Title of Invention	A PALLETIZER FOR PALLETIZING INTO SQUARE/RECTANGULAR MATRIX PAINT PAILS/DRUMS
Abstract	The pail Palletizer were designed to make an automatic arrangement for pails, by making an arrangement for the carriage assembly by carrying it from slat conveyor and downloading it to the pallet, reducing the manual effort to a greater extent increasing time as well as energy. The carriage contains rectangular flats for holding pails or plates for holding drums. The carriage is directly connected to a hydraulic cylinder. The purpose of the carriage is to hold the matrix of pails/drums and to release the matrix on the palletization stand. There is also a step-by-step procedure arrangement, known as process for sequential acress of pails/drums accordingly with the help of components used during the process to make the process faster and get completed within the stipulated period of time. The efficiency of pail Palletizers with respect to Customers is fully 100%, as it is designed as per the Customer satisfaction & if taken into consideration of I/P/ O/P, it comes to 90%. The Pail Palletizers are provided with safety mesh to avoid any accidents & also view the process running successfully.

Title of Invention

A PALLETIZER FOR PALLETIZING INTO SQUARE/RECTANGULAR MATRIX PAINT PAILS/DRUMS

Abstract

The pail Palletizer were designed to make an automatic arrangement for pails, by making an arrangement for the carriage assembly by carrying it from slat conveyor and downloading it to the pallet, reducing the manual effort to a greater extent increasing time as well as energy. The carriage contains rectangular flats for holding pails or plates for holding drums. The carriage is directly connected to a hydraulic cylinder. The purpose of the carriage is to hold the matrix of pails/drums and to release the matrix on the palletization stand. There is also a step-by-step procedure arrangement, known as process for sequential acress of pails/drums accordingly with the help of components used during the process to make the process faster and get completed within the stipulated period of time. The efficiency of pail Palletizers with respect to Customers is fully 100%, as it is designed as per the Customer satisfaction & if taken into consideration of I/P/ O/P, it comes to 90%. The Pail Palletizers are provided with safety mesh to avoid any accidents & also view the process running successfully.

