Packaging apparatus and methods

[0001] Benefit is claimed of the filing date of Dec. 5, 2001 of U.S. provisional patent application Ser. No. 60/336,963. Such application is expressly incorporated herein by reference as if fully set forth herein.

[0002] This invention relates to packaging, and more particularly to packaging apparatus and methods and to product handling apparatus and methods.

[0003] In current systems handling products and packages such as cartons, for example, it is common to use conveyors or transfers to convey cartons, to transfer products and to handle products. Such conveyors or transfers typically define elements such as carton or product lugs, trays, buckets or the like, where the elements are typically linked together by a drive system. Such trays, buckets, lugs or the like will be referred to herein as “elements”, i.e. carton conveying elements or product conveying elements, wherein an element is typically one of a plurality of elements disposed for movement in a path as a conveyor function. Such elements typically bear a relation to one another. That is, the elements are interconnected in a common drive system so that displacement of one element in said path causes or requires displacement of another element. This is due to the mechanical, pneumatic, hydraulic, electric or other form of drive which, when operated, causes all elements to move, one in relation to another.

[0004] While there have been several devices allowing one element to stop while others keep moving in a short range, or very limited area such as traveling conveyors, floating or hesitating bucket systems, variable loops or other mechanical expedients, the general limitation of having to move or index all elements defining a single conveyor throughout most of the range of movement continues. In many of these, the pitch of the elements is also a constant through at least a portion of the circuit.

[0005] In many packaging or cartoning processes, it is common to operably juxtapose one conveyor having elements, with another conveyor system having elements, and with an operable indexing of adjacent elements of the respective conveyors to provide a desired operation. Thus, for example, a carton conveyor may have a plurality of carton conveying lugs, comprising elements, carried in a path, part of which is operably aligned adjacent to a bucket conveyor having a plurality of buckets which can be filled with groups of articles to be cartoned. When a filled bucket is operably indexed, by alignment or position, acceleration and velocity, with an empty carton carried between lugs, the article group in the bucket can be transferred into the adjacent carton, such as by a pusher or other device.

[0006] Likewise, in a product handling operation, a net or sequential weigh scale weighs a product. Product receptors or elements are conveyed under the scale to receive appropriately weighed product loads from the scale, and then to a discharge location over a pouch filler wheel, for example.

[0007] While such conveyor or handling systems have worked well and have been the core of cartoning, product handling or other packaging systems, there remain inherent difficulties. For example, random events upstream of or affecting one conveyor system or packaging operation, or downstream of or affecting another conveyor system or packaging operation, can cause overall system shutdowns. For example, if there is a jam associated with feeding articles from buckets in a bucket conveyor to cartons on a carton conveyor, the whole system might be stopped or locked up until the problem is cleared. This could jam upstream production or motion or downstream operation. For example, cartons being closed or glued might be delayed in that process, requiring rejection of cartons and loads between the jams and the last fully glued carton. Moreover, if there is a problem or jam at one conveyor position, all conveyor “elements” are, or must be stopped, inherently.

[0008] Also, it may be desirable to operate a product or carton or conveyor element at one speed through one area and at another speed or stop at another area. In the past, this has been possible, if at all, only through very limited ranges or areas, since motion of one conveyor element or component necessarily is linked to and subject to the motion or phase or cycle of that conveyor at another point.

[0009] Thus, the combination of both asynchronous motion and synchronous motion and all the benefits of such motions in single conveyor path are only possible in the past, if at all, through very limited ranges. Also, it can only be accomplished within the limitations of overall conveyor system inertia, which is typically a function of the sum of all conveyor elements and whatever conveyor mechanisms are employed.

[0010] Likewise, in a product handling mode, such as weighing, a receptor conveying problem can cause or require load rejection and waste due to conveying aberrations unrelated to the actual weighing or product receiving operation. A receptor might receive no load, or a double load, for example.

[0011] These are but a few examples of the potential problems or difficulties inherent with typical conveyance or handling systems where the conveyor elements are inherently linked or coupled to a common drive through most of their path.

[0012] Accordingly, it is desirable to overcome these and similar difficulties in product packaging, cartoning and product handling methods and apparatus, now susceptible to these problems, and to offer at least more windows of opportunity for such difficulties to be cleared, or operational benefits to be provided.

[0013] To these ends, the invention contemplates a packaging system wherein operative elements can be moved through a path asynchronously with respect to operatively adjoining, but externally controlled elements or functions, except in a selected path portion where the elements are registered and synchronized with the adjoining or external elements or function. For purposes of this application, it is useful to refer to the elements or functions as responsive to an “external axis” which provides a signal defining at least one of the position, velocity and/or acceleration parameters of the adjoining external element, function or system. Thus, the invention in one aspect contemplates asynchronous operation in a path of a plurality of independent elements and the operation and control of some, but not all of these, in a selected portion or section of a path by its drive but in response to a signal from an external axis.

[0014] Generally, this involves the registration of certain of the elements in a path with operatively adjoining or external elements or functions by way of synchronization of them in the parameters of position, velocity and/or acceleration. Thus, according to the terminology used herein, the invention contemplates registration of certain elements, moving in a path and operating independently of other elements in the path, with operationally adjoining or external elements or functions by synchronization through the influence of an external axis signal from the adjoining system.

