Carton magazine and means for loading the same

[57] ABSTRACT

A carton magazine in which successive flat tubular cartons are advanced and withdrawn wherein provision is made for loading succesive cartons into the magazine as they are produced and transferred from a carton side seaming machine and wherein provision is further made for controlling the loading operation to maintain a substantially constant supply of cartons in the magazine.

Claims, 8 Drawing Figures

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CARTON MAGAZINE AND MEANS FOR LOADING THE SAME

BACKGROUND OF THE INVENTION ₅1. Field of the Invention

The present magazine is employed in the packaging art wherein prescored, folded and side seamed flat tubular cartons are advanced on edge, successive cartons being withdrawn from the front of the stack to open the 10 cartons which are then bottom sealed and transferred to a carton filling machine.

2. Description of the Prior Art

Prior to the present invention, so far as applicant is aware, it has been the practice for producers of pack- 15 aged goods to purchase prescored and side seamed cartons from others, and part of the duty of the attendant for the filling machines was to keep the carton magazines filled manually. This practice has been unsatisfactory in some instances, such as, where the purchased 20 cartons may have been stored for some time during which time they are liable to warp or become curved or set in their folded condition so as to be incapable of being handled succesfully in the normal manner in the magazine. 25 scribed having control means for discontinuing transfer of cartons to the magazine when the latter becomes filled and for again starting the transfer of cartons to the magazine when the cartons are depleted to a predetermined point. Provision is also made for discontinuing operation of the entire apparatus in the event that cartons fail to be transferred to the magazine within a predetermined time after a signal is transmitted to start the feed.

With these general objects in view and such others as may hereinafter appear, the invention consists in the carton magazine and in the various structures, arrangements and combinations of parts hereinafter described and particularly defined in the claims at the end of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawing illustrating the preferred embodiment of the invention:

FIG. 1 is a view in side elevation of a carton magazine embodying the present invention;

FIG. 2 is a plan view of the same;

FIG. 3 is a view in side elevation at a larger scale of the receiving end of the magazine shown in FIG. 1;

SUMMARY OF THE INVENTION

In accordance with the present invention, the prescored cartons which are folded and side seamed in a carton producing machine are transferred directly to the magazine to be withdrawn, squared up, bottom sealed and transferred to a filling machine, thus avoiding any liability of failure of the carton feeding operation due to changes in the cartons during storage thereof. The side seaming machine discharges the cartons in a horizontal position, and since the present magazine supports the cartons on edge, provision is made for delivering the cartons to the magazine in a vertical position to form a horizontal stack.

In operation, the stack of cartons stand on edge on a pair of chains which are driven to advance the chains a predetermined increment each cycle of operation whereby to move the stack forwardly toward the front of the magazine to compensate for the cartons being withdrawn. When the front of the stack engages stops, the chains may slip along the bottom of the stack in frictional engagement therewith. The receiving end of the stack has provision for moving successive cartons forwardly to engage the rear of the stack and to leave space for succeeding cartons transferred from the side seaming machine. Control means is also provided for discontinuing production of cartons when the magazine is'filled.

Accordingly, the invention has for one object to provide a novel and improved carton magazine having provision for receiving successive cartons as they are delivered from a carton producing machine in a simple and efficient manner.

The invention has for another object to provide a novel and improved carton magazine of the character described wherein provision is made for transferring cartons discharged from the carton producing machine in a horizontal position to present the cartons to the magazine in a vertical position to form a horizontal stack.

A further object of the invention is to provide a novel and improved carton magazine of the character deFIG. 4 is a front elevation of the carton transfer or loading means shown in FIG. 1;

FIG. 5 is a cross sectional view taken on the line 5—5 of FIG. 1;

³⁰ FIG. 6 is a plan view of control switches and associated switch operating mechanism shown in FIG. 3;

FIG. 7 is an elementary wiring diagram to be referred to; and

FIG. 8 is a wiring diagram showing the motors con³⁵ trolled by the circuits shown in FIG. 7.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, and particularly to FIG. 1, in general, 10 represents the delivery end of a carton producing machine, of the type illustrated and described in my copending applications, Ser. No. 813,172, filed Apr. 3, 1969, now abandoned, Ser. No. 863,436, filed Oct. 3, 1969, now U.S. Pat. No.

