WO2003042040A1

WO2003042040A1 - Method and device for loading cartons in a container

Info

Publication number: WO2003042040A1
Application number: PCT/SE2002/001639
Authority: WO
Inventors: Håkan ANDERSSON
Original assignee: Svenska Lantagg AB
Current assignee: Svenska Lantagg AB
Priority date: 2001-09-24
Filing date: 2002-09-13
Publication date: 2003-05-22
Anticipated expiration: 2004-03-24
Also published as: SE520020C2; SE0103188D0; SE0103188L

Abstract

A method and a device for loading several layers of cartons (14) in a container (19) having side walls and a bottom (19’). The following steps are taken in accordance with the invention: a) bringing the cartons on a first conveyor (15) designed as an endless belt to a position above the container, b) supporting the cartons in a position above the container with a plurality of standards (10) projecting through apertures (21) in the bottom of the container, c) lowering the standards a distance corresponding to the height of a carton while conveying cartons resting thereupon, d) repeating the steps a-c until desired filling of the container is obtained, e) lowering the standards through the bottom of the container, so that one layer of cartons is resting against the bottom (19’) of the container. A first conveyor (15) designed as an endless belt is arranged for feeding the cartons, and a plurality of standards (10) are arranged projectable through apertures (21) in the bottom (19’) of the container. The standards are stepwise moveable in vertical paths downwardly while conveying cartons and takes in a lower position a position below the bottom of the container.

Description

METHOD AND DEVICE FOR LOADING CARTONS IN A CONTAINER

TECHNICAL FIELD OF THE INVENTION The invention relates to a method and a device for loading several layers of cartons in a container having side walls and a bottom. Said cartons may contain eggs or other products and are loaded in several layers in said container.

STATE OF THE ART

Large and effective loading machines for loading eggs in egg cartons, hereinafter designated cartons, are present today. Common carton sizes are 6, 10, 12, 15 and 18 eggs. So called trays having a larger number of eggs are present too.

From the loading machine the cartons containing eggs are conveyed onto conveying tracks and are transported to accumulating stations. At the accumulating stations the cartons are manually loaded in containers, which are used for distribution to sales places. It is also becoming more common to use the cartons at exposure of eggs in shops.

As the loading machines are very efficient, the carton feeding frequency is high. One drawback with the manual handling and loading of eggs in the cartons in the containers is the risk of occupational injuries. It may also imply difficulties to reach desired speed in the manual handling.

SUMMARY OF THE INVENTION

Accordingly, an object of the invention is to eliminate the above mentioned disadvantages and problems and provide a method allowing auto- matic loading of cartons in a container. The method is particularly suitable for use in connection with cartons containing fragile goods, e.g. eggs, but may also be used generally in connection with loading. According to the invention a device allowing automatic loading of cartons in a container is also provided. The container is designed with at least side walls and a bottom. A set of cartons is, according to the invention, conveyed automatically to a position above the container. Through apertures in the bottom of the container, standards are projected for carrying the cartons. The standards are then lowered a distance corresponding to the height of a carton layer and a new set of cartons is conveyed forward. These measures are repeated until the container is filled to a desired level, whereupon the standards are withdrawn from the container. The container may then automatically be fed onto a conveyor for further handling.

This object is achieved by the invention having received the features described in the independent claims. Further objects,, advantages and features are evident from the following description and dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described with the aid of exemplary embodiments and with reference to the accompanying drawings, in which

Fig. 1 is a schematic perspective view of one embodiment of a device according to the invention,

Fig. 2 is a schematic perspective view of the device according to Fig.

1 ,

Fig. 3 is a schematic front view of a the device according to Fig. 1 , Fig. 4 is a schematic plane view from above of a somewhat modified device according to Fig. 1 ,

Fig. 5 is a schematic plane view of the device according to Fig. 1 , but provided with a feeding mechanism for empty containers,

Fig. 6 is a schematic perspective view of an alternative embodiment of a device according to the invention, Fig. 7 is a schematic side view of a portion of an alternative embodiment of the invention and

Fig. 8 is a schematic plane view of the device according to Fig. 7. DESCRIPTION

In the embodiment according to Fig. 1 there is shown a device without a container. A plurality of standards 10 having supporting plates 11 are ex- tended upwards in pairs from supporting arms 12. Said supporting arms 12 are connected to a hoist 13 (see Fig. 3 and Fig. 4) and may be lifted and lowered in several steps. A carton 14 is indicated with dash and dot lines. The number of supporting arms 12 and their relative positions are selected with regard to the application and other circumstances. Cartons 14 are conveyed onto the standards 10 from a first conveyor

