PRODUCT PACKAGING APPARATUS

STATEMENT REGARDING GOVERNMENT SUPPORT

None.

FIELD OF THE INVENTION

The present invention relates to apparatus and methods for automated loading different items into a container in a desired arrangement, and more specifically, apparatus and methods for automated packaging of varieties of bottled or canned beverages into beverage containers in a desired arrangement.

BACKGROUND—INTRODUCTION

Automated bottle and can packaging has been around for decades. These products are often delivered in 12-pack or 24-pack containers. Numerous machines are used that package bottles or cans from a bottling line into a container. Most rely on conveyor belts to moving product from an origination source, such as the bottling facility or containers, to a packaging unit. Typically, the packaging unit allows a set number of products to flow from a conveyor belt along a defined path and into a container, relocates the filled container for sealing, and positions an empty container at the conveyor belt. Such packaging units may be adequate to handle a single type of product, but are inadequate when packaging multiple types of product (e.g., different flavor beverages) in a single container, particularly if the arrangement or configuration of the products in the container is important.

Some packaging units use grasping mechanisms to pick up one or more bottles from a conveyor for transition to a packaging unit. In-line feeds send the products down one or more lanes toward counting and packaging systems. The counting system allows a predetermined number of products to pass a certain point along the conveyor, then applies a brake to temporarily halt the product flow. During the brake cycle, the packaging system directs the predetermined number of products into the packaging unit for packaging into a container, such as a carton. The packaged product then proceeds downstream closing units (e.g., adhesives, tape, etc.). These types of packaging units tend to rely on static grasping locations and configurations, and are either limited in the number of types of product they can package, limited in terms of packaging speed, or both. These types of packaging units are also inadequate when packaging multiple types of product in a single container, and especially if the arrangement or configuration of the products in the container is important.

Given the rising popularity of variety packs—single containers having more than one type of product—others have attempted to develop product packaging units that can package two or more types of product in the same container. The typical solution is to rely on multiple conveyor belts, each belt supplying a particular type of product. In packaging systems having multiple conveyor belt feeds, the ultimate configuration of the packaged products is limited by the number of conveyor belts. Further, these systems are bulky, and therefore expensive, difficult to reconfigure, and typically can achieve minimal product configurations (e.g., simple rows of product).

Conventional product packaging units are thus limited at least in terms of cost and size, the number of product types they can package, the arrangement or configuration of the packaged products, and the ability for simple re-configuration to achieve different packaging results.

What is needed is a solution for rapidly packaging and sealing packages containing various numbers and configurations of products in each package. What is further needed is a solution that may be easily reconfigured for use with different numbers and configurations.

BRIEF SUMMARY

Beverage makers, including breweries, typically produce and package one flavor or type of beverage at a time, due to the limitations on automated packaging technology. Although some beverage makers produce multiple varieties, those varieties are normally packaged separately. Given the rise of micro-breweries and craft beer makers, the market demand for variety packages is steadily increasing. Beverage makers and distributors are manually repackaging the separate beverage types into variety packages that contain two or more varieties. The result is the creation of the 12-unit or 24-unit variety pack, sometimes referred to as a “family pack.” As the number and variations of variety packs increases, manual repackaging becomes uneconomic, and large-scale variety pack manufacturing is unattainable.

The present approach enables a beverage maker or distributor to repack several different varieties of beverages into 12-unit and/or 24-unit variety packs. Instead of relying on manual repackaging, the present approach provides automated processes producing packed and sealed variety packs, including configuring the variety packs generate the desired distribution and layout of beverage varieties. As a result, the present approach reduces the cost of labor and increases the throughput of variety packs.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an example container for a 24-count package.

FIG. 2 shows an example of a 4-type variety pack in a 24-count package.

FIG. 3 shows a product packaging configuration achievable by embodiments of the present approach.

FIG. 4 illustrates a side view of an embodiment of a rotating head assembly.

FIG. 5 illustrates a product configuration following rotation.

FIG. 6 shows a schematic of an embodiment of a product packaging process using the present approach.

FIGS. 7A and 7B shows a schematic of an embodiment for packaging multiple types of a product in a desired configuration.

FIG. 8 illustrates an embodiment of a rotating head assembly unit.

FIGS. 9A-9C show various elements of an embodiment of a case flap guidance system.

FIGS. 10A-10E shows various demonstrative package configurations that may be processed according to the present approach.

FIG. 11 shows a perspective view of an embodiment of a rotating head assembly according to an embodiment of the present approach.

FIG. 12 shows a side view of an embodiment of a rotating head assembly according to an embodiment of the present approach.

FIG. 13 shows a perspective view of an embodiment of a rotating head assembly in an expanded configuration according to an embodiment of the present approach.

