EP3699098A1

EP3699098A1 - Feed device for forming product groups which are formed of a plurality of flat baked items, and feeding the product groups to a packaging machine

Info

Publication number: EP3699098A1
Application number: EP20158344.0A
Authority: EP
Inventors: Bart HOUDIJK
Original assignee: Machinefabriek Houdijk BV
Current assignee: Royal Houdijk BV
Priority date: 2019-02-19
Filing date: 2020-02-19
Publication date: 2020-08-26
Also published as: NL2022601B1

Abstract

The present invention relates to a feed device and an auxiliary frame for conveying flat baked items, such as biscuits or cookies, to a packaging machine, and to a method for conveying flat baked items to a packaging machine. The feed device for forming product groups which are formed of a plurality of individual flat baked items, such as biscuits, and feeding the product groups to a packaging machine, comprises: a conveying device comprising a conveying means with a number of pushers, wherein the pushers are arranged to convey the product groups along a conveying path of the conveying device from a start position to an end position of the conveying path to the packaging machine, and to transfer the product groups from the end position of the conveying path to a conveyor chain of the packaging machine, wherein the product groups are formed into at least one product group consisting of a plurality of individual flat baked items during the journey along the conveying path, characterized in that the feed device is further provided with at least one auxiliary frame that is movable along with the pushers, wherein the auxiliary frame is arranged to keep the flat baked items in the product group in a predetermined orientation during conveying along the conveying path independently of the pushers, wherein the at least one auxiliary frame is arranged so as to be able to be removed at the end position of the conveying path, wherein the orientation of the flat baked items predetermined by the auxiliary frame is maintained.

Description

The present invention relates to a feed device and an auxiliary frame for conveying flat baked items, such as biscuits or cookies, to a packaging machine, and to a method for conveying flat baked items to a packaging machine.
It is known practice to form product groups from flat baked items such as biscuits and cookies in order to convey same to and to place same into the conveyor chain of a packaging machine where the product groups can be packaged by, for example, a film wrapper into end products.
Such product groups are formed by placing the individual flat baked items one by one in a vertical orientation into a (plastic) tray. However, the flat baked items tilt towards a horizontal orientation and slip over in the tray. To keep the flat baked items in the desired vertical orientation, currently known feed devices are arranged for the tray to be conveyed at an angle of 45° along a conveying path by the feed device. By virtue of this angle, the orientation of the flat baked items is maintained until the tray is full. At this point in time, the tray should be returned to an orientation that is suitable for allowing the tray with the product group to be packaged by the packaging machine.
A drawback of this known feed device is that it is relatively complex. In particular, various additional steps are necessary to position the tray in the correct orientation and to re-establish this orientation prior to transfer to the packaging machine. Moreover, such a known feed device is dependent on the use of trays. Product groups that consist of rolls or stacks of individual flat baked items cannot be made without trays. Lastly, such known feed devices are not flexibly employable. In other words, switching between forming rolls and stacks, or between use with or without trays, means converting the device to a fundamental extent. It is therefore not possible to switch over in a straightforward manner.
One object of the present invention is to provide an improved feed device, in which at least some of the drawbacks mentioned above are remedied.
Another object of the present invention is to provide an improved feed device in which product groups are formed in a more straightforward manner and in which conversion between various types of product groups is simplified.
According to a first aspect of the present invention, the object is achieved by means of a feed device for forming product groups which are formed of a plurality of individual flat baked items, such as biscuits, and feeding the product groups to a packaging machine, the feed device comprising:

a conveying device comprising a conveying means with a number of pushers, wherein the pushers are arranged to convey the product groups along a conveying path of the conveying device from a start position to an end position of the conveying path to the packaging machine, and to transfer the product groups from the end position of the conveying path to a conveyor chain of the packaging machine, wherein the product groups are formed into at least one product group consisting of a plurality of individual flat baked items during the journey along the conveying path, characterized in that the feed device is further provided with at least one auxiliary frame that is movable along with the pushers, and at least one pusher that is movable independently of the auxiliary frame, wherein the auxiliary frame is arranged to keep the flat baked items in the product group in a predetermined orientation during conveying along the conveying path independently of the pushers, wherein the at least one auxiliary frame is arranged so as to be able to be removed at the end position of the conveying path, wherein the orientation of the flat baked items predetermined by the auxiliary frame is maintained, and wherein the auxiliary frame is open on an underside that is oriented towards the conveying device at the end position of the conveying path, and is open on an upper side that is oriented away from the conveying device during conveying along the conveying path.

