System and method of processing and packing disk-like objects

Abstract

A system for automatically forming several parallel rows of disk-like objects on a conveyor into stacks and packing those stacks into boxes is disclosed along with a method of operating the system. The system includes a stacker receiving the disk-like objects as they fall of the conveyor, a buffer receiving stacks from the stacker in groups of a first number, a transfer device for removing the stacks from the buffer in groups of a second number, and a packer for packing the stacks into boxes. The second number can be less than, greater than, or equal to the first number.

1 - 31 . (canceled)  
   
   
       32 . A method for processing a flow of disk-like objects comprising: 
 conveying at least two rows of disk-like objects toward and over a lip;    providing at least two catchers adjacent said lip;    catching the disk-like objects of each row as said disk-like objects fall over said lip and forming a stack of objects on each of said catchers;    providing a buffer comprising a plurality of stack holders individually movable around a closed loop;    transferring said at least two stacks of objects from said catchers to at least two of said stack holders;    moving said at least two stack holders from a first location on said closed loop to a second location on said closed loop;    removing a number of stacks from the second location on said closed loop and placing said removed stacks on a platform to form a first column;    removing additional stacks from the second location on said closed loop and placing said removed additional stacks on said platform to form a second column;    placing a box over said first and second columns of stacks;    inverting said box and said platform to transfer said stacks from said platform to said box; and    moving said box away from said platform.    
   
   
       33 . The method of  claim 32  wherein the step of catching the disk-like objects of each row as the disk-like objects fall over said lip and forming a stack of objects on each of said catchers comprises the step of catching the disk-like objects on a first plurality of supports and transferring stacks formed on said first plurality of supports to a second plurality of supports.  
   
   
       34 . The method of claim of  claim 32  wherein the step of catching the disk-like objects of each row as the disk-like objects fall over said lip and forming a stack of objects on each of said catchers comprises the step of catching the disk-like objects on a first plurality of supports, transferring stacks formed on said first plurality of supports to a second plurality of supports and transferring stacks formed on said second plurality of supports to a third plurality of supports comprising a first transfer mechanism.  
   
   
       35 . The method of  claim 34  wherein the step of transferring said at least two stacks of objects from said catchers to at least two of said stack holders comprises the step of moving said first transfer mechanism from a first location to a second location adjacent said buffer.  
   
   
       36 . The method of claim of  claim 32  wherein the step of catching the disk-like objects of each row as the disk-like objects fall over said lip and forming a stack of objects on each of said catchers comprises the step of catching the disk-like objects on a first plurality of supports, transferring stacks formed on said first plurality of supports to a second plurality of supports, transferring stacks formed on said second plurality of supports to a third plurality of supports comprising a first transfer mechanism, and catching additional disk-like objects on said first plurality of supports as said first transfer mechanism moves from a first position to a second position adjacent said buffer.  
   
   
       37 . The method of  claim 32  including the additional step of counting the disk-like objects in one of the at least two rows of disk-like objects as they approach the lip.  
   
   
       38 . The method of  claim 32  wherein the step of transferring said at least two stacks of objects from said catchers to at least two of said stack holders comprises the step of inverting said at least two of said stack holders.  
   
   
       39 . The method of  claim 32  wherein the step of removing a number of stacks from the second location on said closed loop and placing said removed stacks on a platform to form a first column comprises the step of gripping said number of stacks and simultaneously moving said number of stacks from the second location.  
   
   
       40 . The method of  claim 32  wherein the step of removing a number of stacks from the second location on said closed loop and placing them on a platform to form a first column comprises the steps of: 
 providing a movable frame having a top and a bottom and a center opening;    providing a plurality of lower supports on said frame bottom;    positioning said frame at a first location around a plurality of stacks of discrete objects with one of said lower supports adjacent each of said stack bottoms and with said frame top adjacent the tops of said stacks;    moving at least a portion of said frame top against said stacks to hold said stacks between said frame top and said frame bottom;    moving said frame to said second location; and    moving said at least a portion of said frame top away from said stacks to release said stacks at said second location.    
   
   
       41 . The method of  32  wherein the step of removing a number of stacks from the second location on said closed loop and placing them on a platform to form a first column comprises the steps of: 
 providing a movable frame having a top and a bottom and a center opening;    providing a plurality of lower supports on said frame bottom;    providing a plurality of actuators on said frame top each connected to a plate member and aligned with one of said plurality of lower supports;    positioning said frame at a first location around a plurality of stacks of discrete objects with one of said plurality of lower supports beneath each one of said plurality of stacks and one of said plate members above each of said stacks;    moving said plate members against said stacks to compress each of said stacks between one of the supports and one of the plate members;    pivoting said frame about an axis parallel to said bottom;    moving said frame to said second location; and    moving said lower supports away from said upper supports to release said stacks at said second location.    
   
   
       42 . An apparatus for packing disk-like objects comprising: 
 a stacker receiving a first number of rows of objects from a conveyor and forming the rows into stacks;    a buffer for receiving the stacks in groups of a first number;    a packer for packing the stacks in a box; and    a transfer mechanism for transferring the stacks from said buffer to said packer in groups of a second number.    
   
   
       43 . The apparatus of  claim 42  wherein said stacker includes a plurality of catchers arranged in a row.  
   
   
       44 . The apparatus of  claim 43  wherein said catchers include a first support and a transfer mechanism and means for transferring said stacks from said first support to said transfer mechanism.  
   
   
       45 . The apparatus of  claim 44  wherein said buffer comprises a plurality of individual stack holders.  
   
   
       46 . The apparatus of  claim 45  wherein said buffer comprises a continuously moving drive belt and wherein said plurality of individual stack holders are connected to said drive belt.  
   
   
       47 . The apparatus of  claim 45  wherein said buffer comprises a carousel.  
   
   
       48 . The apparatus of  claim 42  wherein said transfer mechanism comprises a plurality of grippers for simultaneously gripping a plurality of stacks.  
   
   
       49 . The apparatus of  claim 42  wherein said packer comprise a first platform for supporting a plurality of stacks and a second platform for supporting a box.  
   
   
       50 . The apparatus of  claim 49  wherein said second platform is movable relative to said first platform.  
   
   
       51 . A method of packing disk-like objects comprising: 
 moving a first number of rows of disk-like objects along a conveyor toward a conveyor end edge;    providing the first number of catchers in a row adjacent said end edge, each of said catchers being aligned with one of said first number of rows of disks;    catching the disks in each of said rows of disks on the aligned catcher to form a stack on each of said catchers;    transferring said first number of stacks from said row of catchers to a buffer;    transferring stacks from said buffer to a packer in groups of a second number; and    automatically packing said stacks on said packer into a box.