FIG. 14 shows a side view of an embodiment of a rotating head assembly in an expanded configuration according to an embodiment of the present approach.

FIG. 15 shows a perspective view of an embodiment of a rotating head assembly in a rotated configuration according to an embodiment of the present approach.

FIG. 16 shows a side view of an embodiment of a rotating head assembly in a rotated configuration according to an embodiment of the present approach.

FIG. 17 shows an example of a packing unit configured for a specific packing configuration according to an embodiment of the present approach.

FIG. 18 shows an example of a packing unit configured for another packing configuration according to an embodiment of the present approach.

FIG. 19 shows an example of a packing unit configured for another packing configuration according to an embodiment of the present approach.

FIGS. 20-26 show different examples of packing configurations achievable through embodiments of the present approach.

DESCRIPTION

Described herein are embodiments of apparatus and methods for packaging multiple varieties of a product, such as a bottled or canned beverage, into a container and in a particular arrangement or configuration. Although embodiments described herein relate to bottled or canned beverages, it should be appreciated that embodiments may be useful for other types of products that have different varieties and require packaging in desired configurations.

When it comes to multiple-variety beverage packages, traditional bottle and can packaging units are limited to basic packaging configurations. For example, a 12-pack or 24-pack case may include randomized contents or linear arrangements. Moreover, traditional bottle and can packaging units are not easily configured for different configurations of products in the container. The only other option has been hand-packaging, which is generally expensive and slow. Embodiments of the present approach overcome such limitations and more, and permit numerous packaging configurations for more than one product variety in the same package, and may be easily modified to produce different packaging configurations.

The present approach provides systems and methods for packaging products, such as bottles and cans, in various packaging configurations. The products to be packaged may include multiple varieties of a product (e.g., different flavors of a bottled beverage), such that the desired packaging configuration includes a predetermined number of each variety (e.g., four of one variety, and four pairs of different varieties) and a predetermined location of each individual product within the package. Embodiments of the present approach may be configured to produce a wide variety of packaging configurations. Embodiments of the present approach may include one or more in-line feed lines. A feed line may be, for example, a conveyor system, delivering a linear array of a product. Embodiments may include multiple feed lines, and each feed line may deliver a particular variety of product. For example, an embodiment may include four feed lines, each line delivering a unique product variety. In some embodiments, more than one feed line may deliver the same unique product variety. For example, an embodiment may include six feed lines, two of which deliver the same product variety, and four of which deliver unique product varieties. The particular number and configuration of feed lines may be determined depending on the desired packaging configuration, but it should be appreciated than embodiments may include multiple feed lines that may be adjusted for a particular packaging configuration. For example, some feed lines available in an embodiment may not be used to achieve a particular packaging configuration. As another example, some feed lines may be unused to achieve a particular packaging configuration. The feed lines deliver product in an initial configuration. One or more of the feed lines may direct products to a rotating head assembly. As described herein, the rotating head assembly may selectively rotate products to produce a desired packaging configuration. The rotation may be used to rotate one or more linear arrays of one or more product varieties, such that the resulting product varieties have a new configuration relative to the initial configuration. It should be appreciated the rotating head assembly does not have to rotate to achieve certain packaging configurations. For example, if the desired packaging configuration is the same as the initial configuration, then the rotating head assembly need not rotate any products. It should also be appreciated that one or more feed lines may be diverted around the rotating head assembly, such that one or more product varieties retain their initial configuration. Achievable packaging configurations may be determined by the number of feed lines, the number of product varieties, the total number of products in a single package, and the product varieties that rotate.

Many of the embodiments described herein relate to packaging bottles or cans, such as beverage varieties. For example, the present approach may be used to package multiple varieties of beer into desired packaging configurations. It should be appreciated, however, that the present approach may be applied to packaging other products. In the case of packaging bottles and cans, the packaging normally calls for either six, twelve, or twenty-four products in a package. Depending on the number of varieties, and the count of each variety in a package, a number of packaging configurations may be achieved. Additionally, embodiments of the present approach may be configured to pack more than one packages per packaging cycle. For example, some embodiments may pack four six-pack packages in a single cycle. Some embodiments may be configured for adjustment to package different product counts, for example, an embodiment may be adjustable between eight six-pack packages, four twelve-pack packages, or two twenty-four-pack packages. Those of skill in the art should appreciate the flexibility achievable by the present approach.

