Surge control method and apparatus

A method of surge control for products being transported via a moving conveyor belt means between two production areas, said method comprising:

• providing an accumulator device alongside the conveyor belt means intermediate the two production areas so that one of such areas is upstream of the accumulator device and the other production area is downstream of such device, such device being capable of controllably removing products from the conveyor belt means if there is a back-up of products being fed to the downstream production area;
• selectively holding back products emerging from the downstream end of the accumulator device so as to maintain a predetermined distance gap between adjacent products moving towards the downstream production area;
• and
• controllably removing products from the conveyor belt means with the accumulator device if a predetermined queue of products develops within the accumulator device before the predetermined distance gap occurs between products emerging from the accumulator device;
• wherein
• said accumulator device includes a generally vertical conveyor mechanism with a plurality of spaced, outwardly extending veins thereon for the accumulation of products between adjacent such veins, said removing step includes indexing such vertical conveyor mechanism so as to remove from the conveyor belt means a line of products queued within the accumulator device, and said predetermined queue comprises a slug of products extending along the length of the entire vertical conveyor mechanism;
• and
• wherein said accumulator device further includes a movable transfer plate operatively situated relative the conveyor belt means and the distal ends of the accumulator device outwardly extending veins, and wherein the position of the movable transfer plate is controlled during the removing of products from the conveyor belt means so as to prevent the occurrence of lateral shear points for such products as they are so removed.

A method of surge control for products being transported via a moving conveyor belt means between two production areas, said method comprising:

• providing an accumulator device alongside the conveyor belt means intermediate the two production areas so that one of such areas is upstream of the accumulator device and the other production area is downstream of such device, such device being capable of controllably removing products from the conveyor belt means if there is a back-up of products being fed to the downstream production area;
• selectively holding back products emerging from the downstream end of the accumulator device so as to maintain a predetermined distance gap between adjacent products moving towards the downstream production area;
• and
• controllably removing products from the conveyor belt means with the accumulator device if a predetermined queue of products develops within the accumulator device before the predetermined distance gap occurs between products emerging from the accumulator device;
• wherein
• said accumulator device includes a generally vertical conveyor mechanism with a plurality of spaced, outwardly extending veins thereon for the accumulation of products between adjacent such veins, said removing step includes indexing such vertical conveyor mechanism so as to remove from the conveyor belt means a line of products queued within the accumulator device, and said predetermined queue comprises a slug of products extending along the length of the entire vertical conveyor mechanism;
• wherein said accumulator device further includes a locator mechanism, relatively just downstream from the downstream edges of the plurality of outwardly extending veins, and against which products queued within the accumulator device are permitted to shift relatively downstream during the removing step, whereby a product shear point is prevented at the downstream edges of the veins during the removing step.

A method of operating an accumulator device generally of the type having a vertically-oriented conveyor with a plurality of spaced, outwardly extending veins for accumulating products therebetween, with indexing of such conveyor in selected directions resulting alternatively in removal or return of products relative a carrying surface of a production line, said method including:

• positioning the accumulator device adjacent a production line of products such that given extending veins may be situated in a null position for the passage of products therethrough with such veins acting as guide rails;
• providing a movable transfer plate generally opposite the distal edges of the extending veins in the vicinity of the production line, and having a transfer edge situated generally laterally from the carrying surface of the production line;
• and
• alternately lowering the transfer edge beneath the production line carrying surface whenever indexing the vertically-oriented conveyor for removing products from the production line, and raising the transfer edge above the production line carrying surface whenever indexing the vertically-oriented conveyor for returning products to the production line;
• whereby edges of the products being handled on the production line are protected from damage due to operation of the accumulator device.

A method of controlling the flow of products advancing along a conveyor from a first workstation to a second workstation, including the temporary accumulation off-line of excessive numbers of such products queued up between the two workstations, such method including:

• providing an apparatus adjacent the conveyor between the two workstations, and having accumulator means for selectively alternately removing and returning groups of products relative such conveyor, such apparatus having an infeed side receiving products from the first workstation upstream therefrom, and an outfeed side from which products emerge on their way to the second workstation downstream therefrom, said accumulator means being situated generally between such apparatus infeed and outfeed sides;
• preventing all products from leaving the apparatus outfeed side during normal running operations until each predetermined number of products previously released therefrom have passed a sensing point along the conveyor a predetermined distance downstream towards the second workstation from the apparatus, so as to maintain a predetermined distance gap between each predetermined number of products emerging from the apparatus outfeed side, by ensuring the presence of said predetermined distance gap before the release of a subsequent said predetermined number of products;
• and
• initiating a product removal sequence if the preventing step results in a queue of products extending through the apparatus from the outfeed side thereof back to the infeed side thereof;
• wherein such product removal sequence includes stopping the flow of further products into the apparatus infeed side;
• relatively shifting slightly downstream the products within the apparatus queue;
• and thereafter operating the accumulator means for removing products from the conveyor within the apparatus, whereby such products are isolated from line pressure along the conveyor such stopping and shifting steps, to prevent shear point damage thereto during their removal.