⁵ 3,626,820, and Ser. No. 818,034, filed Apr. 21, 1969, now U.S. Pat. No. 3,611,886, and assigned to the same assignee as the present application, from which successive prescored, folded and side seamed cartons 12 pro₅θ viding flat tubular cartons are discharged in a horizontal position to be received at one end of a transfer conveyor indicated generally at 14. The illustrated transfer conveyer follows an upwardly inclined path and then curves downwardly to present the flat tubular cartons ₅₅ on edge in a vertical position in the carton magazine indicated generally at 16. The cartons rest on edge on a pair of spaced chains 18—18 which effect incremental advance of the cartons each cycle to provide a horizontal stack 15 thereof, the front of the stack being held ₆₀ against stops 20—20. Successive foremost cartons are withdrawn from the stops by suction means indicated generally at 22, forming a part of the carton opening and bottom sealing mechanism not shown.

The carton transfer or loading conveyer 14 includes 65 a pair of spaced belts 24—24 arranged to run over drive pulleys 26—26 fast on a shaft 28. The shaft 28 is journaled in bearings 30—30 secured to spaced brackets 32 attached to a plate 34. The plate 34 is supported

3,831,784 by angle members 36,38 secured to and extended from side frame members 40,42 forming a part of the carton producing machine. A motor 44 mounted on the plate 34 is belted to a pulley 46 fast on the drive shaft 28. Each belt 24 may be provided with a rubber or like surface having spaced projections 25 for frictional engagement with the cartons. Extending from the drive pulley in the direction of travel of the belts, each belt first passes over idler or take-up rolls 48, 50, 52 and then follows up the inclined path defined by a belt board 54 having a metal plate 56 secured to its upper surface as shown. The belt board 54 is supported at one end by upright members 58 which are secured to side rails 60. The side rails 60 are attached at one end to the brackets 32 and are supported at an intermediate portion by a floor stand 62 and bracket 64 which latter is fastened to a tie bar 66 extending between the side rails 60. At the receiving end of the transfer conveyer, the cartons pass between guide rails 68—68 carried by studs adjustably carried by the side rails 60—60. A top rail 70 also provided with studs is carried by clamp members 72 secured to tie rods 74. One of the tie rods 74 is mounted in slots formed at the upper ends of the brackets 32. The other tie rod 74 is carried in slots formed at the upper ends of upright members 76 secured to the side rails 60 which members also support the take-up roll 50 which is rotatably mounted on a tie rod 78 extending between the the lower ends of the members 76 as shown. A similar top rail 80 for the inclined portion of the conveyor is also provided with studs adjustably mounted in clamps 82 carried by tie rods 84. One of the tie rods 84 is supported in slots formed in the upright member 58. Intermediate members 86, also provided with slots, carry the other tie rod 84.

At the upper end of the inclined portion of the conveyor, the belts 24—24 follow a curved path defined by idler rolls 92 mounted on tie rods 94 carried between angle brackets 96. The angle brackets 96 are mounted on angle members 98 attached to upright side plates 100 which in turn are attached to side rails 60—60 as shown. A curved top rail 102 is supported above the idler rolls 92 by angularly extended members 104 which are attached to the endmost angle brackets 96 as shown. Each member 104 is slotted at its upper end to receive the rods 106 to which clamps 108 are secured. The clamps are arranged to receive studs extended from the curved top rail 102.

After passing over the idler rolls 92, the spaced conveyor belts 24—24 pass around pulleys 110—110 to commence the lower runs of the conveyor, the lower runs passing over idler rolls 112—112 and under idler rolls 114—114 before returning to the drive pulleys 26—26. The idler rolls 112—112 are rotatably mounted on studs carried by the free ends of arms 116, the other ends of the arms being adjustably clamped to a tie rod 118 extending between the side plates 100. The idler rolls 114—114 are rotatably mounted on a tie rod 120 extending between depending members 122 attached to the side rails 60—60.