Full Text	FORM 2 THE PATENT ACT 1970 (39 of 1970) & The Patents Rules, 2003 PROVISIONAL/COMPLETE SPECIFICATION (See section 10 and rule 13) 5. 1. TITLE OF THE INVENTION An Improvised automatic pail/drum palletizer unit 2. APPLICANT (S) (a) NAME : Mr. Harikumar S. Menon (b) NATIONALITY: Indian (c) ADDRESS : B-204, ETERNIA, HIRANANDANI GARDENS, POWAI MUMBAI-400 076 PROVISIONALThe following specification describes the invention. COMPLETEThe following specification particularlyDescribes the invention and the manners inWhich it is to be performs. 4. DESCRIPTION (Description shall start from next page.) 5. CLAIMS (not applicable for provisional specification. Claims should start with the preamble "I/We claim" on separate page) 6. DATE AND SIGNATURE (to be given at the end of last page of specification) 7. ABSTRACT OF THE INVENTION (to be given along with complete specification on separate page) Note : - * Repeat boxes in case of more than one entry. * To be signed by the applicant(s) or by authorized registered patent agent. * Name of the applicant should be given in full, family name in the beginning. * Complete address of the applicant should be given stating the postal index no. / code, state and country. * Strike out the column which is/are not applicable. 1. TITLE OF INVENTION: - An improvised Automatic Pail/Drum Palletizer Unit. 2. FIELD OF INVENTION:- The present invention pertains to an automatized assembly unit for arrangement of pails/drums, specifically designed for paint industry wherein the paints are packed in pails/drums using Process & Carriage for reducing manual labour by providing a conveying system for transferring objects in layers on a pallet and is improved by addition of sensors that provide early indications of movement of component parts of pail palletizer to a control panel where the signals are used in a more efficient operation of pail palletizer and thereby providing a cost effective method for carriage of said pails and drums. 3 PRIOR ART- 1. Cylindrical object Palletizer Patent No. 5733100 Date:- Mar 31, 1998 This invention relates to packing of cylindrical cans in large quantities. In this invention, the first layer of cans is gripped and released on the pallet, which is kept at a certain height. For the second layer the pallet is moved downwards, distance equal to the height of the can. In this invention the layer holding assembly is fixed, whereas the pallet is moved up or down. In the present invention the layer holding carriage is movable and the pallet is fixed. In the above said invention the complete layers of cans are gripped at the sides, whereas in the present invention the layers of objects are held at the bottom. 2. Device for automatically loading a conveyor Patent No. 5921740 Date :- July 13, 1999 This invention is used for automatic loading of rectangular packages on a trailer or shipping containers. Our invention is used for palletization of cylindrical objects on a pallet. In this invention the packages to be loaded are pushed on to the loading area, whereas in our invention the items are released on the pallet. 3. Layer palletizing method Patent no. 5,004,401 Date of patent: Apr. 2, 1991 This invention is used for palletization of rectangular articles on a load-carrying platform. A layer of articles are gripped at their sides and then placed on a load-carrying platform. In the present invention instead of gripping the articles (which are cylindrical in shape) are held at their sides. 4. Palletizer Patent no. 4,302,140 Date of patent: Nov. 24,1981 This is an invention used for palletization of rectangular articles such as cartons. The first layer is prepared and is lifted up by means of tines or fingers and gripped using side grippers. Then the second layer is prepared below the suspended layer and then the first suspended layer is made to fall on the second layer. In this way stacking is done. 2 4. SUMMARY OF INVENTION:- the present invention comprises of the following components- 1. Lifting table. 2. Pusher mechanism. 3. Conveyor. 4. Track forward pusher mechanism. 5. Drum/pail holding carriage. 6. Carriage lowering/raising mechanism. 7. Drum/Pail releasing mechanism. The arrangement of the carriage and the process used makes the Palletization process faster and within a stipulated period of time, directly reducing the manual effort. The Palletizer is fully satisfied by the customer point of view taking into consideration the Safety as well as the Productivity. A protective safety mesh is provided externally at the perimeter of the palletizer, thereby reducing the chances of accidents. 5 COMPLETE DESCRIPTION OF THE INVENTION: - Palletizer is a machine that is used for arranging a matrix of required number of rows and columns of pails, drums or other cylindrical container on a pallet or any load-carrying platform. The above said machine is specifically designed for use in paint or oil industry wherein the paints or oils are packed in pails or drums. The machine is designed for load capacity ranging from l0kgs to 35kgs per weight of unit pail or drum. The machine utilizes three main systems: 1. Mechanical System. 2. Hydraulic System. 3. Electrical System. 3 The Mechanical System consists of Conveyor and Frame structure. The Hydraulic System consists of Hydraulic Cylinders and Power Pack. The Electrical System consists of P.L.C., Starters, Contactors, Relays, Sensors, etc. Mechanical System:- The following are essential components of the machine:- 1. Lifting table. 2. Pusher mechanism. 3. Conveyor. 4. Track forward pusher mechanism. 5. Drum/Pail holding carriage. 6. Carriage lowering/raising mechanism. 7. Drum/Pail releasing mechanism. Hydraulic System:- The following are the essential components of the system:- 1. Table Lifting Cylinder, C1. 2. Forward pusher cylinder, C2. 3. Track forward pusher cylinder, C3. 4. Carriage holding/lowering cylinder, C4. 5. Pail/Drum releasing cylinder, C5. Electrical System:- the electrical system in the present invention comprises of a control panel. The following are the essential components on the control panel:- 1. Emergency stop. 2. Auto/Manual selector switch. 3. Individual switches for operating each cylinder (only in manual mode). 4. Cycle pause switch. 4 5. Hydraulic motor On/Off switch. 6. Conveyor On/Off switch. 7. Process start switch. 8. 201tr/101tr selector switch (Only for drum palletizer). 9. Selector switch for 2/3 layers (for 20Kgs pails). 10. Selector switch for 3 to 4 layers (for l0ltrs drum). INDUSTRIAL APPLICABILITY;- The description maintained in the above paragraphs does not limit or restrict the scope of the present embodiment of the invention. Thus the same assembly unit can also be used for lifting of cartons, boxes, drums etc. WORKING MECHANISM OF DIFFERENT SYSTEMS Mechanical System;- I. Lifting Table: - Standard Lifting tables are equipped to function long & reliably with "normal" use. Lifting tables meant for intensive use with heavy loads, fast speed, extreme environment & perhaps continuous working shifts. It is an angle frame structure fitted with idler rollers. The frame structure along with the idler rollers is mounted on a hydraulic cylinder. The essential purpose of the lifting table is to lift the pail/drum from the height of filling station to the height of the slat conveyor. II. Pusher Mechanism; - It is a simple arrangement of flats capable of pushing the pail/drum from the lifting table to the slat conveyor. A hydraulic cylinder operates the pusher mechanism. This mechanism enables the drum/pail to move from the lifting table to the slat conveyor. Once the pail/drum is on the conveyor then the conveyor moves and carries the pails/drums to a predetermined position on the conveyor. III. Conveyor:-It is basically a mechanical apparatus used for carrying bulk material from place to place; for e.g. an endless moving belt or a chain of receptacles. It is a slat belt conveyor driven by an electric motor. The slat conveyor accomplishes the first linear stacking of pails/drums. IV. Track forward pusher mechanism: - It is a simple arrangement of angles and flats, of sufficient strength/ tenacity, used to push the linearly stacked pails/drums on to the pail/drum holding carriage. It consists of hydraulic operated pushers arranged in parallel lines, such that when the pails/drums move from the conveyor belt the pusher forward mechanism pushes the already placed drum/pails onto the conveyor utilizing the track forward pusher mechanism. This arrangement of pushing linearly stacked pails/drums from the slat conveyor to the pail/drum holding carriage creates a rectangular stacking arrangement or matrix in pail/drum holding carriage. V. Pail/Drum holding carriage.-It is fabricated from flats and channels wherein the flats are used to hold and subsequently release the complete layer of pails. The carriage contains rectangular flats for holding pails or plates for holding drums. The carriage is directly connected to a hydraulic cylinder. The primary purpose of the carriage is to create and hold the matrix of pails/drums and to release the matrix on the palletization stand. VI. The up or down motion of the carriage is controlled by a hydraulic cylinder C4. The carriage is connected by means of chain and sprocket to the hydraulic cylinder. VII. The release mechanism is a rectangular structure made of flats. The pails are held at the necks by a rectangular flat, termed as neck holding flat. The pails are made to rest on the flats at their necks. The flats are supported at two ends. The end supports are in such a way so as to allow the flats to rotate about their longitudinal axis. One end of the flat is supported at the front side of the carriage and the other end is attached to a cam. The cams are connected to a hydraulic cylinder by a frame structure. The neck-releasing cylinder C5 controls the action of the frame structure. Initially the neck holding flats are horizontal in position. While releasing the necks, the cylinder moves downward and pushes the frame structure downwards. This downward motion causes the cams to rotate and simultaneously the neck holding flats rotate at 90° on its own axis. For release of Pail/drum a 90° turn (from horizontal to vertical) is given to the Pail/drum holding mechanism. A hydraulic cylinder C5 controls the release mechanism. The hydraulic cylinder is connected to the release mechanism by cams. The to and fro motion of the cylinder is converted by the cam to the rotary motion of the holding flats. Hydraulic System: -It basically consists of 5 hydraulic cylinders as mentioned below: - a. Table lifting cylinder, CI. b. Forward pusher cylinder, C2. c. Track forward pusher cylinder, C3. d. Carriage holding/lowering cylinder, C4. e. Pail/Drum releasing Cylinder, C5. 1. There are a total of 5 cylinders. Oil under a certain pressure, which is 35 bar, obtained from a power pack, is delivered to the cylinders. 2. Power Pack is a hydraulic pump system-supplying machine with high- pressure oil, wherein the motor is fitted with thermal overload protection. The power pack consists of a tank for holding oil, a pump and the motor, used for converting hydraulic energy into rotary motion, either fixed or variable for driving pump, which operates at 35bar pressure. 3. The pump sucks the oil from the tank, creates certain 35bar pressure in the oil and delivers the oil to the hydraulic cylinders via Direction control valves; it is a device for directing or preventing the oil flow in a system. 4. The Direction control valves are mounted on the top of the power pack plate besides the motor used to run the power pack. Two ports are provided on the Direction control valve, wherein ports form the internal or external terminals of passage, the point where fitting mechanism for control valves is attached which allows passage of oil from the respective hydraulic cylinders. 5. Similarly, two ports are provided for activation/working of the cylinder. Each cylinder is provided with a control valve. 6. The two ports of the valve are connected to the two ports of each cylinder. 7. When oil under a certain pressure is supplied to one of the ports then the cylinder piston moves forward/backward depending on the port on which oil under pressure is applied. 8. While oil is supplied to one port of the hydraulic cylinder, simultaneously oil from other port is removed, because it is imperative to make sure the oil is delivered clean to the gearbox. This may mean dispensing through a filter-cart or using a one-shot type sealed lubricant container supplied at a certified level of cleanliness. The fill port must also be clean prior to use. Like minimises sampling ports, two ports of the valve minimizes the risk of ingested contamination providing space for the incoming oil. 9. The P.L.C controls the said Direction control valves. 10. The cylinder piston moves forward/backward or up/down direction depending on the port in which oil is being supplied. 11.Cylinder CI has top & down position. C2 has forward or backward position. C3 has forward and backward position. C4 has a) uppermost 8 position b) pail loading position c) level 1 position d) level 2 positions and e) level 3 positions. C5 has up and down position. 12.The oil pressure is obtained from a power pack, which is an integral part of the hydraulic system. Electrical System: - The Palletizer is fully automatic in operation. The automation is controlled by a P.L.C. (Programmable Logic Controller) mounted in the control panel. The various sensors mounted on the machine at relevant locations provide inputs to the P.L.C. The different types of sensors used are as follows: - 1. Inductive sensors:.- Inductive sensor detects only metals. Inductive sensors are used to determine the positions of the entire hydraulic cylinders. Every cylinder except C4 has two positions. Cylinder C4 has five positions. Inductive sensors control all these positions. Each sensor is fixed at the exact backward/forward or up/down of each cylinder. Each cylinder is operated through a direction control valve, which in turn is controlled by the P.L.C. The sensors detect the exact position of each cylinder and this position is communicated to the P.L.C. controller. The P.L.C. then directs that particular cylinder according to the programmable logic. In all there are 13 inductive sensors used to detect the positions of Hydraulic Cylinders. 2. Reflective sensors: - Reflective sensors can detect any object. In the palletizer these sensors are used to detect pails/drums and are also called as I/R sensors. These reflective sensors perform two functions. Total there are six reflective sensors. The first three reflective sensors control the On Off motion of the conveyor. Other three reflective sensors detect the stacking layers. 9 Based on the inputs obtained from the sensors and according to a predetermined logic the P.L.C. then directs the operation of the various cylinders and conveyors. There are two types of sensors used, namely Inductive sensors and I/R sensors. The inductive sensors can sense only metals, whereas I/R sensors can sense any object. The sensing range for inductive sensor is 5mm and for I/R sensor is 200mm. The position of all the hydraulic cylinders is sensed by the inductive sensor and the product eg. (Pails / drums) is sensed by the I/R sensor. All cylinders except C4 have two positions, i.e. forward or backward. Cylinder C4 has five positions. The five positions are:- 1. Topmost position. 2. Pail/Drum loading position. 3. Level 1 position. 4. Level 2 position. 5. Level 3 position. Two inductive sensors are provided for each cylinder at their extreme positions, i.e. forward or backward. For cylinder C4 in addition to the two sensors, three more are provided for its Pail/Drum loading position, level 2 positions and level 3 positions. WORKING PROCESS OF PAIL PALLETIZER To be able to start the palletizer in auto mode an empty load-carrying platform (pallet) has to be placed in the machine. The operation starts by pressing the 'Process On' switch provided on the control panel. 1. During the start of the operation cycle all the hydraulic cylinders move to their respective initial positions. Cylinder CI moves to its down most 10 position, cylinder C2 moves to its forward most position, Cylinder C3 moves to its forward most position, Cylinder C4 moves to its pail loading position and cylinder C5 moves to its upper most position. An indication is given to the operator informing that the palletizer is ready for receiving pails/drums. 2. A packed pail/drum is placed on the lifting table. A reflective sensor mounted on the lifting table senses the pail/drum. A hydraulic cylinder (CI) operates the lifting table by moving it forward/backward movement. The cylinder lifts the table to the height of the slat conveyor. Once the table reaches the height of the Slat conveyor the pail/drum is pushed on to the conveyor by the pushing mechanism. The pushing mechanism is hydraulically operated by Forward pusher cylinder C2 wherein the pails/drums are loaded individually on a conveyor belt arrangement; the pusher mechanism consists of a rectangle flat attached to one end of the frame structure. 3. As the pushing mechanism reaches its back most position, a signal is given to the conveyor through PLC control to operate. The conveyor moves and carries the pail/drum along with it. When the pail/drum passes a reflective sensor mounted on the conveyor senses the pail/drums, whereby a stop signal through PLC control is given to the conveyor. In this way the pail/drum reaches a predetermined position on the conveyor. 4. The above process continues for the required number of rows. Once the required numbers of pails/drums are on the conveyor, an I/R sensor present at the end of the conveyor senses the pails/drums. This sensor gives a signal to the P.L.C., which in turn activates cylinder C3. The complete line of pails/drums is pushed in the pail/drum holding frame. 11 5. The above process continues for the required number of columns. A sensor is located at the backside of the carriage. This sensor senses the completion of Layer and accordingly gives a signal to the P.L.C. The P.L.C. then directs the cylinder C4 to move and the carriage is moved to its required position. 6. For a matrix of three layers, there are three positions for the carriage to release the pails/drums, i.e. level 1, level 2 and level 3. Three I/R sensors are placed vertically on the columns of the carriage assembly to determine the layer completion. Initially all the three levels are empty. The filled carriage moves to the position of level 1 and releases the pails/drums. The I/R sensor present senses this layer and gives a signal to the P.L.C. about the completion of layer 1. Following filled carriage is directed to move to the second layer position and releases the pails/drums. The third layer stacking follows this. In this way the three layers are stacked. 7. The holding mechanism is different for pails and drums. The pails have a protruding edge along the upper rim termed as neck. Two rectangular section flats which are attached to the inner side of the columns of the carriage assembly possessing/bearing a gap 215mm for l0Kgs and 284mm for 20Kgs, corresponding to the diameter of the pail at the upper rim. The pail neck is made to rest on the rectangular flats, termed as neck holding flats. In this way the pails are held. The design of the pail holding mechanism, using neck-holding flats allows movement of the pails along the length of the flats. The flats are supported at two ends. The supports are in such a way so as to allow the flats to rotate about their longitudinal axis. One end of the flat is supported at the front side of the carriage and the other end is attached to a cam. The linear motion of the hydraulic cylinder is converted by the cams to rotary motion of the neck holding flats. The cams are connected to a hydraulic cylinder by a frame 12 structure. The pails are made to rest on the pallet and the release mechanism is thereby activated thus rotating the flats through 90° making them vertical thereby giving enough clearance for the flats to pass through. 8. The above present invention can also be used for drums, not bearing protruding edges as in the case of pails. The drums are held at the bottom edge by two L-shaped side grippers. The grippers are designed in such a way to allow the drum to travel along its entire length of the flat assembly. The grippers are positioned in such a way so that they can rotate about their longitudinal axis. The side grippers rotate about their centres and while rotating the grippers separate away, thereby releasing the drums on the pallet. The two grippers rotate in opposite direction. The inside distance between the side grippers is slightly more than the maximum diameter of the drum. The bottom rim of the drum is made to rest on the side gripers. There is no positive or friction grip on the drum by the grippers. Separating the grippers and allowing the drums to fall freely on the load-carrying platform release the drums. The individual grippers are connected to a rectangular flat paced between the grippers rotating the flat through 90° separates the grippers. A hydraulic cylinder via a cam provides the rotary motion to the flats. 9. After releasing a layer of pails/drums on the load-carrying platform the pail/drum holding carriage returns to its pail/drum loading position. 10.The above-mentioned process continues for a required number of layers. Once the layers are completed then all the cylinders, except cylinder C4, move to their start position and cylinder C4 moves to its top most position. 1l.An alarm is sounded indicating the completion of one cycle of operation, which hardly takes 10-12 minutes. The platform on which the subsequent 13 pails are stacked has to be removed and an empty platform has to be placed in the Palletizer for the start of the second cycle. ADVANTAGES OF INVENTION:- 1. As compared to other Pail Palletizers they have advantages over cost & functioning of the carriage. 2. Previously, patented Palletizers were used only for lifting cans, small rectangular boxes, etc. But by making proper arrangement for process & the carriage assembly they have made an invention by automatically lifting pails for the Customers. 3. The equipment or the materials used for designing the Palletizer are easily available in the market. 4. Proper usage of the resources has been maintained. 5. Maintenance cost is very low, because of less wear & tear of the internal components. 6. The new Palletizer can handle matrix up to 5 5 pails in single procedure. 7. Initially, the pails/drums were lifted manually from filling station and were placed on the pallet, which takes much time for single operation. 8. It has an added advantage of saving the manual effort by providing a conveying system for transferring objects such as pails, where the present invention arranges the object in layers on a pallet and is improved by the addition of sensors that provide early indications of movements of components parts of the pail palletizer to a control panel where signals are used in a more efficient operation of the pail palletizer. 9. In the future designs there may be a slight variation in the arrangement of various components, but the holding and release mechanism will be same for all designs. 14 DESCRIPTION WITH ACCOMPANYING DIAGRAMS The following is the explanation of the entire Palletization process. Fig no. 1: - This view shows the first stage of the Palletizer. During the initial position a filled pail/drum is kept on the lifting table. A pail presence sensor present on the lifting table senses the pail/drum and starts the successive operations. Fig no.2:- This diagram shows the second stage of the palletizer. After the pail presence sensor has sensed the pail/drum, a signal is sent to the P.L.C. The P.L.C. then signals the lifting table to rise up to the level of the conveyor taking the pail/drum with it. Once the table has reached its level, a signal is sent to the P.L.C, which in turn activates the Forward pusher cylinder. Fig no.3;- This diagram shows the third stage. In this view the forward pusher cylinder has pushed the pail/drum on to the conveyor. Once the forward pusher cylinder reaches it backmost position a signal is sent to conveyor to start. This conveyor moves for a specific period and stops. Fig no.4:- In this diagram, the Lifting table and Forward pusher cylinder are back to their initial position. The conveyor has moved for a specific period and has stopped, and thereby carrying the pail/drum along with it. Fig no.5:- In this diagram, five pails are seen on the conveyor table. The above-mentioned process has repeated for five times. Once five pails/drums are on the conveyor table, a conveyor stop sensor present at the end of the conveyor senses the pails/drums and accordingly sends a signal to the P.L.C. The P.L.C. Controller in turn activates the Track Forward pusher 15 mechanism, which pushes the line of five pails/drums in to the pail/drum holding carriage. Fig no.6;- In this diagram, the five pails are pushed in to the pail/drum holding carriage by the Track forward pusher mechanism. A hydraulic cylinder C3 operates the Track forward pusher mechanism. Notice the Track forward pusher mechanism is at its back-most position. Fig no.7:- In this diagram, the pail/drum holding carriage is filled with the required number of pails/drums. The above-mentioned process has repeated five times and subsequently filled the pail/drum holding carriage. Once the carriage is full, a layer completion sensor present at the end of the carriage senses and accordingly signals the P.L.C. Controller. The P.L.C. Controller then signals the carriage lowering mechanism, which lowers the entire filled carriage on to the pallet. Fig no.8:- In this diagram, the filled carriage has lowered the layer of pail/drum on to the pallet. Once the carriage reaches this position, a signal is sent to the P.L.C. Controller to release the pail/drum on the pallet. Fig no.9:- In this diagram, the complete matrix of pails/drums is placed on the pallet and the carriage is back to its loading position. All the above-mentioned process repeats till the required numbers of layers are stacked. 16 DETAILED EXPLANATION FOR PAIL CARRIAGE Fig no.10: - represents the perspective view of the assembled Pail holding Carriage. Fig noil: - represents the side elevation of the assembled Carriage wherein: 11.1 Represents Carriage frame. 11.2 Represents Cam. 11.3 Represents Front Support. 