LINER SYSTEM, AND UNLOAD STACKING ASSEMBLY AND METHOD THEREFOR

Abstract

An unload stacking assembly includes a discharge hopper for receiving container closures from a conveyance assembly. A deflector deflects the container closures into the discharge hopper in a desired orientation, and a control system detects the container closures and operates a pusher assembly to control movement of the container closers. The conveyance assembly is disposed in a horizontal plane and the discharge hopper is disposed at a discharge angle with respect to the horizontal plane.

Claims

1. An unload stacking assembly comprising: a discharge hopper structured to receive a plurality of container closures from a conveyance assembly; a deflector structured to deflect said container closures into said discharge hopper in a desired orientation; a pusher assembly; and a control system adapted to detect said container closures and operate said pusher assembly to control movement of said container closers.

2. The unload stacking assembly of claim 1 wherein the control system includes at least one presence sensor for detecting said container closures and, responsive to detecting said container closures, adjusts said pusher assembly.

3. The unload stacking assembly of claim 2 wherein the control system includes a first presence sensor for detecting said container closures upstream of said discharge hopper and a second presence sensor for detecting the location of said container closures with respect to said discharge hopper.

4. The unload stacking assembly of claim 1 wherein said conveyance assembly is disposed in a horizontal plane; and wherein said discharge hopper is disposed at a discharge angle with respect to said horizontal plane.

5. The unload stacking assembly of claim 4 wherein said discharge angle is between 15-60 degrees.

6. The unload stacking assembly of claim 5 wherein said discharge angle is between 33-37 degrees.

7. The unload stacking assembly of claim 4 wherein said deflector is structured to induce a rotation motion of said container closures inside said discharge hopper.

8. The unload stacking assembly of claim 9 wherein said discharge hopper further comprises a vacuum structured to induce a force on said container closures to facilitate stacking of said container closures.

9. A liner system comprising: a liner machine for lining a plurality of container closures; a conveyance assembly for conveying said plurality of container closures from the liner machine; and an unload stacking assembly comprising: a discharge hopper for receive a plurality of said container closures from said conveyance assembly, a deflector for deflecting said container closures into said discharge hopper in a desired orientation, a pusher assembly, and a control system adapted to detect said container closures and operate said pusher assembly to control movement of said container closers.

10. The liner system of claim 9 wherein the control system includes at least one presence sensor for detecting said container closures and, responsive to detecting said container closures, adjusts said pusher assembly.

11. The liner system of claim 10 wherein the control system includes a first presence sensor for detecting said container closures upstream of said discharge hopper and a second presence sensor for detecting the location of said container closures with respect to said discharge hopper.

12. The liner system of claim 9 wherein said conveyance assembly is disposed in a horizontal plane; and wherein said discharge hopper is disposed at a discharge angle with respect to said horizontal plane.

13. The liner system of claim 12 wherein said discharge angle is between 15-60 degrees.

14. The liner system of claim 13 wherein said discharge angle is between 33-37 degrees.

15. The liner system of claim 12 wherein said deflector is structured to induce a rotation motion of said container closures inside said discharge hopper.

16. The liner system of claim 15 wherein said discharge hopper further comprises a vacuum structured to induce a force on said container closures to facilitate stacking of said container closures.

17. The liner system of claim 9 wherein said conveyance assembly includes a first conveyor belt and a second conveyor belt disposed between said liner machine and said discharge hopper.

18. A method of stacking container closures comprising the steps of: conveying a plurality of container closures from a liner machine to a discharge hopper on a conveyance assembly, inducing a rotation motion of said container closures using a deflector to move said container closures into said discharge hopper in a desired orientation, detecting said container closures using a control system including at least one presence sensor, and responsive to detecting said container closures with said at least one presence sensor, operating a pusher assembly to apply a vacuum and control movement of said container closers.

19. The method of claim 18 wherein said conveyance assembly includes a number of conveyor belts disposed in a horizontal plane; and wherein said discharge hopper is disposed at a discharge angle with respect to said horizontal plane.

20. The method of claim 19 wherein said discharge angle is preferably between 15-60 degrees and more preferably is between 33-37 degrees.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:

[0013] FIG. 1 is an isometric view of a liner system and unload stacking assembly therefor in accordance with a non-limiting embodiment of the disclosed concept;

[0014] FIG. 2 is an isometric view of the unload stacking assembly of FIG. 1;

[0015] FIG. 3 is a section view of a portion of the unload stacking assembly taken along line 3-3 of FIG. 2; and

[0016] FIG. 4 is an enlarged view of a portion of FIG. 3 showing a plurality of stacked container closures in accordance with aspects of the disclosed concept.