[0015] Stated with reference, for example only, to a packaging system, the invention in one embodiment contemplates a conveyor having a plurality of first elements moving or driven in a path, independently of each other, a second conveyor having a plurality of second elements moving or driven in a second path independently of each other, the two paths extending through a common area in which the first and second paths are operatively juxtaposed for a packaging function and one or more of said first elements in said path in said area being driven independently of other first elements in said path but outside said area and in a machine direction in synchronization with selected ones of said second elements in said second path in said area.

[0016] The invention thus contemplates packaging, cartoning and product handling apparatus wherein elements of a conveyor are not permanently linked or coupled by a common drive, but where each element can be driven in an element path independent of the condition or motion of other elements in the same path. No longer will movement or stoppage of one element cause or require movement or stoppage of another element in the same path. Some elements, individually or as groups, can be slowed, stopped or accelerated wholly independently of those same parameters associated with other elements in the path.

[0017] Thus, both synchronous and asynchronous motion can be accomplished in the same conveyor path with elements, cartons and articles, each driven wholly independently of like components in the same path. Said in another way, independent elements in one path are, in a selected portion of that path, synchronized by the common drive for elements in that path with another packaging operation under the influence of an external axis signal from that other operation, without also affecting the position or movement of other elements not in the selected portion of the one path. Stated in yet another way, the invention contemplates a packaging process wherein selected elements moveable independently in a path are made synchronous in a portion of the path to an external axis signal and independently of other elements in the path.

[0018] In this manner, carton lugs can be slowed or stopped to allow operable indexing with a slowed or stopped article bucket to enhance the transfer. At the same time downstream, carton lugs can be accelerated, slowed or stopped for carton closing or gluing without requiring stopping, acceleration or slowing of upstream elements where cartons are loaded. And, after carton discharge, lugs can be accelerated to pick up new carton blanks.

[0019] At the same time, the article bucket elements can be similarly independent, for accommodation of carton loading bucket discharge or for accommodation of bucket filling at another path position, and independent of the motion status of other bucket elements in the path.

[0020] In a product handling application, product receptors such as dump buckets may be positioned under net weigh scale discharge points and retained there for proper weight discharges independently of the status of other dump buckets in other positions on the same path, such as at filler wheels or the like.

[0021] Accordingly, the invention contemplates the use of one or more conveyor paths, wherein at least one conveyor path is defined by movement of elements driven or positioned in or through said path independently of other elements in the same path and the motion of certain elements in a path is under the influence of an external axis. These are applied, according to the invention, in the packaging, cartoning or product handling fields to overcome prior inherent disadvantages or obstacles therein, and to provide enhanced packaging, cartoning and product handling operations.

[0022] In an even more specific example, the invention provides, for example, split operation for glue cycle completion. There will be absolute control of complete carton gluing. In the event of a loading jam, cartons with good loads will continue to travel through gluing, completing the process without unglued flaps. Upstream portions of transport will be stopped prior to gluing. Lugs which are part of the gluing process will cycle through to discharge and be subsequently queued on the return portion of the lug circuit or path.

[0023] Cycle stop flap closing and emergency stop flap closing have long been machine features which are required by users. Its effectiveness has also been less than perfect in emergency stop situations. The split operation described above according to the invention will perfect the functionality of this feature for both emergency stop and cycle stop situations.

[0024] The invention enhances many carton operations, including: horizontal product transfers; vertical product transfers; floating bucket systems; floating carton systems; scale interface systems; and flexible carton transport systems.

[0025] Accordingly, it will be appreciated that the invention contemplates a packaging operation in which article or package conveying elements in a conveyor path are moved independently of others in the path, even asynchronously, until brought under the influence of an external axis, synchronizing them with another packaging function or apparatus.

[0026] Further, the invention contemplates a material handling process and apparatus wherein first and second separate conveyor paths are operably juxtaposed, each having respective first or second elements independently driven respectively in said paths wherein there are four possibilities of control and coordination of elements of one path from the external axis represented by the other path:

[0027] First: asynchronous elements are synchronized with synchronous elements;

[0028] Second: synchronous elements are synchronized with asynchronous elements;

[0029] Third: synchronous elements are synchronized with synchronous elements; and

[0030] Fourth: asynchronous elements are synchronized with asynchronous elements.

[0031] The invention thus contemplates the operative linking of a synchronous system with an asynchronous system, two synchronous systems or two asynchronous systems, one being at least partially brought under the influence of an external axis represented by the other.

[0032] For example, an independently movable element system with packaging elements is synchronized under the influence of an external axis or external event occurring in another operable packaging system.

[0033] For further example, the position, velocity and/or acceleration of one independently moveable element in a packaging system, driven by a drive common to all such moveable elements, is influenced by an external axis or an event in another packaging system.

[0034] For further example, one system of elements is event-driven and another system of elements is synchronized to the one system through its external axis. The system representing or presenting the external event or external axis can itself be an independently movable element system, element conveyor, packaging function, encoder, vision system, photo-eye, proximity switch or the like.

[0035] It will, of course, be appreciated that the invention has particular application in the package field where articles or products are transferred into packages such as, but not limited to, pouches, trays or cartons, for example. The packages or cartons are formed, filled and/or sealed on a high speed basis, either intermittently or continuously.

