A method of loading and loading station for filling tobacco industry trays

Abstract

The present disclosure concerns a loading station (4) for filling a tobacco-industry tray (10) with rod-like articles (3), comprising at least one loading assembly (30) that comprises a hopper (6) supplied with a mass flow of rod-like articles (3) for receiving and temporarily storing said articles (3), arranged to cooperate with the tray (10) in such a manner that the walls of the tray (10) encompass the hopper (6). A blocking valve (7) is positioned in the lower portion of the hopper (6) for intermittently opening and closing the mass flow of the rod-like articles (3) in order to fill the tray (10) with the rod-like articles (3). The assembly further comprises a lift (31) provided with a support element (32) for supporting the tray (10), arranged to lower the tray (10) while filling the tray (10) with the rod-like articles (3). The station according to the invention is characterized in that it is provided with an industrial robot (9) with a gripper (12) arranged to move the tobacco-industry tray (10) in a cycle comprising the stages of moving the empty tray (10) from a storage location to the hopper (6) in the filling area and set down the tray (10) on the support element (32) of the lift (31), as well as retrieving filled trays (10) from the support element (32) of the lift (31) and moving the filled tray (10) from the hopper (6) in the filling area into the storage location. The present disclosure also concerns a method of filling tobacco-industry trays.

Description

[0001] P1437PC00 1

[0002] A METHOD OF LOADING AND LOADING STATION FOR FILLING TOBACCO INDUSTRY TRAYS

[0003] The invention relates to a method of loading and a loading station for filling trays in the tobacco industry. The invention is applicable in tobacco-industry systems that convey rod-like articles in tobacco-industry production lines, such as semi-finished products in the form of multi-segment filter rods of multiple or single length, as well as finished tobacco-industry products delivered to subsequent stages of production or packaging.

[0004] Tray loaders are known in the prior art. Tray loaders are devices typically dedicated to performing a single operation of filling a tray with rod-like articles. Tray loaders are supplied with rod-like articles by a transporter that delivers a mass flow of rod-like articles to a hopper, from which portions of these articles are put in a tray, the flow of the articles into the tray being alternately interrupted by a shut-off valve. The loaders are also provided with a set of transporters, namely a transporter that feeds an empty tray to the filling assembly, a transporter that retrieves a filled tray after filling, and a lift responsible for handling the tray's movement during the filling process. Various designs of loaders dedicated for trays, containers, and cardboard boxes are known in the prior art. In this description, the term "tray” is understood to mean any container for rodlike articles.

[0005] From publication W02011PL50048A1 is known a filling station for filling trays, provided with a hopper, a movable shut-off valve, a lift that lowers trays during filling, and a transporter that delivers empty trays and a transporter that retrieves filled trays. This station is operated manually by an operator who provides empty trays and retrieves trays filled with rod-like articles.

[0006] From publication EP2100834A1 is known another filling station for filling trays, provided with a hopper, a shut-off valve, a lift that lowers the tray during filling, and two transporters: a first transporter that delivers empty trays and a second transporter that retrieves filled trays. This station is operated by an industrial robot, which places empty trays on the first empty-tray transporter and retrieves trays filled with rod-like articles from the second transporter.

[0007] Document US 2007 / 000209 A1 discloses a loading station for filling containers with rod-like articles such as cigarettes. The system comprises a hopper supplied with a mass flow of cigarettes, a movable shutter located at the outlet of the hopper for controlling the flow of cigarettes into a container, and a carrier assembly that lowers the container during filling. The station further comprises manipulators provided with grippers for transferring empty containers to the filling position and for removing filled containers after filling. The containers are transported through the system by conveyor belts cooperating with the manipulators. Document CN 111700303 A discloses a device for handling cigarette trays in a cigarette processing line. In this system, trays filled with cigarettes are manipulated by a robotic arm which grips and transfers the trays between different stations of a production or packaging process. The robotic arm may grip trays of different dimensions and enables automated handling of cigarette trays in a production environment. However, the trays handled are already filled with cigarettes and the document does not disclose a station for filling trays with rod-like articles.

[0008] Document US 5 106254 A relates to conveying and managing mass flows of cigarettes in tobacco-industry production lines. The document describes systems in which cigarettes are transported from cigarettemaking machines to downstream processing machines through various conveying and buffering arrangements. The document also refers to the use of multiple parallel production lines in cigarette manufacturing systems. However, it does not disclose a specific loading station for filling trays with rod-like articles using a robot for handling trays during the filling process.P1437PC00 2

[0009] A problem common to known loading stations is the high complexity of the system, which comprises many mutually cooperating assemblies, as well as the need for precise handover of trays between these assemblies, which affects the stability of the location of rod-like articles in the tray. This structural complexity of known loaders also entails a need to monitor the tray's position relative to the system assemblies. Moreover, known loaders require a highly complex control process, necessitating numerous sensors for monitoring the positions of both the transporters and the tray itself and they also occupy a large footprint area, making their use impossible in older factories with limited production space.