A method of controlling the flow of products advancing along a conveyor from a first workstation to a second workstation, including the temporary accumulation off-line of excessive numbers of such products queued up between the two workstations, such method including:

• providing an apparatus adjacent the conveyor between the two workstations, and having accumulator means for selectively alternately removing and returning groups of products relative such conveyor, such apparatus having an infeed side receiving products from the first workstation upstream therefrom, and an outfeed side from which products emerge on their way to the second workstation downstream therefrom, said accumulator means being situated generally between such apparatus infeed and outfeed sides;
• preventing products from leaving the apparatus outfeed side until products previously released therefrom have passed a sensing point along the conveyor a predetermined distance downstream towards the second workstation from the apparatus, so as to maintain a predetermined gap between
• initiating a product removal sequence if the preventing step results in a queue of products extending through the apparatus from the outfeed side thereof back to the infeed side thereof;
• wherein such product removal sequence includes stopping the flow of further products into the apparatus infeed side;
• relatively shifting slightly downstream the products within the apparatus queue;
• and thereafter operating the accumulator means for removing products from the conveyor within the apparatus, whereby such products are isolated from line pressure along the conveyor by such stopping and shifting steps, to prevent shear point damage thereto during their removal;
• wherein the accumulator means includes a generally vertical escalator-type device having a traveling belt with a plurality of outwardly extending members thereon forming flights, between which groups of products may be located and accumulated off-line of the conveyor, and wherein said apparatus further includes respective infeed brake means and outfeed brake means, for selectively stopping the flow of products at the infeed and outfeed sides, respectively, of the apparatus;
• and
• wherein the shifting step includes situating a locator member in the flow path of products along the conveyor at a point just downstream from the outfeed brake means, and thereafter releasing the outfeed brake means to permit the queue of products extending through the apparatus to shift downward into engagement with such locator member, whereby at least one of such products is shifted downstream beyond the accumulator means so that products upstream thereof may be cleanly removed from the conveyor without damage to the products.

A method of controlling the flow of products advancing along a conveyor from a first workstation to a second workstation, including the temporary accumulation off-line of excessive numbers of such products queued up between the two workstations, such method including:

• providing an apparatus adjacent the conveyor between the two workstations, and having accumulator means for selectively alternately removing and returning groups of products relative such conveyor, such apparatus having an infeed side receiving products from the first workstation upstream therefrom, and an outfeed side from which products emerge on their way to the second workstation downstream therefrom, said accumulator means being situated generally between such apparatus infeed and outfeed sides;
• preventing products from leaving the apparatus outfeed side until products previously released therefrom have passed a sensing point along the conveyor a predetermined distance downstream towards the second workstation from the apparatus, so as to maintain a predetermined gap between products emerging from the apparatus outfeed side;
• and
• initiating a product removal sequence if the preventing step results in a queue of products extending through the apparatus from the outfeed side thereof back to the infeed side thereof;
• wherein such product removal sequence includes stopping the flow of further products into the apparatus infeed side;
• relatively shifting slightly downstream the products within the apparatus queue;
• and thereafter operating the accumulator means for removing products from the conveyor within the apparatus, whereby such products are isolated from line pressure along the conveyor by such stopping and shifting steps, to prevent shear point damage thereto during their removal;
• wherein the accumulator means includes a generally vertical escalator-type device having a traveling belt with a plurality of outwardly extending members thereon forming flights, between which groups of products may be located and accumulated off-line of the conveyor, and wherein said apparatus further includes respective infeed brake means and outfeed brake means, for selectively stopping the flow of products at the infeed and outfeed sides, respectively, of the apparatus;
• and wherein said method further includes
• providing the apparatus with a movable transfer plate generally opposite certain of the distal edges of the outwardly extending members of the accumulator means, and having a transfer edge situated generally laterally from the carrying surface of the conveyor;
• and
• alternately lowering such transfer edge beneath the conveyor carrying surface whenever removing products from the conveyor, and raising the transfer edge above the conveyor carrying surface whenever returning products to the conveyor;
• whereby edges of the products being handled on the conveyor are protected from damage due to operation of the accumulator means.

