Tray Positioning and Loading System

Abstract

The container packaging system (20) is comprised of an alignment system (22) for arranging the articles (24) into a loading alignment configuration at a staging location (26). A loader (28) lifts the articles (24) from the staging location (26) for placement in a predefined location within a container (30). Although this is not always the case, the container (30) may be sized and configured to receive multiple articles (24). A control system (32) controls the operation of the packaging system, including controlling the alignment system (22) to place the articles (24) in the correct alignment configuration at the staging location (26) and controlling the operation of the loader (28) to transport the articles (24) to the predefined location within the container (30).

Description

[Background technology]

[0001] background In the food distribution process, it is typically necessary to consolidate individual items or packages containing food into larger groupings, such as containers, boxes, cartons, trays, etc. Very often, this operation is performed manually, where the items or packages arrive on a conveyor at a packing station, and workers then manually place the items or packages into the containers, boxes, cartons, or trays.

[0002] In some situations, the packaging of items or packages into larger groupings is currently performed using automated equipment. Groups of items or packages are picked up using lifting heads mounted on a robot. The lifting heads are configured to move the items or packages relative to one another so that they are in the proper position to be placed in a container / box / carton / tray. This requires a fairly complex configuration of the lifting heads. The lifting heads have individual parts that are attachable to the items of the package, and these parts of the lifting head must be movable relative to one another to achieve the proper alignment of the items of the package. Summary of the Invention [Problem to be solved by the invention]

[0003] The present disclosure seeks to address the shortcomings of previous methods and systems for packing packaged items into larger groupings, and is applicable not only for food distribution, but also for distribution of many other types of items that are aggregated for shipping or distribution. [Means for solving the problem]

[0004] overview This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0005] According to one embodiment of the present disclosure, a container packaging system for placing items into one or more containers includes an alignment system for arranging the items into a loading alignment configuration at a staging location of the packaging system, the positions of the items corresponding to the locations and configurations of the one or more containers, and the container packaging system further includes a loader for transferring the items from the staging location to predetermined locations within the one or more containers, and a control system for controlling operation of the alignment system to arrange the items into the loading alignment configuration at the staging location and for operating the loader to transfer the items from the staging location into the one or more containers.

[0006] In any of the embodiments disclosed herein, the registration system includes a first conveyor for delivery of articles to a second conveyor that are positioned relative to one another such that the articles are in a loading registration configuration.

[0007] In any of the embodiments disclosed herein, the second conveyor includes a staging location.

[0008] In any of the embodiments disclosed herein, the container packaging system further includes a sensor for sensing a location of an item on the first conveyor and generating data related to such location, and the control system uses the data from the sensor to controllably operate the first and second conveyors such that the item is delivered from the first conveyor to the second conveyor so that it is in loading alignment on the second conveyor.

[0009] In any of the embodiments disclosed herein, the loader includes an interface for attachment to an item to be placed in the container and an actuation system for moving the interface between the staging location and the one or more containers to transfer the item from the staging location into the one or more containers, and a control system controls operation of the actuation system.

[0010] In any of the embodiments disclosed herein, the interface includes a lift head for attachment to the article to lift the article from the staging location.

[0011] In any of the embodiments disclosed herein, the article includes a top portion and the lifting head is configured to be attached to the top portion of the article.

[0012] In any of the embodiments disclosed herein, the actuation system includes a five-bar linkage arrangement to which the interface is mounted.

[0013] In any of the embodiments disclosed herein, the five-bar link array is located above the staging location.

[0014] In any of the embodiments disclosed herein, the five-bar linkage arrangement is configured to removably mount the interface.

[0015] In any of the embodiments disclosed herein, two of the links of the five-bar linkage arrangement are powered to move the interface between the staging location and one or more containers.

[0016] In any of the embodiments disclosed herein, the container packaging system further includes an auxiliary interlocking arrangement mounted on the five-bar interlocking arrangement and connected to the interface surface to maintain the interface surface at a selected orientation relative to articles lifted from the staging location and placed in the one or more containers.

[0017] In any of the embodiments disclosed herein, the auxiliary linking array is linked to the 5-bar linking array, thereby acting relative to the auxiliary linking array based on movement of the 5-bar linking array.