[0010] The essence of the present disclosure is a loading station according to claim 1.

[0011] The essence of the invention is a loading station for filling a tobacco-industry tray with rod-like articles. This station comprises at least one loading assembly that comprises a hopper supplied with a mass flow of rodlike articles for receiving and temporarily storing those articles, arranged to cooperate with the tray in such a way that the walls of the tray encompass the hopper. A blocking valve, located in the lower part of the hopper, alternately opens and closes the mass flow of rod-like articles to fill the tray with rod-like articles. The loading assembly also has a lift provided with a support element for holding the tray, arranged to lower the tray while filling the tray with the rod-like articles. The loading station is characterized in that it is provided with an industrial robot having a gripper arranged to move the tobacco-industry tray in a cycle that comprises the following stages: moving the empty tray from a storage location to the hopper in the filling area and setting down the tray on the lift's support element, then retrieving the filled tray from the lift's support element and moving the filled tray from the hopper in the filling area to the storage location.

[0012] Advantageously, in the loading station according to the invention, the hopper comprises an upper portion in the form of a chamber arranged to receive rod-like articles from a conveyor that delivers them in a mass flow, and a lower portion in the form of channels through which the rod-like articles move downward under the force of gravity.

[0013] Advantageously, in the loading station according to the invention, the hopper comprises an upper portion in the form of a chamber arranged to receive rod-like articles from a conveyor that delivers them in the form of a mass flow, and a lower portion in the form of a downward-widening funnel, through which the rod-like articles move downward under the force of gravity.

[0014] Advantageously, in the loading station, the gripper is arranged to grip one lateral wall of the tray.

[0015] Advantageously, in the loading station, the gripper is arranged to grip both lateral walls of the tray.

[0016] Advantageously, in the loading station, the gripper is arranged to grip one lateral wall of the tray and the bottom of the tray.

[0017] Advantageously, in the loading station according to the invention, there are two loading assemblies. Advantageously, in the loading station, the industrial robot alternately serves two loading assemblies. Advantageously, in the loading station according to the invention, the tray-filling cycle on the first loading assembly is phase-shifted relative to the tray-filling cycle on the second loading assembly so that, when in the first loading assembly a tray is being filled, in the second loading assembly a tray is being set down for filling.

[0018] Advantageously, in the loading station according to the invention, the tray-filling cycle on the first loading assembly is phase-shifted relative to the tray-filling cycle on the second loading assembly so that, when inP1437PC00 3

[0019] the first loading assembly a tray is being filled, in the second loading assembly a filled tray is being retrieved.

[0020] Furthermore, the essence of the invention is also the method according to claim 11.

[0021] The essence of the invention is a method for filling trays with rod-like tobacco-industry articles in a loading station according to the invention, comprising the following steps performed by the industrial robot provided with a gripper: moving the empty tray from the storage location to the hopper in the filling area of the loading assembly, setting down the tray on the lift's support element, retrieving the filled tray from the lift's support element, and moving the filled tray from the hopper in the filling area to the storage location. Advantageously, in the method according to the invention, the industrial robot performs the aforementioned steps for two loading assemblies, alternately.

[0022] Advantageously, in the method according to the invention, the tray-filling cycle on the first loading assembly is phase-shifted relative to the tray-filling cycle on the second loading assembly such that, when a tray is being filled in the first loading assembly, a tray is being set down for filling in the second loading assembly.

[0023] Advantageously, in the method according to the invention, the tray-filling cycle on the first loading assembly is phase-shifted relative to the tray-filling cycle on the second loading assembly such that, when a tray is being filled in the first loading assembly, a filled tray is being retrieved in the second loading assembly.

[0024] An advantage of the invention is the significant simplification of the structure of the loader by providing a loading station without any transporters responsible for moving a tray horizontally and by eliminating the need for manual operation of the loader. This substantial simplification of the structure reduces the footprint of the loading station according to the invention, enabling placement of an automated loading station in areas where traditional loaders cannot fit, regardless of whether those loaders are operated by humans or by robots.