Apparatus for surge control of products being transported via a moving conveyor belt means between two production areas, said apparatus comprising:

• accumulator means for being positioned alongside a conveyor belt means intermediate two production areas so as to be upstream and downstream respectively of such areas, said accumulator means controllably removing products from the conveyor belt means, and having a relative infeed side and outfeed side;
• outfeed brake means, associated with said accumulator means outfeed side, for controllably holding back products emerging from said accumulator device outfeed side;
• and
• control means, operatively associated with said accumulator means and said outfeed brake means, respectively, for actuating said outfeed brake means to hold back all products emerging from said accumulator means during normal running operations so as to maintain a predetermined distance gap between each predetermined number of products moving towards the downstream production area by ensuring the presence of said predetermined distance gap before the release of a subsequent said predetermined number of products, and for controlling said accumulator means to remove products from the conveyor belt means if a predetermined queue of products develops within the accumulator means before said outfeed back means is de-actuated.

Apparatus for surge control of products being transported via a moving conveyor belt means between two production areas, said apparatus comprising:

• accumulator means for being positioned alongside a conveyor belt means intermediate two production areas so as to be upstream and downstream respectively of such areas, said accumulator means controllably removing products from the conveyor belt means, and having a relative infeed side and outfeed side;
• outfeed brake means, associated with said accumulator means outfeed side, for controllably holding back products emerging from, said accumulator device outfeed side;
• and
• control means, operatively associated with said accumulator means and said outfeed brake means, respectively, for actuating said outfeed brake means to hold back products emerging from said accumulator means so as to maintain a predetermined distance gap between adjacent products moving towards the downstream production area, and for controlling said accumulator means to remove products from the conveyor belt means if a predetermined queue of products develops within the accumulator means before said outfeed brake means is de-actuated;
• wherein
• said accumulator means includes a generally vertical conveyor mechanism with a plurality of spaced, outwardly extending veins thereon for the accumulation of products between adjacent such veins, wherein indexing of such vertical conveyor mechanism removes a queued line of products situated on the conveyor belt means within the accumulator means, with reversing of such indexing returning such products to the conveyor belt means, and further wherein said predetermined queue of products comprises a slug of products extending along the accumulator means from its outfeed side back to its infeed side;
• and wherein said apparatus further includes
• a movable transfer plate operatively situated relative the conveyor belt means and the distal ends of said accumulator means outwardly extending veins;
• and
• means for controlling the position of said movable transfer plate relative the conveyor belt means during either the removing or returning of products relative such conveyor belt means so as to prevent the occurrence of lateral shear points for such products.

Apparatus for surge control of products being transported via a moving conveyor belt means between two production areas, said apparatus comprising:

• accumulator means for being positioned alongside a conveyor belt means intermediate two production areas so as to be upstream and downstream respectively of such areas, said accumulator means controllably removing products from the conveyor belt means, and having a relative infeed side and outfeed side;
• outfeed brake means, associated with said accumulator means outfeed side, for controllably holding back products emerging from said accumulator device outfeed side;
• and
• control means, operatively associated with said accumulator means and said outfeed brake means, respectively, for actuating said outfeed brake means to hold back products emerging from said accumulator means so as to maintain a predetermined distance gap between adjacent products moving towards the downstream production area, and for controlling said accumulator means to remove products from the conveyor belt means if a predetermined queue of products develops within the accumulator means before said outfeed brake means is de-actuated;
• wherein
• said accumulator means includes a generally vertical conveyor mechanism with a plurality of spaced, outwardly extending veins thereon for the accumulation of products between adjacent such veins, wherein indexing of such vertical conveyor mechanism removes a queued line of products situated on the conveyor belt means within the accumulator means, with reversing of such indexing returning such products to the conveyor belt means, and further wherein said predetermined queue of products comprises a slug of products extending along the accumulator means from its outfeed side back to its infeed side;
• and wherein said apparatus further includes
• downstream locator means, for establishing a stop point relatively just downstream from said accumulator means outfeed side, against which queued products are shifted relatively downstream just prior to removal of products from the conveyor belt means, whereby adjacent product shear point interaction with a vertical conveyor mechanism vein is prevented.