[0036] Stated then in yet another way, the invention contemplates the packaging of articles through the use of linear motors driving at least one of an article or group of articles or packages and registering and synchronizing one of those with the other in position, velocity and/or acceleration in a machine direction under the influence of an external axis from the other.

[0037] The invention thus contemplates driving a plurality of cartons and/or article buckets through the use of a linear motor to accomplish these aforesaid objectives. The application of a linear motor to a cartoner, for example, in this fashion, provides advantages not before obtained in such packaging systems.

[0038] While the term “synchronization” is used herein to described the relative position, velocity and/or acceleration of an element with respect to another element or function, it will be appreciated that it is desired to render an element “position synchronous” with another element or function. That criteria includes the circumstance of both position and time, and it will be appreciated the circumstances of position and time subsume the parameters of both velocity and acceleration. Accordingly, the invention contemplate a packaging system wherein a plurality of elements in a common path are, in at least a section of the path, moved independently of other elements in the path in a position synchronous mode under the influence of an external axis signal.

[0039] These and other objectives will become readily apparent from the following detailed written description and from the drawings in which:

[0057] It will be appreciated that the invention is useful in many kinds of packaging operations, including but not limited to pouching or cartoning where products, items or articles are transferred into packages which are closed then transported for use. In such processes, the invention is useful in synchronizing the elements of two operationally joined systems, one to the other, so that an article can be registered with a package, for example, or a package can be synchronized with a sealing function, for example, independently of other articles or packages moving in the same path, and under the control of an external axis represented by the operationally adjoining system.

[0058] Thus, the following detailed description of specific embodiments of the invention is by way of example only.

[0059] Moreover, it will be appreciated that while linear motor technology is contemplated by the invention to carry out its objectives, the structure, form or control of the linear motors used do not in themselves constitute any part of the invention. Any suitable linear motor system can be used to accomplish the objectives of the invention consistent with this disclosure.

[0060] Linear motor technology is well known. Information concerning such technology can be found in many sources. As an example, disclosures concerning linear motor technology can be found in

Patent Cooperation Treaty (PCT) Applications as follows:

[0061]

	INTERNATL
SER. NO.	PUBLICATION NO.	PUBLICATION DATE
PCT/US00/11345	WO 00/64751	Nov. 2, 2000
PCT/US00/11346	WO 00/64753	Nov. 2, 2000
PCT/US00/11361	WO 00/64742	Nov. 2, 2000
PCT/US00/11342	WO 00/64791	Nov. 2, 2000
PCT/US00/32120	WO 01/38124	May 31, 2001

Each of these applications is herewith expressly incorporated herein by reference as if fully reproduced herein.

[0062] Also, further information concerning linear motor technology can be found in the following publications:

• • [0063] a. Technical Papers, Distributed Control of a PM Brushless Motor With Multiple Moving Elements, by Wayne Robinson and Rob Lankin, Agile Systems, Inc., Waterloo, Ontario, Canada, January 2001, 6 pages (see www.agile-systems.com/databook/)
  • [0064] b. Brochure entitled, High Speed Assembly Automation System, 5 pages, by Lanco and MagneMotion, 2001
  • [0065] c. Brochure entitled, Automation Tooling Systems Automation, Supertrak by Automation Tooling Systems of Ontario, Canada, 2001, 4 pages.
  • [0066] d. Webpage entitled, Supertrak: Linear Motor Conveyor Systems by Agile Systems 2001, 3 pages (www.agile-systems.com)
  • [0067] e. Brochure entitled, Automation Tooling Systems Automation SUPERTRAK TM Modular Conveyor System by Automation Tooting Systems of Cambridge, Ontario, Canada, 2002, 6 pages

[0068] Each of said publications is herewith expressly incorporated herein by reference as if fully reproduced herein.

[0069] Also, information concerning linear motor technology is also found in the following two U.S. Pat. Nos. 6,011,508 and 6,191,507, each of which is herewith expressly incorporated herein by reference as if fully reproduced herein.

[0070] It will be appreciated that, according to the invention, given the parameters of step and direction as an external axis from the adjoining system, any such linear motor control can be brought under the influence of an external signal to register and synchronize the elements driven by the linear motor in an operably adjoining area with elements of an adjacent packaging system to carry out carton loading ,product feeding into buckets or the like

[0071] Turning now to the drawings, the invention is depicted therein in particular application to various packaging or cartoning operations. In one embodiment, the invention contemplates the use of a linear motor as the driver for independently driving a plurality of elements such as buckets, lugs, sets of lugs, product receptors or the like, in a common path. Each such element is driven, and controlled, independently of other elements in the path, but selected elements in selected path sections are driven by the linear motor under the influence of an external axis signal in register and synchronization with components of the adjacent system generating such external axis.

[0072] It will be appreciated that the term “elements” is broadly and conceptually used herein to refer to a moveable site, bucket, lug, paddle, tray, pusher, receptor, or other conveyor device for handling products, articles, items, packages, pouches, cartons or the like. The term “external axis” or “external event” has the same conceptual meaning as noted above and includes, but is not limited to, a control signal, position, acceleration, velocity, or happening in a separate handling or function system other than that ordinarily controlling the elements in one path or system.

[0073] Thus, the elements of one system, conveyor, linear motor path or the like can, according to the invention, be brought under the influence of an “external axis” or “external event” in a section of their paths to, for example, be registered or indexed, and synchronized in position, velocity and/or acceleration with one element or function of a different system.

[0074] Linear motors per se are well known, but have not heretofore been applied to operationally adjoining conveyor systems to receive groups of articles or to combine them into cartons as described herein.

[0075] The invention thus contemplates moving magnet linear motor technology with unique application where magnets, carts, elements, buckets, lugs, lug sets, product receptors and the like are passive, requiring no tether wires for power or position feedback. Each element is provided with a magnet and is independently driven by the linear motor, moving along a series of stationary coils, providing substantial advantages over conventional transport systems. Conventional transport systems typically employ chains, sprockets, belts, racks, gears, lead screws, etc., none of which conveniently lend themselves to independent control of the elements.

[0076] Another benefit of the moving magnet linear motor technology is the reduction of system inertia. Since each element is independent, the inertia of the system is only that of the individual element and its payload. In conventional transport systems, the elements are generally interconnected through a transmission. The interconnection and the addition of the transmission substantially increase the inertia of the system, which is a composite, then, of all elements in the system and the drive of that system. Lower inertia provided by the moving magnet linear motor system invention provides the basis for higher speeds and greater efficiency in packaging, cartoning and product handling environments, not before available.

[0077] Suitable linear motor systems from varied sources can be used in carrying out the invention. One particular form of linear motor apparatus found useful in the packaging application of the invention is that known as the “SUPERTRAK” system by Automation Tooling Systems of Cambridge, Ontario, Canada. This is further described in U.S. Pat. No. 6,191,507. According to the invention, such a linear motor system is provided with any form of suitable control which is operable to drive and synchronize the individual elements of the system in a zone, section or segment of the track under the influence of an external axis, as described herein. Once the parameters of the invention described herein are known, such a system is controlled to provide such parameters in a packaging process. In this system, for example, micro-controllers for zones may be networked with a CPU or other form of controller with input from an external axis to not only provide a linear motor system with high position accuracy, but to control individual and independent elements responsive to or under the influence of an external axis.

[0078] Another form of linear motor system used according to the invention is by MagneMotion, Inc. of Acton, Mass. See also U.S. Pat. No. 6,011,508 for such linear motor system. Each system can be adopted to be brought under the influence of an external axis. In such systems, an indefinite length track defines an extended linear motor represented by coils, one or more of which define a zone of the track. Individual elements, each having magnets thereon, are driven along the track and the zones or coils, according to the invention, and controlled by the linear motor controller in any suitable way, such as through a CPU, to bring an individual element, independently of others on the track, under the influence of an external axis. Such axis might take the form, for example, of one or more encoders, vision systems, position sensors, control or any other position and/or timing signal of an operably adjoining synchronous or asynchronous system.

[0079] Referring now to FIG. 1 of the drawings, there is depicted therein a cartoning apparatus 10 according to the invention. In use, products, items or articles (not shown) comprising respective loads are carried singly or in groups of a plurality of respective trays or buckets 12 in the machine direction of arrow MD. The buckets are registered and synchronized with a plurality of erected cartons 14, which also move in the machine direction MD, so that the products, items or articles are transferred, such as by pushing, through funnels 16 into the erected cartons 14. This indexing and transfer takes place throughout area 18 wherein the paths of the buckets 12 and cartons 14 operationally coincide, i.e. are operably juxtaposed, so the buckets 12 can be synchronized with the motion of the cartons 14 and the load transferred. In this regard, and in other embodiments described herein, it will be appreciated that the elements of a linear motor system are brought under the influence of an external axis where the elements are first registered with, then synchronized operably in position and time with an element of an adjacent conveyor system by way of influencing the linear motor drive for such elements with an external axis of the adjacent system. Given the step and direction, for example, of the adjacent system elements, the linear motor and its control registers and synchronizes each element in an operating zone with the adjacent system and independently of other elements driven by the linear motor.

[0080] Thereafter, the cartons are transported in the direction MD, wherein they are finally sealed and discharged. Such an operation, wherein similar buckets and cartons have been traditionally conveyed and indexed in the past described, for example, in U.S. Pat. No. 6,105,338, which is expressly incorporated herein as if fully reproduced herein.

[0081] In accordance with the invention, however, it will be appreciated that the buckets and the sets of lugs 20 (FIGS. 4–4E) which move the cartons are each preferably driven by respective suitable linear motor, represented, for example, at 22 for the buckets and at 24 for the lugs (FIG. 1). Accordingly, as all the buckets 12 are moved through their oval path P (FIG. 1), all the buckets 12 are driven in said path independently of each other by the linear motor. Path P₁, of course, runs through area 18. Thus, one bucket can be driven at a velocity, acceleration or to a position independently of the velocity, acceleration or position of any other bucket in the path (allowing, of course, for collision avoidance). Likewise, the lug sets 20, including leading lug 21a and trailing lug 21b are each driven independently of each of the lug sets moving in the same oval lug path P₂ (FIG. 4). Path P₂ also runs through area 18.

[0082] This is particularly useful in area 18 (FIG. 1) where the buckets 12 are registered and synchronized respectively with cartons 14 for load transfer. More particularly, the buckets 12 are respectively synchronized with carton 14 in position, velocity and/or acceleration so the loads can be transferred into the cartons. In order for this to occur, one or more of the buckets 12 in area 18 are driven by linear motor 22 under the influence of an external axis represented by the lugs 20 and their drive. Thus, independently of other buckets 12 in Path P₁, buckets 12 in area 18 are registered and synchronized with cartons by the demands of an external axis represented by a position signal for the system of lugs 20, with lugs 20 and cartons 14 therein for loading.

[0083] More particularly, a bucket 12 in area 18 is synchronized with a carton 14 in a lug set 20 in position, velocity and/or acceleration of the carton 14 in lug set 20, so the bucket 12 is driven by its associated linear motor under the influence of, the external axis or event represented by the lug sets, and independently of any other bucket 12 in Path P₁.

[0084] This has enormous operational advantages in a packaging environment. For example, if the infeed of a load to buckets 12 in Path P₁ upstream of area 18 is stopped or changed, downstream buckets in area 18 can still be synchronized with cartons 14 so that loading and downstream carton filling and sealing is not interrupted. Once the infeed process is equalized, buckets 12 can be independently rushed to area 18 to continue the load transfer process.

[0085] Similarly, if there is a downstream stoppage of cartons 14 and lugs 20, for example, filled cartons can be independently moved through the carton gluer, then accumulated, so the gluing process is not interrupted causing carton rejection due to incomplete gluing or sealing. In this condition, of course, certain of the lug sets 20 in the Path P₂ are, for a selected path segment, brought under the influence or control of an external axis or event represented by a downstream system such as a carton gluer, discharge or the like, and independently of other lug sets 20 in Path P₂.

[0086] Moreover, it will be appreciated that while the cartoner 10 is preferably provided with linear motor drives for both cartons 14 and load buckets 12, one of these may be driven synchronously by a conventional conveyor and another by a linear motor as described above.

[0087] Accordingly, if the lug sets 20 are carried on adjustable chains moving synchronously as in conventional cartoning, the buckets 12 moving asynchronously on Path P₁ are nevertheless in area 18 registered and synchronized under the influence of and with the synchronous external axis of the lug conveyor.

[0088] This could of course, be reversed, with buckets 12 carried on the chains of a conventional conveyor and lug sets 20 moving asynchronously in Path P₂ but nevertheless synchronized in area 18 with the buckets 12 under the influence of the external axis of the bucket conveyor.

[0089] Also, it should be appreciated that the two independent linear motor systems 22, 24 could be operated so all respective buckets and carton conveying lug sets are moved independently in their paths but are synchronized in their respective paths under the influence of an external axis represented operationally by the adjacent system.

[0090] Thus, it will be appreciated that the invention contemplates two operationally adjoined or juxtaposed systems where asynchronous elements are synchronized with synchronous elements, where synchronous elements are synchronized with asynchronous elements; where synchronous elements are synchronized with synchronous elements; or where asynchronous elements are synchronized with asynchronous elements, with one set or system of elements being brought under the influence of the external axis signal provided by the adjoined or juxtaposed system.

[0091] Turning now to FIGS. 4–4E, details of the lug sets or lug elements 20 and their operation are described. FIG. 4 depicts a plurality of lug sets 20, each including leading lug 21a and lug 21b. All the lugs 21a, 21b are mounted for independent movement in a Path P₂ defined by coils of a linear motor (not shown). Each lug 21a, 21b of each lug set 20 is driven independently of each other lug, although one leading lug 21a and one trailing lug 21b are typically conducted or synchronized in association to form a lug set 20 for erecting and carrying a carton 14 (see FIG. 1).

[0092] As depicted in FIG. 4, the respective lugs 21a, 21b can each be driven independently in a recirculating Path P₂, for example, while the lugs 21a, 21b of lug sets 20 are coordinated to carry a carton therebetween, lugs 21a, 21b of lug set 20a are spaced further apart for receiving a not fully erected carton blank. Lugs 21a, 21b are shown closing together with lug 21b accelerating toward and independently of lug 21a to erect a carton blank and thus to form lug set 20(b) and then later the lugs are finally positioned as in sets 20, to hold and convey a loaded carton therebetween.

[0093] The carton blanks in lug sets 20a, 20b are progressively erected into squared up or erected cartons as the trailing and leading lugs 21b, 21a close together. Thereafter, each closed lug set 20a is driven independently of any other lug set through an operative or upper run of Path P₂ and is returned or recycled through a lower return run of Path P₂. It will be appreciated that lug sets 20 can be driven, independently of other lug sets in Path P₂ and under the influence of an external axis represented or imported by an adjoining or juxtaposed packaging system or event. Preferably, lugs 21a, 21b are returned in the return path P₂ at a different pitch than when erecting or conveying cartons. When they reach the area in Path P₂ for receiving another carton blank, the linear motor driving them is operable to space them widely apart for receiving the blank, then to accelerate a lug 21b independently toward a lug 21a to close the separation distance and erect a carton.

[0094] Details of one lug 21b for example, are shown in FIGS. 4A–4D. Each includes an upstanding lug 21 mounted on a carriage 25 carrying rollers 26 for supporting the lug 21 on a track portion (P₂) of a linear motor. A magnet 27 is disposed on each carriage 25 and serves to pull the carriage through Path P₂ when coils of the linear motor are energized to move that carriage n a selected portion of the track or path.

[0095] Each lug 21 has a face 28 for engaging and pushing or receiving a carton (not shown).

[0096] FIG. 4E depicts a time/velocity graph for a lug as it moves from and at velocities V₁ and V₂. At time T₁ and velocity V₁, a lug 21b forms up behind a feeding carton blank. At time T₂, the velocities of the lugs 21 are such that the carton is erected. Between times T₃, T₄, the cartons are loaded. They are accelerated and discharged from times T₄ to T₅ and from time T₅ to T₁, the lugs move at V₁ or some other speed to return in their oval Path P₂ for recycle. Since V₂ is slower than V₁, the trailing lug 21b is accelerated, relative to leading lug 21a from time T₂ to T₃ to close up the separation and distance between the lugs and erect the carton.

[0097] Once the cartons are filled, sealed and discharged, first leading lug 21a at the time T₄ is accelerated away to recycle, followed by trailing lug 21b when it reaches its time T₄ The lugs may also be accelerated and conveyed at different velocities and pitches int eh return run.

[0098] In another alternate embodiment, it will be appreciated that a trailing lug 21b for one carton can be combined on a single carriage in a common form or unit 29 with a leading lug 21a for a succeeding carton. In this manner, one element of the linear motor system comprises a trailing lug 21b and a following leading lug 21a in a unit 29. This combined function lug unit 29 is driven in the recirculating path independently of all other such units, with the carton erecting and conveyor operation, and lug return, being similar to that described above.

[0099] In particular, one such leading unit precedes a carton blank, introduced there behind. A following unit then accelerates toward the leading unit; its trailing lug engaging and erecting the carton against the leading lug of the leading unit. As this following unit progresses, a succeeding carton is introduced, behind it,just preceded by the leading lug of the following unit. A succeeding unit closes up the space, erecting this carton between the leading lug of the following unit and the trailing lug of the succeeding unit.

[0100] FIGS. 2, 2A and 2B illustrate a horizontal product transfer according to the invention. In FIG. 2, a horizontal product transfer 32 feeds a product bucket conveyor 34. A product infeed 36 feeds products 38 toward transfer 32, having a plurality of product transfer buckets or elements 39 defined by paddles or walls 40. In this configuration, three walls 40 define two product receptors or spaces 41, 42 having open bottoms.

[0101] As these move in a horizontal plane around an oval path P₃, products 38 therein slide on plate 43 until they approach drop off edge 44. Guide rails 45, 46 then support the products 38 as they are transferred in machine direction MD until they drop from the rail ends into a bucket such as bucket 48. Two products 28 are shown in like bucket 49 for illustration, the buckets 48, 49 being buckets of a product bucket conveyor 34.

[0102] Buckets of conveyor 34 move in a Path P₄ about horizontal axes (50 is shown) while Path P₃ is oriented about vertical axes 51, 52. FIG. 2A illustrates the apparatus of FIG. 2 from a different viewpoint. FIG. 2B is a plan view of the embodiment of FIGS. 2 and 2A.

[0103] In this configuration, the horizontal transfer 32 feeds a continuous motion cartoner article bucket conveyor 34 wherein the buckets such as 48, 49 are connected and driven by a preferably continuous motion conveyor chain in a typical fashion.

[0104] The elements 39, however, are driven by linear motors such as depicted at 54, 56. These elements are registered then synchronized with the buckets of conveyor 34 according to the invention.

[0105] Linear motors 54, 56 may be extended around the end curves of Path P₃ or mechanical drives may be used in these semicircular path segments. One linear motor could be used, two (as numbered) or a plurality to define a Path P₃. In any event, elements or receptors 39 are each driven independently of each other through the extent of linear motors 54, 56 and in two areas are synchronized via an external axis. In particular, the elements 39 driven by linear motor 54 are synchronized with the belts of the product infeed 36 (or with product thereon) so that a receptor is in place and synchronized in position, velocity and/or acceleration to receive a first, then second article 38. Elements 39 will not move from the infeed until filled, assuring a two product fill for each bucket of the downstream bucket conveyor 34. Thereafter, the elements are moved through Path P₃ where they are driven by linear motor 56 where they are, in this section of Path P₃, registered and synchronized in position, velocity and/or acceleration, with a bucket 48 to drop products therein.

[0106] The motion of elements 39 then at the product infeed 36 and over the continuously moving receiving buckets of the conveyor 34 are independent in both operationally coordinated areas of Path P₃ of other elements 39 in other sections or areas of the path. Thus, the elements 39 in Path P₃ are driven asynchronously then synchronized with infeed 36 which may be delivering products 38 synchronously or asynchronously, and are then registered and driven synchronously with synchronously-driven buckets or conveyor 34.

[0107] It will be appreciated that bucket conveyor 34, while continuously and synchronously-driven in the foregoing illustration could be comprised of buckets themselves driven independently of each other by further linear motors according to this invention where its advantages were desired in that system. Such further linear motors could be controlled under the influence of a yet further external axis from a yet further adjoining operational packaging function or system.

[0108] And in any event, it will be appreciated that the elements 39 are brought under the influence of an external axis for synchronization twice in their travel around Path P₃, once under the external axis of the product infeed 36 and once under the external axis of the bucket conveyor 34.

[0109] Turning now to FIGS. 3 through 3F, there is illustrated a form of vertical transfer according to the invention. This embodiment is somewhat similar to that of FIG. 2 excepting it provides a vertical transfer 60, as opposed to a horizontal transfer 32. Parts of this embodiment similar to that of FIG. 2 will be indicated with the same numbers. In this instance, product transfer 60 operates in a vertically oriented oval Path P₅ (represented by guide tracks 61, 62) about horizontal axes 63, 64.

[0110] An infeed 36 feeds article 38 into elements 66, comprising single buckets with dual product spaces 67, 68. These sweep around under guide tracks 61, 62 which eventually support the products 38 until they fall into buckets 48, 49 of conveyor 34, also operating in a vertical plane in Path P₆. Again, preferably two or more linear motors 54, 56 drive elements 66 about Path P₅. One linear motor could be used to define Path P₅

[0111] As in the FIG. 2 embodiment, elements 66 are asynchronously driven by linear motors 54, 56 except in the section of Path P₅ operable through the infeed area at 36 and through the drop-off area 70 over buckets 48, 49.

[0112] Elements 66 are thus independently driven by motors 54, 56 and are driven under the influence of the external axis of product infeed 36 and of the external axis of the product buckets in conveyor 34.

[0113] FIG. 3B illustrates how the elements 66 are mounted on roller carriages 68 driven along tracks 69 by the linear motors 54, 56 (not shown in FIG. 3B) and the end drives about the semicircular portions of the Path P₅. FIG. 3B also illustrates how the elements 66 can be comprised of two sub-buckets or trays 66a, 66b, with element 66 formed up under the influence of an external axis of the infeed 36 and the bucket conveyor 34, and then sub-elements 66a, 66b transported independently through the remainder of the Path P₅.

[0114] FIGS. 3C–3F illustrate further details of a mechanical drive for buckets of conveyor 34 about the semicircular segments of Paths P₄, P₆ respectively. End sprockets 71, 72 operably disposed at the ends of carriage guide rails 73, 74 receive the bucket chain or mechanical belt and pull the buckets about the semicircular section of the paths.

[0115] Turning now to FIGS. 5 and 5A, there is shown a product or packaging system 78 according to the invention wherein product hoppers or elements 80 are conveyed by one or more linear motors along a three-sided Path P₇ for receiving product from an infeed such as a weigh scale (not shown) and conveying product to a filler wheel for filling in pouches. In this embodiment, straight conveyor runs A, B and C define, along with turns 81, 82, 83, the three-sided Path P₇ Turns 81, 82, 83 may be mechanical devices, separate linear motors themselves, part of linear motors 86, 87, 88 or part of a single linear motor. A respective linear motor 86, 87, 88 is respectively associated with a run A, B or C which are segments of Path P₇. One linear motor could be used, operably extending around the entire path.

[0116] Run C is operatively disposed over a pouching filler wheel 89 having a plurality of receptors, chambers or gates 90 to receive weighed measures of product from elements 80 and for delivering them to a pouch for filling and sealing in the pouch. This is especially useful for packaging particular products such as particulates, powders, chemicals, foods or the like.

[0117] Each element or hopper 80 is provided with a dump gate mechanism 92 shown closed in the beginning of run C and open at the end of run C after dumping contents of hoppers 80 into openings 90 of filler wheel 89. These gates 92 are synchronized according to the invention with an opening at about 90a in wheel 89 to dump contents of hoppers 80 therein with a separate opening 90 presented seriatim beneath a following hopper 80.

[0118] It will be appreciated that linear motors 86, 87, 88 drive the carriage-mounted hoppers about Path P₇, each independently of the other and each in a selected segment of the Path P₇. The elements may be operated by the motors under the influence of an external axis, either for receiving a measured product load from a weigh scale, for example, in run A, or to synchronize a hopper with an opening 90 in wheel 89 in run C.

[0119] The hoppers 80 may be lined up in groups such as groups of four at the beginning of run C to receive product drops one through four from an operative weigh scale situated above the hoppers. In this configuration then, hoppers 80 in at least part of run C will be independently driven in Path P₇ by linear motor 87 under the influence of the external axis of the weigh scale.

[0120] And in run C, hopper 80 will be driven in a segment of Path P₇ so as to synchronize in position, velocity and/or acceleration with an opening 90 in filler wheel 89 to dump a measured product load for pouching.

[0121] It will be appreciated that some hoppers 80 can be grouped in groups independent of other hoppers 80 and in a different synchronous move to those of other hoppers 80, and the filler wheel discharge in run C, for example. Thus, the movement of hoppers 80 in run C and those hoppers 80 in run A are totally independent and asynchronous.

[0122] Moreover, the system 89 also independently operates hoppers 80 in run B to line them up for receipt in run C but asynchronously or synchronously with respect thereto.

[0123] It will thus be appreciated that a product or packaging system transfer may have a plurality of segments in a recirculating conveying path through which operative elements are moved independently of all other elements in the path, and with an inertia at any position point of only the element at that position, i.e. exclusive of other elements or drive components in the same system.

[0124] With attention to FIG. 6, there is illustrated therein an overall packaging operation wherein products are fed into buckets, loaded into cartons and cartons are discharged. This illustrates the function of the packaging operation of FIG. 1, for example, wherein buckets are independently driven by linear motors, filled, and product transferred into cartons which are sealed or discharged. At the product infeed, buckets are driven by a linear motor under the influence of an external axis defined by random events occurring at the infeed and independently of other buckets at other points along the bucket path to synchronize with the infeed. As buckets are filled, they are moved into the cartoner for transfer of their product loads into cartons. Here, the buckets are driven in synchronization with cartons of the cartoner, wholly independent of other buckets along the bucket path. Filled cartons are then sealed and discharged from the cartoner.

[0125] Accordingly, the buckets, driven along a path by a linear motor, are driven in portions of the path under the influence of the external axis of random events, such as at the infeed or the influence of an external axis of a synchronous or asynchronous operation of the cartoner. Position of one bucket with respect to another is not critical and any bucket can be registered and synchronized in position, velocity and/or acceleration with an adjoining or operational element or function independent of other buckets in the bucket path.

[0126] For further understanding of the invention, attention is directed to FIG. 7 wherein two adjoining conveying systems noted as System 1 and System 2 are depicted. System 1 comprises a linear motor-driven conveyor system including a plurality of buckets B, each independently driven in Path P₈ by the linear motor. System 2 comprises a plurality of lug sets, driven by a drive of either convention form or by a linear motor to move cartons C around Path P₉. Respective controls operate the linear motor or the drive as illustrated. An infeed is operationally adjoined to System 1 to feed products into buckets B in registration, synchronization area 1.

[0127] From the infeed, an external axis signal is generated and operationally connected in any suitable manner to Control 1 so that buckets B in area 1 are driven by the linear motor under the influence of the external axis from the infeed. These buckets in area 1 are first registered then synchronized to receive selected loads from infeed. The linear motor drive for these buckets in area 1 is independent also of any external axis from System 2.

[0128] Thereafter, buckets B exit area 1 and are driven by the linear motor in Path P₈ to area 2. There, the buckets B are driven by the linear motor under the influence of an external axis signal from System 2 to register with an in synchronization with cartons C in area 2. The buckets B here are driven independently of other buckets B anywhere in Path P₈ and independently of the external axis of the infeed.

[0129] Once the position, velocity and/or acceleration of the adjoining system components are known, any suitable software and control input representing the external axis can be used to influence the linear motor for driving in synchronization the independent registering and elements of the linear motor driven system, and the particular linear motor system or extended axis signal or software is not critical to a part of the invention claimed herein.

[0130] It will be further appreciated that in a packaging system and process according to the invention, the linear motor-driven elements are first registered then synchronized with the operationally adjoining elements of an adjacent packaging operation. For example, an element may be registered with an adjoining component in one area of the system, then actually synchronized with the position, velocity and/or acceleration with that component in the synchronization area. It is not necessary that registration control for any element takes place in a coextensive synchronous area. Registration and synchronization may overlap or may not, but the element is synchronized in a synchronization area with the adjoining component to carry out product insertion into a carton, product infeed into a bucket or some other packaging function.

[0131] For the purposes of this disclosure, the term “registration” includes determining where a component or element needs to be downstream and the taking of steps such as release, acceleration or deceleration to be there. The term “synchronization” means the transport of a component or element in operative position, velocity and/or acceleration with another element for a time period over a distance to accomplish a function, such as the packaging function of article transfer or insertion.

[0132] The packaging operations demonstrated through the application of the invention are numerous. Upstream or downstream aberrations will no longer cause waste or undue delay. A packaging system can accommodate between operational areas or events so primes are provided in clearing any aberrations. System inertia is reduced to that of a single product or package component carrier and lighter weight, less costly, less noisy apparatus can be used. Packaging system flexibilities are increased and operational delays in system components can be assuaged or smoothed without having the entire system slowed due to the slowest component. Emergency stop circumstances are ameliorated.

[0133] In yet another advantage of the invention, it will be appreciated that the use of a linear motor, independently driving separate system elements, can greatly reduce the cost and expense of both change over parts and the downtime expense of change over protocols when articles or packages of different sizes or requiring different pitch or spacing are to be handled. In this regard, it is known that packaging machines of various types, such as cartoners or pouch machines, are designed so they can be modified to handle items such as articles, article groups or packages (including but not limited to cartons and pouches) of different sizes and at different pitch or spacings. Such modifications require and are attended by the cost of change over parts, bigger, smaller or the like, and the expense of downtime to take off and add, or adjust, the components of the equipment. Thus, product guides, for example, or lugs, are mechanically adjusted with regard to their spacing or are changed to accommodate the parameters of different articles, article groups or packages.

[0134] Application of the benefit of linear motors independently driving the normally changed or adjusted components eliminates substantially, if not all, these costs and expenses. For example only, to handle cartons of different sizes or at different speeds or pitch, it is only necessary to adjust the programming of a linear motor to independently drive the carton conveying lugs at different speeds, accelerations or spacing. The new carton erection and conveying speeds, sizes and pitch are thus readily accommodated through the linear motors independently controlling and driving the elements or lugs. Mechanical change parts and changeover downtime are substantially reduced or eliminated.

[0135] Accordingly, article buckets can be formed by front and back walls, each defined by an independently driven element driven by a linear motor. Those can be adjusted with respect to spacing from each other, and each cooperating set with respect to spacing from another set to accommodate different articles and article group sizes and different pitch between articles or article groups. Such adjustment is through the independent drive of the linear motor, without need for extensive change parts or downtime.

[0136] These and other modifications, embodiments and advantages will become readily apparent to those of ordinary skill in the art without departing from the scope of the invention, and applicant intends to be bound only by the appended claims.