CLIAMS:We Claim
1. Machine for inspecting product identifier code on a carton for packing a product, including a split belt linear conveyor disposed for rotation about a horizontal axis along the length of an elevated basal support and having a carton feed end and carton discharge end and consisting of a plurality of conveyor elements spaced from one another, a carton feed unit located on the basal support at the carton feed end of the linear conveyor, a product identifier code capturing unit located on the basal support at an intermediate position of the linear conveyor, an incorrect carton rejection unit located on the basal support at the carton discharge end of the linear conveyor and a control unit for controlling the operation of the machine and indicating the operational status of the machine, wherein the carton feed unit comprises a pair of flat vertical carton holder plates disposed above the linear conveyor at the carton feed end thereof spaced from each other across the linear conveyor and facing each other widthwise and mounted on the basal support, the transverse distance between the carton holder plates corresponding to the length of an empty and unopen carton, a plurality of carton feed regulators disposed between the carton holder plates spaced from one another and mounted on the basal support, a pair of vertical carton support members disposed above the linear conveyor at the carton feed end thereof spaced from each other across the linear conveyor and facing each other and mounted on the basal support, the carton support plates being disposed at a longitudinal distance with the carton holder plates along the linear conveyor corresponding to the width of an empty and unopen carton, the transverse distance between the carton support members being short of the transverse distance between the carton holder plates and a cam roller disposed for rotation about a horizontal axis within and across the linear conveyor between the carton holder plates and carton support members, the cam roller having a plurality of cam profiles as equally spaced as the spaces between the conveyor elements, each cam profile being disposed in the space between adjacent conveyor elements and having a small diameter lobe remaining flush with the top surface of the linear conveyor and a large diameter lobe remaining above the top surface of the linear conveyor and wherein the machine includes a carton discharge regulator located on the basal support at the discharge end of the linear conveyor.

2. The machine as claimed in claim 1, wherein the carton holder plates comprise a first adjustable mounting means for transversely and longitudinally adjustably mounting the carton holder plates on the basal support with respect to the linear conveyor and wherein the carton support members comprise a second adjustable mounting means for transversely and longitudinally adjustably mounting the carton support plates on the basal support with respect to the linear conveyor.

3. The machine as claimed in claim 1, wherein each carton feed regulator comprises a curved flat spring having its one end mounted to the basal support and its other end disposed above the linear conveyor describing a gap matching with the thickness of an empty unopen carton, a feed regulating vertical finger disposed above the linear conveyor and mounted to the basal support with the lower end of the vertical finger aligned with the other end of the flat spring and defining a gap with the linear conveyor matching the thickness of an empty and unopen carton and an oblong slider vertically freely slidably supported on the basal support aligned and spaced from the vertical finger and having a dead weight at the lower end thereof.

4. The machine as claimed in claim 3, wherein the carton feed regulator comprises adjustable support means for transversely and longitudinally adjustably mounting the curved flat spring, vertical finger and oblong slider with dead weight on the basal support with respect to the linear conveyor and for vertically adjustably mounting the vertical finger to the basal support.

5. The machine as claimed in claim 3, wherein the flat spring consists of tension adjustment means for adjusting the tension on the other end of the flat spring to adjust the gap between the other end of the flat spring and the linear conveyor.

6. The machine as claimed in claim 3, wherein the lower end of the vertical finger is tapered.

7. The machine as claimed in claim 1, wherein the carton discharge regulator comprises a carton guide roller disposed across the linear conveyor at the discharge end thereof spaced above the discharge end thereof and mounted to the basal support and having a plurality of soft flexible material rings mounted thereon spaced from one another, the outer circumference of the flexible material rings defining a gap with the linear conveyor matching the thickness of an empty and unopen carton.

8. The machine as claimed in claim 7, wherein the soft flexible material rings are rubber rings.

9. The machine as claimed in claim 7, wherein the carton guide roller consists of tension adjustable means for tension adjustably mounting the carton guide roller to the basal support at the discharge end of the linear conveyor to adjust the tension thereof towards the linear conveyor.

10. The machine as claimed in claim 1, wherein the incorrect carton rejection unit comprises an openable angular carton guide flap having one limb disposed at level with the discharge end of the linear conveyor and the other limb slopping down from the discharge end of the linear conveyor and hinged to the basal support at the discharge end of the linear conveyor and a linear actuator coupled to the carton guide flap to move the one limb of the carton guide flap inwardly and outwardly about the hinge thereof and an open top reject carton drawer retractably disposed below the discharge end of the linear conveyor across the discharge end of the linear conveyor.