An improved accumulator device generally of the type having a vertically-oriented conveyor with a plurality of spaced, outwardly extending veins for accumulating products therebetween, with indexing of such conveyor in selected directions resulting alternatively in removal or return of products relative a carrying surface of a production line with which such accumulator device is associated in such fashion that given of the extending veins may be situated in a null position for the passage of products therethrough carried on the conveyor with such veins acting as guide rails, said improved accumulator device including a movable transfer plate generally opposite the distal edges of the extending veins in the vicinity of the production line, and having a transfer edge situated generally laterally from the carrying surface of the production line;.and means for controllably moving said movable transfer plate so as to lower said transfer edge thereof beneath the production line carrying surface whenever the conveyor is being indexed for the removal of products from the production line, and so as to raise said transfer edge above the production line carrying surface whenever the conveyor is being indexed for the return of products to the production line, whereby edges of products being handled on the production line are protected from damage due to operation of the vertically-oriented conveyor.

Product handling apparatus for controlling the flow of products advancing along a conveyor from a first workstation to a second workstation, said apparatus including:

• accumulator means, adjacent the conveyor between the first and second workstations, for controllably alternately removing and returning products relative the conveyor, said accumulator means having respective infeed and outfeed sides generally between which products may be removed from the conveyor;
• infeed brake means, associated with said accumulator means infeed side, for being controllably actuated for stopping the entry of products along the conveyor into said accumulator means infeed side;
• outfeed brake means, associated with said accumulator means outfeed side, for being controllably actuated for stopping products along the conveyor from emerging from said accumulator means outfeed side;
• downstream sensor means, situated alongside the conveyor a predetermined distance downstream from said accumulator means outfeed side, for detecting the passage of products thereby;
• and
• control means operatively associated with said accumulator means, infeed brake means, outfeed brake means, and downstream sensor means, respectively, for temporarily accumulating products off-line of the conveyor whenever excessive numbers of products queue up between the first and second workstations;
• wherein said control means operates in a normal run mode to alternately actuate and de-actuate said outfeed brake means for preventing all products from leaving said accumulator means outfeed side until a predetermined number of previously released products have passed said sensor means, by ensuring the passage of previously released products passed said sensor means before the release of a subsequent said predetermined number of products, and wherein said control means operates in a product removal mode whenever actuation of said outfeed brake means in the normal run mode results in a queue of products extending through the accumulator means from said outfeed side thereof back to said infeed side thereof;
• and wherein such product removal mode includes actuating said infeed brake means to stop upstream products on the conveyor from entering said accumulator means infeed side, de-actuating said outfeed brake means to permit relative downstream shifting of products on the conveyor within said accumulator means, and controlling said accumulator means for removing such products from the conveyor.

Product handling apparatus for controlling the flow of products advancing along a conveyor from a first workstation to a second workstation, said apparatus including:

• accumulator means, adjacent the conveyor between the first and second workstations, for controllably alternately removing and returning products relative the conveyor, said accumulator means having respective infeed and outfeed sides generally between which products may be removed from the conveyor;
• infeed brake means, associated with said accumulator means infeed side, for being controllably actuated for stopping the entry of products along the conveyor into said accumulator means infeed side;
• outfeed brake means, associated with said accumulator means outfeed side, for being controllably actuated for stopping products along the conveyor from emerging from said accumulator means outfeed side;
• downstream sensor means, situated alongside the conveyor a predetermined distance downstream from said accumulator means outfeed side, for detecting the passage of products thereby;
• and
• control means operatively associated with said accumulator means, infeed brake means, outfeed brake means, and downstream sensor means, respectively, for temporarily accumulating products off-line of the conveyor whenever excessive numbers of products queue up between the first and second workstations;
• wherein said control means operates in a normal run mode to alternately actuate and de-actuate said outfeed brake means for preventing products from leaving said accumulator means outfeed side until a predetermined number of previously released products have passed said sensor means, and operates in a product removal mode whenever actuation of said outfeed brake means in the normal run mode results in a queue of products extending through the accumulator means from said outfeed side thereof back to said infeed side thereof;
• and wherein such product removal mode includes actuating said infeed brake means to stop upstream products on the conveyor from entering said accumulator means infeed side, de-actuating said outfeed brake means to permit relative downstream shifting of products on the conveyor within said accumulator means, and controlling said accumulator means for removing such products from the conveyor;
• and wherein said apparatus further includes
• movable locator means, situated relatively just downstream from said outfeed brake means, and responsive to said control means for stopping the flow of products on the conveyor just downstream from said outfeed brake means whenever said outfeed brake means is de-actuated during said product removal mode functioning of said control means.

