Packaging system and method

Abstract

There is provided a lifting apparatus (16) comprising a lifting frame (16a) configured to be mechanically coupled to a packaging machine (12), and configured to couple with a feed device (14), wherein the lifting frame (16a) is configured to translate, raise and lower the feed device (14) relative to the packaging machine (12), and a packaging system comprising a packaging machine (12) with said lifting apparatus (16) wherein said packaging machine (12) is configured to detachably couple to a feed device (14), wherein the mass of the packaging machine (12) acts to counterbalance at least a portion of the mass of the feed device (14) whilst the feed device (14) is being translated, raised or lowered relative to the packaging machine (12). There is further provided methods of operating said packaging system for installing to and removing from the packaging machine (12) the feed device (14).

Claims

1. A packaging system comprising: a feed device; a packaging machine configured to detachably couple to the feed device; a lifting apparatus comprising a lifting frame mechanically coupled to the packaging machine, and configured to couple with the feed device; wherein the lifting frame is configured to translate, raise and lower the feed device relative to the packaging machine; wherein the mass of the packaging machine acts to counterbalance at least a portion of the mass of the feed device whilst the feed device is being translated, raised or lowered relative to the packaging machine; and wherein the packaging machine comprises at least one: bag maker; tray sealer; cartonising machine; or thermoformer.

2. The system according to claim 1, wherein the lifting apparatus is configured to detachably couple with the feed device.

3. The system according to claim 1, wherein the lifting frame may be rotated about a substantially vertical axis, such that, when the feed device is coupled to the lifting frame, the feed device may be rotated about the substantially vertical axis, and/or, wherein the lifting frame may be rotated about a substantially horizontal axis, such that, when the feed device is coupled to the lifting frame, the feed device may be simultaneously raised or lowered in a vertical plane and translated in a horizontal plane relative to the packaging machine.

4. The system according to claim 1, wherein the feed device comprises a grader, a batcher, a volumetric feeder or a computer controlled weigher (CCW) such as: a combination weigher; a multihead weigher; a screw feeder weigher; a cut gate weigher; a linear weigher; or a mix weigher.

5. The system according to claim 1, wherein the mass of the packaging machine acts to counterbalance at least 50% of the mass of the feed device whilst the feed device is being raised, lowered or translated relative to the packaging machine.

6. The system according to claim 1, wherein the lifting frame is mechanically coupled to the packaging machine by a cantilever.

7. The system according to claim 1, further comprising at least one sensor able to detect the presence of foreign object in the path of the feed device.

8. The system according to claim 7, wherein said at least one sensor is a laser sensor.

9. The system according to claim 1, wherein the packaging machine further comprises a first service connector, the first service connector configured to engage with a corresponding second service connector when the packaging machine and the feed device are coupled.

10. The system according to claim 9, wherein the service connectors transfer at least one of electrical power, fluids, gases, or control signals between the packaging machine and the feed device.

11. The system according to claim 9, wherein the service connectors may be disengaged from one another by raising the feed device away from the packaging machine, and/or the service connectors may be engaged together by lowering the feed device towards the packaging machine.

12. The system according to claim 1, further comprising: a recess disposed on a first surface and a corresponding protrusion disposed on a second surface, wherein the protrusion engages the recess when the packaging machine and feed device are coupled.

13. The system according to claim 12 wherein the packing machine further comprises a first service connector, the first service connector configured to engage with a corresponding second service connector when the packaging machine and the feed device are coupled, wherein the protrusion extends further from the second surface than the first service connector or the second service connector, such that during the coupling of the feed device and the packaging machine the protrusion will enter the recess before the first and second service connectors engage.

14. The system according to claim 12, wherein: the recess comprises a base surface which is inset within the first surface, and at least one recess side provided between the base surface and the first surface; wherein said at least one recess side continuously or discontinuously narrows from the first surface to the base surface of the recess; and/or, wherein: the protrusion comprises a top surface which is raised from the second surface, and at least one protrusion side provided between the top and the second surface; wherein said at least one protrusion side continuously or discontinuously narrows from the second surface to the top surface of the recess.

15. The system according to claim 1, wherein the feed device is configured to feed food or drink to the packaging machine.

16. The system according to claim 1, wherein the packaging machine is configured to package food or drink received from the feed device.

17. A method of operating a system to install a feed device to a packaging machine, the system comprising: a packaging machine configured to detachably couple to the feed device; a lifting apparatus comprising a lifting frame mechanically coupled to the packaging machine, and configured to couple with the feed device; wherein the lifting frame is configured to translate, raise and lower the feed device relative to the packaging machine; wherein the mass of the packaging machine acts to counterbalance at least a portion of the mass of the feed device whilst the feed device is being translated, raised or lowered relative to the packaging machine; and wherein the packaging machine comprises at least one: bag maker; tray sealer; cartonising machine; or thermoformer; the method comprising the steps of: positioning the feed device adjacent to the packaging machine; coupling the feed device to a lifting apparatus; operating the lifting apparatus to raise and translate the feed device relative to the packaging machine; operating the lifting apparatus to lower the feed device, such that feed device is coupled to the packaging machine; wherein the mass of the packaging machine acts to counterbalance at least a portion of the mass of the feed device whilst the feed device is being raised, lowered or translated relative to the packaging machine.