From the description thus far it will be seen that successive flat tubular cartons are transferred from the carton producing machine to a point where the cartons pass over a downwardly curved section preparatory to being deposited into the magazine 16. In order to assure positive downward feeding into the magazine, an auxiliary belt 124 is provided which is disposed between the spaced belts 24—24. As herein illustrated, see FIG. 3, the spaced pulleys 110—110 are fast on a shaft 126 which is mounted for rotation in bearings 128—128 secured to the side plates 100—100, the belts 24—24 effecting rotation of the shaft 126. Also mounted fast on the shaft 126 intermediate the pulleys 110—110 is a pulley 130 over which the auxiliary belt 124 runs. From pulley 130 the belt 124 passes over an idler roll 132, pulley 134 and idler roll 136 and then returns to the pulley 130. Thus, in operation, the cartons pass from the spaced belts 24—24 to the single downwardly directed run of the auxiliary belt 124 and then drop on edge onto the spaced chains 18—18 of the carton magazine 16. In order to prevent upward displacement of the carton during its downward movement, a top guide rail 138 is provided. This rail is provided with studs carried by clamp members 140 attached to tie rods 142 and 106, respectively. The tie rod 142 extends between slotted portions of the side plates 100—100.

In order to assure positive delivery of successive cartons downwardly into the magazine to join the previously delivered group or stack of cartons, an idler roll 144 is arranged to cooperate with the idler roll 132. The idler roll 144 is fast on a shaft 146 journaled in ball bearings carried by spaced arms 148—148. The arms 148—148 are bolted to the arms of a yoke 150—150 which is clamped to a shaft 152 journaled in bearings 154—154 clamped in slotted portions 155 of the side plates 100—100. A coiled spring 156 is attached at one end to a stud carried by a lever 158 clamped to the shaft 152. The other end of the spring 156 is connected to a spring stud secured to the end of a tie rod 160 on which the idler roll 132 is rotatably mounted. The tie rod 160 is adjustably secured in slotted portions 161 formed in the side plates 100—100 for adjustment therein to accommodate cartons of different sizes. The shaft 152 and its clamp bearings 154—154 are similarly adjustable in the slotted portions 155 to effect cooperation of the roll 144 with the roll 132. The continuously moving auxiliary belt 124 runs between the rolls 144 and 132 and the pressure of the spring urged roll 144 against the carton in cooperation with the backing roll 132 effects positive feeding of successive cartons downwardly into the magazine. A guide rail 162, adjustably carried by one of the side rails 100, assures alignment of one edge of successive cartons delivered to the magazine. In order to further assist feeding of the cartons downwardly into the magazine, rotary brushes 164—164 are also mounted on the shaft 146, one brush being provided on each side of the roll 144 as shown. The brushes are slightly larger in diameter than the roll 144.

The spaced chains 18—18 provide a chain conveyer 166 on which the cartons rest on edge and by which they are advanced in the magazine, the chains being arranged to run over drive sprockets 168—168 at one end of the conveyer. The chains run over idler sprockets 169—169 at the other end of the conveyer. The chain conveyer 166 includes an elongated support 170 attached to the machine frame 172 and provides suitable guides 174—174 for the chains 18—18, the guides being secured to the top of the support 170. The magazine 16 includes carton side rails 176—176 between which the upstanding cartons are guided as they are advanced against the stops 20—20 at the front end of the magazine.

3,831,784

In practice, the chains are advanced a small increment of movement each cycle of operation by drive means including a one-direction clutch 178 attached to the sprocket shaft 180. A lever 182 extended from the clutch 178 is connected at its other end to a stud 184 connected by a link 186 to a rack 188 slidably mounted in the machine frame. The rack is arranged to be reciprocated by an eccentric 190 connected by a crank lever 192 to a stud 194 extended from the slide rack 188. The eccentric is fast on a shaft 196 which may be connected by a chain and sprocket drive 198 to a motor 200. Thus, in operation, each reciprocation of the slide rack 188 effects a small rotation of the sprocket shaft 180 in one direction through the clutch 178 to advance the chains and the horizontal stack a small increment, the return movement of the clutch being arranged to slip. Successive cartons 12 are withdrawn from behind the stops 20—20 at the front of the magazine 16 by known means which includes rockingly mounted arms 202 provided with suction cups 204. The arms 202 are fast on a vertical rocker shaft 206 supported in the machine frame. The lower end of the shaft 206 is provided with a gear 208 for cooperation with the reciprocable rack 188 whereby to effect withdrawal of a carton from behind the stops 20—20 each cycle of operation. The suction withdrawing means is arranged to deliver the carton to squaring and bottom sealing means not shown. A second eccentric 210 on the shaft 196 is connected by a link 212 to an arm 214 fast on a shaft 216 journaled in the machine frame. A second arm 218 also fast on the shaft 216 is connected to a slide bar 220 mounted in the frame and which cooperates with the suction mechanism to effect withdrawal and opening of the carton.