Conventional packaging devices are limited to in-line configurations. For example, product varieties are fed in linear arrays into a packaging unit. Conventional machine packaging units are therefore limited to packaging configurations based on the feed line initial configurations. The present approach may package based on feed line initial configurations, but may also rotate one or more linear arrays of product from one or more feed lines to achieve different packaging configurations. For example, in one embodiment five different flavors A, B, C, D, and E, may be packaged in two separate twelve-pack packages, such that each twelve-pack package includes four variety A products, and two each of varieties B, C, D, and E. In this example, linear arrays of products B, C, D, and E (e.g., linear arrays containing four each of B, C, D, and E) may be rotated by a rotating head assembly, while two separate linear arrays of product A (e.g., two linear arrays each containing four of variety A) are diverted around the rotating head assembly. Following rotation, the desired number of each variety is in the desired configuration for packaging into two separate twelve-pack packages (e.g., each twelve-pack package contains 4×A, 2×B, 2×C, 2×D, and 2×E). Such a packaging configuration is not achievable by contemporary packaging machinery because of the limitations of in-line feed lines and the need for fast cycle times, and manual packaging would be extremely inefficient. Other demonstrative packaging configurations are described herein, but it should be appreciated that numerous packaging configurations may be achieved.

FIG. 1 shows an example 24-pack case 100. Case 100 is configured to contain 24 items 101 of one or more products, such as 24 bottles or cans of beverage. Case 100 may include one or more top flaps 103 and one or more side flaps 105, depending on the particular case.

FIG. 2 shows an example of a 4-type variety pack in a 24-count package such as shown in FIG. 1. The configuration of the types 1, 2, 3, and 4 is linear, and there are an equal number (6) of each variety in this configuration. This basic configuration represents the typical capability of traditional packaging units, and is severely limited in terms of flexibility in the configuration, and ease of adjustment, to say the least.

FIG. 3 shows an example of a more complicated configuration that embodiments of the present approach can achieve. The package 300 in FIG. 3 includes two 12-pack containers 301 and 303, though it should be appreciated that package 300 could be a single 24-pack. Each 12-pack container includes four units of product A, and two units each of products B, C, D, and E. This configuration is increasingly popular in the beverage industry, in which the producer desires a variety pack with more of a particular variety (e.g., a traditional or well-known beverage), and samples of alternatives or new varieties (e.g., seasonal beverages).

Embodiments of the present approach achieve complicated product configurations through the use of one or more rotating head assemblies. A rotating head assembly may capture a specific number of products of specific types in a first configuration, and selectively rotate those products to a second configuration. The second configuration may be joined with one or more additional configurations to result in the desired configuration of products. In some embodiments, each type of product begins in a separate container, such as a pallet. For example, in a process packaging five varieties of bottled beer, each variety of bottled beer may arrive at the packaging location in a separate container. Each container may have a conveyor belt specific to that container, removing product from each container and moving the product down the respective conveyor belt and toward a packaging unit.

FIG. 4 illustrates an embodiment of a rotating head assembly 400 receiving a plurality of feed lines 407. This embodiment includes three rotating head units 402A, 402B, and 402C. A plurality of bottles B, C, D, and E (viewed from above, to show a first or initial configuration) are positioned at a loading location 401 in proximity to the rotating head units. In this embodiment, the plurality of the bottles includes four types (B, C, D, and E), and arrives to loading position 401 from a conveyor belt system 407. Each type arrives in its own feed line. Line brakes 405 halt the flow of incoming bottles from conveyor belt system 407 after a predetermined number are present at loading location 401. In this illustration, 48 bottles are present in three 16-count groups 403A-403C, and arrive in a linear arrangement (e.g., type B bottles are on the same conveyor belt or feed line, type C bottles are on the same conveyor belt or feed line, etc.). In other words, each row of four bottles has the same variety, and each column has one of each variety B, C, D, and E. Rotating head unit 402A may rotate subset of bottles 403A, rotating head unit 402B may rotate subset of bottles 403B, and rotating head unit 402C may rotate subset of bottles 403C. It should be appreciated that other embodiments may employ different numbers of rotating heads, conveyor belts, product types, and the like. As will be described herein, rotating head assembly 400 rotates the plurality of bottles from the first configuration to a second configuration, to achieve the desired configuration.

In an exemplar embodiment described herein, the desired configuration included five unique product types packed into a 24-unit container, and may be, for example, two 12-unit containers in a 24-unit container tray. In this embodiment, the product was bottled beer, and the unique types included varieties A, B, C, D, and E.

In this embodiment, six pallet loads of product were stationed next to unload conveyor belts. Stations 1 and 6 contained variety A, station 2 contained variety B, station 3 contained variety C, station 4 contained variety D, and station 5 contained variety E. Each station had an associated conveyor belt, or lane on a conveyor belt.

The process started with unloading each container onto the respective conveyor belt. Unloading may be accomplished manually or, in some embodiments, may be automated with conventional machinery. The conveyor belts travel in parallel toward a case packer, in the same orientation as the initial pallets (A-B-C-D-E-A). Thus, the two outside conveyor belts transported variety A. In this embodiment, due to the desired configuration of the packed product, the two outside conveyor belts transported variety A directly to the case packer, while the conveyor belts transporting varieties B, C, D, and E proceed to a line brake at the end of the unload conveyors leading to the rotating head clamp assembly.