18. The method according to claim 17, wherein operating the lifting apparatus to raise the feed device comprises a first raising step where the feed device is raised at a relatively low speed and a second raising step where the feed device is raised at a relatively high speed.

19. A method of operating a system to remove a feed device from a packaging machine, the system comprising: a packaging machine configured to detachably couple to the feed device; a lifting apparatus comprising a lifting frame mechanically coupled to the packaging machine, and configured to couple with the feed device; wherein the lifting frame is configured to translate, raise and lower the feed device relative to the packaging machine; wherein the mass of the packaging machine acts to counterbalance at least a portion of the mass of the feed device whilst the feed device is being translated, raised or lowered relative to the packaging machine; and wherein the packaging machine comprises at least one: bag maker; tray sealer; cartonising machine; or thermoformer; the method comprising the steps of: coupling the feed device to a lifting apparatus; operating the lifting apparatus to raise the feed device, such that feed device is decoupled from the packaging machine; operating the lifting apparatus to translate and lower the feed device relative to the packaging machine; decoupling the feed device from the lifting apparatus; wherein the mass of the packaging machine acts to counterbalance at least a portion of the mass of the feed device whilst the feed device is being raised, lowered or translated relative to the packaging machine.

20. The method of claim 19, wherein operating the lifting apparatus to lower the feed device comprises a first lowering step where the feed device is lowered at a relatively high speed and a second lowering step where the feed device is lowered at a relatively low speed.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) Examples of security documents and methods for their manufacture will now be described with reference to the accompanying drawings, in which:

(2) FIG. 1(a) depicts a schematic side view of packaging system in operation in accordance with a first embodiment of the present invention;

(3) FIG. 1(b) depicts a schematic side view of packaging system wherein a feed device has been dismounted in accordance with a first embodiment of the present invention;

(4) FIG. 2(a) depicts a schematic side view of packaging system in operation in accordance with a second embodiment of the present invention;

(5) FIG. 2(b) depicts a schematic side view of packaging system wherein a feed device has been dismounted in accordance with a second embodiment of the present invention;

(6) FIG. 3(a) depicts a schematic side view of packaging system in operation in accordance with a third embodiment of the present invention;

(7) FIG. 3(b) depicts a schematic side view of packaging system wherein a feed device has been dismounted in accordance with a third embodiment of the present invention;

(8) FIGS. 4(a), 4(b), 4(c) and 4(d) depict projection views of a packaging system in accordance with a first embodiment of the present invention;

(9) FIGS. 5(a) and 5(b) depict a projection view of a packaging system in accordance with the first embodiment of the present invention in further detail;

(10) FIGS. 6(a) and 6(b) depict a projection view of a packaging system in accordance with the first embodiment of the present invention in further detail;

(11) FIGS. 7(a) to 7(c) depict a projection view of a packaging system in accordance with the first embodiment of the present invention in further detail;

(12) FIG. 8 depicts a projection view of a packaging system in accordance with a first embodiment of the present invention;

(13) FIGS. 9(a) and 9(b) depict cross sections of protrusions and recesses suitable for use within packaging systems in accordance with the present invention.

DETAILED DESCRIPTION

(14) FIGS. 1 to 7 illustrate schematically four packaging systems which offer improved means of installing, removing and maintaining feed devices. Such maintenance work includes inspecting, cleaning, servicing and repairing feed devices.

(15) In each case, the feed devices may include graders, batchers, a volumetric feeders or computer controlled weighers (CCWs) such as combination, multihead, feeder, cut gate, linear, or mix weighers. Such feed devices typically have a mass of between 300 kg and 700 kg. Whereas, suitable packaging machines include bag makers, tray sealers, cartonising machines and thermoformers. Typically such packaging machines have a mass of between 500 kg and 800 kg. In conventional packaging systems the feed device tends to be of a lower mass than the correspondingly scaled packaging machine. Consequently, the inventors have realised that the mass of a packaging machine may be used to counteract or counterbalance the mass of a feed device when it is mounted or dismounted.

(16) FIGS. 1 to 3 illustrate schematically three alternative embodiments of packaging systems. The reference signs for corresponding features (which may have similar properties or features as described in reference to any of the other figures) have been incremented by 10 between each embodiment.

(17) FIGS. 1(a) and 1(b) show a packaging system 10 comprising a packaging machine 12, a feed device 14 and a lifting apparatus 16.

(18) In FIG. 1(a) the feed device 14 is installed to a packaging machine 12, as it would be in normal operation. As will be seen, the feed device 14 is coupled to the top of the packaging machine 12. Whereas, in FIG. 1(b) the feed device 14 has been dismounted from the packaging machine 12, i.e. the feed device 14 has been uncoupled from the packaging machine 12 and lowered by the lifting apparatus 16 to a position adjacent to the packaging machine 12 and close to the ground. In this dismounted position the feed device 12 may be easily inspected, serviced or cleaned. Alternatively, from the dismounted position shown in FIG. 1(b) the feed device 12 may easily uncoupled from the lifting apparatus 16 and removed completely if required.

(19) The lifting apparatus 16 comprises lifting frame 16a, which has the form of a substantially vertical mast, and a moveable carriage 16b. The movable carriage 16b may move linearly up and down the lifting frame 16a, as shown by arrow D.sub.1, and may rotate about a substantially vertical axis, as shown by arrow D.sub.2. Control of this motion may be performed by one or more actuators (not shown).

