Intermediate infeed shaft

Abstract

An intermediate infeed machine unit for a machine line and a machine line with an intermediate infeed machine are disclosed. The intermediate infeed machine unit includes an intermediate infeed chute for feeding articles into an article process flow of the machine line. The intermediate infeed machine unit further includes an intermediate shaft configured to accept an infeed starwheel for transferring the articles from the infeed chute into the article process flow and configured to accept an idle transfer starwheel for accepting articles from an upstream transfer starwheel of an upstream machine unit of the article process flow of the machine line. The intermediate infeed machine unit further includes a motor configured to rotate the intermediate shaft according to at least two rotational speeds for rotating the infeed starwheel and for rotating the idle transfer starwheel at different rotations per minute.

Description

INTERMEDIATE INFEED SHAFTCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of, and priority to, U.S. Provisional Patent Application No. 63 / 599,857, filed November 16, 2023, and U.S. Provisional Patent Application No. 63 / 705,173, filed October 9, 2024, each of which is hereby incorporated by reference herein in its entirety.FIELD

[0002] The present disclosure relates generally to the control of a starwheel within a machine line. More specifically, the invention relates to a variable speed shaft used to control a starwheel within a machine line.BACKGROUND

[0003] FIG. 1 is a front view of a machine line 100. The machine line 100 can be used to process articles, such as processing a container preform by performing a series of mechanical operations on the preform. The machine line 100 is formed of multiple machine units 102a- 102e (referred to collectively as “machine units 102”). Each machine unit 102 can be a separate free-standing unit that is connected to one or more adjacent units for forming the machine line 100. For example, machine units 102e, 102b, and 102d are separate units with their borders generally represented by the dashed lines shown in FIG. 1. Machine unit 102b can be connected to machine units 102e and 102d, either directly, such as through the housings of adjacent units unit being connected, or indirectly, such as gears of adjacent units unit being connected together. Each one of the machine units 102 can be configured to perform an operation on the articles that pass through the machine line 100, such as a mechanical operation or an operation that passes the article to the next machine unit.

[0004] The machine line 100 includes an infeed chute 104. The infeed chute 104 feeds articles into the machine line 100, such as the first machine unit 102a in the machine line 100.

[0005] The machine line 100 can also include an intermediate infeed chute 106. The intermediate infeed chute 106 feeds articles into the machine line 100 from a machine unit 102b that is not the first machine unit.

[0006] After the articles pass through the machine line 100, such as after passing through the last machine unit 102c, the articles pass out of the machine line 100 at the discharge chute 108.

[0007] Focusing on the machine unit 102b, the machine unit 102b has a specific configuration to accept articles from upstream within the machine line 100 or a specificconfiguration to accept articles from the intermediate infeed chute 106. Specifically, according to one configuration, the machine unit 102b can include an idle transfer starwheel 118a that is configured to accept articles from the transfer starwheel 120e of the machine unit 102e immediately upstream from the machine unit 102b within the machine line 100. The idle transfer starwheel 118a is configured to pass the article to the transfer starwheel 120a of the machine unit 102b. From there, the article passes to a process turret 114d of the machine unit 102d immediately downstream from the machine unit 102b within the machine line 100. The turret 114d can perform a mechanical operation on the article and then pass the article to the transfer starwheel 120d of the machine unit 102d.

[0008] According to another configuration, the machine unit 102b can include an infeed starwheel 112b, such as a second stage infeed starwheel. The infeed starwheel 112b accepts articles from an infeed chute starwheel 112a (also referred to as a first stage infeed starwheel) that is immediately downstream from the intermediate infeed chute 106. The infeed starwheel 112b transfers the articles from the infeed chute starwheel 112a to the transfer starwheel 120a of the machine unit 102b.

[0009] The machine unit 102b must include various shafts to support the above-described starwheels. For example, the machine unit 102b must include a shaft 110a for the infeed chute starwheel 112a, a shaft 110b for the idle transfer starwheel 112b, a shaft 116a for the idle transfer starwheel 118a, and a shaft 116b for the transfer starwheel 120a.

