Can liner system and restacker assembly for the can liner system

Abstract

A restacker assembly used to stack the container closures output by the can liner system includes at least one off-loading assembly having a receptacle, at least one loading device coupled to the off-loading assembly, and a motion control system for detecting movement of the container closures and driving the loading device in response to detecting the movement to stack or restack the container closures in a predetermined manner.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Patent Application No. 17 / 818,130, filed August 8, 2022, entitled "Can Liner System And Re-Stacker Assembly Therefor." <Technical field>

[0002] The disclosed concepts generally relate to machines for container closures, and more particularly to can liner systems for container closures such as can ends. The disclosed concepts also relate to re-stacker assemblies for can liner systems. [Background technology]

[0003] It is known to apply a sealant material, commonly referred to as a compound, to the underside of a container closure to facilitate subsequent sealing attachment (e.g., without limitation, seaming) of that container closure to containers such as beer / beverage and food cans.

[0004] For example, but not by way of limitation, liner machines, such as rotary liner machines, are used to line (i.e., apply sealant or compound to) container closures commonly referred to as can lids, shells, or can ends. Conventional liner machines (sometimes simply referred to as "liners") typically include a base with a processing assembly. For example, in a rotary liner, the processing assembly may include a chuck assembly having several rotatable chucks and a pivotal upper turret assembly disposed above the chuck assembly, which may include an electric tank assembly, a rotary compound tank assembly, and several peripherally arranged fluid distribution devices (e.g., sealant or compound guns), each associated with a corresponding rotatable chuck in the chuck assembly. During operation, can ends or shells entering the liner are fed to a downstacker in a "stick" configuration (i.e., nested in vertical columns or stacks). The liner machine strips the bottom can end or shell from the bottom of the stack and deposits it in the processing assembly described above, where a lining compound is subsequently applied. Once fully lined, the can ends or shells 4 are linearly discharged in the direction of arrow 1 onto a flat belt conveyor 2 (shown in simplified schematic form in FIG. 1). As shown in FIG. 1, the newly lined shells 4 are then transported directly to a vacuum hopper 13, where they are stacked or re-stacked (not shown) for transport.

[0005] Among other drawbacks, this method of transporting and restacking newly lined shells does not use time-gating devices to ensure that the shells are restacked efficiently or that the compound on the shells has sufficiently cured before restacking. As a result, conventional liner machines cannot restack shells at high speeds (e.g., without limitation, 2100 ends per minute (EPM) or greater) without damaging the shells and / or displacing the shell compound. More specifically, because there is no mechanism to prevent shells from being restacked in a suboptimal configuration, jams can occur, for example, due to undesirable overlapping of shells, known as "shingling." Furthermore, lining compound can migrate from the shells, a phenomenon commonly referred to as compound spillover. Additionally, forces applied to the shells during the restacking process can cause physical damage to the shells. These issues have historically limited the operating speed of liner machines to 2100 EPM or less. Thus, production output, or throughput, is limited.

[0006] Therefore, there is room for improvement in can liner systems and restacker assemblies therefor. Summary of the Invention

[0007] These and other needs are met by embodiments of the disclosed concepts related to a restacker assembly and can liner system. Among other benefits, the restacker assembly reduces the force applied to the container closure, thereby overcoming known disadvantages of prior art liner systems and allowing the liners to operate at higher speeds and increased production volumes.

[0008] In one aspect of the disclosed concept, a restacker assembly includes at least one offloading assembly having a receptacle configured to receive a plurality of container closures, at least one loading device coupled to the offloading assembly, and a motion control system 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.

[0009] The motion control system may include at least one presence sensor and a motor operably coupled to the loading device, the off-loading assembly may include an opening disposed proximate to the presence sensor and the receptacle, the motor configured to move the loading device to orient the container closure through the opening in the off-loading assembly. The motion control system may further include a control unit, the motor and the at least one presence sensor communicatively coupled to the control unit. The at least one presence sensor may include a primary presence sensor and a secondary presence sensor, the primary presence sensor disposed proximate to the receptacle and the secondary presence sensor disposed offset from the primary presence sensor.

