STACKING DEVICE FOR SIDE LOADER

Abstract

1. Method of preparing confectionary products for packaging in a side-loader packaging machine, where the confectionary products are conveyed one by one on a first pocket conveyor, and where a picking robot is arranged for picking up a predetermined number of ice cream products from said first pocket conveyor and transferring the confectionary products to a bulking conveyor, said bulking conveyor having compartments suitable to accommodate a predetermined number of confectionary products in one or more layers in each compartment, where the picking robot can be in a first position above one or more compartments to be filled, and a second position above the pocket conveyor, where a) in a first step the picking robot, pick up a predetermined number of confectionary products corresponding to the number of confectionary products in a first layer from the pocket conveyor and thereafter positions the picking robot above one or more empty compartments on the bulking conveyor; b) in a further step determine that a further predetermined number of confectionary products corresponding to the total number of confectionary products needed for filling all consecutive layers are available on the pocket conveyor, ready to be picked up; c) releases the picked up confectionary products into the one or more compartment, and d) the picking robot moves to pick up the further predetermined number of confectionary products from the pocket conveyor, and e) transfers the further predetermined number of products to the compartment creating a further layer of confectionary products, and f) repeat steps d) and e)) until the desired number of layers are arranged in the compartment, whereafter g) repeat steps a) to f).

Claims

1. Method of preparing confectionary products for packaging, where the confectionary products are conveyed one by one on a first pocket conveyor, and where a picking robot comprising one or more picking arms is arranged for picking up a predetermined number of confectionary products from said first pocket conveyor and transferring the confectionary products to a bulking conveyor, said bulking conveyor having compartments suitable to accommodate a predetermined number of confectionary products in one or more layers in each compartment, where the method comprises the following steps; a) in a first step the one or more arms of the picking robot, picks up a predetermined number of confectionary products corresponding to the number of confectionary products in a first layer from the pocket conveyor and thereafter positions the one or more arms of the picking robot above one or more empty compartments on the bulking conveyor; b) in a further step determining that a further predetermined number of confectionary products corresponding to the total number of confectionary products needed for filling one or more consecutive layers are available on the pocket conveyor, ready to be picked up before releasing the first layer of confectionary products; c) releasing the picked up confectionary products into the one or more compartments in a first layer, and d) the one or more arms of the picking robot moving to pick up the further predetermined number of confectionary products from the pocket conveyor and picks up the further predetermined number of confectionary products, and e) transfers the further predetermined number of confectionary products to the one or more compartment creating a further layer of confectionary products.

2. Method according to claim 1 wherein the confectionary products are frozen ice cream products.

3. Method according to claim 1, where the bulking conveyor and/or the pocket conveyor moves at constant or variable speed.

4. Method according to claim 1, where the predetermined number of confectionary products is between 3 and 24 confectionary products.

5. Method according to claim 1, where the picking robot comprises a plurality of separate picking arms, each arm provided with a vacuum collection member, and a valve mechanism for activating a desired number of vacuum collecting members corresponding to the desired predetermined number of confectionary products in each layer.

6. Method according to claim 1, where the predetermined number of confectionary products may correspond to the desired number of confectionary products in a single layer in two or more adjacent compartments, such that when the predetermined number of confectionary products are released in step c) and e) a layer of confectionary products will be positioned in two or more adjacent compartments.

7. Method according to claim 1, wherein said bulking conveyor and/or pocket conveyor stops moving during the process.

8. Method according to claim 1, wherein the method comprises the following steps: f) repeating steps d) and e) until the desired number of layers are arranged in the one or more compartments.

9. Method according to claim 8, wherein the method comprises the following steps: repeat steps a) to f).

10. Method according to claim 1, wherein the method comprises an additional step of conveying the total number confectionary products in said one or more compartment to a side-loader.

11. Method according to claim 1, wherein the one or more compartments comprises a carton or a box.

12. Method according to claim 1, wherein said first layer is a first layer placed in two or more compartments at the same time/simultaneously.

13. Method according to claim 1, wherein further layers are placed in the two or more compartments at the same time/simultaneously.

14. Method according to claim 1, wherein an additional picking robot is used for the second layer of confectionary products.

15. Method according to claim 1, wherein the confectionary products are picked from a plurality of pocket conveyors.

16. Method according to claim 1, wherein unpicked confectionary products may be recycled automatically or manually.

17. Method according to claim 1, wherein unpicked confectionary products are picked by an additional picking robot.

Description

DESCRIPTION OF THE DRAWINGS

[0021] in the drawing

[0022] FIG. 1a to 1f illustrate the method steps of the present invention

[0023] FIG. 2 illustrates a schematic overview of a possible lay out facilitating the invention

DETAILED DESCRIPTION OF THE INVENTION

[0024] In FIG. 1a through 1f the inventive method of preparing confectionary products for packaging in a side-loader machine will be described.