[0025] The object of the invention is presented in more detail in an advantageous embodiment shown in the drawings, in which:

[0026] Fig. 1 presents a perspective view of a loading station and a storage unit,

[0027] Fig. 2 shows a loading assembly of the loading station according to the invention,

[0028] Fig. 3 schematically presents a lift of a loading assembly of the loading station according to the invention in another embodiment,

[0029] Fig. 4 shows the loading station in a first embodiment,

[0030] Figs. 5a and 5b show an empty tray being placed on the lift of the loading assembly, Fig. 6 presents the loading system, the tray being in the process of filling in the loading station according to the invention,

[0031] Fig. 7 presents the lower portion of the hopper and the blocking valve before the beginning of filling,

[0032] Fig. 8 shows a fragment of the blocking valve in the open position,P1437PC00 4

[0033] Fig. 9 shows the lower portion of the hopper, the blocking valve being closed and the tray being filled,

[0034] Fig. 10 presents a view of the loading system, the robot transferring a filled tray to the storage unit,

[0035] Fig. 11 shows an empty segment-type tray positioned at the hopper in a filling position, Fig. 12 shows, in a second embodiment, the hopper of the loading station according to the invention,

[0036] Fig. 13 shows the loading station in the second embodiment, with the robot retrieving an empty tray from the storage area,

[0037] Fig. 14 shows the loading station of Fig. 13, the robot placing the tray on the lift,

[0038] Fig. 15 shows the loading station of Fig. 13, the robot setting down the filled tray into the storage unit, and

[0039] Fig. 16 presents a cycle diagram of the station of Fig. 13.

[0040] The embodiments disclosed in the present application share a common inventive concept relating to the manner in which trays containing rod-like tobacco industry articles are handled during the filling process. More specifically, the invention is based on the concept of robot-controlled placement and retrieval of trays directly at the filling position beneath the hopper, in combination with a filling process in which the tray is supported by a lift and lowered relative to the hopper during filling. According to this concept, an industrial robot retrieves trays from a storage location, places the trays directly on a support element of the lift beneath the hopper, and retrieves the trays after completion of the filling operation.

[0041] This robot-controlled tray handling architecture enables the tray to be positioned relative to the hopper such that the walls of the tray at least partially encompass a lower portion of the hopper during filling. The various embodiments described in the application represent different implementations and refinements of this general concept. In particular, the embodiments include configurations in which:

[0042] tray transport within the loading station is performed exclusively by the industrial robot without conveyor-based tray transport systems traditionally responsible for horizontal transport of trays, the loading station comprises multiple loading assemblies served by the industrial robot, and the geometric relationship between the hopper and the tray is configured to facilitate controlled filling of the tray while the tray is lowered by the lift.

[0043] Despite these variations, all embodiments share the same underlying technical idea, namely the use of an industrial robot to directly control the placement and retrieval of trays at the hopper-based filling position. The technical contribution of the invention therefore lies in the integration of robot-controlled tray handling with the hopper-based tray filling process. The common inventive concept disclosed in the present application provides several technical effects associated with the integration of robot-controlled tray handling with a hopper-based tray filling process. In particular, the use of an industrial robot to retrieve trays from a storage location and place the trays directly on the support element of the lift beneath the hopper enables precise positioning of the tray relative to the hopper during filling.P1437PC00 5

[0044] This configuration allows the tray to be positioned such that the walls of the tray at least partially encompass a lower portion of the hopper, thereby facilitating controlled filling of the tray with rod-like articles while the tray is lowered by the lift. As a result, the filling process can be performed in a stable and repeatable manner while maintaining proper containment of the rod-like articles during filling. Furthermore, the robot-controlled tray handling architecture simplifies the mechanical layout of the loading station by enabling direct placement and retrieval of trays at the filling position. This approach reduces the reliance on complex tray transport mechanisms and allows greater flexibility in the configuration of the loading station.