(20) These one or more actuators may be of any suitable design capable of translating, raising and lowering the feed device 14 relative to the packaging machine 12.

(21) The substantially vertical axis about which the movable carriage 16b may rotate is preferably substantially parallel to the centreline of the mast of the lifting frame 16a. For instance, the lifting frame 16a and the movable carriage 16b may rotate together about a single axis which is close to the centreline of the lifting frame 16a. Alternatively, the movable carriage 16b may be configured to rotate around the outside of the lifting frame 16a, which may be fixed in position.

(22) In both of these embodiments the substantially vertical axis may be coincident with the centreline of the lifting frame 16a. However, in alternative embodiments the substantially vertical axis is within 0.3 m of the centreline of the lifting frame 16a, or within 0.15 m of the lifting frame 16a.

(23) Additionally, the movable carriage 16a is configured to detachably couple with the feed device 14. Consequently, the feed device 14 may also be raised, lowered and rotated (i.e. translated) about a substantially vertical axis by the movable carriage 16a.

(24) The lifting apparatus 16 is supported by a cantilever 12a. This cantilever extends between, and is coupled to, the base of the packaging machine 12 and the base of the lifting frame 16a. Therefore, whilst the feed device 14 is being raised, lowered and translated by movable carriage 16a, or during maintenance operations, the combined mass of the feed device 14 and lifting apparatus 16 is counterbalanced or counteracted by the mass of the packaging machine. By counterbalancing the lifting apparatus in this manner, the structure required to install, remove and maintain the feed device is significantly simplified.

(25) The system 10 further comprises a sub frame 18 coupled to the feed device 14. This sub frame 18 supports the feed device 14 when it is coupled to the packaging machine 12.

(26) The lifting apparatus 16, lifting frame 16a, moveable carriage 16b, cantilever 12a and sub frame 18 may be formed of any suitable material capable of supporting the feed device 14 during the installation, removal or maintenance. For instance, each component may comprise a metal (such as steel, aluminium, titanium, or an alloy thereof), a plastic or a composite.

(27) To dismount the feed device 12 in order to remove or maintain the feed device 14 the system must move from the arrangement of FIG. 1a to the arrangement shown in FIG. 1b.

(28) This lowering operation requires first that the feed device 14 be uncoupled from the packaging machine 12. This is typically achieved by lifting the feed device 14 relative to the packaging machine 12.

(29) The feed device 14 and the movable carriage 16b are then rotated about a substantially vertical axis (as shown by arrow D.sub.2), such that the feed device 14 is swung out from above the packaging machine 12. In other words, the feed device 14 is translated relative to the packaging machine 12, such that it is not positioned over and does not overlap the packaging machine 12 in a vertical direction.

(30) Finally, the movable carriage 16b lowers the feed device 14 to the lowered or dismounted position shown in FIG. 1b. Once in this dismounted position an operator may conduct maintenance whilst the feed device 14 is still connected to the lifting apparatus 16 or, if necessary, completely remove the feed device 14 from the packaging system 10.

(31) In this dismounted position the feed device 12 may be easily inspected, serviced or cleaned. Alternatively, from the dismounted position shown in FIG. 1(b) the feed device 12 may easily uncoupled from the lifting apparatus 16 and removed completely if required.

(32) To install or mount the feed device 14 to the packaging system 10 this process is reversed, and the feed device 14 must be conveyed from its dismounted position shown in FIG. 1b to the installed position of FIG. 1a.

(33) Specifically, the feed device 14 is raised or lifted to a height above the packaging machine 12 by the movable carriage 16b, swung over the packaging machine 12 by rotating the movable carriage 16b and the feed device 14 about a substantially vertical axis, and finally lowered to couple the feed device 14 to the packaging machine 12.

(34) These mounting and dismounting cycles or processes (and each of the steps therein) may be performed under manual or automatic control. Furthermore, they may be performed in response to an input received from a user, or automatically, e.g. in response to a control signal issued by a control system following the detection of a fault with the feed device.

(35) FIGS. 2(a) and 2(b) show a packaging system 20 comprising a packaging machine 22, a feed device 24 and a lifting apparatus 26. FIG. 2(a) shows the packaging system 20 in its operating arrangement where the feed device 24 is coupled to the packaging machine 22. FIG. 2(b) shows the system in an arrangement where the feed device 34 has been dismounted for maintenance (e.g. inspection, cleaning, servicing or repairs).

(36) Lifting apparatus 26, which is able to convey the feed device 24 between the positions shown in FIGS. 2(a) and 2(b), comprises a lifting frame 26a, in the form of substantially vertical mast, and horizontal guides 26b.

(37) The feed device 24 may be raised and lowered linearly up and down the lifting frame 26a in direction D.sub.1, and translated in a substantially horizontal direction D.sub.2 along horizontal guides 26b. Control of these motions may be performed by one or more actuators (not shown). In further embodiments the lifting apparatus may further comprise a movable carriage to which one or more actuators are coupled, wherein the movable carriage is configured to detachably couple to the feed device 24 and to move along the lifting frame 26 in substantially vertical direction D.sub.1.

(38) The lifting apparatus 26 is supported by cantilever 22a which extends between and couples to the base of the packaging machine 22 and the base of the lifting frame 26. The mass to one side of the cantilever is at least partially counterbalanced by the mass on the other side. In effect, the mass of the lifting apparatus and feed device, when coupled to the lifting apparatus, is at least partially counterbalanced by the mass of the packaging machine.

