WO2009106879A1

WO2009106879A1 - Loading machine

Info

Publication number: WO2009106879A1
Application number: PCT/GB2009/050175
Authority: WO
Inventors: Abol Panahi
Original assignee: Abol Panahi
Priority date: 2008-02-26
Filing date: 2009-02-22
Publication date: 2009-09-03
Also published as: GB0803432D0

Abstract

The invention relates to a device for loading any products into any positions in a Layout (18) of trays or containers, and able to add any pastes and or sauces to them. It comprises of an Infeed (0) conveyor that select the right products and transfer them to the Collator (2) via Guide (1) conveyor, where they are spaced correctly as the Lane (20) being loaded and then transferred to Dispenser (3) where they are positioned and loaded into the Lanes (20). Then the Dispenser (3) is placed over the next Lane (20) by means of Shifter (4) and hence loading the whole trays of the Layout (18).

Description

LOADING MACHINE

The invention refers to a Device for fully automated single or multiple placing of portions of the same or different products into any desired position within a rectangular area defined by strokes of the Device.

A brief explanation of the reference numbers used is given on page 7.

The Device could load any products into any trays in any Layout (18) of the trays or positions presented by a packaging system for example a Thermoformer or a tray Sealer, etc. These trays are often of a simple shape; for example Oval, Rectangular; and the like, to be loaded with a portion of a particular product. However, nowadays more complex Trays having subdivisions for rations of different products are becoming popular; For example, some Lunch Packs containing rations of Cheese, Ham, Biscuits and Dips, and in promotional cases such as "50% EXCTRA-FREE" or in the instances of packs containing various products like confectionary, the said products are all presented neatly in their own allotted compartments within the tray. The above-mentioned Device could easily load these trays with various products. The device is particularly suitable for loading ready-made foods like pasta or the like on top of a tomato-based paste or sauce which can again be topped with some sort of sauce or cheese or the like. Being capable of these tasks, the said device will save both time and space.

Some loaders presently available in the market can generally place identical type of product(s) into trays of same size, spaced evenly in a Layout (18) defined by the Die Set that forms the Trays. The said loaders basically consist of two conveyors placed at right angle to one another with one at right angle to the packaging machine; an arrangement that needlessly occupies invaluable floor space.

Other loaders have tried to place different products into different positions in a trey. These types generally use one conveyor and one hopper for each different product placed into the pack. The conveyor to carry the product and the hopper to put the product into required position. This method may be acceptable for dry and solid or countable products. The presentation and contamination and may not be satisfactory particularly in industries such as food industry. It also needs a lot space on the shop floor.

Some other loaders are even cruder and not able to easily load products into a different Layout of trays.

This loader, on the other hand, offers a Device whose drives and sequences are all controlled by a single controller; and meanwhile all of the said drives are but slaves, not requiring any special programming; and so the device's setting up is much easier. It is also user friendly as it guides the user(s) through the setup process and monitors the basic shape and size of products on the move, and warns the user if some unusual products are introduced. It is able to handle different products of different shapes and different sizes, via same route even within the same mode of operation with minimum contact to the device or its parts, and it can load a measured amount of any sauce or paste before and / or after the product is loaded.

It comprises of (see Fig 1 ) lnfeed Conveyor (0), a Guide Conveyor (1 ), a Collating Conveyor (2), a Dispenser (3) and a Shift Mechanism referred to as Shifter (4) (not shown) which linearly moves the Dispenser (3) in a direction (26) which is at a right angle to its convey direction (24) and positions it such that its centerline is exactly above that of a corresponding Lane (20) below. It also has at least a set of nozzles for loading a measured amount of any sauce in the trays (Fig 9). The lnfeed (0) conveyor, Guide (1 ) conveyor, Collator (2) and the dispenser (3) are linked together such that the flow path of product from supply conveyor (15) to the Dispenser (3) is not broken or interrupted at any time while the Dispenser (3) moves to different positions across the Lanes (20) of the packaging machine. The mechanisms and conveyors are arranged such that they can all be placed over the packaging machine (17) and hence save the valuable shop floor spaces.

The Device collects the products by the lnfeed Conveyor (0), transfers them to the Collator (2) via Guide Conveyor (1 ) where they are collated with correct spacing and after the entire products for the Lane (20) is collated, they are transferred to the Dispenser (3), where they are moved to their exact dispense positions, i.e. above the trays in the Lane (20) below, by the Dispenser (3), and then they will be stopped and dropped into their positions by retraction of the Dispenser (3). The shifter (4) then moves the dispenser (3) linearly across and positions it above the next lane (20) and hence it loads the whole layout

(18) of the trays. In cases where the rate of products is not (relatively) high, it is possible to pass the products directly to the Dispenser (3) and the Dispenser in turn (3) positions and dispenses each product independently, and hence it loads the whole Lane (20) of the Layout (18).

