This application claims the priority of the corresponding German patent application Ser. No. 199 59 061.3 filed Dec. 8, 1999. The disclosure of the aforesaid priority application, as well as the disclosure of each and every US and/or foreign patent and/or patent application identified in the specification of the present application, is incorporated herein by reference.
The invention relates to improvements in methods of and apparatus for manipulating containers, and more particularly to improvements in methods of and in apparatus for manipulating containers of the type known as trays and often utilized for temporary storage of arrays or groups of rod-shaped articles such as plain or filter cigarettes, cigars, cigarillos, filter rod sections and other rod-shaped products of the tobacco processing industry.
Examples of rod-shaped articles which can be confined in containers (hereinafter called trays for short) of the type to which the present invention pertains are filter rod sections or filter mouthpieces which can be united with plain cigarettes, cigarillos, cigars or analogous rod-shaped tobacco-containing products to form therewith filter cigarettes, cigarillos, cigars or the like. Many types of filter mouthpieces contain a rod-like filler of acetate fibers and hardened droplets of a plasticizer which bonds portions of neighboring fibers to each other to thus establish a maze of paths for the flow of tobacco smoke from the lighted end, through the tobacco-containing part, through the filter mouthpiece and into the mouth of a smoker.
Heretofore known and presently utilized plasticizers (such as triacetin) for acetate fibers or the like require a certain period of time to set and to thus establish reliable bonds between neighboring portions of fibers in the mouthpiece of a filter cigarette or the like. Therefore, it is desirable to ensure that filter mouthpieces of unit length or multiple unit length which issue from a filter rod making machine remain unattached to plain cigarettes for certain intervals of time which are required by the plasticizer to set, i.e., which are needed to ensure that the appearance and/or other desirable characteristics of filter-tipped smokers"" products are not affected during transport of filter mouthpieces into and/or during their treatment in a so-called tipping machine wherein plain cigarettes and filter mouthpieces of unit length or multiple-unit length are connected to each other by so-called uniting bands (e.g., webs of cigarette paper, imitation cork or the like) to form therewith filter cigarettes or analogous rod-shaped smokers"" products.
Filter rod making machines which are of the type utilized for the making of continuous filter rods ready to be subdivided into filter rod sections of unit or multiple unit length are disclosed, for example, in U.S. Pat. No. 3,974,007 (granted Aug. 10, 1976 to Greve for xe2x80x9cMETHOD AND APPARATUS FOR THE PRODUCTION OF FILTER ROD SECTIONS OR THE LIKExe2x80x9d) and in commonly owned U.S. Pat. No. 4,412,505 (granted Nov. 1, 1983 to Haxc3xcsler et al. for xe2x80x9cAPPARATUS FOR APPLYING ATOMIZED LIQUID TO A RUNNING LAYER OF FILAMENTARY MATERIAL OR THE LIKExe2x80x9d).
Filter tipping machines which can be utilized to unite filter rod sections with plain cigarettes are known under the name MAX-S (distributed by the assignee of the present application). Reference may also be had to commonly owned U.S. Pat. No. 5,135,008 granted Aug. 4, 1992 to Oesterling et al. for xe2x80x9cMETHOD OF AND APPARATUS FOR MAKING FILTER CIGARETTESxe2x80x9d.
The apparatus of the present invention can be utilized to transport filter rod sections between a filter rod making machine (such as that disclosed by Greve or by Hxc3xa4usler et al.) and a filter tipping machine (such as that disclosed by Oesterling et al.). Certain presently known transporting apparatus of such character are disclosed in commonly owned U.S. Pat. No. 5,123,798 granted January 23, 1992 to Glxc3x6ssmann et al. for xe2x80x9cAPPARATUS FOR MANIPULATING TRAYS FOR CIGARETTES AND
THE LIKExe2x80x9d. One presently utilized embodiment of the patented apparatus is designed to manipulate cigarettes, and more specifically to accept the surplus of cigarettes advancing in the form of a mass flow from a cigarette maker to a processing machine (such as a tipping machine of the type disclosed in the patent to Oesterling et al.) and to admit cigarettes into the mass flow when the requirements of the processing machine exceed the output of the maker. Such apparatus employs trays which are filled with cigarettes when the output of the maker exceeds the requirements of the processing machine and which are emptied into the mass flow when the need arises. The just described apparatus employs storage facilities for filled trays at one or more first levels and storage facilities for empty or emptied trays at one or more second levels. A transfer unit is provided to transport trays between various levels and, when necessary, to change the orientation of the trays.