[0045] The integration of robot-controlled tray handling with the filling process therefore provides improvements in the efficiency and operational flexibility of tray filling stations used in tobacco industry processing lines. These technical effects are achieved in all embodiments described in the present application, including embodiments in which tray transport is performed exclusively by the industrial robot, embodiments comprising multiple loading assemblies served by the robot, and embodiments defining specific geometric relationships between the hopper and the tray. Accordingly, the various embodiments disclosed in the present application share common technical effects resulting from the same underlying inventive concept. Presented in Fig. 1, a loading system 1 for filling tobacco-industry trays 10 with rod-like articles 3 (the rodlike articles 3 are visible in subsequent figures) comprises a loading station 4 and a storage unit 5. The loading station 4 comprises a loading assembly 30 which comprises a hopper 6, at least one blocking valve 7, a conveyor 8 and a lift 31. Moreover, the loading station 4 comprises an industrial robot 9. The loading station 4 does not comprise conveyors configured to transport trays 10 horizontally. Traditional conveyors responsible for horizontal transportation of trays are the ones that transport trays such that velocity vector attached to a tray comprises an essentially non zero horizontal component. The hopper 6 for tobaccoindustry articles 3 comprises an upper portion 6A and a lower portion 6B. The upper portion 6A is in the form of a chamber in which rod-like articles 3 are temporarily accumulated. The upper portion 6A is arranged to receive the rod-like articles 3, whereas the quantity of articles 3 accumulated may vary during operation of the loading assembly 30. The lower portion 6B of the hopper 6 may take the form of vertically oriented channels or a downward-widening chamber. The lower portion 6B is arranged to deliver rod-like articles to the tray 10. Directly beneath the lower portion 6B of the hopper 6 there is at least one blocking valve 7, in other words, the blocking valve 7 is situated at the outlet 6C of the hopper 6. An embodiment is possible in which one blocking valve 7 will control the entire mass flow of rod-like articles fed into the tray, as well as a solution in which multiple blocking valves 7 will be used, each controlling a partial mass flow of rod-like articles, e.g. flowing out of channel 6D. The blocking valve 7 is arranged to take either an open position or a closed position. In the closed position, the mass flow of the rod-like articles 3 is blocked, in the open position, the rod-like articles 3 may flow as a mass flow from the hopper 6 into the tray 10, which is positioned so that the walls of the tray 10 at least partially encompass the hopper 6. The term "partial encompassing of the hopper 6 by the tray 10” refers to a position of the tray 10 in which at least the lower portion 6B of the hopper 6 is located at least partially inside the tray 10. The rod-like articles 3 may be delivered to the hopper 6 in the form of a mass flow, i.e., a multi-layer stream. In the presented embodiment, the hopper 6 is fed with a stream S of rod-like articles 3 delivered by the conveyor 8. In the presented embodiment, the conveyor 8 moves the stream S of rod-like articles 3 (shown with dashed arrows) from the right side of the hopper 6. The hopper 6 may be supplied with the rod-like articles 3 by any suitable means, also be means of a channel in which the rod-like articles 3 move under the force of gravity.

[0046] The lift 31 is arranged to lower the tray 10 while filling the tray 10 with rod-like articles 3 that are supplied from the hopper 6 once the valve 7 has been opened. The lift 31 is located beneath the hopper 6 (Fig. 2). The lift 31 of the loading assembly 30 is provided with a support element 32. The support element 32 may have the form of a single element, two or more elements. In the embodiment shown in Fig. 2, the support element 32 takes the form of a plate arranged to support the bottom of the tray 10 across its entire width orP1437PC00 6

[0047] almost the entire width of the tray 10. The support element 32 is arranged to execute a working downward stroke and a return upward stroke along the same path. The drive system may be any linear actuator, for example, a pneumatic cylinder.

[0048] The support element 32 may comprise two support elements 32A, 32B (Fig. 3) in the form of plates designed to support the lateral edge regions of the bottom 10C of the tray 10, whereas the support elements 32A, 32B may be mounted on a chain conveyor comprising two chains 34, 35, whereas the support elements 32A, 32B move along a closed path. Several pairs of support elements 32A, 32B may be arranged on the chains 34, 35. The support element 32 may take any shape that enables placement of the tray 10 and its lowering by means of the lift 31.

[0049] The loading station 4 according to the invention is provided with an industrial robot 9. The term "industrial robot 9” refers to a programmable mechanical device provided with at least one movable arm, intended to perform automated tasks such as gripping, transferring, and setting down objects. The movable arm consists of segments joined by articulations, enabling multi-axis motion controlled by an electronic system. The robot may operate autonomously or be controlled externally, and its design is adapted to the specific requirements of the tobacco industry. The loading station 4 shown in Fig. 1 comprises one loading assembly 30 and an industrial robot 9. Another loading station 4, discussed further underneath and shown in Fig. 13, comprises two loading assemblies 30 and an industrial robot 9.

[0050] Fig. 4 presents the beginning of the stage in which the empty tray 10 is transferred from a storage location to the hopper 6. The storage location is essentially any location within the storage unit 5 that is within reach of the industrial robot 9. The robot 9 retrieves an empty tray 10 from the storage unit 5, where the retrieving point is a shelf 11 of the storage unit 5. The robot 9 is provided with a gripper 12 arranged to grip the tray 10. After the tray 10 is retrieved, the industrial robot 9 transfers the empty tray 10 to the loading assembly 30 in the filling area and places it on the support element 32 of the lift 31 of the loading assembly 30, movement of the tray is schematically shown with continuous bold arrows. In the case of a robot breakdown, the empty tray 10 may be placed manually on the support element 32. Fig. 5a presents the tray 10 positioned slightly above the support element 32, the cut-out 32C is visible, where the lower part of the gripper 12 will be located while the tray 10 is placed on the support element 32. Fig. 5b presents the tray 10 after it has been set down on the support element 32. Once the tray 10 has been set down, the robot 9 is moved to a standby position (Fig. 6) for the time of filling the tray with rod-like articles 3.