Referring now to FIGS. 1 and 3, provision is made for urging forwardly the upper edges of the upstanding cartons delivered to the receiving end of the magazine and also for maintaining alignment of the upper edges to assure uniform presentation of the cartons to the carton opening means. As herein shown, a pair of rolls 222—222 are mounted on a shaft 224 supported for rotation in the arms 226 of a bracket 228 attached to the machine frame. The periphery of each roll 222 is provided with a rubber or like material surface for frictional engagement with the upper edges of the cartons. The shaft 224 is arranged to be rotated a small increment each cycle of operation by connections from the rocker arm 214 including a connecting link 230 extended between the arm 214 and a lever 232. The lever 232 is connected to a one direction clutch attached to the shaft 224. Thus, in operation, the rolls in frictional engagement with the upper edges of the cartons effect an incremental advance of the upper edges of the cartons each cycle of operation simultaneously with the advance of the stack by the chains 18.

While the rolls 222—222 also operate to align the upper edges of the cartons by pushing down those cartons extending above the plane of alignment, provision is further made for assuring top edge alignment after they have passed the rolls 222—222 by periodically patting or tapping the upper surface of the stack with a flat plate 234. The plate 234, herein shown as circular, is connected to the piston of an air cylinder 236 which is adjustably clamped to a bar 238 secured to the machine frame. The air cylinder is connected by a conduit 240 to an air valve 242 which in turn is connected to a source of compressed air by a pipe 244. The nor6 mally closed valve 242 is attached to the bracket 228 and is provided with a roll carrying arm 246 for cooperation with the head of a stud 248 adjustably secured to one of the rolls 222—222. Since the rolls 222—222 are rotated a small increment each cycle of operation, it will be seen that the valve 242 is opened only periodically after a predetermined number of cycles to effect patting of the stack by the flat plate 234.

Referring now to FIGS. 2, 3 and 7, provision is made for controlling the transfer of flat tubular cartons 12 to the magazine in a manner such as to discontinue the feed when the magazine is filled to a predetermined point whereby to prevent jamming of succeeding cartons and to automatically initiate the transfer operation when a sufficient number of cartons have been withdrawn from the stack so that in effect the control means maintains a substantially constant stack of cartons in the magazine. It will be understood that in practice it is preferred to feed the cartons into the magazine at a rate slightly faster than the rate of withdrawal therefrom so as to assure a constant supply of cartons in the magazine.

As herein shown, when the cartons are urged downwardly to join the end of the stack, the endmost carton engages a pair of spaced rollers 250—250 mounted for rotation on a shaft 252 carried between arms 254—254. The arms 254—254 are secured to levers 256—256 which in turn are clamped to a shaft 258. The shaft 258 is rockingly mounted in bearings provided in plates 260, 262 secured to the side plates 100—100. One of the plates 262 carries a pair of switches 264, 266 arranged to be actuated by switch plates 268,270, respectively. The switch plates are carried by the free end of a lever 272 which is clamped to the rocker shaft 258. A coil spring 274 extended between a stationary stud 276 and a stud 278 secured to the lever 272 is arranged to pull the lever down in a clockwise direction against a stop screw 279 carried by an angle member 280 attached to the plate 262. The stationary stud 276 is also attached to the angle member 280. Downward rocking of the lever 272 effects rocking of the rollers 250—250 against the end of the horizontal stack as limited by the stop screw 279. Thus, in operation, when a carton is transferred to the receiving end of the stack, it will engage the rollers 250—250 to effect slight rearward rocking of the rollers. As the stack thus expands rearwardly, the shaft 258 is rocked in a counterclockwise direction whereby to rock the lever 272 and its switch operating plates 268, 270 upwardly.

