Continuous loading system

Abstract

A system is disclosed for loading a plurality of items into a plurality of containers. The system may include a plurality of pucks, each puck adapted to retain an item. A puck delivery sub-system may include a puck-infeed conveyor to move each of the pucks along an in-feed conveyor path, and a transition apparatus operable to facilitate the transition of the pucks to a continuous puck unloading conveyor. The puck un-loading conveyor may have a releasable engagement mechanism such that when each of the pucks is engaged with said puck unloading conveyor, each of said pucks is fixed in a relative longitudinal position relative to the puck unloading conveyor. An item transfer apparatus may transfer an item from each puck when engaged with the puck un-loading conveyor, to a corresponding container.

1 . A system for loading a plurality of items into a plurality of containers comprising:
 (a) a plurality of pucks, each of said pucks adapted to retain an item;   (b) a puck delivery sub-system comprising a puck-infeed conveyor operable to move each of said plurality of pucks in series along an in-feed conveyor path portion, and a transition apparatus operable to facilitate the transition of said plurality of pucks from said puck in-feed conveyor to a continuous puck unloading conveyor;   (c) a continuous puck unloading conveyor movable in a longitudinal direction along a first conveyor path portion, said pucks and said puck unloading conveyor having a releasable engagement mechanism operable to facilitate said pucks releasably engaging said puck unloading conveyor, such that when each of said pucks is engaged with said puck unloading conveyor, each of said pucks is fixed in a relative longitudinal position relative to said puck unloading conveyor;   (d) a container conveyor for moving a plurality of containers in series with fixed longitudinal positions relative to said container loading conveyor, and said container loading conveyor moving in a longitudinal direction along a second conveyor path portion proximate said first path portion of said puck unloading conveyor;   (e) an item transfer apparatus for transferring said item from each of said plurality of pucks on said puck unloading conveyor to a corresponding container being moved on said container conveyor;   wherein said item transfer apparatus will transfer each item retained by pucks once engaged with said puck unloading conveyor, to a respective container of said container conveyor, while said puck unloading conveyor is moving along said first path portion and said container conveyor is moving along said second path portion,   wherein after each item retained by said puck has been transferred to a carton, said releasable engagement mechanism is operable to facilitate said pucks being released from engagement with said puck unloading conveyor.   
   
   
       2 . A system as claimed in  claim 42  wherein said releasable engagement mechanism for each puck comprises at least one generally transversely oriented slot and a generally transversely oriented rod member receivable in said slot, wherein when a rod member is received in a slot, the relative longitudinal position of said puck to said respective rods is fixed. 
   
   
       3 . A system as claimed in  claim 2  wherein said at least one slot is provided in each said puck and each corresponding rod is provided on said unloading conveyor. 
   
   
       4 . A system as claimed in  claim 42  wherein said in-feed conveyor moves said pucks along said first path solely by a frictional force engagement mechanism between said in-feed conveyor and said pucks. 
   
   
       5 . A system as claimed in  claim 3  wherein said in-feed conveyor moves said pucks by a frictional force engagement mechanism between said in-feed conveyor and said pucks. 
   
   
       6 . A system as claimed in  claim 4  wherein said in-feed conveyor has a conveyor belt with a belt surface and each of said pucks has a surface, and wherein said frictional force engagement mechanism is provided between said belt surface and said surface of said pucks. 
   
   
       7 . A system as claimed in  claim 42  wherein said container conveyor is a continuous conveyor that moves in synchronization with the movement of said continuous puck unloading conveyor. 
   
   
       8 . A system as claimed in  claim 42  further comprising:
 (a) a PLC; and   (b) a first drive motor for driving the movement of said transition apparatus;   wherein said PLC is operable to control the speed of said first drive motor such that the movement of said pucks can be synchronized with the movement of said puck unloading conveyor, so that said engagement mechanism between each of said pucks and said puck unloading conveyor can be engaged.   
   
   
       9 . A system as claimed in  claim 8  wherein said PLC is operable to control the movement of said puck unloading conveyor and said PLC can adjust the movement of said transition apparatus so that said engagement mechanism between each of said pucks and said puck unloading conveyor can be engaged. 
   