11. The machine as claimed in claim 10, wherein the linear actuator is a pneumatic cylinder connected to an air supply source through a solenoid operated direction control valve and having its piston rod coupled to the carton guide flap.
,TagSPECI:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
As amended by the Patents (Amendment) Act, 2005
and
THE PATENTS RULES, 2003
As amended by the Patents (Amendment) Rules, 2014
COMPLETE SPECIFICATION
(Section 10 and Rule 13)

TITLE OF THE INVENTION

Machine for inspecting product identifier code on a carton for packing a product

APPLICANTS

Sci-tech Centre and ACG Inspection Pvt Ltd, both Indian companies and both of 7 Prabhat Nagar, Jogeshwari West, Mumbai 400 102, Maharashtra

PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the nature of this invention and the manner in which it is to be performed:
FIELD OF THE INVENTION
This invention relates to a machine for inspecting the product identifier code on a carton for packing a product.

In this specification, the term product means any product, whether consumable or non-consumable, and includes pharmaceutical, neutraceutical or food supplement product; the term product literature means product information and details and includes product leaflets and product booklets; and the term product identifier code includes any product identifier details such as marks, emblems, monograms, images, barcodes and pharmacodes. Plurals of these terms shall be understood accordingly.

BACKGROUND OF THE INVENTION
In pharmaceutical, neutraceutical and food supplement packaging industry, pharmaceutical, neutraceutical and food supplement products are packed in primary packagings such as blister packs or bottles and the blister packs or bottles are further packed in secondary packagings such as containers, typically cartons. Bottles may contain products in any form, for example, as tablets, capsules, powders, granules, liquids or syrups. Products also can be ampoules. Product literatures such as leaflets and booklets containing information and details about the products and product identifier code such as barcode and pharmacode are also packed in the cartons. The cartons are also preprinted with the product identifier code such as bar code and pharmacode. It is absolutely essential that the cartons containing the products and product literatures have the same product identifier code as the product literatures as otherwise the consequences can be disastrous.

In our Patent Application No 410/MUM/2015 Filed on 7 February 2015, we have described and claimed a machine and an automated method for inspecting the product identifier code on a product literature. The machine includes an elevated base plate having a product literature feed end and a product literature discharge end. An endless linear conveyor is disposed for rotation along the length of the base plate about the product literature feed end and product literature discharge end of the base plate. A product literature feed unit is located at the product literature feed end of the base plate. A product identifier code capturing unit is located at an intermediate position of the base plate. An incorrect product literature rejection unit is located on the base plate after the product identifier code capturing unit. A correct product literature collector is located at the product literature discharge end of the base plate. The operation of the machine is controlled and the operational status of the machine is indicated by a control unit.

In an embodiment of the machine, the base plate is mounted on a cabinet having a door. The linear conveyor is a split belt conveyor consisting of a plurality of conveyor elements spaced from each other and disposed for rotation on a driver roller rotatably mounted at the product literature feed end of the base plate. A driven roller is rotatably mounted at the product literature discharge end of the base plate. Auxiliary rollers are rotatably mounted underneath the base plate. The driver roller is driven by a motor.

The product literature feed unit comprises a pair of flat vertical members spaced above the feed end of the base plate and spaced from each other corresponding to the width of a product literature and mounted on the base plate. One limb of an L-shaped member is located vertically against each vertical member to form an L-shaped product literature stacking space with the other limb of the L-shaped member. Gate means comprising a curved flat spring is vertically adjustably disposed above and across the linear conveyor between the vertical members describing a gap with the linear conveyor corresponding to the thickness of a product literature to control the product literature feed onto the linear conveyor one by one. The driver roller at the feed end of the base plate consists of a row of spaced radial suction holes extending across the circumference thereof and positioned at the bottom of the stacking space. Each suction hole is located in the space between a pair of linear conveyor elements and connected to a vacuum source through an axial hole in the driver roller communicating with the suction holes.

The incorrect product literature rejection unit comprises an inverted channel member located across the base plate spaced above the linear conveyor and having a row of air blower nozzles located at one end of the inverted channel member and connected to an air supply source through a solenoid operated direction control valve and a reject product literature collection bin located at the other end of the inverted channel member and having air vents.

Before packing the primary packagings such as blister packs or bottles in empty cartons, the empty and unopen cartons are first inspected for their product identifier codes such as bar codes and pharmacodes manually. Manual inspection of the cartons is time consuming, inconvenient and cumbersome, labour intensive, reduces productivity and leads to operature fatigue. It is also prone to human reading errors.

The suction based product literature feed unit of the machine of the above patent application No 410/MUM/2015 has been found to be ineffective in feeding the cartons one by one onto the linear conveyor efficiently, possibly because the cartons are heavier than product literatures and the cartons differ from product literatures in shape, configuration and geometry. Possibly because of the above differences, the pneumatic incorrect product literature rejection unit of the above machine also has been found to be ineffective in rejecting the incorrect cartons on the conveyor efficiently. Furthermore, effective control of suction and positive air pressure to achieve feeding of the cartons and rejection of the incorrect cartons effectively, if at all possible, will be quite difficult and complex and expensive.

