METHOD AND MACHINE FOR PACKING A PRODUCT IN AT LEAST ONE SHEET OF PACKING MATERIAL

• US 20070130888A1
• Filed: 10/06/2006
• Published: 06/14/2007
• Est. Priority Date: 10/06/2005
• Status: Active Grant

• Current Assignee: G.D. Societa per Azioni.
• Original Assignee: G.D. Societa per Azioni.
• Inventors: BIONDI, Andrea, OSTI, Roberto, MINARELLI, Alessandro
• Granted Patent: US 7,430,840 B2
• Time in Patent Office: Days
• US Class Current: 53/466
• CPC Class Codes: B65B 19/105 using rotary drums for withdrawal of successive layers from a hopper
• CPC Class Codes: B65B 19/223 in a curved path; in a combination of straight and curved paths, e.g. on rotary tables or other endless conveyors B65B19/24 takes precedence
• CPC Class Codes: B65B 61/002 for drying glued or sealed packages
• CPC Class Codes: B65B 65/006 Multiple parallel packaging lines

Abstract

A machine for packing a product in at least one sheet of packing material has a number of conveyors, each of which has a number of pockets, each for receiving and conveying a respective product; the products are transferred from each conveyor to the next conveyor at a transfer station defined between the two conveyors; the pockets on each conveyor are divided into a first number of groups, each containing an equal second number, greater than one, of pockets; and, at each transfer station, a second number of products are transferred simultaneously from the pockets in a group of pockets on the releasing conveyor to the pockets in a group of pockets on the receiving conveyor.

Claims

1. ) A method of packing a product in at least one sheet of packing material;

the method comprising;

employing a number of conveyors (13, 19, 25, 39), each of which comprises a number of pockets (12, 22, 28, 42) arranged along an endless path and each for receiving and conveying at least one respective product (3); and

transferring the products (3) from each conveyor (13, 19, 25, 39) to the next conveyor (13, 19, 25, 39) at a transfer station (51, 55, 57) defined between the two conveyors (13, 19, 25, 39);

the method being characterized by

dividing the pockets (12, 22, 28, 42) of each conveyor (13, 19, 25, 39) into a first number (N1) of groups, each of which comprises an equal second number (N2), greater than one, of pockets (12, 22, 28, 42); and

simultaneously transferring, at each transfer station (51, 55, 57), a second number (N2) of products (3) from the pockets (12, 22, 28) in a group of pockets (12, 22, 28) on the releasing conveyor (13, 19, 25) to the pockets (22, 28, 42) in a group of pockets (22, 28, 42) on the receiving conveyor (19, 25, 39).

2. ) A method as claimed in claim 1, wherein, at at least one transfer station (51, 55, 57), all the pockets (12, 22, 28) in a group of pockets (12, 22, 28) on the releasing conveyor (13, 19, 25), and all the pockets (22, 28, 42) in a group of pockets (22, 28, 42) on the receiving conveyor (19, 25, 39) are aligned in a straight line.

3. ) A method as claimed in claim 2, wherein the pockets (12, 22, 28) in a group of pockets (12, 22, 28) on the releasing conveyor (13, 19, 25), and the pockets (22, 28, 42) in a group of pockets (22, 28, 42) on the receiving conveyor (19, 25, 39) are aligned in a straight line by moving at least one pocket (12, 22, 28, 42) with respect to its conveyor (13, 19, 25, 39), so that the pocket (12, 22, 28, 42) is positioned in a given transfer position at the transfer station (51, 55, 57).

4. ) A method as claimed in claim 3, wherein three products (3) are transferred simultaneously from three, respectively one central and two lateral, pockets (12, 22, 28) on the releasing conveyor (13, 19, 25) to three, respectively one central and two lateral, pockets (22, 28, 42) on the receiving conveyor (19, 25, 39).