[0018] In any of the embodiments disclosed herein, the container packaging system further includes a transport system for transporting one or more containers to a staging location to be loaded and then transporting the one or more containers away from the staging location after being loaded, and the control system controls the transport system to position the containers at predetermined positions relative to the staging location.

[0019] Description of the drawings The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, in which: [Brief description of the drawings]

[0020] [Figure 1] 1 is an isometric view of the container packaging system of the present disclosure, viewed from above at the downstream end of the system; [Diagram 2] 2 is an isometric view of FIG. 1 as viewed from the upstream end of the system. [Diagram 3] FIG. 3 is a partial plan view of FIGS. 1 and 2. [Figure 4] FIG. 4 is a front view of FIG. [Diagram 5] FIG. 3 is an upstream end view of FIGS. 1 and 2. [Figure 6] 3 is a downstream end view of FIGS. 1 and 2 showing the loader in one position as it transfers items or packages to a container for consolidation. FIG. [Figure 7] 3 is a downstream end view of FIGS. 1 and 2 showing the loader in one position as it transfers items or packages to a container for consolidation. FIG. [Figure 8]3 is a downstream end view of FIGS. 1 and 2 showing the loader in one position as it transfers items or packages to a container for consolidation. FIG. [Figure 9] 3 is a downstream end view of FIGS. 1 and 2 showing the loader in one position as it transfers items or packages to a container for consolidation. FIG. [Figure 10] FIG. 13 is a schematic diagram illustrating how individual articles are arranged into a registration configuration for subsequent placement into a container. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Detailed Description The following description in conjunction with the accompanying drawings, in which like numerals refer to like elements, is intended as a description of various embodiments of the disclosed subject matter and is not intended to represent the only embodiments. Each embodiment described in this disclosure is provided as an example or illustration only and should not be construed as preferred or advantageous over other embodiments. The illustrative examples provided herein are not intended to be exhaustive or to limit the disclosure to the precise form disclosed. Similarly, any step described herein may be interchangeable with other steps or combinations of steps to achieve the same or substantially similar results.

[0022] In the following description, numerous specific details are set forth to provide a thorough understanding of exemplary embodiments of the present disclosure. However, it will be apparent to those skilled in the art that many embodiments of the present disclosure can be practiced without some or all of these specific details. In some instances, well-known process steps are not described in detail so as not to unnecessarily obscure various aspects of the present disclosure. It will also be understood that embodiments of the present disclosure can employ any combination of the features described herein.

[0023] The present application may include references to "directions" such as "anterior," "rear," "front," "rear," "forward," "backward," "upward," "downward," "above," "below," "top," "bottom," "right-hand," "left-hand," "inner," "outer," "extended," "advanced," "retracted," "proximal," and "distal." These and other similar references in the application are merely to assist in explaining and aiding in understanding the present disclosure and are not intended to limit the invention to these directions or to any particular references.

[0024] The present application may include modifiers such as the words "generally," "approximately," "about," or "substantially." These terms are intended to function as modifiers to indicate that the "dimension," "shape," "temperature," "time," or other physical parameters in question need not be precise and may vary so long as the function required to be performed is operable. For example, the phrase "generally circular in shape" does not necessarily require that the shape be circular so long as the required function of the structure in question is operable.

[0025] In the following description, various embodiments of the present disclosure are described. In the following description and the accompanying drawings, corresponding system assemblies, devices, and units may be identified by the same part numbers with an alpha suffix. In this application, the description of parts / components of such system assemblies, devices, and units that are the same or similar will not be repeated to avoid redundancy.

[0026] In this application and claims, references to "trays," "cartons," "boxes," and "containers" are used interchangeably and are intended to include all manner of trays, cartons, and containers for receiving articles for packaging therein. The application and claims also refer interchangeably to "articles," "packages," and "goods" that are placed or packaged within the trays, cartons, and containers.

[0027] With reference to the drawings, disclosed is a container packaging system 20 comprised of an alignment system 22 for arranging articles 24 into a loading alignment configuration at a staging location 26. A loader 28 lifts the articles 24 from the staging location 26 for placement in a predetermined location within a container 30. Although this is not always the case, the container 30 may be sized and configured to receive multiple articles 24. A control system 32 controls the operation of the packaging system, including controlling the alignment system 22 to place the articles 24 in the correct alignment configuration at the staging location 26, and controlling the operation of the loader 28 to transport the articles 24 to the predetermined location within the container 30.