   
       10 . A system as claimed in  claim 6  wherein said plurality of pucks comprises a plurality of groups of pucks, each of said plurality of pucks having a lead puck, and said transition apparatus is adapted to control the movement of said lead puck in said plurality of pucks so that said releasable engagement mechanism between said lead puck and said puck unloading conveyor can be engaged, and whereby when said lead puck is engaged with said puck unloading conveyor, said puck in-feed conveyor will push the remaining pucks of said group such that said releaseable engagement mechanisms between each of said remaining pucks and said puck unloading conveyor can also be engaged. 
   
   
       11 . A system as claimed in  claim 42  wherein said plurality of pucks comprises at least one group of pucks, each of said at least one group of pucks having a lead puck, and said transition apparatus is operable to control the movement of said lead puck in said plurality of pucks so that said releaseable engagement mechanism between said lead puck and said puck unloading conveyor can be engaged, and wherein when said lead puck is engaged with said puck unloading conveyor, said puck in-feed conveyor will push the remaining pucks of said group such that said releaseable engagement mechanisms between each of said remaining pucks and said puck unloading conveyor can also be engaged. 
   
   
       12 . A system as claimed in  claim 11  wherein said at least one group of pucks comprises a plurality of groups of pucks, each having a lead puck. 
   
   
       13 . A system as claimed in  claim 11  wherein said in-feed conveyor moves at a speed greater than or equal to said puck unloading conveyor. 
   
   
       14 . A system as claimed in  claim 13  wherein each of said plurality of pucks in said group of pucks remains in abutment with adjacent pucks of said group during the transition from said in-feed conveyor at least until engagement with said puck unloading conveyor. 
   
   
       15 . A system as claimed in  claim 12  further comprising:
 (a) a PLC operable to control the movement of said transition apparatus;   (b) a sensor operable to send a signal to said PLC indicative of a minimum number of pucks being available to form a group and for delivery to said puck unloading conveyor;   wherein upon receipt of said signal, said PLC is operable to control said transition apparatus such that the movement of said pucks can be synchronized with the movement of said puck unloading conveyor, so that said engagement mechanism between each of said pucks and said puck unloading conveyor can be engaged.   
   
   
       16 . A system as claimed in  claim 42  further comprising:
 (a) a PLC operable to control the movement of said transition apparatus;   (b) a sensor operable to send a signal to said PLC indicative of a minimum number of pucks being available for delivery to said puck unloading conveyor;   wherein upon receipt of said signal, said PLC is operable to control said transition apparatus such that the movement of said pucks can be synchronized with the movement of said puck unloading conveyor, and so that said engagement mechanism between each of said pucks and said puck unloading conveyor can be engaged.   
   
   
       17 . A system as claimed in  claim 10  wherein said transferring of each item retained by said puck to a respective container is by transverse movement of said items from said pucks into said cartons. 
   
   
       18 . A system as claimed in  claim 17  further comprising a vertical confinement apparatus for vertically confining each said item retained in said puck while said item transfer apparatus is transferring each said item from said puck to a container. 
   
   
       19 . A system as claimed in  claim 42  wherein said containers are cartons. 
   
   
       20 . A system for loading a plurality of items into a plurality of containers comprising:
 (a) a plurality of pucks, each of said pucks adapted to retain an item;   (b) a puck delivery system operable to deliver said plurality of pucks in series to a puck unloading conveyor;   (c) said continuous puck unloading conveyor movable in a longitudinal direction along a first conveyor path;   (d) said pucks and said puck unloading conveyor having a releasable engagement mechanism operable to provide said pucks with a releasable connection to said puck unloading conveyor, such that when said pucks are connected to said puck unloading conveyor, each of said plurality of pucks is fixed in a relative longitudinal position relative to said puck unloading conveyor;   (e) a continuous container loading conveyor for moving a plurality of containers in series with fixed longitudinal positions relative to said container loading conveyor, and said container loading conveyor moving in a longitudinal direction along a second conveyor path having a path portion proximate a path portion of said path of said puck unloading conveyor;   (f) an item transfer apparatus for transferring each said item from each of said plurality of pucks on said puck unloading conveyor to a corresponding container being moved on said container conveyor;   said puck delivery system operable to move said plurality of pucks in series to said puck unloading conveyor to cause each of said pucks to connect with said puck unloading conveyor with said releasable engagement mechanism;   wherein when said puck unloading conveyor moves said pucks along said path portion of said first path while said pucks are releasably connected to said puck unloading conveyor, said item transfer apparatus will transfer each item retained by each said puck to a respective container on said container conveyor while respective containers are moving along said path portion of said second conveyor path;   wherein after each item retained by said puck has been transferred to a carton, said releasable engagement mechanism is operable to facilitate said pucks being released from engagement with said puck unloading conveyor.   
   