Because the feed device is provided with at least one auxiliary frame that is movable along with the pushers, hereinafter also referred to as conveying elements, wherein the auxiliary frame is arranged to keep the flat baked items in the product group in a predetermined orientation during conveying independently of one or more of the pushers, wherein the at least one auxiliary frame is removable at the end position of the conveying path, wherein the orientation of the flat baked items predetermined by the auxiliary frame is maintained, it is possible, in a simplified manner, to form the product groups from a plurality of individual flat baked items and no more additional action is needed to adjust the orientation of the product group for this packaging machine when conveying it to the latter. In this way, the device can be designed without complex means for adjusting the orientation of the flat baked items for the packaging machine, resulting in the assembly being less complex.
In particular, the auxiliary frame is removable from a product group held thereby, in which the product group is (at least substantially) without change in orientation. In other words, the device according to the invention makes it possible to remove the auxiliary frame from a product group at the end position, in which the orientation defined by the auxiliary frame hardly changes or does not change at all. In this way, it is possible for the product group to be conveyed directly to a packaging machine after removal of the auxiliary frame.
The conveying device may consist of a drive, power supply and a conveying means such as a chain, conveyor belt or preferably a linear motor system with a plurality of carriers or pushers. These pushers or conveying elements are often actuated in groups and can therefore transport, in pairs, an individual product such as a baked item, a group of products such as the roll of baked items, or a tray. By employing the pushers in groups for transport along the conveying path, individual products or groups can be trapped or sandwiched. The linear motor system is characterized in that each pusher can be actuated separately in terms of speed and position. Thus, two pushers can be actuated so as to move or to convey an auxiliary frame along the conveying path. During this conveying process, the placing units or robots (preferably delta robots) place the individual products into the auxiliary frame. The auxiliary frame can be arranged to hold each product in a desired orientation separately, or to do so in groups. In the first case, the frame is preferably provided with separate compartments for accommodating and confining the individual products in a form-fitting manner. In the last case, the frame is preferably formed as a large open compartment into which all of the products can be placed next to one another.
Since the pushers can be actuated separately in terms of position and speed, and preferably acceleration, two pushers of a group (for conveying an auxiliary frame) can move relative to one another and move towards or away from one another. Because at least one pusher can move independently of the auxiliary frame, this pusher can press the products in the auxiliary frame against one another during the journey along the conveying path. Thus, the distance between the individual products can be decreased. Moreover, the pusher can also move away from the other pusher during the journey along the conveying path and thereby increase the distance between the individual products. In this way, the right amount of space can be made for the insertion of new products. In the first case, the products are kept held against one another during loading and in the second case, space is kept free for a new product. In the context of this document, what is meant by "flat baked items" is products with a (substantially flat) first main surface, an opposite (substantially flat) second main surface, and a circumferential rim that connects the first main surface to the second main surface. What is meant by a "flat baked item" is a flat baked product such as, for example: a cookie, a rusk, a slice of bread, a biscuit; or cookies, biscuits or the like that consist of a plurality of individual (sandwiched) flat baked items such as cookies that consist of two round chocolate cookies with a soft, sweet, white filling (usually referred to as cream or creme) therebetween.
The inventor has found that the assembly according to the invention is relatively flexibly employable, can be produced inexpensively and in a straightforward manner, and additional complex steps in the conveying process are rendered unnecessary thereby. Namely, the auxiliary frame can comprise one or a plurality of passages for forming stacks of flat baked items, in which the main surfaces of the individual products are positioned substantially horizontally. It is also possible for the auxiliary frame to comprise passages for forming rolls of products, in which the main surfaces of the flat baked items are positioned substantially vertically. In this way, it is thus possible for the assembly according to the invention to be associated with various types of packaging machines and various types of product groups to be packaged. It is not necessary for the entire device or the packaging machine to be converted for this, but rather it is just a case of using an auxiliary frame adapted to the packaging machine.
In the case that the auxiliary frame is arranged for a product group in which a plurality of successive stacks of flat baked items are held in the desired orientation, the use of such an auxiliary frame has the additional advantage that the risk of damaging the flat baked items is minimal. In currently known feed devices, in which no auxiliary frame is provided, the stacks of flat baked items in the case of such a product group are pressed against one another and transported as such. The force that is exerted on the foremost stack is therefore relatively large; this is avoided by using the auxiliary frame.
Embodiments according to the present invention will be described below.
In one embodiment, the at least one auxiliary frame is open on two opposite sides thereof, such that the auxiliary frame is freely removable from the flat baked items. In particular, the auxiliary frame is freely removable from an undercut. What is meant by this is that the flat baked items are free of a form-fitting confinement in at least one direction. An advantage of this is that the auxiliary frame is freely movable in at least one direction along the flat baked items, as a result of which the orientation of the flat baked items in the product group remains (substantially) the same when the auxiliary frame is removed.