[0051] While being placed on the support element 32, the tray 10 is positioned so that its walls 10A, 10B encompass the lower portion 6B of the hopper 6 (Fig. 7), this defined position of the tray 10 relative to the hopper 6 enables a smooth flow of the rod-like articles 3 from the hopper 6 into the tray 10. The distance between the bottom of the tray 10 and the valve 7 depends on the type of tray 10, for single-chamber trays, this distance is small, i.e., smaller than or close to the diameter of the rod-like article 3. For segment-type trays, the distance between the bottom of the tray 10 and the valve 7 may be somewhat greater, due to the preliminary positioning of the rod-like articles 3 in the channels of the hopper 6 and the presence of partitions in the segment tray 10 that prevent the rod-like articles 3 from crossing over one another as they flow from the hopper 6 into the tray 10. Thus, the industrial robot 9 moves empty trays 10 from the storage location to the hopper 6 into the filling area which enables a smooth flow of rod-like articles 3 from the hopper 6 into the tray 10. In the presented embodiment, the tray 10 is gripped by its lateral wall 10B and the bottom 10C of the tray 10 is supported. In other advantageous embodiments, the gripper 12 is arranged to grip two walls of the tray 10, or to grip one or both lateral walls of the tray 10 and the bottom 10C.

[0052] The lower portion 6B of the hopper 6 in the loading assembly 30 of the loading station 4 has outside dimensions adapted to the inside dimensions of the tray 10. The width d of the lower portion 6B of the hopperP1437PC00 7

[0053] 6 is smaller than the inside width D of the tray 10 (Fig. 7), i.e., the distance between the walls 10A and 10B. While filling the tray 10 is placed so that its lateral walls 10A, 10B at least partially encompass the lower portion 6B of the hopper 6, and the bottom 10C of the tray 10 is located beneath the blocking valve 7. The term "encompassing the hopper” means encompassing the portion of the hopper that delivers the rod-like articles 3 to the tray 10. In Fig. 7, channels 6D deliver rod-like articles 3 into the tray 10, so "encompassing the hopper 6” means encompassing the channels 6D of the hopper 6. Advantageously, the bottom 10C of the tray is located as close as possible to the blocking valve 7. In each embodiment, the space in which the tray 10 is filled is the filling area.

[0054] Fig. 7 shows the lower portion 6B of the hopper before the beginning of filling the tray 10 whereas the channels 6D are filled with rod-like articles 3, and the blocking valve 7 is in the closed position. The tray 10 (a single-chamber tray in the presented embodiment) is shown in simplified form with bold lines, namely the lateral walls 10A, 10B and the bottom 10C are shown. The tray 10 is positioned on the support element 32. Fig. 8 shows the blocking valve 7 in the open position during filling. The blocking elements 7A, 7B have been moved so that they are retracted into recesses 13, 14 in walls 15, 16 of the hopper's lower portion 6B, whereas the walls 15, 16 form the channel 6D. During the downward movement of the tray 10, the rod-like articles 3 will move downward along the channels 6D into the interior of the tray 10 under the force of gravity. In the presented embodiment of the blocking valve 7, the blocking elements 7A, 7B take the form of curved plates mounted so that they can swing. The blocking valve 7 may take any other form that ensures that, in the closed position, the flow of rod-like articles 3 is completely blocked while in the open position, the rodlike articles 3 may move along the channels 6D of the hopper's lower portion 6B.

[0055] Fig. 9 shows the end moment of the filling stage of the tray 10, in which the blocking valve 7 is in the closed position, the blocking elements 7A, 7B support the rod-like articles and they disable further flow of the rodlike articles 3 down along the channels 6D. At this stage of the filling process, the tray 10 is essentially below the hopper's lower portion 6B, whereas the filled tray 10 rests on the support element 32 of the lift 31 (not shown in Fig. 9). The tray 10 filled with rod-like articles 3, is in a position from which it may be retrieved by the robot 9, in case of a robot breakdown, it may be retrieved manually. It is possible to fill the tray 10 completely up to its full height with rod-like articles 3. It is also possible to fill the tray 10 such that the tray 10 is not filled up to the brim with rod-like articles 3. This may be caused, for instance, by the filling requirements defined by the manufacturer or a near-depletion of the available rod-like articles. In such cases, the filling stage ends when the hopper's lower portion 6B is still partially inside the tray 10. The blocking valve 7 is arranged to alternately open and close the mass flow in order to fill the tray 10 with rodlike articles 3. After the tray 10 has been filled, the industrial robot 9 repositions itself to grip the filled tray 10 and retrieve it from the support element 32 of the lift 31 in the filling assembly 30. Fig. 10 shows the stage at which the filled tray 10 is being transferred to the storage location, whereas the storage location is a shelf 11 in the storage unit 5. The movement of the filled tray 10 is indicated by bold continuous arrows.