(39) To dismount the feed device 24 (i.e. to move from the arrangement shown in FIG. 2(a) to the arrangement of FIG. 2(b)), the feed device 24 is first uncoupled from the packaging machine 22. The feed device is then translated or slid linearly in a substantially horizontal direction D.sub.2 along, or by, the horizontal guides 26b. Once the feed device 24 no longer sits above or overlays the packaging machine 22 it may be lowered in a substantially vertical direction D.sub.1.

(40) Once the feed device 24 is in this lowered or dismounted position it may be maintained in place by an operator or removed for further work if necessary.

(41) To remount or install a feed device 24 this process is reversed. A feed device is coupled to the lifting frame 26, lifted substantially vertically (as shown by arrow D.sub.1), and translated along guides 26b or by the guides 26 such that the feed device is coupled to the packaging machine 22.

(42) As discussed in reference to the systems shown in FIGS. 1(a) and 1(b), these dismounting and mounting cycles may be performed either under manual control or automatically.

(43) In packaging systems 10 and 20, described with reference to FIGS. 1 and 2, the lifting apparatus 16, 26 may raise, lower and translate the feed device 14, 24 in separate operations. For instance, when a feed device is mounted to the packaging machines using the methods described above, the feed device is firstly raised to an appropriate height above the packaging machine and secondly translated horizontally such that it may be coupled to the packaging machine. Conversely, when the feed device is dismounted it may be translated and then lowered. However, in both systems 10, 20, the lifting apparatus 16, 26 may simultaneously raise and translate, or lower and translate, the feed device 14, 24 if required.

(44) FIGS. 3(a) and 3(b) show a packaging system 30 comprising a packaging machine 32, a feed device 34 and a lifting apparatus 36. FIG. 2(a) shows the packaging system 30 in its operating arrangement where the feed device 34 is coupled (mounted) to the packaging machine 32. FIG. 2(b) shows the system in an arrangement where the feed device 34 has been dismounted for removal or maintenance.

(45) Lifting apparatus 36 is able to convey the feed device 34 between the positions shown in FIGS. 3(a) and 3(b). The lifting apparatus 36 comprises a lifting frame 36a, in the form of two movable arms. The movable arms of the lifting frame 36a are mechanically coupled to either side of the packaging machine 32 by bearings 36b about which the lifting frame 36a may rotate. Control of this rotation may be provided by one or more actuators (not shown). In alternative embodiments the lifting frame 36a may comprise any number of vertical arms.

(46) To mount and dismount a feed device 34, the lifting frame 36a and feed device 34 are rotated about the substantially horizontal axis defined by bearings 36b (as shown by arrow D.sub.3). In each process the motion of the feed device 34 has vertical and horizontal components.

(47) Specifically, the lifting frame 36a may be swung up or raised to couple the feed device 34 to the packaging machine 32 (as shown in FIG. 3(a)). During this step the feed device 34 is simultaneously raised and translated. In this arrangement the lifting frame 36a is substantially vertical and the feed device 34 is above the packaging machine 32. To dismount the feed device 34 the lifting frame 36a is swung down (lowered) to dismount the feed device 34 so that it is located adjacent to the packaging machine 32 (as shown in FIG. 3(b)). In this step the feed device is lowered and translated simultaneously.

(48) The lifting frame 36a further comprises a sub frame 36c, which rotatably couples the lifting frame 36a to the feed device 34. As shown, the sub frame 36c is configured to ensure the feed device 34 remains in its upright (i.e. vertical orientation) whilst it is raised any lowered by the lifting apparatus 36. Control of the orientation may be provided by one or more actuators (not shown) coupled to the feed device 34, the sub frame 36c and/or the lifting frame 36a.

(49) Whilst the feed device 34 is being mounted or dismounted, and whilst the feed device is adjacent to the packaging device 32, as shown in FIG. 3(b), the lifting frame 36a acts as a cantilever. In other words, the forces applied by the mass of the feed device 34 and the weight of the lifting apparatus 36 are transmitted to the packaging machine 32 through bearings 36b. Consequently, these forces are at least partially counterbalanced by the weight of the packaging machine 32, and the mass of the packaging machine 32 acts to counterbalance the mass of the feed device 34 and the lifting apparatus 36.

(50) In further embodiments the sub frame 36c and/or the lifting frame 36a may be configured to raise or lower the feed device 34 once the lifting frame 36a is in a substantially vertical orientation and the feed device is above the packaging machine 32 (as shown in FIG. 3a). This may be necessary to couple or uncouple the feed device 34 to the packaging machine 32, as discussed with reference to FIGS. 1(a) and 1(b).

(51) As discussed above in reference to the systems of FIGS. 1 and 2, the dismounting and mounting processes performed by the packaging system 30 shown in FIGS. 3(a) and 3(b) may be under manual or automatically control and be implemented in response to any suitable input.

(52) FIGS. 4 to 8 show detailed perspective views of a packaging system 100 in accordance with a preferred embodiment of the present invention. The system comprises a packaging machine 120, a feed device 140 and a lifting apparatus 160. This embodiment offers improved means of mounting and dismounting the feed device 140 to and from the packaging machine 120 such that the feed devices 120 may be easily installed, removed and maintained.

(53) In this embodiment, feed device 140 is a combination weigher (sometimes termed a multihead weigher) and packaging machine 120 is a bagmaker, although any other suitable devices may be used.

(54) FIG. 4(a) to FIG. 4(d) show a series of system arrangements illustrating the process to install or mount a feed device 140 to the packaging machine 120.

(55) In FIG. 4(a) the feed device 140 is dismounted from the packaging machine 120 and mechanically coupled to lifting apparatus 160. In this dismounted arrangement feed device 140 is located adjacent to the packaging machine 120 and close to the ground such that it may be easily maintained by an operator.

(56) More specifically, the feed device 140 is coupled to a sub frame 180, wherein the sub frame 180 is detachably coupled to a movable carriage 164 within the lifting apparatus 160. This movable carriage is configured to move linearly up and down the longitudinal axis of the lifting frame 162.

(57) The base of lifting frame 162 is coupled to packaging machine 120 by cantilever 122. Cantilever 122 supports the feed device 140, lifting apparatus 160 and the sub frame 180. During maintenance and mounting and dismounting processes, the mass of the packaging machine acts to counterbalance the combined mass of the feed device 140, lifting apparatus 160 and the sub frame 180. As shown in FIGS. 4(a) to 4(d), lifting frame 162 is coupled to packaging machine 120 at a corner of the packaging machine 120.

(58) Between FIG. 4(a) and FIG. 4(b) the feed device 140 is raised by lifting apparatus 160. This is achieved by raising the movable carriage 164 relative to the lifting frame 162 using a ball screw actuator (not shown) which is positioned within lifting frame 162. Consequently, the movable carriage raises the sub frame 180 and the feed device 140 which it is mechanically coupled to.

(59) Following this lifting or raising step, the feed device 140 is positioned at a greater height than the position of the feed device 140 during operation (when it is coupled to the packaging machine 120).

(60) Once the feed device 140 has been raised to the position shown in FIG. 4(b), it is swung over the packaging machine 120, as shown in FIG. 4(c).

(61) This horizontal translation of the feed device 140 is performed by ball screw actuator 166. This ball screw actuator 166 rotates the lifting frame 162 about a substantially vertical axis parallel to the longitudinal axis of the lifting frame 162. Consequently, the ball screw actuator 166 also rotates the feed device 140 (and the movable carriage and sub frame 180) about this substantially vertical axis because these components are mechanically coupled to the lifting frame 162. As seen from the figures, the substantially vertical axis and the longitudinal axis of the lifting frame 162 are adjacent to the corner of the packaging machine 120.

(62) Finally, the feed device 140 is lowered from its position above the packaging machine 120 (as shown in FIG. 4(c)) so that it contacts and couples with the packaging machine 120 (as shown in FIG. 4(d)). This lowering is performed by the ball-screw actuator located within the hollow lifting frame 162.

(63) Once positioned as shown in FIG. 4(d), the feed device 140 may be operated to provide food, and other products to the packaging machine 120 for packaging.

(64) To dismount a feed device, the above process is reversed. The feed device 140 is raised by the ball-screw actuator within the lifting frame 162, decoupling the feed device 140 from the packaging machine 120 (as would occur between FIG. 4(d) and FIG. 4(c)). The feed device 140 is then swung out (i.e. rotated about a vertical axis) by ball-screw actuator 166 so that it does not overlap the packaging machine 120 (as shown in FIG. 4(b)). Finally, the ball-screw actuator and movable carriage within the lifting frame 162 lower the feed device to the position of FIG. 4(a) where it is adjacent to the packaging machine and may be easily maintained or removed by an operator standing on the same level as the packaging machine as required.

(65) These processes may be performed under user or automatic control, and in response to any suitable input (e.g. a user input, an error or misfeed detected in either the packaging machine 120 or the feed device 140, or in accordance with a pre-configured maintenance schedule).

(66) As discussed above, during maintenance of the feed device 140 whilst it is adjacent to the packaging machine 120 (as shown in FIG. 4(a)), and during the transfer of the feed device between the dismounted and mounted arrangements (FIGS. 4(a) and 4(d) respectively) the mass of the packaging machine acts to counterbalance the majority of the mass of feed device 140. The counterbalanced forces are transmitted across cantilever 122 which is coupled to the packaging machine 120 at one end and the lifting frame 162 at the other.

(67) The weight of the packaging machine 120 and the counterbalanced weight of are transmitted to the surface on which the packaging system 100 is positioned by packaging machine supports 124.

(68) The remaining portion of the mass of the feed device 140 and lifting mechanism is supported by lifting mechanism support 122a. This lifting mechanism support 122a transmits a portion of the weight of the feed device 140 and the lifting mechanism 160 to the surface on which the packaging system is positioned. The lifting mechanism support 122a coupled to cantilever 122a at the end of the cantilever 120 closest to the lifting apparatus 160.

(69) Although two ball-screw actuators are used within lifting apparatus 160, in practice any suitable actuators capable of raising, lowering and translating the feed device 140 may be used instead. These may include hydraulic, pneumatic, electric, magnetic and manual actuators.

(70) FIGS. 5(a) and 5(b) show further detail of the packaging system 100 when in the arrangements previously described with reference to FIGS. 4(c) and 4(d). These figures shall be used to describe the coupling between the feed device 140, sub frame 180 and packaging machine 120 in more detail.

(71) The inset portion of FIG. 5(a) shows service connectors 126a, 126b, 126c, 126d, 186a, 186b, 186c, 186d, which transfer services between the packaging machine 120 and the feed device 140 via the sub frame 180, and a plurality of protrusions 128 which protect these service connectors 126a, 126b, 126c, 126d, 186a, 186b, 186c, 186d.

(72) Female service connectors 126a, 126b, 126c and 126d are positioned on the top surface of the packaging machine 120. These respectively correspond to male service connectors 186a, 186b, 186c and 186d positioned on the underneath surface of sub frame 180, and engage together as shown in the inset portion of FIG. 5(b). The two sets of male and female service connectors are configured to engage and disengage with one another by raising or lowering the male or female service connectors relative to the other. Service connectors 126a and 186a transfer electrical power, service connectors 126b and 186b transfer fluids, service connectors 126c and 186c transfer gases, and service connectors 126d and 186d transfer control signals.

(73) The plurality of protrusions 128 which protect the service connectors 126a, 126b, 126c, 126d, 186a, 186b, 186c, 186d by preventing the sub frame 180 (and the coupled feed device 140) contacting the packaging machine 120 if the two devices are incorrectly aligned. One protrusion is located on either side of each female service connectors 126a, 126b, 126c and 126d on the top surface of the packaging machine 120.

(74) A corresponding plurality of recesses (not shown) are positioned within the underneath surface of the sub frame 180, such that one recess is located on either side of each male service connector 186a, 186b, 186c and 186d.

(75) If the sub frame 180 and feed device 140 are lowered towards the packaging machine 120 when the sub frame 180 is correctly aligned the plurality of protrusions 128 will enter and engage (i.e. mesh with) the corresponding plurality of recesses, and the male service connectors 186a, 186b, 186c, 186d will engage (i.e. mesh with) the female service connectors 126a, 126b, 126c, 126d. Alternatively, and additionally, the service connectors 126a, 126b, 126c, 126d, 186a, 186b, 186c, 186d have a degree of “float” to accommodate minor misalignments between the feed device 140 and the packaging machine 120. The protrusions 128 may guide the service connectors 126a, 126b, 126c, 126d, 186a, 186b, 186c, 186d (i.e. cause them to move within the float) so that the male and female connectors 126a, 126b, 126c, 126d, 186a, 186b, 186c, 186d are in the correct location when they are brought together.

(76) FIGS. 6(a) and 6(b) show additional detail of the packaging system 100. Specifically, the inset portions of these figures show in further detail the coupling between the sub frame 180 and the movable carriage 164. Both figures also provide a perspective view of the underneath of the packaging system 100, from which packaging machine supports 124 and lifting mechanism support 122a may be seen.

(77) FIG. 6(a) shows the packaging system 100 in the arrangement corresponding to instant the sub frame 180 has contacted the packaging machine 120 during a mounting operation or the instance that the sub frame 180 is lifted from the packaging machine 120, such that the mass of the sub frame 120 and feed device 140 is supported by the lifting apparatus 160.

(78) FIG. 6(b) shows the packaging system 100 in operation, where the sub frame 180 and feed device 140 are supported by the packaging machine 120.

(79) In each case, sub frame 180 is connected to lifting frame 162 such that it is free to move along the longitudinal axis of the lifting frame 162 (i.e. in a substantially vertical direction). Similarly, movable carriage 164 may move longitudinally up and down the lifting frame 162 and is driven by a ball-screw actuator (not shown).

(80) The movable carriage 164 is configured to receive a connecting pin 168. This connecting pin 168 extends through the movable carriage 164, and through two apertures 182 on either side of the portion of the sub frame 180 connecting to the lifting frame 162.

(81) These apertures 182 are elongate, such that the connecting pin 168 may move longitudinally (i.e. vertically) within the apertures 182. The bottom of each aperture 182 is wider than the top of the aperture 182 and wider than the width of the connecting pin 168.

(82) When the feed device 140 and sub frame 180 are supported by the movable carriage 164—as shown in FIG. 6a and at any point during the mounting, dismounting or maintenance procedure where the feed device 140 and sub frame 180—the sub frame 180 is suspended on connecting pin 168. This arrangement is shown in the inset portion of FIG. 6a. In this arrangement, the sub frame 180 (and the feed device 140) is constrained in the vertical direction by the connecting pin 168 and the position of the movable carriage 164. The connecting pin 168 is located at the top of apertures 182.

(83) However, when the feed device 140 and sub frame 180 are lowered into contact with the packaging machine 120 (or any other external surface) by the movable carriage 164, the weight of the feed device and the sub frame 180 are transferred from the connecting pin 168 to the packaging machine 120. The sub frame 180 will therefore be supported by the packaging machine 120 as the movable carriage 164 continues to be lowered. Consequently, the connecting pin 168 moves vertically downwards relative to the apertures 182 within the sub frame 180, as shown in the inset portion of FIG. 6(b).

(84) Because the bottom of the apertures 182 are wider than the width of connecting pin 168, the pin 168 does not contact the sides of the apertures and the movable carriage is mechanically isolated from the sub frame 180 and the feed device 140. Consequently, the sub frame 180 is no longer constrained in the vertical direction by the lifting apparatus 160 and is decoupled or isolated from the lifting apparatus in at least the vertical direction (i.e. the lifting apparatus is decoupled in a linear degree of freedom).

(85) This arrangement of the connecting pin 168 of the lifting apparatus 160 relative to the apertures 182 within the sub frame 180 is hereafter termed the “clearance position”.

(86) By decoupling or isolating the sub frame 180 from the lifting apparatus 160 in a vertical degree of freedom in this clearance position, the vibrations or stresses transmitted from the sub frame 180 to the lifting apparatus 160 during operation are significantly reduced. This decoupling ensures the accuracy of the feed device. In particular, by reducing the vibrations transmitted to the weighing and portioning components of the feed device the accuracy of weighing and portioning is increased. Additionally, the reduction of vibration and stresses transmitted between the components of the system may reduce the risk of damage or fatigue during operation of the feed device 140 and/or the packaging machine 120, thereby extending the life of the packaging system 100.

(87) FIGS. 6(a) and 6(b) also show the packaging machine supports 124 and lifting mechanism support 122a of packaging system 100.

(88) The four packaging machine supports 124 are disposed near the four corners of the base of packaging machine 120. Each is formed as a flat foot, i.e. each comprises a projecting part which extends below the packaging machine 120 and a broad, level surface at the end of the projecting part furthest from the packaging machine 120. In use, these packaging machine supports 124 contact the surface on which the packaging machine 120 is placed and transmit mechanical forces between the packaging machine 120 and this surface.

(89) The lifting mechanism support 122a extends downwards through the cantilever 122 from the base of lifting mechanism 160. The lifting mechanism support 122a is close to the substantially vertical plane of the lifting frame 162 and, as such, is “outboard” from the packaging machine, i.e. it is laterally spaced from the extend of the packaging device 120. Again, the support comprises a projecting part which extends below the lifting mechanism 160 and a broad, level surface at the end of the projecting part furthest from the lifting mechanism 160. In use the lifting mechanism support 122a will contact the surface on which the packaging system 100 is placed and will transmit mechanical forces from the cantilever 122 to this surface.

(90) Therefore, when the feed device 140 is supported by the lifting mechanism 160 (i.e. the connecting pin 168 is in contact with sub frame 180) a portion of the weight of the feed device 140 will be transmitted to the surface which the packaging system 100 is positioned on via the lifting mechanism support 122a. This increases the stability of the packaging system 100 when the feed device is lifted. However, given the high mass of conventional feed devices (for instance, CCWs typically weigh 500 to 600 kg) the majority of the mass of the feed device 140 is counterbalanced across cantilever 122 by the mass of the packaging machine 120.

(91) Cantilever 122 and lifting mechanism support 122a effectively shift the balance point of the cantilevered mass. The position of lifting mechanism support 122a can be considered the pivot at the centre of a seesaw. Therefore, the outboard position of lifting mechanism support 122a increases the amount of inboard mass (i.e. mass nearer the packaging machine 120 than the pivot position provided by lifting mechanism support 122a), while reducing the amount of outboard mass (mass which is further from the packaging machine 120 than the pivot point created by lifting mechanism support 122a). This increases the mechanical advantage of the mass of the packing machine 120, as it is required to counterbalance a reduced mass. This results in a system which is more stable and safer whilst the feed device 140 is raised and lowered.

(92) FIGS. 7(a), 7(b) and 7(c) illustrate how a feed device 140 may be removed from the packaging system 100 using trolley T.

(93) FIG. 7(a) shows the packaging system 100 in an arrangement wherein the feed device 140 has been decoupled and dismounted from packaging machine 120. The feed device 140 is supported by the lifting apparatus 160 adjacent to the packaging machine 120.

(94) To remove the feed device 140, an operator places a trolley configured to receive the sub frame 180 and the feed device 140 underneath the sub frame 180 and the feed device 140. The lifting apparatus 160 is then operated to lower the sub frame 180 and feed device 140 onto the trolley T by lowering the movable carriage 164.

(95) As the sub frame 180 contacts the trolley the weight of the sub frame 180 and feed device 140 are transferred from the lifting apparatus 160 to the trolley T. The movable carriage is lowered further and the connecting pin 168 achieves the clearance position discussed above in reference to FIGS. 6(a) and (b). This arrangement is shown in FIG. 8(b).

(96) As the connecting pin 168 is in the clearance position the pin may be removed by an operator and the feed device 140 and sub frame 180 may be removed by the operator on the trolley T, as shown in FIG. 8(c).

(97) To attach or install a feed device 140 to the packaging system 100 this process discussed above is reversed. The feed device 140 and sub frame 180 are brought into contact with the movable carriage 164 of the lifting apparatus 160, the connecting pin 168 is inserted, and the movable carriage 168 is raised to lift the feed device 140 and sub frame 180 from the trolley T. The feed device 140 may then be mounted and coupled to the packaging machine 120 as discussed above.

(98) In preferred methods of operating the packaging system 100 the raising of the feed device 140 during installation and the lowering of the feed device 140 during removal are both two stage processes.

(99) When the feed device is mounted to the packaging system 100 preferably the movable carriage 168 is initially raised at a slow speed, and under operator control (although this is not essential), to ensure that the feed device 140 has been correctly coupled to the lifting apparatus 160. Once the coupling has been inspected by an operator the feed device 140 may be raised at a relatively higher speed to reduce the time required to couple a feed device 140 to the packaging machine.

(100) Similarly, when a feed device is removed from the packaging system 100 the feed device is lowered from a position above the packaging machine 140 at a relatively high speed. However, the feed device 140 is preferably lowered onto trolley T at a relatively slow speed, and under operator control (although this is not essential to ensure that the feed device 140 has been correctly located on trolley T.

(101) These two step processes increase the safety and reduce the risk of damage to the system 100 during the mounting and dismounting process.

(102) The safety of packaging systems may be further improved using sensors able to which are configured to detect the presence of foreign objects (e.g. people, other machinery, and consumables) in the path of the feed device 140 during translation, raising or lowering. If a sensor does detect a foreign object the movement of the feed device 140 may be slowed or stopped.

(103) Suitable sensors may include a laser sensor, such as a laser area scanner, a light gate, a visible light sensor or a UV sensor. These sensors may be mounted on one or more components of the packaging systems including the packaging machine 120, feed device 140, lifting apparatus 160 and sub frame 180.

(104) For instance, as shown in FIG. 8 (which illustrates a packaging system in accordance with the first embodiment of the invention in further detail), a laser area sensor 125 is positioned on the side of packaging machine 120, within packaging system 100. The packaging system further comprises feed device 140, lifting apparatus 160 and sub frame 280 and may comprise any of the features and components discussed above in reference to FIGS. 1 to 7.

(105) Laser sensor 125 is positioned near the base of packaging machine 120. Accordingly, it is located near to the surface that the packaging machine 120 is placed on when in use. Specifically, laser sensor 125 is positioned approximately 150 mm above the bottom of packaging machine 120 and the surface on which the packaging machine 120 stands.

(106) This positioning ensures that the laser sensor 125 has good line of sight below the feed device 140 during typical raising and lowering operations. In other words, the path of the feed device 140 is not obscured from the laser sensor 125 and as such the laser sensor 125 may detect any foreign objects.

(107) Where a trolley (such as the trolley T shown in FIGS. 7a to 7c) is used to remove or install a feed device 140. The trolley T will be positioned between the feed device 140 and the laser sensor 125 and therefore obscure or block the feed device 140 from the laser sensor 125. In this arrangement the system 100 may be prevented from automatically raising or lowering the feed device 140 as the trolley is detected by the laser sensor 125. However, the feed device 140 may still be raised and lowered (e.g. onto and off of the trolley) under manual control. The raising and lowering of the feed device 140 under manual control may be performed at a reduced speed in comparison to other raising and lowering operations. These features ensure the safety of the operators and the machinery.

(108) FIGS. 9(a) and 9(b) show cross sections of recesses 300 and protrusions 400 suitable for use within packaging systems in accordance with the present invention.

(109) As discussed above, preferably a feed device or a sub frame and a packaging machine are provided with corresponding recesses and protrusions, such that the recesses and protrusions will only engage when the feed device and the packaging machine are correctly aligned and help ensure that the feed device is correctly retained in contact with the packaging machine.

(110) These protrusions 300 and recesses 400 may be positioned on either side of service connectors which couple the feed device to the packaging machine. Or be positioned at any other location on the surfaces of the packaging machine and either the feed device or sub frame which are in contact when the system is in use.

(111) FIGS. 9(a) and 9(b) show examples of such corresponding recesses 300 and protrusions 400 which will engage when correctly aligned. Additionally each set of recesses 30 and protrusions 400 will additionally correct small misalignments between a feed device and a packaging machine as the feed device is brought into contact with the packaging machine.

(112) Each recess 300 extends into a surface 310 of either the packaging machine, or the feed device or the sub frame configured to connect to the feed device. The recesses 300 are defined by a base surface 320 and recess sides 330. In both cases the recess sides 330 narrow from the surface 310 to the base surface 320 of the recess 300. In both FIGS. 9(a) and 9(b) this narrowing is continuous, and the width of the recess is tapered. Alternatively, the narrowing may be discontinuous and the recess sides 330 may be stepped.

(113) Each protrusion 400 extends from a surface 410 of either the packaging machine, or the feed device or the sub frame configured to connect to the feed device. The protrusions 400 are defined by a top surface 420 and protrusion sides 430. In both cases the protrusion sides 430 narrow from the surface 410 to the top surface 420 of the recess 400. In FIG. 9(a) the narrowing of the protrusion 400 is continuous and the protrusion is formed as a truncated cone, i.e. the protrusion 400 is tapered. Whilst the protrusion 400 shown in FIG. 9(b) discontinuously narrows, and its shape is formed of a truncated cone positioned on the top of a cylinder.

(114) Consequently, the recesses 300 and protrusions 400 together may be termed as a “cup and cone”, and will mechanically centre, i.e. align to each other, when they are brought together.

(115) When the recesses 300 and protrusions 400 of FIGS. 9(a) and 9(b) are brought into contact along a first direction when there is a small misalignment the recess sides 330 and the protrusion sides 430 will cause the recess 300 and protrusion 400 (and the devices to which the recess 300 and protrusion are mounted) to move laterally to the first direction of the movement. This will cause the protrusion 400 and recess 300 to align or centre relative to one another.

(116) To achieve this effect the “small misalignment” must be less than the largest of the difference between the difference in thickness between the protrusion top 420 and the width of the protrusion 400 at surface 410 and the difference in thickness between the recess base 320 and the width of the recess 300 at surface 310.

(117) It is noted that a similar effect may also be achieved where only one of the recess sides 340 or protrusion sides 430 narrows or tapers. Additionally, the recess and protrusion may be of different heights, as shown in FIG. 9b.