It is also known to employ pneumatic conveyor systems as a means for transporting filter rod sections from a filter rod maker to a filter tipping machine (such as the aforementioned MAX-S machine). As a. rule, a pneumatic conveyor employs a receiving station with magazines which contain supplies of filter rod sections and cooperate with pneumatic senders which propel filter rod sections to the magazine of a filter tipping machine. Such apparatus are rather complex, bulky and expensive because they must be provided with special feeders for admission of filter rod sections into the senders and with special transfer units which advance filter rod sections from the senders into the magazine(s) of one or more tipping machines. On their way from the maker to the magazine of a filter tipping machine, the filter rod sections are subjected to repeated mechanical stressing which is bound or apt to affect their quality if it takes place prematurely, i.e., before the various constituents and/or ingredients of the filter rod sections are ready to withstand such stressing.
An object of the present invention is to provide a novel and improved method of manipulating filled and empty receptacles (such as the aforediscussed trays) for groups of rod-shaped articles of the tobacco processing industry in such a way that filled trays remain intact for periods of time which are required to optimize the quality of their contents prior to admission into the next processing station.
Another object of the invention is to provide a method which can be resorted to with particular advantage in connection with the manipulation of trays for rod-shaped products of the type that require a certain minimum interval of time to xe2x80x9cripenxe2x80x9d or xe2x80x9cagexe2x80x9d starting with the instant of issuance from a maker and ending with the instant of admission into a processing machine or with the instant of undergoing mechanical stresses.
A further object of the invention is to provide a novel and improved method of manipulating filter mouthpieces for tobacco smoke between a filter rod making machine and a tipping machine wherein filter rod sections are united with plain cigarettes, cigars, cigarillos or the like to form therewith filter cigarettes, cigars or cigarillos of unit length or multiple unit length.
An additional object of the invention is to provide a method which renders it possible to optimally reconcile the need for adequate setting of certain hardenable substances in rod-shaped smokers"" products and the requirements of modern high-speed processing machines or production lines wherein the rod-shaped products undergo further treatment or treatments such as uniting with other types of rod-shaped commodities, packing in containers (such as so-called soft packs and hinged-lid packs for plain or filter cigarettes) and/or others.
Still another object of the invention is to provide an apparatus for the practice of the above outlined method.
A further object of the invention is to provide a compact and relatively simple but highly versatile apparatus for the manipulation of empty, filled and emptied trays for groups of rod-shaped articles, such as filter rod sections, on their way from one or more makers to one or more processing stations.
Another object of the invention is to provide an apparatus which can select the periods of dwell of certain types of smokers"" products in an economical time and space-saving manner.
An additional object of the present invention is to provide the apparatus with a novel and improved regulating system which renders it possible to prevent premature processing of rod-shaped articles while at the same time avoiding excessive periods of dwell of such articles prior to further processing.
One important feature of the present invention resides in the provision of a method of manipulating trays or analogous receptacles or containers (hereinafter called trays for short) for groups of rod-shaped articles, especially for stacks of parallel plain or filter cigarettes, cigars, cigarillos, filter rod sections or analogous smokers+ products. The improved method comprises the steps of filling successive empty trays at a filling station (e.g., at the discharge end of a filter rod making machine), transporting successive filled trays from the filling station to a predetermined storage facility (normally the first of two or more storage facilities for filled trays), monitoring the periods of dwell of filled trays at the predetermined facility (hereinafter called first facility for short), conveying filled trays from the first facility to a tray emptying or evacuating station (e.g., to the magazine of a filter tipping machine if the rod-shaped articles are filter rod sections or plain cigarettes), and regulating the timing of the conveying step as a function of the monitored periods of dwell of the filled trays at the first facility.