In one embodiment, the at least one auxiliary frame is formed so as to support the individual flat baked items in the auxiliary frame during conveying from the start position to the end position. The flat baked items are kept at least substantially in their original orientation by the auxiliary frame. In other words, they are, for example, positioned vertically in the auxiliary frame for a product group to be formed that consists of a vertical roll of flat baked items. The flat baked items may however also be positioned horizontally in the auxiliary frame for a product group to be formed that consists of one or more horizontal stacks of flat baked items. In one embodiment, the auxiliary frame is arranged to freely support the flat baked items in the auxiliary frame so that they are kept clear of the conveying member over which the auxiliary frame with the flat baked items is moved along the conveying path from the start position to the end position. This conveying member may be a fixed flat plate over which this auxiliary frame is transported by the conveying device. Supporting the flat baked items in the auxiliary frame has the advantage that there is less risk of damaging the baked items. In particular, the holder can, to this end, be provided with supporting members that are located on the inner side of the auxiliary frame and prevent contact between the flat baked items and the conveying member (the baked items are suspended just thereabove) or with a thick underside on which the baked items rest. In this last case, the thick underside is preferably attached to the auxiliary frame in a hinged manner so that the auxiliary frame can be removed at the end position while leaving the orientation of the flat baked items unchanged.
In one embodiment, the at least one auxiliary frame consists of two parts which are attached to one another in a hinged manner, such that a side of the auxiliary frame may be opened by hinging the parts so that the auxiliary frame is freely removable from the flat baked items. The auxiliary frame preferably comprises two parts that hinge relative to one another along a longitudinal axis of the holder which form a gripper for simultaneously opening and closing the gripper for all of the individual flat baked items. The auxiliary frame can form a gripper from two mutually hinging parts. In this embodiment, the auxiliary frame forming a gripper is closed at the start of the conveying path and it will open only at the end position. The opening of the auxiliary frame forming a gripper can be initiated by an element of the conveying device, a placing unit (robot), or there can be a fixed trigger element that is received at the end of the conveying path and compels the auxiliary frame to open.
In one embodiment, the auxiliary frame comprises a pressure element that is movable between two ends of the auxiliary frame in order to apply pressure to the plurality of individual flat baked items of the product group and thereby decrease the respective distances therebetween. The invention is characterized in that the auxiliary frame is arranged to be able to be removed at the end position of the conveying path while leaving the orientation of the flat baked items unchanged thereby. Vertically positioned flat baked items should never or hardly ever slip out. To this end, the auxiliary frame can be further provided with supporting elements that are located entirely or partially between the individual flat baked items. These supporting elements separate the flat baked items from one another and keep them in their predetermined orientation. Thus, an accommodating space is defined between neighbouring supporting elements in which an individual flat baked item can be accommodated. In the absence of such supporting elements, the auxiliary frame in one embodiment is provided with a pressure element that is movable in the longitudinal direction of the auxiliary frame, between the two ends. To this end, the auxiliary frame preferably comprises two runners that are fitted parallel to the longitudinal axis of the auxiliary frame. The pressure element can move back and forth over these runners in order to press the individual flat baked items together and minimize the respective distances therebetween.
In one embodiment, the individual flat baked items are placeable in the auxiliary frame according to the direction of the conveying path. To keep the flat baked items in the desired orientation during conveying along the conveying path, use can be made of the forward speed of the auxiliary frame or the acceleration of the auxiliary frame during the journey along the conveying path. This will result in a force in the opposite direction to the conveying path and if the flat baked items are loaded into the auxiliary frame according to this conveying path as a roll, then they will be pressed against the rear side of the auxiliary frame and thus prevented from slipping out.
In one embodiment, the auxiliary frame comprises an RFID tag and the feed device is provided with an RFID reader for identifying the auxiliary frame. By using the auxiliary frame, the feed device is flexibly employable and, by using other auxiliary frames, it is possible to switch between packaging rolls or stacks of flat baked items, in a tray or without a tray, quickly and in a straightforward manner. By providing the auxiliary frame with an RFID tag and providing the feed device with an RFID reader near the start position of the conveying path, the auxiliary frame can be identified and the type recognized, for example, as for rolls with trays, without trays or stacks with or without trays. The loading of the auxiliary frames and the transfer of the product group to or into the conveyor chain of the packaging machine can be managed in a corresponding manner. Adjusting the line individually for the type of product groups to be packaged is thus not necessary and can be carried out automatically. RFID tags also make it possible to process (automatically) varying configurations of products to be packaged or to combine packaging types or forms in one package (for example partially stacked products and partially products formed into a roll).
In one embodiment, the feed device is provided with a removing means for removing the at least one auxiliary frame at the end position. An advantage of this is that the flat baked items are free of an auxiliary frame downstream of the end position. In this way, it is possible for the product group formed by the flat baked items to be fed directly to a packaging machine.
In one embodiment, the at least one auxiliary frame is movable in the conveying direction by means of at least one of the conveying elements or pushers. An advantage of this is that the feed device is free of an actuator for actuating the at least one auxiliary frame.
In one embodiment, the auxiliary frame defines at least one compartment for accommodating a plurality of flat baked items therein. In this case, the compartment is for example formed by a passage that extends from an upper side to an underside of the auxiliary frame, wherein the passage is open on both the upper side and the underside. Preferably, the shape of the cross section of the passage corresponds to the circumference of the flat baked items. With this embodiment, it is possible to fill the at least one compartment, with a stack of products being formed with the flat baked items being oriented substantially horizontally. It is also possible for the auxiliary frame to comprise a plurality of passages extending from the upper side to the underside that are open on both the upper side and the underside, which passages have a cross section that corresponds to the thin side of the flat baked items. In this way, it is possible for a roll of products to be formed, in which the flat baked items extend substantially vertically.
In one embodiment, the feed device further comprises a placing means for placing an auxiliary frame on the conveying path downstream of a conveying element. In this way, it is possible to transport an auxiliary frame over the conveying path using at least one conveying element.