There is thus need for machines for inspecting the product identifier codes of products on cartons for packing the products to address the problems associated with manual inspection thereof.

DESCRIPTION OF THE INVENTION
According to the invention there is provided a machine for inspecting product identifier code on a carton for packing a product, including a split belt linear conveyor disposed for rotation about a horizontal axis along the length of an elevated basal support and having a carton feed end and carton discharge end and consisting of a plurality of conveyor elements spaced from one another, a carton feed unit located on the basal support at the carton feed end of the linear conveyor, a product identifier code capturing unit located on the basal support at an intermediate position of the linear conveyor, an incorrect carton rejection unit located on the basal support at the carton discharge end of the linear conveyor and a control unit for controlling the operation of the machine and indicating the operational status of the machine, wherein the carton feed unit comprises a pair of flat vertical carton holder plates disposed above the linear conveyor at the carton feed end thereof spaced from each other across the linear conveyor and facing each other widthwise and mounted on the basal support, the transverse distance between the carton holder plates corresponding to the length of an empty and unopen carton, a plurality of carton feed regulators disposed between the carton holder plates spaced from one another and mounted on the basal support, a pair of vertical carton support members disposed above the linear conveyor at the carton feed end thereof spaced from each other across the linear conveyor and facing each other and mounted on the basal support, the carton support plates being disposed at a longitudinal distance with the carton holder plates along the linear conveyor corresponding to the width of an empty and unopen carton, the transverse distance between the carton support members being short of the transverse distance between the carton holder plates and a cam roller disposed for rotation about a horizontal axis within and across the linear conveyor between the carton holder plates and carton support members, the cam roller having a plurality of cam profiles as equally spaced as the spaces between the conveyor elements, each cam profile being disposed in the space between adjacent conveyor elements and having a small diameter lobe remaining flush with the top surface of the linear conveyor and a large diameter lobe remaining above the top surface of the linear conveyor and wherein the machine includes a carton discharge regulator located on the basal support at the discharge end of the linear conveyor.

DESCRIPTION OF THE ACCOMPANYING SCHEMATIC DRAWINGS
Fig 1 is an isometric view of the machine for inspecting the product identifier code on a carton for packing a product according to an embodiment of the invention;

Fig 2 is an isometric view of the machine of Fig 1 without the cabinet;

Fig 3 is an isometric view of the linear conveyor and basal support of the machine of Fig 1;

Fig 4 is a view of the linear conveyor of the machine of Fig 1 including the rear support plate;

Fig 5 is a view of the drive roller or driven roller and the split conveyor of the machine of Fig 1;

Fig 6 is an isometric view of the cam roller of the machine of Fig 1;

Figs 7 and 8 are elevation and end view of the cam roller of Fig 6;

Figs 9 and 10 are enlarged scrap isometric views of the carton feed unit of the machine of Fig 1;

Fig 11 is an enlarged scrap view of a feed regulator of the carton feed unit of the machine of Fig 1;

Fig 12 is an enlarged scrap view of the product identifier code capturing unit of the machine of Fig 1;

Fig 13 is an enlarged scrap view at A in Fig 10;

Fig 14 is a scrap isometric view of the carton discharge regulator and incorrect carton rejection unit of the machine of Fig 1;

Fig 15 is a sectional view of the carton discharge regulator and incorrect carton rejection unit of Fig 14;

Fig 16 is a scrap view of the linear conveyor and the carton guide roller;

Fig 17 is a sectional view of the carton discharge regulator in Fig 14;

Fig 18 is an enlarged view at B in Fig 17; and

Fig 19 is a block diagram of the control unit of the machine of Fig 1.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION
The machine 200 for inspecting the product identifier code on a carton (not shown) as illustrated in Figs 1 to 19 of the accompanying drawings includes an elevated basal support 201 consisting of a front support plate 201a and a rear support plate 201b spaced from each other and mounted on a cabinet 202 (Figs 1, 2, 3). The basal support plate can be of a different construction. Instead of mounting the support plates on the cabinet they can be mounted at an elevated or raised position on another suitable elevated support structure.

An endless split belt linear conveyor 203 is disposed for rotation about a horizontal axis along the length of the basal support 201 on a driver roller 204 and a driven roller 205. The linear conveyor consists of a plurality of conveyor elements 206 spaced from one another having spaces 206a therebetween. The conveyor elements are engaged in position on the driver and driven rollers between pairs of raised rims or ridges 207 on the driver and driven rollers (Figs 1, 2, 3, 4, 5, 6, 7). Driver roller 204 is driven by motor 208 coupled to it. 209 is a tension roller (Fig 4). The linear conveyor has a carton feed end 210 and a carton discharge end 211.