Upon releasing bottles from the line break to the rotating head clamp assembly, the rotating head clamp assembly is in what this disclosure references as the initial position. At the line brake, varieties B, C, D, and E were released into a rotating clamp head assembly. Because of the desired configuration, the rotating clamp head assembly in this embodiment included three rotating head units. Each rotating head unit was configured for clasping or gripping and rotating 16 bottles, and thus each cycle of the process involved 48 bottles. Because the conveyor flow rate of each variety B through E was similar, each rotating head unit clasped 4 bottles of each of the B through E varieties, such that each row of four bottles had the same variety, and each column had one of each variety. Once each rotating head unit received 16 bottles, the line brake dropped to momentarily stop the flow of bottles. At this point, clamp cylinders in each rotating head unit actuated to clamp or secure each row of bottles in the rotating clamp head. It should be appreciated that other embodiments may clamp or secure bottles in different manners.

In this embodiment, each rotating clamp head then expand both internally and separately to create the room needed for each rotating clamp head to individually rotate. There are three Rotate Clamp Heads for cans and three for bottles in this embodiment. Each clamp head for the bottles (5 Flavor pack using the Rotate Head) contain 16 bottles. When the bottles enter there are four lanes, one containing flavor 2, one for flavor 3, one for flavor 4, and one for flavor five. The line brakes open and all three heads are filled with four rows, one of each flavor in line. Once fully loaded, the clamp cylinders on the side of each clamp head extend and clamp the four rows of bottles in the heads. Then, three pairs of expansion cylinders mounted above the clamp cylinders extend to create a separation between each of the three clamp heads. This provides clearance for the three heads to then rotate and shift to the packer loading conveyor. The clamp cylinders are then retracted to release the three 16-bottle groups. Next, the head raises and, once it is high enough to clear the bottles, the packer conveyor MatTop chain starts up slowly so the bottles do not fall over. The conveyor then accelerates and transfers them to the packer lanes. During this process the three clamp heads rotate back to their load position, lower and retract back together and move back up to the line brake ready for the next load of bottles. Of course, other embodiments may include adequate space between the rotating clamp heads to provide rotation space. Each rotating clamp head then rotated 90 degrees, such that each row had one bottle of each variety, and each column had four bottles of the same variety. The rotation serves to produce the desired configuration. In this embodiment, the head assembly then transferred from the initial position to about 90 degrees across the conveyor, while the heads are rotating, and stops at a position in line with the conveyor lanes for the case packer. It should be appreciated that the layout of the head unit relative to the case packer may vary in other embodiments, such that the heads merely rotate to change the configuration from a first configuration to a second configuration.

FIG. 5 illustrates a product configuration following rotation, also referred to as a rotated configuration. In this embodiment, rotating head assembly 500 has already moved and rotated plurality of bottles from conveyor belt 505 to downstream conveyor 507. In this embodiment, each rotating head unit 402A, 402B, and 402C independently rotated 16 bottles by 90 degrees, such that bottle groups 501A, 501B, and 501C are in a second configuration or a desired packing configuration (that may also include products diverted from the rotating head assembly unit and not shown in this drawing). In particular, each row in the second configuration shown in this embodiment has one bottle of each variety B, C, D, and E, and each column had four bottles of the same variety. The plurality of bottles, now in a second configuration, may continue along conveyor belt 507 towards a packaging unit. As described below, conveyor belt 507 may join with other conveyor belts to add product to bottle groups 501A, 501B, and 501C, and thereby complete the desired configuration.

The rotating head units then released the bottles and elevate to allow the bottles to continue to the packaging unit. At this point, the bottles are in a second configuration. In one embodiment, the rotating head units elevate through 12″ stroke pneumatic cylinders, though it should be appreciated that other mechanical devices may be used to move the rotating head units and allow the product to continue in the process. The rotating head units then returned to the initial position, while the bottle conveyor belt transferred the bottles in the second configuration to the case packer. In one embodiment, the post-rotation conveyor belt used a variable frequency drive motor to transfer the bottles into the lanes of the case packer, thereby accelerating the belt speed at a controlled rate. The conveyor belts transporting varieties B, C, D, and E, now in the second configuration, join with the conveyor belts transporting variety A, toward the case packer. Because the desired configuration included 8 bottles of variety A on the outside rows of the container, and the second configuration of varieties B, C, D, and E in the inside rows of the container, the configuration of the product moving to the packaging unit is thus in the desired configuration. The packaging unit places the product into the package in the desired configuration, and seals the package as appropriate. The process repeated continuously for the entire batch of product in the initial pallets.