[0010] Although FIG. 1 shows the machine unit 102b with both the infeed starwheel 112b and the idle transfer starwheel 118a, in operation, the machine unit 102b includes only one of those starwheels. If the machine unit 102b is configured to pass articles into the machine line 100 through the infeed chute 106, the machine unit 102b includes the infeed starwheel 112b and does not include the idle transfer starwheel 118a. Alternatively, if the machine unit 102b passes articles from the machine unit 102e to the machine unit 102d, the machine unit 102b does not include the infeed starwheel 112b and instead includes the idle transfer starwheel 118a. However, although the machine unit 102b includes only one of the infeed starwheel 112b and the idle transfer starwheel 118a at a time, the machine unit 102b must include, or at least provide room for, the shafts 110b and 118a at the same time. The machine unit 102b must also include the necessary gearing (not shown) to rotate the shafts 110b and 118a. This results in wasted space and / or an overly complicated configuration for the machine unit 102b.

[0011] Accordingly, it would be desirable to have a machine unit that can perform the functions of the machine unit 102 with the infeed starwheel 112b and the idle transfer starwheel 118a without the redundant additional components, such as without both shafts 110b and 118a.SUMMARY

[0012] A first implementation of the present disclosure includes an intermediate infeed machine unit for a machine line. The intermediate infeed machine unit includes an intermediate infeed chute for feeding articles into an article process flow of the machine line. The intermediate infeed machine unit further includes an intermediate shaft configured to accept an infeed starwheel for transferring the articles from the infeed chute into the article process flow and configured to accept an idle transfer starwheel for accepting articles from an upstream transfer starwheel of an upstream machine unit of the article process flow of the machine line. The intermediate infeed machine unit further includes a motor configured to rotate the intermediate shaft according to at least two rotational speeds. The at least two rotational speeds are for rotating the infeed starwheel and for rotating the idle transfer starwheel at different rotations per minute.

[0013] An aspect of the first implementation, alone or in combination with any other aspect of the first implementation, includes the idle transfer starwheel being connected to the intermediate shaft for accepting articles from the upstream transfer starwheel of the upstream machine unit of the article process flow of the machine line.

[0014] An aspect of the first implementation, alone or in combination with any other aspect of the first implementation, includes the idle transfer starwheel having 12 pockets configured to accept the articles.

[0015] An aspect of the first implementation, alone or in combination with any other aspect of the first implementation, includes the infeed starwheel being connected to the intermediate shaft for transferring articles from the infeed chute into the article process flow.

[0016] An aspect of the first implementation, alone or in combination with any other aspect of the first implementation, includes an infeed chute shaft for rotating an infeed chute starwheel that accepts articles from the intermediate infeed chute and transfers the articles to the infeed starwheel.

[0017] An aspect of the first implementation, alone or in combination with any other aspect of the first implementation, includes the infeed chute starwheel that accepts articles from the intermediate infeed chute and transfers the articles to the infeed starwheel.

[0018] An aspect of the first implementation, alone or in combination with any other aspect of the first implementation, includes a downstream transfer shaft for rotating a downstream transfer starwheel that accepts articles from the infeed chute starwheel and transfers the articles to a downstream machine unit.

[0019] An aspect of the first implementation, alone or in combination with any other aspect of the first implementation, includes the downstream transfer starwheel that accepts articles from the infeed chute starwheel and transfers the articles to a downstream machine unit.

[0020] An aspect of the first implementation, alone or in combination with any other aspect of the first implementation, includes the intermediate infeed machine unit having only three shafts.

[0021] An aspect of the first implementation, alone or in combination with any other aspect of the first implementation, includes the infeed starwheel having 14 pockets configured to accept the articles.

[0022] A second implementation of the present disclosure includes a machine line for processing articles. The machine line includes a first machine unit and a main infeed chute configured to feed articles into the first machine unit. The machine line further includes a last machine unit and a discharge chute configured to discharge processed articles from the last machine unit in the machine line. The machine line further includes an intermediate infeed chute and an intermediate machine unit between the first machine unit and the last machine unit. The intermediate machine unit is connected to the intermediate infeed chute to accept articles from the intermediate infeed chute. The intermediate machine unit includes an intermediate shaft configured to accept a first starwheel for receiving articles originating from the intermediate infeed chute and a second starwheel for receiving articles originating from the infeed chute.