[0010] The off-loading assembly may further include a hopper having an opening, and the loading device is a kicker wheel disposed above the opening of the hopper. The kicker wheel may include a plurality of protrusions configured to direct the plurality of container closures through the opening and into stacking within the hopper. The motion control system may further include an auxiliary presence sensor disposed within the hopper.

[0011] A liner system using the above-described restacking assembly is also disclosed. [Brief explanation of the drawings]

[0012] The invention can be best understood from the following description of the preferred embodiment when read in conjunction with the accompanying drawings.

[0013] [Figure 1] FIG. 1 is a perspective view of a prior art rotary liner.

[0014] [Figure 2] FIG. 2 is a perspective view of a can liner system and a restacker assembly therefor in accordance with a non-limiting embodiment of the disclosed concepts.

[0015] [Figure 3] 3 is a perspective view of the restacker assembly of FIG. 2. FIG.

[0016] [Figure 4] FIG. 4 is a perspective view of a portion of the restacker assembly of FIG. 3, with the hopper shown in cross section.

[0017] [Figure 5] FIG. 5 is a schematic diagram of the restacker assembly. DETAILED DESCRIPTION OF THE INVENTION

[0018] While the restacker assembly according to the disclosed concepts is shown and described herein as being used in connection with a rotary liner for applying a sealant or compound to container closures such as, but not limited to, can ends, it will be understood that in other applications it may alternatively be used to transport container closures using a wide variety of other types of equipment and machinery (not shown).

[0019] Directional terms used herein, such as up, down, clockwise, counterclockwise, and derivatives thereof, relate to the orientation of elements illustrated in the drawings and do not limit the scope of the claims, unless expressly stated.

[0020] The specific elements illustrated in the drawings and described herein are merely exemplary embodiments of the disclosed concepts, and thus, specific dimensions, orientations, and other physical characteristics of the embodiments disclosed herein are not to be considered limitations on the scope of the disclosed concepts.

[0021] As used herein, the phrase "coupled" or "attached" to two or more components means that the components are either directly connected or connected via one or more intermediate components.

[0022] As used herein, the term "terminally connected" means that a first component is connected to a terminal end of a second component having a definable longitudinal axis.

[0023] As used herein, the term "operably coupled" means that two or more components are functionally linked through one or more intermediate parts such that displacement, manipulation, or actuation of any of the two or more components causes a predetermined response in the remaining component.

[0024] As used herein, the term "communicatively coupled" means that two or more electrical components are connected so that power, information, or both, can be exchanged between the coupled electrical components.

[0025] As used herein, the term "distributed" means that a plurality of first components are arranged within, around, or across a second component. Furthermore, one or more of the above statements may apply to the distribution of a plurality of first components relative to a second component. Furthermore, the plurality of first components may be arranged regularly or randomly.

[0026] As used herein, "configured to [verb]" means that the specified element or assembly has a structure that is shaped, sized, arranged, coupled, and / or configured to perform the specified verb. For example, a member "configured to move" may be movably coupled to another element and include an element that moves that member, or the member is otherwise configured to move in response to another element or assembly. Thus, as used herein, "configured to [verb]" describes structure, not function. Furthermore, as used herein, "configured to [verb]" means that the specified element or assembly is intended and designed to perform the specified verb. Thus, an element that is merely capable of performing the specified verb, but is not intended and designed to perform the specified verb, is not "configured to [verb]."

[0027] As used herein, "several" means one or more than one (i.e., a plurality).