11.4 Represents Bolts for front support. 11.5 Represents pins for Front support. 11.6 Neck holding flats. 11.7 Represents Bearing blocks. 11.8 Represents Cross angles. 11.9 Represents Middle Support. 11.10Represents Stepped portion of the Neck holding flats. 11.11 Represents Pins for Middle Support. Fig no. 12: - represents the front elevation of the assembled Carriage wherein: 12.1 Represents Carriage frame. 12.2Represents Front Support. 12.3Represents Bolts for front support. 12.4Represents Pins for front support. Fig no.13: - represents the isometric view of the Middle Support. This part is fabricated from M.S. square. The dimension of the top rectangular portion is 25mm x 25mm x 40mm and of the cylindrical portion is 12mm diameter x 130mm long wherein: 13.1 Represents Holes on middle support for fixing it on to the frame. 13.2Represents Pins for Middle support. This cylindrical pin rests on the slots provided on the Neck holding flats and supports them. The function of Middle Support is to provide support to the Neck 17 holding flats at the middle and at the same time allow rotational motion of the Neck Holding Flat. The entire matrix of pails is carried by the Neck Holding Flats, placing enormous weights on them. Without any supports the flats would bend and break due to the load. Fig no.14:- This figure shows the isometric view of Bearing block. The block is fabricated from M.S. Plates and its dimensions are 100mm long x 60mm height x 24mm width wherein: 14.1 Represents Ball Bearings. 14.2Represents holes on bearing blocks for fixing the block to the frame. The function of this block is to hold the Neck holding flats and at the same time allow rotational motion of the flats. Fig no.15:- This diagram shows the isometric view of the Stepped portion of the Neck Holding Flats. It is fabricated from M.S. Round and the dimension is 40mm diameter x 115mm long wherein: 5.1 represents slots on stepped portion for fixing the neck holding flats. Fig no.16;- This diagram shows the isometric view of cam. It is fabricated from M.S.Flats. The dimension are 190mm long x 40mm width x 12mm thick wherein: 16.1 represents slots on cams. The function of the Cam is to translate the linear motion of the cylinder into rotary motion of the Neck holding flats. Fig no.17;- This diagram shows the isometric view of Neck holding flat. It is fabricated from M.S. flats and its dimension are 1416mm long 40mm width * 12mm thick wherein: 17.1 represents slots on pins on middle support on neck holding flats. 17.2 represents holes for pins of front support on neck holding flats. The function of this flat is to hold the complete layer of pails and also release them. The structure of this flat coupled with the Cam makes possible the holding and releasing of the pails easily. 18 Fig no.18:- This diagram shows the isometric view of Front support. It is fabricated from M.S. squares. The dimension of the support is 170mm long x 20mm width x 20mm thick wherein: 18.1 represent holes for pins on front support. 18.2 represent holes on front support for fixing bolts. The function of this support is to provide support to Neck holding flats. Fig no.19:- This diagram shows the Carriage. It is fabricated from M.S. flats and dimension is 1450mm long * 1432mm wide * 200mm thick wherein: 19.1 represents cross angles. 19.2represents back flats for placing bearing block. 19.3represents holes on back plates of carriage. Fig no.20:- This diagram shows the isometric view of Carriage. The cross-angles are seen and also the holes at the backside and the Support flat. Fig no.21:- This diagram shows the isometric view of assembly of Neck holding flat with stepped portion wherein: 21.1 represents neck holding flats. 21.2 represents stepped portion of the neck holding flats. Fig no.22:- This diagram shows the isometric view of assembly of Neck holding flat with front support wherein: 22.1 represents front support. 22.2 represents pins for front support. 22.3 represents neck holding flats. Fig no.23;- This diagram shows the isometric view of assembly of Stepped portion with bearing blocks wherein: 23.1 represents neck holding flats. 23.2 represents bearing blocks. 23.3 represents stepped portion of the neck holding flats. This arrangement makes it possible for the Neck holding flats to rotate. 19 Fig no.24:- This diagram shows the isometric view of assembly of Neck holding flat with middle support wherein: 24.1 represents neck holding flats. 24.2 represents middle support. This arrangement gives support to the Neck holding flat and also allows rotational motion of the Neck holding flat. Fig no.25:- This diagram shows the isometric view of Cam with Stepped portion wherein: 25.1 represents cam. 25.2 represents stepped portion of the neck holding flats. The Cam is fixed only after the Stepped portion is assembled with the Bearing block. The Bearing block is omitted for the sake of clarity. This arrangement of the Stepped portion and Cam converts the to and fro motion of the cylinder into rotary motion of the Neck holding flat. Fig no.26:- This diagram shows the isometric view of Bearing block with the Carriage wherein: 26.1 represents carriage frame. 26.2 represents bearing blocks. The Bearing blocks are placed at the backside of the Carriage. 20 EXPLANATION OF DRAWINGS OF CARRIAGE OF DRUM PALLETIZER. The following are the explanation of the drawings. Some of the drawings are shown in isometric view for ease in understanding. Given below is the nomenclature of the individual items. Sr.no. Item name 27.1 Carriage frame 27.2 Rotating flats 27.3 Movable Grippers 27.4 Fixed Grippers 27.5 Springs 27.6 Gripper Supporting Rod 27.7 Bush on Gripper 27.8 Cam 27.9 Bearing Block 27.10 Back side holes for Rotating flats 27.11 Front side holes for Rotating flats 27.12 Back side holes for Gripper support Rod. 27.13 Front side holes for Gripper support Rod 27.14 Cross support Channels 27.15 Front holes on Rotating flats 27.16 Front holes on Gripper supporting flats 27.17 Back holes on Gripper supporting flats 27.18 Slot on Cam for fixing Rotating flats 27.19 Holes on Bush for passing Support rod 27.20 Hole in Cam for fixing Support rod 27.21 Slot on Cam for fixing Pin 27.22 Mating part of Cam of Stepped portion. 27.23 Mating part of Bearing of Stepped portion. 27.24 Ball bearing 27.25 Stepped portion of Rotating flats. 21 FIG. NO. 27-A This diagram shows the perspective view of the assembled Drum holding Carriage. This view gives an idea of how the carriage looks. The details of the assemblies and subassemblies are mentioned in the preceding drawings. FIG. NO. 27-B This diagram shows the isometric view of the carriage frame (27.1). The dimension of the frame is 1430mm long x 980mm wide x 460mm thick. The carriage is fabricated from M.S. Plates. Two cross support channels (27.14) are placed laterally above the frame. At the backside and at the front side of the carriage holes are drilled for the supporting the Support rods and Rotating flats. The holes 27.10 and 27.11 carry the Rotating flats and the holes 27.12 and 27.13 carry the Support rods. FIG. NO. 27-C This diagram shows the isometric view of the Support rods (27.6) and the Rotating flats (27.2). The holes drilled at the front (27.16,27.15) and at the backside (not shown) enable it to be bolted to the main carriage frame. The dimension of the Support rod is 25mm diameter x 1425mm long and is manufactured from M.S. Rods. The dimension of the Rotating flats is 1425mm long x 40mm wide x 12mm thick and is manufactured from M.S. Flats. The Support rods carry the entire rows of Grippers. The round shape of these rods enables the Grippers to rotate, which is essential for the release of the Drums. The Rotating flats aid in the releasing of the Drums. FIG. NO. 27-D This diagram shows the isometric view of Cam. It is fabricated from M.S. Flats. The dimension are 190mm long x 40mm width x 12mm thick. The Cam is fixed to the stepped portion of the Neck holding flat as shown in fig. no.27-K. A slot (27.21) is provided in the rectangular part. The function of the Cam is to translate the linear motion of the cylinder into rotary motion of the Neck holding flats. FIG. NO. 27-E This diagram shows the isometric view of the Stepped portion of the Rotating flats. It is fabricated from M.S. Round and the dimension is 40mm diameter x 115mm long. A rectangular slot (27.18) is provided at the front portion. The Rotating flat is inserted in this slot and is joined permanently by welding as shown in fig. No.27-J FIG. NO. 27-F This diagram shows the isometric view of the Grippers. These Grippers hold the Drums at their bottom. There are two types of Grippers i.e. Movable (27.3) and Fixed (27.4). The movable Grippers are allowed to rotate whereas the fixed Grippers remain stationary. The movable and the fixed Grippers are arranged alternately. When the complete matrix 21. of drums is filled in the carriage only the alternate Grippers hold the drums. The rest of the Grippers are empty. Therefore while releasing only the alternately arranged Movable Grippers rotate thereby releasing the complete matrix of drums. These Grippers are fabricated from M.S. plates and their dimension is 180mmlong x 120mm wide x 20mm thick. The Bush (27.7) are fabricated from M.S. rounds and their dimension are 40mm diameter x 50mm long. The Support rods are inserted in the hole provided on the bush (27.9) and gives support to the Grippers. FIG. NO. 27-G This diagram shows the isometric view of Bearing bush. It is fabricated from M.S. round and its dimension is 40mm diameter x 20mm long. A ball bearing (27.24) is inserted in the bearing block. This block gives support to the back end of the Rotating flats and also allows the rotary motion of the Rotating flats. FIG. NO. 27-H This diagram shows the isometric view of Springs. It is manufactured from standard spring materials. These springs are attached to back side of the Movable Grippers. They pull the grippers inside while the drums are being released. The exact mechanism of the Springs is given elsewhere. FIG. NO. 27-1 This diagram shows the isometric view of the assembly of 1. Fixed grippers (27.4) 2. Movable grippers (27.3) 3. Springs (27.5) 4. Supporting rods (2 7.6) 5. Rotating flats. (27.2) A common Supporting rod (27.6) is passed through the Grippers thereby giving support to them. A Spring (27.5) is attached at the backside of the movable grippers (27.3). A common Rotating flat (27.2) is passed between the corresponding lines of Grippers. In the initial position the springs tend to pull the corresponding Grippers inside but is prevented by the Rotating flat. Only when the Rotating flats have rotated through 90°, the springs pull the grippers inside thereby releasing the complete matrix of drums. FIG. NO. 27-J This diagram shows the isometric view of the assembly of /. Rotating flat (27.2) 2. Stepped portion (27.25) 3. Bearing block (27.9) The Rotating flat (27.2) is inserted in the slot of the Stepped portion (27.25) and is welded permanently. The Stepped portion is then inserted in the bearing (27.24) provided in the Bearing block. 22 FIG. NO. 27-K This diagram shows the isometric view of Cam (27.8) with Stepped portion (27.25). The Cam is fixed only after the Stepped portion is assembled with the Bearing block. The Bearing block is omitted for the sake of clarity. This arrangement of the Stepped portion and Cam converts the to and fro motion of the cylinder into rotary motion of the Rotating flat. FIG. NO. 27-L This diagram shows the isometric view of assembly of Bearing block (27.9) with Carriage frame (27.1). The Bearing blocks are permanently fixed on the backside of the frame as shown in the diagram. FIG. NO. 27-M This diagram shows the mechanism of the Release mechanism. In the initial position (fig A) the Movable Grippers (27.3) are vertical and a Spring (27.5) is attached to the backside. The tension in the spring tends to pull the Grippers inside but is prevented by the Rotating flats (27.2). During the release operation (fig B) the Rotating flats have rotated through 90° making them vertical. As soon as the flats have rotated the springs pull the Grippers inside thereby affecting the release of the Drums. DIAGRAMMATIC REPRESENTATION OF AUTOMATIC PAIL PALLETIZER Fig no.28:- It shows the front elevation of the Palletizer machine wherein: 28.1-represents the Lifting table. 28. 2-represents the pusher mechanism. 28. 3-represents the slat conveyor. 28. 4-represents the power pack. 28. 5-represents the power pack motor. 28. 6-represents the conveyor motor. 28. 7-represents the frame structure. 28. 8-represents the pulley chain assembly. Fig no.29:- It shows the side elevation of the Palletizer machine wherein: 29.1-represents forward pusher mechanism. 24 29. 2-represents pail/drum holding carriage. 29.3-carriage lowering mechanism. 29.4-represents neck releasing mechanism. 29. 5-represents neck holding flats. 29.6-represents lifting table. 29. 7-represents lifting cylinder. 29.8-represents forward pusher, cylinder. 29. 9-represents track forward pusher cylinder. 29.10-represents neck releasing cylinder. 29.11-represents control panel. Fig no 30:- It shows the side elevation showing all the inductive sensors for various cylinder. Each cylinder except C4 has two inductive sensors. Cylinder C4 has five inductive sensors to account for its five positions. All the remaining cylinders have only two positions, i.e. forward or backward wherein: 30.1-represents lifting table. 30.2-represents lifting cylinder. 30. 3-represents forward pusher cylinder. 30. 4-represents track forward pusher cylinder. 30. 5-represents carriage lowering cylinder. 30.6-represents neck releasing cylinder. 30. 7-represents rollers. 30.8-represents inductive sensors for cylinder C1. 30. 9-represents inductive sensor for cylinder C2. 30.10-represents inductive sensors for cylinder C3. 30.11-represents inductive sensors for cylinder C4. 30.12-represents inductive sensors for cylinder C5. Fig no.31:- 1. It shows the various I.R. sensors. 2. Unless the pallet presence sensor detects a pallet, the operation cycle will not start. 3. After placing an empty pallet the operation starts and the operator places a filled pail/drum on the lifting table. 4. The pail presence sensor detects the pail/drum on the lifting table and then signals the various operations. 5. The conveyor stop sensor senses the first stacking of pail/drum and then the track forward pusher cylinder pushes the line into the pail/drum holding carriage. 6. Layer completion sensor senses the completion of a single layer of pails/drums wherein: 31.1-represents lifting table. 31. 2-represents forward pusher cylinder. 31. 3-represents track forward pusher cylinder. 31.4-represents carriage lowering cylinder. 31. 5-represents neck releasing cylinder. 31.6-represents rollers. 31. 7-represents pail presence sensor. 31. 8-represents conveyor stop sensor. 31. 9-represents layer completion sensor. 31.10-fepresents IR sensors for layers. 31.11-represents pallet presence sensor. Fig no.32;- It shows the action of the neck releasing mechanism wherein: 32.1-represents neck holding flats. 32.2-represents neck releasing cylinder. 32.3-represents cams. 25 A. Initially the neck holding flats are horizontal in position. B. While, releasing the necks, the cylinder moves downward and pushes the frame structure downwards. C. This downward motion causes the cams to rotate and simultaneously the neck holding flats. D. The position of neck holding flats during release is shown. E. This vertical position of the neck holding flats releases the pails/drums. F. A detailed view of the release mechanism is shown. Fig no.33;- It comprises of: 33.1-represents neck holding flats. 33. 2-represents pallet. 33. 3-represents pails. Fig no.34:- It comprises of: 34.1-represents neck holding flats. 34. 2-represents pallet. 34. 3-represents pails. Fig no.35:- It comprises of: 35.1-represents neck holding flats. 35. 2-represents pallet. 35. 3-represents pails. Fig no.36: In this diagram the neck holding flats along with the carriage has moved up leaving the layer of pails on the pallet. In this way all the subsequent layers are filled. 27 We claim, Claim 1 :- The automatic pail palletizer assembly unit which inordinately comprises of Mechanical, Hydraulic and Electrical systems which work simultaneously with each other wherein the mechanical system comprises of a Conveyor and a Carriage assembly in which, said conveyor is an endless moving belt or a chain of receptacles usually driven by an electric motor, used for carrying bulk material from place to place; and a frame structure consisting of different mechanisms which are hydraulically operated by individual hydraulic cylinders for the pails/drums, by lifting it from the lifting table to the height of slat conveyor with the help of said hydraulic cylinder , pushing it to the slat conveyor with the help of Pusher mechanism comprising rectangular flats attached to the end of an hydraulic cylinder which works in conjunction with said pusher mechanism through which it is forwarded to the end of the conveyor from where it is carried to the pail/drum holding carriage assembly with the help of track forward pusher mechanism consisting of hydraulic pushers arranged in two parallelly horizontal manner operated by one more hydraulic cylinder wherein the purpose of the pail/drum holding carriage for holding the matrix of pails/drums is further operated by an individual hydraulic cylinder and thereby releasing the matrix on the pallet platform stand using an hydraulic cylinder; operating with a Power Pack, consisting of tank for holding oil, a pump and a motor for driving the pump which sucks the oil at predetermined bar pressure and delivers the oil to the respective hydraulic cylinders via direction control valves for lubrication which are mounted on the top of power pack besides motor provided with the ports on the extreme ends of each cylinder, one for supplying the oil and the other for removing it to make sure the oil is delivered to the gearbox, dispensing through a filter-cart or using a one-shot type sealed lubricant container, the said mechanical and hydraulic system operating through Starters, Relays, 28 Contactors located in the P.L. C. (Programmable Logic Controller) mounted in the control panel which works in tandem with various Reflective and Inductive sensors situated on the carriage assembly unit wherein inductive sensors detects only metals and are used to determine the position of all the hydraulic cylinders and reflective sensors can detect any object and are used to detect pails/drums possessing predetermined sensing range, with received inputs from sensors according to a programmable logic controller, which then directs the process operation of various cylinders and the conveyor so that a matrix of pails and drums is releasably placed on the platform pallet. Claim 2:- The said Pail holding Carriage assembly as claimed in claim 1 comprising of following components mentioned as the neck holding flat, cross-angles, bearing block, Central support (Middle), Cam, Stepped portion of the neck holding flat, Front support, Neck holding flat with stepped portion, Neck holding flat with Front support, Carriage, Neck holding flat with Middle support, Stepped portion with Bearing block, Bearing block with the Carriage, Cam with Stepped portion. Claim 3:- The said neck holding flat as claimed in claim (2) is fabricated from flats with its predetermined dimensions of length, width & thickness provided with a slots made at the centre to accompany the central support (Middle support) and a hole drilled at the front side to accommodate the pins of front support, structure of flat being coupled with cam enabling it to grip or hold the complete layer of pails/drums and accordingly release it. 29 Claim 4:- The said carriage as claimed in claim (2) is fabricated from flats with its predetermined dimensions provided with two cross angles and a hole drilled at the backside of the carriage to allow the neck holding flats, which are placed at distance equal to the diameter of the pail to pass through the carriage provided with a support flat for the bearing block to be fixed at the backside of the carriage. Claim 5:- The said cross-angles as claimed in claim (2) are placed inside the carriage at an equal distance used for lifting the matrix of pails/drums in a form of layers onto the carriage. Claim 6;- The said Central support (Middle support) as claimed in claim (2) is fabricated from square flats with predetermined dimension for top rectangular portion and a hole is drilled at rectangular portion to enable a bolt to fix it to the cross angles of the carriage wherein a middle support pin is placed at the bottom of the cylindrical portion of predetermined dimensions thereby resting the pin on the slots providing supports to the neck holding flats and allow rotational motion of the neck holding flats. Claim 7:- The said Front support as claimed in claim (2) is fabricated from square flats of predetermined dimensions, wherein the cylindrical portion is cut in the middle and a hole is drilled in the down rectangular portion to accommodate a pin to provide support to the neck holding flats. 30 Claim 8:- The said Bearing block as claimed in claim (2) is fabricated from plates of predetermined dimensions with holes provided at either side to enable bolts to fix the block on the carriage and a ball bearing inserted in the center of the block to hold the neck holding flats and at the same time allow rotational motion of the flats. Claim 9;- The said Stepped portion of the neck holding flats as claimed in claim (2) is fabricated from round flats of predetermined dimensions provided with a neck holding flats being welded to the rectangular slot at the front portion. Claim 10:- The said Cam as claimed in claim (2) is fabricated from flats of predetermined dimensions, which is fixed to the stepped portion of the neck holding flats used to transform the linear motion of the cylinder into rotary motion of the neck holding flats. Claim 11:- The said Neck holding Flat with Stepped portion as claimed in claim (2) is coupled together by welding to enhance strength. Claim 12:- The said neck holding flat with front support as claimed in claim (2) is coupled by welding and a pin is inserted through front support to neck holding flat thereby supporting it. 31 Claim 13:- The said Stepped portion with bearing block as claimed in claim (2) wherein the stepped portion is drilled in the bearing which makes the neck holding flat to rotate. Claim 14;- The said Neck holding flat with middle support as claimed in claim (2) thereby places the middle support in the slot of neck holding flat, providing support as well as rotation to the neck holding flats. Claim 15:- The said Cam with stepped portion as claimed in claim (2) in which the cam is fixed only after the stepped portion is assembled with the bearing block and the arrangement of the stepped portion and cam converts to and fro motion of the cylinder into rotary motion of the neck holding flats. Claim 16:- The said bearing block with the carriage as claimed in claim (2) in which the bearing blocks are placed at the backside of the carriage. Claim 17: - The above said process as claimed in claim (1) comprising of sequential working of said components, wherein at the start of said process, filled pail/drum are kept on the lifting table and Cylinder C4 is at the loading position and all other respective cylinders are at their backward position, indicating to the operator informing that the palletizer is ready for receiving pails/drums wherein the pail presence sensor mounted in the lifting table lifts the required number of pails/drums making the process faster using hydraulic cylinder CI up to the height of the slat conveyor 32 taking the pail/drum with it and once the table has reached its level, a signal is sent to the P.L.C Controller, which in turn activates the forward pusher cylinderC2, making the process of pushing the pail/drum on to the conveyor to start and moves for a specific period and stops, thereby carrying the pail/drum along with it, a conveyor stop sensor present at the end of the conveyor senses the pails/drums and accordingly sends a signal to the P.L.C. Controller which in turn activates the track forward pusher mechanism controlled by hydraulic cylinder C3, which pushes the line of pails/drums in to the pail/drum holding carriage, and the above mentioned process repeats for required number of pails/drums and subsequently fills the pail/drum holding carriage, a layer completion sensor present at the end of the carriage senses and accordingly signals the P.L.C Controller which in turn signals the Carriage lowering mechanism controlled by hydraulic cylinder C4, for lowering the entire filled carriage on to the pallet and respectively when the pails/drums have reached a certain predetermined distance, sensed by inductive sensors, hydraulic cylinder C5 acts thereby releasing the entire matrix of pails/drums on the pallet, the complete matrix of pails/drums is placed on the pallet and the carriage moves back to its loading position and whereby said process is repeated till the required numbers of layers are stacked. Claim 18:- The said automatic pail palletizing assembly unit as described in the complete specification and accompanied by drawings in the complete specification. 33 ABSTRACT;- The Pail Palletizer were designed to make an automatic arrangement for pails, by making an arrangement for the carriage assembly by carrying it from slat conveyor and downloading it to the pallet, reducing the manual effort to a greater extent increasing time as well as energy. The carriage contains rectangular flats for holding pails or plates for holding drums. The carriage is directly connected to a hydraulic cylinder. The purpose of the carriage is to hold the matrix of pails/drums and to release the matrix on the palletization stand. There is also a step-by-step procedure arrangement, known as process for sequential access of pails/drums accordingly with the help of components used during the process to make the process faster and get completed within the stipulated period of time. The efficiency of Pail Palletizer with respect to Customer is fully 100%, as it is designed as per the Customer satisfaction & if taken into consideration of I/P / O/P, it comes to 90%. The Pail Palletizers are provided with safety mesh to avoid any accidents & also view the process running successfully. 34

