Container-packing unit, system having a container-packing unit, and method of packing a container

Abstract

A container-packing system includes container-packing unit configured to facilitate loading of articles in a container at a loading station. The container-packing system further includes an article conveyor configured to transport articles to the loading station and a container conveyor configured to transport an empty container to and away from the loading station. The container-packing unit is located at the loading station and is configured to facilitate filling of the container with the articles.

1 . A container-packing system, comprising:
 an article conveyor configured to transport articles to a loading station,   a container conveyor including a first conveyor segment configured to transport a container to the loading station and a second conveyor segment configured to transport the container away from the loading station after being filled with the articles, and   a container-packing unit located at the loading station and configured to facilitate filling of the container with the articles,   wherein the container packing unit includes a foundation configured to rest on a surface to support the container above the surface, an agitator coupled to the foundation and configured to move the foundation and the container as the container is filled with the articles to cause the articles to settle within the container prior to the container leaving the loading station with the second conveyor segment, and a motion-control system coupled to the foundation and configured to control movement of the container relative to the foundation before and after activation of the agitator, the motion-control system including a container-guide system configured to engage the container at the loading station to block movement of the container relative to the foundation so that the container remains on the foundation and moves with the foundation while the agitator is activated and the container is filled with the articles, and a packing-unit conveyor configured to transfer the container from the loading station on the foundation to the second conveyor segment of the container conveyor after the container is filled with the articles.   
     
     
         2 . The container-packing system of  claim 1 , wherein the container-guide system includes a first clamp coupled to a first side of the foundation and a second clamp coupled to an opposite, second side of the foundation, and the first and second clamps are configured to engage the container when the container reaches the loading station. 
     
     
         3 . The container-packing system of  claim 2 , wherein the container-guide system further includes a first linear actuator coupled to the first clamp and a second linear actuator coupled to the second clamp, and the first and second linear actuators are configured to move the first and second clamps between a retracted position spaced a first distance from one another prior to the container reaching the loading station, and an extended position spaced a second distance from one another less than the first distance when the container reaches the loading station to exert a compressive force on the container prior to activating the agitator and filling the container with the articles. 
     
     
         4 . The container-packing system of  claim 3 , wherein first and second linear actuators each include a threaded piston coupled with the first clamp and the second clamp, respectively, so that the first clamp and the second claim can be moved toward or away from one another in the extended position and the retracted position. 
     
     
         5 . The container packing system of  claim 3 , wherein the container-guide system further includes a third linear actuator coupled to the first clamp and a fourth linear actuator coupled to the second clamp, and the third and fourth linear actuators are spaced apart from the first and second linear actuators and are configured to move the first and second clamps between the retracted position and the extended position with the first and second linear actuators. 
     
     
         6 . The container-packing system of  claim 1 , wherein the packing-unit conveyor includes a conveyor belt, a conveyor actuator configured to drive the conveyor belt, and plurality of rollers coupled to the foundation and underlying a portion of the conveyor belt to locate the conveyor belt between the portion of the plurality of rollers and the container. 
     
     
         7 . The container-packing system of  claim 6 , wherein the conveyor belt is a first conveyor belt and the plurality of rollers is a first plurality of rollers, and wherein the packing-unit conveyor includes a second conveyor belt spaced apart from the first conveyor belt and a second plurality of rollers coupled to the foundation and spaced apart from the first plurality of rollers. 
     
     
         8 . The container-packing system of  claim 7 , wherein the conveyor actuator includes a conveyor motor coupled to the foundation, a first actuator roller coupled to the conveyor motor and to the first conveyor belt to move the first conveyor belt relative to the first plurality of rollers, and a second actuator roller coupled to the conveyor motor and the second conveyor belt to move the second conveyor belt relative to the second plurality of rollers. 
     
     
         9 . The container-packing system of  claim 8 , wherein the conveyor motor is coupled to the foundation between the first and second actuator rollers, the first and second conveyor belts, and the first and second plurality of rollers. 
     
     
         10 . The container-packing system of  claim 9 , wherein the conveyor actuator further includes a gearbox coupled between the conveyor motor and the first actuator roller and between the conveyor motor and the second actuator roller, and the gearbox is configured to rotate the first and second actuator rollers in the same direction and at the same time to drive the first and second conveyor belts at the same rate. 
     
     
         11 . The container-packing system of  claim 1 , wherein the agitator includes an agitator motor and at least one eccentric weight coupled to the agitator motor and configured to impart vibrations on the foundation when activated. 
     
     
         12 . The container packing system of  claim 1 , wherein the foundation includes a foundation base configured to rest on the surface, a container support spaced apart from the foundation base and configured to support the container above the surface, and a suspension system interconnecting the foundation base and the container support. 
     
     
         13 . The container packing system of  claim 12 , wherein the suspension system includes a plurality of spring guides and a plurality of springs located in internal spaces defined at least partially by the plurality of spring guides. 
     
     
         14 . The container packing system of  claim 13 , wherein each of the plurality of spring guides includes a foundation-base guide coupled to the foundation base and a container-support guide coupled to the container support, and each of the plurality of springs is surrounded by at least one of the foundation-base guide and the container-support guide. 
     
     
         15 . The container packing system of  claim 14 , wherein the foundation-base guide includes a first guide post and the container-support guide includes a cylindrical tube surrounding a spring included in the plurality of springs. 
     
     
         16 . The container packing system of  claim 15 , wherein the spring surrounds the first guide post to locate the spring radially between the first guide post and the cylindrical tube, the container-support guide further includes a second guide post, and the spring surrounds the second guide post to locate the spring radially between the second guide post and the cylindrical tube. 
     
     
         17 . The container packing system of  claim 12 , wherein the container support includes a support plate coupled to the packing-unit conveyor, a first side wall coupled to a first lateral end of the support plate and extending in an upward direction away from the support plate, and a second side wall coupled to a second lateral end of the support plate and extending in the upward direction away from the support plate. 
     
     
         18 . The container packing system of  claim 17 , wherein the container-guide system includes a first clamp coupled to the first side wall and a second clamp coupled to the second side wall, and the first and second clamps are configured to engage the container when the container reaches the loading station. 
     
     
         19 . The container packing system of  claim 18 , wherein the first and second clamps are movable between a retracted position spaced a first distance from the first and second side walls, respectively, and an extended position spaced a second distance greater than the first distance from the first and second side walls, respectively. 
     
     
         20 . The container packing system of  claim 19 , wherein the first and second side walls are spaced apart from one another by a distance within a range of about 40 inches to about 46 inches and the first and second clamps are spaced apart from the support plate by a distance of at least 6 inches. 
     
     
         21 . A container packing unit comprising:
 a foundation configured to rest on a surface to support a container above the surface,   an agitator coupled to the foundation and configured to move the foundation and the container as the container is filled with articles to cause the articles to settle within the container, and   a motion-control system coupled to the foundation and configured to control movement of the container relative to the foundation before and after activation of the agitator, the motion-control system including a container-guide system configured to engage the container to block movement of the container relative to the foundation so that the container remains on the foundation and moves with the foundation while the agitator is activated and the container is filled with the articles, and a packing-unit conveyor configured to move the container relative to the foundation.