The lnfeed Conveyor (0), Guide Conveyor (1 ), Collator (2) and Dispenser (3) are all placed one after the other and end-to-end in the stated order. The lnfeed Conveyor (0), the Guide Conveyor (1 ) and the Collator (2) have their own independent sensors and drives and they could convey forward, stop or turn back at ease and apart from their Main task, they would act as multiple buffer conveyors, if the Dispenser (3) is busy and not ready to accept any more products; and in this way the buffer saves that extra fraction of second the Dispenser (3) may need to dispense the products into their proper locations.

The lnfeed Conveyor (0), Guide conveyor (1 ), Collator (2) and the Dispenser (3) are placed such that they convey in directions (21 ), (22), (23) and (24) respectively the Dispenser (3) is parallel to the Lanes (20) of the Layout (18) of the trays. The conveying belts of Collator (2) and Dispenser (3) are normally stationary, while the Dispenser (3) normally resides such that its centerline is exactly above the centerline of a particular Lane (20).

The lnfeed Conveyor's (0) Outlet (6) is pivoted about its roller and hence it selects the desired supply line for the needed products, by positioning its Inlet (5) in a way to align with the supplying conveyors (15) and to transfer the Right products to the Guide conveyor (1 ). See Fig2

Inlet (7) of the Guide Conveyor (1 ) is pivoting (13) and hence its Outlet (8) will move in a path in a horizontal plane, as and when the Shifter (4) moves the Dispenser (3) across the width of the Packaging Machine (17) - i.e. across the Rows (19) - since it is linked to the Collator (2) such that its conveying belts always stays in line.

The collator's (2) Outlet (10) is pivoted about its roller bearings and so the Inlet (9) can move up in a circular motion to reject a portion. The Collator (2) has a device to monitor its conveying belt's movements and additionally it has at least one sensor to detect the products as they approach, the said sensor(s) also serves as a rejecting-action synchronizer. Sensors are also used for calculating the width and length of the product and could be used as Datum sensor. The Collator's (2) conveying Belt has a closed-Loop Control.

In an embodiment of the device The Dispenser (3) is basically a Conveying Belt/ Belts (See Fig 2) placed either at the same level as the collator's conveyor as shown or low enough to be able to be displaced under the Collator (2) (not shown). It is able to displace either or both of its end-rollers (11 ) and (12) by means of a drive; with the top portion of its conveying belts stationary relative to the ground. It can dispense the products by either moving both ends (11 ) and (12) in the conveying direction (24) or opposite to it; Additionally it can simultaneously move the top portion of belt with the same speed in the opposite direction in order to keep the product stationary; As well, it can also displace one end of the conveyor [i.e., end (11 ) or end (12)] in or counter to its conveying direction (24), towards the product, with top portion of belt stationary, relative to ground, hence removing the support from base of the products while the belt is maintaining its tension.

Any device with a retracting belt (end less or open ended belt) would be suitable, although the drive for its conveying Belt should be responsive because the belt has to start and stop rapidly and repeatedly; for example any reasonable three-phase ac motor with frequency inverter or a Stepper motor or a brushed DC motor would be suitable. The Master Controller controls the movement of the belt. The position of the roller at its Retracting end (12) or (11 ) and hence the belt tensioning could be achieved by pneumatics and/ or electric or any other means; although an electric drive would be preferable as it could be done under a closed-loop control. The Dispenser (3) normally resides at its fully stretched position above and along a Lane (20) of the Layout (18) parallel to the direction of the advance of the packs (27) in the packaging Machine (17), but it retracts fully back with its top portion of belt stationary relative to the ground in order to dispense the Collated products onto the Lane (20) of trays below.

In a further embodiment of the device the Dispenser's Inlet (11 ) and Outlet (12) ends are not displaceable and dispensing action is performed by the moving the conveying belt with a sudden snapping action in a direction (25) at right angle to its convey direction (24), i.e. acting as a trapdoor (see fig 6), the acceleration time of the belt should be as low as possible and the speed of belt retraction should be as high as possible to minimize the disturbance to the product.

In a further embodiment of the device the Retractor (3) has two adjacent conveying belts (28) and (30) placed such that their adjacent edges form the centerline (29) of the Retractor (3), which coincides, with that of the Collator (2), see fig 7. In which case to dispense the product (16), Left Half (28) and Right Half (30) of the conveying belts retract simultaneously in Direction (25) away from the centerline (29) with fast and identical speeds and accelerations, making the two belts reduce the required retracting speed, as well as belts (28) and (30), acceleration, because their disturbing effect on the base of the product (16) is equal and in opposite direction they cancel each other out.