Full Text

FORM 2
THE PATENT ACT 1970
(39 of 1970)
&
The Patents Rules, 2003
PROVISIONAL/COMPLETE SPECIFICATION
(See section 10 and rule 13)
5. 1. TITLE OF THE INVENTION An Improvised automatic pail/drum palletizer unit
2. APPLICANT (S)
(a) NAME : Mr. Harikumar S. Menon
(b) NATIONALITY: Indian
(c) ADDRESS : B-204, ETERNIA, HIRANANDANI GARDENS, POWAI MUMBAI-400 076

PROVISIONALThe following specification describes the invention. COMPLETEThe following specification particularlyDescribes the invention and the manners inWhich it is to be performs.
4. DESCRIPTION (Description shall start from next page.)
5. CLAIMS (not applicable for provisional specification. Claims should start with the
preamble
"I/We claim" on separate page)
6. DATE AND SIGNATURE (to be given at the end of last page of specification)
7. ABSTRACT OF THE INVENTION (to be given along with complete specification on separate page)
Note : -
* Repeat boxes in case of more than one entry.
* To be signed by the applicant(s) or by authorized registered patent agent.
* Name of the applicant should be given in full, family name in the beginning.
* Complete address of the applicant should be given stating the postal index no. / code, state and country.
* Strike out the column which is/are not applicable.