15, the first conveyor 15 comprising rollers in the embodiment shown. In alternative embodiments said conveyor comprises a conveying belt or other means for automatic feeding of cartons. The cartons fed from the first conveyor 15 are sliding forward onto a first set of supporting means 16 compris- ing two opposite and hinged base plates in the embodiment shown. The length of said plates is somewhat shorter than the length of the container the cartons are to be positioned in. In the position shown in Fig. 1 the base plates are pivoted to a horizontal starting position. The starting position is taken before the cartons are fed forward from the first conveyor 15. Instead, the conveyor of the egg loading machine may constitute the first conveyor 15 for the egg cartons, so that these are brought directly onto the supporting means without any particular driving station.

The container in which the cartons are to be loaded rests upon a second set of supporting means 17 during a loading phase. In the embodiment shown, the second set of supporting means 17 comprises two opposite and hinged supporting plates. On a level below the second set of supporting means 17 is a second conveyor arranged in the form of driving rollers 18. In an alternative embodiment the driving rollers are replaced by a conveying belt. The driving rollers 18, or a corresponding device, are used when a filled container is brought out from the device according to the invention to a subsequent conveyor or another device. Cartons fed forwards on the first conveyor 15 are hindered from reaching the first set of supporting means 16 by a stopper 23 in particular situations, e.g. when the supporting plates are filled or pivoted down. According to an alternative embodiment, the second set of supporting means comprise vertically adjustable plates between the driving rollers. The vertically adjustable plates are designed for lifting the container to an upper filling position when the egg cartons are lowered into the container. When the container is filled, the vertically adjustable plates are pulled down between the driving rollers, so that the container may be fed out.

Fig. 2 schematically shows the device in Fig. 1 with a container 19 indicated with dash and dot lines. The container is resting upon the supporting plates of the second set of supporting means 17 and is positioned in a filling position. A platform 20, or another type of filling station, is arranged in front of and at the same level as the supporting plates of the second set of supporting means 17. Empty containers 19 may be pushed onto the supporting plates of the second set of supporting means 17 from the platform 20. It is also evident that the standards 10 extend between the driving rollers 8. It is also possible to arrange more driving rollers 18, or a longer conveying belt, so that the filling station may receive more empty containers. The filling station may be fed manually or may be provided with a container erector. Suitably, an empty container is fed into the filling position in connection with feeding out a container filled with egg cartons. The container 19 is designed with four in pairs parallel side walls and a bottom wall. Apertures 21 are arranged in the bottom wall in positions corresponding to the positions of the standards. In the embodiment according to Fig. 2 the apertures are circular, but figure and size may be adjusted to the application and the design of the container. After a container is brought to a filling position and is positioned on the supporting plates of the second set of supporting means 17 in position for receiving cartons 14, the standards 10 may be projected through the apertures The standards are projected to a level somewhat below the first set of supporting means 16 for receiving the cartons 14 when the supporting means 16 are pivoted down, which is indi- cated at the arrow A in Fig. 3.

Fig. 3 shows a starting position having a first set of cartons 14 in position above a container 19. The standards 10 are projected through the bottom 19^'of the container 19. The carton showed is indicated to contain eggs and is resting upon the first set of supporting means 16. The standards 10 are set in a position just below the supporting means 16. In this position the supporting arms 12 take a first position P1. When a desired number of cartons 14 are fed into the supporting means 16, these are pivoted down in the direction of the arrow A. As a result, the cartons 14 slide down onto the sup- porting plates 11 of the standards. The plates of the supporting means 16 are pivoted around an axis 25, positioned somewhat outside the side walls of the container 19. At pivoting down the plates, said side walls of the container are pressed out, which facilitates the movement of the cartons 14 down into the container 19. The side walls of the container 19 are indicated with dash and dot lines in the pressed out position.

A control unit 22, connected with the hoist 13 and the supporting means 16, 17, is arranged for controlling the different movable units. Suitable control means, such e.g. a computer, memory units and driving means for driving the hoist 13 and other pneumatic, electric or hydraulic movement means, are arranged in the control unit 22 in a conventional fashion.

The supporting arms 12, connected with the hoist 13, are lowered a distance corresponding to the height of a carton 14 and takes a second position P2. The supporting arms 12 in this position are indicated with dash and dot lines. During this phase, new cartons are prevented from being fed onto the first set of supporting means 16. This may take place by the means of a stopper 23, which is shown in a raised position in Fig. 3, arranged in front of the first set of supporting means 16. The stopper 23 is arranged pivoting down to a position in the movement path of the cartons 14 to the position shown with dash and dot lines. The stopper 23 may in an alternative em- bodiment be arranged in the lower part of the first conveyor. In a such embodiment the stopper is pivoted upwards instead of downwards to prevent the cartons from being fed in above the container.