[0023] An aspect of the second implementation, alone or in combination with any other aspect of the second implementation, includes a motor configured to rotate the intermediate shaft according to at least two rotational speeds. The at least two rotational speeds are for rotating the first starwheel and for rotating the second starwheel at different rotations per minute.

[0024] An aspect of the second implementation, alone or in combination with any other aspect of the second implementation, includes the idle transfer starwheel having 12 pockets configured to accept the articles.

[0025] An aspect of the second implementation, alone or in combination with any other aspect of the second implementation, includes the infeed starwheel having 14 pockets configured to accept the articles.

[0026] A third implementation of the present disclosure includes a method for setting a function of a machine unit within a machine line that processes articles. The method includes providing one of an idle transfer starwheel or an infeed starwheel on a shaft of the machineunit. The idle transfer starwheel is configured to accept the articles from an upstream transfer starwheel of an upstream machine unit of the machine line. The infeed starwheel is configured to transfer the articles from an infeed chute of the machine unit into an article process flow of the machine line. The method further includes setting a rotational speed of a motor connected to the shaft of the machine unit according to the installed one of the idle transfer starwheel or the infeed starwheel. The method further includes running the machine line with the machine unit at the set rotational speed.

[0027] An aspect of the second implementation, alone or in combination with any other aspect of the second implementation, includes the idle transfer starwheel having 12 pockets configured to accept the articles.

[0028] An aspect of the second implementation, alone or in combination with any other aspect of the second implementation, includes the infeed starwheel having 14 pockets configured to accept the articles.

[0029] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.BRIEF DESCRIPTION OF THE DRAWINGS

[0030] These and other features, aspects, and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.

[0031] FIG. 1 shows a front view of a conventional machine line for processing articles formed of a series of machine units.

[0032] FIG. 2 shows a front view of a machine line, according to aspects of the present disclosure.

[0033] FIG. 3 shows a back view of the machine line of FIG. 2, according to aspects of the present disclosure.

[0034] While the invention is susceptible to various modifications and alternative forms, specific forms thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but, on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.DETAILED DESCRIPTION

[0035] A machine line is disclosed with an intermediate machine unit. The intermediate machine unit has the ability to accept articles, which are processed by the machine line, from an intermediate infeed chute and the ability to pass articles between upstream and downstream machine units. However, unlike conventional machine units with a similar ability, the intermediate machine units of the present disclosure require a single shaft and associated starwheel connected to the shaft to perform both functions. The starwheel can selectively be configured to accept articles from the intermediate infeed chute or accept articles from a starwheel of an upstream machine unit. The starwheels can be controlled at different speeds via the same shaft depending on the desired configuration.

[0036] Referring to FIG. 2, shown is a front view of a machine line 200, according to aspects of the present disclosure. The machine line 200 is similar to the machine line 100 of FIG. 1. Thus, elements of the machine line 200 that are similar to elements in the machine line 100 share the same reference number.

[0037] However, unlike the machine line 100 with the machine unit 102b, the machine line 200 of FIG. 2 instead includes a machine unit 202b. The machine unit 202b lacks the shafts 110b and 116a associated with the infeed starwheel 112b and the idle transfer starwheel 118a of the machine line 100. Instead, the machine unit 202b includes a single shaft 240 that replaces the shafts 110b and 116a. Thus, the machine unit 202b can include only three shafts, such as the shaft 240 along with the shafts 110a and 116b.

[0038] The shaft 240 is an intermediate shaft 240 that is configured to accept an infeed starwheel 242 for transferring articles from the infeed chute 106, or the idle infeed starwheel 112a that is immediately before the infeed chute 106, into the article process flow. The intermediate shaft 240 also is configured to accept an idle transfer starwheel for accepting articles from the upstream transfer starwheel 120e of the upstream machine unit 120e of the article process flow of the machine line 200. For the purpose of convenience, however, only the infeed starwheel 242 is shown. However, the infeed starwheel 242 and the idle transfer starwheel are generally similar, except that, for example, the idle transfer starwheel can include 12 pockets configured to accept the articles, and the infeed starwheel 242 may have more or less pockets. For example, the infeed starwheel can includes 14 pockets configured to accept the articles.

[0039] Referring to FIG. 3, shown is a back view of the machine line 200, according to aspects of the present disclosure. The intermediate shaft 240 is connected to a motor 208. The motor 208 is configured to rotate the intermediate shaft 240 according to at least two rotationalspeeds. The at least two rotational speeds are for rotating the infeed starwheel and for rotating the idle transfer starwheel at different rotations per minute. This allows the intermediate shaft 240 to perform two different functions and allows the machine unit 202b to have a single shaft 240 rather than two shafts, such as rather than the two shafts 110b and 116a of the machine unit 102b in FIG. 1. For example, the motor 208 can be a servo motor than can spin at two different assigned rotational speeds.

[0040] According to some embodiments, other shafts of the machine unit 202b can be mechanically linked via gears to the machine units 102e and 102d, and thereby be rotated by one or more motors that rotate the other shafts of the machine line 200. Alternatively, each one of the shafts on the machine unit 202b can be rotated by its own servo motor. Even further alternatively, combinations of the two previous embodiments are possible, such as the shafts 110a and 240 being rotated by a single servo motor that is mechanically linked to the shafts 110a and 240 via one or more belts, one or more gears, or a combination thereof. In the same embodiment, the shaft 116b can be rotated by being tied into the gears of the machine unit 102d or rotated by its own servo motor. Alternatively, the shafts 116b and 240 can be linked, and the shaft 110a can be rotated by being tied into the gears of the machine unit 102e or 102d or rotated by its own servo motor.

[0041] Thus, the machine line 202b allows for running a single shaft at multiple speeds to suit its active usage mode. The elimination of a shaft reduces the number of parts on the machine unit 202b. Elimination of a shaft also creates more room in a machine unit 202b, which allows for additional features in this area. Further, the additional open area makes maintenance and change-overs easier and also reduces changeover time, which is particularly a problem in conventional layouts.

[0042] The layout of the present disclosure allows for “staging,” which is a gradual increase in tangential velocity of the article (e.g., can) as the article goes through the infeed starwheels. The present layout could be used to maximize the effect of “staging” by allowing smaller diameter cans to have more pockets in the first stage infeed starwheel, thereby reducing the velocity differential to a stack of articles within the chute 106.

[0043] Although the shaft 240 is disclosed above as being configured to accept an infeed starwheel 242 and an idle transfer starwheel, with each starwheel being for a different function, according to some embodiments the shaft 240 can accept a single starwheel for accomplishing both functions. For example, a single starwheel can be driven (e.g., rotated) at different speeds to accomplish both the functions of the infeed starwheel 242 and the idle transfer starwheel at different times. This allows for the same starwheel to be on the machine unit 202b for bothfunctions, which allows for changing functions of the machine unit 202b without needing to switch out the starwheel on the shaft 240.

[0044] Further, according to some embodiments, the number of pockets of a starwheel used for both functions can be configured according to the number of pockets on the upstream transfer starwheel 120e and the infeed chute starwheel 112a, or the number of pockets of a starwheel can be configured according to the speed-up staging requirements of the articles from the chute 106 or the upstream transfer starwheel 120e.

[0045] Although the focus of the present disclosure is on a motor than can rotate the shaft 240, according to some aspects, the present layout also could be applied to geared machines with a set of gears to accomplish the speed change.

[0046] Each of the above embodiments and obvious variations thereof are contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims. Moreover, the present concepts expressly include any and all combinations and subcombinations of the preceding elements and aspects.

[0047] As utilized herein, the terms “approximately,” “about,” “substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

[0048] It should be noted that the terms “exemplary” and “example” as used herein to describe various embodiments are intended to indicate that such embodiments are possible examples, representations, and / or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0049] Any references herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the Figures. It should be noted that the orientation of various elements may differ according to other exemplary embodiments and that such variations are intended to be encompassed by the present disclosure.

[0050] Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may also be made in the design, operating conditions, and arrangement of the various exemplary embodiments without departing from the scope of the present invention.

Claims

CLAIMSWe claim:

1. An intermediate infeed machine unit for a machine line, the intermediate infeed machine unit comprising: an intermediate infeed chute for feeding articles into an article process flow of the machine line; an intermediate shaft configured to accept an infeed starwheel for transferring the articles from the infeed chute into the article process flow and configured to accept an idle transfer starwheel for accepting articles from an upstream transfer starwheel of an upstream machine unit of the article process flow of the machine line; and a motor configured to rotate the intermediate shaft according to at least two rotational speeds, the at least two rotational speeds being for rotating the infeed starwheel and for rotating the idle transfer starwheel at different rotations per minute.

2. The intermediate infeed machine unit of claim 1, further comprising: the idle transfer starwheel connected to the intermediate shaft for accepting articles from the upstream transfer starwheel of the upstream machine unit of the article process flow of the machine line.

3. The intermediate infeed machine unit of claim 2, wherein the idle transfer starwheel includes 12 pockets configured to accept the articles.

4. The intermediate infeed machine unit of claim 1, further comprising: the infeed starwheel connected to the intermediate shaft for transferring articles from the infeed chute into the article process flow.

5. The intermediate infeed machine unit of claim 4, further comprising: an infeed chute shaft for rotating an infeed chute starwheel that accepts articles from the intermediate infeed chute and transfers the articles to the infeed starwheel.

6. The intermediate infeed machine unit of claim 5, further comprising: the infeed chute starwheel that accepts articles from the intermediate infeed chute and transfers the articles to the infeed starwheel.

7. The intermediate infeed machine unit of claim 5, further comprising:a downstream transfer shaft for rotating a downstream transfer starwheel that accepts articles from the infeed chute starwheel and transfers the articles to a downstream machine unit.

8. The intermediate infeed machine unit of claim 7, further comprising: the downstream transfer starwheel that accepts articles from the infeed chute starwheel and transfers the articles to a downstream machine unit.

9. The intermediate infeed machine unit of claim 7, wherein the intermediate infeed machine unit includes only three shafts.

10. The intermediate infeed machine unit of claim 4, wherein the infeed starwheel includes 14 pockets configured to accept the articles.

11. A machine line for processing articles, the machine line comprising: a first machine unit; a main infeed chute configured to feed articles into the first machine unit; a last machine unit; a discharge chute configured to discharge processed articles from the last machine unit in the machine line; an intermediate infeed chute; and an intermediate machine unit between the first machine unit and the last machine unit, the intermediate machine unit connected to the intermediate infeed chute to accept articles from the intermediate infeed chute, the intermediate machine unit including an intermediate shaft configured to accept a first starwheel for receiving articles originating from the intermediate infeed chute and a second starwheel for receiving articles originating from the infeed chute.

12. The machine line of claim 11, further comprising: a motor configured to rotate the intermediate shaft according to at least two rotational speeds, the at least two rotational speeds being for rotating the first starwheel and for rotating the second starwheel at different rotations per minute.

13. The machine line of claim 12, wherein the idle transfer starwheel includes 12 pockets configured to accept the articles.

14. The machine line of claim 12, wherein the infeed starwheel includes 14 pockets configured to accept the articles.

15. A method for setting a function of a machine unit within a machine line that processes articles, the method comprising: providing one of an idle transfer starwheel or an infeed starwheel on a shaft of the machine unit, the idle transfer starwheel configured to accept the articles from an upstream transfer starwheel of an upstream machine unit of the machine line, and the infeed starwheel configured to transfer the articles from an infeed chute of the machine unit into an article process flow of the machine line; setting a rotational speed of a motor connected to the shaft of the machine unit according to the installed one of the idle transfer starwheel or the infeed starwheel; and running the machine line with the machine unit at the set rotational speed.

16. The method of claim 15, wherein the idle transfer starwheel includes 12 pockets configured to accept the articles.

17. The method of claim 15, wherein the infeed starwheel includes 14 pockets configured to accept the articles.

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