DETAILED DESCRIPTION OF THE INVENTION

[0017] It will be appreciated that although an unload stacking assembly in accordance with the disclosed concept is shown and described herein as used with respect to a rotary liner for applying a sealant or compound to container closures, e.g., without limitation can ends, it could alternatively be employed to convey container closures with a wide variety of other types of equipment and machines (not shown) in other applications.

[0018] Directional phrases used herein, such as, for example, up, down, clockwise, counterclockwise and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein.

[0019] The specific elements illustrated in the drawings and described herein are simply exemplary embodiments of the disclosed concept. Accordingly, specific dimensions, orientations and other physical characteristics related to the embodiments disclosed herein are not to be considered limiting on the scope of the disclosed concept.

[0020] As employed herein, the statement that two or more parts are coupled or mounted together shall mean that the parts are joined together either directly or joined through one or more intermediate parts.

[0021] As used herein, the term operatively coupled shall mean two or more components are functionally connected through one or more intermediate parts such that displacement, manipulation, or actuation of any of the coupled components causes a predefined response in the remaining components.

[0022] As used herein, the term communicably coupled shall mean that two or more electrical components are connected in such a way that power, information, or both may be exchanged between the coupled components.

[0023] As used herein, structured to [verb] means that the identified element or assembly has a structure that is shaped, sized, disposed, coupled and/or configured to perform the identified verb. For example, a member that is structured to move is movably coupled to another element and includes elements that cause the member to move or the member is otherwise configured to move in response to other elements or assemblies. As such, as used herein, structured to [verb] recites structure and not function. Further, as used herein, structured to [verb] means that the identified element or assembly is intended to, and is designed to, perform the identified verb. Thus, an element that is merely capable of performing the identified verb but which is not intended to, and is not designed to, perform the identified verb is not structured to [verb].

[0024] As used herein, number means one or a number greater than one (i.e., a plurality).

[0025] Referring generally to FIGS. 1-4, the disclosed concept is directed to an assembly built for the purpose of transitioning a plurality of lined container closures 2 or lids from a horizontal orientation to a nested and stacked column configuration, commonly referred to as a stick, as shown in FIG. 4. In more detail. lining compound is applied, for example and without limitation, into the curl of the container closures 2 (e.g., lids, shells or can ends) in a liner 100 (e.g., without limitation, the rotary liner partially shown in FIG. 1) in a generally well-known manner. Once completely lined, the container closures 2 are then ejected from the liner 100 and transported (e.g., conveyed) in a horizontal orientation by a conveyance assembly 200 to an unload stacking assembly 300, where they are unloaded into a unique discharge hopper 302 and stacked in the desired aforementioned orientation, in stick form as will be discussed in greater detail hereinbelow.

[0026] In the non-limiting example embodiment of FIG. 1, the conveyance assembly 200 includes a first conveyor belt 202 and a second conveyor belt 204 disposed between said liner machine 100 and said discharge hopper 302, although it will be appreciated that any known or suitable number and/or configuration of conveyor belts and/or alternative conveyance equipment (not shown) could be employed without departing from the scope of the disclosed concept. Among other things, the linear velocity of the container closures 2 is progressively slowed down by the series of conveyor belts (e.g., without limitation, 202, 204), as desired, and the container closures 2 are preferably inspected as they are conveyed or transported by the conveyor belts 202, 204 to the discharge hopper 302.

[0027] As will be discussed, among other benefits, the disclosed concept provides a means for increasing the speed at which the container closures 2 can be processed. Specifically, the disclosed concept enables processing speeds and throughput of more than 2100 ends per minute (EPM), and in accordance with one preferred non-limiting embodiment, speeds of up to 3500 EPM. Further, the disclosed concept improves upon previous technology utilized in the industry by reducing the forces applied to container closures 2 during the unloading and stacking process. The reduction of forces applied to the container closures 2 minimizes, or eliminates, the occurrence of physical damage to the container closures 2. The reduced forces applied to the container closures 2 also minimizes, or eliminates, the possibility of a lining compound being undesirably displaced (e.g., without limitation, spilling out of the curl of the shell or can end).