It should be appreciated by those skilled in the art that numerous desired configurations may be achieved through simple adjustments to the embodiment as described. For example, the number of varieties, the placement of initial containers, and the counts in the various configurations, may be modified to provide the desired configuration.

FIG. 6 is a schematic of an embodiment of a process using the present approach. Process 600 separates and prepares incoming products 601 for packaging pursuant to a desired configuration. In this embodiment, incoming products 601 include five types of products A, B, C, D, and E. Due to the desired configuration, product type A is conveyed on conveyor belts 603A and 603B around the loading location 609, while product types B, C, D, and E proceed through line breaks 607 to loading location 609. Line breaks 607 may be configured to allow a predetermined number of products from incoming feed lines 605 to the rotating head assembly loading location 609. After a predetermined number of product are present at loading location 609, rotating head assembly 611 rotates all of the product presents at loading location 609, in three separate 16-count groups. In this embodiment, each of rotating heads 613A, 613B, and 613C rotates sixteen products, such that each set of sixteen products is changed from a first configuration to a second or rotated configuration. Following rotation, products continue downstream at conveyors 615 and join with any diverted lines 603A and 603B, thereby producing the desired packing configuration downstream and traveling towards a packing location (not shown in this view). It should be appreciated that variations in feeds, products rotated, products diverted, and desired packaging configurations are feasible without departing from the present approach.

FIGS. 7A and 7B show schematics of an embodiment for packaging multiple types of a product in a desired configuration. In particular, this embodiment shows a process 700 for packaging five different beverage types (e.g., varieties of bottled or canned beverages) in a 12- or 24-count container. The initial pallets 701 provide the different products A through E, and may be arranged as needed to generate both the initial configuration of products and the desired configuration. In some embodiments, packing containers may be recycled along conveyor 711 and re-used at the packing location 707. After rotation at rotating head assembly 703, the product in the second configuration are conveyed along conveyor belts 706 toward a packaging unit 707. Product enters loading location 702 in a first configuration, and may be re-configured to a second configuration at rotating head assembly 703. For some desired configurations, certain number of products may circumvent loading location 702 through diverting conveyor belts 705A and 705B. Rotated products exit the loading location 702 and rejoin any circumvented products at conveyor belts 706 and proceed to packaging unit 707. Packed units may proceed to downstream package sealing stage 709.

FIG. 7B shows a side view of packing location 707. Some embodiments may include height changes, as shown in FIG. 7B. Loading location 702 feeds products in the desired packaging configuration towards conveyor belts 706, which direct products towards drop packer 707. Drop packer 707 guides product in the desired packaging configuration into dropping unit 707a, which receives product packages (not shown) at the desired height level along conveyor 709a. Reused containers may be loaded in position through conveyor 711. It should be appreciated that variations may be made without departing from the present approach.

FIG. 8 illustrates an embodiment of a rotating head assembly unit, in both a closed position 800, and an expanded position 801 to allow individual head units to rotate without contacting other head units. Initially, each individual clamp head works in this embodiment is composed of ¼″ thick Kydex Plastic lane guides mounted on ½″ diameter stainless steel shafts, separated by a series of clamp collars and springs to set them at the their exact loading locations within their clamp head for each lane of bottles/cans. Additionally, each of the lanes has a machined groove matching the radius of the bottle or can. When the clamp heads are full and the pneumatic cylinders extend the bottles/cans are captured in the grooves holding them in place during the 90 degree rotation and transfer to the packer loading conveyor. Once the heads are completed and transferred the clamp cylinders release, then the heads are raised and once clear of the top of the bottles/cans, the MatTop conveyor transfers the bottles/cans to the case packer lanes in the correct pattern for the family pack cases.

In this embodiment, the rotating head assembly unit 800 includes three rotating heads 803A, 803B, and 803C positioned on a mobile rail system 805. The rail system 805 allows rotating heads 803A, 803B, and 803C to move as a single unit and as individual units, with at least two degrees of freedom. Some embodiments may provide vertical displacement in addition to horizontal displacement. Individual rotating heads 803A, 803B, and 803C may also rotate, thereby changing the configuration of the product. The operation of the rotating head assembly unit may proceed as described herein.

Some embodiments may include a unique case flap control and guidance system. Containers have various flaps, i.e., foldable portions that may be configured to form one or more side walls of a container. For example, many containers have a top comprised of two flaps that originate from opposing side walls, and may be folded inward to form the top surface of the container. FIG. 1 shows, for example, a container 100 with a pair of opposing top flaps 103, and a pair of side flaps 105. These flaps can vary in position, and frequently cause processing units to jam. A unique case flap control and guidance system enables the automatic handling and transporting of packed units that include one or more flaps. In embodiments without a flap control and guidance system, cases having flaps may require manually handling before entry to the case packer unit, in which one or more flaps are configured as necessary and sealed, such as through tape or adhesive.

