) electronically transmitting the weight of the product to a printer held downstream of the product chute; (d) automatically clipping the covering material encasing the product; automatically attaching a label from the printer with the product weight printed thereon onto the encased product proximate to the clipping step; (e) pivoting the printer laterally away from the clipper mechanism; and (f) sliding the printer to allow external access to the printer for reloading consumable items.
Some embodiments are directed to computer program products for operating a packaging apparatus. The packaging apparatus includes a product chute and a clipping apparatus that applies at least one closure clip to target gathered covering material. The computer program product includes a computer readable storage medium having computer readable program code embodied in the medium. The computer-readable program code including: (a) computer readable program code that automatically controllably actuates a clipper mechanism actuation cylinder to direct the clipper mechanism to travel through a retracted home position, a pre-clip dwell position and a full-clip position; and (b) computer readable program code that automatically controllably directs the clipper mechanism to apply at least one clip during a clipping operation when the clipper mechanism is in the full-clip position.
The product may also further comprising computer readable program code that automatically controllably directs an automated handle maker to form a handle, and computer readable program code that directs the clipper mechanism to travel from the home to the pre-clip position during the handle making operation, then to the full clip position after the handle is formed.
These and other objects and/or aspects of the present invention are explained in detail in the specification set forth below.
The present invention will now be described more fully hereinafter with reference to the accompanying figures, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like numbers refer to like elements throughout. In the figures, certain layers, components or features may be exaggerated for clarity, and broken lines illustrate optional features or operations, unless specified otherwise. In addition, the sequence of operations (or steps) is not limited to the order presented in the claims unless specifically indicated otherwise. Where used, the terms “attached”, “connected”, “contacting”, “coupling” and the like, can mean either directly or indirectly, unless stated otherwise. The term “concurrently” means that the operations are carried out substantially simultaneously. The term “frame” means a generally skeletal structure used to support one or more modules and/or components. The term “modular” means that a frame is configured to accept one or more subassemblies designed with standardized dimensions or configurations for interchangeable use with replacement modules of the same and/or similar type and/or other different modules, and may be configured for selectable mounting on a right or left hand side of a common frame.
In the description of the present invention that follows, certain terms are employed to refer to the positional relationship of certain structures relative to other structures. As used herein, the terms “front,” “forward” and derivatives thereof refer to the general or primary direction that a target product travels for enclosure and/or clipping; this term is intended to be synonymous with the term “downstream,” which is often used in manufacturing or material flow environments to indicate that certain material traveling or being acted upon is farther along in that process than other material. Conversely, the terms “rearward,” “upstream” and derivatives thereof refer to the directions opposite, respectively, the forward and downstream directions. It is also noted that different mounting orientation configurations of one or more modules and/or apparatus may be shown in the figures. Thus, the figures may show certain of the devices in different views with different mounting configurations and the views in different figures do not necessarily correspond to a common or single mounting arrangement as different views may have certain components and/or devices oriented differently.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the application and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
The present invention is particularly suitable for applying closure clips to discrete objects held in a covering material. The covering material may be natural or synthetic and may be a casing material that can be sealed about a product. In other embodiments, the covering material can be netting. The casing can be any suitable casing (edible or inedible, natural or synthetic) such as, but not limited to, collagen, cellulose, plastic, elastomeric or polymeric casing. The term “netting” refers to any generally open mesh material in any form including, for example, knotted, braided, extruded, stamped, knitted, woven or otherwise. Typically, the netting is configured so as to be stretchable in both axial and lateral directions.
Netting or other covering material may be used to package discrete meat products such as loaves of meat, boned ham, spiral sliced ham, deboned ham, turkey, turkey loaves held in molds, or other meat or items directly or with the items held in subcontainers and/or wraps such as molds, trays, boxes, bags, absorbent or protective sheets, sealant, cans and the like. In particular embodiments, the systems of the present invention can be adapted for packing whole birds (such as turkeys). The term “whole bird” means that the bird is generally intact but the head and internal organs and the like may be removed.
Other embodiments of the present invention may be directed to package other types of food such as cheese, bread, fruit, vegetables, and the like. Examples of non-food items that may be packaged using embodiments of the present invention include living items such as flora, trees, and the like, as well as inanimate objects. Additional examples of products include discrete, semi-solid or solid objects such as firewood, pet food (typically held in a container if the wet type), recreational objects (such as balls), or other solid or semi-solid objects. The product may be packaged for any suitable industry including horticulture, aquaculture, agriculture, or other food industry, environmental, chemical, explosive, or other application. Netting may be particularly useful to package hams or turkeys (such as vacuum-wrapped hams or turkeys), manufactured hardware such as automotive parts, firewood, explosives, molded products, and other industrial, consumable, and/or commodity item(s).
Generally stated, embodiments of the present invention are directed at automating packaging of piece goods or discrete items by forcing them through a product chute and wrapping or enveloping the objects at the other end of the chute in a covering material, such as netting, and automatically clipping the covering material with a closure clip or other attachment means to close the covering and hold the object or objects inside of the covering material. As noted above, clippers are available from Tipper Tie, Inc., of Apex, N.C. Examples of suitable clips include metallic generally “U”-shaped clips available from Tipper Tie, Inc., in Apex, N.C. Other clips, clip materials and clip configurations or closure means may also be used.
As shown in
It is noted that the floors 121 and/or 122 of apparatus 100, may include additional and/or other floor configurations, typically comprising moving floors or product advancement systems may be used, for example, rollers, rolling bars, belts or drives that advance trays or other support members and the like. In addition, the floor(s) 121, 122 may extend substantially horizontal and/or be angularly oriented to travel up, down, or otherwise to advance the product. In addition, the apparatus 100 can include an automated continuous advancement system with discrete product(s) separated at desired intervals on the moving floor to serially introduce product for packaging to the chute 30. In certain embodiments, the moving floor can include partitions, channels, or other spacer configurations to hold the product(s) in desired alignment on the moving floor.
For groups of objects, manual or automated bins or feeders can accumulate the desired amount of grouped objects upstream and place them together on the moving floor (not shown). In other embodiments, an automated counter can be used to count the number of products that pass a target location so that a desired number of products are accumulated (not shown). The conveyor 121 and/or 122 (
Generally described, the scale 125 can take a number of weight measurements, and accepts one when the weight measurement has stabilized to within a predetermined (statistically valid) range. In some embodiments, 10 or more, and typically about 25 or more weight measurements can be taken and when successive weight measurements for a product varies by less than a specified percentage or value, a weight can be “locked-in”. The first floor 121 can be configured to automatically advance and/or move after the weight is successfully obtained. The scale 125 can be in communication with the moving floor 121 and the controller 126. The controller 126 can direct the movement of the floor 121 and/or relay the measured weight to the printer 150 in a queue order. The weight measurement can be electronically relayed to a label printer. In some embodiments, the label printer 150 can be a remote label printer, such as a printer module that is mounted to the frame 40f of the clipper module 40m as shown in
The product chute floor may comprise a stationary floor with an anti-stick coating or material. It is also noted that the product chute 30 may include a moving floor such as those types described above with respect to the infeed floor configurations. The chute 30 may be sized relative to the product 180 so that the product 180 extends across a major portion of the width of the cavity, and in certain embodiments, extends across at least about 75% of the width of the cavity. In certain embodiments, the product 180 and chute cavity 30c are sized so that the sides and/or top and bottom of the product 180 are pressed against the sidewalls of the cavity as the product is pushed therethrough. In other embodiments the chute cavity is sized to allow the product 180 to freely pass therethrough. The product chute 30 may comprise stainless steel and be coated with a friction reducing material such as TEFLON. Lubricants may also be disposed on the inner surface(s) of the product chute 30.
In certain embodiments, the product chute 30 has a cross-sectional profile that is non-circular. The product chute 30 may be configured with a planar top and/or bottom portion and semi-circular side portions. Other cross-sectional profile configurations may also be used including, but not limited to, circular, oval, triangular, rectangular, square and the like.
The chute widths may range from between about 9-13 inches and the height of the chutes 30 may be between about 5-12 inches. A smaller chute 30 may have a cavity that is about 9 inches wide by 5.75 inches tall while a larger chute 30 may have a cavity that is about 13 inches wide by about 11.25 inches tall. The chutes 30 may have a length (at least for the portion having a generally constant cross-sectional area) that is between about 28-30 inches, with a tolerance of about ± 1/16 of an inch, facilitating alignment where replacement chutes are used. The chutes 30 may also have a flared or funnel-like entry portion 30a (
As well known to those of skill in the art, a sleeve of covering material can be positioned about the external surface of the product chute 30 and configured to be drawn downstream thereof so as to automatically encase the product as the product emerges from the discharge end of the product chute 30. In some embodiments, a supplemental sleeve material holder may also be used instead of placing the sleeve of casing material on the product chute (not shown). The supplemental sleeve holder can be configured to surround a downstream portion of the product chute (not shown). The sleeve of covering material may be sized to stretch to substantially conform to the external wall or surface of the product chute 30 or may be more loosely held thereon.
In operation, the sleeve of covering material may be clipped, welded, fused, knotted or otherwise closed and sealed at a leading edge portion thereof. When the product exits the product chute 30, it is held in the covering material as the covering material is drawn downstream. The covering material may be loaded onto the product chute 30 and the leading edge portion thereof closed before or after the product chute 30 is mounted to the apparatus 100.
In some embodiments, as shown for example in
The voiding assembly 69 shown in
As described above, the apparatus 100 can include a brake assembly with brake gripping members 90 (
When the handle maker 60 is not assembled, a generally planar upstanding housing sidewall 11s can be used to close the module 40m similar to the sidewall enclosing the clipper mechanism 40 as shown in
As with the clipper 40, in some embodiments, the handle maker 60 and frame 40f can also be configured to allow the handle maker 60 to mount to either the left or right hand side 40L, 40R, respectively, of the frame 40f (and primary product travel path) with their respective housing guards 11 (
Typically, the handle maker 60 (where used) will mount to a different opposing side of the frame 40f from the clipper 40. An example of a suitable handle-maker is described in U.S. Pat. No. 6,729,102, the contents of which are hereby incorporated by reference as if recited in full herein. The handle maker 60 is configured to automatically form a handle on (typically from) the covering material as the product exits the chute 30.
The frame 40f can have pre-formed apertures, brackets, alignment indicia and/or other structures or members that can allow the clipper 40 and/or handle maker 60 to mount to the desired side of the frame 40f without requiring specialized individual frame modifications or brackets for a particular customer. For example, the clipper mechanism 40 can be an assembly with a mounting bracket configuration that can be interchangeably mounted to either side of the frame 40f and still clip at a substantially common location in the product path. The handle maker 60 with the bracket 160 (
The clipper 40 will typically mount to a top portion of the frame 40f in a manner that allows the clipper 40 to dynamically retract and advance into clipping position as discussed above. For example, as shown in
In any event, the modules 40m, 40m′ can be configured to align with the chute 30 such that the discharge end portion of the product chute 30d terminates proximate the clipper 40 with minimal adjustment. The modules 40m, 40m′ are configured to hold the clipper 40 so that the clip window can be axially aligned with a desired axial location of the product travel path in the full clip position, typically substantially aligned with the axial centerline of the chute 30, irrespective of whether the clipper 40 is mounted to the right or left hand side of the frame 40f.
As shown, in
In some embodiments, the clipper mechanism 40 can operate with an automatic stroke cycle that comprises three dwell positions: a first retracted home position; a second pre-clip position; and a third clipping (“full-clip”) position. When in the home position, the clipper body is retracted out of the product travel path as shown in
In certain embodiments, as shown in
In certain embodiments, the second position of the clipper mechanism 40 can be at least 50% of the stroke distance between the first and third clipper mechanism positions, typically at about 75% of the stroke distance. The travel from the first home to the second pre-clip position can be carried out as the product is exiting the product chute 30 to save the cycle time that it would take to clip the product while waiting for the clipper to travel the full “home to clip” position cycle. For example, where a handle maker 60 is used (the handle maker being an optional device and/or operation and may reside upstream of the clipper), the clipper mechanism 40 can advance from the home to the pre-clip second position during the handle-making operation. It is noted that the dwell times in each position can be different. The home dwell time may have the longest duration in any stroke cycle.
Additional description of examples of components used in packaging apparatus can be found in co-pending, co-assigned U.S. applications identified by Attorney Docket Nos. 9389-3PR, 9389-16PR and 9389-17PR, the contents of which are hereby incorporated by reference as if recited in full herein.
The apparatus 100 may include a sensor positioned proximate the receiving end of the product chute 30. The sensor can be configured to confirm that the product chute 30 is in operative position. An exemplary sensor is a two-part magnetic switch 31; one part can be positioned on a mounting bracket attached to a chute bracket and the other part held on a mounting frame. When the two matable parts of the switch engage, the chute 30 is determined to be in proper position. Other types and/or additional sensors may also be used as suitable as is known to those of skill in the art.
A controller/processor (such as a Programmable Logic Controller) may be configured to monitor a signal from this sensor and deactivate certain components whenever a product chute 30 position-error is noted at any time during the process. The signal can be automatically monitored through a Safety Circuit Module. If the product chute 30 is missing or out of position, the apparatus 100 can be held in a low energy state that removes power to air supplies and controls to inhibit machine operation. To reinitiate the procedure, an operator may press a restart or reset button. In certain embodiments, the clipper 40 may be operated on override even when the chute 30 is absent. Once the product chute 30 is in location and the stop is reset, power air can be applied to the machine control valves and electric power can be applied to the control (PLC) outputs. After the PLC confirms the operative positions of the components (such as the clipper 40, the product holding member and the like) an automatic reset can be performed and those components automatically moved to a respective home position as needed.
The HMI 55 can include an input display screen, an emergency stop button, a reset button and a clipper only activation button. The HMI can also include a pressure regulator for corresponding gages. The pressure regulators can be for the retractable product holding member on a discharge tray (which may be described as a product clamp bar), and/or one for a retractable brake system 90 (
The apparatus 100 may be configured to allow the clipper 40 to operate irrespective of the upstream devices using the “clipper only” push button instead of the apparatus-start push button. Alternatively, the modules 40m, 40m′ can-be stand-alone devices that operate the clipper 40. The HMI 55 and/or modules 40m, 40m′ can also include an emergency stop 56 (
As is well known to those of skill in the art, in operation, with reference to
As shown in
As shown in
One long edge portion of the cutting member 165, 165′ can be retained in the cutting guide channel 166c as the cutting member 165, 165′ travels across the guide window 165w into the extended cutting, shearing and/or severing position. Where used, this positive retention of the cutting member 165, 165′ may provide additional alignment stability in some applications. The cutting member 165 can comprise a generally planar blade 165b with a leading angled knife-edge portion. Other cutting configurations can be used including, but not limited to, heat (of whatever type), water, pressure, and other knife and/or blade shapes, as well as combinations thereof. Accordingly, the term “cutting” as used herein is used broadly to mean separating and/or severing adjacent portions of covering material and is not limited to physically cutting with a sharp implement.
In addition, it is noted that the present invention is not limited to the cutting operations described. Other cutting mechanisms can be used, for example, hot-knife devices as described in U.S. Pat. Nos. 4,683,700 and 5,161,347, the contents of which are hereby incorporated by reference as if recited in full herein.
As shown in
In operation, once the covering material is gathered, a clip or clips can be applied to secure the encased product in the covering material. The covering material can then be severed to release the encased product in the clipped package. In certain embodiments, two clips are applied substantially concurrently proximate to each other using a dual clipper so that one clip closes the trailing edge of the covering material forming a first encased package and the other closes a leading edge of the covering material forming the next encased package. The clipped configuration of the covering material encasing the product may be configured to substantially conform to the shape of the enclosed product(s) or may be more loosely configured.
In position, as shown in
In certain embodiments, the printer assembly 150 also includes a slide plate 150s that allows the printer 151 to slide away from its operative mounting position to allow an operator easier external access to replace consumable items (such as labels, ink and the like) and to slide back into the desired position providing increased “automatic” realignment.
As shown in
In some embodiments, as discussed generally above, the modules 40m, 40m′ can include a product-holding member (i.e., a product clamp) that can automatically be moved into position by actuating a clamp drive cylinder, thereby blocking or trapping the product to inhibit same from moving further downstream as noted above. One example of a product holding member is shown in
The holding member flaps 67f1, 67f2 can hold the encased product so that the upstream covering material is relatively firmly or tightly held proximate the clipper 40 and/or facilitate centering the covering material during the gathering and clipping operations. The present invention is not limited to this configuration as other holding members may be used, such as, for example, that described in co-pending, co-assigned U.S. Provisional Application Ser. No. 60/508,609, which describes a clamp bar; the contents of which is hereby incorporated by reference as if recited in full herein.
The actuation of the legs and/or flaps can be controlled by the PLC using proximity sensors and operation feedback as will be understood by one of skill in the art. The discharge table 66 may be stationary (with or without rollers as shown). In other embodiments, the product table 66 may include a traveling floor (such as a conveyor) that advances the packaged product to another processing or subsequent workstation (not shown).
In certain embodiments, after the product moves past (and may be stopped by) the product-holding member 67f1, 67f2 (
The operation and sequence of certain events can be controlled by a programmable logic controller and/or other controller. Certain operations may be selected by an operator input using a HMI to communicate with the controller as is well known to those of skill in the art. In certain embodiments, the apparatus 100 can be configured with control program code that includes OEM selectable pre-programmed run modes and options to direct what signals are monitored, the timing, powering and/or other control parameters or input/output of certain automated features. The run modes may be independent of or dependent on the RH or LH mounting of the clipper and/or handle maker. The program run mode will typically be different where the handle-maker is not employed and for each front-end module type employed as certain operational sequences will be different (different actuators, sensor monitoring, and the like). The program run mode may also vary depending on other build modules employed (or not employed). For example, the type of discharge table and/or the type of product clamp employed and whether a printer module is used to print labels.
In some embodiments, the obtained weight can be electronically transmitted to a remote label-making printer (block 301) and the fist conveyor can be automatically advanced to move the product to the second conveyor in response to data collected by a scale after a reliable weight has been obtained (block 306).
Other operations can automatically move the flappers and legs as discussed above.
As shown in
The data 456 may include a look-up chart of different module part lists, configurations, run sequences, target products, covering material type, proximity sensor feedback, safety interlock circuits and the like 451 corresponding to particular or target products for one or more producers or module build types.
As will be appreciated by those of skill in the art, the operating system 452 may be any operating system suitable for use with a data processing system, such as OS/2, AIX, DOS, OS/390 or System390 from International Business Machines Corporation, Armonk, N.Y., Windows CE, Windows NT, Windows95, Windows98 or Windows2000 from Microsoft Corporation, Redmond, Wash., Unix or Linux or FreeBSD, Palm OS from Palm, Inc., Mac OS from Apple Computer, LabView, or proprietary operating systems. The I/O device drivers 458 typically include software routines accessed through the operating system 452 by the application programs 454 to communicate with devices such as I/O data port(s), data storage 456 and certain memory 414 components. The application programs 454 are illustrative of the programs that implement the various features of the data processing system and can include at least one application, which supports operations according to embodiments of the present invention. Finally, the data 456 represents the static and dynamic data used by the application programs 454, the operating system 452, the I/O device drivers 458, and other software programs that may reside in the memory 414.
While the present invention is illustrated, for example, with reference to the Module 450 being an application program in
The I/O data port can be used to transfer information between the data processing system, the product pusher, and the clipper mechanism or another computer system or a network (e.g., the Internet) or to other devices controlled by the processor. These components may be conventional components such as those used in many conventional data processing systems, which may be configured in accordance with the present invention to operate as described herein.
For example, certain embodiments of the present invention are directed to a computer program product for operating an automated clipped (netting) packaging apparatus so that the clipper mechanism operates from either a left or right hand side.
The computer program product can include: (a) computer readable program code that automatically controllably actuates a clipper mechanism to position a clipping apparatus in a clipping position in response to product pushed by the product pusher out of the product chute and covered in netting. In particular embodiments, the computer program product can also include one or more of: (a) computer readable program code that monitors a proximity sensor positioned to detect when a product is in position to be packaged and automatically controllably actuates the clipper and/or tray cylinder in response thereto; (b) computer readable program code that actuates a cutting tool actuation cylinder to controllably advance the cutting tool and automatically sever netting intermediate two clips thereon; (c) computer readable program code that supplies heat to the cutting tool; (d) computer readable program code that controls the actuation of a braking mechanism to advance the braking mechanism to contact the product chute and selectively apply pressure to netting thereat; and (e) computer readable program code that automatically controllably moves the flaps upstream, downstream and/or pivots the flaps out and/or in, in cooperation with the clipping mechanism.
While the present invention is illustrated, for example, with reference to particular divisions of programs, functions and memories, the present invention should not be construed as limited to such logical divisions. Thus, the present invention should not be construed as limited to the configuration of
The flowcharts and block diagrams of certain of the figures herein illustrate the architecture, functionality, and operation of possible implementations of the present invention. In this regard, each block in the flow charts or block diagrams represents a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that in some alternative implementations, the functions noted in the blocks may occur out of the order noted in the figures. For example, two blocks shown in succession may in fact be executed substantially concurrently or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.
The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. In the claims, means-plus-function clauses, where used, are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the appended claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.
This application claims priority to U.S. Provisional Patent Application Ser. No. 60/579,709 filed Jun. 15, 2004, the contents of which are hereby incorporated by reference as if recited in full herein.
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