[0025] A side-loader machine is used in many production lines where singular objects are packaged for example in cartons. In order to achieve the optimum packing, the objects to be packaged are pre-stacked, such that a complete stack of products may be slid into the carton sideways (i.e. without being handled further). A stack may comprise a number of layers, where each layer comprises a predetermined number of objects. For example, each layer may comprise four objects, and by creating three layers, twelve products are prepared for being introduced into the package in the side-loader machine.

[0026] The schematic steps illustrated in FIG. 1a through FIG. 1f is a simplified sketch of the actual procedure. Many details relating to the robot(s), conveyors, machine etc. are left out on purpose in order to illustrate the concept.

[0027] In FIG. 1a is illustrated a compartment 10 arranged in a bulking conveyor 1. A pocket 20 arranged in a pocket conveyor 2 is arranged next to the bulking conveyor 1. There may be arranged a plurality of parallel pocket conveyors 2. In order to illustrate the principles of the present invention only a single pocket conveyor 2 is illustrated.

[0028] In the pocket 20 is arranged a product 30. This product 30 may in principle be any type of product but typically this method is used with frozen ice cream products or other confectionary products.

[0029] A picking robot, illustrated by the robots' engagement pad 40 is illustrated above the compartment 10.

[0030] Further a sensor 50 is arranged such that the sensor may detect the presence or non-presence of a product 30 in the pocket 20. Typically, the sensor 50 will be arranged such that it detects the presence or absence of a plurality of products 30.

[0031] In a first method step the sensor detects that a predetermined number of confectionary products 30 corresponding to the number of confectionary products in a first layer is present on the pocket conveyor 2. The robot picks 40 up the predetermined number of products 30 and thereafter positions the products 30 above one or more empty compartments 10 on the bulking conveyor 1.

[0032] Depending on the number of products in each layer, the robot may pick up a number of products corresponding to filling a first layer in more than one compartment.

[0033] This is illustrated in FIG. 1b, where the robot 40 with products 30 is waiting above an empty compartment 10. The pocket 20 is empty.

[0034] In FIG. 1c the sensor 50 detects that products 30 corresponding to the predetermined number of confectionary products 30 for a layer is present on the pocket conveyor 2. The robot 40 then releases the first collected products 30, such that the products 30, as illustrated in FIG. 1d are placed as a first layer of products 30 in the compartment 10. The robot 40 then moves on to collect the next layer of products 30 from the pocket conveyor. These products 30 are then placed on top of the former layer of products 30 in the compartment 10, as illustrated in FIG. 1e. The pockets 20 on the pocket conveyor are empty.

[0035] In the next step, as illustrated in FIG. 1f the sensor detects the presence of products 30 on the pocket conveyor corresponding to the number of products in a layer, and prepares the robot 40 to collect the products and place the robot as described above with reference to FIG. 1a, above an empty compartment, see FIG. 1b. At this time a complete cycle is completed filling two layers into a compartment. The compartment 10 may at this time proceed to the side-loader machine.

[0036] For some products or applications, it is desirable to stack more than two layers. In these instances, the sensor 50 in the method step, corresponding to FIG. 1c must make sure that products are available on the pocket conveyor, corresponding to the total number of products necessary for completing the additional layers. For example, if four layers comprising four products in each layer is to be packaged, the robot will pick up the first four products and wait above an empty compartment until the sensor registers that twelve products are available on the pocket conveyor. When the twelve products are registered the robot will release the first four products into the empty compartment. The robot will then pick up the next layer, deposit it on top of the first layer, pick up the third layer and deposit it on top of the second layer and finally pick up the fourth layer and deposit it on top of the third layer. At this time four layers of four products are deposited in the compartment. The compartment can then proceed to the side-loader machine for packaging. Once the compartment is filled up with desired layers, the robot will return to the position as described above with reference to FIG. 1a.

[0037] In FIG. 2 is schematically illustrated part of a production line 100 comprising a bulking conveyor 110, a pocket conveyor 120, and a picking robot 140 and a sensor 150.

[0038] The products 30 are loaded onto the pocket conveyor upstream (not illustrated) in such a manner that one product 30 is placed in each pocket 20. Some pockets 20 may be empty due to failure to fill them correctly upstream. In practice only very few pockets are empty.

[0039] If an array of filled pockets 20 does not correspond to the number of products to fill a layer in the compartment 10, the robot let the products pass. These products 30 are recycled and refilled into pockets upstream. In embodiments where additional layers on top of the first layer are to be placed on top of the first layer, the robot 140 will only be activated when the sensor 150 detect that sufficient products are available on the pocket conveyor, corresponding to the total number of products needed to fill all layers in the compartment.