FIGS. 9A-9C show various elements of an embodiment of a case flap guidance system. FIG. 9A shows a portion of a case flap guidance system 901 in a prototype embodiment, extending along a conveyor belt 902 after a rotating head assembly (not shown) has already oriented the product (e.g., bottles in a package) in the desired configuration. As shown in FIG. 9A, flap guidance system includes components for addressing major flaps and minor flaps as commonly found on can and bottle packages, and may be configured for both top-sealed and side-sealed packages. Flap diverters 905 suspended from crossbeams 903 may be positioned to divert flaps into the desired position along the conveyor belt. Each diverter 905 may be positioned on a crossbeam 903 in the desired location, to receive, guide, and/or reposition a flap. As shown in FIG. 9A, a flap guidance system may include multiple crossbeams 903 between parallel vertical beams 907 down the conveyor belt, and one or more successive diverters 905 may be connected by a guide rod to prevent a flap from changing position during transit. Some embodiments may include separate guide rods 904 to ensure that other flaps located on side surfaces are also positioned as desired, prior to entering a sealing unit. For example, guide rod 904 has a tapered elevation from the conveyor to a desired height, such that any side flap in a downward configuration will be elevated to an appropriate height upon exiting the case flap guidance system.

Some embodiments may include static diverters and guide rods that remain in a fixed position during operation. Some embodiments may include moving diverters and/or guide rods. For example, some embodiments may employ one or more diverters to position a flap from an initial position to a desired position, upon entering the case flap guidance system. FIG. 9B shows an example of a prototype case flap guidance system including an automatic diverter supported by pneumatic cylinder 909. Some embodiments may include one or more mechanisms for activating one or more movable diverters and/or guide rods from an initial position to a new position. For example, in the embodiment shown in FIG. 9B, photo eye 911 senses the approach of a container unit. It should be appreciated that other sensory technology may be used to identify the approach of a container unit, and in some embodiments, to determine the position of one or more flaps on a container unit. Pneumatic cylinder 909 receives an instruction from a controller to divert one or more flaps of the container as it enters the case flap guidance system. The pneumatic cylinder expands or contracts the space between the diverters, as may be needed depending on the particular situation, such that the flap(s) of the container are positioned as needed for entry into the case flap guidance system. In other embodiments, the sensory technology may adjust the movement of one or more movable diverters and/or guide rods, depending on the initial position of one or more flaps. For example, in some instances the initial flap position may be inconsistent. Photo eye 911 (or other sensory device) may recognize the initial flap position(s) for each container unit, and instruct the movable diverters and/or guide rods as needed on a case-by-case basis. It should be appreciated that control logic may be implemented as needed, and that this application is not intended to be limited based on any particular control logic.

FIG. 9C shows a prototype embodiment of a case flap guidance system 908 in line with an exit side of a case packing unit 900. In this embodiment, container units packed with products in the desired configuration exit the case packing unit 900 along a conveyor belt (moving toward the left in FIG. 9C), and enter the case flap guidance system 908. Case flap guidance system 908 may include initial flap guide rods 915 to make initial adjustments on one or more flaps of the container unit. For example, if flaps on container units exiting the rotating head assembly are folded top-down, parallel to sidewalls, then initial flap guide rods 915 may gradually increase from the conveyor belt to a desired height, such that the flaps are in a raised position upon entering the case flap guidance system 908. It should be appreciated that a number of potential flap configurations are possible, and thus aspects of the case flap guidance system may be modified to suit a particular embodiment, and different orientations of the same container unit.

There are numerous types of container units in the beverage industry. Embodiments of the present approach may be configured for use with most existing container units, and in various orientations. FIGS. 10A-10E show six exemplar container unit configurations, along with sample product packaging configurations. FIG. 10A shows a four-flavor package of 24 bottles, and has a major flap (e.g., the top), with a short major flap and a pair of minor side flaps. FIG. 10B shows a five-flavor package of 12 bottles, and also has a major flap (e.g., the top), with a short major flap and a pair of minor side flaps. FIG. 10C includes two of the FIG. 10B containers oriented such that the short major flaps are adjacent. The containers in FIG. 10C may be placed into a secondary container, such as a corrugated tray, for ease of handling.

As discussed above, the present approach may be configured for use with bottles as well as other packages, such as cans. FIG. 10D is a four-flavor package of 24 cans—therefore having a shorter height than FIG. 10A—and has a major flap (e.g., the top), with a short major flap and a pair of minor side flaps. FIG. 10E shows a five-flavor package of 12 cans, and also has a major flap (e.g., the top), with a short major flap and a pair of minor side flaps. Another example configuration includes two of the Fig. E containers oriented such that the short major flaps are adjacent. The containers in such a configuration may be placed into a secondary container, such as a corrugated tray, for ease of handling. It should be appreciated that these are merely examples of desired packaging configurations, and that many other configurations are achievable under the present approach.

