TECHNICAL FIELD
The present application relates to packaging machines and more particularly to a packaging machine including a system for use in counting containers.
BACKGROUND
Cups are typically packaged for retail or commercial sale as nested stacks of cups. For example, it is not unusual to provide cups nested in single or multiple stacks such as two stacks (e.g., of 10 cups each for a total of 20 cups) within a plastic bag for retail sale, for example, in a grocery store, supermarket, gas station, etc.
Automated processes and machines have been provided to sort and arrange the containers into the nested stacks for packaging. Additionally, systems have been proposed for counting cups, usually relying on a pronounced lip or flange that can easily be detected, for example using a mechanical finger. Cups having relatively broad lips with somewhat constant outer diameters can be difficult to accurately count. What is needed is a system and apparatus for counting containers of various configurations.
SUMMARY
In an aspect, a container packaging machine includes a container handling and counting apparatus including an upstream accumulation portion and a downstream container separation and counting portion. The containers having a relatively tightly nested configuration as the containers move through the accumulation portion and having a relatively loosely nested configuration as the containers move through the container separation and counting portion where separation of the containers form distinct peaks and valleys for use in counting the containers.
The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of a container handling and counting apparatus;
FIG. 2 is a side, detail view of the container handling apparatus of FIG. 1 showing an interface between an upstream accumulation portion and a downstream separation and counting portion;
FIG. 3 is a side, detail view of the container handling apparatus of FIG. 1 showing a container being separated from an adjacent container using a conveyor system of the downstream separation and counting portion;
FIG. 4 is side, detail view of the container handling apparatus of FIG. 1 showing formation of a loosely nested stack of containers using the conveyor system of the downstream separation and counting portion;
FIG. 5 is a side, detail view of the container handling apparatus of FIG. 1 showing the loosely nested stack of containers passing by a counting sensor for use in counting containers as they pass thereby; and
FIG. 6 is a side, detail view of the container handling apparatus of FIG. 1 feeding containers onto a packaging portion where the containers are again tightly nested and moved downstream.
DETAILED DESCRIPTION
Referring to FIG. 1, a container handling and counting apparatus 10 includes an accumulation portion 12 and a container separation and counting portion 14. Accumulation portion 12 may receive containers 16 from a source such as a container infeed (not shown) that provides a container path to the accumulation portion where the containers 16 are located for separating and counting operations.
Accumulation portion 12 includes an upstream conveyor system 18 that includes a first conveyor belt assembly 20 and an opposing conveyor belt assembly 22 that operate in unison to deliver the containers along a path toward the container separation and counting portion 14. The conveyor belt assemblies 20 and 22 each include belt members 24 that are driven by pulleys 26. In some embodiments, the belt members 24 are formed of an elastic material to apply a low amount of force to the containers 16. The pulleys 26 are operatively connected to a drive system 28 that drives the conveyor belt assemblies 20 and 22. In some embodiments, a controller (not shown) is used to control operation of the drive system.
The container and separation portion 14 includes a downstream conveyor system 30 that includes a first conveyor belt assembly 32 and an opposing conveyor belt assembly 34 that operate in unison to deliver the containers 16 along a path toward a downstream accumulation portion 52 (FIG. 6). The conveyor belt assemblies 32 and 34 each include belt members 36 that are driven by pulleys 38. As above, the belt members 36 may be formed of an elastic material to apply a low amount of force to the containers 16. The pulleys 38 are operatively connected to a drive system 40 that drives the conveyor belt assemblies 32 and 34 at a different velocity than that of the conveyor belt assemblies 20 and 22. In some embodiments, the controller (not shown) is used to control operation of the drive system 40.
Referring to FIG. 2, the containers 16 are typically directed from the accumulation portion 12 toward the container separation and counting portion 14 as a continuous stack 30 of containers 16, each container being nested with an adjacent container. The stack of containers 30 are driven at a first velocity using the upstream conveyor system 18 until each container 16 reaches the container separation and counting portion 14.
Referring now to FIG. 3, as noted above, the downstream conveyor system 30 operates at a velocity that is different that that of the upstream conveyor system 18. In this embodiment, the downstream conveyor system 30 operates at a higher velocity than the upstream conveyor system 18. As can be seen by FIG. 3, this difference in velocity provides separation between container 16a, which has been engaged between conveyor belt assemblies 32 and 34, and adjacent container 16b, which has yet to be engaged by conveyor belt assemblies 32 and 34.
Referring to FIG. 4, as each container 16 is initially engaged by the downstream conveyor system 30, it separates from its adjacent, upstream container until the adjacent, upstream container is also engaged by the downstream conveyor system. Once adjacent containers 16 are both engaged by the downstream conveyor system 30, the separation between the adjacent containers remains substantially unchanged as the containers move along the path within the container separation and counting portion 14.
In some embodiments, it is preferable that the containers 16 remain nested to (albeit separated slightly from) adjacent containers as they move through the container separation and counting portion 14. Maintaining a loosely nested configuration can facilitate downstream tightening of the nest of containers. In some embodiments, the downstream conveyor system 30 may be no more than about 7 percent, no more than 6 percent, no more than 5 percent, no more than 4 percent, between about 3 percent and about 7 percent, between about 4 percent and about 6 percent, such as about 5 percent faster than the velocity of the upstream conveyor system 18 in order to maintain nesting of the stack of containers 16. As can be appreciated, the container handling and counting apparatus 10 moves containers 16 having a first, tightly nested configuration through the accumulation portion 12 and having a second, loosely nested configuration through the container separation and counting portion. As can be seen by FIG. 4, once separated, the nest of containers 16 has relatively well-defined peaks 44 and valleys 46 that can be used in counting the containers.
Referring to FIG. 5, a sensor assembly 48 is located adjacent the container path so as to detect peaks 44 that are formed by lips 50 of the containers 16. In some embodiments, the sensor assembly 48 may be an optical detector system or other no-touch detector system. In the illustrated embodiment, the sensor assembly 48 includes both a counting eye 49 that is located between verification eyes 51 and 53, which are used to verify counts detected by the counting eye. The sensor assembly 48 is connected to a controller that tracks the number of containers 16 detected by the sensor assembly.
Referring to FIG. 6, the counted containers 16 are fed onto a second accumulation portion 52 where friction is used to place the containers in their tightly nested configuration. The second accumulation portion 52 includes a conveyor system 54 that may be, for example, stopped or moving relatively slowly as the counted containers 16 are fed thereon. In some embodiments, the second accumulation portion 52 may be a packaging station where the counted containers 16 are to be packaged as a tightly nested stack having a counted number of containers. Once a pre-selected number of containers 16 have been counted using the sensor assembly, the conveyor system 54 may quickly accelerate, separating a tightly stacked portion 56 of containers 16 from an adjacent, loosely stacked portion 58 of containers. In some embodiments, one or both of the conveyor systems 18 and 30 may stop or slow down once a pre-selected number of containers 16 are counted.
As can be appreciated, the above-described container handling and counting apparatus 10 can provide for reliable counting of containers for a packaging operation. The container handling and counting apparatus 10 may be particularly useful in packaging cups having relatively broad lips of substantially constant outer diameter, such as is common with Styrofoam cups. By loosening the nested cups, distinct peaks and valleys can be formed which can be used by, for example, an optical cup detector system to count the cups.
It is to be clearly understood that the above description is intended by way of illustration and example only and is not intended to be taken by way of limitation, and that changes and modifications are possible.
Patent Application
20080184673