In a further embodiment of the invention the Dispenser (3) is comprised of one or more open-ended belts placed under the Collator (2), (See fig3), with one side protruding from the Front-End (31 ). It has a fixed end (33) and a displaceable end (34). Belt is folded over a retractable support edge (32) being properly tensioned. When products are being transferred from collator, its Front-End (31 ) protrudes out with a speed and direction (24) (by means of a linear drive (3D) such as a pneumatic cylinder or lead screw and nut, see fig (16)) which is synchronized with that of the collator's (2) belt, collecting the collation from the collator (2) and positioning the products over the trays in the Lane (20) below and stops; then, the supporting edge (32) retracts from its normal position (by means of a drive) toward the fixed edge (33) removing the support from base of the products; the displaceable end (34) of belt pulls itself, and in effect, it peels off the belt from base of the products, dispensing the latter into their positions. Once the products are dispensed, the supporting edge (32), and the displaceable end (34) of the belt and the Front-End (31 ) of the belt all move to their original positions, waiting for new products. When more belts are used, the belts are either identical or the mirror image of one another, and their retracting edges are parallel and almost touching, but the way it operates is same as one with a single belt, described above. See Fig 8. It can be placed such that the movement of its retracting edge/s (32) virtually is at any angle in a given horizontal plane - but preferably, at a right angle to the convey direction (24) of the belt, When it is placed such that the direction of retract (25) of the support edge (32) and displaceable edge (34) are in line with the conveying direction (24) of the collator (2), then having end (33) also displaceable, enables the belt to convey the products as well.

In a further preferred embodiment of the invention the Dispenser (3) is a protruding table, placed under the collator (2) with its Front End (31 ) just protruding out. (See fig 4) It is comprised of two or more displaceable table-halves (28) and (30) placed in a plane with adjacent edges having straight or jigged lines, placed symmetrically about the Center line (29) of the table such that they form a platform to accommodate the products. The table-halves are placed in a linear slide system such that the table- halves would slide in it in direction (25) and hence form a pair of trapdoors. The table protrudes out by a drive in direction (24) (by means of a linear drive (3D) such as a pneumatic cylinder or lead screw and nut, see fig (16)) having a speed synchronized with that of the Collator (2) as products reach it and hence it positions the products as desired without disturbing the products spacing. To unload the products, the table-halves move in direction (25) away from centerline of the table with a fast speed snapping them off the base of the products without disturbing the products. Having two table-halves (28) and (30) helps the unloading, as it tends to cancel out the dragging effect of tabletop to base of the products, however a system with only one sliding trapdoor, with negligible disturbance to the products is possible if the retracting speed is high enough. Device has at least one set of nozzles (35) fixed to the Dispenser (3) such that there is one nozzle for every Rows (19) and the said nozzles are spaced so that they would cross all the trays of the Layout (18) when shifter moves the Dispenser (3) from one extreme to the other and hence they could dispense a measured quantity of sauce, paste and the like, into trays before and/or after other products are being loaded into the tray(s). Fig 9 Further It has a sensor, e.g., a photocell or the like (NOT SHOWN) on its front-end looking down and moved by dispenser's (3) conveying system and shifter (4) and hence it scans its loading area in order to get a map of the layout (18) i.e. the positions and sizes of trays.

In a further embodiment of the invention, the Collator (2) and dispenser (3) have their own independent Shift Mechanism enabling one or more Lanes (20) and/or Rows (19) to be paced with every Retracting actions.

At the startup, (see fig2) the lnfeed Conveyor (0) and the Guide conveyor (1 ) belts start running, and the Shifter (4) (not shown) moves the Collator (2) as well as the Dispenser (3) assembly linearly across the width of the Layout of trays (18) in direction (26) right angle to Lanes (20) and positions the Dispenser such that the belt of the collator (2) is directly above the first Lane (20) of the Layout of trays i.e. the first one at the edge of the Layout (18) of trays.