[0028] To now describe the above supplement to the container packaging system 20 in more detail, the packaging system includes a frame structure 40 having a forward portion that supports the alignment system 22 and the loader 28 above the alignment system. Although not shown, a housing encloses the frame structure 40 and the alignment system 22 and the loader 28. The housing has been removed from the drawing to allow an unobstructed view of the components of the packaging system 20.

[0029] The frame structure 40 is also configured with a rear portion that supports a conveyor system 42 disposed within the housing and on which the containers 30 are positioned relative to the registration system 22 for receiving the articles 24 from the loader 28. The conveyor system 42 includes a central belt conveyor 44 that corresponds to the location on the registration system 22 where the containers 30 will be located when loaded. Upstream from the central belt conveyor 44, a feed conveyor 46 delivers empty containers 30 to the central belt conveyor.

[0030] Empty containers 30 proceed on a lower conveyor 48, which moves from right to left in Figures 1-4, to a supply conveyor 46. The supply conveyor 46 pivots so that its end adjacent the central belt conveyor 44 can lower to receive containers 30 from the lower conveyor system 48 and then rise to the level of the central conveyor belt 44, thereby transferring the empty containers from the supply conveyor to the central belt conveyor. This transfer operation is controlled by the control system 32, which also controls the overall operation of the conveyor system 42, including the central conveyor belt 44, the supply conveyor 46, and the lower conveyor 48.

[0031] A pick-up conveyor 49, also controlled by the control system 32, is positioned to receive the filled containers 30 from the central belt conveyor 44. The pick-up conveyor 49 is shown as a roller conveyor, but may be of other configurations, and the pick-up conveyor 49 may be interconnected with one or more other conveyors (not shown) for transporting the filled containers to other downstream locations, such as a cold room or shipping area.

[0032] The basic registration system 22 includes a first infeed conveyor 50 aligned with a second registration conveyor 52, both of which are supported on a frame structure 40 and extend along and are positioned in front of the conveyor system 42. The conveyors 50 and 52 are comprised of corresponding endless flat belts 54 and 56 that are adjacent end-to-end to facilitate the transfer of articles 24 from belt 54 to belt 56 as described below. The conveyor belts 54 and 56 are each driven by a separate servo motor such that the belts can be started, moved and stopped under the control of the control system 32 to arrange the articles 24 on the conveyor 52 in a desired registration configuration as described below.

[0033] An optical sensor system 58 is positioned near the downstream end of the supply conveyor 50 to sense the position and size (length) of the articles 24 being supplied by the conveyor 50. A reflector 59 is mounted opposite the optical sensor 58 from the supply conveyor 50 to receive and reflect the optical signal emitted by the sensor 58. As can be appreciated, other types of position sensing systems, such as radar or lidar systems, can also be employed to sense the position and size of the articles 24 on the conveyor 50.

[0034] An outgoing conveyor 60 delivers the articles 24 to the inlet conveyor 50. The outgoing conveyor 60 includes a frame structure 62 supported by legs 64. A conveyor belt 66 is mounted on the frame structure 62 for delivering the articles 24 to the inlet conveyor 50.

[0035] A side rail 68 extends along the conveyor belt 66 for positioning the articles 24 at a desired location across the width of the conveyor belt 66. To this end, the side rail 68 is laterally adjustable by loosening a knob screw 70 that extends through a slot formed in a lateral tab extending from the side rail 68 and then offsetting the side rail laterally relative to the width of the conveyor belt 66. As will be appreciated, such adjustment of the side rail 68 may be made to accommodate the width of the articles 24 and to align the articles 24 relative to the width of the supply conveyor 58.

[0036] As shown in Figures 1-4, an exit conveyor 80 is positioned at the downstream end of the alignment conveyor 52. The exit conveyor 80 receives articles 24 that are not lifted from the alignment conveyor 52 for any reason, such as failure of the loader 28 to attach to the article. The articles 24 slide down the exit conveyor 80 to its end wall 82, from where they may be manually removed. Side walls 84 are provided along the exit conveyor to retain the articles 24 on the conveyor. If necessary, a pick-up conveyor (not shown) may be positioned at the end of the exit conveyor 80 or at the end of the alignment conveyor 52 to route articles not engaged by the loader to a desired location for further handling.