A product handling apparatus for controlling the flow of products advancing along a conveyor from a first workstation to a second workstation, said apparatus including:

• accumulator means, adjacent the conveyor between the first and second workstations, for controllably alternately removing and returning products relative the conveyor, said accumulator means having respective infeed and outfeed sides generally between which products may be removed from the conveyor;
• infeed brake means, associated with said accumulator means infeed side, for being controllably actuated for stopping the entry of products along the conveyor into said accumulator means infeed side;
• outfeed brake means, associated with said accumulator means outfeed side, for being controllably actuated for stopping products along the conveyor from emerging from said accumulator means outfeed side;
• downstream sensor means, situated alongside the conveyor a predetermined distance downstream from said accumulator means outfeed side, for detecting the passage of products thereby;
• and
• control means operatively associated with said accumulator means, infeed brake means, outfeed brake means, and downstream sensor means, respectively, for temporarily accumulating products off-line of the conveyor whenever excessive numbers of products queue up between the first and second workstations;
• wherein said control means operates in a normal run mode to alternately actuate and de-actuate said outfeed brake means for preventing products from leaving said accumulator means outfeed side until a predetermined number of previously released products have passed said sensor means, and operates in a product removal mode whenever actuation of said outfeed brake means in the normal run mode results in a queue of products extending through the accumulator means from said outfeed side thereof back to said infeed side thereof;
• and wherein such product removal mode includes actuating said infeed brake means to stop upstream products on the conveyor from entering said accumulator means infeed side, de-actuating said outfeed brake means to permit relative downstream shifting of products on the conveyor within said accumulator means, and controlling said accumulator means for removing such products from the conveyor;
• and further wherein
• said accumulator means includes a vertically-oriented conveyor mechanism having a plurality of spaced, outwardly extending flights received thereon for the accumulation of products between adjacent of such flights;
• and
• wherein said product handling apparatus further includes a movable transfer plate situated generally laterally from the conveyor along which such products advance, generally opposite the distal edges of the accumulator means outwardly extending flights;
• and further includes means for alternately lowering said transfer plate beneath the conveyor during the removing of products therefrom, and raising the movable transfer plate above the conveyor during the return of products thereto from said accumulator means, whereby edges of such products being handled by the accumulator means are protected from damage due to operation thereof.

An accumulator for use with packages moving between workstations, such as situated along a conveyor belt moving from a filler machine towards a straw-applicator or packing machine, said accumulator comprising:

• respective infeed and outfeed ends situated upstream and downstream, respectively, relative the moving conveyor belt;
• a vertically-oriented escalator-type mechanism situated substantially over the conveyor belt, and located generally between said accumulator infeed and outfeed ends, said mechanism having a controllably movable conveyor belt with plural, spaced flights thereon for selectively removing packages from the conveyor belt and returning packages thereto;
• an infeed brake associated with said infeed end for controllably stopping the flow of packages along the conveyor belt into said accumulator;
• an outfeed brake associated with said outfeed end for controllably stopping the flow of packages along the conveyor belt from said accumulator;
• infeed sensor means for detecting the presence of packages at said accumulator infeed end;
• outfeed sensor means for detecting the presence of packages at said accumulator outfeed end;
• downstream sensor means for detecting the presence of packages on the conveyor belt at a predetermined distance downstream from said accumulator outfeed end;
• a controllably movable locator member, situated at a point relatively just downstream from said outfeed brake and said accumulator outfeed end, for selectively interrupting the flow of packages along the conveyor belt at such point;
• a back-up mechanism, situated at said point relatively just downstream from said outfeed brake for selectively forcing packages at least slightly back upstream against the conveyor belt so as to be stopped thereat by said outfeed brake;
• and
• accumulator control means, responsive to said infeed, outfeed, and downstream sensor means, and controlling said escalator-type mechanism, said infeed and outfeed brakes, said locator member, and said backup mechanism, for selectively removing and returning packages relative the conveyor belt without damage to such packages, so that queued up packages are first isolated from production line pressure and thereafter temporarily accumulated on said escalator-type mechanism for subsequent reinsertion onto the production line.