As a rule, the regulating step includes initiating the conveying of filled trays to the emptying station (either directly or through one or more additional storage facilities) when the respective monitored periods of dwell at least match a predetermined minimum period of dwell (e.g., a period of dwell which suffices to ensure that the aforediscussed plasticizer for acetate fibers of standard filter mouthpieces has set and/or that the adhesive for the overlapping seams of the tubular wrappers of filter mouthpieces can stand the treatment of filter mouthpieces in the tipping machine). The conveying step of such method preferably includes conveying filled trays from the first facility to the emptying station when the respective monitored periods of dwell at the first facility at least match the predetermined period of dwell.
The regulating step can include comparing the monitored periods of dwell with the predetermined minimum period of dwell and delaying the conveying step when the minimum period of dwell exceeds the monitored periods of dwell. The conveying step of such method can include advancing filled trays from the first facility to the emptying station along a first path when the respective monitored periods of dwell at least match the minimum period of dwell, and advancing filled trays along a longer second path when the minimum period of dwell exceeds the monitored periods of dwell.
The monitoring step can include establishing and assigning to each of the filled trays information denoting the time of entry into the first facility, and monitoring the assigned information on conveying of filled trays from the first facility to thus ascertain the periods of dwell of filled trays in the first facility.
The method can further comprise the steps of establishing a magazine for the delivery of filled trays received, for example, from the first facility to the emptying station within a predetermined interval of time, and the regulating step of such method can include ascertaining for each filled tray the sum of the respective monitored period of time and the predetermined interval; the conveying step of such method preferably includes advancing filled trays from the first facility directly into the magazine when the respective sums at least match the predetermined minimum period of time. Such method can further include the step of ascertaining for each filled tray the aforesaid predetermined interval of time; this further step can comprise establishing and assigning to each filled tray the information denoting the time of entry into the magazine, and monitoring the assigned information upon arrival of the respective filled tray at the emptying station to thus ascertain the predetermined interval of time.
The just described embodiment of the method can further comprise the step of advancing filled trays from the first facility to a second storage facility when the predetermined minimum period of dwell exceeds the respective sum. Such method can further comprise the step of advancing filled trays from a third storage facility to the magazine at the emptying station for at least some of the filled trays which are advanced from the first facility to the second facility. Still further, such method can include the steps of monitoring the periods of dwell of filled trays in the second facility, ascertaining for each filled tray at the second facility the sum total of the predetermined interval of time and the monitored periods of time at the first and second storage facilities, and conveying filled trays from the second facility to the magazine when the respective sums total at least match the predetermined maximum period of time. Each step of monitoring the period of dwell of a filled tray in the second storage facility can include establishing and assigning to each of the filled trays information denoting the time of entry into the second storage facility, and monitoring the assigned information on conveying the filled tray from the second facility to thus ascertain the period of dwell of the. filled tray at the second storage facility. Still further, such method can comprise the step of advancing filled trays from the second storage facility into a third storage facility upon ascertainment that the sum total of the predetermined interval of time and the respective monitored periods of time is less than the predetermined minimum interval or period of time.
The step of advancing filled trays from the second storage facility to the third storage facility can be carried out in automatic response to the ascertainment that the sum total of the predetermined interval of time and of the respective monitored periods of time is less than the aforementioned predetermined minimum period or interval of time.
Such method can further comprise the step of advancing filled trays from the second storage facility, along a preselected bypass route (e.g., by hand), and into the third storage facility upon completion of ascertainment that the sum total of the predetermined interval of time and the respective monitored periods of time is less than the predetermined minimum period of time.
The method can further comprise the steps of establishing a third storage facility for retention of each filled tray during a second interval of time, establishing for each filled tray in the second storage facility a second sum total of the second and predetermined intervals of time and the respective monitored periods of time, and conveying filled trays from the second storage facility directly into the third storage facility when the respective second sum total at least matches the predetermined minimum period of time.