[0056] In the presented embodiment, the industrial robot 9 is provided with a gripper 12 for gripping the tray 10 by a single side wall 10A or 10B. The robot 9 may also be provided with a gripper designed to grip both lateral walls 10A and 10B, or else one lateral wall 10A or 10B plus the bottom 10C.

[0057] Fig. 11 shows a segment tray 20 set down on the support element 32 in a filling position. The segment tray 20 has partitions 21 (shown with dashed lines) that are inserted into slots 22 in the hopper's lower portion 6B. During filling, the segment tray 20 is located in the hopper's lower portion 6B so that the hopper channels 6D lie between two adjacent partitions 21 of the tray 20. The procedure for filling the segment tray 20 is analogous to that for filling the single-chamber tray 10.P1437PC00 8

[0058] Fig. 12 shows an embodiment of a hopper 17 in which the upper portion 17A is shaped as a chamber, as in the first embodiment, while the lower portion 17B is funnel-shaped and widens downward toward the blocking valve 18. In this embodiment, the lower portion 17B of the hopper 17 does not contain channels. A method of filling a tray 10 with tobacco-industry rod-like articles 3 in the loading station 4 involves the following steps: the conveyor 8 delivers a stream S of rod-like articles 3 in the form of a mass flow, and the rod-like articles 3 are accumulated in the hopper 6 of the loading station 4. Next, the empty tray 10 is moved from the storage location to the hopper 6: the industrial robot 9 provided with a gripper 12 retrieves the empty tray 10 from the storage location in the storage unit 5. The industrial robot 9 then places the tray 10 in the filling area under the hopper 6 such that the walls 10A, 10B of the tray 10 encompass the hopper 6 and the bottom 10C of the tray 10 is positioned above the support element 32 of the lift 31 , below the blocking valve 7. Next, the gripper 12 releases the tray 10, i.e., it sets the tray 10 on the support element 32, and then the blocking valve 7 opens. The lift 31 lowers the tray 10 to enable filling of the tray 10, and the rodlike articles 3 move downward in the hopper 6, once the tray 10 is filled, the blocking valve 7 is closed. The robot 9 then retrieves the filled tray 10: the robot 9 grips the filled tray 10 and transfers it to the storage location in the storage unit 5. The industrial robot 9 moves the empty tray 10 from the storage location to the hopper 6 in the filling area so as to enable a smooth flow of the rod-like articles from the hopper 6 into the tray 10, and subsequently it retrieves the filled tray 10 from the filling area.

[0059] In the embodiment shown in Fig. 13, the loading station 4 comprises two loading assemblies 30, 30' and an industrial robot 9. In this embodiment, the loading assemblies 30, 30' are each supplied with different mass flows of rod-like articles 3 via two conveyors 8. The robot 9 is arranged to alternately supply trays 10 to the filling areas of two different hoppers 6 belonging to the two different loading assemblies 30, 30'. In Fig. 13, the robot 9 retrieves an empty tray 10 from the storage area of the storage unit 5 and may place it into the filling area of the hopper 6 of the first loading assembly 30, namely by setting down the tray 10 on the support element 32 of the lift 31, as shown in Fig. 14. Then, while the tray 10 delivered to the hopper 6 of the first loading assembly 30 is undergoing a filling cycle, the robot may retrieve a filled tray 10 from the filling area of the hopper 6 of the second loading assembly 30' and set it down in the storage location in the storage unit 5 (Fig. 15). In the loading assembly 30' shown in Fig. 14, the tray 10 is positioned immediately after being filled. Next, the robot 9 may retrieve another empty tray 10 and move it from the storage area in the storage unit 5 to the filling area of the hopper 6 of the second loading assembly 30', placing this tray on the support element 32 of the lift 31. Then, while the tray 10 delivered to the hopper 6 of the second loading assembly 30' is undergoing its filling cycle, the robot may retrieve a filled tray 10 from the filling area of the hopper 6 of the first loading assembly 30 and set it down in the storage location in the storage unit 5. An alternative embodiment is also possible, in which the alternation of delivering trays 10 to the loading assemblies 30, 30' is carried out so that an empty tray 10 is first moved from the storage area to the filling area of the hopper 6 of the first loading assembly 30, and, once it is filled, it is taken from the filling area to the storage area. In the next step, an empty tray 10 is moved from the storage area to the filling area of the hopper 6 of the second loading assembly 30', and, once it is filled, it is retrieved from the filling area and moved to the storage area.