1. TITLE OF INVENTION: - An improvised Automatic Pail/Drum Palletizer Unit.
2. FIELD OF INVENTION:- The present invention pertains to an automatized assembly unit for arrangement of pails/drums, specifically designed for paint industry wherein the paints are packed in pails/drums using Process & Carriage for reducing manual labour by providing a conveying system for transferring objects in layers on a pallet and is improved by addition of sensors that provide early indications of movement of component parts of pail palletizer to a control panel where the signals are used in a more efficient operation of pail palletizer and thereby providing a cost effective method for carriage of said pails and drums.
3 PRIOR ART-
1. Cylindrical object Palletizer
Patent No. 5733100
Date:- Mar 31, 1998 This invention relates to packing of cylindrical cans in large quantities. In this invention, the first layer of cans is gripped and released on the pallet, which is kept at a certain height. For the second layer the pallet is moved downwards, distance equal to the height of the can. In this invention the layer holding assembly is fixed, whereas the pallet is moved up or down. In the present invention the layer holding carriage is movable and the pallet is fixed. In the above said invention the complete layers of cans are gripped at the sides, whereas in the present invention the layers of objects are held at the bottom.

2. Device for automatically loading a conveyor
Patent No. 5921740 Date :- July 13, 1999
This invention is used for automatic loading of rectangular packages on a trailer or shipping containers. Our invention is used for palletization of cylindrical objects on a pallet. In this invention the packages to be loaded are pushed on to the loading area, whereas in our invention the items are released on the pallet.
3. Layer palletizing method
Patent no. 5,004,401
Date of patent: Apr. 2, 1991
This invention is used for palletization of rectangular articles on a load-carrying platform. A layer of articles are gripped at their sides and then placed on a load-carrying platform. In the present invention instead of gripping the articles (which are cylindrical in shape) are held at their sides.
4. Palletizer
Patent no. 4,302,140
Date of patent: Nov. 24,1981
This is an invention used for palletization of rectangular articles such as cartons. The first layer is prepared and is lifted up by means of tines or fingers and gripped using side grippers. Then the second layer is prepared below the suspended layer and then the first suspended layer is made to fall on the second layer. In this way stacking is done.
2
4. SUMMARY OF INVENTION:- the present invention comprises of the following components-
1. Lifting table.
2. Pusher mechanism.
3. Conveyor.
4. Track forward pusher mechanism.
5. Drum/pail holding carriage.
6. Carriage lowering/raising mechanism.
7. Drum/Pail releasing mechanism.
The arrangement of the carriage and the process used makes the Palletization process faster and within a stipulated period of time, directly reducing the manual effort. The Palletizer is fully satisfied by the customer point of view taking into consideration the Safety as well as the Productivity. A protective safety mesh is provided externally at the perimeter of the palletizer, thereby reducing the chances of accidents.
5 COMPLETE DESCRIPTION OF THE INVENTION: - Palletizer is a machine that is used for arranging a matrix of required number of rows and columns of pails, drums or other cylindrical container on a pallet or any load-carrying platform. The above said machine is specifically designed for use in paint or oil industry wherein the paints or oils are packed in pails or drums. The machine is designed for load capacity ranging from l0kgs to 35kgs per weight of unit pail or drum. The machine utilizes three main systems:
1. Mechanical System.
2. Hydraulic System.
3. Electrical System.
3

The Mechanical System consists of Conveyor and Frame structure.
The Hydraulic System consists of Hydraulic Cylinders and Power Pack.
The Electrical System consists of P.L.C., Starters, Contactors, Relays, Sensors,
etc.
Mechanical System:-
The following are essential components of the machine:-
1. Lifting table.
2. Pusher mechanism.
3. Conveyor.
4. Track forward pusher mechanism.
5. Drum/Pail holding carriage.
6. Carriage lowering/raising mechanism.
7. Drum/Pail releasing mechanism.
Hydraulic System:-
The following are the essential components of the system:-
1. Table Lifting Cylinder, C1.
2. Forward pusher cylinder, C2.
3. Track forward pusher cylinder, C3.
4. Carriage holding/lowering cylinder, C4.
5. Pail/Drum releasing cylinder, C5.
Electrical System:- the electrical system in the present invention comprises of a control panel. The following are the essential components on the control panel:-
1. Emergency stop.
2. Auto/Manual selector switch.
3. Individual switches for operating each cylinder (only in manual mode).
4. Cycle pause switch.
4

5. Hydraulic motor On/Off switch.
6. Conveyor On/Off switch.
7. Process start switch.
8. 201tr/101tr selector switch (Only for drum palletizer).
9. Selector switch for 2/3 layers (for 20Kgs pails).
10. Selector switch for 3 to 4 layers (for l0ltrs drum).
INDUSTRIAL APPLICABILITY;-
The description maintained in the above paragraphs does not limit or restrict the scope of the present embodiment of the invention. Thus the same assembly unit can also be used for lifting of cartons, boxes, drums etc.
WORKING MECHANISM OF DIFFERENT SYSTEMS Mechanical System;-
I. Lifting Table: - Standard Lifting tables are equipped to function long & reliably with "normal" use. Lifting tables meant for intensive use with heavy loads, fast speed, extreme environment & perhaps continuous working shifts. It is an angle frame structure fitted with idler rollers. The frame structure along with the idler rollers is mounted on a hydraulic cylinder. The essential purpose of the lifting table is to lift the pail/drum from the height of filling station to the height of the slat conveyor.
II. Pusher Mechanism; - It is a simple arrangement of flats capable of pushing the pail/drum from the lifting table to the slat conveyor. A hydraulic cylinder operates the pusher mechanism. This mechanism enables the drum/pail to move from the lifting table to the slat conveyor. Once the pail/drum is on the conveyor then the conveyor moves and carries the pails/drums to a predetermined position on the conveyor.

III. Conveyor:-It is basically a mechanical apparatus used for carrying bulk material from place to place; for e.g. an endless moving belt or a chain of receptacles. It is a slat belt conveyor driven by an electric motor. The slat conveyor accomplishes the first linear stacking of pails/drums.
IV. Track forward pusher mechanism: - It is a simple arrangement of angles and flats, of sufficient strength/ tenacity, used to push the linearly stacked pails/drums on to the pail/drum holding carriage. It consists of hydraulic operated pushers arranged in parallel lines, such that when the pails/drums move from the conveyor belt the pusher forward mechanism pushes the already placed drum/pails onto the conveyor utilizing the track forward pusher mechanism.
This arrangement of pushing linearly stacked pails/drums from the slat conveyor to the pail/drum holding carriage creates a rectangular stacking arrangement or matrix in pail/drum holding carriage.
V. Pail/Drum holding carriage.-It is fabricated from flats and channels wherein the flats are used to hold and subsequently release the complete layer of pails. The carriage contains rectangular flats for holding pails or plates for holding drums. The carriage is directly connected to a hydraulic cylinder. The primary purpose of the carriage is to create and hold the matrix of pails/drums and to release the matrix on the palletization stand.
VI. The up or down motion of the carriage is controlled by a hydraulic cylinder C4. The carriage is connected by means of chain and sprocket to the hydraulic cylinder.
VII. The release mechanism is a rectangular structure made of flats. The pails are held at the necks by a rectangular flat, termed as neck holding flat. The pails are made to rest on the flats at their necks. The flats are

supported at two ends. The end supports are in such a way so as to allow the flats to rotate about their longitudinal axis. One end of the flat is supported at the front side of the carriage and the other end is attached to a cam. The cams are connected to a hydraulic cylinder by a frame structure. The neck-releasing cylinder C5 controls the action of the frame structure. Initially the neck holding flats are horizontal in position. While releasing the necks, the cylinder moves downward and pushes the frame structure downwards. This downward motion causes the cams to rotate and simultaneously the neck holding flats rotate at 90° on its own axis. For release of Pail/drum a 90° turn (from horizontal to vertical) is given to the Pail/drum holding mechanism. A hydraulic cylinder C5 controls the release mechanism. The hydraulic cylinder is connected to the release mechanism by cams. The to and fro motion of the cylinder is converted by the cam to the rotary motion of the holding flats.
Hydraulic System: -It basically consists of 5 hydraulic cylinders as mentioned below: -
a. Table lifting cylinder, CI.
b. Forward pusher cylinder, C2.
c. Track forward pusher cylinder, C3.
d. Carriage holding/lowering cylinder, C4.
e. Pail/Drum releasing Cylinder, C5.
1. There are a total of 5 cylinders. Oil under a certain pressure, which is 35
bar, obtained from a power pack, is delivered to the cylinders.
2. Power Pack is a hydraulic pump system-supplying machine with high-
pressure oil, wherein the motor is fitted with thermal overload protection.
The power pack consists of a tank for holding oil, a pump and the motor,
used for converting hydraulic energy into rotary motion, either fixed or
variable for driving pump, which operates at 35bar pressure.

3. The pump sucks the oil from the tank, creates certain 35bar pressure in the oil and delivers the oil to the hydraulic cylinders via Direction control valves; it is a device for directing or preventing the oil flow in a system.
4. The Direction control valves are mounted on the top of the power pack plate besides the motor used to run the power pack. Two ports are provided on the Direction control valve, wherein ports form the internal or external terminals of passage, the point where fitting mechanism for control valves is attached which allows passage of oil from the respective hydraulic cylinders.
5. Similarly, two ports are provided for activation/working of the cylinder. Each cylinder is provided with a control valve.
6. The two ports of the valve are connected to the two ports of each cylinder.
7. When oil under a certain pressure is supplied to one of the ports then the cylinder piston moves forward/backward depending on the port on which oil under pressure is applied.
8. While oil is supplied to one port of the hydraulic cylinder, simultaneously oil from other port is removed, because it is imperative to make sure the oil is delivered clean to the gearbox. This may mean dispensing through a filter-cart or using a one-shot type sealed lubricant container supplied at a certified level of cleanliness. The fill port must also be clean prior to use. Like minimises sampling ports, two ports of the valve minimizes the risk of ingested contamination providing space for the incoming oil.
9. The P.L.C controls the said Direction control valves.
10. The cylinder piston moves forward/backward or up/down direction
depending on the port in which oil is being supplied.
11.Cylinder CI has top & down position. C2 has forward or backward position. C3 has forward and backward position. C4 has a) uppermost
8

position b) pail loading position c) level 1 position d) level 2 positions
and e) level 3 positions. C5 has up and down position. 12.The oil pressure is obtained from a power pack, which is an integral part
of the hydraulic system. Electrical System: -
The Palletizer is fully automatic in operation. The automation is controlled by a P.L.C. (Programmable Logic Controller) mounted in the control panel. The various sensors mounted on the machine at relevant locations provide inputs to the P.L.C. The different types of sensors used are as follows: -
1. Inductive sensors:.- Inductive sensor detects only metals. Inductive
sensors are used to determine the positions of the entire hydraulic
cylinders. Every cylinder except C4 has two positions. Cylinder C4
has five positions. Inductive sensors control all these positions.
Each sensor is fixed at the exact backward/forward or up/down of each cylinder. Each cylinder is operated through a direction control valve, which in turn is controlled by the P.L.C. The sensors detect the exact position of each cylinder and this position is communicated to the P.L.C. controller. The P.L.C. then directs that particular cylinder according to the programmable logic. In all there are 13 inductive sensors used to detect the positions of Hydraulic Cylinders.
2. Reflective sensors: - Reflective sensors can detect any object. In the
palletizer these sensors are used to detect pails/drums and are also
called as I/R sensors. These reflective sensors perform two functions.
Total there are six reflective sensors. The first three reflective sensors
control the On Off motion of the conveyor. Other three reflective
sensors detect the stacking layers.
9