5. ) A method as claimed in claim 4, wherein only the lateral pockets (12, 22, 28, 42) are moved with respect to the relative conveyor (13, 19, 25, 39) to position each lateral pocket (12, 22, 28, 42) in a given transfer position at the transfer station (51, 55, 57).

6. ) A method as claimed in claim 5, wherein the lateral pockets (12, 22, 28, 42) perform two equal, opposite rotations with respect to the relative conveyor (13, 19, 25, 39) as they approach the transfer station (51, 55, 57).

7. ) A method as claimed in claim 2, wherein at least one conveyor (13, 19, 25, 39) is rotary, and comprises a drum (14, 20, 26, 40) rotating about a respective central axis (15, 21, 27, 41) to feed the relative pockets (12, 22, 28, 42) along a circular path.

8. ) A method as claimed in claim 2, wherein two conveyors (19, 25) are rotary, and each comprise a drum (20, 26) rotating about a respective central axis (21, 27) to feed the relative pockets (22, 28) along a circular path.

9. ) A method as claimed in claim 7, wherein the drum (14, 20, 26, 40) is polygonal, and comprises a first number (N1) of flat faces, each of which supports all the pockets (12, 22, 28, 42) in a group of pockets (12, 22, 28, 42) aligned with one another in a line parallel to the flat face.

10. ) A method as claimed in claim 1, wherein at least one conveyor (13, 19, 25, 39) is rotary, and comprises a drum (14, 20, 26, 40) rotating about a respective central axis (15, 21, 27, 41) to feed the relative pockets (12, 22, 28, 42) along a circular path.

11. ) A method as claimed in claim 10, wherein the rotary conveyor (13, 19, 25, 39) comprises a first number (N1) of groups of pockets (12, 22, 28, 42), rotates in steps about its central axis (15, 21, 27, 41), and at each step rotates by an angle equal to a full turn divided by the first number (N1).

12. ) A method as claimed in claim 11, wherein all the rotary conveyors (13, 19, 25, 39) comprise the same first number (N1) of groups of pockets (12, 22, 28, 42);

and, at each step, all the rotary conveyors (13, 19, 25, 39) rotate by the same angle equal to a full turn divided by the first number (N1).

13. ) A method as claimed in claim 1, wherein the pockets (12) in a group of pockets (12) on an initial conveyor (13) simultaneously receive a second number (N2) of products (3) from a feed unit (11).

14. ) A method as claimed in claim 1, wherein the pockets (42) in a group of pockets (42) on an final conveyor (39) simultaneously release a second number (N2) of products (3) to an output unit (44).

15. ) A method as claimed in claim 1, wherein the pockets (12, 22, 28, 42) in a group of pockets (12, 22, 28, 42) receive respective sheets (5, 6, 7) of packing material at a feed station (9b, 9d, 9f) adjacent to the conveyor (19, 25, 39) and comprising a feed device (17, 23, 30).

16. ) A method as claimed in claim 15, wherein the feed device (17, 23, 30) feeds a second number (N2) of sheets (5, 6, 7) of packing material simultaneously to the pockets (12, 22, 28, 42) in a group of pockets (12, 22, 28, 42), when the pockets (12, 22, 28, 42) are stationary.

17. ) A method as claimed in claim 16, wherein the pockets (12, 22, 28, 42) in a group of pockets (12, 22, 28, 42) are arrested at a transfer station (51, 55, 57, 59) where they receive/release the products (3), and are arrested at a feed station (9b, 9d, 9f) where they receive sheets (5, 6, 7) of packing material.

18. ) A method as claimed in claim 15, wherein the feed device (17, 23, 30) feeds one first sheet (5, 6, 7) of packing material to one pocket (12, 22, 28, 42) when the pocket (12, 22, 28, 42) is moving and is travelling past the feed device (17, 23, 30).

19. ) A method as claimed in claim 18, wherein the pockets (12, 22, 28, 42) in a group of pockets (12, 22, 28, 42) are arrested at a transfer station (51, 55, 57, 59) where they receive/release the products (3), and travel at substantially constant speed, without stopping, past a feed station (9b, 9d, 9f) where they receive sheets (5, 6, 7) of packing material.

20. ) A packing machine for packing a product in at least one sheet of packing material;

the packing machine (1) comprising;

a number of conveyors (13, 19, 25, 39), each of which comprises a number of pockets (12, 22, 28, 42) arranged along an endless path and each for receiving and conveying at least one respective product (3); and

a number of transfer stations (51, 55, 57) for transferring the products (3) and defined between each conveyor (13, 19, 25) and the next conveyor (19, 25, 39);

the packing machine (1) being characterized in that;

the pockets (12, 22, 28, 42) of each conveyor (13, 19, 25, 39) are divided into a first number (N1) of groups, each of which comprises an equal second number (N2), greater than one, of pockets (12, 22, 28, 42); and

at each transfer station (51, 55, 57), a transfer device (54, 56, 58) simultaneously transfers a second number (N2) of products (3) from the pockets (12, 22, 28) in a group of pockets (12, 22, 28) on the releasing conveyor (13, 19, 25) to the pockets (22, 28, 42) in a group of pockets (22, 28, 42) on the receiving conveyor (19, 25, 39).

21. ) A packing machine as claimed in claim 20, wherein at least one conveyor comprises an actuating device for aligning, at at least one transfer station (51, 55, 57), all the pockets (12, 22, 28) in a group of pockets (12, 22, 28) on the releasing conveyor (13, 19, 25), and all the pockets (22, 28, 42) in a group of pockets (22, 28, 42) on the receiving conveyor (19, 25, 39) in a straight line.

22. ) A packing machine as claimed in claim 21, wherein the pockets (12, 22, 28) in a group of pockets (12, 22, 28) on the releasing conveyor (13, 19, 25), and the pockets (22, 28, 42) in a group of pockets (22, 28, 42) on the receiving conveyor (19, 25, 39) are aligned in a straight line by moving at least one pocket (12, 22, 28, 42) with respect to its conveyor (13, 19, 25, 39), so that the pocket (12, 22, 28, 42) is positioned in a given transfer position at the transfer station (51, 55, 57, 59).

23. ) A packing machine as claimed in claim 22, wherein three products (3) are transferred simultaneously from three, respectively one central and two lateral, pockets (12, 22, 28) on the releasing conveyor (13, 19, 25) to three, respectively one central and two lateral, pockets (22, 28, 42) on the receiving conveyor (19, 25, 39).

24. ) A packing machine as claimed in claim 23, wherein only the lateral pockets (12, 22, 28, 42) are moved with respect to the relative conveyor (13, 19, 25, 39) to position each lateral pocket (12, 22, 28, 42) in a given transfer position at the transfer station (51, 55, 57).

25. ) A packing machine as claimed in claim 24, wherein the lateral pockets (12, 22, 28, 42) perform two equal, opposite rotations with respect to the relative conveyor (13, 19, 25, 39) as they approach the transfer station (51, 55, 57).

26. ) A packing machine as claimed in claim 21, wherein at least one conveyor (13, 19, 25, 39) is rotary, and comprises a drum (14, 20, 26, 40) rotating about a respective central axis (15, 21, 27, 41) to feed the relative pockets (12, 22, 28, 42) along a circular path.

27. ) A packing machine as claimed in claim 21, wherein two conveyors (19, 25) are rotary, and each comprise a drum (20, 26) rotating about a respective central axis (21, 27) to feed the relative pockets (22, 28) along a circular path.

28. ) A packing machine as claimed in claim 26, wherein the drum (14, 20, 26, 40) is polygonal, and comprises a first number (N1) of flat faces, each of which supports all the pockets (12, 22, 28, 42) in a group of pockets (12, 22, 28, 42) aligned with one another in a line parallel to the flat face.

29. ) A packing machine as claimed in claim 20, wherein at least one conveyor (13, 19, 25, 39) is rotary, and comprises a drum (14, 20, 26, 40) rotating about a respective central axis (15, 21, 27, 41) to feed the relative pockets (12, 22, 28, 42) along a circular path.

30. ) A packing machine as claimed in claim 29, wherein the rotary conveyor (13, 19, 25, 39) comprises a first number (N1) of groups of pockets (12, 22, 28, 42), rotates in steps about its central axis (15, 21, 27, 41), and at each step rotates by an angle equal to a full turn divided by the first number (N1).

31. ) A packing machine as claimed in claim 30, wherein all the rotary conveyors (13, 19, 25, 39) comprise the same first number (N1) of groups of pockets (12, 22, 28, 42);

and, at each step, all the rotary conveyors (13, 19, 25, 39) rotate by the same angle equal to a full turn divided by the first number (N1).

32. ) A packing machine as claimed in claim 28, and comprising a feed unit (11) which simultaneously transfers a first number (N1) of products (3) to the pockets (12) in a group of pockets (12) on an initial conveyor (13).

33. ) A packing machine as claimed in claim 32, wherein the feed unit (11) comprises a second number (N2) of outlets, each of which transfers a product (3) to a respective pocket (12) on the initial conveyor (13).

34. ) A packing machine as claimed in claim 28, and comprising an output unit (44) which simultaneously receives a second number (N2) of products (3) from the pockets (42) in a group of pockets (42) on the final conveyor (39).

35. ) A packing machine as claimed in claim 34, wherein the output unit (44) comprises a second number (N2) of parallel output paths, each of which receives a product (3) from a respective pocket (42) on the final conveyor (39).

36. ) A packing machine as claimed in claim 28, for packing a group (3) of cigarettes in an inner sheet (5) of packing material and an outer sheet (6) of packing material;

the packing machine (1) comprising;

a hopper (11) having a second number (N2) of outlets;

a first forming conveyor (13), in the form of a drum, comprising a first number (N1) of groups of first pockets (12), each comprising a second number (N2) of first pockets (12);

a first transfer device (50) for simultaneously transferring a second number (N2) of groups of cigarettes to the first pockets (12) in a group of first pockets (12) on the first forming conveyor (13);

a second packing conveyor (19), in the form of a drum, comprising a first number (N1) of groups of second pockets (22), each comprising a second number (N2) of second pockets (22);

a second transfer device (54) for simultaneously transferring a second number (N2) of groups of cigarettes from the first pockets (12) in a group of first pockets (12) on the first forming conveyor (13) to the second pockets (22) in a group of second pockets (22) on the second packing conveyor (19);

a third packing conveyor (25), in the form of a drum, comprising a first number (N1) of groups of third pockets (28), each comprising a second number (N2) of third pockets (28);

a third transfer device (56) for simultaneously transferring a second number (N2) of groups of cigarettes from the second pockets (22) in a group of second pockets (22) on the second packing conveyor (19) to the third pockets (28) in a group of third pockets (28) on the third packing conveyor (25);

a fourth packing conveyor (39), in the form of a drum, comprising a first number (N1) of groups of fourth pockets (42), each comprising a second number (N2) of fourth pockets (42);

a fourth transfer device (58) for simultaneously transferring a second number (N2) of groups of cigarettes from the third pockets (28) in a group of third pockets (28) on the third packing conveyor (25) to the fourth pockets (42) in a group of fourth pockets (42) on the fourth packing conveyor (39);

a drying unit (44) having a second number (N2) of output paths; and

a fifth transfer device (60) for simultaneously transferring a second number (N2) of groups of cigarettes from the fourth pockets (42) in a group of fourth pockets (42) on the fourth packing conveyor (39) to the output paths of the drying unit (44).

37. ) A packing machine as claimed in claim 36, wherein the drying unit (44) comprises a second number (N2) of straight, parallel conveyor belts (45) defining the output paths.

38. ) A packing machine as claimed in claim 36, and comprising a first feed device (17) located along the periphery of the second packing conveyor (19) to feed a first sheet (5) of packing material to each second pocket (22) on the second packing conveyor (19).

39. ) A packing machine as claimed in claim 38, wherein the first feed device (17) feeds one first sheet (5) of packing material to one second pocket (22) on the second packing conveyor (19) when the second pocket (22) is moving and is travelling past the first feed device (17).

40. ) A packing machine as claimed in claim 36, and comprising a second feed device (30) located along the periphery of the fourth packing conveyor (39) to feed a second sheet (6) of packing material to each fourth pocket (42) on the fourth packing conveyor (39).

41. ) A packing machine as claimed in claim 40, wherein the second feed device (30) feeds one second sheet (6) of packing material to one fourth pocket (42) on the fourth packing conveyor (39) when the fourth pocket (42) is moving and is travelling past the second feed device (30).

42. ) A packing machine as claimed in claim 28, for packing a group (3) of cigarettes in an inner sheet (5) of packing material and an outer sheet (6) of packing material;

the packing machine (1) comprising;

a hopper (11) having a second number (N2) of outlets;

a first forming conveyor (13), in the form of a belt, comprising a first number (N1) of groups of first pockets (12), each comprising a second number (N2) of first pockets (12);

a first transfer device (50) for simultaneously transferring a second number (N2) of groups of cigarettes to the first pockets (12) in a group of first pockets (12) on the first forming conveyor (13);

a second packing conveyor (19 ), in the form of a drum, comprising a first number (N1) of groups of second pockets (22), each comprising a second number (N2) of second pockets (22);

a second transfer device (54) for simultaneously transferring a second number (N2) of groups of cigarettes from the first pockets (12) in a group of first pockets (12) on the first forming conveyor (13) to the second pockets (22) in a group of second pockets (22) on the second packing conveyor (19);

a third packing conveyor (25), in the form of a drum, comprising a first number (N1) of groups of third pockets (28), each comprising a second number (N2) of third pockets (28);

a third transfer device (56) for simultaneously transferring a second number (N2) of groups of cigarettes from the second pockets (22) in a group of second pockets (22) on the second packing conveyor (19) to the third pockets (28) in a group of third pockets (28) on the third packing conveyor (25);

a fourth packing conveyor (39), in the form of a belt, comprising a first number (N1) of groups of fourth pockets (42), each comprising a second number (N2) of fourth pockets (42);

a fourth transfer device (58) for simultaneously transferring a second number (N2) of groups of cigarettes from the third pockets (28) in a group of third pockets (28) on the third packing conveyor (25) to the fourth pockets (42) in a group of fourth pockets (42) on the fourth packing conveyor (39);

a drying unit (44) having a second number (N2) of output paths; and

a fifth transfer device (60) for simultaneously transferring a second number (N2) of groups of cigarettes from the fourth pockets (42) in a group of fourth pockets (42) on the fourth packing conveyor (39) to the output paths of the drying unit (44).

43. ) A packing machine as claimed in claim 42, wherein the drying unit (44) comprises a second number (N2) of straight, parallel conveyor belts (45) defining the output paths.

44. ) A packing machine as claimed in claim 42, and comprising a first feed device (17) located along the periphery of the second packing conveyor (19) to feed a first sheet (5) of packing material to each second pocket (22) on the second packing conveyor (19).

45. ) A packing machine as claimed in claim 44, wherein the first feed device (17) simultaneously feeds a second number (N2) of first sheets (5) of packing material to the second pockets (22) in a group of second pockets (22) on the second packing conveyor (19) when the second pockets (22) are stationary.

46. ) A packing machine as claimed in claim 45, wherein the first feed device (17) comprises a second number (N2) of suction heads (65) fitted to a movable member (66) which moves back and forth between a receiving position at a strip (18) of first sheets (5) of packing material, and a release position at the second packing conveyor (19).

47. ) A packing machine as claimed in claim 46, wherein each suction head (65) is hinged to the movable member (66) to rotate, with respect to the movable member (66), about an axis of rotation (67) parallel to the axis of rotation (21) of the drum (62) of the second packing conveyor (19).

48. ) A packing machine as claimed in claim 42, and comprising a second feed device (30) located along the periphery of the fourth packing conveyor (39) to feed a second sheet (6) of packing material to each fourth pocket (42) on the fourth packing conveyor (39).

49. ) A packing machine as claimed in claim 48, wherein the second feed device (30) simultaneously feeds a second number (N2) of second sheets (6) of packing material to the fourth pockets (42) in a group of fourth pockets (42) on the fourth packing conveyor (39) when the fourth pockets (42) are stationary.

50. ) A packing machine as claimed in claim 49, wherein the second feed device (30) comprises a second number (N2) of insertion heads (71) which move back and forth to simultaneously insert a second number (N2) of second sheets (6) of packing material, positioned in a feed position in front of the insertion heads (71), into the fourth pockets (42) of a group of fourth pockets (42) on the fourth packing conveyor (39).

51. ) A packing machine as claimed in claim 50, wherein the second feed device (30) comprises a second number (N2) of conveying devices (72), each of which rotates in steps about an axis of rotation to withdraw a second sheet (6) of packing material from a line (74) supplying the second sheets (6) of packing material, and to position the second sheet of packing material in a feed position in front of a respective insertion head (71).

52. ) A packing machine as claimed in claim 51, wherein each conveying device (72) rotates in steps in the same direction at all times, and rotates 360°

at each step.

53. ) A method of controlling a tobacco processing system comprising at least one machine (1) employing at least one base material (5, 6, 7) to produce an end product (2);

the method comprising the steps of;

assigning the machine (1) a number of end products (2) to be produced;

loading an amount of base material (5, 6, 7) at a feed station (9b, 9d, 9f) of the machine (1);

starting the machine (1) to produce the end products (2);

cyclically determining the number of acceptable end products (2) produced;

cyclically determining the outstanding number of end products (2) to be produced as a function of the number of end products (2) to be produced and the number of acceptable end products (2) produced; and

cyclically determining the amount of base material (5, 6, 7) left at the feed station (9b, 9d, 9f) of the machine (1);

the method being characterized by comprising the further steps of;

cyclically determining the amount of base material (5, 6, 7) required to produce the outstanding number of end products (2);

cyclically determining the outstanding amount of base material (5, 6, 7) to be loaded at the feed station (9b, 9d, 9f) of the machine (1) as a function of the amount of base material (5, 6, 7) required to produce the outstanding number of end products (2), and the amount of base material (5, 6, 7) left at the feed station (9b, 9d, 9f) of the machine (1); and

cyclically informing an operator of the outstanding amount of base material (5, 6, 7) to be loaded at the feed station (9b, 9d, 9f) of the machine (1).

54. ) A method as claimed in claim 53, wherein the base material (5, 6, 7) is stocked and handled in units, each comprising a given amount of base material (5, 6, 7);

the step of cyclically informing an operator of the outstanding amount of base material (5, 6, 7) to be loaded at the feed station (9b, 9d, 9f) of the machine (1) comprising the further steps of;

rounding up to a whole number of units of base material (5, 6, 7) the outstanding amount of base material (5, 6, 7) to be loaded at the feed station (9b, 9d, 9f) of the machine (1); and

communicating to the operator the rounded-up whole number of units of base material (5, 6, 7).

55. ) A method as claimed in claim 53, wherein the outstanding amount of base material (5, 6, 7) to be loaded at the feed station (9b, 9d, 9f) of the machine (1) is increased by a given percentage to allow for rejects.

56. ) A method as claimed in claim 55, wherein the reject-related percentage increase is a constant of the machine (1).

57. ) A method as claimed in claim 56, wherein the reject-related percentage increase is real-time updated during manufacture of the current production lot.