[0037] As will be explained more fully below, the operation of the infeed conveyor 50, alignment conveyor 52, outfeed conveyor 60, and exit conveyor 80 are all controlled by the control system 32. To this end, encoders may be integrated into the conveyors 50, 52, 60, and 80, as well as into the conveyors of system 42, so that the positions of the articles / containers on the conveyors are known. The control system also sends signals to servo motors or other types of motors used to drive the various conveyors of packaging system 20.

[0038] With reference to the drawings, the loader 28 includes an interface 90 for attachment to articles 24 aligned and arranged on the alignment conveyor 52 for placement of the articles within the container 30. The loader 28 also includes an actuation system 92 to which the interface 90 is mounted for operation. As with the various conveyors described above, operation of the loader and interface is controlled by the control system 32.

[0039] Actuation system 92 is in the form of a five-bar linkage arrangement mounted above frame structure 40 by an upper frame structure 94 which is suspended above alignment station 22 by a pair of upright posts 96 which extend upwardly from frame structure 40. A cross bar 98 is attached to the upper ends of posts 96. Side plates 100 and 101 of upper frame structure 94 are in turn attached to cross bar 98. Front and rear connecting brackets 102 and 104 interconnect the upper edge portions of side plates 100 and 101 and maintain the side plates at the desired spacing from one another.

[0040] Proximal ends of actuator links 110 and 112 are rotatably mounted to frame structure 94 at the bottom of side plates 100 and 101. Motors 114 and 116 are mounted on plate 101 and extend outwardly thereof. Motors 114 and 116 are operable to rotate actuator links 110 and 112 through various actuator operating positions as shown in FIGS. 6-9. Torque tubes 118 and 120 span between actuator links 110 and 112, which are mounted to corresponding side plates 100 and 101, respectively. The torque tubes are attached to the actuator links and span between actuator links 110 and 112 mounted to side plates 100 and 101, respectively, so that during operation of motors 114 and 116, actuator links on both sides of actuation system 92 rotate together. Torque tubes 118 and 120 also function to maintain a desired spacing between the bottom of side plates 100 and 101.

[0041] The five-bar linkage arrangement of actuation system 92 also includes a link 122 that extends between a distal end of link 110 and interface 90. A corresponding link 124 extends between a distal end of link 112 and interface 90. The ends of links 122 and 124 are pivotally attached to corresponding links 110 and 112, respectively, and to interface 90.

[0042] The interface 90 includes an attachment head 126 to which the distal ends of the links 112 and 124 are pivotally connected. The interface 90 also includes a longitudinally extending quick release attachment tool 130 removably connected to the attachment head 126. The attachment tool 130 includes an upper beam 132 from which three sets of suction plates 134 depend downwardly via connector posts 136 that span between the beams 132 and the suction plates 134. Suction tubes 140 also depend downwardly from the beams 132 to extend through longitudinal slots formed in the suction plates. A suction head 142 is mounted to a lower end of the suction tubes 140 for engaging an upper portion of the articles 24 arranged on the alignment conveyor 52. The suction tubes 140 are connected to a vacuum source associated with the container packaging system 20.

[0043] Although the attachment tool 130 as described above utilizes a vacuum to be attached to the top of the article 24, other types of attachment tools may be utilized, such as, for example, a clamping or gripping unit to secure the article for transfer from the alignment conveyor 52 to the container 30.

[0044] 5-9, an auxiliary interlocking arrangement 150 is provided to maintain interface 90, and in particular attachment tool 130, in a fixed orientation with suction head 142 while article 24 is being transferred from registration conveyor 52 to container 30. During this transfer, article 24 is maintained in a horizontal position or orientation, as shown in the drawings.

[0045] To this end, the auxiliary link arrangement 150 includes a first link 152 having a proximal end rotatably attached to the side plates 100 and 101 of the frame structure. A distal end of the first link 152 is rotatably attached to an end of a longer arm 154 of a first crank 156. The crank includes a shorter arm 158 extending generally perpendicular to the longer arm 154 for pivotal connection to a proximal end of a second link 160. The first crank is rotatably mounted in alignment with the pivot joint between the links 112 and 124. A distal end of the second link 160 is pivotally attached to a mounting link 162. The mounting link 162 has a base portion fixedly connected to an end of the mounting head 126. As shown in Figures 6, 7, 8 and 9, through the auxiliary interlocking arrangement 150, the articles 24 are maintained in a horizontal orientation as they are lifted from the alignment conveyor 52, moved laterally relative to the alignment conveyor toward the central conveyor 49, and then lowered into the container 30.

[0046] For example, if the article being transported is located within container 30 in a non-horizontal orientation, such as an orientation that is inclined relative to the horizontal, auxiliary coupling arrangement 150 may be designed in other manners. Also, the article may not have a flat upper surface like article 24, and therefore may need to grip or attach to a surface of the article that is not horizontal but is instead inclined from the horizontal. In this situation, auxiliary coupling arrangement 150 may be designed such that the orientation of the attachment tool in use may be such that it can be attached to a desired surface or portion of the article being transported. For example, one or both of first link 152 and second link 160 may be designed to be adjustable in length, including during actual operation of loader 28.

[0047] Also, the articles may be to be placed in the container in a different orientation than their orientation when in the registration position on the registration conveyor, in which case the auxiliary connection may be designed to accommodate the "packed" position of the articles.

[0048] As mentioned above, the control system 32 is used to control and operate the container packaging system 20 of the present disclosure, including the various conveyors and the loader 28. As shown generally in FIG. 1, the control system 32 includes a computer or processor 170 operatively connected to an interface 172 for receiving signals and information from the encoders of the various conveyors, as well as data from various sources of the system 20, including the loader 28 and the optical sensor 58, as described herein. In response, the computer / processor 170 sends control signals to the motors that operate the conveyors, to the motors that operate the loader, to the valves that provide vacuum to the attachment tool 130, and to other components of the system 20. A memory unit 174 is provided for storing information for use by the control system, including the computer / processor 170. A touch screen interface 176 is provided to allow an operator to communicate with the control system 32, as well as to output information from the control system, including from the computer / processor 170, about the entire system 20. The components of the control system 32 may be located in the housing 177 in which the touch screen interface 167 is mounted, or may be in different locations on the packaging system 20 .

[0049] The control system 32 may be connected to a network 178. Also, rather than employing a local computer / processor 170, a network computing system may be used for this purpose.

[0050] As shown, filled packages or items 24 are loaded into containers 30 using a pick and place loader 28. Two side-by-side items 24 are shown being placed in each container 30. For this to occur automatically, the items 24 need to be in the correct position or alignment at the staging location 26 located below the tool 130 as the tool is operated by the actuation system 92 to lower to the top of the items 24, grasp the items, lift them from the staging location, properly position them above the container 30, and then place them in a predetermined location within the container 30. Such container locations change each time a set of items is placed within the container. It will be understood that in other situations, more or less than two side-by-side packages may be placed within the container 30.

[0051] To accurately position the articles at the staging location 26, the articles arrive at the staging location on a first servo-driven supply conveyor 50 from an outgoing conveyor 60 with random spacing between the articles. An article sensing / measuring device 58 optically senses the location of the articles on the first conveyor 50. The articles are transferred to a second servo-driven alignment conveyor 52 with the correct relative spacing to match the relative spacing required for loading the articles into the container 30. This is accomplished by pre-programmed coordinated motion of the two conveyors 50 and 52. In this regard, the alignment conveyor 52 is intermittently driven by a servo-driven motor so that it is in the proper position when receiving the articles 24 from the first supply conveyor 50.

[0052] For example, to achieve the spacing of the side-by-side pairs of articles 24 shown in FIG. 10, the registration conveyor 52 receives a first article from the supply conveyor 50 and then increments forward sufficiently to receive a second article from the supply conveyor 50 such that the second article is positioned in contacting relationship with the first article. The registration conveyor 52 then moves forward a greater distance to receive a third article 24 such that there is a space between the second and third articles. Thereafter, the registration conveyor 52 increments forward sufficiently to receive a fourth article from the supply conveyor 50 in contacting relationship with the third article 24.

[0053] Continuing with the above sequence, the registration conveyor 52 moves / increments forward a greater distance than its previous movement so that there is space between the fifth article and the previously received fourth article. The registration conveyor then increments forward sufficiently so that a sixth article is loaded from the supply conveyor onto the registration conveyor 52 in contacting relationship with the fifth article. In this manner, six articles 24 are positioned with three sets of two adjacent articles in contact.

[0054] The operation of conveyors 50 and 52 may be pre-programmed such that the conveyors automatically position articles in the appropriate relative positions on the alignment conveyor which serves as a staging location so that the articles may be automatically loaded into container 30. In this regard, it will be appreciated that the programming of the operation of conveyors 50 and 52 will take into account the number and size of the articles / packages, as well as the size and shape of the container 30 to be filled. It will also be appreciated that the installation tool 130 may be modified to accommodate the number, type, size, shape, configuration, material composition, etc. of the articles being loaded into container 30.

[0055] Once the article 24 is in the correct alignment position at the staging location 26, the article is transferred to the container 30 using, for example, a loader 28 operating in the sequence shown in Figures 6-9. In Figure 6, an attachment tool 130 is positioned above the article 24 which is in the aligned position at the staging location 26. The attachment tool 130 applies suction to the top of the article, thereby securely locking the article to the attachment tool.

[0056] Motors 114 and 116 then operate on five-bar links 110 and 112 to spread the distal ends of these links as shown in Figure 7, thereby simultaneously lifting the article upwardly from staging location 26 and moving the article laterally from the staging location towards carton 30. Further rotation of links 110 and 112 in a clockwise direction as shown in Figure 8 causes installation tool 130 to position article 24 above the open space between the previously positioned articles in container 30. In Figure 9, installation tool 130 is lowered to place article 24 in the open space in the container by a slight rotation of link 110 in a counterclockwise direction and a slight rotation of link 112 in a clockwise direction.

[0057] It will be appreciated that during transfer of the articles from the staging location 26 to the container 30 in the manner described above, the auxiliary coupling arrangement 150 operates to maintain the attachment tool 130 in a vertical position (see Figures 6-9) such that the articles 24 remain in a horizontal orientation.

[0058] It will also be appreciated that due to the configuration of container 30, lowering the article 12 directly downwardly into the container may not be possible due to a lip or flange extending inwardly from the upper edge of the container end wall toward the interior of the container. Thus, if the article were lowered vertically into the container, the lip or flange of the container would interfere with the downward movement of the article. In this situation, the article could be lowered inwardly away from the lip or flange and then, once lowered fully into the container, gently move the article under the protruding lip or flange toward the container end wall.

[0059] Once the containers 30 are filled with articles 12, the central conveyor 44 may be advanced to place the containers on the pick up conveyor 49. A new set of containers 30 may then be transferred from the supply conveyor 46 to the central conveyor 49, thereby placing the containers in position to receive a new set of articles 12 from the loader 28. This process may continue until all of the articles 12 have been loaded into the containers 30.

[0060] The packaging system 20 may then be "tuned" for loading other articles into the continuation 30 or other containers. This may require a change in the installation tool 130 used for the new article. This is easily accomplished by simply removing the installation tool 130 from the installation head 126 using the various configurations of the "quick connect" system. Also, the operation of the various conveyors of the packaging system 20 may be adjusted using a program stored in the control system 32. Alternatively, the necessary parameters for operating the various conveyors and other components of the packaging system 20 for the new article may be entered into the control system using the interface 172. These new parameters may be stored in the memory unit 174 for future use.

[0061] While illustrative embodiments have been illustrated and described, it will be understood that various changes can be made herein without departing from the spirit and scope of the invention.