In case of complex trays the Device treats all sub-compartments of a tray as a collection of simple trays and sets the number and centers of Lanes (20) and Rows (19) accordingly, see fig 13A, 13B and 13C. For example, Fig13A shows a Layout (18) having 6 trays arranged in two Lanes (20) by three Rows (19), each tray having two compartments for two different products P1 and P2 as shown, But the Program treats the Layout (18) as having 4 Lanes (20) and 3 Rows (19) as shown. R1 , R2... point to the centerline of Rows (19) of the Layout (18) and L1 , L2... point to the centerline of Lanes (20) of the Layout (18). Fig 13B and Fig 13C shows other examples of how the program treats the complex trays in the Layout (18). To load the trays with different products P1 , P2... etc, the lnfeed (0) conveyor aligns its Inlet (5) with a supply (15) conveyor, collects the right number of products and then moves its Inlet to the next supply conveyor and repeats the above process. For example, in order to collect products for the Layout (18) shown in Fig 13A, the said conveyor align itself with supply (15) conveyor of product P1 , collect 3 products (see Fig13) and then moves to P2 supply (15) conveyor and collects 3 product and repeats the above process until all the product for the Layout (18) are collected; i.e., the numbers and orders of products for the Layout (18) in Fig 13A are: 3 x P1 , 3 x P2, 3 x P1 and 3 x P2. Similarly numbers and orders for the Layout (18) in Fig 13B are: P1 , P3, P1 , P3, 4 x P2, P1 , P3, P1 and P3 and similarly for Fig 13c are: 2 x P2, 2 x P1 , 4 x P3, 2 x P1 and 2 x P2.

In Fig 11 , a Layout (18) of 2 trays each with 2 compartments (need) to be loaded with product P1 , as shown. In Fig 11A the sequences to load one Lane (20) of this Layout (18), are shown in eleven sketches, S1 to S11. Sketch S1 shows products being conveyed to lnfeed (0) and Guide (1 ) conveyors toward the Collator (2) which has one product P1 on it and waiting with its conveying belt Stationary, for more Products and the Dispenser is empty. At S2, next product has reached the Collator (2) and Collator

(2) is conveying as well with the same speed as the Guide (1 ) conveyor. Sketch 3 shows the Collator (2) with two products on it and again waiting for the next product, but notice that now the second product is waiting a bit further down the line. This is the gap between the product 2 and product 3; S4 shows the third product entering the collator (2) and S5 shows the third product positioned, the collator (2) stopped and waiting again. Sketch 6 shows the forth product positioned and the whole collation is being transported towards the Dispenser (3) and S7 shows them being transferred to the Dispenser (3), at S8, product is completely on the Dispenser, being positioned for loading into the Lane (20) below, and the Collator (2) can Collate the new batch of products again. While the Collator (2) is transferring the collation to the Dispenser (3), it cannot collate, and therefore the Guide (1 ) conveyor will slow down in order to give the collation adequate time to clear the Collator (2), In other words, the Guide (1 ) conveyor acts as a Buffer. The collator's delayed action enables it to handle products with random spacing. At sketch S9, products are positioned over the Lane (20), S10 shows the Dispenser (3), in retracted position, dispensing the products into their proper positions. At S11 the Dispensing is complete and the Dispenser

(3) is ready to receive the next batch. As soon as the Dispenser (3) is finished with its task, the Shifter moves the Dispenser to the next Lane (20) and the sequence is repeated. Fig 15 shows the paths of products while the dispenser (3) is loading 3 different Lanes (20).

Portions of products to be loaded into the trays are presented to the lnfeed Conveyor (0) by their conveyors (15). The rate(s) or gaps between the presented products do not need to be consistent, because the collator (2) spaces them exactly as required. The lnfeed Conveyor's (0) Inlet (5) is aligned with the required supply belt and hence the product is collected and transferred to the Guide conveyor (1 ) and on to Collator's sensor. If the Collator (2) is not ready to receive any more products at this moment, its Inlet (9) will move up in order to let the said products drop into a Reject bin or a Reject conveyor below; the sensor(s) also calculates the length and width of the products.

The Collator's (2) belt is normally stationary but it moves for a specified distance every time it gets a signal from its sensor and then it stops again waiting for next product. This distance is related to the distance between the positions of the two consecutive trays in the Lane (20) below. It repeats above process when the next portion of the product arrives, and hence it collates the products on it, spaced exactly as required. Once the last product for the Lane (20) of the Layout (18) is collated, the belt transfers the row of the collated products to the dispenser (3) when the product reaches the Dispenser's (3) conveying belts/ tables, belt / table will start conveying the product with same speed as collator (2), then dispenser (3) moves the collation to a position exactly above the trays in the Lane (20) down below, then it will stop and unloads the products into the trays down below.

The position of the products on the dispenser (3) can be calculated by various methods:

A: use a sensor of any conveyors as a Datum and then track the position of products by monitoring movements of conveying belts. For example, if we take the position of the collator's (2) sensor as the Datum, then when the product reaches the sensor we know how far it has to go to reach the dispense position, and therefore, by monitoring the movements of the belts, both Collator's (2) and the Dispenser's (3), we can calculate the position of the product, and in this way to position it in any desired position. It is preferable, however, to use the Dispenser's (3) sensor as datum for reasons of simplicity.

B: by means of an analogue non-contact distance-measuring sensor (such as ultra sonic, Laser, etc) looking directly at the product on the belt.