In one embodiment, the feed device further comprises a product placing means for placing flat baked items into the auxiliary frame on the conveying path. The product placing means is for example configured as an arm of a robot. This robot is preferably a delta robot or pick-and-place robot. An advantage of this is that flat baked items can be placed into the auxiliary frame accurately and quickly, in which a complicated transfer from a conveyor belt located upstream to the start position of the conveying path is obviated through the use of the product placing means.
In one embodiment, the feed device comprises a plurality of placing units that are arranged parallel to the conveying path, in which each placing unit is arranged and configured to place preferably one flat baked item into the auxiliary frame. Preferably, there is at least one robot that puts the individual products into the auxiliary frame, but more preferably there is a plurality of robots, resulting in a higher throughput. Most preferably, the number of robots corresponds to the number of individual flat baked items in a product group. In one example, the device comprises at least one or preferably two additional robots that put an auxiliary frame into the conveying device at the start of the conveying path and take the auxiliary frame out of the conveying device at the end of the conveying path.
In one embodiment, the conveying elements or pushers are controllable along the conveying path in terms of speed and/or position relative to one another. Removing an auxiliary frame filled with flat baked items can, in particular within a product group, result in a (mostly limited) change in the position of the flat baked items relative to one another. An advantage of this embodiment is that it is possible to correct this potential change in position by means of the one or more conveying elements or pushers. For example, this may be achieved by accelerating a conveying element located upstream relative to a product group or slowing down a conveying element located downstream thereof, in both of which cases the conveying element is brought to bear against the product group formed by the flat baked items. If, for each auxiliary frame, there is a pair of adjacent conveying elements, namely one conveying element located upstream of the auxiliary frame and one conveying element located downstream of the auxiliary frame, it is possible to correct a change in the position of the flat baked items relative to one another by moving the pair of conveying elements towards one another, whereby the conveying elements hold the respective product group between them. It is also possible for one of the two conveying elements to move towards the other conveying element in order to decrease the respective distances between the individual products.
In practice, a plurality of auxiliary frames with flat baked items are often conveyed over the conveying path in series, i.e. one after the other, by means of the conveying elements. With such conveying elements, i.e. conveyors, in which the speed and/or position is controllable independently of one another, it is also possible for the distance, or pitch, between two free product groups formed by the auxiliary frames to be adjusted after the auxiliary frames have been removed. In the context of this document, what is meant by such independently controllable conveying elements, i.e. conveyors, is a linear motor system. Such a system has a conveyor track that can be configured as a finite track and forms one of the two electromagnetic parts of the motor system. The other part is formed by the conveyors or motor units that move along this conveyor track. This transport process can be controlled individually, with the speed, acceleration and position of each conveyor being able to be configured individually. Preferably, the conveyors are provided with one or more pushing elements, or pushers, or with one or more carriers. For example, the invention provides a conveyor with one, two or more carriers and/or pushing elements, and/or supporting elements. These supporting elements have no drive function but serve only to support the products to be conveyed. In one example, the one or more carriers and/or pushers can be arranged to clamp an auxiliary frame or product group before conveying it. In this way, auxiliary frames or groups of flat baked items, for example, can be conveyed towards a packaging machine.
In one embodiment, the auxiliary frame is arranged so that pressure is applied to the product group by means of at least one of the conveying elements in order to decrease the distance between the plurality of individual flat baked items of the product group in the auxiliary frame. In this way, it is possible for pressure applied to the flat baked items to be maintained by designing the auxiliary frame suitably, for example by having an opening in the auxiliary frame into which a member can be received that for example forms part of a placing unit (loading robot) or of the conveying device. The auxiliary frame may however also be provided with a pressure element that forms part of the auxiliary frame and is movable relative to the auxiliary frame. It can be moved by the placing unit or by the conveying device.
In the embodiment in which the conveying device is arranged for independent relative movement in terms of speed and/or position, for example in the case of a linear motor system, the auxiliary frame can, in a further example, be transported by at least one carrier of the conveying device. In another example, the auxiliary frame can also be transported by two carriers that enclose the auxiliary frame. In yet another example, three carriers of the speed- and position-independent conveying device can also be used for each auxiliary frame. Of these, one carrier will push the auxiliary frame onwards, one carrier will brace or clamp the auxiliary frame, and one carrier will be used to apply pressure to the flat baked items during loading so that the orientation thereof is maintained. In an alternative embodiment, the last carrier can also drive the pressure element.
In one embodiment, the placing unit comprises a robot vision system. A robot vision system consists of at least one robot, but preferably a plurality of robots, which are preferably delta robots fitted above the conveying path. This system further comprises at least one camera unit that sends a feedback signal to a control unit of the robot. The feedback signal comprises the exact (absolute or relative) position of the flat baked items on the conveying member so that the robot can move the gripper to this position in order to pick up the flat baked item to place it into the auxiliary frame. The robot is preferably provided with a vacuum gripper for this purpose.
In one embodiment, the feed device further comprises a packaging machine downstream of the end position of the conveying device. In this case, it is possible for the product groups to be conveyed directly to the packaging machine.
According to a second aspect of the present invention, an auxiliary frame is provided for use in the feed device according to the first aspect of the present invention. In particular, it is possible for the auxiliary frame to comprise one or more of the features described for the first aspect that are attributed to the auxiliary frame. Advantages of the second aspect are the same as those of the first aspect.
According to a third aspect of the present invention, a method is provided for conveying a plurality of flat baked items to a packaging machine, comprising the steps of:

conveying flat baked items along a conveying path of a conveying device from a start position to an end position of the conveying path by means of conveying elements, in which the flat baked items together form a product group;
in which the flat baked items are kept in a predetermined orientation relative to one another by means of at least one auxiliary frame.

In one embodiment according to the second aspect of the present invention, the method comprises the step of placing an auxiliary frame downstream of a conveying element.
In one embodiment according to the second aspect of the present invention, the method comprises the step of:

placing flat baked items into the auxiliary frame.

In one embodiment according to the second aspect of the present invention, the method comprises the step of:

removing the auxiliary frame at the end position of the conveying path.

Advantages of the third aspect of the present invention are the same as those of the first and second aspects of the invention.

Description of the Figures

The present invention will be explained in more detail below by means of embodiments of an assembly according to the present invention shown in the drawings, in which:

Fig. 1 is a perspective view of a feed device according to the first aspect of the invention;
Fig. 2 is a perspective view of part of the feed device according to Figure 1, at a start position;
Fig. 3 is a perspective view of part of the feed device according to Figure 1, at an end position;
Fig. 4 is a perspective view of a first embodiment of an auxiliary frame according to the second aspect of the invention;
Fig. 5 is a perspective view of a second embodiment of an auxiliary frame according to the second aspect of the invention;
Fig. 6 is a perspective view of a third embodiment of an auxiliary frame according to the second aspect of the invention;
Fig. 7 is a perspective view of a fourth embodiment of an auxiliary frame according to the second aspect of the invention;
Fig. 8a is a perspective view of a fifth embodiment of an auxiliary frame according to the second aspect of the invention;
Fig. 8b shows a portion of the auxiliary frame shown in Figure 8a;
Fig. 9 shows a sixth embodiment of an auxiliary frame according to the second aspect of the invention.