Based on the inputs obtained from the sensors and according to a predetermined logic the P.L.C. then directs the operation of the various cylinders and conveyors. There are two types of sensors used, namely Inductive sensors and I/R sensors. The inductive sensors can sense only metals, whereas I/R sensors can sense any object. The sensing range for inductive sensor is 5mm and for I/R sensor is 200mm. The position of all the hydraulic cylinders is sensed by the inductive sensor and the product eg. (Pails / drums) is sensed by the I/R sensor.
All cylinders except C4 have two positions, i.e. forward or backward. Cylinder C4 has five positions. The five positions are:-
1. Topmost position.
2. Pail/Drum loading position.
3. Level 1 position.
4. Level 2 position.
5. Level 3 position.
Two inductive sensors are provided for each cylinder at their extreme positions, i.e. forward or backward. For cylinder C4 in addition to the two sensors, three more are provided for its Pail/Drum loading position, level 2 positions and level 3 positions.
WORKING PROCESS OF PAIL PALLETIZER
To be able to start the palletizer in auto mode an empty load-carrying platform (pallet) has to be placed in the machine. The operation starts by pressing the 'Process On' switch provided on the control panel.
1. During the start of the operation cycle all the hydraulic cylinders move to their respective initial positions. Cylinder CI moves to its down most
10

position, cylinder C2 moves to its forward most position, Cylinder C3 moves to its forward most position, Cylinder C4 moves to its pail loading position and cylinder C5 moves to its upper most position. An indication is given to the operator informing that the palletizer is ready for receiving pails/drums.
2. A packed pail/drum is placed on the lifting table. A reflective sensor mounted on the lifting table senses the pail/drum. A hydraulic cylinder (CI) operates the lifting table by moving it forward/backward movement. The cylinder lifts the table to the height of the slat conveyor. Once the table reaches the height of the Slat conveyor the pail/drum is pushed on to the conveyor by the pushing mechanism. The pushing mechanism is hydraulically operated by Forward pusher cylinder C2 wherein the pails/drums are loaded individually on a conveyor belt arrangement; the pusher mechanism consists of a rectangle flat attached to one end of the frame structure.
3. As the pushing mechanism reaches its back most position, a signal is given to the conveyor through PLC control to operate.
The conveyor moves and carries the pail/drum along with it. When the pail/drum passes a reflective sensor mounted on the conveyor senses the pail/drums, whereby a stop signal through PLC control is given to the conveyor. In this way the pail/drum reaches a predetermined position on the conveyor.
4. The above process continues for the required number of rows. Once the
required numbers of pails/drums are on the conveyor, an I/R sensor
present at the end of the conveyor senses the pails/drums. This sensor
gives a signal to the P.L.C., which in turn activates cylinder C3. The
complete line of pails/drums is pushed in the pail/drum holding frame.
11

5. The above process continues for the required number of columns. A sensor is located at the backside of the carriage. This sensor senses the completion of Layer and accordingly gives a signal to the P.L.C. The P.L.C. then directs the cylinder C4 to move and the carriage is moved to its required position.
6. For a matrix of three layers, there are three positions for the carriage to release the pails/drums, i.e. level 1, level 2 and level 3. Three I/R sensors are placed vertically on the columns of the carriage assembly to determine the layer completion. Initially all the three levels are empty. The filled carriage moves to the position of level 1 and releases the pails/drums. The I/R sensor present senses this layer and gives a signal to the P.L.C. about the completion of layer 1. Following filled carriage is directed to move to the second layer position and releases the pails/drums. The third layer stacking follows this. In this way the three layers are stacked.
7. The holding mechanism is different for pails and drums. The pails have a protruding edge along the upper rim termed as neck. Two rectangular section flats which are attached to the inner side of the columns of the carriage assembly possessing/bearing a gap 215mm for l0Kgs and 284mm for 20Kgs, corresponding to the diameter of the pail at the upper rim. The pail neck is made to rest on the rectangular flats, termed as neck holding flats. In this way the pails are held. The design of the pail holding mechanism, using neck-holding flats allows movement of the pails along the length of the flats. The flats are supported at two ends. The supports are in such a way so as to allow the flats to rotate about their longitudinal axis. One end of the flat is supported at the front side of the carriage and the other end is attached to a cam. The linear motion of the hydraulic cylinder is converted by the cams to rotary motion of the neck holding flats. The cams are connected to a hydraulic cylinder by a frame
12

structure. The pails are made to rest on the pallet and the release mechanism is thereby activated thus rotating the flats through 90° making them vertical thereby giving enough clearance for the flats to pass through.
8. The above present invention can also be used for drums, not bearing
protruding edges as in the case of pails. The drums are held at the bottom
edge by two L-shaped side grippers. The grippers are designed in such a
way to allow the drum to travel along its entire length of the flat
assembly. The grippers are positioned in such a way so that they can
rotate about their longitudinal axis. The side grippers rotate about their
centres and while rotating the grippers separate away, thereby releasing
the drums on the pallet. The two grippers rotate in opposite direction. The
inside distance between the side grippers is slightly more than the
maximum diameter of the drum. The bottom rim of the drum is made to
rest on the side gripers. There is no positive or friction grip on the drum
by the grippers. Separating the grippers and allowing the drums to fall
freely on the load-carrying platform release the drums. The individual
grippers are connected to a rectangular flat paced between the grippers
rotating the flat through 90° separates the grippers. A hydraulic cylinder
via a cam provides the rotary motion to the flats.
9. After releasing a layer of pails/drums on the load-carrying platform the
pail/drum holding carriage returns to its pail/drum loading position.
10.The above-mentioned process continues for a required number of layers.
Once the layers are completed then all the cylinders, except cylinder C4,
move to their start position and cylinder C4 moves to its top most
position. 1l.An alarm is sounded indicating the completion of one cycle of operation,
which hardly takes 10-12 minutes. The platform on which the subsequent
13

pails are stacked has to be removed and an empty platform has to be placed in the Palletizer for the start of the second cycle.
ADVANTAGES OF INVENTION:-
1. As compared to other Pail Palletizers they have advantages over cost & functioning of the carriage.
2. Previously, patented Palletizers were used only for lifting cans, small rectangular boxes, etc. But by making proper arrangement for process & the carriage assembly they have made an invention by automatically lifting pails for the Customers.
3. The equipment or the materials used for designing the Palletizer are easily available in the market.
4. Proper usage of the resources has been maintained.
5. Maintenance cost is very low, because of less wear & tear of the internal components.
6. The new Palletizer can handle matrix up to 5 *5 pails in single procedure.
7. Initially, the pails/drums were lifted manually from filling station and were placed on the pallet, which takes much time for single operation.
8. It has an added advantage of saving the manual effort by providing a conveying system for transferring objects such as pails, where the present invention arranges the object in layers on a pallet and is improved by the addition of sensors that provide early indications of movements of components parts of the pail palletizer to a control panel where signals are used in a more efficient operation of the pail palletizer.
9. In the future designs there may be a slight variation in the arrangement of various components, but the holding and release mechanism will be same for all designs.
14

DESCRIPTION WITH ACCOMPANYING DIAGRAMS
The following is the explanation of the entire Palletization process.
Fig no. 1: - This view shows the first stage of the Palletizer. During the initial position a filled pail/drum is kept on the lifting table. A pail presence sensor present on the lifting table senses the pail/drum and starts the successive operations.
Fig no.2:- This diagram shows the second stage of the palletizer. After the pail presence sensor has sensed the pail/drum, a signal is sent to the P.L.C. The P.L.C. then signals the lifting table to rise up to the level of the conveyor taking the pail/drum with it. Once the table has reached its level, a signal is sent to the P.L.C, which in turn activates the Forward pusher cylinder.
Fig no.3;- This diagram shows the third stage. In this view the forward pusher cylinder has pushed the pail/drum on to the conveyor. Once the forward pusher cylinder reaches it backmost position a signal is sent to conveyor to start. This conveyor moves for a specific period and stops.
Fig no.4:- In this diagram, the Lifting table and Forward pusher cylinder are back to their initial position. The conveyor has moved for a specific period and has stopped, and thereby carrying the pail/drum along with it.
Fig no.5:- In this diagram, five pails are seen on the conveyor table. The above-mentioned process has repeated for five times. Once five pails/drums are on the conveyor table, a conveyor stop sensor present at the end of the conveyor senses the pails/drums and accordingly sends a signal to the P.L.C. The P.L.C. Controller in turn activates the Track Forward pusher
15
mechanism, which pushes the line of five pails/drums in to the pail/drum holding carriage.
Fig no.6;- In this diagram, the five pails are pushed in to the pail/drum holding carriage by the Track forward pusher mechanism. A hydraulic cylinder C3 operates the Track forward pusher mechanism. Notice the Track forward pusher mechanism is at its back-most position.
Fig no.7:- In this diagram, the pail/drum holding carriage is filled with the required number of pails/drums. The above-mentioned process has repeated five times and subsequently filled the pail/drum holding carriage. Once the carriage is full, a layer completion sensor present at the end of the carriage senses and accordingly signals the P.L.C. Controller. The P.L.C. Controller then signals the carriage lowering mechanism, which lowers the entire filled carriage on to the pallet.
Fig no.8:- In this diagram, the filled carriage has lowered the layer of pail/drum on to the pallet. Once the carriage reaches this position, a signal is sent to the P.L.C. Controller to release the pail/drum on the pallet.
Fig no.9:- In this diagram, the complete matrix of pails/drums is placed on the pallet and the carriage is back to its loading position. All the above-mentioned process repeats till the required numbers of layers are stacked.
16

DETAILED EXPLANATION FOR PAIL CARRIAGE
Fig no.10: - represents the perspective view of the assembled Pail holding
Carriage.
Fig noil: - represents the side elevation of the assembled Carriage wherein:
11.1 Represents Carriage frame.
11.2 Represents Cam.
11.3 Represents Front Support.
11.4 Represents Bolts for front support.
11.5 Represents pins for Front support.
11.6 Neck holding flats.
11.7 Represents Bearing blocks.
11.8 Represents Cross angles.
11.9 Represents Middle Support.
11.10Represents Stepped portion of the Neck holding flats.
11.11 Represents Pins for Middle Support.
Fig no. 12: - represents the front elevation of the assembled Carriage wherein:
12.1 Represents Carriage frame.
12.2Represents Front Support.
12.3Represents Bolts for front support.
12.4Represents Pins for front support.
Fig no.13: - represents the isometric view of the Middle Support. This part is fabricated from M.S. square. The dimension of the top rectangular portion is 25mm x 25mm x 40mm and of the cylindrical portion is 12mm diameter x 130mm long wherein:
13.1 Represents Holes on middle support for fixing it on to the frame.
13.2Represents Pins for Middle support. This cylindrical pin rests on the slots provided on the Neck holding flats and supports them. The function of Middle Support is to provide support to the Neck
17

holding flats at the middle and at the same time allow rotational motion of the Neck Holding Flat. The entire matrix of pails is carried by the Neck Holding Flats, placing enormous weights on them. Without any supports the flats would bend and break due to the load.
Fig no.14:- This figure shows the isometric view of Bearing block. The block is fabricated from M.S. Plates and its dimensions are 100mm long x 60mm height x 24mm width wherein:
14.1 Represents Ball Bearings.
14.2Represents holes on bearing blocks for fixing the block to the frame. The function of this block is to hold the Neck holding flats and at the same time allow rotational motion of the flats.
Fig no.15:- This diagram shows the isometric view of the Stepped portion of the Neck Holding Flats. It is fabricated from M.S. Round and the dimension is 40mm diameter x 115mm long wherein:
5.1 represents slots on stepped portion for fixing the neck holding flats. Fig no.16;- This diagram shows the isometric view of cam. It is fabricated from M.S.Flats. The dimension are 190mm long x 40mm width x 12mm thick wherein: 16.1 represents slots on cams.
The function of the Cam is to translate the linear motion of the cylinder into rotary motion of the Neck holding flats.
Fig no.17;- This diagram shows the isometric view of Neck holding flat. It is fabricated from M.S. flats and its dimension are 1416mm long * 40mm width * 12mm thick wherein:
17.1 represents slots on pins on middle support on neck holding flats.
17.2 represents holes for pins of front support on neck holding flats.
The function of this flat is to hold the complete layer of pails and also release them. The structure of this flat coupled with the Cam makes possible the holding and releasing of the pails easily.
18