C: open-loop control by directly controlling a stepper motor via the Controller; assuming the stepper does not encounter any errors.

D: open loop-control by taking into account the belt's speed and time duration of product conveying.

The Speed of the retracing ought to be as fast as possible as the Dispenser (3) must finish dispensing the products and be back just in time to accept more products before the next collation of products arrives. Otherwise, the Collator (2) will be forced to reject packs; and in the case of handling different products, the said collator may even be forced to reject all the packs on the lnfeed Conveyor (0) and the Guide conveyor (1 ) as well to be able to get back into the sequence again. This will greatly increase the cycle time of the machine and cause unwanted nuisance.

The collating also can be done by the Dispenser (3) where as the product gets to the Dispenser (3) it moves a distant equal to pack spacing and then stops and waits for the next product and hence collates all the products for a lane at correct spacing and then moves the whole collation of the products to a position over the trays in the lane below and dispenses them into their positions. Here again the Datum sensor can be either of Collator (2), Dispenser's (3) sensors or the non-contact distance transducer looking directly at the products on the dispenser (3). The Collating on Dispenser (3) would be less prone to error but it could cause cycle time to increase as the Dispenser (3) has got to be able to work at least four times as fast.

In less critical cases the positioning can be done by Open-Loop control using a Stepper Motor assuming the motor completes its steps with no Errors, selecting the right stepper; this assumption is reasonable and the errors are minute. And in more tolerant cases where the tray sizes are fairly large compared to the length of the products, Stopping of the Dispenser (3) belt could even be done on a time delay basis, when the speed of the belt is known and the drive is responsive.

The above process is repeated for different products by selecting the required supply conveyor in sequence. In multiple placing modes, the process of loading is repeated as dictated by the mode.

Once the products have been dispensed into a Lane (20) of the Layout (18) then the Shifter (4) moves the Dispenser (3), linearly to a new position placing the Dispenser (3) above the next Lane (20) of the Layout (18). While Dispenser (3) is moving to its new position, it can still accept products, since the Dispenser (3), Collator (2) and the Outlet (8) of the Guide conveyor (1 ) are all linked and move together and hence the process of collating can continue continuously.

Collator (2) and Dispenser (3) repeat the above process and hence load the packs of the new Lane (20). In the same way, if different products need to be loaded into any position the lnfeed Conveyor (0) selects the appropriate supply conveyor (15) of the product and the above process is repeated. The timing of supply conveyor selection is coordinated with collator's (2) action, enabling the products reach to both the collator (2) and Dispenser (3) in time.

Once the last row of the collated Products for the Layout (18) is loaded into the last Lane (20) of the Layout (18). It signals when the loading of products into the Layout (18) is complete and then the sequence starts all over again by either the Dispenser (3) moving back to the first Lane (20), Loading lane 1 , 2, ... successively, or by loading the lanes in reverse order. Hence, the combined action of the lnfeed conveyor (0), Collator (2), Dispenser (3) and the shifter (4) enables the device to place any products and/or sauces in any position within the pattern of a complex tray within the Layout (18). It will keep on loading the Machine (17) unless it receives a signal to indicate the Packaging Machine is not ready.

All data for a particular or various mode(s) of operation, could be set or selected by one or more of the followings remotely controlled devices, e.g., via an HMI, a Switch or a Sensor. The Device can scan the area to be loaded and gets a map of the layout of the Layout; i.e. the number of lanes and rows, the pack sizes and spacing, and details of the pack patterns. It could (also) measure the length and width of the products and warn the user if sizes of products and packs do not match - this could be helpful if data entered in the setup was not correct or when wrong mode of operation was accidentally selected, etc; All the users data and the settings like the rates, and the mode of operations, pack sizes, pack coordinates within the Layout, speeds of the belts etc. are readily available to the user to change if need be. All these changes and alterations are automatically saved for that Particular Mode for that Particular Products but the user could select to restore the previous settings if necessary.

In a preferred embodiment of the device the Dispenser (3) is also a Collator (2), i.e. it collates the products, then positions them over their corresponding trays and then loads them into the trays, i.e. the Dispenser (3) does all three tasks of spacing the products, positioning them above the products' corresponding trays and unloading the products into the trays. Dispenser (3) has at least one set of nozzles (35) fixed to it such that there is one nozzle for every Rows (19) and the said nozzles are spaced so that they would cross all the trays of the Layout (18) when shifter moves the Dispenser (3) from one extreme to the other and hence they could dispense a measured quantity of sauce, paste and the like, into trays before and/or after other products are being loaded into the tray(s).

It is also permissible to have the Device placed such that its Dispenser (3) is parallel to the Rows (19) of the Layout (18), i.e. perpendicular to Lanes (20) or in forward movement towards the Packaging Machine (27).