[0028] As shown in FIG. 2, in addition to the discharge hopper 302, the disclosed unload and stacking assembly 300 includes a deflector 304 structured to deflect container closures 2 into the hopper 302 in a desired orientation, best shown in the section view of FIG. 4, a pusher assembly 306, and a control system 310 (shown in simplified schematic form in FIG. 2) adapted to detect the container closures 2 and operate the pusher assembly 306 to control movement of the container closures 2, as desired. The control system 310 may, for example and without limitation, optionally include features such as a user interface 350 (generally shown in FIG. 1) and is operable to control any number of components and aspects of the liner system 10, including but not limited to components and aspects of the unload and stacking assembly 300 and pusher assembly 306 and subcomponents thereof.

[0029] Continuing to refer to FIG. 1, as well as FIGS. 2-4, prior to leaving the last conveyor belt (e.g., third conveyor belt 204), the container closures 2 preferably travel through a presence sensor 312, which is used, for example and without limitation, to detect the position of the container closures 2 upstream of the discharge hopper 302, as well as to detect jams or other problems or issues with respect to the container closures, and in response, facilitate control of the pusher assembly 306. The control system 10 (FIG. 2) preferably also includes a second presence sensor 314 for detecting the location of container closures 2 within and/or with respect to the discharge hopper 302 and, in response, facilitate control of the pusher assembly 306, for example and without limitation, to operate the pusher assembly 306 at the appropriate speed. The is important because, among other reasons, for example and without limitation, pulling container closures 2 away at the wrong speed can cause the mechanical clearance to change at the load point of the hopper 302. Either too much, or too little clearance is likely to result in a jam.

[0030] As best shown in FIGS. 3 and 4, the conveyance assembly 200 is generally disposed in a horizontal plane 208 and the discharge hopper 302 is preferably disposed at a discharge angle 308 with respect to the horizontal plane 208. In more detail, the discharge angle is preferably between 15-60 degrees and, more preferably is about 35 degrees. This unique angle 308 is a novel and important aspect of the disclosed concept, which in combination with other aspects of the disclosed concept helps to control the movement, positioning and stacking of container closures 2 in the stick orientation as previously discussed and as shown in the enlarged section view of FIG. 4.

[0031] As shown in FIG. 4, the unload stacking assembly 300 includes a deflector 304 structured to induce a rotation motion of the container closures 2 in the direction generally indicated by arrow 400, shown in FIG. 4 with respect to the roller 210 of conveyor belt 206 (partially shown in FIG. 4). This rotation motion, in addition to the aforementioned unique discharge angle 308 of the discharge hopper 302, further facilitates positioning of the container closures 2 within the discharge hopper 302 as generally indicated by arrows 402 and 404 in FIG. 4. It will be appreciated that the deflector 304 could have any known or suitable configuration or combination of components and features to induce the desired motion of the container closures 2. In the non-limiting example shown and described herein, a number of movable or adjustable elements 330, 340 (best shown in the enlarged section view of FIG. 4) are included each of which individually, or in any suitable combination, can be moved or adjusted as needed to impart the desired movement or motion on the container closures 2.

[0032] Additionally, the liner system 10 preferably further includes a vacuum (generally indicated by reference 320 in FIG. 4 (see also vacuum 320 and elements thereof shown in FIGS. 1-3). It will be appreciated that the vacuum 320 is plumbed to induce force on the container closures 2 to facilitate nesting of the container closures into and among the stack or stick of container closures within the system.

[0033] Accordingly, a method of stacking container closures 2 in accordance with a non-limiting embodiment of the disclosed concept includes the steps of: conveying a plurality of container closures 2 from a liner machine 100 to a discharge hopper 302 on a conveyance assembly 200; inducing a rotation motion of the container closures 2 using a deflector 304 to move the container closures 2 into the discharge hopper 302 in a desired orientation (best shown in FIG. 4); detecting the container closures 2 using a control system 310 including at least one presence sensor 312, 314; and responsive to detecting the container closures 2, operating a pusher assembly 306 to apply a vacuum and control movement of the container closures 2.

[0034] Among other advantages, the disclosed unload stacking assembly 300 and discharge hopper 302 therefor reduces forces on the container closures 2, thereby reducing or eliminating displacement of lining compound and mechanical damage to the container closures 2. The lower forces imparted on the container closures 2 enables higher operating speeds and throughput. Accordingly, operating speeds in accordance with the disclosed concept can be up to 3500 EPM, or more, while reducing forces applied to the container closures 2 by up to 50 percent, or more, compared to the known prior art.

[0035] While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of disclosed concept which is to be given the full breadth of the claims appended and any and all equivalents thereof.