[0028] With reference to FIGS. 2 through 5, the disclosed concept relates to an assembly constructed for the purpose of transitioning a plurality of lined container closures 4 (FIGS. 3 and 4) from an initial vertical orientation to a horizontal orientation and finally back to a vertical orientation. More specifically, the arrows shown in FIG. 2 generally indicate 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 "lids," are introduced into the can liner system 1 in a vertical stack configuration, commonly referred to as a "stick," whereby the container closures 4 are nested and stacked together in a vertical column. Accordingly, the term "stick" is used herein to refer to a vertical column of stacked, 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 by way of limitation, a lining compound is applied to curls in the container closures 4 (e.g., shells or can ends). Once fully lined, the container closures 4 are then discharged from the can liner system 10 and conveyed (e.g., transported) in a horizontal orientation by a conveyor system 20 to a restacker assembly 3, where they are restacked in a vertical orientation in stick form.

[0029] As will be described below, among other advantages, the disclosed concepts provide a means for increasing the speed at which container closures 4 can be processed. Specifically, in preferred embodiments, the disclosed concepts enable processing speeds of 2100 ends per minute (EPM) or greater. Additionally, the disclosed concepts improve upon prior art utilized in the industry by reducing the force applied to the container closures 4 during the restacking process. Reducing the force applied to the container closures 4 minimizes or eliminates the occurrence of physical damage to the container closures 4. Reducing the force applied to the container closures 4 also minimizes or eliminates the possibility of undesirable migration of the lining compound (e.g., but not limited to, spillage from curled shells or can ends).

[0030] As best shown in FIGS. 3 and 4 , the disclosed concepts provide a means for restacking side-by-side container closures 4 that are initially moving horizontally. An exemplary conveyor system 20 includes multiple conveyor belts 12. Container closures 4 placed on the conveyor belts 12 are initially spaced apart by the can liner system 10. While on the horizontal conveyor belts 12, the container closures 4 may be inspected and slowed down before reaching the input area of the listacker assembly 3. The container closures 4 are then fed to the listacker assembly 3 along the same horizontal direction of movement as the conveyor system 20. In one non-limiting example, the conveyor system 20 may use, for example and without limitation, a series of multiple conveyor belts 12 (only one is shown and described in detail herein for simplicity of disclosure), with each conveyor belt 12 in the series moving slower than the previous conveyor belt 12 to slow the speed of the container closures 4.

[0031] As described in more detail below, in an exemplary embodiment, the restacker assembly 3 uses several presence sensors (e.g., presence sensors 332, 333, both shown in FIG. 3 ) to determine the location and speed of the container closures 4 moving along the conveyor belt 12. The presence sensors 332, 333 are used to determine the physical location of the container closures 4. It will be understood that the presence sensors 332, 333 may include, for example, but are not limited to, ultrasonic sensors, optical sensors, proximity sensors, and computer vision systems. This information is used to modify the rate at which the loading device 32 deposits the lined container closures 4 into the hopper 313. The number of presence sensors 332, 333 and the associated structure and operation of the off-loading assembly 31 advantageously space the container closures 4 as they are deposited into the hopper 313 in a predetermined, desired manner.

[0032] 3 and 4, hopper 313 allows for a controlled area (e.g., receptacle) where container closures 4 are restacked and presented to end module trackwork 100 (shown in FIG. 2). Additionally, a vacuum generator 315 (FIG. 5) may be attached to hopper 313 to induce a vacuum to urge (e.g., move) container closures 4 toward the bottom of hopper 313 to facilitate proper restacking. These features reduce physical forces applied to container closures 4 and provide an effective method of controlling the orientation and movement of container closures 4 within and / or through hopper 313 in a predetermined manner.

[0033] 3-5, the exemplary restacker assembly 3 shown and described herein utilizes an off-loading assembly 31, a loading device 32, and a motion control system 33 (FIG. 5) to manipulate and move container closures 4 to a hopper 313 in a predetermined and controlled manner. Furthermore, the disclosed concepts utilize the motion control system 33 (FIG. 5) to coordinate the operation of the off-loading assembly 31 and the loading device 32 such that the rate at which the loading device 32 places container closures 4 in the hopper 313 is dynamically varied based on the position and rate of movement of the first container closure 4 in a series of container closures 4. That is, the loading device 32 is positioned to load a container closure 4 into the hopper 313 each time that container closure 4 is moved by the conveyor belt 12 to the receptacle 311 of the off-loading assembly 31. The loading device 32 is designed to manipulate and orient the container closure 4 in a manner that avoids undesirable problems such as damage, clogging, or compound migration (eg, spillage).