A carton feed unit 212 is located on the basal support at the carton feed end of the linear conveyor (Figs 1, 2, 9, 10). The carton feed unit comprises a pair of flat vertical carton holder plates 213, 213 disposed above the linear conveyor at the feed end thereof spaced from each other across the linear conveyor and facing each other widthwise. The carton holder plates are mounted to first support blocks 214a slidably supported on first transverse rods 215a and held in position by tightening bolts (not shown) in holes 216 in the first support blocks against the respective first transverse rod.

The first transverse rods are supported in first upright blocks 217a slidably supported on longitudinal members 218 extending along the length of the basal support and supported on the support plates 201a and 201b. The upright blocks are held in position on the longitudinal members by tightening bolts (not shown) in holes 219 at the bottom of the upright blocks against the longitudinal members (Fig 13).

The first support blocks 214a are slidable and adjustable transversely across the linear conveyor on the first transverse rods 215a. The first upright blocks 217a are slidable and adjustable on the longitudinal members 218 along the length thereof and hence longitudinally with respect to the linear conveyor. Because of the adjustability of the first support blocks on the first transverse rods and the adjustability of the first upright blocks on the longitudinal members, the carton holder plates can be adjusted across the width of the linear conveyor and along the length of the linear conveyor. Therefore, the transverse distance between the carton holder plates across the linear conveyor and the longitudinal distance of the carton holder plates along the length of the linear conveyor can be adjusted.

A plurality of carton feed regulators 220 are disposed between the carton holder plates 213 spaced from one another (Figs 1, 2, 9, 10, 11). Only one carton feed regulator has been shown in detail in Figs 9, 10 and 11 for clarity. Each carton feed regulator comprises a support member 220a slidably supported on the first transverse rods 215a. The support member is held in position on the first transverse rods with bolts (not shown) tightened in holes 221 in the support member against the respective first transverse rods.
A curved flat spring 222 is held aligned with each support member with its one end 222a fixed to the support member and its other end 222b disposed above the linear conveyor describing a gap 222c with the linear conveyor matching the thickness of an empty and unopen carton (Fig 11). The tension on the other end 222b of the flat spring 222 is adjustable with a bolt 223 passing through the support member and having its tip bearing against the other end of the flat spring (Fig 11). The bolt 223 is operated to adjust the tension on the other end of the flat spring and the gap between the other end of the flat spring and the linear conveyor.

A feed regulating vertical finger 224 is disposed above the linear conveyor with its lower end aligned with the other end of the flat spring and defining a gap 222d with the linear conveyor matching the thickness of an empty and unopen carton (Fig 11). A mounting block 225 is held at the top of the support member and the vertical finger up and down movably extends down through the mounting block. The height of the vertical finger and hence the gap between the lower end of the vertical finger and the linear conveyor is adjustable by moving the vertical finger up and down in the mounting block. The vertical finger is held in position by tightening a bolt (not shown) in an oblong slot 226 on support member and a corresponding oblong slot (not shown) in the vertical finger. Head 227 of the vertical finger prevents dismantling or removal of the mounting block 225 while adjusting the slider 228 on the carton stacking.

An oblong slider 228 is vertically freely slidably held in the mounting block 225 aligned and spaced from the vertical finger and having a dead weight 229 at the lower end thereof. Head 230 of the oblong slider abuts against the mounting block at the lowest position of the oblong slider and prevents it from falling down completely and getting detached from the mounting block.

Because the support members 220a are transversely adjustable on the first transverse rods 215a, the vertical fingers 224 and oblong sliders 228 with dead weights 229 and the flat springs 222 are adjustable transversely across the linear conveyor. Because the upright blocks 217a carrying the first transverse rods are adjustable along the length of the longitudinal members 218, the vertical fingers and oblong sliders with dead weights and the flat springs 222 are also adjustable along the length of the linear conveyor.

A pair of vertical carton support members 231, 231 are disposed above the linear conveyor at the carton feed end thereof spaced from each other across the linear conveyor and facing each other (Figs 1, 2, 9, 10). The carton support members are disposed at a longitudinal distance with the carton holder plates along the linear conveyor corresponding to the width of an empty and unopen carton. The carton support members are fixed to second support blocks 214b slidably mounted to second transverse rods 215b disposed across the linear conveyor. The second transverse rods are mounted to second upright blocks 217b slidably supported on longitudinal members 218. The second support blocks are held in position on the second transverse rods 215b and the second upright blocks 217b are held in position on the longitudinal members in the same manner as the first support blocks 214a and second upright blocks 217a are held in position on the first transverse rods 215a and the longitudinal members, respectively.