In a further embodiment of the device, it comprises of one or more independent dispensers (3) and shift mechanisms NOT linked to the Collator (2) and /or Guide conveyor (1 ), collecting the products from Collator (2) in turn or otherwise and dispensing them into their (proper) positions. In this case, guide conveyor (1 ) could have its own mechanism to displace its Outlet (8). In a further embodiment of the device, the Dispenser (3) is as wide as the width of the tray Layout (18). Since the said dispenser also collates the products, it does not require any shift mechanism or a collator (2); yet, it can collect and collate the products directly from the Guide conveyor (1 ), which is placed at a height, low enough to get relocated to the space below the Guide conveyor (1 ). In this configuration, the shifter (4) moves the Guide (1 ) conveyor's Outlet (8) across the width of the Layout (18). The products are collated by collating successive Rows (19) of the Layout (18) one after the other until the Whole collation for the Layout (18) is formed. The collation of one Row is done as follows: As the product reaches the Dispenser's (3) belt, the belt starts moving synchronized with belt speed of the Guide (1 ) conveyor, thus collecting the first product for the first Row (19). As soon a product is off the Guide (1 ) conveyor, the Shifter (4) moves the Outlet (8) of Guide (1 ) conveyor one tray width to place the next product above the next Lane (20) In other words, the Shifter (4) moves the Guide (1 ) conveyor such that the Midpoint of its Outlet (8) is above the centerline of a Lane (20) of the Layout (18) and simultaneously, the conveying belt of the Dispenser (3) moves back exactly to same distance in order that the next product can be placed in line with the first one, and then the process is repeated until all products for the Row (19) have been collated, then the Conveying belt of the Dispenser (3) does NOT move back, rather it moves forward such that the next product arriving at the Dispenser (3) would lag behind the first row distancing evenly from the successive trays of the Lane (20) it is loading and then the second Row (19) is collated and hence the whole collation for the Layout (18) is formed, before being positioned and dispensed into the trays of the Layout (18). See Fig 14

Here is a brief introduction to Reference numbers used in drawings and what they refer to is given. Fig 2

(0): is the lnfeed conveyor, it could place its Inlet (5) in any desired position by moving in a vertical and/or a horizontal path.

(1 ): is the Guide conveyor, it is pivoted at its Inlet (7) about point (13) and hence its Outlet (8) could move in direction (14).

(2): is the Collating conveyor, it is pivoted about its Outlet (10) such that its Inlet (9) can move up and down and it has a closed loop control for its Conveyor belt's Motion and Speed.

(3): is the Dispensing mechanism

(3F): is the frame of Dispenser (3)

(3D): is the drive that moves frame of Dispenser (3F) in or opposite to convey direction (23) of collator (2)

(4): is the Shifter, the mechanism for moving Dispenser (3) and/or Collator (2) laterally, i.e. a direction at right angle to convey direction of Collator (2)

(5): Inlet edge of the lnfeed (0) conveyor (6): Outlet edge of the lnfeed (0) conveyor (7): Inlet edge of the Guide (1 ) conveyor (8): Outlet edge of the Guide (1 ) conveyor (9): Inlet edge of the Collating (2) conveyor (10): Outlet edge of the Collating (2) conveyor (11 ): Inlet edge of the Dispensing (3) conveyor (12): Outlet edge of the Dispensing (3) conveyor (13): Center of swing of the Guide (1 ) conveyor

(14): Direction of swing of the Guide (1 ) conveyor, the double arrowheads indicating the to and fro movements.

(15): a selection of conveyors supplying different products to the lnfeed (0) conveyor. (16): a portion of a particular product. (17): packaging machine. Fig 12

(18): Layout of the trays. It is referred to number trays equally spaced in rows and columns in a given rectangular area, this is presented with every clocked advance of the packaging machine (17), in fig 12 three successive Layouts presented with three advances are shown.

(19): Row, is referred to a set of adjacent packs at right angle to a Lane (20). (20): Lane is referred to packs, which are in Line of motion of the packs (27), Fig 2 (21 ): is the arrowhead indicating the convey direction of the lnfeed (0) conveyor. (22): is the arrowhead indicating the convey direction of the Guide (1 ) conveyor. (23): is the arrowhead indicating the convey direction of the Collating (2) conveyor.

(24): is the arrowhead indicating the convey direction of the Dispensing (3) conveyor. This may be either direction of movement of belt or the frame of the dispenser. For example in Fig (1 ) conveying of products on dispenser is done by means of movement of BELT of the dispenser whereas in figure (4) the conveying of product is done by means of movement Frame of the dispenser.