[0060] When filling trays 10 with rod-like tobacco-industry articles 3 in a loading station 4 that comprises two loading assemblies 30, the filling method comprises the steps in which each loading assembly's conveyor 8 delivers a mass-flow stream S of the rod-like articles 3 to the hopper 6, and the rod-like articles 3 are accumulated in the hopper 6 of each loading assembly 30. The industrial robot 9 then places the tray 10 under the hopper 6 of the first loading assembly 30 such that the walls of the tray 10 encompass the hopper 6, and the bottom 10C of the tray 10 is located beneath the blocking valve 7. Next, the robot's gripper 12 releases the tray, i.e., the tray 10 is set down on the support element 32 of the lift 31 , and the blocking valve 7 is opened. The process of filling the tray 10 in the first loading assembly 30 then begins, the tray 10 being lowered by theP1437PC00 9

[0061] lift 31. In the subsequent step, the robot 9 repositions itself so it may retrieve the next empty tray 10 from the storage location and, as in the first loading assembly 30, sets the tray 10 onto the support element 32 of the lift 31 in the second loading assembly 30'. That is, there is a step of moving the empty tray 10 from the storage location to the hopper 6, in which the industrial robot 9 provided with the gripper 12 retrieves the empty tray 10 from the storage area in the storage unit 5 and transfers it to the second loading assembly. The robot 9 sets down the empty tray 10 in the second loading assembly 30' while the first loading assembly 30 is filling the tray 10. During that time, the lift 31 in the first loading assembly 30 lowers the support element 32 along with the tray 10, and the rod-like articles 3 move downward in the hopper 6. Once the tray 10 is filled, the blocking valve 7 in the first loading assembly 30 is closed, and the robot 9 repositions itself to grip the filled tray 10 in the first loading assembly 30, whereupon it retrieves the filled tray 10 and transfers it to the storage location in the storage unit 5. Meanwhile, the lift in the second loading assembly 30' lowers the support element 32 together with the tray 10, and the rod-like articles 3 move downward in the hopper 6. When the tray 10 in the second loading assembly 30' is filled, the blocking valve 7 is closed, and the robot 9 repositions itself to grip that filled tray 10, then retrieves the tray 10 and moves the tray 10 to the storage location in the storage unit 5.

[0062] In the method described above, the tray-filling cycles of the first loading assembly 30 and the second loading assembly 30' are phase-shifted in such a way that the robot 9 sets down the empty tray 10 in the second loading assembly 30' while the tray 10 in the first loading assembly 30 is being filled.

[0063] Fig. 16 presents graphs illustrating the motion of the support element 32 of the first loading assembly 30 marked as 32(1) in the figure and the motion of the support element 32 of the second loading assembly 30' marked as 32(2) during operation of the loading station 4. The upper positions of the support elements 32 in the first and second loading assemblies 30 are indicated by 32(1 )H and 32(2)H, while the lower positions of the support elements 32 in the first and second loading assemblies 30 are indicated by 32(1 )L and 32(2)L. Between the upper graph depicting the motion of the support element 32 in the first loading assembly 30 and the lower graph depicting the motion of the support element 32 in the second loading assembly 30', a rectangle represents the storage unit 5. Wavy lines show the movement of the robot's gripper 12, and circles on these wavy lines contain icons denoting either an empty or a filled tray.

[0064] In the work cycle, the robot 9:

[0065] a) retrieves an empty tray 10 from the storage unit 5 and places this tray 10 on the support element 32(1) in its upper position 32(1)H,

[0066] b) moves without a tray to the storage unit 5,

[0067] c) retrieves an empty tray 10 from the storage unit 5 and sets that empty tray 10 down on the support element 32(2) in its upper position 32(2)H,

[0068] d) moves without a tray to the support element 32(1) in the lower position 32(1 )L (there is a filled tray 10 located on the support element 32(1)),

[0069] e) retrieves the filled tray 10 from the support element 32(1) in the lower position 32(1 )L and transfers this filled tray 10 to the storage unit 5,

[0070] f) moves without a tray to the support element 32(2) in the lower position 32(2)L (there is a filled tray 10 located on the support element 32(2)),P1437PC00 10

[0071] g) retrieves the filled tray 10 from the support element 32(2) in the lower position 32(2)L and transfers it to the storage unit 5,

[0072] h) repeats the above sequence of movements.

[0073] It is possible to phase-shift the filling cycles of the first loading assembly 30 and the second loading assembly 30' such that, while the first loading assembly 30 is filling a tray 10, a filled tray 10 is retrieved on the second loading assembly 30'.

[0074] The mentioned robot's work cycle corresponds to the situation, when in Fig. 13, the upper graph represents movements of the support element 32 in the second assembly 30', and the lower graph represents movements of the support element 32 in the first assembly 30.