Fig no.18:- This diagram shows the isometric view of Front support. It is fabricated from M.S. squares. The dimension of the support is 170mm long x 20mm width x 20mm thick wherein:
18.1 represent holes for pins on front support.
18.2 represent holes on front support for fixing bolts.
The function of this support is to provide support to Neck holding flats.
Fig no.19:- This diagram shows the Carriage. It is fabricated from M.S. flats and dimension is 1450mm long * 1432mm wide * 200mm thick wherein:
19.1 represents cross angles.
19.2represents back flats for placing bearing block.
19.3represents holes on back plates of carriage.
Fig no.20:- This diagram shows the isometric view of Carriage. The cross-angles are seen and also the holes at the backside and the Support flat.
Fig no.21:- This diagram shows the isometric view of assembly of Neck holding flat with stepped portion wherein:
21.1 represents neck holding flats.
21.2 represents stepped portion of the neck holding flats.
Fig no.22:- This diagram shows the isometric view of assembly of Neck holding flat with front support wherein:
22.1 represents front support.
22.2 represents pins for front support.
22.3 represents neck holding flats.
Fig no.23;- This diagram shows the isometric view of assembly of Stepped portion with bearing blocks wherein:
23.1 represents neck holding flats.
23.2 represents bearing blocks.
23.3 represents stepped portion of the neck holding flats.
This arrangement makes it possible for the Neck holding flats to rotate.
19

Fig no.24:- This diagram shows the isometric view of assembly of Neck holding flat with middle support wherein:
24.1 represents neck holding flats.
24.2 represents middle support.
This arrangement gives support to the Neck holding flat and also allows rotational motion of the Neck holding flat.
Fig no.25:- This diagram shows the isometric view of Cam with Stepped portion wherein:
25.1 represents cam.
25.2 represents stepped portion of the neck holding flats.
The Cam is fixed only after the Stepped portion is assembled with the Bearing block. The Bearing block is omitted for the sake of clarity. This arrangement of the Stepped portion and Cam converts the to and fro motion of the cylinder into rotary motion of the Neck holding flat.
Fig no.26:- This diagram shows the isometric view of Bearing block with the Carriage wherein:
26.1 represents carriage frame.
26.2 represents bearing blocks.
The Bearing blocks are placed at the backside of the Carriage.

20

EXPLANATION OF DRAWINGS OF CARRIAGE OF DRUM PALLETIZER.
The following are the explanation of the drawings. Some of the drawings are shown in isometric view for ease in understanding. Given below is the nomenclature of the individual items.

Sr.no. Item name
27.1 Carriage frame
27.2 Rotating flats
27.3 Movable Grippers
27.4 Fixed Grippers
27.5 Springs
27.6 Gripper Supporting Rod
27.7 Bush on Gripper
27.8 Cam
27.9 Bearing Block
27.10 Back side holes for Rotating flats
27.11 Front side holes for Rotating flats
27.12 Back side holes for Gripper support Rod.
27.13 Front side holes for Gripper support Rod
27.14 Cross support Channels
27.15 Front holes on Rotating flats
27.16 Front holes on Gripper supporting flats
27.17 Back holes on Gripper supporting flats
27.18 Slot on Cam for fixing Rotating flats
27.19 Holes on Bush for passing Support rod
27.20 Hole in Cam for fixing Support rod
27.21 Slot on Cam for fixing Pin
27.22 Mating part of Cam of Stepped portion.
27.23 Mating part of Bearing of Stepped portion.
27.24 Ball bearing
27.25 Stepped portion of Rotating flats.
21

FIG. NO. 27-A
This diagram shows the perspective view of the assembled Drum holding Carriage. This view gives an idea of how the carriage looks. The details of the assemblies and subassemblies are mentioned in the preceding drawings.
FIG. NO. 27-B
This diagram shows the isometric view of the carriage frame (27.1). The dimension of the frame is 1430mm long x 980mm wide x 460mm thick. The carriage is fabricated from M.S. Plates. Two cross support channels (27.14) are placed laterally above the frame. At the backside and at the front side of the carriage holes are drilled for the supporting the Support rods and Rotating flats. The holes 27.10 and 27.11 carry the Rotating flats and the holes 27.12 and 27.13 carry the Support rods.
FIG. NO. 27-C
This diagram shows the isometric view of the Support rods (27.6) and the Rotating flats (27.2). The holes drilled at the front (27.16,27.15) and at the backside (not shown) enable it to be bolted to the main carriage frame. The dimension of the Support rod is 25mm diameter x 1425mm long and is manufactured from M.S. Rods. The dimension of the Rotating flats is 1425mm long x 40mm wide x 12mm thick and is manufactured from M.S. Flats. The Support rods carry the entire rows of Grippers. The round shape of these rods enables the Grippers to rotate, which is essential for the release of the Drums. The Rotating flats aid in the releasing of the Drums.
FIG. NO. 27-D
This diagram shows the isometric view of Cam. It is fabricated from M.S. Flats. The dimension are 190mm long x 40mm width x 12mm thick. The Cam is fixed to the stepped portion of the Neck holding flat as shown in fig. no.27-K. A slot (27.21) is provided in the rectangular part. The function of the Cam is to translate the linear motion of the cylinder into rotary motion of the Neck holding flats.
FIG. NO. 27-E
This diagram shows the isometric view of the Stepped portion of the Rotating flats. It is fabricated from M.S. Round and the dimension is 40mm diameter x 115mm long. A rectangular slot (27.18) is provided at the front portion. The Rotating flat is inserted in this slot and is joined permanently by welding as shown in fig. No.27-J
FIG. NO. 27-F
This diagram shows the isometric view of the Grippers. These Grippers hold the Drums at their bottom. There are two types of Grippers i.e. Movable (27.3) and Fixed (27.4). The movable Grippers are allowed to rotate whereas the fixed Grippers remain stationary. The movable and the fixed Grippers are arranged alternately. When the complete matrix
21.

of drums is filled in the carriage only the alternate Grippers hold the drums. The rest of the Grippers are empty. Therefore while releasing only the alternately arranged Movable Grippers rotate thereby releasing the complete matrix of drums. These Grippers are fabricated from M.S. plates and their dimension is 180mmlong x 120mm wide x 20mm thick. The Bush (27.7) are fabricated from M.S. rounds and their dimension are 40mm diameter x 50mm long. The Support rods are inserted in the hole provided on the bush (27.9) and gives support to the Grippers.
FIG. NO. 27-G
This diagram shows the isometric view of Bearing bush. It is fabricated from M.S. round and its dimension is 40mm diameter x 20mm long. A ball bearing (27.24) is inserted in the bearing block. This block gives support to the back end of the Rotating flats and also allows the rotary motion of the Rotating flats.
FIG. NO. 27-H
This diagram shows the isometric view of Springs. It is manufactured from standard spring materials. These springs are attached to back side of the Movable Grippers. They pull the grippers inside while the drums are being released. The exact mechanism of the Springs is given elsewhere.
FIG. NO. 27-1
This diagram shows the isometric view of the assembly of
1. Fixed grippers (27.4)
2. Movable grippers (27.3)
3. Springs (27.5)
4. Supporting rods (2 7.6)
5. Rotating flats. (27.2)
A common Supporting rod (27.6) is passed through the Grippers thereby giving support to them. A Spring (27.5) is attached at the backside of the movable grippers (27.3). A common Rotating flat (27.2) is passed between the corresponding lines of Grippers. In the initial position the springs tend to pull the corresponding Grippers inside but is prevented by the Rotating flat. Only when the Rotating flats have rotated through 90°, the springs pull the grippers inside thereby releasing the complete matrix of drums.
FIG. NO. 27-J
This diagram shows the isometric view of the assembly of
/. Rotating flat (27.2)
2. Stepped portion (27.25)
3. Bearing block (27.9)
The Rotating flat (27.2) is inserted in the slot of the Stepped portion (27.25) and is welded permanently. The Stepped portion is then inserted in the bearing (27.24) provided in the Bearing block.
22

FIG. NO. 27-K
This diagram shows the isometric view of Cam (27.8) with Stepped portion (27.25). The Cam is fixed only after the Stepped portion is assembled with the Bearing block. The Bearing block is omitted for the sake of clarity. This arrangement of the Stepped portion and Cam converts the to and fro motion of the cylinder into rotary motion of the Rotating flat.
FIG. NO. 27-L
This diagram shows the isometric view of assembly of Bearing block (27.9) with Carriage frame (27.1). The Bearing blocks are permanently fixed on the backside of the frame as shown in the diagram.
FIG. NO. 27-M
This diagram shows the mechanism of the Release mechanism. In the initial position (fig A) the Movable Grippers (27.3) are vertical and a Spring (27.5) is attached to the backside. The tension in the spring tends to pull the Grippers inside but is prevented by the Rotating flats (27.2). During the release operation (fig B) the Rotating flats have rotated through 90° making them vertical. As soon as the flats have rotated the springs pull the Grippers inside thereby affecting the release of the Drums.
DIAGRAMMATIC REPRESENTATION OF AUTOMATIC PAIL
PALLETIZER
Fig no.28:- It shows the front elevation of the Palletizer machine wherein:
28.1-represents the Lifting table. 28. 2-represents the pusher mechanism.
28. 3-represents the slat conveyor. 28. 4-represents the power pack.
28. 5-represents the power pack motor. 28. 6-represents the conveyor motor.
28. 7-represents the frame structure. 28. 8-represents the pulley chain assembly.
Fig no.29:- It shows the side elevation of the Palletizer machine wherein: 29.1-represents forward pusher mechanism.
24

29. 2-represents pail/drum holding carriage.
29.3-carriage lowering mechanism.
29.4-represents neck releasing mechanism.
29. 5-represents neck holding flats.
29.6-represents lifting table.
29. 7-represents lifting cylinder.
29.8-represents forward pusher, cylinder.
29. 9-represents track forward pusher cylinder.
29.10-represents neck releasing cylinder.
29.11-represents control panel.
Fig no 30:- It shows the side elevation showing all the inductive sensors for various cylinder. Each cylinder except C4 has two inductive sensors. Cylinder C4 has five inductive sensors to account for its five positions. All the remaining cylinders have only two positions, i.e. forward or backward wherein:
30.1-represents lifting table.
30.2-represents lifting cylinder.
30. 3-represents forward pusher cylinder.
30. 4-represents track forward pusher cylinder. 30. 5-represents carriage lowering cylinder. 30.6-represents neck releasing cylinder. 30. 7-represents rollers.
30.8-represents inductive sensors for cylinder C1. 30. 9-represents inductive sensor for cylinder C2. 30.10-represents inductive sensors for cylinder C3. 30.11-represents inductive sensors for cylinder C4. 30.12-represents inductive sensors for cylinder C5.