The lowering of the supporting arms 12 is vertical, as indicated in Fig. 3 at the arrow B. By the lowering of the supporting arms 12, the cartons rest- ing upon the supporting plates 11 are brought down into the container 19.

The supporting plates of the first set of supporting means 16 are then pivoted back to the starting position. The stopper 23 is pivoted upwards and a new set of cartons 14 is fed forwards on the first set of supporting means 16. The stopper 23 is then pivoted down again to prevent further cartons 14 from be- ing fed in above the container. In the same fashion as described above the supporting plates of the first set of supporting means are then pivoted down in the direction of the arrow A, wherein the set of cartons is positioned on top of the set of cartons previously positioned in the container 19. These steps are repeated until the container 19 is filled to a desired level. In the embodiment shown in Fig. 3, the supporting arms 12 are lowered two further steps, first to a position P3 and then to a position P4.

With the container 19 filled to desired level, the container is resting upon the supporting plates of the second set of supporting means 17. How- ever, the cartons 14 arranged in the container are in this position supported by the standards 10. Hence, the supporting plates of the second set of supporting means 17 may be pivoted down, which is indicated at the arrow C in Fig. 3, or lowered vertically down. In immediate connection to the pivoting motion of the supporting plates or the lowering, the supporting arms 12 are lowered further to a position P5. In the position P5 the supporting plates 11 of the standards 10 are positioned at a level below the driving rollers 18, which means that the container 19 with its content is resting upon the driving rollers 18 in this position.

By the means of the driving rollers 18 the filled container 19 is brought from the filling position to further treatment stations, e.g. for imprinting information or labelling and packing in a larger container or loading on a pallet. If required, further conveyors are used for the further handling of the filled container. It may then be suitable to arrange an automatic queuing device preventing a container to be fed out while another just is passing by. Fig. 4 shows a container 19 in the filling position resting upon the supporting plates of the second set of supporting means 17. The supporting arms 12 and the supporting plates 11 are visible through the apertures 21 in the bottom of the container. It is also evident that there are four supporting arms 12 in this embodiment and that they extend into the hoist 13. In other embodiments more supporting arms are arranged. One carton 14 is resting upon the first conveyor 15 and one carton is indicated with dash and dot lines, resting upon the first set of supporting means 16.

The carton 14 on the first conveyor 15 engages on the stopper 23, which is pivoted down for stopping arriving cartons 14. The conveyor 15 may have a larger extension in a direction from the stopper 23 towards a loading machine, in which objects are loaded in the cartons 14. The control unit 22 is shown on top of the hoist 13, but may also be integrated therein or be arranged in an apparatus cabinet or the similar in a distance from the hoist 13. The modification made on the device in Fig. 4, compared to the device in the rest of the figures, relates to rolling means 24 of the first set of supporting means 16. The rolling means 24 facilitates the movement of the cartons 14 in above the container 19 and may be designed as rolls carried in bearings, as shown in Fig. 4, or as mounted needles, balls or the similar. A transducer 26 is suitably arranged to indicate when a set of cartons

14 is ready to be lowered into the container 19. The cartons are brought in above the container 19 from the first conveyor 15 connected to a side of the container 19. In the embodiment according to Fig. 4, the transducer is pressure-sensitive and is arranged opposite the side of the container 19 con- nected to the first conveyor 15. Hence, the transducer 26 will indicate when the first of the cartons brought in above the container 19 has reached the farther side of the container 19 relative the first conveyor 15. In other embodiments of the device according to the invention, the transducer comprises optic means and is arranged in a suitable position. The transducer 26 is con- nected with the control unit 22, as well as the stopper 23 and the first set of supporting means 16 and the second set of supporting means 17.

In an alternative embodiment the second set of supporting means 17 comprises a plurality of plate elements extended between the driving rollers 18. These plate elements can be lowered to a position below the driving roll- ers 18, when the container is filled to a desired level.

In a simple embodiment, empty containers 19 are manually positioned on the second set of supporting means 17. In the embodiment according to Fig. 5, the device according to the invention is provided with feeding means 27 for empty containers. The feeding means 27 comprises rolls in the em- bodiment shown, on which a container 19 automatically may be brought into a position above the second set of supporting means 17. The rolls are connected with the control unit 22 and are brought to rotate in connection with a full container being fed away from the second set of supporting means, so that a new container is in position without unnecessary delay. The feeding means 27 may also comprise a conveyor belt, or the similar, and a container erector may be included for automatic erection of containers 19.