Figure 1 shows a feed device 1 for forming product groups of flat baked items from a plurality of individual flat baked items, such as biscuits. In Figure 1 and also in Figures 2 and 3, these are round biscuits that are placed individually into auxiliary frames by the placing unit or robot 25. By means of these auxiliary frames, the groups of products are formed and conveyed to a packaging machine. The overall system comprises a feed device 3. This consists of a conveying means or conveyor 13 such as a conveyor belt. In particular, the conveying means are formed by a pair of pushers 131 and 132 as shown in detail in Figure 9. These pushers or fingers therefore convey the product groups in the direction T of the packaging machine from a start position to an end position. There, they can be transferred to a conveyor chain of the packaging machine.
During the conveying process T by the conveying device 3, the conveying means, consisting of a plurality of groups of two pushers 131, 132, will be used to form the product group by each robot 25 placing at least one product into an auxiliary frame 11. The auxiliary frame may be placed into a tray (if the products are ultimately packaged in a tray, but the auxiliary frame can also be used without a tray), such as in the case of products that are to be packaged as a roll or stack without a tray.
The auxiliary frames are arranged to allow the robots to place the individual products inside via the upper side or via the lateral side of the auxiliary frame during conveying by the conveying device along the path T and thereby fill them. Once there are enough products in the auxiliary frame, at the end of the path T, the auxiliary frame opens on the underside, which is the side adjacent to the conveyor belt or conveying device. Thus, the auxiliary frame can be removed, but the product group remains in the conveying device. The pushers always stay in contact with the product group, including after removal of the auxiliary frame. They keep the products in the predetermined orientation. Preferably, the pushers then move slightly further towards one another, in order to eliminate the space that has arisen due to the removal of the auxiliary frame. The feed device 1 for forming product groups of flat baked items 14 and feeding these product groups to a packaging machine according to the invention comprises a conveyor 13 for conveying a plurality of auxiliary frames 11 along a conveying path T, an auxiliary frame conveying device 12 for conveying auxiliary frames 11, a supplying device 6 for supplying individual flat baked items 14, and a placing unit 4 for placing flat baked items 14 into auxiliary frames 11 conveyed by the conveyor 13.
The conveyor 13 is arranged to move auxiliary frames 11 along the conveying path T thereof from a start position A to an end position B. Upstream of the start position A, there is a tray feed device 2, or a denester 2, for denesting trays 7 and for feeding denested trays 7 to the conveyor 13. Downstream of the end position B, there is a packaging device.
The conveyor 13 is in particular a linear motor system, in which the speed and position by which the auxiliary frames 11 can be conveyed along the conveying path T are controllable independently of one another.
The auxiliary frame conveying device 1' comprises a conveyor belt 12 with a conveying upper surface. The conveyor belt 12 is placed next to the conveyor 13, with the conveyor belt 12 running parallel to the conveyor 13. The conveyor belt 12 then runs up to the vicinity of the start position A of the conveyor 13.
On a side of the conveyor 13 located opposite the conveyor belt 12, the supplying device 6 for individual flat baked items is placed. The supplying device 6 is likewise a conveyor belt 6 that runs substantially close to and parallel to the conveying path T. The conveyor belt 6 has an infinite conveying upper surface over which the flat baked items 14 can be conveyed to the start position A of the conveyor 13.
Above the conveyor 13 and along a substantial portion of the conveying path T, there is a placing unit 4. The placing unit 4 comprises a vision system 8 and a number of what are known as delta robots 25. Each of the delta robots 25 comprises a rigid base frame 20 with a pair of movable arms 26. The rods 21 are connected to a gripping means 22 by an end that is at a distance from the base frame 20. The first and the last gripping means 22 are provided with a gripper for gripping an auxiliary frame 11, while the gripping means 22 between the foremost gripping means 22 in the upstream direction and the endmost gripping means 22 in the downstream direction are provided with a suction cup 24.
The gripping means 22, in particular those with a vacuum gripper such as a suction cup 24, are pivotable on a pivot axis 23. In particular, each suction cup 24 is pivotable from a picking position, where an engaging surface of the suction cup 24 is parallel to the conveying upper surface of the conveyor belt 6, to a placing position, where the engaging surface of the suction cup 24 is substantially perpendicular to the conveying upper surface of the conveyor belt 6. For this, the arms 26 are freely movable above the conveying upper surface of the conveyor belt 6 and above the conveying upper surfaces of the conveyor 13 and the conveyor belt 12.
The vision system 8 comprises a camera with a field of view 9 and a processor, the vision system 8 being arranged to detect individual flat baked items 14 on the upper surface of the conveyor belt 6. The location data of detected flat baked items on the upper surface of the conveyor belt 6 are provided to the delta robots 25, the delta robots 25 being configured, on the basis of this information and by means of the suction cups 24 thereof, to pick the detected flat baked items up off the upper surface of the conveyor belt 6 and to convey them to the conveyor 13 in a substantially transverse direction relative to the conveying path T.
In the embodiment of Figures 1, 2 and 3, a denester 2 is in each case placed upstream of the conveyor 13. The denester 2 provides the conveyor 13 with trays 7 at the start position A, where the first delta robot 25 takes an auxiliary frame 11 from the conveyor belt 12 each time and places it into each tray 7. The use of the denester 2 is however optional. In this case, it is possible for the first delta robot 25 to place an auxiliary frame 11 into the conveyor 13 at the start position A, after which the conveyor 13 conveys the auxiliary frame 11 along the conveying path T with the auxiliary frame 11 making no contact with a tray 7.
Various embodiments of an auxiliary frame 11 according to the present invention are shown in Figures 4 to 8. The auxiliary frames 11 each have a front side 31, a rear side 32, and a connecting portion 33 that connects the front side 31 to the rear side 32. Each of the auxiliary frames 11 is open from above so as to receive flat baked items 14 from a delta robot 25 via the open upper side. Furthermore, each of the auxiliary frames 11 is provided with a groove 43 in both the front side 31 and the rear side 32 that is arranged to cooperate with the pushers or carriers of a linear motor system.
The embodiments of Figures 5, 6, 7 and 8 each form a plurality of compartments 42, 51 for accommodating flat baked items 14 therein. For this, an elongated cavity 41 is provided in the connecting portion 33. This cavity is arranged to cooperate with a projection (not shown) from the gripping means 22 of the foremost and endmost delta robots 25.