Claims

1. A container packaging system (20) for placing items (24) within one or more containers (30), comprising: an alignment system (22) for arranging the items (24) into a staging alignment configuration at a staging location (26) of the container packing system (20), the location of the items (24) in the staging alignment configuration corresponding to the location and configuration of the one or more containers (30), the container packing system (20) further comprising: a loader (28) for transporting said items (24) from said staging location (26) to predetermined locations within said one or more containers (30); a control system (32) for controlling operation of the alignment system (22) to arrange the articles (24) in a loading alignment configuration at the staging location (26) and for operating the loader (28) to transfer the articles (24) from the staging location (26) into the one or more containers (30); the alignment system (22) includes a first conveyor (50) for delivering the articles (24) with random spacing between the articles (24) to a second conveyor (52) comprising the staging location (26) where the articles (24) are positioned relative to one another in the loading alignment configuration having correct relative spacing to match relative spacing required for loading the articles (24) into the one or more containers (30); a sensor (58) for sensing a location of the article (24) on the first conveyor (50) and generating data relating to such location; the control system (32) using the data from the sensors (58) for pre-programmed coordinated movement of the first and second conveyors (50, 52), the second conveyor (52) being intermittently driven by a servo drive motor so as to be in the proper position when receiving the article (24) from the first conveyor (50), and the first and second conveyors (50, 52) automatically positioning the article (24) in the proper relative position on the second conveyor (52); The loader (28) comprises: an interface (90) for attachment to the article (24) to be placed within the one or more containers (30); an actuation system (92) controlled by said control system (32) for moving said interface (90) between said staging location (26) and said one or more containers (30) to transfer said items (24) from said staging location (26) into said one or more containers (30); the actuation system (92) includes a five-bar linkage arrangement (110, 112) to which the interface (90) is mounted; The five-bar linkage arrangement (110, 112) with an auxiliary linkage arrangement (150) is configured to lift the article (24) upwardly from the staging location (26) and move the article (24) laterally from the staging location (26) toward and downwardly into the one or more containers (30).

2. The container packaging system of claim 1, wherein the interface (90) includes a lifting head for attachment to the article (24) for lifting the article (24) from the staging location (26).

3. The article (24) includes an upper portion; The container packaging system of claim 2 , wherein the lifting head is configured to be attached to the top of the article (24).

4. The container packaging system of claim 1 , wherein the five-bar linkage arrangement (110, 112) is located above the staging location (26).

5. 5. The container packaging system of claim 1 or 4, wherein the five-bar linkage arrangement (110, 112) is configured to removably mount the interface (90).

6. 2. The container packaging system of claim 1, wherein two of the links of the five-bar linkage arrangement (110, 112) are powered to move the interface (90) between the staging location (26) and the one or more containers (30).

7. A container packaging system as described in any one of claims 1 to 6, wherein the auxiliary connecting arrangement (150) is mounted on the five-bar connecting arrangement (110, 112) and connected to the interface surface (90) so as to maintain the interface surface (90) in a selected orientation relative to the article (24) that has been lifted from the staging location (26) and placed within the one or more containers (30).

8. 8. The container packaging system of claim 7, wherein the auxiliary linking arrangement (150) is linked to the five-bar linking arrangement (110, 112) such that movement of the five-bar linking arrangement (110, 112) moves relative to the auxiliary linking arrangement (150).

9. a transport system for transporting the one or more containers (30) to the staging location (26) to be loaded and then transporting the one or more containers (30) away from the staging location (26) after being loaded; The container packaging system according to any one of claims 1 to 8, wherein the control system (32) controls the transport system to position the one or more containers (30) at a predetermined position relative to the staging location (26).

10. A method for automatically disposing items (24) within one or more containers (30), comprising the steps of: arranging the items (24) into a loading alignment configuration at a staging location (26) using an alignment system (22), the location of the items (24) corresponding to the location and configuration of the one or more containers (30), the method further comprising: transferring said items (24) from said staging location (26) to a predetermined location within said one or more containers (30) using a loader (28) by attaching an interface (90) to said items (24) disposed within said one or more containers (30), moving said items (24) laterally from said staging location (26) towards said one or more containers (30), and lowering said items (24) into said one or more containers (30) by means of a five-bar linkage arrangement (110, 112) and an auxiliary linkage arrangement (150); controlling operation of the alignment system (22) to arrange the articles (24) at the staging location (26) into the loading alignment configuration, and controlling operation of the loader (28).

11. The method of claim 10, further comprising the step of positioning the five-bar linkage array (110, 112) above the staging location (26).

12. 12. The method of claim 10 or 11, further comprising maintaining the article (24) elevated from the staging location (26) in a selected orientation until placed within the one or more containers (30).

13. transporting the one or more containers (30) to the staging location (26) to be loaded, and then transporting the one or more containers (30) away from the staging location (26) after being loaded; The method of any one of claims 10 to 12, further comprising the step of: positioning the one or more containers (30) at a predetermined position relative to the staging location (26).

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