   
       21 . A system as claimed in  claim 20  wherein said releasable engagement mechanism for each puck comprises at least one generally transversely oriented slot and a generally transversely oriented rod member receivable in said slot, wherein when a rod member is received in a slot, the relative longitudinal position of said puck to said respective rods is fixed. 
   
   
       22 . A system as claimed in  claim 21  wherein said at least one slot is provided in each said puck and each corresponding rod is provided on said unloading conveyor. 
   
   
       23 . A system as claimed in  claim 20  wherein puck delivery conveyor comprises a puck in-feed conveyor that moves said pucks by a frictional force engagement mechanism between said in-feed conveyor and said pucks. 
   
   
       24 . A system as claimed in  claim 23  wherein said in-feed conveyor has a conveyor belt with a belt surface and each of said pucks has a surface, and wherein said frictional force engagement mechanism is provided between said belt surface and said surface of said pucks. 
   
   
       25 . A system as claimed in  claim 24  wherein said container conveyor is a continuous conveyor that moves in synchronization with the movement of said continuous puck unloading conveyor. 
   
   
       26 . A system as claimed in  claim 23  wherein said plurality of pucks comprises a plurality of groups of pucks, each of said plurality of pucks having a lead puck, and said delivery system and a PLC are adapted to control the movement of said lead puck in said plurality of pucks so that said engagement mechanism between said lead puck and said puck unloading conveyor can be engaged, and whereby when said lead puck is engaged with said puck unloading conveyor, said puck in-feed conveyor will push the remaining pucks of said group such that said engagement mechanisms between each of said remaining pucks and said puck unloading conveyor can also be engaged. 
   
   
       27 . A system as claimed in  claim 26  wherein said at least one group of pucks comprises a plurality of groups of pucks, each having a lead puck. 
   
   
       28 . A system as claimed in  claim 27  wherein each of said plurality of pucks in said group of pucks remains in abutment with adjacent pucks of said group during the transition from said in-feed conveyor at least until engagement with said puck unloading conveyor. 
   
   
       29 . A system as claimed in  claim 28  further comprising:
 (a) a PLC operable to control the operation of said puck delivery system;   (b) a sensor operable to send a signal to said PLC indicative of a minimum number of pucks being available to form a group and for delivery by said puck delivery system to said puck unloading conveyor;   wherein upon receipt of said signal, said PLC is operable to control said puck delivery system such that the movement of said pucks can be synchronized with the movement of said puck unloading conveyor, so that said engagement mechanism between each of said pucks and said puck unloading conveyor can be engaged.   
   
   
       30 . A system for loading items into a plurality of containers comprising:
 (a) a first puck conveyor for moving a plurality of pucks, each of said pucks retaining an item, along a first path with a frictional force exerted on said pucks by said first puck conveyor;   (b) a second continuous puck conveyor for moving said plurality of pucks along a second path in series while each of said pucks is in a fixed longitudinal connection with said second continuous conveyor;   (c) an apparatus for facilitating the transition of each of said plurality of pucks from said first puck conveyor to said second puck conveyor;   (d) a container conveyor moving a plurality of containers in series with fixed longitudinal positions relative to said container conveyor along a third path;   said second continuous puck conveyor having a path portion of said second path proximate a path portion of said third path of said container conveyor;   wherein said apparatus will facilitate the transistion of said plurality of pucks form said first puck conveyor to said puck conveyor.   
   
   
       31 . A system as claimed in  claim 30  wherein wherein said transferring of each item retained by said puck to a respective container is by transverse movement of said items from said pucks into said containers. 
   
   
       32 . A system as claimed in  claim 30  wherein said containers are cartons. 
   