Because of the adjustability of the second support blocks transversely on the second transverse rods across the linear conveyor and because of the adjustability of the second upright blocks on the longitudinal members longitudinally with respect to the linear conveyor, the carton support plates are adjustable transversely across the linear conveyor and along the length of the linear conveyor.

A cam roller 232 is disposed for rotation about a horizontal axis within and across the linear conveyor 203 between the carton holder plates 213 and carton support plates 231 (Figs 6, 7, 8, 9, 10). The cam roller has a plurality of cam profiles 233 as equally spaced as the spaces 206a between the conveyor elements 206. Each cam profile is disposed in the space between adjacent conveyor elements and has a small diameter lobe 233a remaining flush with the top surface of the linear conveyor and a large diameter lobe 233b remaining above the top surface of the linear conveyor. The cam roller is rotated by motor 234 coupled to it (Figs 2, 3).

A product identifier code capturing unit 7 of the same configuration and function as that of patent application No 410/MUM/2015 is located on the basal support at an intermediate position of the linear conveyor (Figs 1, 2, 12). It comprises a vision camera 48 with an inbuilt focusing light source 49 located above the linear conveyor 203 facing the linear conveyor and an image grabber circuit 48a (Fig 18). As explained in application No 410/MUM/2015, the vision camera with the light source is adjustable linearly along the length of the linear conveyor and across the linear conveyor. The vision camera with light source is also height adjustable on the basal support.

Adjustability of the vision camera with light source and functioning of the product identifier code capturing unit have been clearly described in application No 410/MUM/2015 and have not been repeated here for the sake of brevity and as it is not necessary to understand the invention. Adjustability of the vision camera and light source affords flexibility to change the position of the vision camera with light source depending upon the length width and thickness of the carton moving on the linear conveyor to achieve better focusing and better image capturing of the product identifier code on the carton.

A trigger sensor 74 is disposed ahead of the product identifier code capturing unit 7 and mounted to a cross bar 400 with a bracket 401 mounted to a third support block 401a slidably held on the cross bar (Figs 12 and 18). The support block 401a with the trigger sensor is held in position on the cross bar with a bolt (not shown) tightened against the cross bar through hole 402 in the support block 401a. The cross bar is mounted to third upright blocks 403 slidably supported on the longitudinal members 218.

The upright blocks 403 are held in position on the longitudinal members by tightening bolts (not shown) against the longitudinal members through holes 404 in the upright blocks 403. Because the support block 401a is slidable on the cross bar, the trigger sensor is adjustable across the linear conveyor. The support block 401a with the trigger sensor is also adjustable along the length of the linear conveyor by sliding the upright blocks 403 on the longitudinal members.

A carton discharge regulator 235 is located on the basal support 201 at the discharge end 211 of the linear conveyor 203 (Figs 1, 2, 14, 15, 16, 17, 18). The carton discharge regulator comprises a carton guide roller 236 disposed across the linear conveyor 203 at the discharge end thereof spaced above the linear conveyor. The carton guide roller is mounted in a pair of mounting blocks 237, 237 located above the basal support across the discharge end of the linear conveyor with support pins 238 held in the mounting blocks and in a top plate 239. The carton guide roller is tensioned towards the linear conveyor with tension springs 240 held over the support pins and tightened with nuts 241. The mounting blocks are supported on the longitudinal members 218 passing through mounting holes 242 in the mounting blocks.

The guide roller consists of a plurality of soft flexible material rings 243 mounted thereon spaced from one another. The flexible material rings are preferably rubber rings. The outer circumference of the flexible material rings define a gap 243a with the linear conveyor matching with the thickness of an empty or unopen carton (Fig 16). The gap between the soft material rings and the linear conveyor is adjusted by loosening or tightening the springs with the nuts. By adjusting the tension of the springs and the gap between the flexible material rings and the linear conveyor, cartons of different thickness can be handled in the machine of the invention.

An incorrect carton rejection unit 244 is located on the basal support 201 at the discharge end 201 of the linear conveyor 203 (Figs 1, 2, 14, 15). The carton rejection unit 244 comprises an openable angular carton guide flap 245 having one limb 245a disposed at level with the discharge end of the linear conveyor and the other limb 245b slopping down from the discharge end of the linear conveyor and hinged (hinge 246) to a support plate 247 mounted to the basal support 201 at the discharge end 211 of the linear conveyor 203. A pneumatic cylinder 248 is connected to an air supply source (not shown) through a solenoid operated direction control valve 249 (Fig 19).

The pneumatic cylinder is coupled to the carton guide flap to move the one limb of the carton guide flap inwardly and outwardly about the hinge thereof. An open top reject carton drawer 250 is retractably disposed in the cabinet 202 below the discharge end of the linear conveyor across the discharge end of the linear conveyor (Figs 1, 2). The drawer has a handle 251. 251a is a looking window (transparent portion) at the front of the drawer. The pneumatic cylinder is a linear actuator which can be any other known linear actuator for instance an inner tube moving in an outer tube.