Fig. 6 shows an alternative embodiment, in which the first set of supporting means is replaced by a sheeting 28, or another material that may be rolled up. The sheeting, shown in Fig. 6 with a cut out section 30, is unrolled from a cylinder 29 before a first carton 14 is admitted on the first conveyor 15 passed the stopper 23. When the desired number of cartons 14 has been fed onto the sheeting, the sheeting 28 is pulled off in the direction of the arrow D and is rolled up on the cylinder 29. The standards 10 arranged on the sup- porting arms 12 thereby receive the cartons. The supporting arms 12 are then lowered down between the driving rollers 18, in the same fashion as described above, to make room for a further layer of cartons. The sheeting 28 is then pulled out in the opposite direction for covering the container again. The sheeting 28 should be rigid in the cross-direction and is suitably running in some sort of bars. In the embodiment according to Fig. 6 two bars 31, having C-profile, are arranged along the long sides of the sheeting. Thereby, it is ensured that the sheeting does not fold in connection with cartons being brought thereon. According to the embodiment of Fig. 7 the first conveyor 15 comprises an endless conveyor belt running over two rotating rollers 32. An upper track of the conveyor belt runs in a plane substantially similar to the first set of supporting means 16 so that arriving cartons 14 are brought onto the supporting means 16. The stopper for stopping arriving cartons used in the other embodiments is excluded. Instead the endless conveyor belt is run in a reversed direction for a short period, when the desired number of cartons has been brought onto the first set of supporting means 16 to a correct position over the container 19, when the container 19 is in a loading position. During the movement in reversed direction the cartons to be lowered into the con- tainer are separated from those cartons which are to be brought over the container in the next turn.

The backward movement of the conveyor belt is controlled by the transducer 26, which is effected by the cartons arriving onto the first set of supporting means 16. The transducer 26 may be designed as a micro breaker or any other suitable structure. For example, the transducer may comprise turning-sensitive or pressure-sensitive means. Fig. 7 also show a flexible guiding plate 33 extending substantially vertical down into a container 19 positioned in loading position. The guiding plate 33 is flexible so that it can be bent aside when an empty container is brought in the direction illustrated by arrow E. When the first set of supporting means 16 is pivoted aside to admit the cartons to be lowered down into the container the guiding plate 33 will guide the cartons down and into the container 19.

In the embodiment of Fig. 7 the hoist 13 comprises a driving motor and a synchronous drive belt (not shown). As in embodiments described above the hoist 13 is displaced in fixed positions corresponding to a layer of cartons.

Fig. 8 shows a production line having the device of Fig. 7 in the centre. A first container 19 is positioned in loading position and four cartons 14 are laying on the first conveyor 15. Two additional cartons rest upon the first set of supporting means 16. Supporting plates 11 are visible through apertures in the bottom of the container 19. The hoist 13 has lifted the supporting plates 11 to the position illustrated in Fig. 7 so that a layer of cartons can be received. The first conveyor 15 comprises an endless belt running over two rotating rollers 32 and a conveying plate 34 arranged between the rollers. An outer rotating roller is arranged adjacent to a conveyor of a machine preparing the cartons, e.g. an egg loading machine. The conveyor of the egg loading machine may comprise conveying rollers 35 as is shown in Fig. 8. At the outer rotating roller the conveying plate 34 is designed with two position detectors 36, one detector on each side of the endless belt. The position detectors detect if any arriving cartons are in a tilted position. In one embodiment the position detectors are optic. The position detectors are connected to control means, which detect if any time difference between signals from the both position detectors is present. The control unit 22 suitably comprises the control means.

When a tilted position is detected a control signal is sent to alignment means. In the embodiment shown the alignment means comprises two erectable guiding pins 37 arranged in line by the position detectors. A control signal results in the erection of the guiding pins 37 and that they stay erected until the carton is brought into correct position resting upon the both guiding pins by means of the motion of the endless belt.

Fig. 8 also shows a simple loading storage 38 for empty containers. The loading storage 38 comprises two corner bars 39 arranged by a long side of the container and a flat bar 40 arranged on the opposite long side. Both of the corner bars 39 and the flat bar 40 are designed with a length corresponding to the height of the desired number of containers to be positioned in the loading storage. In the embodiment shown the flat bar 40 is provided with a sliding release pin 41 stopping containers positioned above the loading storage from sliding down to a level corresponding to loading position when projecting and permitting a container to slide down to said level when retracted. A horizontal conveyor (not showed), e.g. designed as a pushing cylinder, pushes a container 19 forward from the loading storage to the load- ing position below the first set of supporting means 16 in the direction of arrow E.

Containers of different length may be loaded by adjustment of the supporting arms, the standards and the supporting means. Also the transducer 26 is movable to different positions.

Claims

1. A method for loading several layers of cartons (14) in a container (19) having side walls and a bottom (19^'), comprising the steps of a) bringing the cartons to a position above the container via a first conveyor (15) in a first direction D, b) supporting the cartons in a position above the container with a plurality of standards (10) projecting through apertures (21) in the bottom of the container, c) lowering the standards a distance corresponding to the height of a carton while conveying cartons resting thereupon, d) repeating the steps a-c until desired filling of the container is obtained, e) lowering the standards through the bottom of the container, so that one layer of cartons is resting against the bottom (19^') of the container,

c h a ra c t e ri s e d by the following steps: supporting the cartons in a first phase in the position above the container on a first set of pivotal plates (16) arranged along two opposite sides of the container, pivoting the first set of pivotal plates (16) in a second phase down into the container (19), wherein the cartons (14) are brought in abutment against the standards (10), bringing the cartons into position above the container on a backwards and forwards running belt in a direction forward and bringing the backwards and forwards running belt in a direction backwards before the first set of pivotal plates (16) in the second phase are pivoted down into the container (19), wherein cartons are separated from the cartons supported by the first set of pivotal plates (16) on the backwards and forwards running belt.

2. A method according to claim 1 , wherein at least an upper part of the two opposite sides of the container (19) are moved from each other in connection with cartons being lowered down in the container.

3. A method according to claim 1 , wherein the orientation of the cartons in relation to the direction D is detected and the cartons are directed to a position perpendicular to the direction D.

4. A method according to claim 3, wherein the cartons are directed to a position perpendicular to the direction D by erecting erectable guiding pins from the first conveyor (15) at a predetermined deviation from desired orientation.

5. A device for packaging several layers of cartons (14) into a container (19) having side walls and a bottom (19^'), wherein a first conveyor (15) is arranged for feeding cartons, a plurality of standards (10) are arranged pro- jectable through apertures (21) in the bottom (19^') of the container, said standards are stepwise moveable in vertical paths downwardly while conveying cartons and said standards takes in a lower position a position below the bottom of the container, c h a r a c t e ri s e d in that a first set of plates (16) is arranged along two opposite sides of the container to support cartons (14) above the container (19), that the first conveyor (15) is designed as a backwards and forwards running endless belt and that said first set of plates (16) are pivoted between at least a first position, in which the cartons are resting upon them, and a second position, in which the plates (16) extend down into the container (19) so that cartons are allowed to pass down into the container (19) and to abutment against the standards (10).

6. A device according to claim 5, wherein said first set of plates (16) in the second position displace two opposite side walls of the container (19) from each other.

7. A device according to claim 5, wherein a sheeting (28) is arranged withdrawable over the container to support cartons (14) above the container (19).

8. A device according to claim 5, wherein a plurality of standards (10) together are connected to a supporting arm (12) and a plurality of supporting arms (12) are connected to a hoist (13).

9. A device according to claim 5, wherein said supporting arms (12) can be lowered between driving rollers (18).

10. A device according to claim 5, wherein a second set of plates (17) is arranged to support the container (19) during loading thereof.

11. A device according to claim 10, wherein said second set of plates (17) is designed vertically adjustable.

12. A device according to claim 9 and claim 10, wherein said second set of plates (17) is adjustable into at least a first position, in which a container (19) is resting thereupon, and into a second position in which the container (19) is allowed to pass by the second set of plates (17) to engage the driving rollers (18).

13. A device according to claim 5, wherein a stopping means (23) is adjustable into at least a first position, in which arriving cartons (14) are allowed to pass by on the first conveyor (15), and into a second position, in which arriving cartons (14) are prevented from passing by on the first conveyor (15).

14. A device according to claim 5, wherein feeding means (27) are arranged for automatic feeding of containers (19) to a position in a filling position on the second set of plates (17).

15. A device according to claim 5, wherein a position detector (36) is ar- ranged in one end portion of the first conveyor (15) on each side of the endless belt and alignment means (37) are arranged in the first end portion of the first conveyor (15) for alignment of cartons tilted in relation to the conveying direction.

16. A device according to claim 15, wherein the alignment means (37) comprise erectable and retractable guiding pins.

17. A device according to claim 5, wherein a flexible guiding plate 33 is arranged partially lowered into a container (19) arranged in filling position to guide cartons down into the container when the first set of plates (16) is pivoted down.