The switches 264,266 both serve to control the operation of feeding flat prescored carton blanks to the carton producing machine referred to generally as the “side seamer”. Thus, in operation, when the side seamed cartons 12 in the stack 15 are reduced by continued withdrawal therefrom to an extent wherein the lever 272 rests against the stop screw 279, the circuit to the motor 282, which drives the flat blank feeder is closed by engagement of the switch operating plate 270 with the switch 266, as diagrammatically illustrated in FIG. 7. This will start feeding of flat carton blanks to the side seamer, the side seamed cartons being transferred to the carton magazine 16. Successive cartons added to the stack 15 will effect gradual upward rocking of the lever 272 during which time the cartons will continue to be fed and transferred to the magazine 16. When the magazine is filled to a predetermined point,

3,831,784 the switch operating plate 268 will engage its switch 264 to effect opening of the circuit to the motor 282. Since the side seamer operates to supply side seamed cartons to the magazine 16 at a rate slightly faster than the rate of withdrawal from the magazine, this opera- 5 tion of starting and stopping feeding of carton blanks to the side seamer continues periodically as required to maintain an adequate supply in the magazine 16 at all times. It will be noted that provision is made for adjusting the switch operating plates 268, 270 whereby to 10 vary the times of starting and stopping the operation of the flat blank feeder 284.

Provision is further made for controlling the operation of the apparatus whereby to discontinue operation of the same in the event of failure of the flat carton 15 feeder to supply cartons to the side seamer in response to closing of the switch 266. In such event, failure of cartons to replenish the supply in the magazine 16 during continued withdrawal therefrom may effect jamming of cartons therein. In order to avoid this condi- 20 tion, switch 266 is connected to a time delay relay 286 adjusted so as to discontinue operation of the entire apparatus in the event that cartons are not received by the magazine 16 within a predetermined time. However, under normal operating conditions when additional 25 cartons are supplied to the magazine 16 within such predetermined time, the time delay relay will be inoperative to stop the apparatus. Failure of cartons to be supplied to the magazine 16 is usually due to a jamming of a carton at the flat blank feeder and thus, in effect, ³⁰the time delay relay comprises a safety mechanism to stop the apparatus in the event of a jam at the flat blank feeder and to permit such fault to be corrected before again starting the apparatus. As above stated, the carton blank feed is shown in my copending application, ³⁵Ser. No. 813,172, filed Apr. 3, 1969, to which reference may be had.

In the elementary wiring diagrams, FIGS. 7 and 8, the side seamer motor relay is represented by the numeral 285 (Ml), in line 1 of FIG. 7, which is energized by ⁴⁰pressing the start button 288. This effects closing of holding contacts 289, 290 (Ml) in lines 1 and 2, respectively, and also closing of the motor contacts 291 (Ml), as shown in FIG. 8, to start the side seamer motor 282. The carton blank feed motor relay 292 ⁴⁵(M2) indicated in line 2, is included in a circuit having contacts 293 (R2), 290 (Ml) and 295 (Rl). Contacts 290 (Ml) in line 2 were closed by relay 285 (Ml) in line 1. Contacts 295 (Rl) in line 2, and contacts 296 (Rl) in line 3, are closed upon closing of switch 266 ⁵⁰(SW2) by switch operating plate 270, see FIG. 3, when cartons in the magazine 16 are depleted to a predetermined point of contraction of the stack. Closing of switch 266 actuates relay 197 (Rl) in line 3 to effect closing of holding contacts 295, 296. Line 4 includes ⁵⁵the carton blank feed motor relay 298 (R2) which is energized upon closing of start contacts 300 to effect closing of holding contacts 302 (R2) in line 4, and motor contacts 304 (M2) as shown in FIG. 8. The relay 298 (R2) also effects closing of contacts 293 (R2) in line 2, thus energizing relay 292 (M2) in FIG. 8 to start the motor 305 for feeding carton blanks to the side seamer. As soon as the carton magazine 16 is replenished to a predetermined point of expansion, the switch _6g264 (SW1) will be opened by the switch operating plate 268, see FIG. 3, to deenergize the relay 297 (Rl) in line 3, and opening contacts 295 (Rl) in line 2 to deenergize relay 292 (M2), thus stopping the motor 305 and discontinuing the feed of carton blanks. Line 5 includes the motor relay 306 (M3) operated by start button 308 to close holding contacts 310 (M3) and motor contacts 312 (M3). The motor 314 drives the conveyer chains for advancing the cartons on edge in the magazine 16 and is stopped by stop button 316. Line 6 includes the time delay relay 286 (TDR1) which serves to open the normally closed contacts 318 (TDR1) in line 1 if the side seamed cartons fail to be received by the magazine 16 within a predetermined time.

From the above description, it will be seen that novel provision is made for transferring successive flat tubular cartons from a carton producing machine to a carton magazine from which successive cartons are withdrawn. It will also be seen that provision is made for controlling the feed of cartons to the magazine whereby to prevent overloading and jamming of the same and to assure a constant supply.