Fig no.31:-
1. It shows the various I.R. sensors.
2. Unless the pallet presence sensor detects a pallet, the operation cycle will not start.
3. After placing an empty pallet the operation starts and the operator places a filled pail/drum on the lifting table.
4. The pail presence sensor detects the pail/drum on the lifting table and then signals the various operations.
5. The conveyor stop sensor senses the first stacking of pail/drum and then the track forward pusher cylinder pushes the line into the pail/drum holding carriage.
6. Layer completion sensor senses the completion of a single layer of pails/drums wherein:
31.1-represents lifting table.
31. 2-represents forward pusher cylinder.
31. 3-represents track forward pusher cylinder.
31.4-represents carriage lowering cylinder.
31. 5-represents neck releasing cylinder.
31.6-represents rollers.
31. 7-represents pail presence sensor.
31. 8-represents conveyor stop sensor.
31. 9-represents layer completion sensor.
31.10-fepresents IR sensors for layers.
31.11-represents pallet presence sensor.
Fig no.32;- It shows the action of the neck releasing mechanism wherein: 32.1-represents neck holding flats.
32.2-represents neck releasing cylinder.
32.3-represents cams.
25

A. Initially the neck holding flats are horizontal in position.
B. While, releasing the necks, the cylinder moves downward and pushes the
frame structure downwards.
C. This downward motion causes the cams to rotate and simultaneously the neck
holding flats.
D. The position of neck holding flats during release is shown.
E. This vertical position of the neck holding flats releases the pails/drums.
F. A detailed view of the release mechanism is shown.
Fig no.33;- It comprises of:
33.1-represents neck holding flats. 33. 2-represents pallet.
33. 3-represents pails.
Fig no.34:- It comprises of:
34.1-represents neck holding flats.
34. 2-represents pallet.
34. 3-represents pails.
Fig no.35:- It comprises of:
35.1-represents neck holding flats.
35. 2-represents pallet.
35. 3-represents pails.
Fig no.36: In this diagram the neck holding flats along with the carriage has moved up leaving the layer of pails on the pallet. In this way all the subsequent layers are filled.

27

We claim,
Claim 1 :-
The automatic pail palletizer assembly unit which inordinately comprises of Mechanical, Hydraulic and Electrical systems which work simultaneously with each other wherein the mechanical system comprises of a Conveyor and a Carriage assembly in which, said conveyor is an endless moving belt or a chain of receptacles usually driven by an electric motor, used for carrying bulk material from place to place; and a frame structure consisting of different mechanisms which are hydraulically operated by individual hydraulic cylinders for the pails/drums, by lifting it from the lifting table to the height of slat conveyor with the help of said hydraulic cylinder , pushing it to the slat conveyor with the help of Pusher mechanism comprising rectangular flats attached to the end of an hydraulic cylinder which works in conjunction with said pusher mechanism through which it is forwarded to the end of the conveyor from where it is carried to the pail/drum holding carriage assembly with the help of track forward pusher mechanism consisting of hydraulic pushers arranged in two parallelly horizontal manner operated by one more hydraulic cylinder wherein the purpose of the pail/drum holding carriage for holding the matrix of pails/drums is further operated by an individual hydraulic cylinder and thereby releasing the matrix on the pallet platform stand using an hydraulic cylinder; operating with a Power Pack, consisting of tank for holding oil, a pump and a motor for driving the pump which sucks the oil at predetermined bar pressure and delivers the oil to the respective hydraulic cylinders via direction control valves for lubrication which are mounted on the top of power pack besides motor provided with the ports on the extreme ends of each cylinder, one for supplying the oil and the other for removing it to make sure the oil is delivered to the gearbox, dispensing through a filter-cart or using a one-shot type sealed lubricant container, the said mechanical and hydraulic system operating through Starters, Relays,
28
Contactors located in the P.L. C. (Programmable Logic Controller) mounted in the control panel which works in tandem with various Reflective and Inductive sensors situated on the carriage assembly unit wherein inductive sensors detects only metals and are used to determine the position of all the hydraulic cylinders and reflective sensors can detect any object and are used to detect pails/drums possessing predetermined sensing range, with received inputs from sensors according to a programmable logic controller, which then directs the process operation of various cylinders and the conveyor so that a matrix of pails and drums is releasably placed on the platform pallet.
Claim 2:-
The said Pail holding Carriage assembly as claimed in claim 1 comprising of following components mentioned as the neck holding flat, cross-angles, bearing block, Central support (Middle), Cam, Stepped portion of the neck holding flat, Front support, Neck holding flat with stepped portion, Neck holding flat with Front support, Carriage, Neck holding flat with Middle support, Stepped portion with Bearing block, Bearing block with the Carriage, Cam with Stepped portion.
Claim 3:-
The said neck holding flat as claimed in claim (2) is fabricated from flats with its predetermined dimensions of length, width & thickness provided with a slots made at the centre to accompany the central support (Middle support) and a hole drilled at the front side to accommodate the pins of front support, structure of flat being coupled with cam enabling it to grip or hold the complete layer of pails/drums and accordingly release it.
29

Claim 4:-
The said carriage as claimed in claim (2) is fabricated from flats with its predetermined dimensions provided with two cross angles and a hole drilled at the backside of the carriage to allow the neck holding flats, which are placed at distance equal to the diameter of the pail to pass through the carriage provided with a support flat for the bearing block to be fixed at the backside of the carriage.
Claim 5:-
The said cross-angles as claimed in claim (2) are placed inside the carriage at an equal distance used for lifting the matrix of pails/drums in a form of layers onto the carriage.
Claim 6;-
The said Central support (Middle support) as claimed in claim (2) is fabricated from square flats with predetermined dimension for top rectangular portion and a hole is drilled at rectangular portion to enable a bolt to fix it to the cross angles of the carriage wherein a middle support pin is placed at the bottom of the cylindrical portion of predetermined dimensions thereby resting the pin on the slots providing supports to the neck holding flats and allow rotational motion of the neck holding flats.
Claim 7:-
The said Front support as claimed in claim (2) is fabricated from square flats of predetermined dimensions, wherein the cylindrical portion is cut in the middle and a hole is drilled in the down rectangular portion to accommodate a pin to provide support to the neck holding flats.
30

Claim 8:-
The said Bearing block as claimed in claim (2) is fabricated from plates of predetermined dimensions with holes provided at either side to enable bolts to fix the block on the carriage and a ball bearing inserted in the center of the block to hold the neck holding flats and at the same time allow rotational motion of the flats.
Claim 9;-
The said Stepped portion of the neck holding flats as claimed in claim (2) is fabricated from round flats of predetermined dimensions provided with a neck holding flats being welded to the rectangular slot at the front portion.
Claim 10:-
The said Cam as claimed in claim (2) is fabricated from flats of predetermined dimensions, which is fixed to the stepped portion of the neck holding flats used to transform the linear motion of the cylinder into rotary motion of the neck holding flats.
Claim 11:-
The said Neck holding Flat with Stepped portion as claimed in claim (2) is coupled together by welding to enhance strength.
Claim 12:-
The said neck holding flat with front support as claimed in claim (2) is coupled by welding and a pin is inserted through front support to neck holding flat thereby supporting it.
31
Claim 13:-
The said Stepped portion with bearing block as claimed in claim (2) wherein the stepped portion is drilled in the bearing which makes the neck holding flat to rotate.
Claim 14;-
The said Neck holding flat with middle support as claimed in claim (2) thereby places the middle support in the slot of neck holding flat, providing support as well as rotation to the neck holding flats.
Claim 15:-
The said Cam with stepped portion as claimed in claim (2) in which the cam is fixed only after the stepped portion is assembled with the bearing block and the arrangement of the stepped portion and cam converts to and fro motion of the cylinder into rotary motion of the neck holding flats.
Claim 16:-
The said bearing block with the carriage as claimed in claim (2) in which the bearing blocks are placed at the backside of the carriage.
Claim 17: -
The above said process as claimed in claim (1) comprising of sequential working of said components, wherein at the start of said process, filled pail/drum are kept on the lifting table and Cylinder C4 is at the loading position and all other respective cylinders are at their backward position, indicating to the operator informing that the palletizer is ready for receiving pails/drums wherein the pail presence sensor mounted in the lifting table lifts the required number of pails/drums making the process faster using hydraulic cylinder CI up to the height of the slat conveyor
32

taking the pail/drum with it and once the table has reached its level, a signal is sent to the P.L.C Controller, which in turn activates the forward pusher cylinderC2, making the process of pushing the pail/drum on to the conveyor to start and moves for a specific period and stops, thereby carrying the pail/drum along with it, a conveyor stop sensor present at the end of the conveyor senses the pails/drums and accordingly sends a signal to the P.L.C. Controller which in turn activates the track forward pusher mechanism controlled by hydraulic cylinder C3, which pushes the line of pails/drums in to the pail/drum holding carriage, and the above mentioned process repeats for required number of pails/drums and subsequently fills the pail/drum holding carriage, a layer completion sensor present at the end of the carriage senses and accordingly signals the P.L.C Controller which in turn signals the Carriage lowering mechanism controlled by hydraulic cylinder C4, for lowering the entire filled carriage on to the pallet and respectively when the pails/drums have reached a certain predetermined distance, sensed by inductive sensors, hydraulic cylinder C5 acts thereby releasing the entire matrix of pails/drums on the pallet, the complete matrix of pails/drums is placed on the pallet and the carriage moves back to its loading position and whereby said process is repeated till the required numbers of layers are stacked.
Claim 18:-
The said automatic pail palletizing assembly unit as described in the complete specification and accompanied by drawings in the complete specification.

33

ABSTRACT;-
The Pail Palletizer were designed to make an automatic arrangement for pails, by making an arrangement for the carriage assembly by carrying it from slat conveyor and downloading it to the pallet, reducing the manual effort to a greater extent increasing time as well as energy. The carriage contains rectangular flats for holding pails or plates for holding drums. The carriage is directly connected to a hydraulic cylinder. The purpose of the carriage is to hold the matrix of pails/drums and to release the matrix on the palletization stand. There is also a step-by-step procedure arrangement, known as process for sequential access of pails/drums accordingly with the help of components used during the process to make the process faster and get completed within the stipulated period of time. The efficiency of Pail Palletizer with respect to Customer is fully 100%, as it is designed as per the Customer satisfaction & if taken into consideration of I/P / O/P, it comes to 90%. The Pail Palletizers are provided with safety mesh to avoid any accidents & also view the process running successfully.

34

Documents:

479-mum-2005-abstract(06-08-2007).doc

479-mum-2005-abstract(06-08-2007).pdf

479-mum-2005-abstract.doc

479-mum-2005-abstract.pdf

479-mum-2005-cancelled page(06-08-2007).pdf

479-mum-2005-claim(granted)-(06-08-2007).doc

479-mum-2005-claim(granted)-(06-08-2007).pdf

479-mum-2005-claims.doc

479-mum-2005-claims.pdf

479-mum-2005-correspondence(06-08-2007).pdf

479-mum-2005-correspondence(ipo)-(24-03-2008).pdf

479-mum-2005-correspondence-received-ver-080405.pdf

479-mum-2005-correspondence-received-ver-300905.pdf

479-mum-2005-description (provisional).pdf

479-mum-2005-drawing(06-08-2007).pdf

479-mum-2005-form 1(08-06-2007).pdf

479-mum-2005-form 13(06-08-2007).pdf

479-mum-2005-form 13(08-06-2007).pdf

479-mum-2005-form 18(30-09-2005).pdf

479-mum-2005-form 2(granted)-(06-08-2007).doc

479-mum-2005-form 2(granted)-(06-08-2007).pdf

479-mum-2005-form 26(23-09-2005).pdf

479-mum-2005-form 3(08-06-2007).pdf

479-mum-2005-form 5(04-04-2005).pdf

479-mum-2005-form 5(08-06-2007).pdf

479-mum-2005-form 9(24-05-2005).pdf

479-mum-2005-form-1.pdf

479-mum-2005-form-18.pdf

479-mum-2005-form-2.doc

479-mum-2005-form-2.pdf

479-mum-2005-form-26.pdf

479-mum-2005-form-3.pdf

479-mum-2005-form-5.pdf

479-mum-2005-form-9.pdf

abstract 1.jpg

« Previous Patent

Next Patent »

Patent Number

217920

Indian Patent Application Number

479/MUM/2005

PG Journal Number

19/2008

Publication Date

09-May-2008

Grant Date

31-Mar-2008

Date of Filing

19-Apr-2005

Name of Patentee

HARIKUMAR S. MENON

Applicant Address

B-204, ETERNIA, HIRANANDANI GARDENS POWAI MUMBAI-400 076

Inventors:

#	Inventor's Name	Inventor's Address
1	HARIKUMAR S. MENON	B-204, ETERNIA, HIRANANDANI GARDENS POWAI MUMBAI-400 076

PCT International Classification Number

B 65 G 47/24

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA