Tank lining machine system and restacker assembly for tank lining machine system

Abstract

A re-stacker assembly for stacking container closures output by a can lining machine system includes: at least one unloading assembly having a receiving portion; at least one loading device coupled with the unloading assembly; and a motion control system for detecting motion of the container closures and, in response to detecting such motion, driving the loading device to stack or re-stack the container closures in a predetermined manner.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. patent application serial number 17 / 818,130, filed on August 8, 2022, entitled “Can Liner System And Re-Stacker Assembly.” Technical Field

[0003] The disclosed concept generally relates to a machine for container closures, and more particularly, to a can liner system for container closures, such as, for example, can ends. The disclosed concept also relates to a restacker assembly for a can liner system. Background Art

[0004] It is known to apply a sealant material, often referred to as a compound, to the underside of a container closure, for example to facilitate subsequent sealing attachment (such as but not limited to seaming) of the closure to containers such as, for example, beer / beverage and food cans.

[0005] Lining machines (such as, for example but not limited to, rotary lining machines) are used to line (i.e., apply sealants or glues) container closures, commonly referred to as can lids, can shells, or can ends. Conventional lining machines (sometimes simply referred to as "lining machines") typically include a base having a processing assembly. For example, in a rotary lining machine, the processing assembly may include a chuck assembly having a plurality of rotatable chucks and a pivoting upper turntable assembly disposed on the chuck assembly, the pivoting upper turntable assembly including an electric can assembly, a rotating glue can assembly, and a plurality of fluid dispensing devices (e.g., sealant or glue guns) disposed at the periphery, each of the fluid dispensing devices being associated with a corresponding rotatable chuck of the chuck assembly. In operation, can ends or can shells entering the lining machine are delivered to a lower stacker in "stick" form (i.e., nested together in a vertical row or stack). The lining machine strips the bottom can end or can shell from the bottom of the stack and places it into the aforementioned processing assembly, where the lining glue is subsequently applied. Once fully lined, the can ends or shells 4 are ejected linearly in the direction of arrow 1 onto a flat belt conveyor 2 (shown generally in simplified form in FIG. 1 ), which conveys the freshly lined shells 4 directly into a vacuum hopper 13, as shown in FIG. 1 , where they are stacked or restacked (not shown) for transport.

[0006] Among other disadvantages, this method of conveying and restacking newly lined shells does not employ any time-gating device to ensure that the shells are restacked in an efficient manner, or to ensure that the adhesive in the shells has been sufficiently cured prior to restacking. As a result, conventional lining machines are unable to restack shells at high speeds (e.g., but not limited to, 2100 can ends per minute (EPM) or more) without damaging the shells and / or displacing the adhesive in the shells. More specifically, there is no mechanism to prevent the shells from being restacked in a suboptimal configuration, for example, where the shells are undesirably overlapped (commonly referred to as "shingling"), which can result in jams. In addition, the lining adhesive may be displaced from the shells, which is commonly referred to as adhesive spillage. In addition, the forces applied to the shells during the restacking process may result in physical damage to the shells. These issues have in the past limited the operating speed of lining machines to 2100 EPM or less. As a result, production output or throughput is limited.

[0007] Therefore, there is room for improvement in can liner systems and restacker assemblies thereof. Summary of the invention

[0008] These needs and others are met by embodiments of the disclosed concept, which relates to a restacker assembly and a can liner system. Among other advantages, the restacker assembly reduces the forces applied to container closures, thereby overcoming known disadvantages of prior art liner systems and allowing the liner to run at faster speeds and increase production throughput.

[0009] As one aspect of the disclosed concept, a restacker assembly includes at least one unloading assembly having a receiving portion configured to receive a plurality of container closures; at least one loading device coupled to the unloading assembly; and a motion control system configured to detect movement of the container closures and, in response to detecting such movement, drive the loading device to stack the container closures in a predetermined manner.

[0010] The motion control system may include at least one presence sensor and a motor operatively coupled to the loading device, and the unloading assembly may include an opening disposed proximate the presence sensor and the receiving portion, wherein the motor is configured to move the loading device to guide the container closure through the opening of the unloading assembly. The motion control system may also include a control unit, wherein the motor and the at least one presence sensor are communicatively coupled to the control unit. The at least one presence sensor may include a primary presence sensor and a secondary presence sensor, wherein the primary presence sensor is disposed proximate the receiving portion, and wherein the secondary presence sensor is disposed offset from the primary presence sensor.

[0011] The unloading assembly may further include a hopper having an opening, wherein the loading device is a kicker wheel positioned above the opening of the hopper. The kicker wheel may include a plurality of protrusions, wherein the protrusions are configured to guide the container closures through the opening to be stacked within the hopper. The motion control system may further include a supplemental presence sensor disposed within the hopper.

[0012] A lining machine system using the aforementioned restacking assembly is also disclosed. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] A complete understanding of the present invention can be obtained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings, in which:

[0014] FIG1 is a perspective view of a prior art rotary lining machine;

[0015] Figure 2 is a perspective view of a can liner system and restacker assembly thereof according to a non-limiting embodiment of the disclosed concept;

[0016] Figure 3 yes Figure 2 A perspective view of a restacker assembly of FIG.

[0017] Figure 4 yes Figure 3 a perspective view of a portion of a restacker assembly of , wherein the hopper is shown in cross-section; and

[0018] Figure 5 is a schematic diagram of the restacker assembly. DETAILED DESCRIPTION

[0019] It should be understood that while the restacker assembly according to the disclosed concepts is shown and described herein as being used with respect to a rotary lining machine for applying sealant or glue to container closures (such as, but not limited to, can ends), it can alternatively be used in other applications to convey container closures in conjunction with various other types of equipment and machines (not shown).

[0020] Directional phrases used herein, such as, for example, up, down, clockwise, counterclockwise and their derivatives refer to the orientation of elements shown in the figures and do not limit the claims unless explicitly stated herein.

[0021] The specific elements shown in the drawings and described herein are merely exemplary embodiments of the disclosed concepts. Hence, specific dimensions, orientations and other physical characteristics related to the embodiments disclosed herein should not be considered as limiting the scope of the disclosed concepts.

[0022] 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 together through one or more intermediate parts.

[0023] As used herein, the term "terminally connected" shall mean a terminal portion of a first component connected to a second component having a definable longitudinal axis.

[0024] As used herein, the term "operably coupled" shall mean that two or more components are functionally connected through one or more intermediate parts so that displacement, manipulation or actuation of any one of the coupled components results in a predefined response of the remaining components.

[0025] As used herein, the term "communicably coupled" shall mean that two or more electrical components are connected such that power, information, or both can be exchanged between the coupled components.

[0026] As used herein, the term "distributed" shall mean that the plurality of first components are positioned within, around, or throughout the second component. In addition, one or more of the foregoing descriptions may apply to the distribution of the plurality of first components relative to the second component. Furthermore, the plurality of first components may be arranged in an ordered or random configuration.

[0027] As used herein, "constructed to [perform an action]" means that the identified element or component has a structure that is shaped, sized, arranged, connected, and / or configured to perform the identified action. For example, a member that is "constructed to move" is movably connected to another element and includes an element that moves the member, or the member is otherwise constructed to move in response to other elements or components. Therefore, as used herein, "constructed to [perform an action]" describes structure rather than function. In addition, as used herein, "constructed to [perform an action]" means that the identified element or component is intended and designed to perform the identified action. Therefore, an element that is only capable of performing an identified action but is not intended and designed to perform an identified action is not "constructed to [perform an action]".

[0028] As used herein, "number" means one or a number greater than one (ie, a plurality).

[0029] Overall reference Figure 2-Figure 5 The disclosed concept relates to a method for assembling a plurality of lined container closures 4 ( Figure 3 and Figure 4 ) is a component that is constructed by transitioning from an initial vertical orientation to a horizontal orientation and finally back to a vertical orientation. In more detail, Figure 2The arrows shown in generally depict the direction of movement of the container closures 4. That is, the overall process performed by the disclosed concept is as follows; first, the container closures 4 or "caps" are introduced into the can liner system 1 in a vertical stack (commonly referred to as a "stick"), where the container closures 4 are nested and stacked together in the form of a vertical column. Therefore, the term "stick" is used herein to refer to the vertical column of stacked and nested container closures 4. The container closures 4 are peeled or removed from the bottom of the stack and moved to the can liner system 10, where, for example but not limited to, a lining adhesive is applied to the curl of the container closures 4 (e.g., can shells or can ends). Once fully lined, the container closures 4 are then ejected from the can liner system 10 and transported (e.g., conveyed) in a horizontal orientation by the conveyor system 20 to the restacker assembly 3, where the container closures are restacked again in a vertical orientation in the form of a stick.

[0030] As will be discussed, among other benefits, the disclosed concepts provide a method of increasing the speed at which container closures 4 can be processed. Specifically, in preferred embodiments, the disclosed concepts enable processing speeds of 2,100 can ends per minute (EPM) or faster. In addition, the disclosed concepts improve upon prior art techniques used in the industry by reducing the forces applied to the container closures 4 during the restacking process. Reducing the forces applied to the container closures 4 minimizes or eliminates the likelihood of physical damage to the container closures 4. The reduced forces applied to the container closures 4 also minimize or eliminate the likelihood of undesirable displacement of the lining adhesive, such as, but not limited to, spillage from the curl of the can shell or can end.

[0031] like Figure 3 and Figure 4 As best shown, the disclosed concept provides a method for restacking lined container closures 4 that are initially traveling in a horizontal direction. The exemplary conveyor system 20 includes a plurality of conveyor belts 12. Container closures 4 placed on one or more conveyor belts 12 are initially spaced apart by the can liner system 10. During their time on the one or more horizontal conveyor belts 12, the container closures 4 may be inspected and decelerated prior to reaching the input area of ​​the restacker assembly 3. The container closures 4 are then conveyed to the restacker assembly 3 in the same horizontal direction of travel as the conveyor system 20. In one non-limiting exemplary embodiment, the conveyor system 20 may decelerate the container closures 4, for example, but not limited to, by using a series of multiple conveyor belts 12 (only one conveyor belt is shown and described in detail herein to simplify the disclosure), wherein each successive conveyor belt 12 moves at a slower speed than the previous conveyor belt.

[0032] As will be discussed in more detail below, in an exemplary embodiment, the restacker assembly 3 employs a plurality of presence sensors (e.g., each at Figure 3 12) to determine the location and rate of travel of container closures 4 traveling along one or more conveyor belts 12. One or more presence sensors 332, 333 are used to determine the physical location of container closures 4. It should be understood that one or more presence sensors 332, 333 may include, for example, but not limited to, ultrasonic sensors, optical sensors, proximity sensors, and computer vision systems. This information is in turn used to modify the rate at which the loading device 32 places lined container closures 4 into the hopper 313. The number of presence sensors 332, 333 and the structure and operation of the associated unloading assembly 31 advantageously serve to create spacing between container closures 4 because the container closures 4 are placed into the hopper 313 in a predetermined desired manner.

[0033] Continue to refer Figure 3 and Figure 4 The hopper 313 allows a controlled area (eg, a receiving portion) where the container closures 4 are restacked and provided to the tank end module rail 100 (eg, Figure 2 In addition, the vacuum generator 315 ( Figure 5 ) can be attached to the hopper 313 to create a vacuum that biases (e.g., moves) the container closures 4 toward the bottom of the hopper 313 to facilitate proper restacking. These features reduce the physical forces exerted on the container closures 4 while providing an effective method of controlling the orientation and travel of the container closures 4 within and / or through the hopper 313 in a predetermined manner.

[0034] refer to Figures 3 to 5 The exemplary restacker assembly 3 shown and described herein uses an unloading assembly 31, a loading device 32, and a motion control system 33 ( Figure 5 ) to manipulate and move the container closures 4 into the hopper 313 in a predetermined controlled manner. In addition, the disclosed concept utilizes a motion control system 33 ( Figure 5 ) to coordinate the operation of the unloading assembly 31 and the loading device 32 so that the rate at which the loading device 32 places container closures 4 into the hopper 313 is dynamically modified based on the position and travel rate of the leading container closure 4 in a series or series of container closures 4. That is, each time the container closure 4 is moved by one or more conveyor belts 12 to the receiving portion 311 of the unloading assembly 31, the loading device 32 is positioned to load each container closure 4 into the hopper 313. The loading device 32 is designed to manipulate and orient the container closures 4 in a manner that avoids damage or other undesirable problems such as jamming and adhesive displacement (e.g., spillage).

[0035] Continue to refer Figure 4 and Figure 5 To achieve the above functions, the unloading assembly 31 is designed to receive a series of container closures 4 traveling in a generally horizontal direction and move (e.g., re-orient; re-stack) them into a generally vertical stack, such as Figure 4 , is best shown in a cross-sectional view of . Typically, the loading device 32 is a mechanical actuator for changing the position of an object (e.g., a container closure 4). Specifically, embodiments of the disclosed concept may use a loading device 32, such as, but not limited to, a beater wheel (shown), a robotic arm (not shown), and a piston (not shown). The loading device 32 is preferably coupled and cooperates with the unloading assembly 31. In the example shown, the beater wheel 32 includes a plurality of protrusions 132 (three are shown) such that as the beater wheel 32 rotates, the protrusions 132 engage corresponding container closures 4 in a predetermined desired manner and move them through the opening 312 in the hopper 313 to form a stack, such as. Figure 4 Thus, as used herein, the term "beater wheel" refers to a loading device configured to reorient a container closure 4 from a horizontal orientation to a vertical orientation, and expressly includes, but is not limited to, a rotating member having any known or suitable number, type and / or configuration of protrusions configured to engage and move a container closure 4 in a desired manner.

[0036] Motion Control System 33 ( Figure 5 ) is preferably an automatic control system for analyzing the status of a series of container closures 4 and controlling and moving (e.g., rotating) the loading device 32 (e.g., a beater wheel) accordingly. Specifically, the motion control system 33 is configured to rotate the loading device 32 in response to detecting motion within the receiving portion 311 of the unloading assembly 31. That is, the motion control system 33 drives (e.g., rotates) the loading device 32 to place a series of container closures 4 in an incremental manner so that the time required for the loading device 32 to place any container closure 4 and then reposition to receive a subsequent container closure 4 at the receiving portion 311 is less than or equal to the time required for the subsequent container closure 4 to reach the receiving portion 311 and be engaged and manipulated into the hopper 313 by the next protrusion 132 of the loading device (e.g., the beater wheel 32) as needed.

[0037] refer to Figures 3 to 5 , Motion Control System 33 ( Figure 5 ) preferably includes the aforementioned presence sensors 332, 333, a motor 334 and a control unit 335 ( Figure 5). The control unit 335 is a processing system designed to perform the data analysis and component control operations required to operate the disclosed restacker assembly 3. The control unit 335 can be, for example, but not limited to, a smart phone, a local microcontroller, or a remote server. The motor 334 and one or more presence sensors 332, 333 are communicatively coupled to the control unit 335. The opening 312 of the unloading assembly 31 is disposed proximate to the presence sensor 332 and the receiving portion 311. For example, the opening 312 of the unloading assembly 31 can be a feed port or channel designed to transport the container closures 4 through the receiving portion 311 and out of the receiving portion 311 and into, for example, but not limited to, the aforementioned hopper 313 for storage, transportation, and / or further processing.

[0038] In more detail, one or more presence sensors 332, 333 detect the arrival of container closures 4 from one or more conveyor belts 12 onto the disclosed restacker assembly 3. This information is forwarded to a control unit 335. As described above, a motor 334 is operably coupled to a loading device (e.g., a beater wheel 32). More specifically, the control unit 335 uses the information received from the one or more presence sensors 332, 333 to generate instructions that cause the motor 334 to make fine and / or coarse adjustments to the positioning (e.g., but not limited to, rotation; rotation speed) of the loading device 32. These adjustments enable the motor 334 to drive (e.g., rotate) the loading device 32 so as to move the container closures 4 through the opening 312 of the unloading assembly 31 in a desired predetermined manner. As described above, in the non-limiting embodiment shown and described herein, the loading device 32 is a beater wheel having a plurality of protrusions 132 (three shown), and the motor 334 controls the rotational speed of the beater wheel 32 so that the beater wheel 32, and specifically the protrusions 132 of the beater wheel, can engage and manipulate corresponding container closures 4 through the openings 312 at a rate controlled as desired by the control unit 335. Thus, little force is required to move the container closures 4 through the receiving portion 311 and into the hopper 313. Once through the openings 312, the vacuum generator 315 draws the container closures 4 through the hopper 313 until the container closures 4 are nested together in the form of a rod in a predetermined desired orientation.

[0039] refer to Figure 3 and Figure 4, the exemplary restacker assembly 3 preferably includes a plurality of presence sensors, specifically a first or primary presence sensor 332 and a second or secondary presence sensor 333, as well as a supplemental presence sensor 316. The primary presence sensor 332 is preferably disposed adjacent to the receiving portion 311 of the unloading assembly 31 and is used to determine whether fine adjustments must be made to the positioning of the loading device 32 as the container closures 4 move into and through the opening 312 of the unloading assembly 31. The secondary presence sensor 333 is preferably disposed offset from the primary presence sensor 332, as shown in FIG. Figure 3 20 and are used to determine whether coarse adjustments must be made to the positioning of the loading device 32 as the container closures 4 move along the conveyor system 20. It should be understood that embodiments (not shown) in which multiple secondary presence sensors 333 may be distributed along the length of the conveyor system 20 are also contemplated without departing from the scope of the disclosed concept. Such embodiments can be advantageously employed, for example, but not limited to, for determining the status of multiple container closures 4 at one time, for tracking individual container closures 4 at multiple locations along the conveyor system 20, and / or for generally monitoring one or more operating characteristics of the conveyor system 20. The information collected by each presence sensor 332, 333 can be used, for example, to increase or decrease the conveying rate by increasing or decreasing the speed of one or more corresponding conveyor belts 12 at multiple locations along the conveyor system 20.

[0040] like Figure 3 and Figure 4 As shown, the disclosed embodiment of the restacker assembly 3 is designed with an unloading assembly 31, which includes the aforementioned hopper 313. In the example shown, the hopper 313 is mounted adjacent to the opening 312 of the unloading assembly 31, so that the loading device is arranged opposite the hopper 313 across the opening 312. The hopper 313 is advantageously positioned to receive the container closures 4 to be placed by the loading device 32. It will be understood that the hopper 313 can be, for example, a removable storage device, which can be removed and transported once it is filled with container closures 4. It should also be understood that the hopper 313 can be part of the conveyor track 100, or can cooperate with the conveyor track 100, such as Figure 2 Approximately shown.

[0041] It should therefore be appreciated that the disclosed restacker assembly 3 is designed to facilitate a rapid restacking operation, which reduces the forces applied to the container closures 4. To facilitate this, the exemplary embodiment of the disclosed restacker assembly 3 also includes the aforementioned vacuum generator 315 ( Figure 5 ; Also in Figure 2 ) and a supplemental presence sensor 316 ( Figure 4313). A vacuum generator 315 is in fluid communication with the hopper 313 to create a vacuum therein. As previously described, such a vacuum draws the container closures 4 into the hopper 313 and prevents undesirable interactions (e.g., overlap, jamming) between the container closures 4 within the hopper 313. A supplemental presence sensor 316 is disposed within the hopper near the entrance or opening 312 of the hopper 313 and is communicatively coupled to the control unit 335. Among other functions, for example and without limitation, the supplemental presence sensor 316 is capable of determining when the hopper 313 is full or nearly full.

[0042] Thus, among other advantages and benefits, the restacker assembly 3 and can liner system 1 according to the disclosed concept is preferably capable of achieving a processing speed of at least 2100 EPM, and more preferably, up to 3500 EPM or more, while also reducing the forces applied to the container closures 4 during the restacking process to minimize or eliminate physical damage to the container closures 4, and to minimize or eliminate displacement of the lining adhesive. In addition, the disclosed concept provides a system for quickly and efficiently forming a predetermined desired configuration (e.g., a stick) of lined container closures 4 ready for transport (e.g., shipping) or further processing.

[0043] Although specific embodiments of the present invention have been described in detail, those skilled in the art will recognize that various modifications and substitutions to these details can be developed based on the overall teachings of the present disclosure. Therefore, the specific arrangements disclosed are merely illustrative and do not limit the scope of the disclosed concept as given by the full scope of the appended claims and any and all equivalents thereof.

Claims

1. A restacker assembly, the restacker assembly comprising: at least one unloading assembly having a receiving portion configured to receive a plurality of container closures; at least one loading device coupled to the unloading assembly; as well as A motion control system is configured to detect movement of the container closures and, in response to detecting the movement, drive the loading device to stack the container closures in a predetermined manner.

2. The restacker assembly of claim 1, wherein: The motion control system includes at least one presence sensor and a motor operably coupled to the loading device; wherein the unloading assembly includes an opening disposed proximate the presence sensor and the receiving portion; and wherein the motor is configured to move the loading device to guide the container closure through the opening of the unloading assembly.

3. The restacker assembly of claim 2, wherein: The motion control system further includes a control unit; and wherein the motor and the at least one presence sensor are communicatively coupled to the control unit.

4. The restacker assembly of claim 3, wherein: the at least one presence sensor comprising a primary presence sensor and a secondary presence sensor; wherein the primary presence sensor is disposed adjacent the receiving portion; and wherein the secondary presence sensor is disposed offset from the primary presence sensor.

5. The restacker assembly of claim 1, wherein: The unloading assembly also includes a hopper having an opening; wherein the loading device is a beater wheel; and wherein the beater wheel is positioned above the opening of the hopper.

6. The restacker assembly of claim 5, wherein: The beater wheel includes a plurality of protrusions; and wherein the protrusions are configured to guide the container closures through the opening for stacking within the hopper.

7. The restacker assembly of claim 5, wherein: The unloading assembly further includes a vacuum generator; and wherein the vacuum generator is in fluid communication with the hopper.

8. The restacker assembly of claim 4, wherein: The unloading assembly further includes a hopper having an opening; wherein the motion control system further includes a supplemental presence sensor; and wherein the supplemental presence sensor is disposed within the hopper.

9. The restacker assembly of claim 8, wherein: The supplemental presence sensor is communicatively coupled to the control unit.

10. A tank lining machine system, the tank lining machine system comprising: a lining machine for lining a plurality of container closures; a conveyor system for transferring the plurality of container closures from the lining machine; as well as A restacker assembly, the restacker assembly comprising: at least one unloading assembly disposed adjacent the conveyor system and including a receiving portion configured to receive the container closures from the conveyor system, at least one loading device coupled to the unloading assembly, and A motion control system is configured to detect movement of the container closures and, in response to detecting the movement, drive the loading device to stack the container closures in a predetermined manner.

11. The tank lining machine system of claim 10, wherein: The motion control system includes at least one presence sensor and a motor operably coupled to the loading device; wherein the unloading assembly includes an opening disposed proximate the presence sensor and the receiving portion; and wherein the motor is configured to move the loading device to guide the container closure through the opening of the unloading assembly.

12. The tank lining machine system of claim 11, wherein: The motion control system further includes a control unit; and wherein the motor and the at least one presence sensor are communicatively coupled to the control unit.

13. The tank lining machine system of claim 12, wherein: The at least one presence sensor comprises a primary presence sensor and a secondary presence sensor; wherein the primary presence sensor is disposed adjacent to the receiving portion; and wherein the secondary presence sensor is disposed offset from the primary presence sensor.

14. The tank lining machine system of claim 10, wherein: The unloading assembly also includes a hopper having an opening; wherein the loading device is a beater wheel; and wherein the beater wheel is positioned above the opening of the hopper.

15. The tank lining machine system of claim 14, wherein: The beater wheel includes a plurality of protrusions; and wherein the protrusions are configured to guide the container closures through the opening to be stacked within the hopper.

16. The tank lining machine system of claim 14, wherein: The unloading assembly further includes a vacuum generator; and wherein the vacuum generator is in fluid communication with the hopper.

17. The tank lining machine system of claim 13, wherein: The unloading assembly further includes a hopper having an opening; wherein the motion control system further includes a supplemental presence sensor; and wherein the supplemental presence sensor is disposed within the hopper.

18. The tank lining machine system of claim 17, wherein: The supplemental presence sensor is communicatively coupled to the control unit.

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