The embodiment of the auxiliary frame 11 of Figure 4 differs from the other embodiments in that the connecting portions 33 are provided with a bar 35 and a pressure element such as a clamping portion 34 that is movable along the bars 35. The clamping portion 34 is for example driveable by means of a pusher of a linear motor system. In use, a space corresponding to a thickness of a baked item 14 is created in the trough-shaped auxiliary frame 11 by means of the clamping portion 34. By increasing the space sequentially, it is possible to accommodate more baked items 14 in the auxiliary frame 11, with the orientation of the product group (in the process of being formed) being maintained. Along with the front and rear sides 31, 32, the clamping portion 34 has a cavity 36 that is open from above so as to create space for the gripping means 22 when a flat baked item 14 is placed into the auxiliary frame 11.
The auxiliary frames 11 of Figures 4, 5, 6 and 7 are each a fixed frame for holding the flat baked items 14 therein, in which the underside is open so as to allow the flat baked items 14 through via the underside of the frame 11 when the auxiliary frame 11 is removed from the conveyor 13 in an upwards direction. In this way, the orientation of the flat baked items 14 relative to one another, within a product group, is maintained.
In contrast, the auxiliary frame 11 according to Figure 8 is formed of two portions 63, 64 that are hingeable on a hinge axis 61. The hinge axis 61 runs from the side 31 to the side 32. In particular, the hinge axis 61 is parallel to the direction of the conveying path T. In this case, the auxiliary frame 11 is provided with a support 62 on the underside of the portions 63, 64. This support 62 is in particular suitable for protecting the flat baked items 14 during conveying along the conveying path T. In practice, the conveying path T can be several tens of metres long. As such, it is possible for the flat baked items 14 to suffer damage during conveying. The support 62 formed by the portions 63, 64 provides a static base for the flat baked items 14 during conveying over the conveying path T.
Figure 8b shows a portion of the auxiliary frame 11 shown in Figure 8a when it is picked up by a delta robot 25. It can be seen that the portions 63, 64 hinge relative to one another on the hinge axis 61 when the auxiliary frame 11 is lifted, resulting in the portions 62 moving apart from one another. This creates an opening on the underside of the auxiliary frame 11 through which the flat baked items 14 can move when the auxiliary frame 11 is lifted (substantially) without a change in orientation relative to one another. In this way, the orientation of the product group is substantially maintained.
Figure 7 shows an auxiliary frame 11 for forming stacks of flat baked items 14. This auxiliary frame 11 has three compartments 51 with a diameter that corresponds to the flat baked items 14, in which, after being placed into the auxiliary frame 11, the flat baked items 14 are held with the main surfaces thereof substantially horizontal.
The embodiments of the auxiliary frame of the invention are all usable in the feed device of the invention. Incidentally, when using the feed device according to the invention, there is nothing to rule out using a combination of embodiments of the auxiliary frame.
The auxiliary frame according to all embodiments can be made of a plastic, and this is preferably a plastic which is suitable for additive manufacturing or for machining techniques. Most preferably, the plastic used is a plastic suitable for use in the preparation and processing of foodstuffs, i.e. what are referred to as food-grade materials or food-grade plastics, such as high-density polyethylene or polyoxymethylene.
Figure 9 shows an assembly of a sixth embodiment of an auxiliary frame 11 for use in the feed device 1 according to the invention which is further provided with pushing and pulling elements. The auxiliary frame 11 is again composed of a front side and a rear side 31, 32 with, therebetween, a connecting portion 33 connecting the front side to the rear side. The connecting portion 33 is shown in Figure 9 in a simplified manner and in practice forms a wall that limits movement of flat baked items 14 accommodated in the auxiliary frame 11 in a transverse direction relative to the conveying direction T. In particular, the underside of the connecting portion is open. However, it is also possible for the underside to be opened by means of a mechanism comprising a pair of portions 63, 64 that are hingeable on a hinge axis 61, such as shown in Figures 8a and 8b. The auxiliary frame 11 is movable over the conveying path T of conveyor 13 by means of a pusher 131 that is (form-fittingly) coupled to a pushing element 135 that bears detachably against side 32 of the auxiliary frame 11. For this, a form-fitting connection 133 is provided, in which a projection from the pusher 131 engages with a receiving cavity on the underside of element 135. Downstream of side 31 of the auxiliary frame 11, there is a further pusher 132. Pusher 132 is (form-fittingly) coupled to a pulling element 136. For this, a form-fitting connection 134 is again provided between the pusher 132 and element 136, in which a projection from the pusher 132 engages with a cavity on the underside of element 136. An arm 331 is attached to the pulling element 136 which runs along side 31 of the auxiliary frame 11 in the upstream direction. The arm 331 is securely connected to an attachment piece 34 by an end thereof that is located at a distance from the pulling element 136.
The pushers 131, 132 are controllable in terms of speed and/or position independently of one another along the conveying path T. In this way, it is possible for the speed v1 of pusher 131 to be (temporarily) adjusted relative to the speed v2 of pusher 132 in order to adjust the positions of the pushers 131, 132 relative to one another during conveying. Since the arm 331 is securely connected to element 136 and attachment piece 34 is securely connected to the arm 331, the position of attachment piece 34 is dependent on pusher 132 and independent of pusher 131. By changing the position of pusher 132 relative to the position of pusher 131, the size of the accommodating opening 137 in the auxiliary frame 11 for accommodating flat baked items 14 in the auxiliary frame 11 is adjustable.
The auxiliary frame 11 of Figure 9 is further provided with a sloping contact portion 138, where the contact portion 138, and thus also the main surfaces of flat baked items 14 held in the auxiliary frame, forms an angle to the vertical of about 5 to 20°.
The auxiliary frame 11 of Figure 9 is further provided with a guiding means 35 for guiding the arm 331 along the auxiliary frame 11 in the upstream and downstream directions.
It will be clear that the intention of the above description is to shed light on the working of possible embodiments of the present invention, and not to limit the scope of protection of the invention. Starting from the description, a person skilled in the art is able to conceive of and use various embodiments that fall within the inventive concept and scope of protection of the present invention.