It should be appreciated that a control system, such as control system 917 shown in FIG. 9C, may be used to control the automated operation of embodiments of the apparatus. In particular, a control system may permit the selection of a desired configuration. The control system may provide options for the desired configuration, based on the number of types of product to be packed, as well as the number of each type of product to be included in the package. In some embodiments, the control system may instruct a user how to arrange the initial pallets of product. The control system may also instruct the user on any necessary reconfiguration of conveyor belts and/or the rotating head assembly unit to achieve the desired configuration. The control system may also operate the apparatus to achieve the desired configuration. For instance, the control system may monitor product entering the loading location, and operate line breaks as appropriate. The control system may also operate the rotating head assembly to change the configuration of product in the loading location, as well as downstream packaging and sealing aspects.

FIGS. 11-16 show various views and configurations of a rotating head assembly according to an embodiment of the present approach. FIG. 11 shows a perspective view of an embodiment of a rotating head assembly according to an embodiment of the present approach.

Reference 1200 are 6″ stroke pneumatic cylinders for first head expansion. Reference 1201 are 8″ stroke pneumatic cylinders for clamp head rotation. Rotating and expanding collar 1201 may include Aurora Reed Switches (not shown), Aurora 112 Clamp Switch Mounting Clamps (not shown), Aurora Quick Connect Cables Part # Arc 130 (not shown), among other components. Reference 1203 identifies a single rotating head in the assembly. In this embodiment there are three rotating head units 1203. Each rotating head unit 1203 includes a plurality of SML Clamp Cylinders 1204. Clamp cylinders 1204 control flex lanes 1202 for grasping and releasing products (in this embodiment, configured for use with beverage bottles or cans). The 1¼″ linear bearings 1205 permit the rotating head units 1203 to move linearly on 1¼″ linear shafts 1206. Multiple 15″ Stoke pneumatic cylinders 1207 are present to expand the second and third clamp head. A pneumatic band cylinder 1208 may be used to move the head units 1203 apart, thereby allowing space between units for rotation. Also, 36″ stroke rodless cylinder may be used to moves the rotating head assembly from load to unload position.

FIG. 12 shows a side view of an embodiment of a rotating head assembly according to an embodiment of the present approach. Three individual rotating heads are shown in a closed configuration, rotated such that any product released from the head units 1203 would move right-to-left in this view. FIG. 13 shows a perspective view of an embodiment of a rotating head assembly in an expanded configuration according to an embodiment of the present approach. Head units 1203 have expanded along cylinders 1207, creating sufficient space to allow each heat unit 1203 to rotate independently of the other head units. Otherwise, the shape of the head units 1203 in this embodiment prevents them from rotating without contacting neighboring head units. FIG. 14 shows a side view of an embodiment of a rotating head assembly in an expanded configuration according to an embodiment of the present approach. FIG. 15 shows a perspective view of an embodiment of a rotating head assembly in a rotated configuration according to an embodiment of the present approach. In this view, rotating head units 1203 are rotated in a sideways direction, which in this embodiment would be the position for receiving new bottles or cans. FIG. 16 shows a side view of an embodiment of a rotating head assembly in a rotated configuration according to an embodiment of the present approach. In this configuration, the rotating head units 1203 are expanded prior to rotating. The expansion introduces adequate space to allow each head unit 1203 to rotate without contacting a neighboring unit.

FIG. 17 shows an example of a packing unit 1700 configured for a specific packing configuration according to an embodiment of the present approach. A plurality of feedlines 1701 direct varieties B, C, D, and E towards rotating head assembly 1705. When received in the receive or loading area of the rotating head assembly 1705, varieties B, C, D, and E are in a first configuration. Variety A products are diverted in feed lines 1703a and 1703b in this embodiment. After rotation, Product varieties B, C, D, and E are in a rotated configuration 1706. Products in the rotated configuration then join with diverted products at downstream location 1709, and are in the desired packaging configuration. In this embodiment, the desired configuration includes either two 24-unit cartons 1711, or four 12-unit cases 1713. In the former, the desired packaging configuration 1711 includes two separate cartons 1712a and 1712b, each of which include 12×A, 4×B, 4×c, and 4×D in specific locations. In desired packaging configuration 1713, each case 1714a-1714d includes 6×A, 2×B, 2×C, and 2×D. These cases 1714a-1714d may be contained in a corrugated tray 1715 or other container for convenient transportation. It should be appreciated that the initial configuration, number of varieties, number of feed lines, and number of diverted lines (among other variables) may be modified to generate the desired packaging configuration.