[0034] 4 and 5, to achieve the above-described functions, the off-loading assembly 31 is designed to accept a stream of container closures 4 moving along a generally horizontal direction and move (e.g., redirect, restack) them into a generally vertical stack, as best shown in the cross-sectional view of FIG. 4. Generally, the loading device 32 is a mechanical actuator used to modify the position of an object (e.g., a container closure 4). Specifically, embodiments of the disclosed concepts may use loading devices 32 such as, for example, but not limited to, kicker wheels (not shown), robotic arms (not shown), and pistons (not shown). The loading device 32 is preferably coupled to and cooperates with the off-loading assembly 31. In the illustrated example, the kicker wheel 32 includes a plurality of protrusions 132 (three shown) that, as the kicker wheel 32 rotates, engage the protrusions 132 with corresponding container closures 4, causing the container closures 4 to move in a predetermined desired manner through the openings 312 in the hopper 313 to form a stack, as best shown in FIG. 4. Thus, as used herein, the term "kicker wheel" refers to a loading device configured to reorient container closures 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 the container closures 4 in a desired manner.

[0035] The motion control system 33 (FIG. 5), preferably an automatic control system, is used to analyze the status of the stream of container closures 4 and control the movement (e.g., rotation) of the loading device 32 (e.g., kicker wheel) accordingly. Specifically, the motion control system 33 is configured to rotate the loading device 32 in response to detecting movement within the receiver 311 of the off-loading assembly 31. That is, the motion control system 33 drives (e.g., rotates) the loading device 32 to incrementally load the stream of container closures 4 such that the time required for the loading device 32 to load one container closure 4 and then reposition itself in the receiver 311 to receive the subsequent container closure 4 is less than or equal to the time it takes for the subsequent container closure 4 to arrive at the receiver 311 and be engaged and manipulated within the hopper 313 by the next protrusion 132 of the loading device (e.g., kicker wheel 32).

[0036] 3-5, the operation control system 33 (FIG. 5) preferably includes the aforementioned presence sensors 332, 333, a motor 334, and a control unit 335 (FIG. 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 may be, for example, but not limited to, a smartphone, a local microcontroller, or a remote server. The motor 334 and the presence sensors 332, 333 are communicatively coupled to the control unit 335. An opening 312 in the off-loading assembly 31 is positioned proximate to the presence sensor 332 and the receptacle 311. For example, the opening 312 in the off-loading assembly 31 may be, but is not limited to, a feed port or channel designed to move container closures 4 through and from the receptacle 311 to the aforementioned hopper 313, e.g., for storage, transport, and / or further processing.

[0037] More specifically, the presence sensors 332, 333 detect the arrival of a container closure 4 from the conveyor belt 12 at the disclosed listacer assembly 3. This information is relayed to the control unit 335. As described above, the motor 334 is operably coupled to the loading device (e.g., the kicker wheel 32). More specifically, the control unit 335 uses the information received from the presence sensors 332, 333 to generate commands that cause the motor 334 to make fine and / or coarse adjustments to the positioning (e.g., without limitation, rotations, rotational speed) of the loading device 32. These adjustments enable the motor 334 to drive (e.g., rotate) the loading device 32 to move the container closure 4 through the opening 312 of the off-loading assembly 31 in a desired, predetermined manner. As mentioned above, in the non-limiting example embodiment shown and described herein, the loading device 32 is a kicker wheel having a plurality of protrusions 132 (three are shown), and a motor 334 controls the rotational speed of the kicker wheel 32, allowing the kicker wheel 32, and specifically its protrusions 132, to engage and operate corresponding container closures 4 through the openings 312 at a speed controlled as desired by a control unit 335. Thus, minimal force is required to move the container closures 4 through the receivers 311 and into the hopper 313. Once past the openings 312, a vacuum generator 315 draws the container closures 4 through the hopper 313, causing the container closures 4 to nest together in a stick-like manner in a predetermined, desired orientation.