(25): shows the retract direction of the Dispensing (3) conveyor. The double arrowheads indicates reciprocating retract movements the larger arrowhead stresses the importance of high speed.

(26): shows the side shift (lateral) direction of the Dispenser (3) frame, i.e. the direction and path the Dispenser (3) follows, as it is being moved across from over one Lane (20) to another by the Shifter. The double arrowheads indicate to and fro movements.

(27): is the direction of advance of the trays in the packaging machine. Fig 4

(28): is the Left hand side conveying Table or Belt

(29): is the front end of conveying Table or Belt (Fig 3 )

(30): is the displaceable support edge for the belt.

(31 ): is the fixed end of the belt.

(32): is the displaceable end of the belt.

(35): is a set of Nozzles on the dispenser (3) frame for loading some sauce or pastes into trays. Fig 9

In Fig 13 (P1 , P2, P3...): represent 3 products of DIFFERENT types, P1 , P2 and P3 each may consist of more than one product. (R1 , R2, R3...): show the mid points of the Rows (19) of the Layout (18) (L1 , L2, L3...): show the midpoints of the Lanes (20) of the Layout (18)

Claims

1 : A Device and method for placing portions of products into defined tray locations in a rectangular area, comprising of an lnfeed (0) conveyor, selecting products from one or more supply conveyors (15) and a guide conveyor (1 ) transferring product from the infeed conveyor to a collator (2) Characterised in that it will space the products into desired arrangements and then transfer the said arranged products onto a dispenser (3), the dispenser being movable, to a location where the products are held above their corresponding tray locations and operable to unload the product into said locations, the device further comprising at least one set of nozzles for the dispensing of sauces or the like, and also by means of a sensor it scans and gets a map of the layout (18) and all this by one central controller.

2: A device according to claim 1 , wherein Infeed Conveyor's (0) has an inlet (5) Characterised in that it is movable in a vertical and/or a horizontal plane to any required position to select product s from one or more supply conveyor.

3: A device according to claimi , wherein Guide conveyor (1 ) has a sensor for detecting products Characterised in that it is pivoted about a point at infeed end (13) and swings such that its Inlet (7) always stays inline with the Infeed conveyor's (0) Outlet (6) and its Outlet (8) always follows a desired position on 1 Collator's (2) Inlet (9), it transfers the products to the Collator (2) conveyor.

4: A device according to claim 1 , wherein Collator (2) comprising a conveyor, and at least one sensor and a drive whose speed is fully adjustable characterised in that it can space a number of products into any desired arrangements.

5: A device according to claimi , wherein Collator (2) is pivoted about its Outlet (10) Characterised in that it's Inlet (9) could move Up or down to reject a portion of product.

6: A device according to claimi , wherein the Collator's (2) belt Characterised in that it is normally stationary but moves as desired by the controller.

7: A device according to claimi , Characterised in that the Collator's (2) and Dispenser's (3) belts/tables are normally stationary but move with desired speed and direction controlled by the controller.

8: A device according to claim 1 , wherein Dispenser (3) Characterised in that it can collate the products with exact desired spacing between them and hence dispense with the Collator (2).

9: A device according to claim 1 , wherein the Collator (2) characterised in that it has a belt as wide as width of the layout (18) and not movable laterally and placed low enough under the Guide conveyor (1 ), which is movable laterally.

10: A device according to claim9, wherein the Collator (2) characterised in that it collates the whole layout (18) of products by moving its belt to and fro while the guide (1 ) conveyor coordinately supplies the products. (See fig 14)

11 : A device according to claim 1 , wherein the dispenser (3) characterised in that it has a belt as wide as width of the layout (18) and not movable laterally and placed low enough under the Guide conveyor (1 ) which is movable laterally.

12: A device according to claim11 , wherein the Dispenser (3) characterised in that it collates the whole layout (18) of products by moving its belt to and fro while the guide (1 ) conveyor coordinately supplies the products. (See fig 14)

13: A device according to claim 1 , wherein Dispenser (3) is conveyor/conveyors, Characterised in that it conveys with same speed and direction (24) as the collator's (2) belt (23), while receiving portions of products from Collator (2). Fig 7 14: A device according to claimi , wherein Dispenser (3) is comprised of open-ended belts, Characterised in that it conveys products by means of a linear drive (3D). See Fig 8 and Fig 16

15: A device according to claim 1 , wherein Dispenser (3) Characterised in that when product reaches it then it conveys products with same speed and direction as collator's (2) belt and places the collated products above their desired positions.

16: A device according to claim 1 , wherein Dispenser (3) is comprised of two or more displaceable table halves (28) and (30) placed symmetrically about the centerline (29) of the table Characterised in that they form a platform to accommodate the products.

