Patent Application
20060104758
The present invention is directed to a method and apparatus for buffering a flow of stacks of objects, and more specifically, toward a method and apparatus for receiving a first number of stacks of discrete planar objects, such as frozen hamburger patties, from a stacking machine and presenting a second number of those stacks to a packing machine, especially when the first and second numbers are unequal.
Frozen hamburgers, chicken patties, sausage patties, and other disk-like food products typically are prepared by a manufacturer on one piece of equipment and then fed into a freezer. After leaving the freezer, they are screened by a metal detector, which detects contaminated patties, and then conveyed to a stacker. The stacker forms the patties into one or more stacks, and the finished stacks are then placed in cases. Because the stacks formed by some stackers can vary in height, and because the number of stacks formed simultaneously by a stacker may be greater than the number of stacks that will fit in a row in a case, the finished stacks are often removed from the stacker and loaded into cases by hand. This manual loading step is labor-intensive, and, due to the presence of a human element, highly variable.
The problem of forming uniform stacks of patties is addressed by the novel stacking machine disclosed in the co-pending application entitled “Method and Apparatus for Stacking Discrete Planar Objects” filed concurrently herewith and assigned to the assignee hereof. The disclosure of that application is hereby incorporated by reference. However, as with many prior art devices, the subject stacker simultaneously forms more stacks than will fit in one row of a typical case. For example, in a preferred embodiment, the subject stacker receives four rows of frozen patties from a conveyor belt and simultaneously forms four stacks of patties. Cases of patties, however, can often accommodate only three stacks of patties per row, or possibly five stacks or more.
This problem could be addressed by adjusting the stacking machine to form only three stacks of patties at a time, but the reduction from four rows to three rows represents a twenty-five percent decrease in efficiency. Human packers can also address this problem by packing stacks one at a time and positioning each stack as required in a given case. However, as mentioned above, it would be desirable to fully automate the stacking and packing processes to provide greater consistency and to reduce costs.
In addition, not all cases are packed in the same manner. Some cases may hold only two rows of patties, for example, and it would be useful to have a machine that could be rapidly adjusted to convert four incoming rows of stacks into two outgoing stacks, depending on the product being packaged, or even to accommodate cases that alternate between two stacks per row and three stacks per row. Ideally, the change would be software controlled or require no more than the push of button to make. And, while reducing the number of rows is the general problem faced by the industry, under some circumstances it may be desirable to present more stacks to a packing machine than are provided at one time by a stacker—for example, if the stacker forms four rows of stacks at a time and a certain case requires six stacks in a row. Finally, the machine should be able to function under conditions where the number of incoming rows is equal to the number of outgoing rows and to do so in an efficient manner.
These and other difficulties are addressed by the present invention which comprises a novel buffering device that receives a first plurality of stacks of objects from a stacking machine and presents a second number of stacks to a packing machine for removal, where the second number may be greater than, less than, or equal to the first number. The invention includes a plurality of trays or similar receptacles sized and shaped to accommodate the stacked objects, which receptacles are mounted on carriers that can be moved between a first location where the stacks are received from a loading device and a second location where the stacks are removed by an unloading device.
In a preferred embodiment, the invention comprises a carousel around which a belt rotates continuously in a path having two generally parallel linear sections connected by curved portions. Each carrier is attached to the belt by a clamp which engages the belt in a jaw-like manner on opposites sides thereof. The clamp is attached tightly enough to cause the receptacle to move with the belt when the path of the carrier is unobstructed, but loosely enough that the belt will slide through the clamp when the path of the carrier is blocked. In this manner, the position of the carriers can be controlled somewhat independently of the positions of the other carriers without the need to provide separate controllers for the clamps on each carrier.
The movement of the receptacles is controlled so that a first number of receptacles is always available when needed to receive a first number of incoming stacks at a first location. The receptacles are then released to a second location from which the stacks are removed in groups of a second number. When the second number is less than the first number, the stacks must be removed at a rate greater than the rate at which the stacks of patties arrive at the carousel, and full carriers are buffered at a location between the first and second locations. When the second number of carriers is greater than the first number, the full carriers are accumulated at the second location until a second number of carriers is present. When the first and second numbers are the same, the carries merely move around the carousel in equally sized groups. While such a buffer can be incorporated into a stacking or packing machine, in the preferred embodiment, it comprises a stand-alone device that is connected between a stacker and a packer, thus allowing greater flexibility for use with different types stacking and packing machines.
In a preferred embodiment, the device further includes sensors for detecting the presence of carriers at different points around the carousel. A proximity sensor mounted near the path of the carriers detects the carriers as they pass. The sensors are operably connected to stops that block the passage of carriers when the stops are in an extended or in a blocking position. Because the carriers are somewhat loosely connected to the drive belt, the drive belt continues to move through the clamp when a carrier is blocked. Other carriers being moved by the belt engage the stopped carrier, and are likewise stopped. When the stop is moved to a releasing position, the carriers that were blocked begin again to move with the belt. A controller connected to the stops controls them so that so that carriers are released from the first stop in groups of a first number and released from the second stop in groups of a second number, where the first number can be greater than, less than or equal to the second number. Alternately, additional sensors can be used to determine whether the carriers are full or empty. When additional sensors are used, the controller releases only full carriers from the first location, and releases only empty carriers from the second location. Thus, with either embodiment, empty carriers are stopped at the first location and filled with stacks of frozen hamburger patties. When the carriers are full, the controller releases the stop to allow the filled group of carriers to pass and the next empty carrier is stopped. The full carriers travel around the carousel until they reach the second stop, which moves into the blocking position to keep the full carriers from passing. The full carriers remain at this location until stacks are removed by a stack transfer mechanism, and empty carriers are then released to travel back to the first location.
In the preferred embodiment, the number of carriers is related to the maximum number of incoming or outgoing rows of patties in a certain way to minimize the number of carriers needed, and this reduces the amount of space occupied by the machine. Applicant has found, for example, that a buffer for use between a stacking machine that produces four rows of patties and a packaging machine that requires three rows of patties as input, needs eleven carriers. By limiting the number of carriers, the width of the buffer can be kept small and the resulting buffer need not be much greater than the width of the stacking machine.
It is therefore a principal object of the invention to provide an apparatus for receiving a first number of stacks of objects at an input location and presenting a second number of stacks of objects at an output location.
It is another object of the invention to provide a method of buffering the flow of stacks of objects between a stacking machine and a packing machine.
It is a further object of the invention to provide an apparatus for matching the output rate of a first machine to the input rate of a second machine.
It is still another object of the invention to provide a carousel having a plurality of selectively positionable receptacles for receiving a plurality of stacks from a first machine and presenting a plurality of stacks to a second machine.
It is still a further object of the present invention to provide a free-standing stack transfer device that receives a first number of stacks of objects at a first location and presents a second, smaller number of stacks of objects at a second location.
It is yet another object of the present invention to provide a free-standing stack transfer device that receives a first number of stacks of objects at a first location and presents a second, larger number of stacks of objects at a second location.
It is yet a further object of the present invention to provide a buffer device that can be configured to accommodate different numbers of incoming stacks and differing numbers of outgoing stacks.
In furtherance of these objects, a method for buffering a flow of stacks of objects from a first location presenting a first number of stacks to a second location adapted to receive a second number of stacks is provided that includes the steps of providing a frame between the first location and the second location which frame has a first position and a second position. A plurality of carriers each adapted to hold a single stack is associated with the frame and a first number of carriers are moved to the first position. The first number of stacks are transferred from the first location to the first number of carriers at the first position, and then the first number of filled carriers at the first position are moved toward the second position. Whenever at least a second number of filled carriers are present at the second location, the stacks from the second number of filled carriers at the second position are removed to the second location. Lastly, empty carriers are returned from the second position toward the first position.
Another aspect of the invention comprises a system for buffering a flow of stacks between a first location and a second location that includes a frame having a first position with an exit end proximate the first location and a second position with an exit end proximate the second location and a drive. A plurality of carriers is supported by the frame and connected to the drive. The device further includes a first stop at the first position exit end, a second stop at the second position exit end, and a controller for actuating the first stop to allow carriers to pass the first location exit end in groups of a first number and for actuating the second stop to allow carriers to pass the second location exit end in groups of a second number.
A further aspect of the invention involves a method for receiving a first number of stacks of discrete objects from a stacking machine and presenting a second number of the received stacks for removal by a stack transfer machine. The method requires a frame having a periphery, a first location on the periphery, and a second location on the periphery, and a drive on the frame. A plurality of carriers adapted to hold a single stack are mounted on the frame and connected to the drive. A first sensor is provided for counting the number of carriers passing a first point and a second sensor is provided for counting the number of carriers passing a second point. A first stop is provided near the first point for preventing empty carriers from passing the first stop, and one stack is received in each of the first number of carriers at the first location. The first number of carriers are released from the first stop, but stopped at a second location by a second stop near the second point that prevents carriers from passing the second location. A second number of stacks is removed from the first number of carriers at the second location, and the second number of carriers are released by the second stop and moved toward the first location.
Yet another aspect of the invention comprises a buffer including a support frame, a platform having a periphery mounted on the support frame, and a guide extending around the periphery. A drive belt is mounted adjacent the platform along the periphery, and a drive is operatively coupled to the drive belt. A plurality of carriers is supported by the platform, each including a first member engaging the guide and a second member engaging the drive belt such that movement of the drive belt moves the carriers about the periphery of the platform. A first sensor is mounted at a first location for counting the number of carriers passing the first location, and at least one stop is provided that can be shifted between a first position in a path of travel of the carriers around the platform and a second position outside the path of travel of the carriers around the platform. A controller operatively coupled to the first sensor controls the position of the at least one stop.
A further aspect of the invention comprises a carrier having a trolley adapted to support a tray for holding stacks of objects. The trolley has a body with a first side and a second side and includes a first wall portion having an end and a second wall portion extending from the end of the first wall portion at an obtuse angle. An axle extends from the first side of the second wall portion and a wheel is rotatably supported by the second wall portion axle. A clamp is mounted on the first side of the first wall portion.
These and other objects of the invention will become apparent from a reading and understanding of the following detailed description of the invention together with the following drawings of which:
a-h are top plan views of the buffer of
Referring now to the drawings, wherein the showings are for purposes of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting same,
Drive 14 includes a motor 26 mounted on motor support 24 and operably connected to a drive gear 28 which turns a continuous drive belt 30 about a plurality of flanged wheels, including a first wheel 32 and a second wheel 34. First and second wheels 32 and 34 each include a center opening 36 having a notch 38 for receiving a splined shaft. Two splined shafts 40 extend from center openings 36 upwardly through first and second openings 22 in the frame upper support 20.
A bottom plate 42 having first and second openings 44, as best shown in
A top plate 58 having first and second openings 60, a peripheral edge 62 and a raised rail 64 running around the peripheral edge is mounted over bottom plate 42 and spaced apart therefrom by spacers 66, with openings 58 positioned to receive splined shafts 40. Bearings 68 are mounted on top plate 56 to rotatably secure the ends of shafts 40. Thus, motor 26 turns drive gear 28 and causes drive belt 30 to move about first wheel 32 and second wheel 34, which in turn causes splined shafts 40 and wheels 50 mounted thereon to rotate and drive drive belt 56 about a continuous path between bottom plate 42 and top plate 58. Drive belt 56 preferably has a diameter greater than the width of peripheral grooves 54, so that the belt only contacts the wheels about a small portion, less than 180 degrees, of the belt's circumference.
A clamp 116 is mounted on body lower portion 88 between guide wheels 110 and notched wheel 102, and includes an upper clamp member 118 pivotably supported on lower body portion 88 by a shaft 120, and a lower clamp member 122 pivotably supported on a shaft 124 extending between lower body portion 88 and small wall 96. Both the upper and lower clamp members are coated with, or preferably formed from, a low-friction, wear resistant material, such as UHMW polyurethane. The angular relationship between the upper and lower clamp members, and hence the distance separating the ends of the clamp members, can be adjusted by pivoting the upper clamp member and fixing it in place with fastener 126.
The mounting of carriers 16 on the upper and lower plates is best shown in
The upper and lower members 118 and 122, respectively, of clamp 116 are attached to drive belt 56 by placing the belt between the members and clamping the upper member in place so that a small force is exerted against the belt by the clamp members. The force must be great enough that friction between the clamp 116 and the belt 56 will keep the trolleys 72 fixed with respect to the belt when the path of the trolleys 72 is clear. The force also must be small enough that the frictional force between the belt 56 and the clamp 116 can be overcome by the drive motor to cause the belt to slip through the clamp when movement of one or more of the trolleys 72 is blocked by a stop.
A first solenoid-actuated stop 128 is mounted on frame 12 with a trolley-engaging portion 130 shiftable between a first, release position, shown in
The shifting of the stops between stopping and releasing positions is controlled by a controller 136, operably coupled to sensors 132 and 133 mounted on frame 12 below the tray bottom walls 94, as best shown in
As best shown in
In a second embodiment, sensors 132 and 133 are used both to count the number of trays passing thereby and to detect whether the tray adjacent the sensor is full or empty, based upon whether slot 76 is blocked. The controller 136 monitors the status of the trays 70 passing over each of the sensors, and causes the first stop to shift to its stop position whenever an empty tray is detected and to shift to its release position when a full tray is detected. Similarly, controller shifts the second stop into the blocking position when a full tray is detected by sensor 133 and into the releasing position when actuated in an opposite manner, that is, set to prevent the passage of full trays while allowing empty trays to pass.
In operation, motor 26 drives drive belt 30, turning first and second wheels 32, 34 and rotating shafts 40 and wheels 52 mounted thereon. This in turn causes drive belt 56 to move continuously about the periphery of the buffer between plates 42 and 58. The carrier trolleys 72 are clamped to belt 56 tightly enough that they are pulled about the peripheries of the upper and lower plates by the movement of the belt. The trolleys are guided by the engagement of trolley wheels 102 with upper plate raised rail 64 and the engagement of guide wheels 110, 112 and 114 with the peripheral portion 46 of lower plate 42. Stops 128 and 134 are selectively moved into and out of the path of travel of the trolleys and, when positioned in a stopping position, prevent trolleys from moving past the stops. The motor 26 continues to operate at a continuous speed, however, sliding, belt 56 through clamps 116 even when all trolleys are prevented from moving by the positions of the stops. The urethane from which belt 56 is formed is sufficiently wear resistant that it provides reliable operation even after many hours of continuous use. And, as the relative positions of clamp upper member 118 and lower member 122 are adjustable, the clamps can be repositioned in the event that the diameter of belt 56 decreases slightly after a long period of use to maintain the proper pressure on the belt.
The operation of the subject system will now be described with particular reference to
As shown in
As shown in
The above invention has been described above in terms of a preferred embodiment. However, obvious changes and additions to the invention will become apparent to those skilled in the relevant arts upon a reading of the foregoing disclosure. For example, while the trolleys are described as being connected to a urethane belt in a manner that allows the belt to slide through the trolleys when the motion of a trolley is blocked, a plurality of separately controllable clamps could be used on each carrier to independently control whether a given carrier is connected to a drive belt. Additional sensors could also be added to provide additional information on the position and status of carriers as they travel around the buffer. And, while the buffer has been described in terms of reducing a flow of four incoming stacks of patties to three outgoing stacks of patties, the number of incoming patties could be changed, the number of outgoing patty stacks could be greater than the number of incoming stacks or the incoming and outgoing stacks could be equal in number without departing from the scope of this invention. It is intended that all such obvious changes and additions be included within the scope of this invention to the extent that they are defined by the several claims appended hereto.
The present application claims the benefit of U.S. provisional patent application Ser. No. 60/290,342, filed May 14, 2001, the disclosure of which is incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60290342 | May 2001 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10143860 | May 2002 | US |
| Child | 11256933 | Oct 2005 | US |