[0038] 3 and 4, the exemplary restacker assembly 3 preferably includes multiple presence sensors, specifically a first or primary presence sensor 332 and a second or secondary presence sensor 333, and an auxiliary presence sensor 316. The primary presence sensor 332 is preferably located adjacent the receptacle 311 of the off-loading assembly 31 and is used to determine whether fine adjustments need to be made to the positioning of the loader 32 as the container closure 4 enters and moves through the opening 312 of the off-loading assembly 31. The secondary presence sensor 333 is preferably located offset from the primary presence sensor 332, as best shown in FIG. 3, and is used to determine whether coarse adjustments need to be made to the positioning of the loader 32 as the container closure 4 moves along the conveyor system 20. It will be understood that embodiments (not shown) in which multiple secondary presence sensors 333 are distributed along the length of the conveyor system 20 are also contemplated without departing from the scope of the disclosed concepts. Such embodiments may generally be advantageously used, for example, but not limited to, to determine the status of multiple container closures 4 at once, to track a single container closure 4 at multiple locations along the conveyor system 20, and / or to monitor one or more operational characteristics of the conveyor system 20. The information gathered by each presence sensor 332, 333 may be used to increase or decrease the speed of conveyance, for example, by increasing or decreasing the speed of one or more corresponding conveyor belts 12 at certain locations along the conveyor system 20.

[0039] As shown in FIGS. 3 and 4 , the disclosed embodiment of the restacker assembly 3 is designed so that the off-loading assembly 31 includes the above-mentioned hopper 313. In the illustrated example, the hopper 313 is mounted adjacent to the opening 312 of the off-loading assembly 31, such that the loading device is located on the opposite side of the opening 312 from the hopper 313. Advantageously, the hopper 313 is positioned to receive the container closures 4 ready to be placed by the loading device 32. It will be appreciated that the hopper 313 may be, for example, a removable storage device, e.g., detachable and transportable after the container closures 4 have been loaded. It will further be appreciated that the hopper 313 may be part of or cooperate with the transport track work 100, as shown schematically in FIG. 2 .

[0040] Thus, it will be appreciated that the disclosed listaker assembly 3 is designed to facilitate rapid restacking operations that reduce the force applied to the container closures 4. To facilitate this, the exemplary embodiment of the disclosed listaker assembly 3 further includes the aforementioned vacuum generator 315 (also shown generally in FIGS. 5 and 2 ) and an auxiliary presence sensor 316, best shown in the cross-sectional view of FIG. 4 . The vacuum generator 315 is in fluid communication with the hopper 313 to generate a vacuum therein. As previously described, the vacuum draws the container closures 4 into the hopper 313, preventing undesired interactions (e.g., overlapping, jamming) between the container closures 4 within the hopper 313. The auxiliary presence sensor 316 is disposed within the hopper 313 proximate the entrance or opening 312 of the hopper and is communicatively coupled to the control unit 335. Among other functions, but not limitation, the auxiliary presence sensor 316 can determine when the hopper 313 is full or nearly full.

[0041] Thus, among other advantages and benefits, the restacker assembly 3 and can liner system 1 based on the disclosed concepts are preferably capable of processing speeds of at least 2100 EPM, more preferably up to 3500 EPM or more, and reduce the forces applied to the container closures 4 during the restacking process to minimize or eliminate physical damage to the container closures 4 or to minimize or eliminate displacement of the lining compound. Additionally, the disclosed concepts provide a system for quickly and efficiently forming predetermined desired configurations (e.g., sticks) of lined container closures 4 ready for transportation (e.g., shipping) or further processing.