   
       33 . A method for loading items into a plurality of containers comprising:
 (a) moving a plurality of pucks, each of said pucks retaining an item, along a first path with a frictional force exerted on said pucks in a first longitudinal path;   (b) facilitating the transition of said plurality of pucks in series into fixed longitudinal engagement with a continuous puck moving apparatus;   (c) moving said pucks in series along a second longitudinal path while in said fixed longitudinal engagement with said continuous puck moving apparatus;   (d) moving a plurality of containers in series with fixed longitudinal positions relative to and with a container moving apparatus, and along a third longitudinal path having a path portion proximate a path portion of said second longitudinal path;   (e) while said pucks are moving along said path portion of said second longitudinal path and said containers are moving along said third longitudinal path, transferring each item retained by said puck to a respective container.   
   
   
       34 . A method as claimed in  claim 33  wherein said continuous puck moving apparatus comprises a continuous puck unloading conveyor and wherein said transferring of each item retained by said puck to a respective container is by transverse movement of said items from said pucks into said containers. 
   
   
       35 . A method as claimed in  claim 33  further comprising after (e), (f) disengaging each of said pucks in series from moving in said fixed longitudinal engagement with said continuous puck moving apparatus. 
   
   
       36 . A system for loading a plurality of items into a plurality of containers from a plurality of pucks, each of said pucks adapted to retain an item, said method comprising:
 (a) an apparatus operable to move each of said plurality of pucks in series along a puck in-feed conveyor path portion in a longitudinal direction with a frictional force imparted on each of said pucks;   (b) an apparatus operable to facilitate the transition of said plurality of pucks from said puck in-feed conveyor to engage a continuous puck unloading conveyor;   (c) an apparatus having continuous movement which is operable to move said pucks on said continuous puck unloading conveyor in a longitudinal direction along a first path portion wherein each of said pucks is fixed in a relative longitudinal position relative to said puck unloading conveyor;   (d) an apparatus operable to move a plurality of containers in series with fixed longitudinal position relative to said puck unloading conveyor, and in a longitudinal direction along a second conveyor path portion proximate said first path portion of said puck unloading conveyor;   (e) an apparatus for transferring each said item from each of said plurality of pucks on said puck to a corresponding container while said apparatus operable to move said pucks is moving said pucks.   
   
   
       37 . A system as claimed in  claim 30  wherein each puck comprises:
 (a) a body;   (b) a receptacle formed in said body for retaining an item;   (c) at least one cam follower extending from said body, said cam follower having a flange spaced from said body to provide a slot configured to receive a cam track portion therein.   
   
   
       38 . A puck as claimed in  claim 37  wherein said body comprises a base portion configured to support said puck on a conveyor belt and said cam follower extends from a surface on said body other than said base. 
   
   
       39 . A puck as claimed in  claim 38  wherein said receptacle has lower surface and said cam follower extends downwards from said lower surface of said receptacle. 
   
   
       40 . A puck as claimed in  claim 37  comprising at least two cam followers extending from said body, each of said cam follower having a flange spaced from said body to provide a slot configured to receive a cam track portion therein. 
   
   
       41 . A puck as claimed in  claim 40  comprising at least two cam followers extending from said lower surface of said receptacle, each of said cam followers having a flange spaced from said lower surface to provide a slot configured to receive a cam track portion therein. 
   
   
       42 . A system as claimed in  claim 30  wherein:
 said first puck conveyor comprises a puck infeed conveyor operable to move each of said plurality of pucks in series along an in-feed conveyor path portion of said first path;   said second continuous puck conveyor comprises a continuous puck unloading conveyor;   said apparatus for facilitating the transition comprises a transition apparatus operable to facilitate the transition of said plurality of pucks from said puck in-feed conveyor to said continuous puck unloading conveyor;   said pucks and said continuous puck unloading conveyor having a releasable engagement mechanism operable to facilitate said pucks releasably engaging said continuous puck unloading conveyor, such that when each of said pucks is engaged with said continuous puck unloading conveyor, each of said pucks is fixed in a relative longitudinal position relative to said continuous puck unloading conveyor;   said system further comprising an item transfer apparatus for transferring each said item from each of said plurality of pucks on said continuous puck unloading conveyor to a corresponding container being moved on said container conveyor;   wherein said item transfer apparatus will transfer each item retained by pucks once engaged with said puck unloading conveyor, to a respective container of said container conveyor, while said puck unloading conveyor is moving along said first path and said container conveyor is moving along said longitudinal path,   wherein after each item retained by said puck has been transferred to a carton, said releasable engagement mechanism is operable to facilitate said pucks being released from engagement with said puck unloading conveyor.