17: A device according to claim 16, wherein Dispenser (3) Characterised in that the table protrudes to and fro by means of a linear drive (3D) in direction (24), which is in same or counter to convey direction (23) of belt of the Collator (2). See Fig 4 and Fig 16

18: A device according to claim 17, wherein Dispenser (3) Characterised in that it conveys products with same speed and direction (24) as the collator's (2) belt (23), when portions of products being transferred to it by the Collator (2). See Fig 4 and Fig 16

19: A device according to claimi , wherein Dispenser (3) Characterised in that it unloads the products by moving both ends of conveyor (11 ) and (12) (as if they were joined) in a path joining them such that one moves towards product, and the top portion of belt in opposite direction (25), with same speed and hence removing support from base of the products, keeping the product stationary.

20: A device according to claimi , wherein Dispenser (3) Characterised in that unloads the products by displacing one end of the conveyor (i.e. (11 ) or (12)) and corresponding portion of belt towards the product such that the top portion of belt stays stationary relative to ground (i.e. bottom portion of belt moves twice as fast), hence removing the support from base of the products with the belt maintaining its tension.

21 : A device according to claimi , wherein Dispenser (3) Characterised in that it unloads the products by retracting the supporting edge (32) from its normal position toward the fixed edge (33) removing the support from base of the products and also moves the displaceable end (34) in same direction as the supporting edge (32) but twice as fast and in effect peels off the belt from base of the product and hence the products are dispensed into their positions. See Fig 3

22: A device according to claimi , wherein Dispenser (3) Characterised in that it unloads the products; by displacing the two belts/tables halves (28) and (30) move in opposite lateral direction (25) away from centerline (29) of the table with a fast speed, slipping them off the base of the products the disturbing effects of two halves on products will be roughly equal but opposite and therefore cancels out. See Fig 4

23: A device according to claimi , wherein Dispenser (3) characterised in that it positions and dispenses each product independently and hence loads the whole Lane (20) of the Layout (18).

24: A device according to claimi , wherein Dispenser (3) characterised in that it has at least one set of Nozzles (35) which with means of a pump would load a measured amount of one or more types of sauces or the like into the trays, while the dispenser is stationary or moving to a new position, as desired.

25: A device according to claimi , wherein shifter (4) Characterised in that it can moves the dispenser (3) in lateral direction (26), which is at right angle to convey direction (24) of the collator (2) and place it in any desired position within its stroke.

26: Device according to claimi , Characterised in that it can by means of at least one sensor mounted on front-end (31 ) of dispenser (3) and looking downwards and moved by means of dispenser (3) and shifter (4) scans and gets a map of the Layout (18) when desired. 27: Method according to claim 1 , Characterised in that the controller it can fully monitor and control position and movements of the infeed (1 ), guide (2), collator (3) and shifter (4) and all other devices connected to it.

28: Method according to claim 1 , Characterised in that the controller it makes all slaves complete their tasks independently and then controller decides how to utilize the results.

29: Method according to claim 1 , Characterised in that the controller can fully monitor and control position and movements of the infeed (1 ), guide (2), collator (3) and shifter (4).

30: Method according to claim 1 , Characterised in that Infeed (0), Guide (1 ) and Collator (2) Conveyors, each have at least one sensor and can move forward, reverse or stop at will, and hence act as Buffers for products.

31 : Method according to claim 1 , Characterised in that the Collator (2) collates portions of products by moving a portion for a desired distance and then stops and wait for next portion and hence spacing them exactly as desired.

32: Method according to claim 1 , Characterised in that collator's (2) and/or Dispenser (3) sensor/s can measure length and width of the products.

33: Method according to claim 1 , Characterised in that the position of the products on the dispenser (3) can be calculated by the use of a sensor of any conveyors as the Datum sensor and then track the position of products by monitoring movements of conveying belts conveying the products from sensor to its dispense position.

34: Method according to claim 1 , Characterised in that the position of the products on the dispenser (3) can be calculated by means of an analogue non-contact distance measuring sensor (such as ultra sonic, Laser, etc) looking directly at the product on the belt.

35: Method according to claim 1 , Characterised in that the position of the products on the dispenser (3) can be estimated by, directly controlling a stepper motor via the Controller and assuming the stepper has completed all the step pulses without any errors.

36: Method according to claim 1 , Characterised in that the position of the products on the dispenser (3) can be estimated by, multiplying the speed that the belt is running at and the length of time it has been conveying the product.

37: A system according to claimi , Characterised in that the device can be placed such that its dispenser (3) is at right angle to the lanes (20)

38: A system according to claim 1 , Characterized in that the device having a plurality of independent Dispensers (3).

39: A system according to claim 1 , Characterized in that the device having a plurality of independent Collators (2).

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