[0042] While specific embodiments of the present invention have been described in detail, those skilled in the art will recognize that various modifications and substitutions to those details may be made in light of the overall teachings of the present disclosure. Accordingly, the particular configurations disclosed are intended to be illustrative only and not limiting on the scope of the present disclosure, which is given the full scope of the appended claims and any and all equivalents thereof.

Claims

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

2. the motion control system includes at least one presence sensor and a motor operably coupled to the loading device; the off-loading assembly includes an opening disposed proximate to the at least one presence sensor and the receptacle; The listacker assembly of claim 1 , wherein the motor is configured to move the loading device to guide the plurality of container closures through the opening in the off-loading assembly.

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

4. the at least one presence sensor includes a primary presence sensor and a secondary presence sensor; the primary presence sensor is disposed adjacent to the receptacle; The listacker assembly of claim 3 , wherein the secondary presence sensor is positioned offset from the primary presence sensor.

5. the off-loading assembly further comprises a hopper having an opening; The listacker assembly of claim 1 , wherein the loading device is a kicker wheel, the kicker wheel being positioned above the opening of the hopper.

6. The listacker assembly of claim 5 , wherein the kicker wheel includes a plurality of protrusions configured to direct the plurality of container closures through the opening for stacking within the hopper.

7. The restacker assembly of claim 5 , wherein the off-loading assembly further comprises a vacuum generator, the vacuum generator being in fluid communication with the hopper.

8. the off-loading assembly further comprises a hopper having an opening; The restacker assembly of claim 4 , wherein the motion control system further comprises an auxiliary presence sensor, the auxiliary presence sensor being disposed within the hopper.

9. The listacker assembly of claim 8 , wherein the auxiliary presence sensor is communicatively coupled to the control unit.

10. 1. A can liner system comprising: a liner machine for lining a plurality of container closures; a conveyor system for transporting the plurality of container closures from the liner; a restacker assembly; It is equipped with The restacker assembly at least one off-loading assembly positioned adjacent to the conveyor system and including a receiver configured to receive the plurality of container closures from the conveyor system; at least one loading device coupled to the off-loading assembly; a motion control system configured to detect movement of the plurality of container closures and, in response to detecting the movement, drive the loading device to stack the plurality of container closures in a predetermined manner; A can liner system comprising:

11. the motion control system includes at least one presence sensor and a motor operably coupled to the loading device; the off-loading assembly includes an opening disposed proximate to the at least one presence sensor and the receptacle; 11. The can liner system of claim 10, wherein the motor is configured to move the loader to guide the plurality of container closures through the opening in the off-loading assembly.

12. The motion control system further comprises a control unit; 12. The can liner system of claim 11, wherein the motor and the at least one presence sensor are communicatively coupled to the control unit.

13. the at least one presence sensor includes a primary presence sensor and a secondary presence sensor; the primary presence sensor is disposed adjacent to the receptacle; 13. The can liner system of claim 12, wherein the secondary presence sensor is positioned offset from the primary presence sensor.

14. the off-loading assembly further comprises a hopper having an opening; 11. The can liner system of claim 10, wherein the loading device is a kicker wheel, the kicker wheel being positioned above the opening of the hopper.

15. 15. The can liner system of claim 14, wherein the kicker wheel includes a plurality of protrusions configured to direct the plurality of container closures through the opening for stacking within the hopper.

16. 15. The can liner system of claim 14, wherein the off-loading assembly further comprises a vacuum generator, the vacuum generator in fluid communication with the hopper.

17. the off-loading assembly further comprises a hopper having an opening; 14. The can liner system of claim 13, wherein the motion control system further comprises an auxiliary presence sensor, the auxiliary presence sensor being located within the hopper.

18. 18. The can liner system of claim 17, wherein the auxiliary presence sensor is communicatively coupled to the control unit.

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