Claims

P1437PC00 11Patent claims1. A loading station (4) for filling a tobacco industry tray (10) with rod-like articles (3), comprising at least one loading assembly (30), the loading assembly (30) comprising:a hopper (6) supplied with a mass flow of rod-like articles (3) for receiving and temporarily storing the rod-like articles (3),a blocking valve (7) for interrupting the mass flow of the rod-like articles (3), located in a lower portion (6B) of the hopper (6) and arranged to alternately open and close the mass flow of the rod-like articles (3) in order to fill the tray (10) with the rod-like articles (3),a lift (31) provided with a support element (32) for supporting the tray (10), the lift (31) being arranged to lower the tray (10) while filling the tray (10) with the rod-like articles (3),wherein the hopper (6) is arranged to cooperate with the tray (10) such that walls (10A, 10B) of the tray (10) at least partially encompass the lower portion (6B) of the hopper (6) during filling,characterised in thatthe loading station (4) does not comprise conveyors configured to transport trays (10) horizontally,and the loading station (4) comprises an industrial robot (9) having a gripper (12) arranged to transfer trays (10) between a storage location and the loading assembly (30),wherein the industrial robot (9) is arranged to:retrieve an empty tray (10) from the storage location,place the tray (10) directly on the support element (32) of the lift (31) beneath the hopper (6) in alignment with the hopper (6),position the tray (10) such that the walls (10A, 10B) of the tray (10) at least partially encompass the lower portion (6B) of the hopper (6),retrieve the filled tray (10) from the support element (32) of the lift (31), and transfer the filled tray (10) to the storage location.

2. The loading station (4) according to claim 1, wherein the hopper (6) comprises an upper portion (6A) in the form of a chamber arranged to receive the rod-like articles (3) from a conveyor (8) supplying the rod-like articles (3) in the form of a mass flow.

3. The loading station (4) according to claim 2, wherein the hopper (6) further comprises the lower portion (6B) in the form of channels through which the rod-like articles (3) move downward under the force of gravity.

4. The loading station (4) according to claim 2, wherein the hopper (6) further comprises a lower portion (17B) connected to the upper portion (17A) in the form of a downward-widening funnel through which the rod-like articles (3) move downward under gravity.

5. The loading station (4) according to any preceding claim, wherein the lift (31) lowers the tray (10) relative to the hopper (6) during filling.

6. The loading station (4) according to claim 5, wherein the tray (10) surrounds the lower portion (6B) of the hopper (6) during at least part of the filling process.P1437PC00 127. The loading station (4) according to any preceding claim, wherein the gripper (12) is arranged to grip one lateral wall (1 OA, 10B) of the tray (10).

8. The loading station (4) according to any preceding claim, wherein the gripper (12) is arranged to grip both lateral walls (10A, 10B) of the tray (10).

9. The loading station (4) according to any preceding claim, wherein the gripper (12) is arranged to grip one lateral wall (10A, 10B) and a bottom (10C) of the tray (10).

10. The loading station (4) according to any preceding claim, wherein the loading station (4) comprises two loading assemblies (30, 30').

11. The loading station (4) according to claim 10, wherein the industrial robot (9) alternately serves the two loading assemblies (30, 30').

12. The loading station (4) according to claim 11, wherein tray filling cycles of the loading assemblies (30, 30') are phase-shifted.

13. The loading station (4) according to claim 12, wherein while a tray (10) is being filled in a first loading assembly (30) the industrial robot (9) places a tray (10) in a second loading assembly (30').

14. The loading station (4) according to claim 12, wherein while a tray (10) is being filled in a first loading assembly (30) the industrial robot (9) retrieves a filled tray (10) from a second loading assembly (30').

15. A method of filling trays (10) with rod-like tobacco industry articles (3) in a loading station (4) according to any of claims 1-14.

16. The method according to claim 15, wherein the industrial robot (9) retrieves an empty tray (10) from a storage location and places the tray (10) on the support element (32) of the lift (31) beneath the hopper (6).

17. The method according to claim 16, wherein the tray (10) is positioned such that the walls (10A, 10B) of the tray (10) encompass the lower portion (6B) of the hopper (6).

18. The method according to claim 15 or 16, wherein the lift (31) lowers the tray (10) relative to the hopper (6) during filling.

19. The method according to claim 15, wherein the robot (9) retrieves a filled tray (10) after filling and transfers the tray (10) to the storage location.

20. The method according to claim 15, wherein the robot (9) alternately serves two loading assemblies (30, 30').

21. The method according to claim 20, wherein tray filling cycles of the loading assemblies (30, 30') are phase-shifted such that, while a tray (10) is being filled in a first loading assembly (30), a tray (10) is placed in a second loading assembly (30').

22. The method according to claim 20, wherein tray filling cycles of the loading assemblies (30, 30') are phase-shifted such that, while a tray (10) is being filled in a first loading assembly (30), a filled tray (10) is retrieved from a second loading assembly (30').

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