A control unit 73a of substantially the same configuration and function as that of the patent application No 410/MUM/2015 and illustrated as block diagram in Fig 19 controls the operation of the machine. The control unit 73a includes the trigger sensor 74 mounted ahead of the product identifier code capturing unit 7 and a carton presence verifier sensor 75 mounted at the discharge end 211 of the linear conveyor 203 on the top plate 239 with a bracket 253 (Figs 1, 2, 19).

A microcontroller 76 is connected to the motor 208 driving the driver roller 204 and the linear conveyor and to the motor 234 driving the cam roller 232 through speed control devices 254 and 255 such as potentiometers, respectively and is configured to drive the motors. Microcontroller is also configured to receive inputs from the trigger sensor and carton presence verifier sensor and drive the camera 48 with light source 49 through image grabber circuit 48a and the solenoid operated direction control valve 249 and an audio visual alarm 77. 78 is a central processing unit (CPU) configured to receive input from the camera and to communicate two way with the microcontroller and a graphic unit interface (GUI) 79.

The audio visual alarm 77 consists of a hooter (not shown) and three differently colored light emitting diodes 80a, 80b and 80c to indicate the operating status of the machine (Fig 1). The graphic unit interface consists of a mouse (not shown), a keypad (not shown) and a monitor 81. The trigger sensor and carton presence verifier sensor are preferably fiber optic sensors. The image grabber circuit is, preferably, a high speed image grabber circuit and the inbuilt light source is, preferably, a light emitting diode configured to flash light on the carton on the linear conveyor. 82a and 82b are emergency switches connected to the microcontroller (Figs 1, 19).

The monitor 81 is mounted to a stand 87 on the basal support 2 and is hinged (hinge marked 88) to the stand so that the monitor can be rotated about the stand by 270° to move the monitor away from the basal support and to adjust the position of the monitor on the basal support to improve visibility of display on the monitor (Fig 1). Light emitting diodes 80a, 80b and 80c are also mounted on the stand 87 for better visibility.

Before operation of the machine, the transverse distance between the carton holder plates 213 across the linear conveyor 203 is adjusted to match the length of an empty and unopen carton. The transverse distance between the carton support plates 231 is adjusted to be short of the transverse distance between the carton holder plates ie length of the empty and unopen carton. The longitudinal distance between the carton holder plates and the carton support plates with respect to the length of the linear conveyor is adjusted to match the width of an empty or unopen carton.

The gaps 222d and 22c between the lower end of the vertical finger 224 and the other end 22b of the flat spring 222 against the linear conveyor 203 are adjusted to match the thickness of an empty and unopen carton. The gap 243a between the linear conveyor 203 and the flexible material rings 243 on the carton guide roller 236 is also adjusted to match the thickness of an empty and unopen carton. A stack of cartons (not shown) are located in the space between the carton holder plates and carton support plates after lifting up the oblong slider 228 with the dead weight 229. The dead weight is allowed to rest against the top most carton.

In each cycle of rotation of the cam roller 232 during operation of the machine, the large diameter lobes 233b of the cam profiles 233 remain above the top surface of the linear conveyor and the small diameter lobes 233a of the cam profiles remain flush with the top surface of the linear conveyor alternatively. During the short interval the large diameter lobes are progressively rotating upwardly above the top surface of the linear conveyor, the small diameter lobes are rotating downwardly underneath the conveyor and the stack of cartons are lifted up on the larger diameter lobes above the conveyor against the weight of the dead weight. During the short interval the large diameter lobes are progressively rotating down and the small diameter lobes are rotating upwardly in the opposite direction, the stack of cartons are lowered against the small diameter lobes.

When the small diameter lobes are flush with the top surface of the linear conveyor, the stack of cartons are lowered onto the linear conveyor under the weight of the dead weight. While the stack of cartons tend to move forward on the linear conveyor, the vertical fingers 224 stop the movement of the stack of cartons on the linear conveyor. Only the bottommost carton will be allowed to pass through the gaps 222d and 222c between the lower end of the vertical fingers and the other ends 22b of the flat springs 222 and continue to move forward on the linear conveyor. As a result, the cartons move forward on the linear conveyor one by one.

The lower ends of the vertical fingers and the other ends of the flat springs act as gate for the cartons to pass therethrough. The lower ends of the vertical fingers are preferably tapered marked 224a to make point contact against the carton and allow the carton to slide forward on the conveyor against the tapered lower ends of the vertical fingers.

Because of the adjustability of the transverse distance and longitudinal distance between the carton holder plates and carton support plates and because of the adjustability of the gaps between the lower ends of the vertical fingers and the other ends of the flat springs, it is possible to handle cartons of different sizes and thickness in the machine of the invention. The mechanical strength and bearing capacity of the cam roller 232 is sufficient to hold and lift and lower the stack of cartons effectively. As the stack of cartons goes on decreasing in number, the free falling dead weight continue to drop down under its own weight and hold the stack of cartons in position.

