Case loading system

• US 5,971,699 A
• Filed: 07/17/1997
• Issued: 10/26/1999
• Est. Priority Date: 02/11/1991
• Status: Expired due to Fees

• Current Assignee: Ernest P. Winski
• Original Assignee: Ernest P. Winski
• Inventors: Winski, Ernest P.
• Primary Examiner(s): Merritt, Karen B.
• Assistant Examiner(s): MORSE, GREGORY ALLAN
• Application Number:
  US08/895,533
• Time in Patent Office: 831 Days
• Field of Search: 414/791.6, 414/792.6
• US Class Current: 414/791.6
• CPC Class Codes: B65G 47/086 cubiform articles
• CPC Class Codes: B65G 57/245 with a stepwise downward movement of the stack

Abstract

This invention pertains to load forming systems, especially those designed to place cased product on e.g. a pallet. The invention contemplates receiving cases at a high rate of input, and fragmenting the input, sending it to parallel processing elements of the load forming system. A layer creating subsystem has parallel processing elements, and preferably has sufficient designed throughput capacity to continue processing cases at the overall rated capacity of the case loading system when any one of the parallel processing elements in the layer creating subsystem fails. The case loading subsystem also can incoroporate parallel layer transfer elements and load forming elements.

Claims

1. A case loading system for receiving cases of product, and forming loads of the cases, in layers, said case loading system comprising:

(a) a layer creating subsystem, for receiving cases of product, and forming the cases into layers, said layer creating subsystem comprising at least one layer forming station;

(b) a load creating subsystem, for receiving layers formed in said layer creating subsystem, and forming the layers into a load, said load creating subsystem comprising at least one load forming station; and

(c) a layer transfer subsystem, for (i) receiving layers formed in said layer creating subsystem, and for (ii) delivering the layers to said load creating subsystem, said layer transfer subsystem comprising at least first and second movable transfer plates, each of said first and second transfer plates being disposed and configured to receive a layer of cases of product formed in said layer creating subsystem at a position such that movement of said transfer plate from said position enables the layer of cases of product to be delivered to said load creating subsystem.

2. A case loading system as in claim 1, said layer creating subsystem comprising a first layer forming station for forming layers, and delivering the layers, so formed, to said first transfer plate, and a second layer forming station for forming layers, and delivering layers, so formed, to said second transfer plate.

3. A case loading system as in claim 1, said load creating subsystem comprising a first load forming station for receiving layers of cases from said first transfer plate, but not from said second transfer plate, and a second load forming station for receiving cases from said second transfer plate, but not from said first transfer plate.

4. A case loading system as in claim 1, said load creating subsystem comprising first and second load forming stations, for receiving layers of cases from said first and second layer transfer plates.

5. A case loading systems in claim 1 wherein said load creating subsystem includes at least first and second load forming stations, and wherein each load forming station receives layers from only one of said transfer plates.

6. A case loading system as in claim 1 wherein said layer creating subsystem includes at least first and second layer forming stations and at least first and second in-feed conveyors, wherein the case loading system includes a controller for controlling movement of the cases of product through the case loading system, and wherein each said in-feed conveyor includes (i) a product demand sensor for signalling product demand to said controller, and (ii) a conveyor full sensor for signalling said controller that the respective said in-feed conveyor is full.

7. A case loading system for receiving cases of product, and for forming loads of the cases, in layers, said case loading system comprising:

(a) a product conveyor;

(b) a layer creating subsystem comprising at least first and second case converting subsystems, said at least first and second case converting subsystems comprising corresponding (i) at least first and second layer forming stations, and (ii) at least first and second in-feed conveyors, each said in-feed conveyor having a receiving locus configured and positioned to receive cases of product from said product conveyor, and a discharge locus configured and positioned to discharge cases of product to the corresponding said layer forming station, whereby both of said first and second case converting subsystems receive cases of product from said product conveyor, said first and second layer forming stations being configured and positioned to receive cases of product from the corresponding said in-feed conveyors and to form the cases of product into layers;

(c) a load creating subsystem, comprising at least one load forming station for receiving layers of cased product formed in said layer creating subsystem, and for forming the layers into loads; and

(d) a layer transfer subsystem including at least first and second transfer plates for receiving thereon said layers of product from said layer creating subsystem and providing said layers of product to said load creating subsystem.

8. A case loading system as in claim 7 wherein each of said first and second transfer plates are disposed and configured to receive a layer of cases of product from said layer creating subsystem at a position such that movement of said transfer plate from said position enables the layer of cases of product to be delivered to said load creating subsystem.

9. A case loading system as in claim 7 wherein said load creating subsystem includes at least first and second load forming stations, and wherein each load forming station receives layers from only one of said transfer plates.

10. A case loading system as in claim 7 wherein the case loading system includes a controller for controlling movement of cases of product at least through said layer creating subsystem, and wherein each said in-feed conveyor includes (i) a product demand sensor for signalling product demand to said controller, and (ii) a conveyor full sensor for signalling said controller that the respective said in-feed conveyor is full.

11. A case loading system as in claim 7, said first layer forming station delivering the layers formed thereat to said first transfer plate, and said second layer forming station delivering the layers formed thereat to said second transfer plate.

12. A case loading system as in claim 7, said load creating subsystem comprising a first load forming station for receiving layers of cases from said first transfer plate, but not from said second transfer plate, and a second load forming station for receiving cases from said second transfer plate, but not from the first transfer plate.

13. A case loading system as in claim 7, said load creating subsystem comprising first and second load forming stations, for receiving layers of cases from said first and second transfer plates.