The method can further comprise the steps of establishing a third storage facility for the retention of a filled trays during a second interval of timer establishing for each filled tray in the second storage facility a second sum total of the predetermined and second intervals of time and the respective monitored periods of time, and conveying filled trays from the second storage facility, along a time-consuming route, and into the third storage facility when the respective second sum total is less than the predetermined minimum period of time. Such method can further comprise the step of ascertaining the second interval of time for each filled tray in the third storage facility including establishing and assigning to each filled tray information denoting the time of entry of a filled tray into the third storage facility and monitoring the assigned information on conveying of the filled tray from the third storage facility to thus ascertain the second interval of time.
Another important feature of the invention resides in the provision of an apparatus for manipulating trays for groups of rod-shaped articles which constitute or form part of smokers"" products. The improved apparatus comprises a tray filling unit, a tray emptying or evacuating unit including a magazine for filled trays a source of empty trays, a predetermined (first) storage facility for filled trays, a first conveyor which includes means for feeding a succession of empty trays from the source to the filling unit, a second conveyor which includes means for feeding successive filled trays from the filling unit to the first storage facility, and means for transporting filled trays from the first facility to the emptying unit. The transporting means includes means for monitoring intervals of dwell of successive filled trays in the magazine and/or in the first storage facility, and means for transferring filled trays from the first storage facility to the emptying unit along a path which is one of a plurality of different paths and which is selected in dependency upon the lengths or durations of monitored intervals of dwell of filled trays in the first storage facility and/or in the magazine.
The apparatus preferably further comprises means for regulating the operation of the transferring means; such regulating means includes means for comparing the monitored intervals of dwell with a predetermined minimum period of time. Such apparatus can further comprise a second storage facility which is arranged to receive filled trays from the first facility by way of the transferring means and to deliver filled trays to the magazine by way of the transferring means when the predetermined minimum period of time exceeds the monitored intervals of dwell. Still further, such apparatus can comprise a third storage facility for filled trays; the transferring means of such apparatus is preferably arranged to deliver filled trays from the third facility to the magazine.
The just described embodiment of the improved apparatus can further comprise means for effecting transfer of filled trays between the second and third storage facilities. The second and third storage facilities can be said to jointly provide a depository for filled trays being supplied by the transferring means from the first storage facility to the second or to the third facility and from the second or third facility to the magazine.
The trays art or can be provided with identifying indicia, and the monitoring means preferably includes sensors which can identify the trays on the basis of such indicia.
The first storage facility is or can be disposed at a first level, and the magazine can be disposed at a different second level.
The improved apparatus preferably further comprises a suitable receiver for emptied trays; the source of empty trays and the receiver for emptied trays are or can be disposed at different first and second levels, and the magazine and the first storage facility are preferably disposed at different third and fourth levels The (first) difference between the first and second levels can equal or approximate the (second) difference between the third and fourth levels The transferring means of such apparatus preferably includes an elevator having first and second tray conveying receptacles which are respectively disposed at fifth and sixth levels; the difference between the fifth and sixth levels preferably equals or approximates the first and/or the second difference.
The improved apparatus can further comprise a second source of empty trays; such second source and the aforementioned second storage facility for filled trays can be disposed at different first and second levels, and the first storage facility and the first mentioned source of empty trays can be disposed at different third and fourth levels. The aforementioned elevator of the tray transferring means can be set up in such a way that its first and second tray conveying receptacles are respectively disposed at fifth and sixth levels which are selected in a manner such that the difference between the fifth and sixth levels equals or approximates the difference between the first and second levels and/or the difference between the third and fourth levels. Such selection of various levels renders it possible to further speed up and automate the transfer of empty trays to the filling station, the transfer of emptied trays from the emptying station, the transfer of filled trays from the filling station, and the introduction of filled trays into the first, second or third storage facility and from a selected one of such storage facilities into the magazine at the emptying or evacuating station.
The manner in which empty trays are filled with arrays of preferably parallel rod-shaped articles of the tobacco processing industry and in which such articles are evacuated from filled trays is well known in the relevant art and forms no part of the present invention.
The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The improved apparatus itself, however, both as to its construction and the modes of assembling, installing and operating the same, together with numerous additional important and advantageous features and attributes thereof, will be best understood upon perusal of the following detailed description of certain presently preferred specific embodiments with reference to the accompanying drawing.