FIG. 18 shows an example of a packing unit 1800 configured for another packing configuration according to an embodiment of the present approach. A plurality of feedlines 1801 direct varieties B and C towards rotating head assembly 1805. When received in the receive or loading area of the rotating head assembly 1805, varieties B and C are in a first configuration. Variety A products are diverted in feed lines 1803a and 1803b in this embodiment. After rotation, Product varieties B and C are in a rotated configuration in each head unit 1806a-1806c. Products in the rotated configuration then join with diverted products at downstream location 1809, and are in the desired packaging configuration. In this embodiment, the desired configuration can be a single 24-unit container 1811 having 8×A, 12×B, and 4×C. Alternatively, the desired packaging configuration can be two 12-unit containers 1813, each having 4×A, 6×B, and 2×C. It should be appreciated that the initial configuration, number of varieties, number of feed lines, and number of diverted lines (among other variables) may be modified to generate the desired packaging configuration.

FIG. 19 shows an example of a packing unit 1900 configured for another packing configuration according to an embodiment of the present approach. A plurality of feedlines 1901 direct varieties B, C, D, and E towards rotating head assembly 1905. When received in the receive or loading area of the rotating head assembly 1905, varieties B, C, D, and E are in a first configuration. Variety A products are diverted in feed lines 1903a and 1903b in this embodiment. After rotation, Product varieties B, C, D, and E are in a rotated configuration 1906. Products in the rotated configuration then join with diverted products at downstream location 1909, and are in the desired packaging configuration. In this embodiment, the desired configuration includes either two 12-unit cartons 1915a and 1915b in desired configuration 1913, or a single 24-unit case 1911. Desired packaging configuration 1911 includes 8×A, 4×B, 4×XC, 4×D, and 4×E in specific locations. In desired packaging configuration 1713, each case 1914a-1914b includes 4×A, 2×B, 2×C, 2×D, and 2×E. It should be appreciated that the initial configuration, number of varieties, number of feed lines, and number of diverted lines (among other variables) may be modified to generate the desired packaging configuration. These examples serve to demonstrate a handful of the potential configurations achievable under the present approach, as well as the versatility of packaging units embodying the present approach.

FIGS. 20-26 show different examples of packing configurations achievable through embodiments of the present approach. FIG. 20 shows two 12-unit cases, each having four of A, B, and C varieties. FIG. 21 shows one 24-unit carton having 8×A, 8×B, and 8×C. FIG. 22 shows a two-case tray, each case having 6 each of A, B, C, and D. FIG. 23 shows 24-unit carton having 6 each of varieties A, B, C, and D. FIG. 24 shows a two 12-pack cartons having 8×A and 4×B each. FIG. 25 shows one 24-unit having 16×A and 8×B. FIG. 26 shows a 24-unit carton having four each of A, B, C, D, E, and F.

As will be appreciated by one of skill in the art, aspects or portions of the present approach may be embodied as a method, system, and/or process, and at least in part, on a computer readable medium. The computer readable medium may be used in connection with, or to control and/or operate, various pneumatic, mechanical, hydraulic, and/or fluidic elements used in systems, processes, and/or apparatus according to the present approach. Accordingly, the present approach may take the form of combination of apparatus, hardware and software embodiments (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, the present approach may include a computer program product on a computer readable medium having computer-usable program code embodied in the medium, and in particular control software. The present approach might also take the form of a combination of such a computer program product with one or more devices, such as a modular sensor brick, systems relating to communications, control, an integrate remote control component, etc.

Any suitable non-transient computer readable medium may be utilized. The computer-usable or computer-readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the non-transient computer-readable medium would include the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a device accessed via a network, such as the Internet or an intranet, or a magnetic storage device. Note that the computer-usable or computer-readable medium could even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted, or otherwise processed in a suitable manner, if necessary, and then stored in a computer memory. In the context of this document, a computer-usable or computer-readable medium may be any non-transient medium that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.

Computer program code for carrying out operations of the present approach may be written in an object oriented programming language such as Java, C++, etc. However, the computer program code for carrying out operations of the present approach may also be written in conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).

The present approach may include computer program instructions that may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.

These computer program instructions may also be stored in a non-transient computer-readable memory, including a networked or cloud accessible memory, that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function/act specified in the flowchart and/or block diagram block or blocks.

The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to specially configure it to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.

Any prompts associated with the present approach may be presented and responded to via a graphical user interface (GUI) presented on the display of the mobile communications device or the like. Prompts may also be audible, vibrating, etc.

Any flowcharts and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present approach. In this regard, each block in the flowchart or block diagrams may represent 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 block 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. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems which perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the approach. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the claims of the application rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

PRODUCT PACKAGING APPARATUS

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