Method and system for top loading of containers such as cartons, cases and trays, etc.

Abstract

A system comprises an item collating conveyor operable to form a plurality of items into a plurality of groups and transports each group of items in series in a first generally longitudinal direction to an item transfer station. The system also has a container delivery conveyor and a robotic device. The container delivery conveyor moves a plurality of containers from a container input station to the transfer station and then to a container output station. The robotic device has an end effector adapted to transfer each said group of items carried from the item collating conveyor into successive containers. Each item of the group of items is loaded together into each container by the robotic device while each container is moving in the second generally longitudinal direction. A controller controls the operation of the industrial robot. The tray conveyor can be configured with a three spaced chains, and a series of releasable and attachable lugs attached to the medial chain. The lugs can be configured to support the path of the medial chain.

1 . A method of loading an open top container with one or more items comprising: 
 a) forming a plurality items into a first group of items;    b) moving said first group in a first generally longitudinal direction;    c) moving a container in a second generally longitudinal direction    d) transferring the first group into a container by a combination of generally lateral, longitudinal and vertical movements to load said items into said container while said container is moving in said second generally longitudinal direction.    
   
   
       2 . A method as claimed in  claim 1  wherein said plurality of items are fed serially to an collating device adapted to form said plurality of items into said first group.  
   
   
       3 . A method as claimed in  claim 1  wherein a plurality of groups of items are formed in series, and a plurality of containers are fed in series in said second longitudinal direction, and wherein a group of said plurality of groups is each transferred into a different container of said groups of containers by a combination of generally lateral, longitudinal and vertical movements to load each of said items of said group into each said container while each said container is moving in said second generally longitudinal direction  
   
   
       4 . A system for loading a plurality of groups of items in series into a plurality of open top containers, said system comprising: 
 a) an item collating conveyor operable to form a plurality of items into a plurality of groups of items at an item loading station and transport each said group of items in series in a first generally longitudinal direction to an item transfer station;    b) a container delivery conveyor moving a plurality of containers from a container input station to said item transfer station and then to a container output station;    c) a robotic device having an end effector adapted to pick up and release said group of items, said robot operable to transfer each said group of items carried on said item collating conveyor with vertical, longitudinal and transverse movement from said item collating conveyor into successive containers of said plurality of containers, each of said group of items being loaded together into each said container by said robotic device while each said container is moving in said second generally longitudinal direction;    d) a controller for controlling the operation of said industrial robot to effect said transfer of each of said groups of items.    
   
   
       5 . A system as claimed in  claim 4  further comprising an item input conveyor operable to deliver a plurality of containers in series to said collating conveyor.  
   
   
       6 . A system as claimed in  claim 5  further comprising an input conveyor operating continuously to deliver a plurality of containers in series to said container delivery conveyor, and further comprising a container restraining apparatus configured to restrain containers and to successively release containers on said container conveyor so that said container conveyor will deliver a series of containers to said transfer station and then to said output station.  
   
   
       7 . A system as claimed in  claim 4  wherein said container conveyor comprises first, second and third, spaced continuous chains oriented generally parallel to each other in said second direction, said second chain being a medial chain positioned laterally between said first and second chains, said first, second and third chains each having an upper surface on a forward run from said container input station to said item transfer station and to said output station which are generally aligned in a common, transverse and longitudinally oriented plane, and said first, second and third chains having a generally common chain path on said forward run, whereby said each of said plurality of containers can be carried by said upper surfaces of said first, second and third chains, said system further comprising a chain drive mechanism for said first, second and third chains operable to drive said first, second and third chains at substantially the same speed.  
   
   
       8 . A system as claimed in  claim 7  wherein said second chain has a plurality of spaced lug members secured thereto, wherein successive lug members of said plurality of lug members contact a rear surface of a respective container of said plurality of containers, to assist in moving said containers from said container input station, to said item transfer station and then to a container output station.  
   
   
       9 . A system as claimed in  claim 4  further comprising a system controller for controlling the movement items on said collating device and of containers on said container conveyor.  
   
   
       10 . A system as claimed in  claim 9  wherein said controller for said robotic device is operable to also function as said system controller.  
   
   
       11 . A system as claimed in  claim 10  further comprising an input conveyor operating continuously to deliver a plurality of containers to said container delivery conveyor, and further comprising a container restraining apparatus configured to restrain containers and to release a plurality of containers in series such that said container conveyor will deliver a series of containers to said transfer station at an appropriate time so as to be able to receive a group of said plurality of groups of items.  
   
   
       12 . A system as claimed in  claim 11  further comprising a container restraining apparatus configured to restrain containers and to release a container so that said container conveyor will deliver a container to said transfer station.  
   
   
       13 . A system as claimed in  claim 12  wherein said system controller is adapted to control the operation of said container constraining apparatus.  
   
   
       14 . A system as claimed in  claim 13  wherein said second chain has a plurality of spaced lug members secured thereto, wherein successive lug members of said plurality of lug members contact a rear surface of a respective container of said plurality of containers, to assist in moving said containers from said container input station, to said item transfer station and then to a container output station.  
   
   
       15 . A system as claimed in  claim 14  wherein each of said containers is carried along a first portion of said forward run only on said first and third chains, and wherein said second chain provides additional support for said container and said lug engages said rear of a container, after said first portion of said forward run.  
   
   
       16 . A system as claimed in  claim 4  wherein said container conveyor comprises a chain having a chain path, said system further comprising a chain drive mechanism for said chain operable to chain, said chain having a plurality of spaced lug members secured thereto, wherein successive lug members of said plurality of lug members contact a rear surface of a respective container of said plurality of containers, to assist in moving said containers from said container input station, to said item transfer station and then to a container output station.  
   
   
       17 . A system as claimed in  claim 16  further comprising a trigger switch device, operable to send a signal to said controller indicating a lug of said plurality of lugs is at a known position, prior to engagement with a container.  
   
   
       18 . A system as claimed in  claim 17  further comprising an encoder associated with said conveyor drive mechanism, said encoder operable to provide signals to said system controller indicative of the position of said chain as said chain moves around said conveyor path, said system controller configured to respond to said signal from said trigger switch device and said signals from said encoder to facilitate the operation of said container release mechanism and said robot so as to effect the loading of a group of items held by said robot into a container carried by said container conveyor.  
   
   
       19 . A system as claimed in  claim 16  wherein said chain comprises a plurality of interconnected chain links, at least some of said chain links having extended link pins extending on opposite sides of said links, and wherein each of said lugs has a pair of transversely spaced lug arms configured for releasable engagement with said link pins.  
   
   
       20 . A system as claimed in  claim 7  wherein each of said first, second and third chains comprises a plurality of chain links interconnected with link pins, at least said first and second chains being supported on a longitudinally extending chain track mounted to a frame.  
   
   
       21 . A system as claimed in  claim 20  wherein said chain track comprises a slidable member supported by a structural support member, said structural support member being mounted to said frame, said slidable member permitting said chain to slide over said slidable member.  
   
   
       22 . A system as claimed in  claim 21  wherein said slidable member is made from a UHMW polyethylene material.  
   
   
       23 . A container delivery conveyor for moving a plurality of containers from a container input station to a container output station, said container delivery conveyor comprising at least one chain having a chain path, said chain comprising a plurality of interconnected chain links, at least some of said chain links having extended link pins extending on opposite sides of said links said system further comprising a chain drive mechanism for said chain operable to drive said chain, said chain also having a plurality of spaced lug members secured thereto, wherein successive lug members of said plurality of lug members can contact a rear surface of a respective container of said plurality of containers, to assist in moving said containers from said container input station, to said item transfer station and then to a container output station, wherein said lug members each comprise a base have a pair of forwardly directed arm portions each having a generally forwardly directed slotted opening, said base also having a pair of rearwardly directed arm portions each having a generally rearwardly directed slotted opening, only one of said pairs of forwardly and rearwardly directed arm portions having resilient jaw members for providing a releasable connection of pairs of arm portions to link pivot extension that restricts any translation movement of said pin in said respective slots, the other of said one of said pairs of forwardly and rearwardly directed arm portions having an open ended slot for providing permitting some translation movement of said pin in said slot, such that lug can accommodate travel along both generally straight and curved path portions.  
   
   
       24 . A lug for use with a container delivery conveyor for moving a plurality of containers from a container input station to a container output station, said container delivery conveyor comprising at least one chain having a chain path, said chain comprising a plurality of interconnected chain links, at least some of said chain links having extended link pins extending on opposite sides of said links said system further comprising a chain drive mechanism for said chain operable to drive said chain, said chain also having a plurality of spaced lug members secured thereto, wherein said lug members each comprise a base have a pair of forwardly directed arm portions each having a generally forwardly directed slotted opening, said base also having a pair of rearwardly directed arm portions each having a generally rearwardly directed slotted opening, only one of said pairs of forwardly and rearwardly directed arm portions having resilient jaw members for providing a releasable connection of pairs of arm portions to link pin extension that restricts any translation movement of said pin in said respective slots, the other of said one of said pairs of forwardly and rearwardly directed arm portions having an open ended slot for providing permitting some translation movement of said pin in said slot, such that lug can accommodate travel along both generally straight and curved path portions.  
   
   
       25 . A lug as claimed in  claim 24  wherein said rearwardly directed arm portion has resilient jaw members for providing a releasable connection of its pairs of arm portions to the link pin extension.  
   
   
       26 . A lug as claimed in  claim 25  wherein at least one or both of said rearwardly and forwardly directed pairs arm portions provides a pair of opposed generally planar shoulder surfaces adapted to support said lug on a rail.  
   
   
       27 . A lug for use with a conveyor for moving an article, said conveyor comprising at least one continuous conveyor moving member having a path, said lug comprising a base and an upstanding flight member configured to engage said article, said lug being mountable to said moving member said base having at least one upwardly directed support device positioned transversely to said flight member.  
   
   
       28 . A lug as claimed in  claim 27  wherein said support device is a support surface.  
   
   
       29 . A conveyor system comprising: 
 a) at least one continuous conveyor moving member having a path;    b) a lug for moving an article being mounted to said moving member, said lug comprising a base and an upstanding flight member configured to engage said article, and said base having at least one upwardly directed support device positioned transversely to said flight member;    c) a track adapted to support said support device for movement thereon;    wherein when said conveyor moving member is moving on a path such that said upstanding flight member is oriented downwards, said lug and said moving member are supported by said track and said support device.    
   
   
       30 . A system as claimed in  claim 29  wherein said support device is a support surface.  
   
   
       31 . A system as claimed in  claim 29  wherein said support device is pair of support surfaces located transversely apart from each other on opposite sides of said upstanding flight member, and wherein said track supports said lug and said moving member on said pair of surfaces on said path.  
   
   
       32 . A system as claimed in  claim 29  wherein said moving member is a continuous conveyor chain.  
   
   
       33 . A container conveyor systems for supporting and moving a plurality of containers comprising first, second and third, spaced continuous chains oriented generally parallel to each other in a longitudinal direction, said second chain being a medial chain positioned laterally between said first and second chains, said first, second and third chains each having an upper surface which are generally aligned in a common, transverse and longitudinally oriented plane, and said first, second and third chains having a generally common chain path on a forward run for transporting said containers, whereby said each of said plurality of containers can be carried by said upper surfaces of said first, second and third chains, said system further comprising a chain drive mechanism for said first, second and third chains operable to drive said first, second and third chains at substantially the same speed.  
   
   
       34 . A system as claimed in  claim 27  wherein said second chain has a plurality of spaced lug members secured thereto, wherein successive lug members of said plurality of lug members contact a rear surface of a respective container of said plurality of containers, to assist in moving said containers.