The CPU 78 communicates two way with the microcontroller 76 and GUI 79. The microcontroller 76 controls the speed of rotation of the conveyor driver roller 204 and hence conveyor 203 and the cam roller 232 through the drive devices 254 and 255, respectively. The microcontroller 76 senses the presence of the carton on the linear conveyor through the trigger sensor and drives the image grabber circuit 48a which in turn activates the light source 49 and vision camera 48. The vision camera captures the image of the product identifier code on the carton. The CPU compares the image of the product identifier code captured by the camera with the reference image of the correct product identifier code stored in the CPU and feeds the information to the microcontroller.

If the captured product identifier code matches with the product identifier code stored in the CPU and is correct, then the microcontroller, on sensing the presence of the carton on the linear conveyor through the carton presence verifier sensor 75 signals the information to the CPU and the machine continues to operate and the cartons with the correct product identifier code drop down the discharge end of the linear conveyor over the carton guide flap 245 and are collected at the discharge end 211 of the linear conveyor 203 for packing the product and product literature.

In case the captured image of the product identifier code does not match with the reference product identifier code stored in the CPU, the CPU passes on the information to the microcontroller and the microcontroller operates the solenoid operated direction control valve 249 to pressurize the pneumatic cylinder 248 and move the one limb 245a of the carton guide flap 245 outwardly and create a gap (opening) between the discharge end of the linear conveyor and the one limb of the carton guide flap and allow the carton with the incorrect product identifier code to drop down through the gap into the open top drawer 250 below the discharge of the linear conveyor very effectively.

The microcontroller then operates the direction control valve to depressurize the pneumatic cylinder and move the one limb of the carton guide flap inwardly to its original position and close the gap between the discharge end of the linear conveyor and the one limb of the carton guide flap.

The defective cartons are collected from the drawer 250 periodically by retracting the drawer. In case the product literature presence verifier sensor 75 does not sense the opening of the one limb 245a of the carton guide flap 245 and the carton with incorrect product identifier code dropping down, then the microcontroller communicates the information to the CPU and stops operation of the motors 208 and 234 driving the driver roller 204 and linear conveyor 203 and the cam roller 232, respectively and the machine stops operating.

The microcontroller indicates operational status of the machine by operating the differently coloured light emitting diodes (LEDs) 80a, 80b and 80c. Preferably LED 80a is coloured red to indicate rejection of incorrect carton by the incorrect carton rejection unit 244, LED 80b is coloured yellow to indicate that the machine is in operation and LED 80c is coloured green to indicate that the machine is ready for operation. Three LEDs and their colour combinations to indicate operational status of the machine as stated above are only a preference. The number of LEDs and their colour combinations may vary.

The mouse and keypad of the GUI 79 help to manually interact with the CPU to give instructions to the CPU or edit instructions to the CPU. Operational status of the machine can be read on the monitor 81. Emergency switch 82a and 82b are to manually stop operation of the machine in case of emergency. On operating either of the switches 82a and 82b, the microcontroller 76 signals the motors 208 and 234 to be switched off. The microcontroller operates the hooter in case of emergency to alert the operator of the machine.

While travelling through the gap 243a between the flexible material rings 243 on the carton guide roller 236 and the linear conveyor 203, the soft material rings of the carton guide roller abut smoothly against the carton and allow the carton to move out of the discharge end of the linear conveyor one by one. As a result, the movement of the cartons along the discharge end 211 of the conveyor is regulated and controlled and there are no possibilities of the cartons scattering at the discharge end of the linear conveyor and blocking the movement of the cartons on the linear conveyor.

The cabinet can be of a different construction or configuration and may have casters or wheels to facilitate portability thereof. The control unit can be configured differently. The control unit need not be configured to indicate the operational status of the machine. The carton discharge regulator can be of a different construction or configuration. The first adjustable mounting means of the carton holder plates comprising first support blocks and first upright blocks can be of a different construction and configuration. The second adjustable mounting means of the carton support plates comprising second support blocks and second upright blocks can be of a different construction and configuration.

The carton feed regulators can be of a different configuration and construction. The adjustable support means of the carton feed regulators comprising support members can be of a different construction and configuration. The tension adjustment means comprising tensioning screw for the other end of the flat spring can be of a different construction and configuration. The tension adjustable means for the carton guide roller comprising support pins and tension springs can be of a different construction and configuration. Such variations of the invention are obvious to a person skilled in the art and should be construed and understood to be within the scope of the invention.