Claims

Feed device for forming product groups which are formed of a plurality of individual flat baked items, such as biscuits, and feeding the product groups to a packaging machine, the feed device comprising:
- a conveying device comprising a conveying means with a number of pushers, wherein the pushers are arranged to convey the product groups along a conveying path of the conveying device from a start position to an end position of the conveying path to the packaging machine, and to transfer the product groups from the end position of the conveying path to a conveyor chain of the packaging machine, wherein the product groups are formed into at least one product group consisting of a plurality of individual flat baked items during the journey along the conveying path, characterized in that the feed device is further provided with at least one auxiliary frame that is movable along with the pushers, and at least one pusher that is movable independently of the auxiliary frame, wherein the auxiliary frame is arranged to keep the flat baked items in the product group in a predetermined orientation during conveying along the conveying path independently of the pushers, wherein the at least one auxiliary frame is arranged so as to be able to be removed at the end position of the conveying path, wherein the orientation of the flat baked items predetermined by the auxiliary frame is maintained, and wherein the auxiliary frame is open on an underside that is oriented towards the conveying device at the end position of the conveying path, and is open on an upper side that is oriented away from the conveying device during conveying along the conveying path.
Feed device according to Claim 1, wherein the at least one auxiliary frame is open on two opposite sides thereof, such that the auxiliary frame is freely removable from the flat baked items.
Feed device according to Claim 1, wherein the at least one auxiliary frame is formed so as to support the individual flat baked items in the auxiliary frame during conveying from the start position to the end position.
Feed device according to Claim 1, wherein the at least one auxiliary frame consists of two parts which are attached to one another in a hinged manner, such that a side of the auxiliary frame may be opened by hinging the parts so that the auxiliary frame is freely removable from the flat baked items.
Feed device according to one of the preceding claims, wherein the auxiliary frame comprises a pressure element that is movable between two ends of the auxiliary frame in order to apply pressure to the plurality of individual flat baked items of the product group and thereby decrease the respective distances therebetween.
Feed device according to one of the preceding claims, wherein the individual flat baked items are placeable in the auxiliary frame according to the direction of the conveying path.
Feed device according to one of the preceding claims, wherein the auxiliary frame comprises an RFID tag and the feed device is provided with an RFID reader for identifying the auxiliary frame.
Feed device according to one of the preceding claims, wherein the feed device is provided with a removing means for removing the at least one auxiliary frame at the end position.
Feed device according to one of the preceding claims, wherein the at least one auxiliary frame is movable in the conveying direction by means of at least one of the pushers.
Feed device according to one of the preceding claims, wherein the auxiliary frame defines at least one compartment for accommodating a plurality of flat baked items therein, wherein, when filling the compartment, a stack of flat baked items is formed.
Feed device according to one of the preceding claims, wherein the pushers are controllable along the conveying path in terms of speed and/or position relative to one another.
Feed device according to Claim 11, wherein the conveying device is arranged to move, after removal of the auxiliary frame and prior to transfer to the conveyor chain of the packaging machine, the pushers for conveying a single product group towards one another.
Feed device according to Claim 12, wherein the distance by which the pushers for conveying the single product group move towards one another corresponds at least substantially to the sum of the respective distances between the plurality of individual flat baked items of the product group in the auxiliary frame.
Feed device according to Claim 11, 12 or 13, wherein the auxiliary frame is arranged so that pressure is applied to the product group by means of at least one of the pushers in order to decrease the distance between the plurality of individual flat baked items of the product group in the auxiliary frame.
Auxiliary frame such as used in the feed device according to one of the preceding claims.