We Claim
1. Machine for inspecting product identifier code on a carton for packing a product, including a split belt linear conveyor disposed for rotation about a horizontal axis along the length of an elevated basal support and having a carton feed end and carton discharge end and consisting of a plurality of conveyor elements spaced from one another, a carton feed unit located on the basal support at the carton feed end of the linear conveyor, a product identifier code capturing unit located on the basal support at an intermediate position of the linear conveyor, an incorrect carton rejection unit located on the basal support at the carton discharge end of the linear conveyor and a control unit for controlling the operation of the machine and indicating the operational status of the machine, wherein the carton feed unit comprises a pair of flat vertical carton holder plates disposed above the linear conveyor at the carton feed end thereof spaced from each other across the linear conveyor and facing each other widthwise and mounted on the basal support, the transverse distance between the carton holder plates corresponding to the length of an empty and unopen carton, a plurality of carton feed regulators disposed between the carton holder plates spaced from one another and mounted on the basal support, a pair of vertical carton support members disposed above the linear conveyor at the carton feed end thereof spaced from each other across the linear conveyor and facing each other and mounted on the basal support, the carton support plates being disposed at a longitudinal distance with the carton holder plates along the linear conveyor corresponding to the width of an empty and unopen carton, the transverse distance between the carton support members being short of the transverse distance between the carton holder plates and a cam roller disposed for rotation about a horizontal axis within and across the linear conveyor between the carton holder plates and carton support members, the cam roller having a plurality of cam profiles as equally spaced as the spaces between the conveyor elements, each cam profile being disposed in the space between adjacent conveyor elements and having a small diameter lobe remaining flush with the top surface of the linear conveyor and a large diameter lobe remaining above the top surface of the linear conveyor and wherein the machine includes a carton discharge regulator located on the basal support at the discharge end of the linear conveyor.

2. The machine as claimed in claim 1, wherein the carton holder plates comprise a first adjustable mounting means for transversely and longitudinally adjustably mounting the carton holder plates on the basal support with respect to the linear conveyor and wherein the carton support members comprise a second adjustable mounting means for transversely and longitudinally adjustably mounting the carton support plates on the basal support with respect to the linear conveyor.

3. The machine as claimed in claim 1, wherein each carton feed regulator comprises a curved flat spring having its one end mounted to the basal support and its other end disposed above the linear conveyor describing a gap matching with the thickness of an empty unopen carton, a feed regulating vertical finger disposed above the linear conveyor and mounted to the basal support with the lower end of the vertical finger aligned with the other end of the flat spring and defining a gap with the linear conveyor matching the thickness of an empty and unopen carton and an oblong slider vertically freely slidably supported on the basal support aligned and spaced from the vertical finger and having a dead weight at the lower end thereof.

4. The machine as claimed in claim 3, wherein the carton feed regulator comprises adjustable support means for transversely and longitudinally adjustably mounting the curved flat spring, vertical finger and oblong slider with dead weight on the basal support with respect to the linear conveyor and for vertically adjustably mounting the vertical finger to the basal support.

5. The machine as claimed in claim 3, wherein the flat spring consists of tension adjustment means for adjusting the tension on the other end of the flat spring to adjust the gap between the other end of the flat spring and the linear conveyor.

6. The machine as claimed in claim 3, wherein the lower end of the vertical finger is tapered.

7. The machine as claimed in claim 1, wherein the carton discharge regulator comprises a carton guide roller disposed across the linear conveyor at the discharge end thereof spaced above the discharge end thereof and mounted to the basal support and having a plurality of soft flexible material rings mounted thereon spaced from one another, the outer circumference of the flexible material rings defining a gap with the linear conveyor matching the thickness of an empty and unopen carton.

8. The machine as claimed in claim 7, wherein the soft flexible material rings are rubber rings.

9. The machine as claimed in claim 7, wherein the carton guide roller consists of tension adjustable means for tension adjustably mounting the carton guide roller to the basal support at the discharge end of the linear conveyor to adjust the tension thereof towards the linear conveyor.

10. The machine as claimed in claim 1, wherein the incorrect carton rejection unit comprises an openable angular carton guide flap having one limb disposed at level with the discharge end of the linear conveyor and the other limb slopping down from the discharge end of the linear conveyor and hinged to the basal support at the discharge end of the linear conveyor and a linear actuator coupled to the carton guide flap to move the one limb of the carton guide flap inwardly and outwardly about the hinge thereof and an open top reject carton drawer retractably disposed below the discharge end of the linear conveyor across the discharge end of the linear conveyor.

11. The machine as claimed in claim 10, wherein the linear actuator is a pneumatic cylinder connected to an air supply source through a solenoid operated direction control valve and having its piston rod coupled to the carton guide flap.

Dated this 15th day of June 2015

(Jose M A)
of Khaitan & Co
Agent for the Applicants
Reg No IN/PA-44